Jlg 3246E2 ANSI Service Manual User Manual

Models1532E21932E22032E22632E22646E23246E23120737February 14, 2012SERVICE & MAINTENANCE

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31207371.6 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the machin

SECTION 1 - SPECIFICATIONS3120737 – JLG Lift – 1-51.9 PRESSURE SETTINGSPressure Settings for Non Proportional Control Machines Main Relief Max - 3200

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31207371.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILI

SECTION 1 - SPECIFICATIONS3120737 – JLG Lift – 1-7Figure 1-2. Torque Chart

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120737This page left blank intentionally.

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on th

SECTION 2 - PROCEDURES2-2 – JLG Lift – 3120737Pressure-Fit PartsWhen assembling pressure-fit parts, use an “anti-seize” ormolybdenum disulfide base co

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-33. Cloudy oils indicate a high moisture content whichpermits organic growth, resulting in oxidation or c

SECTION 2 - PROCEDURES2-4 – JLG Lift – 3120737machine fitted in the bore of the valve body. Lands on thespool divide the bore into various chambers, w

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-51. Using all applicable safety precautions, activatehydraulic system.WHEN WORKING ON THE LIFT CYLINDER,

SECTION 2 - PROCEDURES2-6 – JLG Lift – 31207375. If applicable, using a suitable spanner wrench,loosen the spanner nut retainer and remove thespanner

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-710. Vise - up on the wrench flats on the end of the rodand remove the piston Locknut.NOTE: Locknut hex s

SECTION 2 - PROCEDURES2-8 – JLG Lift – 3120737WHEN INSTALLING NEW “PARKER” TYPE PISTON SEALS,ENSURE SEALS ARE INSTALLED PROPERLY. IMPROPER SEALINSTALL

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-91. Attach a suitable pulling device to the cylinder rodend.EXTREME CARE SHOULD BE TAKEN WHEN REMOVING TH

SECTION 2 - PROCEDURES2-10 – JLG Lift – 31207378. Inspect seal and o-ring grooves in guide for burrsand sharp edges. Dress applicable surfaces as nec-

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-1111. Remove the cylinder rod from the holding fixture.Cleaning and Inspection1. Clean all parts thorough

SECTION 2 - PROCEDURES2-12 – JLG Lift – 31207373. Carefully install the cylinder rod guide on rod sectionone, ensuring that the wiper ring and rod sea

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-132.13 DRIVE MOTOR (SAUER DANFOSS)Dismantling1. Place motor in proper holding device that allowsaccess to

SECTION 2 - PROCEDURES2-14 – JLG Lift – 3120737AssemblyNOTE: Before assembly, inspect all parts and replace if nec-essary.Before assembly, lubricate a

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-158. Loosen the 8 socket head cap screws on the flangemounting using a 4mm allan wrench.9. Withdraw the f

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120737 – JLG Lift – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section co

SECTION 2 - PROCEDURES2-16 – JLG Lift – 31207373. Remove the five, six, or seven special ring headbolts (1) using an appropriate 1/2 or 9/16 inch size

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-175. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previously loosenedp

SECTION 2 - PROCEDURES2-18 – JLG Lift – 31207379. Remove manifold (7) and inspect for cracks surfacescoring, brinelling or spalling. Replace manifold

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-19NOTE: If rotor set (8) has two stator halves (8B & 8D) andtwo sets of seven vanes (8C & 8E) as

SECTION 2 - PROCEDURES2-20 – JLG Lift – 312073716. 16. Remove and discard seal ring (4) from housing(18).17. Remove thrust bearing (15) and thrust was

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-2121. If the housing (18) assembly has passed inspectionto this point, inspect the housing bearings/bushi

SECTION 2 - PROCEDURES2-22 – JLG Lift – 3120737AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlink™ unit. Lubr

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-232. The Torqlink™ inner housing bearing/bushing (13)can now be pressed into its counterbore in housing(1

SECTION 2 - PROCEDURES2-24 – JLG Lift – 31207374. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, clamping agains

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-25THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-TEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLYPACK

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3120737REVISION LOGOriginal Issue - February 1998May 1998 - RevisedFebruary 1999 - Revised

SECTION 2 - PROCEDURES2-26 – JLG Lift – 312073711. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (18).12. Apply

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-2716. Apply grease to a new seal ring (4) and insert it inthe seal ring groove exposed on the manifold.17

SECTION 2 - PROCEDURES2-28 – JLG Lift – 3120737NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previously scribed on

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-29One Piece Stator ConstructionA disassembled rotor (8A) stator (8B) and vanes (8C) thatcannot be readily

SECTION 2 - PROCEDURES2-30 – JLG Lift – 31207372.16 TILT SWITCH ADJUSTMENTNOTE: The machine is equipped with a tilt switch (sensor),factory set to act

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-31Figure 2-8. Tilt Switch Leveling Voltmeter AdjustmentFigure 2-9. Control Valve Components

SECTION 2 - PROCEDURES2-32 – JLG Lift – 31207372.18 PRESSURE SETTING PROCEDURES NOTE: Make all pressure adjustments with motor operatingand hydraulic

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-33 Table 2-3. Pressure Settings ChartFunction1532E2 1932E2 2032E22632E2/2646E2/3246E23246E2 w/Proportio

SECTION 2 - PROCEDURES2-34 – JLG Lift – 3120737 Figure 2-10. Control Valve Components (2632E2/3246E2 w/Proportional

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-352.19 LIMIT SWITCH ADJUSTMENTElevation SwitchOn the 1532E2/1932E2/3246E2 there is a platform limitswitch

TABLE OF CONTENTS3120737 – JLG Lift – iTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTION

SECTION 2 - PROCEDURES2-36 – JLG Lift – 31207372.21 JLG SMART SYSTEM™ ANALYZER KIT INSTRUCTIONSNOTE: The following instructions involving the JLG SMAR

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-37To Connect the Hand Held Analyzer: 1. Connect the four pin end of the cable supplied withthe analyzer,

SECTION 2 - PROCEDURES2-38 – JLG Lift – 3120737Once the correct password is displayed, press ENTER. The access level should display the following, if

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-39Figure 2-13. Organizational Chart

SECTION 2 - PROCEDURES2-40 – JLG Lift – 31207372.22 MACHINE PERSONALITY SETTINGS Table 2-4. Machine Personality SettingsPERSONALITY MIN MAXDRIVE-ACCE

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-412.23 MACHINE MODEL DEFAULT SETTINGS Table 2-5. Machine Model Default Settings Chart Adjustment 2632E2/

SECTION 2 - PROCEDURES2-42 – JLG Lift – 31207372.24 MACHINE CONFIGURATION INFORMATIONNOTE: The following information is to be used when workingwith th

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-435(FUNCTION CUTOUT)01No function cutout installed.Overload switch for French, Japanese machines. — Cuts

SECTION 2 - PROCEDURES2-44 – JLG Lift – 31207372.25 JLG SMART SYSTEM™ HELP MESSAGES AND FLASH CODES Table 2-7. Help MessagesNO FLASH CODE IS IND

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-45Table 2-8. JLG SMART System™ Flash Codes & Help MessagesCode Description2-1 - Indicates problems wi

TABLE OF CONTENTSii – JLG Lift – 3120737LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . .

SECTION 2 - PROCEDURES2-46 – JLG Lift – 31207373-3 - Indicates that a contactor coil is short-circuit SHORT-CIRCUIT LINE CONTACTOR COIL - The line con

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-472.26 ANALYZER MENU STRUCTURE In the following structure descriptions, an intended item isselected by pr

SECTION 2 - PROCEDURES2-48 – JLG Lift – 3120737DIAGNOSTICS/SYSTEMS (Continued)SYSTEMSBATTERYTEMPERATUREPUMP VOLTPUMP AMPELEVATIONDi

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-49DIAGNOSTICS/SYSTEMS (Continued)DATALOGONDRIVELIFTDECKPUMPRENTALERASE RENTAL(YES:ENTE

SECTION 2 - PROCEDURES2-50 – JLG Lift – 3120737ACCESS LEVEL CODEDisplays the current access levelLevel 3 - Personalities cannot be changedLevel 2 - Mo

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-51PERSONALITIES (Continued) DECKACCELDECELCREEPMAX OUTMAX INDisplays/adjusts deck accelerationDisplays/ad

SECTION 2 - PROCEDURES2-52 – JLG Lift – 3120737MACHINE SETUPCALIBRATIONSMODEL NUMBERTILT SWITCHPOWER DECKDECK EXT. LIMITFUNCTION CUTOUTGROUND ALARMDRI

SECTION 2 - PROCEDURES3120737 – JLG Lift – 2-532.27 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks are

SECTION 2 - PROCEDURES2-54 – JLG Lift – 3120737Table 2-10. Preventive Maintenance and Inspection ScheduleDaily Weekly Monthly 3 Month 6 Month 1 YearPL

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 1 - SPECIFICATIONS3120737 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil Tank1532E2/1932E23.0 gallons (11.4 liters) at

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120737Table 3-1. Electrical Troubleshooting ChartTROUBLE PROBABLE CAUSE REMEDYAll machine functions do no

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-3Table 3-2. Hydraulic System Troubleshooting ChartTROUBLE PROBABLE CAUSE REMEDYHydraulic pump noisyA

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120737 Figure 3-1. Electrical Schematic - Non Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-5 Figure 3-1. Electrical Schematic - Non Proportional Control (Sheet 2 of 2)1870080_G

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120737 Figure 3-2. Electrical Schematic - Non Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-71870116 CFigure 3-2. Electrical Schematic - Non Proportional Control (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120737 U3JLG SMART SYSTEMMICROPROCESSORFigure 3-3. Electrical S

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-9U3JLG SMART SYSTEMMICROPROCESSOR1870107 CNOT USED ON 2632E2NOTE: NO CONNECTION BETWEENELEVATION SWI

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120737NOTE: CASE DRAIN IS ONLY FOR 3246E2;THEREFORE, 2646E2 LIFT CYL HOSES MUSTBE CONNECTED DIRECTLY TO

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-11This page left blank intentionally.

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31207373246E2Low Speed - 1.4 mph (2.1 kmh)Elevated Speed - 0.5 mph (0.8kmh)Maximum Speed - 2.0 mph (3.2 kmh

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120737 Figure 3-5. Hydraulic Schematic - Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-132792496 AFigure 3-6. Hydraulic Schematic - Proportional Control (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120737Figure 3-7. Harness and Cable Assembly - Non Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120737 – JLG Lift – 3-15Figure 3-8. Harness and Cable Assembly - Non Proportional Control (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120737This page left blank intentionally.

JLG Worldwide Locations3120737Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417

SECTION 1 - SPECIFICATIONS3120737 – JLG Lift – 1-3Machine Width1532E2/1932E2 - 31.75 in (0.8 m)2032E2/2632E2 - 31.75 in (0.8 m)2646E2/3246E2 - 45.75 i