JLG 2658E3 Parts Manual

Illustrated Parts Manual

Models

1532E3 1932E3 2033E3 2046E3 2646E3 2658E3

P/N - 3120879

September 26, 2013

REVISION LOG

February 26, 1999 - Issue Of Manual (Manual edited to 0010552 Revision 7)

August 15, 1999 - Revised Manual ( Manual edited to 0010552 Revision 18)

August 17, 2000 - Revised Manual ( Manual edited to 0010552 Revision 30)

February 1, 2001 - Revised Manual (Manual edited to 0010552 Revision 36)

October 2, 2001 - Revised Manual (Manual edited to 0010552 Revision 43)

July 9, 2002 - Revised Manual (Manual edited to 0010552 Revision 52)

January 6, 2003 - Revised Manual (Manual edited to 0010552 Revision 58)

April 29, 2003 - Revised Manual (Manual edited to 0010552 Revision 60)

October 12, 2004 - Revised Manual (Manual edited to 0010552 Revision 62)

August 25, 2008 - Revised Manual

November 8, 2011 - Revised Manual

September 26, 2013 - Revised Manual

3120879 A

REVISION LOG

B 3120879

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

1-2 AXLE/BRAKE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-3 DRIVE MOTOR ASSEMBLY - 1532E3/1932E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-4 DRIVE MOTOR ASSEMBLY - 2033E3/2046E/32646E3/2658E3 . . . . . . . . . . . . . . . . . .1-12

1-5 JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/1932E3. . . . . . . . . .1-14

1-6 JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/2046E3/

2646E3/2658E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-7 FRAME MOUNTED COMPONENTS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

1-8 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

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

2-1 HYDRAULIC COMPONENTS AND COVER INSTALLATION -1532E3/1932E3 . . . . . . . .2-2

2-2 HYDRAULIC COMPONENTS AND COVERS INSTALLATION - 2033E3/

2046E3/2646E3/2658E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4 ELECTRICAL COMPONENTS INSTALLATIONS (At Ground Controls) . . . . . . . . . . . . .2-14

2-5 BATTERY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

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

3-1 SCISSOR ARMS INSTALLATION - 1532E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 SCISSOR ARMS INSTALLATION - 1932E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3 SCISSOR ARMS INSTALLATION - 2033E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-4 SCISSOR ARMS INSTALLATION - 2046E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 SCISSOR ARMS INSTALLATION - 2646E3/2658E3 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-6 PLATFORM DESCENT DELAY SYSTEM INSTALLATION - 1532E3/1932E3/

2033E3/2046E3/2646E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-7 ARM GUARDS INSTALLATION - 2658E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

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

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

4-2 HANDRAILS AND EXTENSION INSTALLATION - STANDARD HANDRAILS

(MANUALLY OPERATED) (1532E3/1932E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-3 HANDRAILS AND EXTENSION INSTALLATION - STANDARD HANDRAILS

(MANUALLY OPERATED) (2033E3/2046E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-4 PLATFORM ACCESS INSTALLATION - STANDARD HANDRAILS

(MANUALLY OPERATED) (1532E3/1932E3/2033E3/2046E3) . . . . . . . . . . . . . . . . . .4-18

4-5 HANDRAILS AND EXTENSION INSTALLATION - FOLDDOWN HANDRAILS

(MANUALLY OPERATED) (1532E3/1932E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-6 HANDRAILS AND EXTENSION INSTALLATION - FOLDDOWN HANDRAILS

(MANUALLY OPERATED) (2033E3/2046E3/2646E3/2658E3) . . . . . . . . . . . . . . . . . .4-26

4-7 PLATFORM ACCESS INSTALLATION - FOLDDOWN HANDRAILS

(MANUALLY OPERATED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

4-8 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

4-9 CONTROLLER ASSEMBLY - PQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

3120879 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

5-2 LIFT CYLINDER COMPONENTS ASSEMBLY 1532E3/1932E3 . . . . . . . . . . . . . . . . .5-4

5-3 LIFT CYLINDER COMPONENTS ASSEMBLY 2033E3/2046E3 . . . . . . . . . . . . . . . . . . .5-8

5-4 LIFT CYLINDER COMPONENTS ASSEMBLY 2646E3/2658E3 . . . . . . . . . . . . . . . . . . .5-12

5-5 STEER CYLINDER ASSEMBLY (PRIOR TO S/N 0200070496). . . . . . . . . . . . . . . . . . . .5-14

5-6 STEER CYLINDER ASSEMBLY (S/N 0200070496 TO S/N 0200078796). . . . . . . . . . . .5-16

5-7 STEER CYLINDER ASSEMBLY (S/N 0200078796 TO S/N 0200105071). . . . . . . . . . . .5-18

5-8 STEER CYLINDER ASSEMBLY (S/N 0200105071 TO PRESENT) . . . . . . . . . . . . . . . . .5-20

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

6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

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

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

7-2 ELECTRICAL SCHEMATIC - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 HARNESS AND CABLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

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

8-1 DECALS INSTALLATION - 1532E3/1932E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION - 2033E3/2046E3/2646E3/2658E3 . . . . . . . . . . . . . . . . . . 8-8

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

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

ii 3120879

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

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

1-2 AXLE/BRAKE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 DRIVE MOTOR ASSEMBLY - 1532E3/1932E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE MOTOR ASSEMBLY - 2033E3/2046E3/2646E3/2658E3 . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/1932E3. . . . . . . . . . . . . . . 1-14

1-6 JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/2046E3/2646E3/2658E3.. 1-18

1-7 FRAME MOUNTED COMPONENTS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 BATTERY CHARGER ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

E C T

I O N

3120879 1-1

SECTION 1 FRAME

131

121

120

127

124

102

109A

109

101A

202

107

103

116

113

114

104

126

101

101B

105

106

106 115

117

108

119

201 (1532E2/1932E2) 202 (2033E3)

3 6

104

118

114

104

110

301

111

122

123

106

12 33

MODELS

1532E3

1932E3

2033E3

MODELS

2046E3

2646E3

2658E3

112 132

S E C T

I O N

FIGURE 1-1. DRIVE AND STEERING INSTALLATION

1-2 3120879

SECTION 1 FRAME

FIGURE 1-1. DRIVE AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258147 DRIVE AND STEERING INSTALLATION - 1532E3/1932E3 Ref. 9 0258148 DRIVE AND STEERING INSTALLATION - 2033E3 Ref. 9

1 Drive Motor Assembly Options: 2

1532E3/1932E3 Motor Options:

3160270 S/N 0200098156 to Present (See Figure 1-3 for

Breakdown)

3160228 Prior to S/N 0200098156 (Items 1A-1D are the only

Replacement Parts)

2033E3 Motor Options:

3160263 S/N 0200098156 to Present (See Figure 1-4 for

Breakdown)

3160230 Prior to S/N 0200088491 (Items 1A-1E are the only

Replacement Parts) — — — — — — — — —

3160228 & 3160230 Replacement Components:

1A 7018997 Nut (1 Per Motor p/n 3160228/3160230) 2 1B 7018996 Key (1 Per Motor p/n 3160228/3160230) 2 1C 7021312 Seal, Shaft (Inner) (Not Shown) (1 Per Motor p/n

3160228/3160230)

1D 7021317 Seal, Dust (Outer) (Not Shown) (1 Per Motor p/n

3160228/3160230)

1E 7016436 Repair Kit for 3160230 Motor (Includes Items 1C,

1D, & Qty 1 O-Ring) (Not Shown) (1 Per Motor)

2 Spindle Options:

4130336 1532E3/1932E3 2 4130329 2033E3 2

3 0641826 Bolt 1/2”-13NC x 3 1/4” 8 4 4740453 Flatwasher 1/2” 10 5 Use 3300450 Nut 1/2”-13NC (Prior to S/N 0200086330 was P/N 3311801) 8 6 Use 0100019 Loctite (Prior to S/N 02000103431) (Was P/N 0100011) A/R 7 3450406 Cotter Pin 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 Options: 1

Use 1684226 Prior to S/N 0200070496 (was p/n 1683428) Use 1684226 S/N 0200070496 to S/N 0200078796 (was p/n 1683841) Use 1684226 S/N 0200078796 to S/N 0200105071 (was p/n 1683936)

1684226 S/N 0200105071 to Present

11 Tie Rod Options:

3841387 1532E3/1932E3 1 3841379 2033E3 1

12 2160008 Grease Fitting (Prior to S/N 0200084439 Only) 2 13 Clevis Pin Options:

Use 3430812 Clevis Pin 1/2” x 1 3/8” (Prior to S/N 0200111444)

(Was P/N 3430811)

3430812

Clevis Pin 1/2” x 1 1/2” 1

S E

I O N

3120879 1-3

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

14 3450403 Cotter Pin 1/8” x 3/4” 2 15 Bolt, Shoulder Options:

0630516 Bolt, Shoulder 3/4” x 1 1/8” - 1532E3/1932E3 2 0630495 Bolt, Shoulder 3/4” x 1” - 2033E3 2

16 Bushing Options:

0962085 1532E3/1932E3 2 0962014 2033E3 2

17 0962013 Bushing, Fiberglide 2 18 3430824 Clevis Pin 1/2” x 3” 1 19 3780166 O-Ring 2 20 4740419 Washer, Thrust 2 21 1120417 Cap 2 22 Bolt Options: 2

0641611 3/8”-16NC x 1 3/8” (1532E3/1932E3 Only) 0641612 3/8”-16NC x 1 1/2” (2033E3 Only)

23 4711600 Flatwasher 3/8” 2 24 4566833 Spacer (2033E3 Only) 2 25 4711800 Flatwasher 1/2” (1532E3/1932E3 Only) (Prior to S/N

0200111444)

26 4761800 Lockwasher 1/2” (Prior to S/N 0200088491 Only) 8 27 0962017 Bushing, Excelite 4

28 to 31 Not Used

32 0100081 Adhesive A/R 33 4891800 Cap, Grease Fitting (Prior to S/N 0200040415 Only) 2

0258149 DRIVE AND STEERING INSTALLATION - 2046E3/2646E3 Ref. 10 0258150 DRIVE AND STEERING INSTALLATION - 2658E3 Ref. 8

101 Drive Motor Assembly Options: 2

3160226 Prior to S/N 0200088491 7021312 Seal, Shaft (Inner) (1 Per Motor p/n 3160226) 2 7021317 Seal, Dust (Outer) (1 Per Motor p/n 3160226) 2

101A 7018997 Nut (1 Per Motor p/n 3160226) 2 101B 7018996 Key (1 Per Motor p/n 3160226) 2

3160264 S/N 0200088491 to Present

(See Figure 1-3 for Breakdown)

102 Spindle Options:

4130332 Standard 2 103 0641826 Bolt 1/2”-13NC x 3 1/4” 8 104 4740453 Flatwasher 1/2” 11 105 3311801 Nut 1/2”-13NC 8 106 Use 0100019 Loctite (Prior to S/N 02000103431) (Was P/N 0100011) A/R 107 3450406 Cotter Pin 1/8” x 1 1/2” 2 108 3300255 Nut, Wheel 10 109 2780216 Hub 2

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

1-4 3120879

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

110 Steer Cylinder Options: 1

Use 1684227 Prior to S/N 0200070496 (was p/n 1683429) Use 1684227 S/N 0200070496 to S/N 0200078796 (was p/n 1683840) Use 1684227 S/N 0200078796 to S/N 0200105071 (was p/n 1683937)

1684227 S/N 0200105071 to Present

111 Tie Rod Options:

3841320 2046E3/2646E3 1 3841324 2658E3 1

112 2160008 Grease Fitting (Prior to S/N 0200088491 Only) 2 113 3430812 Clevis Pin 1/2” x 1 1/2” 1 114 3450403 Cotter Pin 1/8” x 3/4” 2 115 0630495 Bolt, Shoulder 3/4” x 1” 2 116 0962014 Bushing 2 117 0962013 Bushing, Fiberglide 2 118 3430824 Clevis Pin 1/2” x 3” 1 119 3780166 O-Ring 2 120 4740419 Washer, Thrust 2 121 1120417 Cap 2 122 Bolt Options: 2

0641611 3/8”-16NC x 1 3/8” (1532E3/1932E3 Only) 0641612 3/8”-16NC x 1 1/2” (2033E3 Only)

123 4711600 Flatwasher 3/8” 2 124 4566833 Spacer 2 125 Not Required 126 4761800 Lockwasher 1/2” (Prior to S/N 0200088491 Only) 127 0962017 Bushing, Excelite 4 128 Not Used 129 Not Used 130 Not Used 131 0100081 Loctite #454 A/R 132 1120064 Cap, Grease Fitting, (Prior to S/N 0200088491 Only) 2

S E

I O N

201 TIRE AND WHEEL INSTALLATIONS - 1532E3/1932E3 Ref.

0255680 Standard Tire And Wheel Installation (Optional) Ref. - 0255683 Non-Marking Tire And Wheel Installation Ref. -

Tire Options: 4

4520175 Standard A/R 4520177 Non-Marking A/R

3120879 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.

202 TIRE AND WHEEL INSTALLATIONS -

2033E3/2046E3/2646E3/2658E3

0255679 Standard Tire And Wheel Installation (See Note) Ref. - 0255682 Non-Marking Tire And Wheel Installation (See Note) Ref. - 0259475 Non-Marking Flotation Tire And Wheel Installation Ref. 1 0257156 Flotation Tire And Wheel Installation (Optional) Ref. -

Tire & Wheel Options: 4

4520174 Standard A/R 4520176 Non-Marking A/R 4520221 Non-Marking Flotation (Note: Not Available on 2033E3) A/R 4520191 Flotation (Note: Not Available on 2033E3) A/R

301 FRAME WELDMENT OPTIONS Ref.

2360501 Frame Weldment - 1532E3 (Australian Spec) 1 2360499 Frame Weldment - 1532E3/1932E3 (Euro Spec) 1 2360500 Frame Weldment - 1932E3 (Australian Spec) 1 2360473 Frame Weldment - 2033E3 1 2360474 Frame Weldment - 2046E3 (Australian Spec) 1 2360476 Frame Weldment - 2046E3 (Euro Spec) 1 2360476 Frame Weldment - 2646E3 1 2360478 Frame Weldment - 2658E3 (Australian Spec) 1 2360495 Frame Weldment - 2658E3 (Euro Spec) 1

Ref.

1-6 3120879

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120879 1-7

SECTION 1 FRAME

1210710510911010112111102113103101106

S E

I O N

FIGURE 1-2. AXLE/BRAKE INSTALLATIONS

1-8 3120879

SECTION 1 FRAME

FIGURE 1-2. AXLE/BRAKE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BRAKE INSTALLATIONS Ref.

0257183 1532E3/1932E3 Ref. 6 0257184 2033E3 Ref. 6 0257185 2046E3/2646E3 Ref. 3 0257186 2658E3 Ref. 3

1 2780215 Hub Assembly (See Items 101-113 for Breakdown) 2 2 Rod, Brake Options:

3841332 1532E3/1932E3/2033E3 2 3841333 2046E3/2646E3 2 3841334 2658E3 2

3 Cam, Brake Options: 2

4845037 Prior to S/N 0200098156 1100116 S/N 0200098156 to Present

4 3430620 Pin, Clevis 2 5 4711500 Flatwasher 5/16” Narrow 2 6 3450403 Pin, Cotter 2 7 Brake, Cylinder Assembly Options

(See Section 5 for Breakdown):

Use 1683833 Prior to S/N 0200066023 (Was p/n 31683557)

1683833 2046E3/2646E3

8 4160137 Spring 2 9 Spacer Options: A/R

Not Required 1532E3/1932E3/2033E3 0

4567265 2046E3/2646E3/2658E3 2

10 3300255 Lugnut 10

S E

I O N

2780215 HUB ASSEMBLY Ref. C

101 7010649 Seal 1 102 Not Serviced Housing 1 103 Use 7019696 Stud, Wheel (was p/n 7012613) 5 104 Not Used 105 7019697 Washer 1 106 7010641 Nut, Slotted 1 107 7010642 Pin, Cotter 1 108 Use 7010648 Cap, Dust (was p/n 7003902) 1 109 7010646 Cone, Outer 1 110 Use 7010650 Cup, Outer (was p/n 7003903) 1 111 7010651 Cup, Inner 1 112 7010647 Cone, Inner 1 113 1760165 Disc, Brake 1

3120879 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. DRIVE MOTOR ASSEMBLY - 1532E3/1932E3

1-10 3120879

SECTION 1 FRAME

FIGURE 1-3. DRIVE MOTOR ASSEMBLY - 1532E3/1932E3

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160270 DRIVE MOTOR ASSEMBLY (S/N 0200098156 TO PRESENT) Ref. B

Note: See Figure 1-1 for replacement parts for Machines Prior to S/N 0200098156.

Note: Verify Drive Motor machine is equipped with before ordering service parts.

1 to 2 Not Used

3 Use Item 100 Seal, Dust 1 4 Use Item 100 Seal, Shaft 1

5 to 6 Not Used

7 7023452 Bearing, Race 2 8 7023453 Bearing, Needle 1

9 Use Item 100 O-Ring 2 10 Not Used 11 7023465 Cover, End 1

12 to 13 Not Used

14 Not Serviceable Identification Tag 1 15 Not Used 16 7023468 Wheel, Gear Set 1 17 7023469 Screw m8x95mm 7 18 Use Item 100 Washer 82mm 7 19 7023467 Shaft, Cardan 1 20 7023455 Key 1 21 7023456 Shaft, Output 1 22 Not Serviceable Housing 1 23 Not Used 24 Not Serviceable Plug 2 25 Not Used 26 7023451 Nut, Castle 1

27 to 31 Not Used

32 7023454 Bearing, Needle 1 33 7023460 Bearing, Needle 1 34 7023458 Plate, Pressure 1 35 7023459 Disk, Valve 1 36 7023462 Plate 1 37 Use Item 100 O-Ring 1 38 7023457 Washer, Spring 1 39 Use Item 100 O-Ring 1 40

7023461 Washer, Glacier 1

Ref.

S E

I O N

KIT OPTIONS: Ref.

100 7023450 Kit, Seal (Includes Items 3,4,9,18,37 & 39) 1

3120879 1-11

SECTION 1 FRAME

1514151

113

S E

I O N

FIGURE 1-4. DRIVE MOTOR ASSEMBLY - 2033E3/2046E/32646E3/2658E3

1-12 3120879

SECTION 1 FRAME

FIGURE 1-4. DRIVE MOTOR ASSEMBLY - 2033E3/2046E/32646E3/2658E3

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE MOTOR ASSEMBLIES Ref.

3160263 DRIVE MOTOR - 2033E3 (S/N 0200088491 TO PRESENT) Ref. B

Note: See Figure 1-1 for replacement parts for 2033E3 Prior to S/N 0200088491.

3160264 DRIVE MOTOR - 2046E3/2646E3/2658E3 Ref. B

Note: Verify Drive Motor machine is equipped with before ordering service parts.

1 7023307 Housing 1 2 7023308 Bearing, Thrust 1 3 7023309 Shaft 1 4 7023310 Ring, Seal 5 5 7023311 Plate, Wear 5 6 Drive Link Options: 1

7023312 Drive Link - Motor p/n 3160263 7023326 Drive Link - Motor p/n 3160264

7 Assembly, Rotor Options: 1

7023313 Drive Link - Motor p/n 3160263 7023327 Drive Link - Motor p/n 3160264

8 7023314 Manifold 1 9 7023315 Assembly, Commutator 1

10 7023318 Seal, Commutator 1 11 Cover, End Options: 1

7023316 Drive Link - Motor p/n 3160263 7023328 Drive Link - Motor p/n 3160264

12 Bolt Options: 7

7023317 Drive Link - Motor p/n 3160263 7023329 Drive Link - Motor p/n 3160264

13 7023319 Seal 1 14 Not Available Identification Tag N/A 15 7023320 Screw 2 16 7023321 Ring Back-Up 1 17 7023322 Washer, Back-Up 1 18 7023323 Seal, Shaft 1 19 7023324 Key 1 20 7023325 Nut, Castle 1

Ref.

S E

I O N

KIT OPTIONS: Ref.

100 7023412 Seal Kit (Includes Items 4, 10, 13, 16, 17 & 18) 1

3120879 1-13

SECTION 1 FRAME

423

402

131

16261

98272

S E

FIGURE 1-5. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/ 1932E3

I O N

1-14 3120879

SECTION 1 FRAME

FIGURE 1-5. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/1932E3

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258283 JLG POTHOLE PROTECTION SYSTEM INSTALLATION Ref. 10

1 4845360 Bar, Support - Right Side 1 2 4845529 Pivot Weldment 1 3 3570198 Plate, Cam 2 4 4845385 Bushing Weldment 2 5 3841337 Rod, Pivot 1 6 3860079 Roller 1 7 4160133 Spring, Torsion 1 8 0362484 Bar, Link 4

9 0362485 Bar, Actuator 4 10 4160141 Spring, Extension 1 11 4160134 Spring, Extension 2 12 0630543 Eye Bolt 1 13 0362483 Bar, Roller 4 14 0961997 Bearing, Flange 4 15 0362654 Bar, Actuator 4 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” 5 20 4711800 Flatwasher 1/2” 1 21 3440418 Roll Pin 1/8” x 1 1/8” 1 22 3311501 Nut 5/16”-18NC 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 4845319 Weldment, Actuator 1 30 0641506 Bolt 5/16”-18NC x 1” 4 31 3311505 Locknut 5/16”-18NC 4 32 Not Required 33 Switch, Limit Options: 2

4360401 Prior to S/N 0200097741

Use 4360548 S/N 0200097741 to Production (was p/n 4360321)

4360548 Post Production

34 3911024 Screw Machine #10-24NC x 1 1/2” (Prior to S/N 0200097741) 4 35 4751000 Flatwasher #10 (Prior to S/N 0200097741) 4 36 3311005 Locknut #10-24NC (Prior to S/N 0200097741) 4 37 0681622 Bolt 3/8”-16NC x 2 3/4” 4 38 3311605 Locknut 3/8”-16NC 4 39 Not Required 40 1120481 Cap, End 4 41 4845383 Bar, Support - Left Side 1

S E

I O N

3120879 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-5. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/1932E3 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

42 Connector, Strain Relief Options: 2

4460662 Production 4460968 Post Production

43 0902536 Bracket, Limit Switch (S/N 0200096802 to Present) 1 44 0641408 Bolt 1/4”-20NC x 1” (S/N 0200096802 to Present) 2 45 4751400 Flatwasher 1/4” (S/N 0200096802 to Present) 2 46 3900271 Screw #10-32NC x 1” (S/N 0200096802 to Present) 2 47 4460268 Socket, Terminal (S/N 0200096802 to Present) 2 48 4460320 Plug - 2 Position (S/N 0200096802 to Present) 1 49 1100110 Cam (S/N 0200096802 to Present) 1 50 3951603 Screw 3/8”-16NC x 3/8” (S/N 0200096802 to Present) 2 51 0681414 Bolt 1/4”-20NC x 1 3/4” (Grade 8) (S/N 0200096802 to Pres-

ent)

52 3311405 Locknut 1/4”-20NC (S/N 0200096802 to Present) 1 53 0962262 Bushing (S/N 0200096802 to Present) 1 54 1060680 Cable, 18/2

7ft./2.14m

1-16 3120879

SECTION 1 FRAME

FIGURE 1-5. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 1532E3/1932E3 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120879 1-17

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/ 2046E3/2646E3/2658E3

1-18 3120879

SECTION 1 FRAME

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/2046E3/2646E3/ 2658E3

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

JLG POTHOLE PROTECTION SYSTEM INSTALLATIONS Ref.

0258850 2033E3 Ref. 7 0258851 2046E3/2646E3 Ref. 9 0258852 2658E3 Ref. 8

1 0257725 Actuator One Assembly 1 1A 4846014 Actuator Weldment 1 1B 3860079 Roller 1 1C 4711800 Washer 1/2” (Narrow) 1 1D 3450404 Pin, Cotter 1

2 Spring, Torsion Options: 1

Use 4160201 (Prior to S/N 0200111485) (Was P/N 4160180)

4160201 (S/N 0200111485 to Present)

3 4740481 Washer, Special Spacer 1

4 3841428 Bar, Activation 1

5 0257724 PHP Actuator Assembly 2 5A 0962123 Bearing (2 Per Assembly) 4

6 0961997 Bearing, Flange 2

7 4740482 Washer 1

8 Arm, Long Connection Options: 2

3570440 2033E3 3570482 2046E3/2646E3 3570747 2658E3

9 Arm, Short Connection Options: 2

3570439 2033E3 3570483 2046E3/2646E3 3570746 2658E3

10 0257726 Support Arm Assembly 4

10A 0962123 Bearing (3 Per Assembly) 12

11 3570422 Link, Support 8 12 0257766 Bar Assembly 2

12A 0962123 Bearing (4 Per Assembly) 8 12B 4845699 Weldment, PHP Bar 1

13 3430811 Pin, Clevis 16 14 4751800 Flatwasher 1/2” A/R 15 3450403 Pin, Cotter 16 16 4567306 Spacer 1/2” A/R 17 4567307 Spacer 3/4” 8 18 0681822 Bolt 1/2”-13NC x 2 3/4” 8 19 3311805 Locknut 1/2”-13NC 8 20 0681414 Bolt 1/4”-20NC x 1 3/4” 4 21 3311405 Locknut 1/4”-20NC 4 22 1120481 Cap, End 4 23 Use 4360548 Switch, Limit (was p/n 4360321) 1 24 3900271 Screw Machine #10-24NC x 1” 2 25 Not Used 26 0100011 Loctite #242 A/R

S E

I O N

3120879 1-19

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/2046E3/2646E3/ 2658E3 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

27 Connector, Strain Relief Options: 1

4460428 Prior to S/N 0200068552 4460662 S/N 0200068552 to Production 4460968 Post Production

28 1060680 Cable, Electrical 18/2 29 4460320 Terminal, Plug 2 Position A/R 30 4460268 Socket, Terminal 2 31 Actuator Arm Weldment Options: 1

4845886 2033E3 4845581 2046E3/2646E3/2658E3

32 0641508 Bolt 5/16”-18NC x 1” 4 33 3311505 Locknut 5/16”-18NC 4 34 0962262 Bushing 1 35 1100110 Cam 1 36 3951603 Setscrew 3/8”-16NC x 3/8” 2 37 0902536 Bracket 1 38 0641408 Bolt 1/4”-20NC x 1” 2 39 4751400 Flatwasher 1/4” 2 40 4740504 Washer (2033 Only) (S/N 0200096802 to Present) 4

7ft./2.1m

1-20 3120879

SECTION 1 FRAME

FIGURE 1-6. JLG POTHOLE PROTECTION SYSTEM INSTALLATION - 2033E3/2046E3/2646E3/ 2658E3 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120879 1-21

SECTION 1 FRAME

201208202

205

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATIONS

I O N

1-22 3120879

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LADDER INSTALLATIONS Ref.

0258895 1532E3 Ref. 5/C 0258880 1932E3/2033E3/2046E3/2646E3/2658E3 Ref. 4/C

1 Ladder Weldment Options:

4845887 1532E3 1 4845884 1932E3/2033E3/2046E3/2646E3/2658E3 1

2 0641810 Bolt 1/2”-13NC x 1 1/4” 2 3 4751800 Flatwasher 1/2” 6 4 3311805 Locknut 1/2”-13NC 6 5 3520071 Cap 2 6 0902507 Bracket, Ladder (Left Side) 1 7 0902508 Bracket, Ladder (Right Side) 1 8 0641824 Bolt 1/2”-13NC x 3” 4

BATTERY CHARGER INSTALLATIONS Ref.

0258183 1532E3/1932E3 Ref. 8 0258185 2033E3/2046E3/2646E3/2658E3 Ref. 5

S E

I O N

101 0400178 Battery Charger Assembly - 120V/240V-50Hz/60Hz

(See Figure 1-8 for Breakdown)

102 0641506 Bolt 5/16”-18NC x 3/4” 2 103 4711500 Flatwasher 5/16” 4 104 3311505 Locknut 5/16”-18NC 2 105 4060975 Shield (1532E3/1932E3 Only) 1 106 3941406 Screw Self-Tapping 1/4”-20NC x 3/4”

(1532E3/1932E3 Only)

107 0100011 Loctite #242 (1532E3/1932E3 Only) (Prior to S/N

0200111444)

108 Harness, Charger Options: 1

Use 4922233 1532E3/1932E3 (was p/n 4922234) (Prior to

S/N 0200081384)

4922233 1532E3/1932E3 (S/N 0200081384 to Present) 4922233 2033E3/2046E3/2646E3/2658E3

109 1320061 Clamp (Prior to S/N 0200111444) 1 110 0641406 Bolt 1/4”-20NC x 3/4” (Prior to S/N 0200111444) 1 111 3311405 Locknut 1/4”-20NC (Prior to S/N 0200111444) 1 112 1701644 Decal - Battery Charger (S/N 0200081163 to Present) 1

TILT INDICATOR INSTALLATIONS Ref.

0258844

0258841

0258977

0258841

° Tilt - 1532E3/1932E3 (S/N 0200100141 to Present)

1 1/2

° Tilt - 1532E3/1932E3

° Tilt - 2033E3 ° Tilt - 2046E3/2646E3/2658E3

A/R

Ref. 3

201 Switch, Level Indicator Options: 1

4360465

4360435

3120879 1-23

° Tilt Indicator

1 1/2

° Tilt Indicator

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

202 Harness Options (See Section 7 for Breakdown): 1

Use 4922285 Prior to S/N 0200060218 (Was P/N 4921819)

4922285 S/N 0200060218 to Present

203 0641406 Bolt 1/4”-20NC x 3/4” 2 204 Not Used 205 3311405 Locknut 1/4”-20NC A/R

206 to 207 Not Used

208 4751400 Flatwasher 1/4” A/R

LIMIT SWITCH INSTALLATIONS - 1532E3/1932E3 Ref.

0256833 Hi-Drive Limit Switch Ref. 7 0258122 Drive Cutout Limit Switch Ref. 6

301 1440325 Collar 1 302 3951603 Setscrew 3/8”-16NC x.38” 2 303 3570030 Bracket 1 304 Plate, Limit Switch Options: 1

3570029 Hi-Drive Limit Switch (Prior to S/N 0200071788) 3571789 Hi-Drive Limit Switch (S/N 0200071788 to Present) 3571388 Drive Cutout Limit Switch (Prior to S/N 0200071788) 3571789 Drive Cutout Limit Switch (S/N 0200071788 to Present)

305 Use 4360548 Switch, Limit (was p/n 4360321) 1 306 3930820 Screw #8-32NC x 1 1/4” (Hi-Drive Limit Switch) 2

3911020 Screw #10-24NC x 1 1/4” (Drive Cutout Limit Switch) 2

307 4750800 Flatwasher #8 (Hi-Drive Limit Switch) 2

4751000 Flatwasher #10 (Drive Cutout Limit Switch) 2

308 3310801 Locknut #8-32NC (Hi-Drive Limit Switch) 2

3311005 Locknut #10-24NC (Drive Cutout Limit Switch) 2 309 0641405 Bolt 1/4”-20NC x.625 2 310 4751400 Flatwasher 1/4” 4 311 3311405 Locknut 1/4”-20NC 2 312 Strain Relief Options: 1

4460662 Production

4460968 Post Production

313 1060680 18/2 Cable 314 4460320 Housing, Terminal 1 315 4460268 Socket, Terminal 2 316 0100011 Loctite #242 A/R 317 Not Used 318 4760800 Lockwasher #8 (Hi-Drive Limit Switch) 2

9ft/2.74m

0258201 HI-DRIVE LIMIT SWITCH INSTALLATION -

2033E3/2046E3/2646E3/2658E3

351 1100110 Cam 1 352 3951603 Setscrew 3/8”-16NC x.38” 2 353 0100011 Loctite #242 A/R 354 3571116 Plate, Limit Switch 1 355 Use 4360548 Switch, Limit (was p/n 4360321) 1

1-24 3120879

Ref. 9

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