Oshkosh Corporation JLG R2632, Operation And Safety Manual

Page 1: ...Operation and Safety Manual Original Instructions Keep this manual with the machine at all times AS NZS ANSI GB Models R2632 R3246 PVC 2010 31215932 September 1 2020 Rev A...

Page 2: ...ich are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service yo...

Page 3: ...eep it with the machine at all times The purpose of this manual is to provide owners users operators lessors and lessees with the precautions and operating proce dures essential for the safe and prope...

Page 4: ...HIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HA...

Page 5: ...ATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT Contact Pro...

Page 6: ...REVISION LOG d 31215932 REVISION LOG Original Issue A September 1 2020...

Page 7: ...Familiarization 2 2 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Inspection and Maintenance Table 2 3 2 3 PRE START INSPECTION 2 4 2 4 WALK AROUND INSPECTION 2 6 Inspection Diagram 2 7 2 5 FUNCTION...

Page 8: ...3 15 3 10 PLATFORM EXTENSION 3 16 3 11 PLATFORM RAILS FOLD DOWN PROCEDURE IF EQUIPPED 3 17 Platform with Rail in Rail Extension Deck 3 17 Platform with Dual Rails Extension Deck 3 19 3 12 PLATFORM MA...

Page 9: ...N 6 1 Other Publications Available Specific to this Machine 6 1 Serial Number Identification 6 1 6 2 SUPPLEMENTAL INFORMATION 6 2 6 3 MACHINE SPECIFICATIONS 6 2 Operating Specifications 6 2 Machine Di...

Page 10: ...TABLE OF CONTENTS iv 31215932 Diagram 6 14 Decals 6 16 6 9 DIAGNOSTIC TROUBLE CODES DTC 6 18 SECTION 7 INSPECTION AND REPAIR LOG...

Page 11: ...with regard to safety training inspection mainte nance application and operation please contact JLG Industries Inc JLG FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT...

Page 12: ...d for that pur pose by JLG Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel This machine...

Page 13: ...with personnel in the platform except in an emergency Do not carry materials directly on platform railing unless approved by JLG When two or more persons are in the platform the operator shall be res...

Page 14: ...lanyard Attach only one 1 lanyard per lanyard anchorage point Enter and exit only through gate area Use extreme caution when entering or leaving platform Ensure that the platform assembly is fully low...

Page 15: ...ols and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less The minimum approach dista...

Page 16: ...al hazards at the ground level Do not operate the machine when wind conditions exceed specifi cations shown in Section 6 3 or as shown on the capacity placard on the platform billboard Factors affecti...

Page 17: ...ibleinsmoke 2 4 7 1 6 3 3 Lightbreeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallb...

Page 18: ...adjacent structure Never attach wire cable or any similar items to platform If the scissor arm assembly or platform is caught so that one or more wheels are off the ground all persons must be removed...

Page 19: ...ion visibility slope location of personnel and other factors Be aware of stopping distances in all drive speeds When driving in high speed reduce drive speed before stopping Travel grades in low speed...

Page 20: ...machine maintenance are inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these...

Page 21: ...ifferent weight or specification Do not modify the MEWP in any way to affect stability Reference the Service and Maintenance Manual for the weights of critical stability items MODIFICATION OR ALTERATI...

Page 22: ...SECTION 1 SAFETY PRECAUTIONS 1 12 31215932 NOTES...

Page 23: ...fest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes and drop offs exist 8 Means to avoid the hazards of unprotected electrical con duct...

Page 24: ...n operator to use a specific model of MEWP the user shall ensure the operator is familiarized on the follow ing 1 Location of the manual storage compartment and the requirement to ensure the required...

Page 25: ...morethan3months orpurchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManualandappli cableJLGinspectionform AnnualMachine Inspection seeNotebelow Annually nolaterthan13monthsfr...

Page 26: ...il Level Check the hydraulic oil level in the pump reservoir and add as required refer to Section 6 6 8 Accessories Attachments Refer to the Accessories section in this manual or accessory installed u...

Page 27: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 31215932 2 5 Lanyard Attach Points 0...

Page 28: ...rake hoses for damage or leakage Refer to Inspection Note 3 Ground Control Console Placard secure and legible con trol switches return to neutral position when activated and released emergency stop sw...

Page 29: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 31215932 2 7 Inspection Diagram 1 2 3 4 5 6 7 8 9 10 11 1 12 OAD00621 13...

Page 30: ...ion 3 8 d Verify the Pothole Protection bars are fully lowered when the platform is raised 2 From the Platform Control Console a Ensure the control console is firmly secured in the proper location b E...

Page 31: ...nd the platform must be fully lowered stowed to drive NOTE Machine R2632 does not have outdoor functionality in the AUS market Table 2 1 High Drive Cutout Height MODEL HIGH DRIVESPEED CUTBACK HEIGHT D...

Page 32: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 10 31215932 NOTES...

Page 33: ...ELEASED USE THE EMERGENCY STOP SWITCH TO STOP THE MACHINE 3 2 DESCRIPTION This machine is a Mobile Elevating Work Platform MEWP used to position personnel along with their necessary tools and material...

Page 34: ...hin manufacturer s rated capacity 3 All machine systems are functioning properly Stability This machine as originally manufactured by JLG and operated within its rated capacity on a smooth firm surfac...

Page 35: ...CHARGER HAS RECEIVEDA SHARP BLOW BEEN DROPPED OROTHERWISEDAMAGED IN ANYWAY ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR BREAKING THE POSITIVE NEGATIVE CONNECTIONSTO THE BATTERY DO NOT OPE...

Page 36: ...ATION 3 4 31215932 3 6 MACHINE CONTROL LOCATIONS 1 Platform Control Station 2 Ground Control Station 3 SideCompartmentDoor Latch Both Sides 4 A C Plug Battery Charger Input 5 Platform Manual Descent 6...

Page 37: ...TION 31215932 3 5 3 7 GROUND CONTROL CONSOLE 1 Ground Platform OFFKey Selector Switch 2 Platform Lift Lower Switch 3 Inverter ON OFF Switch IfEquipped 4 Ground Emergency Stop Button 5 Hourmeter 6 Over...

Page 38: ...The switch should be set to the OFF position 3 when not using machine or parking the machine overnight Platform Lift Lower Switch A three position momentary contact switch controls raising and lowerin...

Page 39: ...ing switch Hourmeter The Hourmeter indicates the number of hours the machine has been operated Overload Indicator LSS The Overload Indicator indicates when the platform has been overloaded An audible...

Page 40: ...nging to the next DTC Once the last active DTC is displayed the display will recycle indefinitely until they are corrected Also located on the MDI are Battery Discharge Indicators BDI 3 4 5 The three...

Page 41: ...Controller 6 Trigger EnableSwitch 7 Overload Indicator LSS 8 TiltIndicator 9 VariableTilt Platform Restricted Height Indicator 10 Horn Button 11 BatteryDischargeIndicator 12 System FaultIndicator 13...

Page 42: ...ch NOTE When selecting between the Lift and Drive functions the joystick control must be returned to the neutral position for approxi mately 1 2 second before the function change is operable This togg...

Page 43: ...e right will steer the wheels to the right Depressing the switch to the left will steer the wheels to the left Joystick Controller This controls drive and lift Steering and Traveling DO NOT DRIVE WITH...

Page 44: ...returning the joystick to center will stop machine movement NOTE To ensure proper operation of the desired platform function move the joystick in the direction of the black or white arrow that matche...

Page 45: ...chassis is at or beyond the tilt cutout settings IF THE TILT INDICATOR WARNING LIGHT ALARM IS ACTIVATED WHEN PLATFORM IS RAISED LOWER PLATFORM AND DRIVE TO A SMOOTH FIRM SURFACE WITHIN THE LIMITS OF T...

Page 46: ...e Indoor green indicator and the Outdoor yellow indicator displays the mode in which the machine is currently set to operate Indoor Outdoor Operation Mode Switch This button toggles between the indoor...

Page 47: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 31215932 3 15 3 9 GRADE AND SIDESLOPE 0 7 6 21 67 3...

Page 48: ...Press foot down on locking mechanism lever 1 While hold ing the lever slide the top handrails 2 until the locking mechanism pin clears the rear platform extension lock 3 2 Grasp the top handrails 2 of...

Page 49: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 31215932 3 17 3 11 PLATFORM RAILS FOLD DOWNPROCEDURE IF EQUIPPED Platform with Rail in Rail Extension Deck 0...

Page 50: ...s down 3 Remove the pins at the front mid rails then fold down the front panel towards the platform floor 4 Fully open the swing gate and hold Fold down the right side rail then fold down the left sid...

Page 51: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 31215932 3 19 Platform with Dual Rails Extension Deck 0...

Page 52: ...ight side top rail 4 Fold down outer platform rails towards platform floor To raise the rails back to the upright position unfold the rails in the reverse sequence they were folded and replace the rai...

Page 53: ...achine beside the ladder Look for the instruction decal located beside the T handle 1 Locate the manual descent control red T handle KEEP HANDS AND ARMS OUT OF THE PATH OF SCISSOR ARMS AND PLATFORM WH...

Page 54: ...uthorized use NOTE For added protection the platform control station can be secured to its mounting plate Also the side compartment doors can be secured by placing a padlock through the holes provided...

Page 55: ...the platform in the stowed position First adjust the width of the forklift truck lifting tines to fit the machine forklift pockets Then slide the tines into the forklift pockets and carefully lift mac...

Page 56: ...215932 When transporting the machine fully lower the platform stowed position and secure the machine to the truck or trailer deck There are two tie down lift lugs at the rear of the machine and two ti...

Page 57: ...n the drive control valve locate the tow mode needle valve knob 1 Screw out the valve until it stops b On the main valve body to release the brakes push the black brake override button 2 in A detent w...

Page 58: ...ses 1 Chock wheels or secure machine with tow vehicle 2 Pull out emergency stop switch and position the keyswitch to ground mode 3 Press and hold the yellow button at the rear of the machine for one s...

Page 59: ...d with all nec essary details USA 877 JLG SAFE 554 7233 EUROPE 32 0 89 84 82 20 AUSTRALIA 61 2 65 811111 E mail productsafety jlg com Failure to notify the manufacturer of an incident involving a JLG...

Page 60: ...fting equipment used to lift the platform while the chassis is lowered by the forklift or other equipment Platform Caught Overhead If the platform becomes jammed or snagged in overhead structures or e...

Page 61: ...e the ladder Look for the instruction decal located beside the T handle 1 Locate the manual descent control red T handle KEEP HANDS AND ARMS OUT OF THE PATH OF SCISSOR ARMS AND PLATFORM WHILE LOWERING...

Page 62: ...SECTION 4 EMERGENCY PROCEDURES 4 4 31215932 NOTES...

Page 63: ...CCESSORIES 5 1 AVAILABLE ACCESSORIES ACCESSORY MARKET ANSI USA Only ANSI CSA CE AUS China Korea Japan DC ACPowerInverter PipeRacks Anti VandalismPackage Rail MountedPlatformExtensionHandles Footswitch...

Page 64: ...dalismPackage All None Rail MountedPlatform ExtensionHandles Inverter PipeRacks Anti VandalismPackage Footswitch MagneticGateLatch DualRails Footswitch All None MagneticGateLatch All None JLGMobileCon...

Page 65: ...rce other than 24V including any AC power source This system presents a danger of shock or electrocution Treat inverter output equally to commercial AC power Do not allow water or other liquids to con...

Page 66: ...tion 1 Set the built in inverter ON OFF switch to the ON position 2 At the ground control console set the inverter ON OFF switch to the ON position NOTE Only plug in tools or appliances rated within t...

Page 67: ...o the platform Check for missing or damaged components Replace if necessary Check for loose nuts and bolts If necessary torque according to the Torque Chart specifications in Section 1 of the Service...

Page 68: ...age consists of two lockable covers for the Platform and Ground Control Stations that prevent unauthorized use of the machine Locks are not provided with this kit Platform Control Station 1 Lock Posit...

Page 69: ...les provide the operator an optional grip to push the exten sion platform out from the stowed position Operation 1 Swing both extension handles up 90 to extension position 2 While standing on the main...

Page 70: ...form controls Power is removed from the plat form controls when the footswitch is released NOTE This accessory is only available in Japanese and Korean markets Operation To operate a function engage t...

Page 71: ...ith the JLG Mobile Control applica tion This pairs the Mobile Control module on the machine with the mobile device to allow remote operation NOTE The Bluetooth word mark and logos are registered trade...

Page 72: ...E USING JLG MOBILE CONTROL WHILE STANDING IN THE PLATFORM OR WITHOUT CLEAR LINE OF SIGHT BETWEEN THE MACHINE AND ITS TRAVEL PATH AS SERIOUS INJURY COULD OCCUR TO OPERATOR OR BYSTANDER Document Resourc...

Page 73: ...TFORM AND FOLLOW ALL INSTRUCTIONS ON MACHINE PLACARDS AND IN THIS MANUAL THE OPERATOR MUST NOT RELY ON SKYSENSE AS A SUBSTITUTE FOR FOLLOWING THE INSTRUCTIONS AND WARNINGS ON MACHINE PLACARDS AND IN T...

Page 74: ...tton on the notification unit and lift the platform The platform should lift the LED indicator should be red and the alarm should sound If the alarm is muted the mute button light should be red 6 Remo...

Page 75: ...ctivity No LED Normal operation LED Flashing Yellow Machine is in SkySense warning zone and will reduce to elevated drive height speed Flash frequency correlates to proximity of the object LED Red Mac...

Page 76: ...of the SoftTouch system Reset the system by releasing the trigger switch Audible SkySense alarms can be muted although LEDs will con tinue to light OverrideButton The yellow override button allows ope...

Page 77: ...SECTION 5 ACCESSORIES 31215932 5 15 SkySense Coverage Areas Level One NOTE Sensor Cones shown are approximations for reference only...

Page 78: ...SECTION 5 ACCESSORIES 5 16 31215932 Level Two NOTE Sensor Cones shown are approximations for reference only...

Page 79: ...s section is intended to assist the machine operator to perform only daily maintenance tasks and does not replace the more thorough Preventive Maintenance and Inspection Schedule in the Service and Ma...

Page 80: ...TION R2632 R3246 GrossVehicleWeight AllMarkets AUSOnly 4 280lb 1 941kg 4 280lb 1 941kg 5 410lb 2 454kg 5 510lb 2 499kg MaximumWorkingHeight 31 5ft 9 6m 38ft 11 6m LiftUpTime NoLoad RatedLoad 28 38sec...

Page 81: ...roundtoPlatformFloor Stowed Elevated SafetyPropEngaged 3 63ft 1 11m 25 5ft 7 77m 7 15ft 2 18m 4 24ft 1 29m 32ft 9 75m 8 50ft 2 59m RailHeight PlatformFloortoTopofRail TelescopeRails DualRails 3 66ft 1...

Page 82: ...6in 406mm x 5in 127mm Wheel NutTorque 2in 51mm SlottedNut with Cotter Pin 150ft lb 203Nm DESCRIPTION R2632 R3246 LeadAcid Lead Acid Extended Range AGM Voltage 24VSystem 6Vperbattery AmpHour Rating 20h...

Page 83: ...Interlock Current Protection Output ReversePolarity Output Short Circuit AC Overload DC Overload 85 270V AC 100VAC 240VAC RMS 50 60Hz 7 5A IP66 NEMA4Type4 40 F 40 C to 149 F 65 C 24V 36V 27 1A 1A 24V...

Page 84: ...Green LED on Top Panel Green LED on Fault Indicator Red LED on External Error Condition Caution Amber LED flashing Eagle Performance Battery Type Indicator Yellow LED on Battery Charging 30 60 90 Red...

Page 85: ...ut Cable 2 Charge Indicator LEDs 1 COMPONENT R2632 R3246 HydraulicReservoir atFullmark 4gal 15L HydraulicSystem IncludingReservoir 4 75gal 18L 5 5gal 21L KEY SPECIFICATIONS MPG Multipurpose Greasehavi...

Page 86: ...RELO QYLURV Q 0RELO FHO 0RELO FHO 127 0 1 23 5 7 21 86 1 121 33529 5 8 8 6 25 23 5 7 21 2876 2 7 7 03 5 785 281 5 6 287 1 1 7 5 8 8 23 5 7 21 57 0 5 68 7 1 35 0 785 5 25 0 72 20321 176 2 7 5 8 6 67 0...

Page 87: ...ducted engage the machine s red safety prop The safety prop is located at the rear of the machine in the armstack To engage the safety prop 1 From the Ground Control Station raise the platform approxi...

Page 88: ...reservoir Ensure the level of oil is between the two lines 3 If the level of oil in the reservoir is below the minimum level 3 more oil is needed Wipe all dirt and debris from the filler filter cap 4...

Page 89: ...IN AWELL VENTILATEDAREA ADD ONLY DISTILLED WATER TO BATTERIES WHEN ADDING DISTILLED WATER TO THE BATTERIES A NON METALLIC CONTAINERAND ORFUNNEL MUSTBE USED Check the electrolyte level of the batteries...

Page 90: ...ent tire be the same size and brand as originally installed on the machine or offered by JLG as an approved replacement Refer to the JLG Parts Manual for the part number of the approved tires for a pa...

Page 91: ...h to tighten the slotted nuts The proper procedure for attaching wheels is as follows 1 If not already installed install shaft key 5 to shaft and align with wheel keyway install wheel and hub 3 onto t...

Page 92: ...CAL INSTALLATION Diagram 2 5 8 9 12 13 14 16 17 21 25 26 27 29 30 32 30 5 36 21 3 6 15 20 34 6 37 38 OAD00492 5 5 4 36 12 12 12 16 16 21 39 NOTE Placement of platform billboard decals may differ based...

Page 93: ...SECTION 6 SPECIFICATIONS AND OPERATOR MAINTENANCE 31215932 6 15 0...

Page 94: ...1001162864 1001162864 1001162864 1001162864 1001162864 10 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 11 1001212291 1001212291 1001212291 1001212291 1001212...

Page 95: ...1001257174 R2632 1001257175 R3246 1001257174 R2632 1001257175 R3246 1001257174 R2632 1001257175 R3246 1001257174 R2632 1001257175 R3246 30 1706312 1706312 1706312 1706312 1706312 1706312 1706312 1706...

Page 96: ...ll flash on the platform indicator panel when a fault occurs The more detailed three to five digit code numbers in the DTC column of the following tables are only indicated on a JLG hand held diagnost...

Page 97: ...D Driving and lift up are not possible since the platform is elevated and the chassis is not level 006 LIFT UPPREVENTED MAXHEIGHT ZONE A None None LiftUpState PREVENTED The vehicle has reached the max...

Page 98: ...ailure log since the last power upevent 212 KEYSWITCH FAULTY None 2_1 Forceto GroundMode Both the Ground Select and Platform Select signals are energized which means there is an issue with the keyswit...

Page 99: ...TORNOT CENTERED None 2_2 DriveState PREVENTED LiftUpState PREVENTED LiftDownState PREVENTED Selected function Drive or Lift is not allowed because the joystick accelerator was not centered at power up...

Page 100: ...nce the control system detected that the pot hole protection mechanism failed to deploy Clear theobstacle blocking the pot hole protection mechanism repair the mechanical problem re adjust the pot hol...

Page 101: ...ENTED BatteryVoltage VBAT momentarily dropped below14 5Vwhen using flooded lead acid batteries or 16 0V when using AGM batteries With alow battery charge this can occur during heavy current demand due...

Page 102: ...Set BDI Percentage charge at 0 when the pump was activated Effect ShutdownPump PossibleCause Battery is fully discharged BDIparameters are mis tuned 4476 BATTERYVOLTAGETOOHIGH UNPLUG CHARGER None 4_4...

Page 103: ...hinery Directive 2014 30 EU EMC Directive 2014 53 EU RED Directive If fitted with optional equipment 2000 14 EC Outdoor Noise Directive NOTE This declaration conforms with the requirements of annex II...

Page 104: ...SECTION 6 SPECIFICATIONS AND OPERATOR MAINTENANCE 6 26 31215932 NOTES...

Page 105: ...SECTION 7 INSPECTION AND REPAIR LOG 31215932 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ DATE COMMENTS...

Page 106: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 31215932 DATE COMMENTS...

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Page 108: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 Visit our website for JLG Worldwide Locations www jlg com...