Models - JLG Industries

1 SERVICE & maintenance . Models 1532E2. 1932E2. 2032E2. 2632E2. 2646E2. 3246E2. 3120737. February 14, 2012. INTRODUCTION - maintenance SAFETY PRECAUTIONS. SECTION A. INTRODUCTION - maintenance SAFETY. PRECAUTIONS. Relieve system pressure by cycling the applicable GENERAL. control several times with the engine stopped and This section contains the general safety precautions ignition on, to direct any line pressure back into the which must be observed during maintenance of the reservoir. Pressure feed lines to system components aerial platform. It is of utmost importance that main- can then be disconnected with minimal fluid loss. tenance personnel pay strict attention to these warn- ings and precautions to avoid possible injury to themselves or others, or damage to the equipment.

2 maintenance . A maintenance program must be followed to ensure that the machine is safe to operate. FAILURE TO COMPLY WITH SAFETY PRECAUTIONS. LISTED IN THIS SECTION MAY RESULT IN MACHINE. DAMAGE, PERSONNEL INJURY OR DEATH AND IS A. MODIFICATION OF THE MACHINE WITHOUT CERTIFI- SAFETY VIOLATION. CATION BY A RESPONSIBLE AUTHORITY THAT THE. MACHINE IS AT LEAST AS SAFE AS ORIGINALLY NO SMOKING IS MANDATORY. NEVER REFUEL DUR- MANUFACTURED, IS A SAFETY VIOLATION. ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP. IS CLOSED AND SECURE AT ALL OTHER TIMES. The specific precautions to be observed during REMOVE ALL RINGS, WATCHES AND JEWELRY. maintenance are inserted at the appropriate point in WHEN PERFORMING ANY maintenance . the manual. These precautions are, for the most part, those that apply when servicing hydraulic and DO NOT WEAR LONG HAIR UNRESTRAINED, OR.

3 LOOSE-FITTING CLOTHING AND NECKTIES WHICH. larger machine component parts. ARE APT TO BECOME CAUGHT ON OR ENTANGLED. IN EQUIPMENT. Your safety, and that of others, is the first consider- OBSERVE AND OBEY ALL WARNINGS AND CAU- ation when engaging in the maintenance of equip- TIONS ON MACHINE AND IN SERVICE MANUAL. ment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical KEEP OIL, GREASE, WATER, ETC. WIPED FROM. device. Do not allow heavy objects to rest in an STANDING SURFACES AND HAND HOLDS. unstable position. When raising a portion of the USE CAUTION WHEN CHECKING A HOT, PRESSUR- equipment, ensure that adequate support is pro- IZED COOLANT SYSTEM. vided. NEVER WORK UNDER AN ELEVATED BOOM UNTIL. BOOM HAS BEEN SAFELY RESTRAINED FROM ANY.

4 MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED. SINCE THE MACHINE MANUFACTURER HAS NO. DIRECT CONTROL OVER THE FIELD INSPECTION BEFORE MAKING ADJUSTMENTS, LUBRICATING OR. AND maintenance , SAFETY IN THIS AREA RESPON- PERFORMING ANY OTHER maintenance , SHUT. SIBILITY OF THE OWNER/OPERATOR. OFF ALL POWER CONTROLS. BATTERY SHOULD ALWAYS BE DISCONNECTED DUR- ING REPLACEMENT OF ELECTRICAL COMPONENTS. HYDRAULIC SYSTEM SAFETY. KEEP ALL SUPPORT EQUIPMENT AND ATTACH- It should be noted that the machines hydraulic sys- MENTS STOWED IN THEIR PROPER PLACE. tems operate at extremely high potentially danger- USE ONLY APPROVED, NONFLAMMABLE CLEANING. ous pressures. Every effort should be made to SOLVENTS. relieve any system pressure prior to disconnecting or removing any portion of the system.

5 3120737 JLG Lift a INTRODUCTION - maintenance SAFETY PRECAUTIONS. REVISION LOG. Original Issue - February 1998. May 1998 - Revised February 1999 - Revised November 2, 1999 - Revised July 21, 2000 - Revised April 27, 2001 - Revised September 7, 2001 - Revised January 16, 2002 - Revised April 25, 2002 - Revised May 15, 2002 - Revised August 26, 2003 - Revised November 21, 2003 - Revised May 10, 2006 - Revised February 14, 2012 - Revised b JLG Lift 3120737. TABLE OF CONTENTS. TABLE OF CONTENTS. SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - maintenance SAFETY PRECAUTIONS. General .. a-a Hydraulic System Safety .. a-a maintenance .. a-a SECTION 1 - SPECIFICATIONS. Capacities .. 1-1. Component Data .. 1-1. Performance Data.. 1-1. Torque Requirements .. 1-3.

6 Lubrication .. 1-3. Serial Number Locations .. 1-4. Limit Switches .. 1-4. Cylinder Specifications .. 1-4. Pressure Settings .. 1-5. Major Component Weights.. 1-6. Critical Stability Weights .. 1-6. SECTION 2 - PROCEDURES. General .. 2-1. Servicing and maintenance Guidelines .. 2-1. Lubrication Information.. 2-2. Cylinders - Theory of Operation .. 2-3. Valves - Theory of Operation .. 2-3. Component Functional Description .. 2-4. Wear Pads.. 2-4. Cylinder Checking Procedures .. 2-4. Lift Cylinder Removal and Installation .. 2-5. Lift Cylinder Repair .. 2-5. Brake Cylinder Repair.. 2-8. Steer Cylinder Repair .. 2-10. Drive Motor (Sauer Danfoss) .. 2-13. Drive Motor (Rexroth) .. 2-14. Drive Motor (Parker) .. 2-15. Tilt Switch Adjustment .. 2-30. Voltmeter Adjustment .. 2-30.

7 Pressure Setting procedures .. 2-32. Limit Switch Adjustment .. 2-35. Door Adjustment.. 2-35. JLG SMART System Analyzer Kit Instructions .. 2-36. Machine Personality Settings .. 2-40. Machine model Default Settings .. 2-41. Machine Configuration Information .. 2-42. Jlg Smart System Help Messages and Flash Codes .. 2-44. Analyzer Menu Structure .. 2-47. Preventive maintenance and Inspection Schedule .. 2-53. SECTION 3 - TROUBLESHOOTING. General .. 3-1. Troubleshooting Information .. 3-1. Hydraulic Circuit Checks .. 3-1. 3120737 JLG Lift i TABLE OF CONTENTS. LIST OF FIGURES. FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location..1-5. 1-2. Torque Chart ..1-7. 2-1. Lift Cylinder Components Assembly..2-6. 2-1. Barrel Support ..2-6. 2-2. Cylinder Head Retainer Cap Screw Removal.

8 2-6. 2-3. Rod Support ..2-7. 2-4. Rod Seal Installation ..2-7. 2-5. Brake Cylinder Assembly ..2-9. 2-5. Steer Cylinder Assembly ..2-11. 2-5. Drive Motor (Sauer Danfoss)..2-13. 2-6. Parker Drive Motor ..2-16. 2-7. Tilt Switch Leveling Manual Adjustment ..2-30. 2-8. Tilt Switch Leveling Voltmeter Adjustment ..2-31. 2-9. Control Valve Components ..2-31. 2-10. Control Valve Components (2632E2/3246E2 w/Proportional Control) ..2-34. 2-11. Quick Welder Installation ..2-35. 2-12. JLG SMART System Controller ..2-36. 2-13. Organizational Chart ..2-39. 3-1. Electrical Schematic - Non Proportional Control (Sheet 1 of 2) ..3-4. 3-1. Electrical Schematic - Non Proportional Control (Sheet 2 of 2) ..3-5. 3-2. Electrical Schematic - Non Proportional Control (Sheet 1 of 2) ..3-6. 3-2. Electrical Schematic - Non Proportional Control (Sheet 2 of 2).

9 3-7. 3-3. Electrical Schematic - Proportional Control (Sheet 1 of 2)..3-8. 3-3. Electrical Schematic - Proportional Control (Sheet 2 of 2)..3-9. 3-5. Hydraulic Schematic - Non Proportional Control ..3-10. 3-6. Hydraulic Schematic - Proportional Control (Sheet 1 of 2) ..3-11. 3-7. Hydraulic Schematic - Proportional Control (Sheet 2 of 2) ..3-12. 3-8. Harness and Cable Assembly - Non Proportional Control (Sheet 1 of 2) ..3-13. 3-9. Harness and Cable Assembly - Non Proportional Control (Sheet 2 of 2) ..3-14. LIST OF TABLES. TABLE NO. TITLE PAGE NO. 1-1 Torque Requirements ..1-3. 1-2 Hydraulic Oil ..1-3. 1-3 Lubrication Specifications ..1-3. 1-4 Cylinder Specifications ..1-4. 1-5 Major Component Weights ..1-6. 1-6 Critical Stability Weights ..1-6. 2-1 Cylinder Component Torque Specifications.

10 2-8. 2-2 Holding Valve Torque Specifications ..2-8. 2-3 Pressure Settings Chart ..2-33. 2-4 Machine Personality Settings ..2-40. 2-5 Machine model Default Settings Chart ..2-41. 2-6 Machine Configuration Programming Information ..2-42. 2-7 Help Messages ..2-44. 2-8 JLG SMART System Flash Codes & Help Messages ..2-45. 2-9 Analyzer Menu Structure..2-47. 2-10 Preventive maintenance and Inspection Schedule ..2-54. 3-1 Electrical Troubleshooting Chart ..3-2. 3-2 Hydraulic System Troubleshooting Chart..3-3. ii JLG Lift 3120737. SECTION 1 - SPECIFICATIONS. SECTION 1. SPECIFICATIONS. Tires - 2032E2/2632E2/2646E2/3246E2. CAPACITIES. Standard - x - Solid, Non-Marking Hydraulic Oil Tank Optional - x - Solid, Rib 1532E2/1932E2. Parking Brake - All Models - Dual wheel (rear) Single cylin- gallons ( liters) at full mark on tank der, spring applied, hydraulically released gallons ( liters) at add mark on tank Drive Motors 2032E2/2632E2/2646E2/3246E2 1532E2/1932E2 - in3 (126 cm3) displacement gallons ( liters) at full mark on tank 2032E2 in3 ( cm3) displacement gallons ( liters) at add mark on tank 2632E2 in3 ( cm3) displacement 2646E2 in3 ( cm3) displacement Hydraulic System (Including Tank).