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Oshkosh JLG 2632ES Manuals
Manuals and User Guides for Oshkosh JLG 2632ES. We have
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Oshkosh JLG 2632ES manual available for free PDF download: Service Maintenance Manual
Oshkosh JLG 2632ES Service Maintenance Manual (180 pages)
Brand:
Oshkosh
| Category:
Lifting Systems
| Size: 22.29 MB
Table of Contents
Table of Contents
5
Section A. Introduction - Maintenance Safety Precautions
3
General
3
Hydraulic System Safety
3
Maintenance
3
Table of Contents
5
List of Tables Table No. Title Page No.
11
MACHINE Specifications
13
Section 1. Specifications
13
Capacities
14
Fluid Capacities
14
Batteries
15
Battery Charger/Ac Inverter
15
Motors
15
Tires
15
Lift Speed
16
Lift Speed (no Load in Platform)
16
Model Dimensions
17
Travel Speed
17
Hydraulic Oil
18
Lubrication
18
Torque Requirements
18
Pressure Settings
19
High Drive Speed Cutout
20
Limit Switches
20
Tilt Alarm
20
Tilt Settings
20
Critical Stability Weights
21
Cylinder Specifications
21
Major Component Weights
21
Torque Charts
22
Annual Machine Inspection
27
General
27
Machine Preparation, Inspection, and Maintenance
27
Pre-Delivery Inspection and Frequent Inspection
27
Pre-Start Inspection
27
Preparation, Inspection, and Maintenance
27
Preventative Maintenance
27
Section 2 - General
27
Cleanliness
28
Components Removal and Installation
28
General
28
Inspection and Maintenance
28
Safety and Workmanship
28
Service and Guidelines
28
Battery
29
Bearings
29
Bolt Usage and Torque Application
29
Component Disassembly and Reassembly
29
Gaskets
29
Hydraulic Lines and Electrical Wiring
29
Hydraulic System
29
Lubrication
29
Lubrication and Servicing
29
Pressure-Fit Parts
29
Changing Hydraulic Oil
30
Hydraulic Oil
30
Hydraulic System
30
Lubrication and Information
30
Lubrication Specifications
30
Cylinder Drift
31
Cylinder Drift Test
31
Pins and Composite Bearing Repair Guidelines
31
Platform Drift
31
Preventive Maintenance and Inspection Schedule
32
Footnotes
33
Preventive Maintenance and Safety Inspection
33
Section 3 - Chassis & Scissor Arms
35
Theory of Operation
35
Traction System
35
Common Traction System Difficulties
36
Drive Motor Electrical Evaluation
36
Power Module Electrical Evaluation
37
Leak Test
38
Oil Check/Fill Procedure
38
Roll Test
38
Torque Hub
38
Brakes - Manual Disengage Procedure
39
Drive Motor Removal
40
Main Gearbox Disassembly
41
Input Carrier Disassembly
42
Hub Disassembly
43
Spindle Disassembly
44
Spindle Sub-Assembly
45
Hub Sub-Assembly
46
Input Carrier Sub-Assembly
47
Main Gearbox Assembly
48
Motor and Brake Assembly
50
Assembly Tools
51
Tightening and Torquing Bolts
51
1930ES Only
52
Drive Motor Cable Routing
52
2032ES/2632ES/2646ES/3246ES Only
53
Electric Drive Motor Service
54
Drive Motor Disassembly
55
Drive Motor Inspection and Service
55
Drive Motor Troubleshooting
55
Servicing Guidelines
55
Drive Motor Reassembly
56
Power Module - ZAPI
58
ZAPI Power Module Specs
58
ZAPI Power Module Electrical Evaluation
59
MDI (Multifunction Digital Indicator) and Brake Release
60
Battery Removal
62
Battery Charger
63
Battery Maintenance and Safety Practices
63
Battery Charger Maintenance
64
Battery Charger Troubleshooting
64
Battery Charger/Inverter (Option)
67
Battery Charger/Inverter Troubleshooting
67
Limit Switch Locations
69
Pothole Switch Replacement
70
Rotary Angle Sensor Replacement
70
Box Disassembly
71
Ground Control Station
71
Tilt Sensor Replacement
72
Platform Removal
73
Scissor Arms and Platform Positioning and Support
73
Scissor Arms Removal
73
Platform Control Station
76
Printed Circuit Board Replacement
76
Joystick Controller
77
Crossover Relief Valves
79
Cylinders - Theory of Operation
79
Manual Descent Valve
79
Proportional Valve
79
Relief Valves
79
Section 4 - Hydraulics
79
Solenoid Control Valves (Bang-Bang)
79
Valves - Theory of Operation
79
Pump Motor Electrical Evaluation
80
Pump/Motor - Theory of Operation
80
Cylinder Checking Procedure
82
Cylinders Without Counterbalance Valves and Steer Cylinder
82
Lift Pressure Setting Procedure
82
Hydraulic Oil Fill
83
Oil Check Procedure
83
Lift Cylinder Removal
84
Slide Block Lubrication
84
Cylinder Repair
86
Disassembly
86
Cleaning and Inspection
87
Steer Cylinder Piston Removal
87
Assembly
88
Cylinder Piston Nut Torque Specifications
89
Pump Removal
91
Motor Removal
93
Valve Torque Values
94
Diagnostic Port
99
Hand Held Analyzer
99
Section 5 - Jlg Control System
99
To Connect the Hand Held Analyzer
99
Using the Analyzer
100
Changing the Access Level of the Hand Held Analyzer
101
Adjusting Parameters Using the Hand Held Analyzer
102
Machine Model Adjustment
102
Machine Setup
102
Failure Troubleshooting for the Field
103
Tilt Sensor Calibration
103
Elevation Angle Sensor Electrical Evaluation
104
Tilt Sensor Electrical Evaluation
104
Tilt Vs. Allowed Height Evaluation
105
Elevation Sensor Calibration
106
Updating Software
106
Troubleshooting
107
Machine Model Adjustment
125
Machine Configuration Programming Information
126
Section 6 - Diagnostic Trouble Codes Section 6. Diagnostic Trouble Codes
127
DTC Index
127
Introduction
127
Section 6 - Diagnostic Trouble Codes
127
Alarm Sounding - Tilted & above Elevation
130
Driving at Cutback - above Elevation
130
DTC Check Tables
130
Everything Ok
130
Ground Mode Ok
130
Help Comments
130
Drive & Lift up Prevented - Tilted & Elevated
131
Driving at Cutback - Pothole Still Engaged
131
Functions Locked out - System Powered down
131
Lift up Prevented - Max Height Zone a
131
Drive Prevented - Elevated above Drive Cutout Height
132
Function Problem - Drive & Lift Active Together
132
Function Problem - Horn Permanently Selected
132
Function Problem - Indoor / Outdoor Permanently Selected
132
Keyswitch Faulty
132
Platform Controls
132
Power Cycle
132
Power-Up
132
Accelerator Faulty - Wiper out of Range
133
Function Locked out - Accelerator Not Centered
133
Function Problem - Steer Left Permanently Selected
133
Function Problem - Steer Right Permanently Selected
133
Function Problem - Trigger Permanently Closed
133
Steer Switches Faulty
133
2210 Trigger Closed too Long While in Neutral
134
Function Problem - Brake Release Permanently Selected
134
Function Problem - Lift Permanently Selected
134
Ground Controls
134
Ground Lift up / down Active Together
134
Drive & Lift up Prevented - Charger Connected
135
Drive Prevented - Charger Connected
135
Elev Angle Sensor Faulty - Voltage out of Range
135
Elev Angle Sensor Has Not Been Calibrated
135
Function Prevented
135
Platform Overloaded
135
2510 Drive Prevented - Brakes Not Releasing
136
2511 Elev Angle Sensor Faulty - Not Mounted
136
2512 Elev Angle Sensor Not Detecting Change
136
Drive & Lift Prevented - Brakes Electrically Released for Towing
136
Drive Prevented - Pothole Not Engaged
136
Elev Prox Permanently Closed - Check Prox and Angle Adjustment
136
Model Changed - Hydraulics Suspended - Cycle Ems
136
Auxiliary Relay Short to Battery
137
Contactor Driver Permanently off
137
Contactor Driver Permanently on
137
Line Contactor Miswired on or Welded
137
Line Contactor Open Circuit
137
Line Contactor Short Circuit
137
Open Circuit Line Contactor
137
Brake Open Circuit
138
Brake Short to Battery
138
Ground Output Driver
138
Lift Dn Open Circuit
138
Lift Dn Short to Battery
138
Lift up Open Circuit
138
Lift up Short to Battery
138
Steer Left Open Circuit
138
Steer Left Short to Battery
138
3310 Steer Right Open Circuit
139
3311 Ground Alarm Short to Battery
139
3312 Left Brake Short to Battery
139
3313 Right Brake Short to Battery
139
3314 Left Brake Open Circuit
139
3315 Right Brake Open Circuit
139
Steer Right Short to Battery
139
Battery Supply
141
Battery Voltage too Low - System Shutdown
141
Lss Battery Voltage too High
141
Lss Battery Voltage too Low
141
Power Module too Hot - Please Wait
141
Thermal Limit (SOA)
141
Canbus Failure - Power Module
142
Communication
142
Accessory
144
Accessory Fault
144
Canbus Failure - Accessory Module
144
Canbus Failure - Load Sensing System Module
144
Canbus Failure - Platform Module
144
Electric Motor
144
Data from Tilt Sensor - Not Connected or Faulty
146
Lss Cell #1 Error
146
Lss Cell #2 Error
146
Lss Cell #3 Error
146
Platform Load Sense
146
Tilt Sensor
146
Tilt Sensor Not Calibrated
146
Hardware
147
Lss Cell #4 Error
147
Lss Eeprom Error
147
Lss Has Not Been Calibrated
147
Lss Internal Error - Pin Excitation
147
Lss Watchdog Reset
147
Power Module Failure - Internal Error
147
Backprobing
151
General
151
Grounding
151
Min/Max
151
Multimeter Basics
151
Polarity
151
Scale
151
Section 7 - General Electrical Information & Schematics
151
Continuity Measurement over Long Distances
154
Procedure
154
Requirements
154
Applying Silicone Dielectric Compound to Amp Connectors
155
Assembly
156
Disassembly
157
Wedge Lock
158
Service - Voltage Reading
159
DT/DTP Series Assembly
160
DT/DTP Series Disassembly
160
HD30/HDP20 Series Assembly
160
Working with Deutsch Connectors
160
HD30/HDP20 Series Disassembly
161
Basic Check
162
Limit Switches
162
Switches
162
Automatic Switches
163
Switch Wiring - Low Side, High Side
163
Electrical Schematics and Layouts
164
Hydraulic Schematic
174
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