JLG 1532E2 Service & Maintenance
  1. Manuals
  2. Brands
  3. JLG Manuals
  4. Lifting Systems
  5. 1532E2
  6. Service & maintenance
JLG 1532E2 Service & Maintenance

JLG 1532E2 Service & Maintenance

Hide thumbs Also See for 1532E2:
Table of Contents

Advertisement

Quick Links

SERVICE & MAINTENANCE
Models
1532E2
1932E2
2032E2
2632E2
2646E2
3246E2
3120855
May 10, 2006

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 1532E2 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for JLG 1532E2

Summary of Contents for JLG 1532E2

  • Page 1 SERVICE & MAINTENANCE Models 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 3120855 May 10, 2006...

  • Page 3: Hydraulic System Safety

    • 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. 3120855 – JLG Sizzor –...
  • Page 4 - April 17, 2001 Revised January 16, 2002 Revised April 25, 2002 May 15, 2002 - Revised August 26, 2003 - Revised June 25, 2004 - Revised November 8, 2004 - Revised May 10, 2006 - Revised – JLG Sizzor – 3120855...

  • Page 5: Table Of Contents

    Jlg Smart System™ Help Messages and Flash Codes ....... . .2-26...
  • Page 6 JLG SMART System™ Flash Codes & Help Messages ....... . .2-27...

  • Page 7: Section 1. Specifications

    Optional -16.00 x 5.00 - Solid, Rib Low Speed - 2.1 kmh Parking Brake ( rear dual wheel) - Single cylinder, spring Elevated Speed - 0.8 kmh applied, hydraulically released. Maximum Speed - 3.2 kmh 3120855 – JLG Sizzor –...
  • Page 8 2032E2/2632E2/2646E2/3246E2 - 2.3 m 2646E2 - 340 kg Machine Width 3246E2 - 320 kg 1932E2 - 0.8 m Manual Platform Extension Capacity 2032E2 - 0.8 m All Models - 120 kg. - 1 person 2646E2/3246E2 -1.2 m – JLG Sizzor– 3120855...

  • Page 9: Torque Requirements

    SAE viscosity of 10W-30 1932E2 - 6.4 kg/cm and a viscosity index of 152. When temperatures remain consistently below -20 F (-7 C), JLG recom- 2032E2 - 7.0 kg/cm mends the use of MobilDTE13M hydraulic oil.

  • Page 10: Serial Number Locations

    (3.8) (15.9) (1.9) 2032E2 - 2.1 m Brake Cylinder 2.00 1.75 1.00 (All Models) (5.1) (4.4) (2.5) 2632E2 (Australian Only) - 2.9 m 2632E2/2646E2 - 2.6 m 3246E2 - 2.8 m Figure 1-1. Serial Number Location – JLG Sizzor– 3120855...

  • Page 11: Pressure Settings

    (19 kg) Batteries - Std.- Each 63 lb 63 lb 63 lb (29 kg) (29 kg) (29 kg) Batteries - Standard - 252 lb 252 lb 252 lb Combined (114 kg) (114 kg) (114 kg) 3120855 – JLG Sizzor –...

  • Page 12: Torque Chart

    SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart. – JLG Sizzor– 3120855...

  • Page 13: Section 2. Procedures

    Inc. recommends a maximum pressure of 52 bar at a long service life of a machine is to keep dirt and for- minimum distance of 30.5 cm. away. In addition, JLG eign materials out of the vital components. Precau- Industries Inc.

  • Page 14: Lubrication Information

    Clearly mark or tag hydraulic lines and electrical wiring, as fied intervals required in Section 1. Always examine well as their receptacles, when disconnecting or removing filters for evidence of metal particles. them from the unit. This will assure that they are correctly reinstalled. – JLG Sizzor – 3120855...

  • Page 15: Cylinders - Theory Of Operation

    2.4 CYLINDERS - THEORY OF OPERATION ranges. Cylinders are of the double acting type. The Steer sys- 2. JLG recommends Mobilfluid 424, which has an SAE tems incorporate double acting cylinders. A double acting viscosity of 10W-30 and a viscosity index of 152.

  • Page 16: Component Functional Description

    The original thickness of the sliding pads is 47.6 mm. minute, carefully reconnect hose to extend port, Replace sliding pads when they are worn to 42.7 mm. then activate cylinder through one complete cycle and check for leaks. – JLG Sizzor – 3120855...

  • Page 17: Lift Cylinder Removal And Installation

    3. If applicable, remove the cartridge-type holding to the upper inner arm assembly. Drop the cylinder valve and fittings from the cylinder port block. Dis- out of the saddle on the inner arm assembly. card o-rings. 3120855 – JLG Sizzor –...

  • Page 18: Lift Cylinder Assembly

    EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF- CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. Figure 2-2. Barrel Support – JLG Sizzor – 3120855...

  • Page 19: Capscrew Removal

    Pits or scratches that go to the base metal are unaccept- Apply a light film of hydraulic oil to all components able. Chrome should be present over the entire sur- prior to assembly. 3120855 – JLG Sizzor –...

  • Page 20: Rod Seal Installation

    9. Place the piston onto the rod until it abuts the spacer end and install the seal and guidelock ring. 10. Place the locknut on the end of the cylinder rod and tighten. 11. Remove the cylinder rod from the holding fixture. – JLG Sizzor – 3120855...

  • Page 21: Brake Cylinder Repair

    9. Remove the cylinder rod from the holding fixture. the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. 6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture. 3120855 – JLG Sizzor –...

  • Page 22: Steer Cylinder Repair

    Push the piston onto the rod as far as 4. Attach a suitable pulling device to the clevis end of it will go. cylinder rod section one. 2-10 – JLG Sizzor – 3120855...

  • Page 23: Steer Cylinder Assembly

    Scotch Brite or equivalent. Replace rod if necessary. 7. Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering. Replace 3. Inspect threaded portion of rod for excessive dam- age. Dress threads as necessary. as necessary. 3120855 – JLG Sizzor – 2-11...

  • Page 24: Tilt Switch Adjustment

    (Y) nuts until the circuit is closed barrel. Ensure that the piston ring and o-ring are not (the light on the Platform Control Console illumi- damaged or dislodged. nates, the tilt alarm sounds). 2-12 – JLG Sizzor – 3120855...

  • Page 25: Tilt Switch Leveling Manual Adjustment

    If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the (X) nut and repeat steps 3 through 7. 3120855 – JLG Sizzor – 2-13...

  • Page 26: Pressure Setting Procedures

    The port is identified by a stamping on the valve body. 2. Disconnect the hose from valve port 3, then plug the hose and the valve port. 2-14 – JLG Sizzor – 3120855...
  • Page 27 5. Shut down hydraulic system and remove pressure gauge. Table 2-3. Pressure Settings Chart 2632E2/2646E2/ 3246E2 w/Proportional 1932E2 2032E2 3246E2 Control Function Main Relief/High Drive 3200 3200 3200 3000 Lift 2300 2200 2400 2100 Steer 2000 2000 2000 2100 3120855 – JLG Sizzor – 2-15...

  • Page 28: Control Valve Components (3246E2 W/Proportional Control)

    SECTION 2 - PROCEDURES Figure 2-12. Control Valve Components (3246E2 w/Proportional Control) 2-16 – JLG Sizzor – 3120855...
  • Page 29 SECTION 2 - PROCEDURES WELDER TERMINAL CONNECTOR FIRE EXTINGUISHER Figure 2-13. Quick Welder™ Installation 3120855 – JLG Sizzor – 2-17...
  • Page 30 3. The needles bearings will fall out during dismantling and can be collected and reused. The outer ring and 8. Clean all parts carefully with a low aromatic kero- thrust bearing need not be removed. sene. 2-18 – JLG Sizzor – 3120855...
  • Page 31 Turn 3. Position the flange with slight pressure into the the gearwheel set clockwise until the cardan shaft housing. Take care to avoid damage to the seals. 3120855 – JLG Sizzor – 2-19...
  • Page 32 (1) using an appropriate 1/2 or 9/16 inch size mounting flange or port bosses. Remove manifold socket. Inspect bolts for damaged threads, or seal- port O-Rings (18A) if applicable. ing rings, under the bolt head. Replace damaged bolts 2-20 – JLG Sizzor – 3120855...
  • Page 33 4. Remove end cover assembly (2) and seal ring (4). NOTE: Refer to the appropriate “alternate cover construc- Discard seal ring tion” on the exploded view to determine the end cover construction being serviced. 3120855 – JLG Sizzor – 2-21...
  • Page 34 VALVE CAVITY WHEN THE PLUGS ARE REMOVED. NOTE: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part of the end cover. 2-22 – JLG Sizzor – 3120855...
  • Page 35 NOTE: The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice.Compare configura- tion of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set. 3120855 – JLG Sizzor – 2-23...
  • Page 36 No perceptible lash (play) should be noted mum wear life and performance of rotor set and- between mating spline parts. Remove and discard Torqlink™. seal ring (4) from housing (18). 2-24 – JLG Sizzor – 3120855...
  • Page 37 Replace coupling shaft if any of these con- Remove seal (16) and back up washer (17) from ditions exist. Small Frame, housing (18). Discard both. 3120855 – JLG Sizzor – 2-25...
  • Page 38 Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assem- bly. 2-26 – JLG Sizzor – 3120855...
  • Page 39 Torqlink™ housings require the use of bearing man- drel to press bearing/ bushing (19) into the housing to a required depth of 0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. 3120855 – JLG Sizzor – 2-27...
  • Page 40 Use the opposite end of the bearing mandrel that was used to press in the outer 3. Press a new dirt and water seal (20) into the housing bearing/bushing (19). (18) outer bearing counterbore. 2-28 – JLG Sizzor – 3120855...
  • Page 41 Torqlink™, into their respective counter- bores in housing (18) if they were not assembled in NOTE: Torqlinks™ require one thrust washer (14) with procedure 2. thrust bearing (15).The coupling shaft will be seated directly against the thrust 3120855 – JLG Sizzor – 2-29...
  • Page 42 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over 0.5 inch (12.7 mm) longer than the bolts (1) used in the Torqlink™. 2-30 – JLG Sizzor – 3120855...
  • Page 43 (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link manifold by the rotor set is another indication of splines which surface must contact the rotor set. 3120855 – JLG Sizzor – 2-31...
  • Page 44 18. Assemble a new seal ring (3) flat side up, into com- mutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side 2-32 – JLG Sizzor – 3120855...
  • Page 45 Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs. (12-16 N m) if cover is so equipped. Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. 3120855 – JLG Sizzor – 2-33...
  • Page 46 5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble 2-34 – JLG Sizzor – 3120855...

  • Page 47: Limit Switch Adjustment

    2.0 cm to a max. of 4.0 2.20 JLG SMART SYSTEM™ ANALYZER KIT INSTRUCTIONS NOTE: The following instructions involving the JLG SMART System™ Control are used only for Model 3246E2 with the Proportional Control option.
  • Page 48 When the platform is raised, the drive function goes into ACCESS LEVEL creep mode. PERSONALITIES The JLG SMART System™ controller has a built in LED to MACHINE SETUP indicate any faults. The system stores recent faults which may be accessed for troubleshooting. Optional equip-...
  • Page 49 ACCESS LEVEL 2 factory recommended settings. Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit of the password, 3. 3120855 – JLG Sizzor – 2-37...
  • Page 50 SECTION 2 - PROCEDURES NOTE: Refer to the appropriate Machine Personality Set- tings Table, and the Machine Setup Table in the JLG Service Manual for the recommended factory set- tings. Refer to the JLG part number of the controller, printed on the front label, to select the correct table in the manual.
  • Page 51 SECTION 2 - PROCEDURES 3120855 – JLG Sizzor – 2-39...

  • Page 52: Machine Personality Settings

    100% GROUND DECK IN 100% *JLG strongly recommends that these settings not be changed. Changing these settings may adversely affect the performance of your machine. NOTE: Personality settings can be adjusted within the adjustment range in order to achieve opti- mum machine performance.

  • Page 53: Machine Model Default Settings

    NOTE: * JLG strongly recommends that these settings not be changed. Changing these settings may adversely affect the performance of your machine.

  • Page 54: Machine Configuration Information

    Sounds platform alarm for one second on, one second off, one second on, and three seconds off while operator tries to perform the function that has been cut out and dur- ing the LIFT DOWN function (provided the platform alarm has been installed). 2-42 – JLG Sizzor – 3120855...
  • Page 55 LED Only (Flash Codes) LED and lamps in platform control box LED and alarm LED, lamps in control box and alarm 3120855 – JLG Sizzor – 2-43...

  • Page 56: Jlg Smart System™ Help Messages And Flash Codes

    SECTION 2 - PROCEDURES 2.24 JLG SMART SYSTEM™ HELP MESSAGES AND FLASH CODES Table 2-7. Help Messages NO FLASH CODE IS INDICATED FOR THE FOLLOWING HELP MESSAGES; THEY ARE INTENDED TO HINT AT A POSSIBLE PROBLEM IF THE MACHINE IS NOT BEHAVING AS EXPECTED EVERYTHING OK The "normal"...
  • Page 57 SECTION 2 - PROCEDURES Table 2-8. JLG SMART System™ Flash Codes & Help Messages Code Description 2-1 - Indicates problems with EMS inputs STARTUP - Neither EMS is active - the system is just switching on or is discharging the capacitor bank.
  • Page 58 SECTION 2 - PROCEDURES Table 2-8. JLG SMART System™ Flash Codes & Help Messages Code Description 3-3 - Indicates that a contactor coil is short-circuit SHORT-CIRCUIT LINE CONTACTOR COIL - The line contactor was not energized when required, due to coil over current protection.

  • Page 59: Analyzer Menu Structure

    Displays ground lift down switch status (OPEN/CLOSED) Displays ground deck out switch status (OPEN/CLOSED) Not displayed if POWER DECK = NO Displays ground deck in switch status (OPEN/CLOSED) Not displayed if POWER DECK = NO 3120855 – JLG Sizzor – 2-47...
  • Page 60 Displays pothole cutout switch status (OPEN/CLOSED) TILT Displays tilt switch status (LEVEL /TILTED) Not Displayed if TILT SWITCH = NO ARMGUARD Displays armguard cutout switch status (OPEN/CLOSED) Not displayed if ARMGUARD CUTOUT = NO 2-48 – JLG Sizzor – 3120855...
  • Page 61 Some messages are prompts, requiring user intervention ENTER can be pressed if a fault has been noted and to con- tinue the system test. NOTE: A flashing message is critical, and prevents the sys- tem test from running. 3120855 – JLG Sizzor – 2-49...
  • Page 62 CREEP Displays/adjusts minimum lift (up) speed MAX UP Displays/adjusts maximum lift (up) speed MAX DOWN N/A Displays if there is no lift down (gravity) Displays/adjusts for power down machines for maximum lift down speed 2-50 – JLG Sizzor – 3120855...
  • Page 63 Displays/adjusts fixed deck speed out NOTE: Not displayed if POWER DECK = NO DECK IN Displays/adjusts fixed deck speed in NOTE: Not displayed if POWER DECK = NO MACHINE CURRENT Displays/adjusts maximum motor current NOTE: DO NOT ADJUST 3120855 – JLG Sizzor – 2-51...
  • Page 64 Displays/adjusts drive cutout switch presence/function ARMGAURD CUTOUT Displays/adjusts armgaurd cutout switch presence/function FLASH CODE Displays/adjusts how fault flash codes are indicated CALIBRATIONS NOTE: Only available at level 1 CURRENT Displays motor current calibration TEMPERATURE Displays heatsink temperature calibration 2-52 – JLG Sizzor – 3120855...

  • Page 65: Preventive Maintenance And Inspection Schedule

    7. Check for proper operation and freedom of move- Inspection Report" form. Forms are supplied with each ment. new machine and are also available from JLG Customer 8. Check for excessive wear or damage.Check for Service. Form must be completed and returned to JLG proper tightness and adjustment.
  • Page 66 Wheel and Tire Assemblies Drive Motors 1,5,6 Drive Brake Steer Cylinder 5,6,13 Steer Components Wheel Bearings Sizzor Arms Safety Prop Wear Pads Pivot Pins/Bolts Switches, Ground Control 1,11 Control Tags Hose and Cable Pothole Protection System 2-54 – JLG Sizzor – 3120855...

  • Page 67: Section 3. Troubleshooting

    This means that problems for which the proba- ble cause and remedy may be immediately obvious are not listed in this section. 3120855 – JLG Sizzor –...
  • Page 68 Platform above drive cutout height Lower platform below drive cutout height Machine cannot lift down. Lift up function okay Loose wiring on lift cylinder (s) at holding Repair wiring on lift cylinder (s) at holding valve valve – JLG Sizzor – 3120855...
  • Page 69 Oil viscosity too high Drain system and replace with recom- mended oil. Refer to Table 1-2, Hydralic Oil System overheating Oil viscosity too high Drain system and replace with recom- mended oil. Refer to Table 1-2, Hydralic Oil 3120855 – JLG Sizzor –...

  • Page 70: Electrical Schematic - Non Proportional Control (Sheet 1 Of 2)

    SECTION 3 - TROUBLESHOOTING Figure 3-1. Electrical Schematic - Non Proportional Control (Sheet 1 of 2) – JLG Sizzor – 3120855...

  • Page 71: Electrical Schematic - Non Proportional Control (Sheet 2 Of 2)

    SECTION 3 - TROUBLESHOOTING 1870117 C Figure 3-2. Electrical Schematic - Non Proportional Control (Sheet 2 of 2) 3120855 – JLG Sizzor –...

  • Page 72: Electrical Schematic - Proportional Control (Sheet 1 Of 2)

    SECTION 3 - TROUBLESHOOTING JLG SMART SYSTEM MICROPROCESSOR Figure 3-3. Electrical Schematic - Proportional Control (Sheet 1 of 2) – JLG Sizzor – 3120855...

  • Page 73: Electrical Schematic - Proportional Control (Sheet 2 Of 2)

    SECTION 3 - TROUBLESHOOTING JLG SMART SYSTEM MICROPROCESSOR 1870107B Figure 3-4. Electrical Schematic - Proportional Control (Sheet 2 of 2) 3120855 – JLG Sizzor –...
  • Page 74 SECTION 3 - TROUBLESHOOTING – JLG Sizzor – 3120855...
  • Page 75 SECTION 3 - TROUBLESHOOTING 3120855 – JLG Sizzor –...

  • Page 76: Harness And Cable Assembly - Non Proportional Control (Sheet 1 Of 2)

    SECTION 3 - TROUBLESHOOTING Figure 3-7. Harness and Cable Assembly - Non Proportional Control (Sheet 1 of 2) 3-10 – JLG Sizzor – 3120855...

  • Page 77: Harness And Cable Assembly - Non Proportional Control (Sheet 2 Of 2)

    SECTION 3 - TROUBLESHOOTING Figure 3-8. Harness and Cable Assembly - Non Proportional Control (Sheet 2 of 2) 3120855 – JLG Sizzor – 3-11...
  • Page 78 SECTION 3 - TROUBLESHOOTING This page left blank intentionally. 3-12 – JLG Sizzor – 3120855...
  • Page 80 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.

This manual is also suitable for:

1932e22032e22632e22646e23246e2

Table of Contents

Save PDF