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2632ES
JLG 2632ES Service Maintenance Manual
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Ser
vic
e & Maintenance Man
u
al
Models
1930ES
2032ES
2632ES
2646ES
3246ES
USA Built - S/N-0200239382 to
Present
China Built - S/N-B2
00020297 to Present
Mexico Bui
lt - S/N-M200000100 to Present
3121656
March 7, 2016
2
Table of Contents
Introduction - Maintenance Safety Precautions Revision Log
5
Section A. Introduction - Maintenance Safety Precautions
3
General
3
Hydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1. Specifications
13
MACHINE Specifications
13
Capacities
14
Fluid Capacities
14
Batteries
15
Battery Charger
15
Motors
15
Tires
15
Lift Speed (no Load in Platform)
16
Travel Speed
16
Model Dimensions
17
Torque Requirements
18
Lubrication
18
Hydraulic Oil
18
Pressure Settings
19
Limit Switches
19
High Drive Speed Cutout
19
Tilt Alarm
19
Cylinder Specifications
20
Major Component Weights
20
Critical Stability Weights
20
Torque Charts
21
Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
22
Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
23
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
24
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
25
Section 2 - General
27
Machine Preparation, Inspection, and Maintenance
27
Annual Machine Inspection
27
General
27
Pre-Delivery Inspection and Frequent Inspection
27
Pre-Start Inspection
27
Preparation, Inspection, and Maintenance
27
Preventative Maintenance
27
Service and Guidelines
28
Cleanliness
28
Components Removal and Installation
28
General
28
Safety and Workmanship
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
Lubrication and Information
30
Changing Hydraulic Oil
30
Hydraulic Oil
30
Hydraulic System
30
Lubrication Specifications
30
Cylinder Drift Test
31
Cylinder Drift
31
Platform Drift
31
Pins and Composite Bearing Repair Guidelines
31
Preventive Maintenance and Inspection Schedule
32
Preventive Maintenance and Safety Inspection
33
Section 3 - Chassis & Scissor Arms
35
Traction System
35
Theory of Operation
35
Drive Motor Electrical Evaluation
36
Common Traction System Difficulties
36
Power Module Electrical Evaluation
37
Torque Hub
38
Leak Test
38
Oil Check/Fill Procedure
38
Roll Test
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
Drive Motor Cable Routing
52
1930ES Only
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
Wire Harness Connections
57
Power Module - ZAPI
58
ZAPI Power Module Electrical Evaluation
59
MDI (Multifunction Digital Indicator) and Brake Release
60
MDI Installation/Removal
61
Battery Removal
62
Battery Charger
63
Battery Maintenance and Safety Practices
63
Battery Charger Maintenance
64
Battery Charger Troubleshooting
64
Battery Algorithms
66
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
Arms and Platform Positioning and Support
74
Platform Control Station
75
Printed Circuit Board Replacement
75
Joystick Controller
76
Section 4 - Hydraulics
77
Cylinders - Theory of Operation
77
Valves - Theory of Operation
77
Crossover Relief Valves
77
Manual Descent Valve
77
Proportional Valve
77
Relief Valves
77
Solenoid Control Valves (Bang-Bang)
77
Pump/Motor - Theory of Operation
78
Pump Motor Electrical Evaluation
78
Cylinder Checking Procedure
80
Cylinders Without Counterbalance Valves and Steer Cylinder
80
Lift Pressure Setting Procedure
80
Hydraulic Oil Fill
81
Oil Check Procedure
81
Slide Block Lubrication
82
Lift Cylinder Removal
82
Lift Cylinder Removal
83
Cylinder Repair
84
Disassembly
84
Cleaning and Inspection
85
Steer Cylinder Piston Removal
85
Assembly
86
Piston Seal Kit Installation
87
Holding Valve Torque Specifications
88
Pump Removal
89
Motor Removal
91
Lift Cylinder/Pump/Tank Assembly
92
Lift Cylinder Assembly
93
Section 5 - Jlg Control System
95
Diagnostic Port
95
Hand Held Analyzer
95
To Connect the Hand Held Analyzer
95
Using the Analyzer
96
Changing the Access Level of the Hand Held Analyzer
97
Adjusting Parameters Using the Hand Held Analyzer
98
Machine Setup
98
Tilt Sensor Calibration
99
Failure Troubleshooting for the Field
99
Tilt Sensor Electrical Evaluation
100
Elevation Angle Sensor Electrical Evaluation
100
Tilt Vs. Allowed Height Evaluation
101
Elevation Sensor Calibration
102
Updating Software
102
Troubleshooting
103
Machine Model Adjustment
119
Machine Configuration Programming Information
120
Section 6. Diagnostic Trouble Codes
121
Section 6 - Diagnostic Trouble Codes
121
Introduction
121
DTC Index
121
DTC Check Tables
124
JLG Lift
124
Help Comments
124
Error (Displayed on MDI)
124
Everything Ok
124
Ground Mode Ok
124
Alarm Sounding - Tilted & above Elevation
124
Driving at Cutback - above Elevation
124
Drive & Lift up Prevented - Tilted & Elevated
125
Lift up Prevented - Max Height Zone a
125
Driving at Cutback - Pothole Still Engaged
125
Functions Locked out - System Powered down
125
Drive Prevented - Elevated above Drive Cutout Height
126
Function Problem - Drive & Lift Active Together
126
Function Problem - Horn Permanently Selected
126
Function Problem - Indoor / Outdoor Permanently Selected
126
Keyswitch Faulty
126
Platform Controls
126
Power Cycle
126
Power-Up
126
Function Problem - Steer Left Permanently Selected
127
Function Problem - Steer Right Permanently Selected
127
Accelerator Faulty - Wiper out of Range
127
Steer Switches Faulty
127
Function Problem - Trigger Permanently Closed
127
2232 Function Problem - Drive & Lift both Open
128
Elev Angle Sensor Faulty - Voltage out of Range
128
Function Prevented
128
Function Problem - Brake Release Permanently Selected
128
Function Problem - Lift Permanently Selected
128
Ground Controls
128
Ground Lift up / down Active Together
128
Elev Angle Sensor Has Not Been Calibrated
129
Drive Prevented - Charger Connected
129
Drive & Lift up Prevented - Charger Connected
129
Platform Overloaded
129
Drive Prevented - Pothole Not Engaged
129
Elev Prox Permanently Closed - Check Prox and Angle Adjustment
129
2510 Drive Prevented - Brakes Not Releasing
130
2511 Elev Angle Sensor Faulty - Not Mounted
130
2512 Elev Angle Sensor Not Detecting Change
130
Contactor Driver Permanently off
130
Drive & Lift Prevented - Brakes Electrically Released for Towing
130
Line Contactor Open Circuit
130
Model Changed - Hydraulics Suspended - Cycle Ems
130
Open Circuit Line Contactor
130
Auxiliary Relay - Open Circuit
131
Brake Open Circuit
131
Brake Short to Battery
131
Contactor Driver Permanently on
131
Ground Output Driver
131
Lift up Open Circuit
131
Lift up Short to Battery
131
Line Contactor Miswired on or Welded
131
Line Contactor Short Circuit
131
Lift Dn Short to Battery
132
Lift Dn Open Circuit
132
Steer Left Short to Battery
132
Steer Left Open Circuit
132
Steer Right Short to Battery
132
3310 Steer Right Open Circuit
132
3311 Ground Alarm Short to Battery
132
3312 Left Brake Short to Battery
133
3313 Right Brake Short to Battery
133
3314 Left Brake Open Circuit
133
3315 Right Brake Open Circuit
133
33297 Left Brake - Short to Ground
133
33304 Right Brake - Short to Ground
133
33305 Steer Right Valve - Short to Ground
134
33383 Beacon Light- Open Circuit
134
33384 Beacon Light - Short to Ground
134
33406 Lift up Valve - Short to Ground
134
33407 Lift Dn Valve - Short to Ground
134
33562 Beacon Light - Short to Battery
134
Driving at Cutback - Power Module Current Limit
134
Lift up at Cutback - Power Module Current Limit
134
Power Module too Hot - Please Wait
134
Thermal Limit (SOA)
134
Battery Supply
135
Battery Voltage too High - System Shutdown
135
Battery Voltage too Low - System Shutdown
135
Canbus Failure - Power Module
135
Logic Supply Voltage out of Range
135
Lss Battery Voltage too High
135
Lss Battery Voltage too Low
135
Canbus Failure - Platform Module
136
Communication
136
6635 Canbus Failure - Chassis Tilt Sensor
137
Accessory
137
Accessory Fault
137
Canbus Failure - Accessory Module
137
Electric Motor
137
Open Circuit Drive Motor Wiring
137
Capacitor Bank Fault - Check Power Circuits
138
Short Circuit Field Wiring
138
Open Circuit Field Wiring
138
Stalled Pump Motor or Power Wiring Error
138
Open Circuit Pump Motor Wiring
138
Traction T High - Check Power Circuits
138
Traction T Low - Check Power Circuits
138
7710 Pump P High - Check Power Circuits
139
7711 Pump P Low - Check Power Circuits
139
7741 Armature Braking Current too High
139
7742 Field Voltage Improper
139
Lss Cell #1 Error
139
Lss Cell #2 Error
139
No Data from Tilt Sensor - Not Connected or Faulty
139
Platform Load Sense
139
Tilt Sensor
139
Tilt Sensor Not Calibrated
139
Hardware
140
Lss Cell #4 Error
140
Lss Eeprom Error
140
Lss Has Not Been Calibrated
140
Lss Internal Error - Drdy Missing from A/D
140
Lss Internal Error - Pin Excitation
140
Lss Watchdog Reset
140
Power Module Failure - Check Power Circuits or Mosfet Short Circuit
140
Power Module Failure - Internal Error
140
Power Module Failure - Personality Range Error
140
9912 Power Module Failure - System Monitor
141
9950 Power Module Failure - Internal Error
141
9956 Power Module Failure - Internal Error
142
9970 Power Module Failure - Internal Error
143
Section 7 - General Electrical Information & Schematics
145
General
145
Multimeter Basics
145
Backprobing
145
Grounding
145
Min/Max
145
Polarity
145
Scale
145
Voltage Measurement (DC)
146
Continuity Measurement
147
Continuity Measurement over Long Distances
148
Procedure
148
Requirements
148
Applying Silicone Dielectric Compound to Amp Connectors
149
Assembly
150
Disassembly
151
Wedge Lock
152
Service - Voltage Reading
153
DT/DTP Series Assembly
154
DT/DTP Series Disassembly
154
HD30/HDP20 Series Assembly
154
Working with Deutsch Connectors
154
HD30/HDP20 Series Disassembly
155
Basic Check
156
Limit Switches
156
Switches
156
Automatic Switches
157
Switch Wiring - Low Side, High Side
157
Electrical Schematics and Layouts
158
Electrical Components Layout
166
Hydraulic Schematic
168
Hydraulic Schematic - China Manufactured
170
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JLG 2632ES Specifications
General
Gradeability
25%
Platform Width
30 in
Power Source
Electric
Platform Capacity
500 lbs
Turning Radius - Inside
0 in
Batteries
4 x
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