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3248RS/10RS
JLG 3248RS/10RS Service And Maintenance Manual
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Ser
vic
e and Maint
enanc
e Manual
Models
1932RS/6RS
3248RS/10RS
3121273
November 26, 2018 - Rev F
2
Table of Contents
Default Chapter
3
Hydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
13
Platform Capacities
13
Dimensional Data
14
Tires
14
Batteries
14
Battery Quick-Disconnect - (if Equipped)
14
Electrical System
15
Motors
15
Travel Speed
15
Lift Speed
15
Critical Stability Weights
16
Lubrication
16
Hydraulic Oil
16
Pressure Settings
16
Limit Switches
17
Tilt Alarm
17
High Drive Speed Cutout
17
Cylinder Specifications
17
Major Component Weights
17
Torque Requirements
17
Torque Charts
18
Torque Chart (SAE Fasteners - Sheet 2 of 5)
19
Torque Chart (SAE Fasteners - Sheet 3 of 5)
20
Torque Chart (Metric Fasteners - Sheet 4 of 5)
21
Torque Chart (Metric Fasteners - Sheet 5 of 5)
22
General
23
Machine Preparation, Inspection, and Maintenance
23
Preparation, Inspection, and Maintenance
23
Pre-Start Inspection
23
Pre-Delivery Inspection and Frequent Inspection
23
Annual Machine Inspection
23
Preventative Maintenance
23
Preventive Maintenance and Inspection Schedule
24
Maintenance and Inspection Schedule Codes
24
Footnotes
24
Preventive Maintenance & Inspection Schedule
25
Service and Guidelines
27
General
27
Safety and Workmanship
27
Cleanliness
27
Components Removal and Installation
27
Component Disassembly and Reassembly
27
Pressure-Fit Parts
27
Bearings
27
Gaskets
27
Bolt Usage and Torque Application
27
Hydraulic Lines and Electrical Wiring
28
Hydraulic System
28
Lubrication
28
Battery
28
Lubrication and Information
28
Hydraulic Oil
28
Changing Hydraulic Oil
29
Lubrication Specifications
29
Cylinder Drift Test
29
Platform Drift
29
Cylinder Drift
29
Pins and Composite Bearing Repair Guidelines
30
Machine Component Covers
31
Battery Removal/Maintenance
32
Battery Quick-Disconnect - (if Equipped)
32
Battery Maintenance and Safety Practices
32
Battery Charger
33
Battery Charging
34
Battery Charger Fault (LED Flash)
35
Battery Charger Maintenance
35
Battery Charger Troubleshooting
35
DC to AC Inverter (if Equipped)
37
Inverter Location on Machine
37
Inverter Operation
38
Inverter Troubleshooting
38
Inverter Specifications
38
Ground Control Station
39
Components Location
39
Removal (All Models)
39
Installation
39
Main Power Contactor Relay
40
Elevation Limit Switch Assembly
40
Location
40
Installation
40
Switch Adjustment
41
LSS - Scissor Arm Angle Sensor - Location
42
Tilt Sensor Replacement
42
Tilt Sensor Removal
43
Tilt Sensor Installation
43
Tilt Sensor Switch - Adjustment Procedure
43
Traction System
44
Theory of Operation
44
Common Traction System Difficulties
45
Power Control Module - ZAPI
46
Main Electrical Power Connections - (1001129845 - ZAPI Power Module)
47
ZAPI Power Module Electrical Evaluation
48
Drive Motor Servicing
49
Drive Motor Troubleshooting
49
Drive Motor Electrical Evaluation
49
Servicing Guidelines
49
Brake - Manual Disengage Procedure
50
Drive Motor Removal
51
Drive Motor Disassembly
52
Drive Motor Inspection and Service
53
Drive Motor Reassembly
53
Drive Motor Shaft Bearing
54
Drive Motor Installation
55
Torque Hub Servicing
56
Roll Test
56
Leak Test
56
Oil Check/Fill Procedure
56
Main Gearbox Disassembly
57
Input Carrier Disassembly
58
Hub Disassembly
59
Spindle Disassembly
60
Tightening and Torquing Bolts
61
Assembly Tools
61
Spindle Assembly
62
Hub Assembly
63
Input Carrier Assembly
64
Main Gearbox Assembly
65
Steer Assembly Components
67
RS/10RS - Steer Assembly
68
Arms and Platform Positioning and Support
69
Platform Removal
69
Scissor Arms Removal
69
Removing Scissor Arm Assembly as a Complete Unit
69
Removing/Installing Scissor Arms Individually
69
Arms and Platform Positioning and Support
70
RS/6RS - Scissor Arm Assembly
71
RS/6RS - Scissor Arm Assembly - Pin Configuration
72
RS/10RS - Scissor Arm Assembly
73
RS/10RS - Scissor Arm Assembly - Pin Configuration
74
Platform Cable (3248RS/10RS) - Sheet 1 of 4
75
Platform Cable (3248RS/10RS) - Sheet 4 of 4
76
Platform Cable (3248RS/10RS) - Sheet 3 of 4
77
Platform Cable (3248RS/10RS) - Sheet 4 of 4
78
Platform Cable (LSS - 3248RS/10RS) - Sheet 1 of 3
79
Platform Cable (LSS - 3248RS/10RS) - Sheet 2 of 3
79
Platform Cable (LSS - 3248RS/10RS) - Sheet 3 of 3
79
Platform Cable (FTSW - 3248RS/10RS) - Sheet 1 of 4
82
Platform Cable (FTSW - 3248RS/10RS) - Sheet 3 of 4
82
Platform Cable (FTSW - 3248RS/10RS) - Sheet 4 of 4
82
Platform Cable (FTSW - 3248RS/10RS) - Sheet 2 of 4
83
Platform Cable (FTSW - 3248RS/10RS) - Sheet 3 of 4
84
Platform Cable (FTSW - 3248RS/10RS) - Sheet 4 of 4
85
Platform Control Station
86
Installation/Removal
86
Control Station Harness Installation to Scissor Arms
86
Control Station Disassembly
86
Platform Control Station Installation
86
Platform Control Station Disassembly
86
Overview of Control Station Components
87
Platform Control Station Components - External
87
Platform Control Station Components - Internal
87
Joystick Controller
88
Cylinders - Theory of Operation
89
Valves - Theory of Operation
89
Solenoid Control Valves (Bang-Bang)
89
Relief Valves
89
Crossover Relief Valves
89
Proportional Valve
89
Manual Descent Valve
89
Pump/Motor
90
Pump Motor Electrical Evaluation
90
Hydraulic Oil Check Procedure
91
Pump/Tank Disassembly
92
Pump Motor Removal
92
Section 4 - Hydraulics
89
Hydraulic Oil Check Procedure - All Machines
92
Hydraulic Motor, Pump and Tank Assembly (All Machines)
93
Lift Pressure Setting Procedure
94
Cylinder Checking Procedure
94
Lift Cylinder Removal
95
Cylinder Repair
96
Disassembly
96
Cylinder Barrel Support
96
Cylinder Rod Support
96
Steer Cylinder Piston Removal
97
Cleaning and Inspection
97
Gar-Max Bearing Installation
97
Assembly
98
Installation of Head Seal Kit
98
Rod Assembly Installation
99
Lift Cylinder - LSS Pressure Sensor Location (if Equipped)
100
1932RS/6RS - Lift Cylinder
101
RS/10RS - Lift Cylinder
102
1932RS/6RS - Steer Cylinder
103
3248RS/10RS - Steer Cylinder
104
Hand Held Analyzer
105
Diagnostic Port
105
To Connect the Hand Held Analyzer
105
Using the Analyzer
106
Changing the Access Level of the Hand Held Analyzer
107
Adjusting Parameters Using the Hand Held Analyzer
108
Machine Setup
108
Joystick Calibration
109
Updating Software
109
Machine Model Adjustment
117
Machine Configuration Programming Information
118
Introduction
121
System Fault/Dtc Indication
121
Diagnostic Trouble Codes (DTC)
121
X-Connector References
121
DTC Index
122
DTC Check Tables
125
General
137
Multimeter Basics
137
Grounding
137
Backprobing
137
Min/Max
137
Polarity
137
Scale
137
Voltage Measurement (DC)
138
Resistance Measurement
138
Continuity Measurement
139
Current Measurement (DC)
139
Continuity Measurement over Long Distances
140
Requirements
140
Procedure
140
Applying Silicone Dielectric Compound to Amp Connectors
141
Assembly
142
Connector Assembly (2 of 4)
142
Connector Assembly (3 of 4)
142
Connector Assembly (4 of 4)
142
Disassembly
143
Wedge Lock
144
Service - Voltage Reading
145
Working with Deutsch Connectors
146
DT/DTP Series Assembly
146
DT/DTP Series Disassembly
146
HD30/HDP20 Series Assembly
146
HD30/HDP20 Series Disassembly
147
Switches
148
Basic Check
148
Limit Switches
148
Automatic Switches
149
Switch Wiring - Low Side, High Side
149
Circuit Boards: Inputs and Outputs
150
Power Module - J2 Connector Pin Function
151
Electrical Schematics and Layouts
153
Electrical Schematic - (Global) - Sheet 2 of 7
154
Electrical Schematic - (Global) - Sheet 3 of 7
155
Electrical Schematic - (Global) - Sheet 4 of 7
156
Electrical Schematic - (Global) - Sheet 5 of 7
157
Electrical Schematic - (Global) - Sheet 6 of 7
158
Electrical Schematic - (Global) - Sheet 7 of 7
159
Electrical Components Layout - Sheet 1 of 2
160
Electrical Components Layout - Sheet 2 of 2
161
Hydraulic Schematic
162
Other manuals for JLG 3248RS/10RS
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JLG 3248RS/10RS Specifications
General
Platform Capacity
500 lb / 226.80 kg
Weight
6, 200 lb / 2, 812.27 kg
Drive Speed
2.5 mph / 4.02 km/h
Gradeability
25 %
Power Source
24 V DC
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