JLG 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 Illustrated Parts Manual 3120856 – PDF DOWNLOAD

Illustrated Parts Manual

Models 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 3120856 September 24, 2013

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

REVISION LOG July 1998 - Original Issue Of Manual (Edited to 0010549 Revision 10) February 26, 1999 - Revised Manual (Edited to 0010549 Revision 18) May 1, 1999 - Revised Manual (Edited to 0010549 Revision 21) June 29, 1999 - Updated Pages Cover, Effectivity Page, 8-9 & 8-10 August 30, 1999 - Revised Manual (Edited to 0010549 Revision 24) January 1, 2000 - Revised Manual (Edited to 0010549 Revision 31) June 15, 2000 - Revised Manual (Edited to 0010549 Revision 33) October 31, 2000 - Revised Manual (Edited to 0010549 Revision 35) January 30, 2001 - Revised Manual (Edited to 0010549 Revision 40) July 2, 2001 - Revised Manual (Edited to 0010549 Revision 45) October 29, 2001 - Revised Manual (Edited to 0010549 Revision 49) May 23, 2002 - Revised Manual (Edited to 0010549 Revision 57) September 20, 2002 - Revised Manual (Edited to 0010549 Revision 61) February 26, 2003 - Revised Manual (Edited to 0010549 Revision 65) June 26, 2003 - Revised Manual (Edited to 0010549 Revision 70) June 29, 2004 - Revised Manual (Edited to 0010549 Revision 73) April 7, 2005 - Revised Manual (Edited to 0010549 Revision 73) September 9, 2008 - Revised Manual November 30, 2011 - Revised Manual September 24, 2013 - Revised Manual

3120856

A

REVISION LOG

B

3120856

TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7

WHEEL DRIVE AND STEERING INSTALLATION - 1532E2 & 1932E2 . . . . . . . . . . . . . .1-2 DRIVE MOTOR ASSEMBLY - 1532E2 & 1932E2 (S/N 90870 to Present) . . . . . . . . . . . . .1-6 BRAKE INSTALLATION - 1532E2 & 1932E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 FRAME AND STEERING INSTALLATION - 2032E2/2632E2/2646E2/3246E2 . . . . . . . .1-10 WHEEL DRIVE AND BRAKE INSTALLATIONS - 2032E2/2632E2/2646E2/3246E2 . . . .1-14 DRIVE MOTOR ASSEMBLY - (2032E2/2646E2 S/N 90870 to Present) (2632E2/3246E2 S/N 90855 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 FRAME MOUNTED COMPONENTS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

SECTION 2 - GROUND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9

HYDRAULIC COMPONENTS INSTALLATIONS - 1532E2/1932E2 (Left Side) . . . . . . . .2-2 HYDRAULIC COMPONENTS INSTALLATIONS 2032E2/2632E2/2646E2/3246E2 (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 VALVE ASSEMBLY - STANDARD CONTROLS MACHINES . . . . . . . . . . . . . . . . . . . . . .2-10 VALVE ASSEMBLY - PROPORTIONAL CONTROLS MACHINES . . . . . . . . . . . . . . . . . .2-14 ELECTRICAL COMPONENTS INSTALLATION (LEFT SIDE OF MACHINES WITH STANDARD CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 ELECTRICAL COMPONENTS INSTALLATION (LEFT SIDE OF MACHINES WITH PROPORTIONAL CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 ELECTRICAL COMPONENTS INSTALLATION (RIGHT SIDE) . . . . . . . . . . . . . . . . . . . .2-26 BATTERY CHARGER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 POTHOLE PROTECTION AND TRAY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . .2-32

SECTION 3 - SIZZOR ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7

SCISSOR ARMS INSTALLATION - 1532E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 SCISSOR ARMS INSTALLATION - 1932E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 SCISSOR ARMS INSTALLATION - 2032E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 SCISSOR ARMS INSTALLATION - 2632E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 SCISSOR ARMS INSTALLATION - 2646E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 SCISSOR ARMS INSTALLATION - 3246E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 ARM GUARD INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10

PLATFORM AND ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 HANDRAILS INSTALLATION (1532E2/1932E2 AUSTRALIAN SPEC) . . . . . . . . . . . . . .4-6 HANDRAILS INSTALLATION (1532E2/1932E2 CE SPEC) . . . . . . . . . . . . . . . . . . . . . . .4-10 HANDRAILS INSTALLATION (2032E2 AUSTRALIAN SPEC) . . . . . . . . . . . . . . . . . . . . .4-14 HANDRAILS INSTALLATION (2032E2 CE SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 HANDRAILS INSTALLATION (2646E2/3246E2 AUSTRALIAN & CE SPEC) . . . . . . . . .4-22 PLATFORM CONSOLE BOX ASSEMBLIES (STANDARD CONTROLS MACHINES). . .4-26 PLATFORM CONSOLE BOX ASSEMBLIES (PROPORTIONAL CONTROLS MACHINES) . . 4-30 CONTROLLER ASSEMBLY (STANDARD CONTROLS MACHINES) . . . . . . . . . . . . . . .4-34 CONTROLLER ASSEMBLY (PROPORTIONAL CONTROLS MACHINES) . . . . . . . . . . .4-36

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4

3120856

BRAKE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LIFT CYLINDER COMPONENTS ASSEMBLY (1532E2 & 1932E2). . . . . . . . . . . . . . . . .5-4 LIFT CYLINDER COMPONENTS ASSEMBLY (2032E2) . . . . . . . . . . . . . . . . . . . . . . . . .5-8 LIFT CYLINDER COMPONENTS ASSEMBLY (2646E2) . . . . . . . . . . . . . . . . . . . . . . . .5-12

i

TABLE OF CONTENTS FIGURE NO. 5-5 5-6

TITLE

PAGE NO.

LIFT CYLINDER COMPONENTS ASSEMBLY (3246E2) . . . . . . . . . . . . . . . . . . . . . . . . 5-16 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7

HYDRAULIC DIAGRAM - 1532E2 & 1932E2 & 2032E2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HYDRAULIC DIAGRAM - 2646E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HYDRAULIC DIAGRAM - 3246E2 WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . 6-8 HYDRAULIC DIAGRAM - 3246E2 WITH PROPORTIONAL CONTROLS. . . . . . . . . . . . . 6-10 HYDRAULIC DIAGRAM - 2632E2 WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . 6-12 HYDRAULIC DIAGRAM - 2632E2 WITH PROPORTIONAL CONTROLS. . . . . . . . . . . . . 6-14 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-2 7-3 7-4 7-5 7-6

ELECTRICAL SCHEMATIC (AUSTRALIAN SPEC STANDARD CONTROLS MACHINES) . . . 7-2 ELECTRICAL SCHEMATIC (CE SPEC STANDARD CONTROLS MACHINES) . . . . . . . 7-4 ELECTRICAL SCHEMATIC (PROPORTIONAL CONTROLS MACHINES) . . . . . . . . . . . 7-6 ELECTRICAL COMPONENTS INSTALLATION (STANDARD CONTROLS MACHINES) 7-8 ELECTRICAL COMPONENTS INSTALLATION (PROPORTIONAL CONTROLS MACHINE) 7-14 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 8-2

DECALS INSTALLATION - 1532E2 & 1932E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 DECALS INSTALLATION - 2032E2 & 2646E2 & 3246E2 . . . . . . . . . . . . . . . . . . . . . . . . 8-6

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 SECTION 11 - INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

ii

3120856

SECTION 1 FRAME TABLE OF CONTENTS FIGURE

1-1 1-2 1-3 1-4 1-5 1-6 1-7

DESCRIPTION

PAGE

Wheel Drive And Steering Installation - 1532E2 & 1932E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Drive Motor Assembly - 1532E2 & 1932E2 (S/N 90870 to Present) . . . . . . . . . . . . . . . . . . . . . 1-6 Brake Installation - 1532E2 & 1932E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Frame And Steering Installation - 2032E2/2632E2/2646E2/3246E2 . . . . . . . . . . . . . . . . . . . . . 1-10 Wheel Drive And Brake Installations - 2032E2/2632E2/2646E2/3246E2 . . . . . . . . . . . . . . . . . 1-14 Drive Motor Assembly - (2032E2/2646E2 S/N 90870 to Present) (2632E2/3246E2 S/N 90855 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Frame Mounted Components Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

S E C T I O N 1 F R A M E

3120856

1-1

SECTION 1 FRAME S E C T I O N

FIGURE 1-1.

WHEEL DRIVE AND STEERING INSTALLATION - 1532E2 & 1932E2

2 9 1 4 19

1 F R A M E

8 11

22

7

17

1 3

16

12 13 15 14

6

23 10

5

18

25

21 20

12 15

102A 20 102 105

106 109 103 108 107

104

1-2

101

201

3120856

SECTION 1 FRAME .

FIGURE 1-1. WHEEL DRIVE AND STEERING INSTALLATION - 1532E2 & 1932E2 FIG & ITEM #

PART NUMBER 0258015

1 2 3 4 5 6 7 8 9 10

0100019 0100081 0630516 0641611 0962208 0962173 0962174 1120064 1120515 Use 1684225

11 12 13 14 15 16 17 18 19 20 21 22 23

1684225 2160006 3430811 3431014 3450404 3450406 3790218 3841378 4130356 4711600 4711800 4712000 4740419 Use 1440329 1440329

24 25

3020025 3312002

0258171 0271221 101

102 102A 103

0641824 0681822 2780216 7012613 3160229 7018996 7018997

3120856

DESCRIPTION STEERING INSTALLATION Loctite #271 Loctite #454 Bolt, Shoulder Bolt 3/8”-16NC x 1 3/8” Spacer, Bushing Bushing Bushing Cap, Grease Fitting (Prior to S/N 84437) Cap, Plastic Steer Cylinder Assembly (See Section 5 for Breakdown) Prior to S/N 67287 (Was P/N 1683661) S/N 67287 to S/N 108168 (Was P/N 1683832) S/N 108168 to Present Fitting, Grease (Prior to S/N 84437) Pin, Clevis Pin, Clevis (Prior to S/N 50027) Pin, Cotter 1/8” x 1” (Prior to S/N 50027) Pin, Cotter 1/8” x 1 1/2” O-Ring (Prior to S/N 101149) Tie-Rod Spindle Flatwasher 3/8” Narrow Flatwasher 1/2” Narrow Flatwasher 5/8” Narrow (Prior to S/N 50027) Thrustwasher Collar: Prior to S/N 99064(1932E2)/ Prior to June 13, 2001(1532E2)(Was P/N 1440326) S/N 99064 to Present (1932E2)/ June 13, 2001to Present (1532E2) Grease (Not Shown) (Prior to S/N 108196) Jam Nut (S/N 103651 to Present) WHEEL DRIVE INSTALLATION OPTIONS: (Prior to S/N 90870) (S/N 90870 to Present) Bolt Options: Bolt 1/2”-13NC x 3” (Prior to S/N 49303) Bolt 1/2”-13NC x 2 3/4” (S/N 49303 to Present) Hub Assembly Bolt, Wheel (5 Per Hub) Drive Motor Assembly Options: (Prior to S/N 90870) Key, Shaft Nut, Castle

QTY.

REV.

Ref.

J

A/R A/R 2 2 2 2 4 2 2 1

1 F R A M E

2 A/R 1 1 A/R 2 1 2 2 A/R 2 2 2

A/R 2 Ref. Ref. Ref.

S E C T I O N

F A

8

2 10 2 1 1

1-3

SECTION 1 FRAME S E C T I O N

FIGURE 1-1. WHEEL DRIVE AND STEERING INSTALLATION - 1532E2 & 1932E2 (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

103 (cont’d)

7021312 7021317 3160269 3300255 See Note

Seal, Shaft Oil (Inner Seal) Seal, Dust (Outer Seal) (S/N 90870 to Present) (See Figure 1-2 for Breakdown) Nut, Wheel Nut (Note: See Breakdown of Individual Motor) Hardware Options: Locknut 1/2”-13NC (Grade 8) (Prior to S/N 49303) Nut 1/2”-13NC (S/N 49303 to S/N 84080) Nut 1/2”-13NC (S/N 84080 to Present) Pin, Cotter 1/8” x 1 1/2” Flatwasher 1/2” Narrow (Was P/N 4891800 Prior to S/N 90870) Lockwasher 1/2” (S/N 49303 to S/N 84080) Loctite #271(Prior to S/N 84080)

1 1

104 105 106

107 108

3271805 3311801 3300450 3450406 Use 4740453

109 110

4761800 0100019

1 F R A M E

2 8 8 A/R

4860180 4860182

Ref. Ref. Ref. 4 A/R A/R

FRAME OPTIONS Prior to S/N 50363 S/N 50363 to Present

1

2360459 2360482

201

1-4

10 2 8

TIRE AND WHEEL INSTALLATIONS Black Tire and Wheel Installation Gray Non-Marking Tire and Wheel Installation Tire Options: Standard Black Non-Marking Gray

0258167 0258166

REV.

1 1

3120856

SECTION 1 FRAME FIGURE 1-1. WHEEL DRIVE AND STEERING INSTALLATION - 1532E2 & 1932E2 (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 1 F R A M E

3120856

1-5

SECTION 1 FRAME S E C T I O N

FIGURE 1-2.

ENT)

DRIVE MOTOR ASSEMBLY - 1532E2 & 1932E2 (S/N 90870 TO PRES-

1 F R A M E

1-6

3120856

SECTION 1 FRAME .

FIGURE 1-2. DRIVE MOTOR ASSEMBLY - 1532E2 & 1932E2 (S/N 90870 TO PRESENT) FIG & ITEM #

PART NUMBER 3160269

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

7023451 Not Used Use Item 100 Not Serviceable Use Item 100 Use Item 100 7023452 7023453 7023454 7023455 7023456 Use Item 100 7023457 7023458 7023459 7023460 7023461 7023462 7023463 Use Item 100 7023464 7023465 Not Serviceable Use Item 100 7023466 Not Serviceable

DESCRIPTION DRIVE MOTOR ASSEMBLY

3120856

7023450

REV. B

Nut, Castle

1

Seal, Dust Housing O-Ring Seal, Shaft Bearing, Race Bearing, Needle Bearing, Needle Key Shaft, Output O-Ring Washer, Spring Plate, Pressure Disc, Valve Bearing, Needle Washer, Glacier Plate Shaft, Cardan O-Ring Wheel, Gear Set Cover, End I.D. Tag Washer Screw Plug

1

KIT OPTIONS: 100

QTY. Ref.

Kit, Seal (Includes Items 3, 5-6, 12, 20, 24)

1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 7 7 2

S E C T I O N 1 F R A M E

Ref. 1

1-7

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL