JLG Scissor Lift R2632, R3246 Service & Maintenance Manual 31220321 2025

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JLG Scissor Lift R2632, R3246 Service & Maintenance Manual 31220321 2025
Size: 23.72 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Scissor Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG R2632, R3246 Scissor Lift
Part Number: 31220321
Publication Date: 2025
Number of Pages: 314 Pages

Contents:
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications (reference)​

2.1.1 Machine Specification​

2.1.2 Machine Dimensional Data​

2.1.3 Platform Capacities​

2.1.4 Tires​

2.1.5 Batteries​

2.1.6 Motors​

2.1.7 Battery Charger​

2.1.8 Limit Switch Activation​

2.1.9 Hydraulic Pressure Settings​

2.1.10 Hydraulic Cylinder Specifications​

2.1.11 Critical Stability Weights​

2.1.12 Major Component Weights​

Serial Number Location (concept)​

Fluids and Lubrication (task)​

2.3.1 Hydraulic System​

2.3.2 Hydraulic Oil​

2.3.3 Changing Hydraulic Oil​

2.3.4 Specifications​

2.3.5 Capacities​

2.3.6 Hydraulic Oil​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance (task)​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventative Maintenance​

Service and Guidelines (task)​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

Preventive Maintenance and Inspection Schedule (task)​

3.3.1 Maintenance and Inspection Schedule Codes:​

Pins and Composite Bearing Repair Guidelines (task)​

Tires and Wheels (concept)​

3.5.1 Tire Wear and Damage​

3.5.2 Wheel and Tire Replacement​

Battery Charger (task)​

3.6.1 Battery Charging​

3.6.2 DC/AC Power Inverter Installation - Option​

Testing, Calibrations and Special Procedures

Special Tools (concept)​

4.1.1 Multimeter​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing (task)​

4.2.1 LSS Testing​

Calibration Procedures (task)​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System (LSS) Calibration​

4.3.4 LSS Verification​

Special Procedures (task)​

4.4.1 Scissor Arm - Safety Prop​

4.4.2 Joystick Controller​

4.4.3 Arms and Platform Positioning and Support​

4.4.4 Pressure Setting Procedure​

4.4.5 Cylinder Checking Procedure​

4.4.6 Cylinder Drift Test​

System Software

Load Sensing System (LSS) (reference)​

5.1.1 Theory of Operation​

5.1.2 Lift Cylinder - LSS Pressure Sensor Location​

5.1.3 LSS Connector Pin Assignments​

5.1.4 Personalities Menu​

5.1.5 Diagnostic Menu​

JLG Analyzer (task)​

5.2.1 Hand Held Analyzer​

5.2.2 Analyzer Software Version P1.16.3​

Analyzer Software Accessibility (reference)​

5.3.1 Access Level​

5.3.2 Diagnostics​

5.3.3 Machine Configuration Programming Information​

5.3.4 Machine Model Adjustment (Personality Settings)​

Fault Codes

Introduction (concept)​

6.1.1 System Fault/DTC Indication​

Diagnostic Trouble Codes (DTC) (concept)​

DTC Check Tables (reference)​

6.3.1 Diagnostic Trouble Codes (DTC)​

6.3.2 LSS Troubleshooting​

Hydraulics

General Information and Safety (concept)​

Theories of Operation (reference)​

7.2.1 Cylinders​

7.2.2 Valves​

7.2.3 Hydraulic Oil Check Procedure​

7.2.4 Hydraulic Circuits​

7.2.5 Pump/Motor​

Hydraulic Components​

7.3.1 Towing​

7.3.2 Hydraulic Manifold​

7.3.3 Hydraulic Hose Routing​

Torque Values (reference)​

7.4.1 Hydraulic Manifold Assembly​

Hydraulic Diagram (task)​

7.5.1 Hydraulic Manifold Assembly​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Amp Connectors​

8.1.2 Dielectric Grease Application​

8.1.3 Installation​

8.1.4 AMP Mate-N-Lok​

8.1.5 AMP Faston​

8.1.6 AMP Micro-Fit​

8.1.7 AMP Mini Fit Jr​

8.1.8 Mini Fit Sr​

8.1.9 DIN Connectors​

8.1.10 Exceptions​

Electrical Connectors​

Electrical Harness Layout​

8.3.1 Cable Routing​

Board Layouts​

8.4.1 Logic Control Module​

AMP Connector​

8.5.1 Assembly​

8.5.2 Disassembly​

8.5.3 Wedge Lock​

8.5.4 Service - Voltage Reading​

Switches​

8.6.1 Basic check​

8.6.2 Limit Switches​

8.6.3 Automatic Switches​

8.6.4 Switch Wiring - Low Side, High Side​

Removal and Installation

Pothole Protection System​

9.1.1 Pothole Protection System Components​

9.1.2 Installation​

9.1.3 Removal​

Wheels​

9.2.1 Removal​

9.2.2 Installation​

Battery​

9.3.1 Battery Quick-Disconnect​

9.3.2 Battery Maintenance and Safety Practices​

Logic Control Module​

9.4.1 Module Access​

9.4.2 Removal​

9.4.3 Installation​

Tilt Sensor​

9.5.1 Removal​

9.5.2 Installation​

Ground Control Station​

9.6.1 Components Location​

9.6.2 Removal​

9.6.3 Installation​

Hydraulic Tank​

9.7.1 Removal​

9.7.2 Installation​

Side Swing Doors​

Hydraulic Pump and Electric Motor - R2632​

9.9.1 Removal​

9.9.2 Installation​

Hydraulic Pump and Electric Motor - R3246​

9.10.1 Removal​

9.10.2 Installation​

Scissor Arms​

9.11.1 Removal​

9.11.2 Installation​

Arm Angle Sensor​

9.12.1 Removal​

9.12.2 Installation​

Platform Control Station​

9.13.1 Removal​

9.13.2 Installation​

Platform​

9.14.1 Removal​

9.14.2 Installation​

Lift Cylinder​

9.15.1 Removal​

9.15.2 Installation​

Pump Control Module​

9.16.1 Removal​

9.16.2 Installation​

Main Power Contractor Relay and Pump Control Module​

Steer and Spindle Assembly components​

Drive Motor Installation​

9.19.1 Removal​

9.19.2 Installation​

Hydraulic Brake Installation​

Disassembly and Assembly

Drive Assembly​

10.1.1 Drive Hub​

Scissor Arm Assembly​

10.2.1 Scissor Arm Assembly (R3246)​

10.2.2 Scissor Arm Assembly (R2632)​

Hydraulic Pump and Electric Motor​

10.3.1 Disassembly​

10.3.2 Assembly​

Platform Control Station​

10.4.1 Disassembly​

10.4.2 Assembly​

Hydraulic Cylinders​

10.5.1 Disassembly​

10.5.2 Cleaning and Inspection​

10.5.3 Assembly​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​