JLG 1532E2, 1932E2, 2032E2, 2632E2, 2646E2 & 3246E2 Lift Service and Maintenance Manual (ANSI)

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This service manual PDF download for the 1532E2, 1932E2, 2032E2, 2632E2, 2646E2 & 3246E2 JLG Telescopic Boom Lift / Electric Self Propelled Scissor Lifts has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Sizzor 1532E2
JLG Sizzor 1932E2
JLG Sizzor 2032E2
JLG Sizzor 2632E2
JLG Sizzor 2646E2
JLG Sizzor 3246E2


TABLE OF CONTENTS :

Section 1. Specifications
    1.1 Capacities
    1.2 Component Data
    1.3 Performance Data
    1.4 Torque Requirements
    1.5 Lubrication
    1.6 Serial Number Locations
    1.7 Limit Switches
    1.8 Cylinder Specifications
    1.9 Pressure Settings
    1.10 Major Component Weights
    1.11 Critical Stability Weights
    
Section 2. Procedures
    2.1 General
    2.2 Servicing and Maintenance Guidelines
    2.3 Lubrication Information
    2.4 Cylinders - Theory of Operation
    2.5 Valves - Theory of Operation
    2.6 Component Functional Description
    2.7 Wear Pads
    2.8 Cylinder Checking Procedures
    2.9 Lift Cylinder Removal and Installation
    2.10 Lift Cylinder Repair
    2.11 Brake Cylinder Repair
    2.12 Steer Cylinder Repair
    2.13 Drive Motor (Sauer Danfoss)
    2.14 Drive Motor (Rexroth)
    2.15 Drive Motor (Parker)
    2.16 Tilt Switch Adjustment
    2.17 Voltmeter Adjustment
    2.18 Pressure Setting procedures
    2.19 Limit Switch Adjustment
    2.20 Door Adjustment
    2.21 JLG SMART System™ Analyzer Kit Instructions
    2.22 Machine Personality Settings
    2.23 Machine Model Default Settings
    2.24 Machine Configuration Information
    2.25 Jlg Smart System™ Help Messages and Flash Codes
    2.26 Analyzer Menu Structure
    2.27 Preventive Maintenance and Inspection Schedule
    
Section 3. Troubleshooting
    3.1 General
    3.2 Troubleshooting Information
    3.3 Hydraulic Circuit Checks


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3120737
Total Pages : 86


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
    A.A General
    A.B Hydraulic System Safety
    A.C Maintenance
    
Section 1. Specifications
    1.1 Capacities
        Hydraulic Oil Tank
        Hydraulic System (Including Tank)
    1.2 Component Data
        Hydraulic Pump/Electric Motor Assembly (All Models)
        Battery Charger
        Batteries (4)
        Steer/Drive System
        Hydraulic Filter - Inline
        Platform Size
    1.3 Performance Data
        Travel Speed
        Gradeability
        Inside Turning Radius
        Lift (No Load in Platform)
        Platform Capacity
        Manual Platform Extension Capacity
        Machine Weight
        Wheelbase
        Platform Height (Elevated)
        Platform Height (Stowed)
        Machine Height - Standard Handrails (Stowed)
        Machine Length
        Machine Width
        Ground Clearance with Platform Lowered
        Maximum Tire Load
        Maximum Bearing Pressure
    1.4 Torque Requirements
    1.5 Lubrication
        Hydraulic Oil
        Lubrication Specifications
    1.6 Serial Number Locations
    1.7 Limit Switches
        Tilt Alarm
        High Drive Cut-Out
        Overload Protection (Japanese and French Specification Only)
    1.8 Cylinder Specifications
    1.9 Pressure Settings
        Pressure Settings for Non Proportional Control Machines
        Pressure Settings for Proportional Control Machines
    1.10 Major Component Weights
    1.11 Critical Stability Weights
    
Section 2. Procedures
    2.1 General
    2.2 Servicing and Maintenance Guidelines
        General
        Safety and Workmanship
        Cleanliness
        Components Removal and Installation
        Component Disassembly and Reassembly
        Pressure Washing
        Pressure-Fit Parts
        Bearings
        Gaskets
        Bolt Usage and Torque Application
        Hydraulic Lines and Electrical Wiring
        Hydraulic System
        Lubrication
        Batteries
        Lubrication and Servicing
    2.3 Lubrication Information
        Hydraulic System
        Hydraulic Oil
        Changing Hydraulic Oil
        Lubrication Specifications
    2.4 Cylinders - Theory of Operation
    2.5 Valves - Theory of Operation
        Solenoid Control Valves (Bang-Bang)
        Relief Valves
        Crossover Relief Valves
    2.6 Component Functional Description
        Hydraulic Pump
    2.7 Wear Pads
        Sliding Pads
    2.8 Cylinder Checking Procedures
        Cylinder w/o Holding Valves - Brake Cylinder and Steer Cylinder
        Cylinders w/Single Holding Valves - Lift Cylinder
    2.9 Lift Cylinder Removal and Installation
        Lift Cylinder Removal
        Lift Cylinder Installation
    2.10 Lift Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    2.11 Brake Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    2.12 Steer Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    2.13 Drive Motor (Sauer Danfoss)
        Dismantling
        Assembly
    2.14 Drive Motor (Rexroth)
        Disassembly
        Assembly
    2.15 Drive Motor (Parker)
        Disassembly and inspection
        Assembly
        One Piece Stator Construction
    2.16 Tilt Switch Adjustment
        Manual Adjustment
    2.17 Voltmeter Adjustment
    2.18 Pressure Setting procedures
        Lift Relief for Non Proportional Control Machines
        Steer Adjustment for Non Proportional Control Machines
        Main Relief Pressure Switch for Non Proportional Control Machines
        Lift Relief Adjustments for Proportional Control Machines
        Steer Adjustment for Proportional Control Machines
        Main Relief and High Drive Pressure Switch for Proportional Control Machines
    2.19 Limit Switch Adjustment
        Elevation Switch
    2.20 Door Adjustment
    2.21 JLG SMART System™ Analyzer Kit Instructions
        INTRODUCTION
        To Connect the Hand Held Analyzer:
        Using the Analyzer:
        Changing the Access Level of the Hand Held Analyzer:
        Adjusting Configuration Using the Hand Held Analyzer on All 1600286 Controllers:
    2.22 Machine Personality Settings
    2.23 Machine Model Default Settings
    2.24 Machine Configuration Information
    2.25 Jlg Smart System™ Help Messages and Flash Codes
    2.26 Analyzer Menu Structure
    2.27 Preventive Maintenance and Inspection Schedule
    
Section 3. Troubleshooting
    3.1 General
    3.2 Troubleshooting Information
    3.3 Hydraulic Circuit Checks
    
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