JLG 2658E Parts Manual

Illustrated Parts Manual

Models

1532E/1932E 2033E/2046E 2646E/2658E

P/N

3120847

January 27, 2012

REVISION LOG

Power Down Machines include machines built through S/Ns 34920 except those S/Ns listed below.

Gravity Down Machines include machines with S/Ns 33685, 33686, 33687, 33691, 33692, 33693, 33697, 33698,

33699, 33701 to 33707, 34044, 34049, 34141, 34142, 34143, 34172, 34173, 34174 and 34921 to present.

April 1997 Original Issue (Separated 3120838 Complete Manual into 3 Individual Manuals. Added

Gravity Down Machine components.)

June 1997 Change 1

Affected Pages:

Cover and Pages A and i

Section 1 Pages: 1-14, 1-15, 1-20, 1-21, 1-22 Blank, 1-23, 1-30

Section 2 Pages: 2-17/2-18 Blank

Section 4 Pages: 4-1, 4-28 to 4-35/4-36 Blank

Section 5 Pages: 5-3

Section 6 Pages: 6-6, 6-7

Section 7 Pages: 7-6, 7-7, 7-8, 7-10, 7-11, 7-12

Section 9 Pages: 9-1/9-2 Blank

Section 10 Pages: 10-1/10-2 Blank

May 1998 Revised

July 1, 1999 Revised

May 30, 2002 Revised

June 14, 2004 Revised

January 31, 2009 Revised

January 27, 2012 Revised

3120847 1532E/1932E/2033E/2046E/2646E/2658E A

REVISION LOG

B 1532E/1932E/2033E/2046E/2646E/2658E 3120847

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 DRIVE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 DRIVE MOTOR ASSEMBLIES - WHITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 DRIVE MOTOR ASSEMBLIES - EATON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES) . . . . . . . . . . . . . . . . . . . 1-14

1-5 AXLE/BRAKE INSTALLATIONS (GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . 1-18

1-6 JLG POTHOLE PROTECTION SYSTEM INSTALLATION (POWER DOWN MACHINES) 1-20 1-7 JLG POTHOLE PROTECTION SYSTEM INSTALLATION (GRAVITY DOWN MACHINES)1-24 1-8 FRAME MOUNTED COMPONENTS INSTALLATION (POWER DOWN MACHINES) . . 1-28 1-9 FRAME MOUNTED COMPONENTS INSTALLATION (GRAVITY DOWN MACHINES) . 1-32

1-10 BATTERY CHARGER ASSEMBLIES - SINGLE VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . 1-38

1-11 BATTERY CHARGER ASSEMBLIES - DUAL VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . 1-40

1-12 BATTERY CHARGER ASSEMBLIES - REPLACEMENT KIT. . . . . . . . . . . . . . . . . . . . . . 1-42

SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 HYDRAULIC COMPONENTS AND COVER INSTALLATION - 1532E/1932E

(POWER DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 HYDRAULIC COMPONENTS AND COVERS INSTALLATION -1532E/1932E

(GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 HYDRAULIC COMPONENTS AND COVERS INSTALLATION -2033E/2046E/

2646E/2658E (POWER DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 HYDRAULIC COMPONENTS AND COVERS INSTALLATION -2033E/2046E/

2646E/2658E (GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 ELECTRICAL COMPONENTS INSTALLATIONS (AT GROUND CONTROLS) . . . . . . . 2-18

2-7 BATTERY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

SECTION 3 - SCISSOR ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SCISSOR ARMS INSTALLATION - 1532E (POWER DOWN MACHINES) . . . . . . . . . 3-2

3-2 SCISSOR ARMS INSTALLATION - 1532E (GRAVITY DOWN MACHINES) . . . . . . . . . 3-6

3-3 SCISSOR ARMS INSTALLATION - 1932E (POWER DOWN MACHINES) . . . . . . . . . . . 3-10

3-4 SCISSOR ARMS INSTALLATION - 1932E (GRAVITY DOWN MACHINES) . . . . . . . . . 3-14

3-5 SCISSOR ARMS INSTALLATION - 2033E/2046E (POWER DOWN MACHINES) . . . . 3-18

3-6 SCISSOR ARMS INSTALLATION - 2033E/2046E (GRAVITY DOWN MACHINES) . . . . 3-22

3-7 SCISSOR ARMS INSTALLATION - 2646E/2658E (POWER DOWN MACHINES) . . . . 3-26

3-8 SCISSOR ARMS INSTALLATION - 2646E/2658E (GRAVITY DOWN MACHINES) . . . . 3-30

3-9 ARM GUARDS INSTALLATION - 1532E/1932E PRIOR TO S/N 30542 . . . . . . . . . . . . . 3-34

3-10 ARM GUARDS INSTALLATION - 2033E/2046E/2646E BUILT PRIOR TO S/N 30542

AND ALL 2658E BUILT PRIOR TO S/N 51216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-11 ARM GUARDS INSTALLATION - ALL 2658E BUILT S/N 51216 TO PRESENT . . . . . . 3-38

3-12 PLATFORM DESCENT DELAY SYSTEM INSTALLATION - 1532E/1932E/2033E/

2046E/2646E BUILT S/N 30542 TO PRESENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM INSTALLATION - MANUALLY OPERATED EXTENSION . . . . . . . . . . . . . 4-2

4-2 HANDRAILS AND EXTENSION INSTALLATION - STANDARD RAILS

(MANUALLY OPERATED) (1532E/1932E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-3 HANDRAILS AND EXTENSION INSTALLATION -STANDARD RAILS

(MANUALLY OPERATED) (2033E/2046E/2646E/2658E) . . . . . . . . . . . . . . . . . . 4-12

3120847 1532E/1932E/2033E/2046E/2646E/2658E i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

4-4 HANDRAILS AND EXTENSION INSTALLATION - FOLDDOWN RAILS

(MANUALLY OPERATED) (1532E/1932E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-5 HANDRAILS AND EXTENSION INSTALLATION - FOLDDOWN RAILS

(MANUALLY OPERATED) (2033E/2046E/2646E/2658E) . . . . . . . . . . . . . . . . . . . . 4-24

4-6 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4-7 CONTROLLER ASSEMBLY - OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-8 CONTROLLER ASSEMBLY - PQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 BRAKE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LIFT CYLINDER COMPONENTS ASSEMBLY (1532/1932 POWER DOWN MACHINES

BUILT PRIOR TO S/N 27181) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LIFT CYLINDER COMPONENTS ASSEMBLY (1532/1932 POWERDOWN MACHINES

BUILT S/N 27181 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-4 LIFT CYLINDER COMPONENTS ASSEMBLY (1532E/1932E GRAVITY DOWN

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-5 LIFT CYLINDER COMPONENTS ASSEMBLY (2033E/2046E POWER DOWN

MACHINES BUILT PRIOR TO S/N 27085 & 2646E/2658E POWER DOWN

MACHINES BUILT PRIOR TO S/N 26916) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-6 LIFT CYLINDER COMPONENTS ASSEMBLY (2033E/2046E POWER DOWN

MACHINES BUILT S/N 27085 TO PRESENT & 2646E/2658E POWER DOWN

MACHINES BUILT S/N 26916 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-7 LIFT CYLINDER COMPONENTS ASSEMBLY (2033E/2046E/2646E/2658E

GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 HYDRAULIC DIAGRAM (POWER DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM (GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 STANDARD ELECTRICAL DIAGRAM (POWER DOWN MACHINES) . . . . . . . . . . . . . . . 7-4

7-3 STANDARD ELECTRICAL DIAGRAM (GRAVITY DOWN MACHINES) . . . . . . . . . . . . . 7-6

7-4 HARNESS AND CABLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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

8-1 DECALS INSTALLATION - 1532E/1932E POWER DOWN MACHINES . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATION - 1532E/1932E GRAVITY DOWN MACHINES . . . . . . . . . . . . 8-6

8-3 DECALS INSTALLATION - 2033E/2046E/2646E/2658E POWER DOWN MACHINES . 8-12 8-4 DECALS INSTALLATION - 2033E/2046E/2646E/2658E GRAVITY DOWN MACHINES 8-18

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . . 9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 DRIVE AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 DRIVE MOTOR ASSEMBLIES- WHITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 DRIVE MOTOR ASSEMBLIES- EATON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 AXLE/BRAKE INSTALLATIONS (GRAVITY DOWN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 JLG POTHOLE PROTECTION SYSTEM INSTALLATIONS (POWER DOWN MACHINES) . . . 1-20 1-7 JLG POTHOLE PROTECTION SYSTEM INSTALLATIONS (GRAVITY DOWN MACHINES) . . 1-24

1-8 FRAME MOUNTED COMPONENTS INSTALLATIONS (POWER DOWN MACHINES) . . . . . . 1-28

1-9 FRAME MOUNTED COMPONENTS INSTALLATIONS (GRAVITY DOWN MACHINES) . . . . . 1-32

1-10 BATTERY CHARGER ASSEMBLIES - SINGLE VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-11 BATTERY CHARGER ASSEMBLIES - DUAL VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

1-12 BATTERY CHARGER ASSEMBLIES - REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

E C T

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-1

SECTION 1 FRAME

121

120

301

124

102

109A

109

202

107

103

125

116

113

114

104

152

105

115

117

108

119

301

201 (1532E/1932E)

112

104

118

114

104

110

151

122

123 106

MODELS 1532E 1932E 2033E

MODELS 2046E 2646E 2658E

202 (2033E)

S E C T

I O N

FIGURE 1-1. DRIVE AND STEERING INSTALLATION

1-2 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-1. DRIVE AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE AND STEERING INSTALLATION - 1532E/1932E/ Ref. 2033E (STANDARD PARTS)

1 to 2 Not Used

3 0641826 Bolt 1/2"-13NC x 3 1/4" 8 4 4740453 Flatwasher 1/2" Special A/R 5 3311801 Nut 1/2"-13NC 8 6 0100011 Loctite #242 (Not Shown) A/R 7 3450406 Pin, Cotter 1/8" x 1 1/2" 2 8 3300255 Nut, Wheel 10

9 2780216 Hub 2 9A 7012613 Bolt, Wheel (5 Per Hub) 10 10 Steer Cylinder Assembly Options (See Section 5 for 1

Breakdown): 1683351 Prior to S/N 24267 1683428 S/N 24267 to Present

11 Not Used 12 2160002 Fitting, Grease (Prior to S/N 30800) 2

2160006 Fitting, Grease (S/N 30800 to S/N 42315) 2 2160008 Fitting, Grease (S/N 42315 to Present) 2 1120064 Cap, Grease Fitting A/R

13 Not Used 14 3450403 Pin, Cotter 1/8" x 3/4" 2

15 to 16 Not Used

17 0962013 Bushing, Fiberglide 2 18 3430824 Pin, Clevis 1 19 3780166 O-Ring 2 20 4740419 Washer, Thrust 2 21 1120417 Cap 2 22 0641611 Bolt 3/8"-16NC x 1 3/8" 2 23 4711600 Flatwasher 3/8" Narrow 2

24 to 25 Not Used

26 4761800 Lockwasher 1/2" (S/N 28527 to Present) 8

S E

I O N

DRIVE AND STEERING INSTALLATIONS - 1532E/1932E2/ 2033E (VARIABLE PARTS)

0256636 1532E/1932E (Prior to S/N 36748) Ref. 10 0257567 1532E/1932E (S/N 36748 to Present) Ref. 7 0256635 2033E With Manually Operated Extension (Standard

Machines) (Prior to S/N 36748)

0257568 2033E With Manually Operated Extension (Standard

Machines) (S/N 36748 to Present)

0258882 2033E With Power Operated Extension (Standard

Machines)

51 Tie-Rod Options: 1

3841322 1532E/1932E Prior to S/N 45299 3841387 1532E/1932E S/N 45299 to Present 3841321 2033E Prior to S/N 40773 1 3841379 2033E S/N 40773 to Present 1

52 Spindle Options: 2

4130336 1532E/1932E 4130329 2033E

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-3

Ref.

Ref. 9

Ref. 6

Ref. 1

SECTION 1 FRAME

S E

I O N

FIGURE 1-1. DRIVE AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

53 Spacer Options: A/R

Not Required 1532E/1932E 0

4566833 2033E 2

54 Drive Motor Assembly Options: 2

3160207 1532E/1932E Prior to S/N 36748 (See Figure 1-2 for

Breakdown)

3160219 1532E/1932E S/N 36748 to Present (See Figure 1-3 for

Breakdown)

3160214 2033E with Manually Operated Extension Built Prior to

S/N 36748 (See Figure 1-2 For Breakdown)

3160220 2033E with Manually Operated Extension Built S/N

36748 to Present (See Figure 1-3 For Breakdown)

3160208 2033E with Powered Operated Extension (See Figure

1-2 For Breakdown)

55 Pin, Clevis Options: 1

3430811 1532E/1932E 3430812 2033E

56 Bolt, Shoulder Options: 2

0630495 1532E/1932E Prior to S/N 28527 0630516 1532E/1932E S/N 28527 to Present 0630495 2033E

57 Spacer, Bushing Options: 2

0962014 1532E/1932E Prior to S/N 28527 0962085 1532E/1932E S/N 28527 to Present 0962014 2033E

58 Flatwasher 1

4711800 1532E/1932E 4740453 2033E

59 0100001 Adhesive (S/N 41485 to Present) A/R

DRIVE AND STEERING INSTALLATION - 2046E/2646E/ Ref. 2658E (STANDARD PARTS)

101 Not Used 102 4130332 Spindle 2 103 0641826 Bolt 1/2"-13NC x 3 1/4" 8 104 4740453 Flatwasher 1/2" Special 10 105 3311801 Nut 1/2"-13NC 8 106 0100011 Loctite #242 A/R 107 3450406 Pin, Cotter 1/8" x 1 1/2" 2 108 3300255 Nut, Wheel 10 109 2780216 Hub 2

109A 7012613 Bolt, Wheel (5 Per Hub) 10

110 Steer Cylinder Assembly Options (See Section 10-5 for 1

Breakdown): 1683351 Prior to S/N 24267 1683429 S/N 24267 to Present

111 Not Used 112 2160002 Fitting, Grease (Prior to S/N 30800) 2

2160006 Fitting, Grease (S/N 30800 to S/N 42315) 2 2160008 Fitting, Grease (S/N 42315 to Present) 2 1120064 Cap, Grease Fitting A/R

113 3430812 Pin, Clevis 1 114 3450403 Pin, Cotter 1/8" x 3/4" 2

1-4 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-1. DRIVE AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

115 0630495 Bolt, Shoulder 2 116 0962014 Spacer 2 117 0962013 Bushing, Fiberglide 2 118 3430824 Pin 1 119 3780166 O-Ring 2 120 4740419 Thrustwasher 2 121 1120417 Cap 2 122 0641612 Bolt 3/8"-16NC x 1 1/2" 2 123 4711600 Flatwasher 3/8" Narrow 2 124 4566833 Spacer 2 125 4761800 Lockwasher 1/2" 8 126 0100081 Adhesive #454 (Not Shown) A/R

DRIVE AND STEERING INSTALLATIONS - 2046E/2646E/ 2658E (VARIABLE PARTS)

0256653 2046E/2646E Standard Machines (Prior to S/N 36748) Ref. 9 0257570 2046E Standard Machines (S/N 36748 to S/N 37751) Ref. 2 0257571 2646E Standard Machines (S/N 36748 to S/N 37751) Ref. 2 0256653 2046E/2646E Standard Machines (S/N 37751 to Present) Ref. 9 0256654 2658E Standard Machines (Prior to S/N36748) Ref. 9 0257572 2658E Standard Machines (S/N 36748 to S/N 37751) Ref. 2 0256654 2658E Standard Machines (S/N 37751 to Present) Ref. 9

Ref.

S E

I O N

151 Tie-Rod Options: 1

3841320 2046E/2646E 3841324 2658E Prior to S/N 36748 3841320 2658E S/N 36748 to S/N 37751 3841324 2658E S/N 37751 to Present

152 Drive Motor Assembly Options: 2

3160208 2046E/2646E (Prior to S/N 36748) (See Figure 1-2 for

Breakdown)

3160220 2046E (S/N 36748 to S/N 37751) (See Figure 1-3 for

Breakdown)

3160221 2646E (S/N 36748 to S/N 37751) (See Figure 1-3 for

Breakdown)

3160208 2046E/2646E (S/N 37751 to Present) (See Figure 1-2 for

Breakdown) 3160208 2658E (Prior to 36748) (See Figure 1-2 for Breakdown) 3160221 2658E (S/N 36748 to S/N 37751) (See Figure 1-3 for

Breakdown) 3160208 2658E (S/N 37751 to Present) (See Figure 1-2 for

Breakdown)

TIRE AND WHEEL INSTALLATIONS - 1532E/1932E Ref. 0255680 Black Tire And Wheel Installation Ref. 0255683 Standard Non-Marking Tire And Wheel Installation Ref.

201 Tire Options: 4

4520175 Black - 4.50 x 14 A/R 4520177 Non-Marking Standard A/R

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-5

SECTION 1 FRAME

S E

I O N

FIGURE 1-1. DRIVE AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

TIRE AND WHEEL INSTALLATIONS - 2033E/2046E/Ref. 2646E/2658E

0255679 Black Tire And Wheel Installation Ref. 0255682 Standard Non-Marking Tire And Wheel Installation Ref. 0256334 Flotation Tire And Wheel Installation - 7.5 x 16 Ref. 0257156 Flotation Tire And Wheel Installation - 7 x 16 Ref.

202 Tire Options: 4

4520174 Black - 5.0 x 16 A/R 4520176 Non-Marking Standard A/R 4520183 Flotation - 7.5 x 16 A/R 4520191 Flotation - 7 x 16 A/R

FRAME WELDMENTS OPTIONS: Ref.

Note: To determine Power or Gravity Down refer to page A.

2360399 1532E (Power Down) (All Machines) 1 2360428 1532E (Gravity Down) (CE Spec) 1 2360468 1532E (Gravity Down) (Australian Spec) 1 2360399 1932E (Power Down) (All Machines) 1 2360428 1532E (Gravity Down) (CE Spec) 1 2360429 1932E (Gravity Down) (Australian Spec) 1 2360419 2033E (Power Down) (Australian Spec) 1 2360431 2033E (Gravity Down) (Australian Spec) 1 2360395 2033E (Power Down) (CE Spec) 1 2360431 2033E (Gravity Down) (CE Spec) 1 2360396 2046E (Power Down) (All Machines) 1 2360432 2046E (Gravity Down) (All Machines) 1 2360412 2646E (Power Down) (All Machines) 1 2360433 2646E (Gravity Down) (All Machines except Outdoor Spec) 1 2360437 2646E (Gravity Down) (Outdoor Spec) 1 2360397 2658E (Power Down) (All Machines) 1 2360434 2658E (Gravity Down) (All Machines) 1

301 0962017 Bushing 4

1-6 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-1. DRIVE AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-7

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. DRIVE MOTOR ASSEMBLIES - WHITE

1-8 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-2. DRIVE MOTOR ASSEMBLIES - WHITE

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE MOTOR ASSEMBLY (STANDARD PARTS) Ref.

1 Kit Seal, Dust 1 2KitRing, Wire 1 3 Kit Shim, Back-Up 1 4 Kit Seal, High Pressure 1 5 Kit Shim, Back-Up 1 6 Kit Seal, Back-Up 1 7 Kit Seal, Shaft 1 8 Kit Seal, Housing 1

9 Kit Seal, Body 2 10 Kit Seal, End Cover 1 11 Kit Carrier, Seal 1 12 KIt Thrust Washer 1 13 Not Used 14 7016400 Bearing, Front Housing 1 15 7016401 Housing 1 16 7016402 Bearing, Rear Housing 1 17 7016403 Link, Drive 1 18 7016404 Manifold 1 19 7016405 Boot, Manifold 1

20 to 21 Not Used

22 Kit Plate, Balance 1 23 Kit Ball, Steel 4 24 7016413 Cover, End 1 25 Not Serviced Tag, Identification 1 26 Not Used 27 7016410 Shaft 1 28 7016411 Key 1

– – – – – – – – – –

2900665 Seal and Carrier Kit (Includes Kit P/N’s 7005896 and 1

7005897) 7005896 Seal Kit (Includes Items 1-10) 1 7005897 Carrier Kit (Includes Items 11 and 12) 1 7016408 Balance Plate Kit (Includes Items 22 and 23) 1

S E

I O N

DRIVE MOTOR ASSEMBLY (VARIABLE PARTS) Ref. 3160207 1532E/1932E Ref. B 3160214 2033E Ref. B 3160208 2046E/2646E/2658E Ref. B

51 Spacer, Drive Link Options: 1

7016414 1532E/1932E 7016419 2033E 7016406 2046E/2646E/2658E

52 Rotor Assembly Options: 1

7016415 1532E/1932E 7016420 2033E 7016407 2046E/2646E/2658E

53 Bolt, Assembly Options: 6

7016416 1532E/1932E 7016409 2033E 7016409 2046E/2646E/2658E

54 Bearing, Thrust Options: 2

7005899 1532E/1932E 7016418 2033E 7005899 2046E/2646E/2658E

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. DRIVE MOTOR ASSEMBLIES - WHITE (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

55 Nut Options: 1

7016412 1532E/1932E 7016421 2033E 7016412 2046E/2646E/2658E

1-10 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-2. DRIVE MOTOR ASSEMBLIES - WHITE (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-11

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. DRIVE MOTOR ASSEMBLIES - EATON

1-12 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-3. DRIVE MOTOR ASSEMBLIES - EATON

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE MOTOR ASSEMBLY (STANDARD PARTS) Ref.

1 7007892 Ring, Retaining 1 2 7007893 Bearing, Ball 1 3 7007894 Ring, Retaining 1 4 7007895 Ring, Retaining 1 5 7007896 Washer 1 6 7009919 Washer, Back-Up 1 7 7009920 Seal, Pressure 1 8 7007897 Housing 1

9 7007898 Shaft, Output 1 10 Not Used 11 7020300 Seal 2 12 Not Used 13 7020302 Cover, End 1

14 to 17 Not Used

18 7020312 Key 1 19 7009934 Nut 1 20 7020304 Poppet (Not Shown) 2

– – – – – – – – – –

7020305 Seal Kit 1

DRIVE MOTOR ASSEMBLY (VARIABLE PARTS) Ref. 3160219 1532E/1932E Ref. A 3160220 2033E Ref. A 3160221 2046E/2646E/2658E Ref. A

S E

I O N

51 Link, Drive Options: 1

7007899 1532E/1932E 7020306 2033E 7020308 2046E/2646E/2658E

52 Rotor Assembly 1

7020301 1532E/1932E 7020307 2033E 7020309 2046E/2646E/2658E

53 Bolt 6

7020303 1532E/1932E 7020310 2033E 7020310 2046E/2646E/2658E

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-13

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES)

1-14 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-4. AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Note: To determine Power or Gravity Down refer to Page A.

BRAKE INSTALLATION (STANDARD PARTS) Ref.

1 2780215 Hub Assembly (See Items 101-113 for Breakdown) 2 2 Not Used 3 4845037 Cam, Brake 2 4 3430620 Pin, Clevis 2 5 4751600 Flatwasher 3/8" 2 6 3450504 Pin, Cotter (Prior to S/N 33691) 2

3450403 Pin, Cotter (S/N 33691 to Present) 2 7 3300255 Lugnut 5 8 4160137 Spring 2

BRAKE INSTALLATION (VARIABLE PARTS) Ref. 0256596 1532E/1932E Ref. B 0255614 2033E Ref. D 0255636 2046E/2646E Ref. D 0255637 2658E Ref. D

9 Link Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

3010112 2033E 2

10 Bar Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

0362510 2033E 1

11 Bolt 7/8"-9NC x 1 1/2" (Grade 8) Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

0682412 2033E 2

12 0100019 Loctite #271 A/R 13 Latch, Forklift Bar Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

2940097 2033E 1

14 Bolt 1/4"-20NC x 7/8" Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

0641407 2033E 1

15 Bolt 1"-8NC x 2 1/2" (Grade 8) Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

0682620 2033E 2

16 Locknut 1"-8NC (Grade 8) Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

3272605 2033E 2

17 3020017 Grease (S/N 33691 to Present) A/R 18 Decal - Forklift Area Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

1701508 2033E 2

19 3311405 Locknut 1/4"-20NC Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

3311405 2033E 2

20 Flatwasher 1/4" Options: A/R

Not Required 1532E/1932E/2046E/2646E/2658E 0

4751400 2033E 2

21 Rod, Brake Options: 2

3841274 1532E/1932E/2033E 3841280 2046E/2646E

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

22 Brake Cylinder Assembly Options (See Section 5 for 1

Breakdown): 1683362 1532E/1932E/2046E/2646E/2658E Prior to S/N 33691 1683499 1532E/1932E/2046E/2646E/2658E S/N 33691 to

Present

1683362 2033E

2780215 HUB ASSEMBLY Ref. B

101 7010649 Seal 1 102 7019695 Housing 1 103 7019696 Stud, Wheel 5 104 Not Used 105 7019697 Washer 1 106 7010641 Nut, Slotted 1 107 7010642 Pin, Cotter 1 108 7010648 Cap, Dust 1 109 7010650 Cone, Outer 1 110 7003903 Cup, Outer 1 111 7010651 Cup, Inner 1 112 7010647 Cone, Inner 1 113 1760165 Disc, Brake 1

ASSOCIATED FRAME COMPONENTS Ref.

201 Axle Weldment Options: 1

0280145 1532E/1932E/2033E 0280146 2046E/2646E 0280147 2658E

1-16 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-4. AXLE/BRAKE INSTALLATIONS (POWER DOWN MACHINES) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-17

SECTION 1 FRAME

S E

I O N

FIGURE 1-5. AXLE/BRAKE INSTALLATIONS (GRAVITY DOWN MACHINES)

1-18 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-5. AXLE/BRAKE INSTALLATIONS (GRAVITY DOWN MACHINES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Note: To determine Power or Gravity Down refer to Page A.

BRAKE INSTALLATION (STANDARD PARTS) Ref.

1 2780215 Hub Assembly (See Items 101-113 for Breakdown) 2 2 Not Used 3 4845037 Cam, Brake 2 4 3430620 Pin, Clevis 2 5 4711600 Flatwasher 3/8" Narrow 2 6 3450403 Pin, Cotter 2 7 1683557 Brake Cylinder Assembly (See Section 5 for Breakdown) 1 8 4160137 Spring 2 9 3300255 Lugnut 5

BRAKE INSTALLATIONS (VARIABLE PARTS) Ref. 0257183 1532E/1932E Ref. 3 0257184 2033E Ref. 3 0257185 2046E/2646E Ref. 2 0257186 2658E Ref. 2

51 Rod, Brake Options: 2

3841332 1532E/1932E/2033E 3841333 2046E/2646E 3841334 2658E

52 Spacer Options: A/R

Not Required 1532E/1932E/2033E Not Required 2046E/2646E/2658E Prior to S/N35949

4567265 2046E/2646E/2658E S/N35949 to Present

S E

I O N

2780215 HUB ASSEMBLY Ref. B

101 7010649 Seal 1 102 7019695 Housing 1 103 7019696 Stud, Wheel 5 104 Not Used 105 7019697 Washer 1 106 7010641 Nut, Slotted 1 107 7010642 Pin, Cotter 1 108 7010648 Cap, Dust 1 109 7010646 Cone, Outer 1 110 7010650 Cup, Outer 1 111 7010651 Cup, Inner 1 112 7010647 Cone, Inner 1 113 1760165 Disc, Brake 1

ASSOCIATED FRAME COMPONENTS Ref.

201 Axle Weldment Options: 1

0280145 1532E/1932E/2033E 0280146 2046E/2646E 0280147 2658E

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-19

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION (POWER DOWN MACHINES)

1-20 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION (POWER DOWN MACHINES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Note: To determine Power or Gravity Down refer to Page A.

POTHOLE PROTECTION SYSTEM INSTALLATION Ref. (STANDARD PARTS)

1 Not Used 2 4844987 Pivot Weldment 1 3 3538809 Plate, Cam 2 4 3538808 Plate, Cam 2 5 Not Used 6 3860065 Roller 1 7 4160133 Spring, Torsion 1 8 0362484 Bar, Link 4

9 0362485 Bar, Actuator 4 10 4160141 Spring, Extension 1 11 Not Used 12 0630398 Eye-Bolt 1 13 0362483 Bar, Roller 4 14 0961997 Bearing, Flange 4 15 Not Used 16 0961994 Bearing, Spacer 12 17 0641612 Bolt - 3/8"-16NC x 1 1/2" 4 18 4761600 Lockwasher - 3/8" 4 19 3440828 Roll Pin - 1/4" x 1 3/4" 2 20 4711800 Flatwasher - 1/2" Narrow 1 21 3440418 Roll Pin - 1/8" x 1 1/8" 1 22 3951005 Setscrew - #10-24NC x 5/8" 2 23 0961995 Bearing, Flange 4 24 0642224 Bolt - 3/4" - 10NC x 3" 4 25 3312205 Locknut - 3/4"-10NC 4 26 0961996 Bearing, Flange 8 27 0641611 Bolt - 3/8"-16NC x 1 3/8" 8 28 0100011 Loctite - #242 A/R 29 Not Used 30 0641508 Bolt - 5/16"-18NC x 1" 2 31 3311505 Locknut - 5/16"-18NC 2 32 4712400 Flatwasher 7/8" Narrow 1 33 Not Used 34 3911028 Screw Machine - #10-24NC x 1 3/4" 4 35 4751000 Flatwasher - #10 4 36 3311005 Locknut - #10-24NC 4 37 0641622 Bolt 3/8"-16NC x 2 3/4" 4 38 3311605 Locknut - 3/8"-16NC 4 39 Not Used 40 1120481 Cap, End (S/N 24267 to Present Only) 4 41 4460662 Connector, Strain Relief 2 42 Not Used

43 3311501 Nut 5/16”-18NC 2

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-21

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION (POWER DOWN MACHINES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

POTHOLE PROTECTION SYSTEM INSTALLATIONS Ref. (VARIABLE PARTS)

0255724 1532E/1932E Ref. 7 0255516 2033E Ref. 11 0255638 2046E/2646E Ref. 11 0255639 2658E Ref. 11

51 Bar, Support Options: A/R

4845104 1532E/1932E Prior to S/N 24267 2 4845360 1532E/1932E Right Side S/N 24267 to Present 1 4845383 1532E/1932E Left Side S/N 24267 to Present 1 4845268 2033E Prior to S/N 24267 2 4845357 2033E S/N 24267 to Present 2 4845269 2046E/2646E Prior to S/N 24267 2 4845358 2046E/2646E S/N 24267 to Present 2 4845270 2658E Prior to S/N 24267 2 4845359 2658E S/N 24267 to Present 2

52 Spring, Extension Options: 2

4160134 1532E/1932E/2033E 4160146 2046E/2646E/2658E

53 Rod, Pivot Options: 1

3841308 1532E/1932E 3841266 2033E/2046E/2646E/2658E

54 Actuator Options: 1

4845319 1532E/1932E 4845077 2033E/2046E/2646E/2658E

55 Bar, Actuator Options: 4

0362511 Prior to S/N 31231 0362654 S/N 31231 to Present

56 Switch, Limit Options: 2 56A 4360397 Prior to S/N 31231 56B 4360401 S/N 31231 to Present

1-22 1532E/1932E/2033E/2046E/2646E/2658E 3120847

SECTION 1 FRAME

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION (POWER DOWN MACHINES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120847 1532E/1932E/2033E/2046E/2646E/2658E 1-23

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. JLG POTHOLE PROTECTION SYSTEM INSTALLATION (GRAVITY DOWN MACHINES)

1-24 1532E/1932E/2033E/2046E/2646E/2658E 3120847

+ 214 hidden pages