JLG 3246E2 Service Manual

SERVICE & MAINTENANCE

Models

1532E2 1932E2 2032E2 2632E2 2646E2 3246E2

3120855

May 10, 2006

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A.A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

A.B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

A.C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3120855 – JLG Sizzor – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISON LOG

Original Issue - June 1998

Revised - March 5, 1999 (Added 3246E2)

Revised - September 15, 1999 (Added 3246E2 w/ Proportional Control)

Revised - 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

b – JLG Sizzor – 3120855

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a-a

A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a

A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.7 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.11 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.6 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.8 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.9 Lift Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.10 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.11 Brake Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.12 Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.13 Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2.14 Pressure Setting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.15 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2.16 Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2.17 JLG SMART System™ Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.18 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.19 Machine Model Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2.20 Machine Configuration Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.21 Jlg Smart System™ Help Messages and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2.22 Analyzer Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.23 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3120855 – JLG Sizzor – i

TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1. Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-2. Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-4. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-5. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-7. Brake Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-8. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-9. Tilt Switch Leveling Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-10. Tilt Switch Leveling Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-11. Control Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-12. Control Valve Components (3246E2 w/Proportional Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-13. Quick Welder™ Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-14. JLG SMART System™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-15. Organizational Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

3-1. Electrical Schematic - Non Proportional Control (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2. Electrical Schematic - Non Proportional Control (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-3. Electrical Schematic - Proportional Control (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4. Electrical Schematic - Proportional Control (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-5. Hydraulic Schematic - Non Proprtional Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-6. Hydraulic Schematic - 3246E2 Proprtional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-7. Harness and Cable Assembly - Non Proportional Control (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . .3-10

3-8. Harness and Cable Assembly - Non Proportional Control (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . .3-11

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-3 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-5 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2-1 Cylinder Component Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-2 Holding Valve Torque Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3 Pressure Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-4 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-5 Machine Model Default Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2-6 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2-7 Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-8 JLG SMART System™ Flash Codes & Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-9 Analyzer Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2-10 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

3-1 Electricl Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 Hydraulic System Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

ii – JLG Sizzor – 3120855

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Tank

1932E2

11.4 liters at full mark on tank

9.5 liters at add mark on tank

2032E2/2632E2/2646E2/3246E2

14.8 liters at full mark on tank

12.9 liters at add mark on tank

Hydraulic System (Including Tank)

1932E2 - Approximately 15.0 liters

2032E2/2632E2/2646E2/3246E2 - Approximately 19.0 liters

1.2 COMPONENT DATA

Hydraulic Pump/Electric Motor Assembly

24 Volts DC motor w/Single section gear pump

1932E2 8.5 lpm

2032E2/2632E2/2646E2/3246E2 -11.4 lpm

Battery Charger

20 Amp SCR

120/240 Volts AC - 50 Hz input

24 Volts DC - 20 Amp output w/auto timer

Batteries (4)

1932E2/2032E2/2646E2 - 6 Volt, 220 Amp Hour

2632E2/3246E2 - 6 Volt, 245 Amp Hour

Steer/Drive System

Tires -1932E2

Standard - 12.5 x 4 - Solid, Non-Marking, Rib

Optional - 12.5x4 - Solid, Rib

Tires - 2032E2/2632E2/2646E2/3246E2

Standard - 16.00 x 5.00 - Solid, Non-Marking

Optional -16.00 x 5.00 - Solid, Rib

Parking Brake ( rear dual wheel) - Single cylinder, spring applied, hydraulically released.

Drive Motors

1932E2 - 126 cm3 displacement

2032E2 - 229.4 cm3 displacement

2632E2 - 310.3 cm3 displacement

2646E2 - 265.5 cm3 displacement

3246E2 - 294 cm3 displacement

Hydraulic Filter - Inline

Return - Bypass Type

10 Microns Nominal

Platform Size

1932E2 - 0.8 m x 1.6 m

2032E2/2632E2 - 0.8 m x 2.1 m

2646E2/3246E2 - 1.1 m x 2.1 m

1.3 PERFORMANCE DATA

Travel Speed

1932E2

Low Speed - 2.1 kmh

Elevated Speed -1.1 kmh

Maximum Speed - 4.0 kmh

2032E2

Low Speed - 2.1 kmh

Elevated Speed - 1.1 kmh

Maximum Speed - 4.2 kmh

2632E2/2646E2

Low Speed - 2.1 kmh

Elevated Speed - 1.1 kmh

Maximum Speed - 3.6 kmh

3246E2

Low Speed - 2.1 kmh

Elevated Speed - 0.8 kmh

Maximum Speed - 3.2 kmh

3120855 – JLG Sizzor – 1-1

SECTION 1 - SPECIFICATIONS

Gradeability

All Models - 25%

Inside Turning Radius

1932E2 - 0.5 m

2032E2/2632E2 - 1m

2646E2 - 1 m

3246E2 - 1.1 m

Lift (No Load in Platform)

1932E2

Up - 27 seconds

Down -26 seconds

2032E2

Up - 27-35 seconds

Down - 28-35 seconds

2632E2

Up - 34-42 seconds

Down - 39-47 seconds

2646E2

Up - 40-48 seconds

Down - 37-45 seconds

3246E2

Up - 56-64 seconds

Down - 45-55 seconds

Machine Weight

1932E2 - approx. 1360 kg

2032E2 - approx. 2091 kg

2632E2 - approx. 2415 kg

2646E2 - approx. 2086 kg

3246E2 - approx. 2812 kg

Wheelbase

1932E2 -1.3 m

2032E2/2632E2/2646E2/3246E2 - 1.7 m

Platform Height (Elevated)

1932E2 - 5.8 m

2032E2 - 6.1 m

2632E2/2646E2 - 7.9 m

3246E2 - 9.75 m

Platform Height (Stowed)

1932E2 - 1.0 m

2032E2 - 1.0 m

2646E2/3246E2 - 1.2 m

Machine Height (Stowed)

Standard Handrails

1932E2 - 2.0 m

2032E2 - 2.0 m

2632E2 - 1.2 m

2646E2 - 1.8 m

Platform Capacity

1932E2 - 230 kg

2033E2 - 340 kg

2632E2 - 230 kg

2646E2 - 340 kg

3246E2 - 2.3 m

Machine Length

1932E2 - 1.7 m

2032E2/2632E2/2646E2/3246E2 - 2.3 m

Machine Width

3246E2 - 320 kg

Manual Platform Extension Capacity

All Models - 120 kg. - 1 person

1-2 – JLG Sizzor– 3120855

1932E2 - 0.8 m

2032E2 - 0.8 m

2646E2/3246E2 -1.2 m

SECTION 1 - SPECIFICATIONS

Ground Clearance

With Platform Lowered

All Models - 8.0 cm

With Platform Elevated

(Pothole Protection System Lowered)

All Models - 1.9 cm

Maximum Tire Load

1932E2 - 492 kg

2032E2 - 662 kg

2632E2 - 885 kg

2646E2 - 746 kg

3246E2 - 1,065 kg

Maximum Bearing Pressure

1932E2 - 6.4 kg/cm2

2032E2 - 7.0 kg/cm2

2632E2 - 8.4 kg/cm

2646E2 - 7.5 kg/cm

3246E2 - 8.9 kg/cm

1.5 LUBRICATION

Hydraulic Oil

Table 1-2. Hydraulic Oil

HYDRAULIC SYSTEM

OPERATING TEMPERATURE

RANGEc

F to + 23o F

(-18

C to -5o C)

0o F to + 210o F

C to +9 9o C)

(-18

F to + 210o F

C to + 210o C)

(+10

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. When temperatures remain consistently below 20° F (-7° C), JLG recommends the use of MobilDTE13M hydraulic oil.

NOTE: Aside from JLG recommendations, it is not advisable

to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

1.4 TORQUE REQUIREMENTS

Table 1-1. Torque Requirements

Desriciption Torque Value (Dry) Interval Hours

Wheel Lugs 105-120 ft lb (147-168 Nm) 50

Wheel Hub To Drive Motor

Torque nut to 169 -203 Nm (dry), then add extra torque to line up the slot with the hole in the shaft to install the cotter pin.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, to determine proper torque value, refer to Figure 1-2., Torque Chart.

125-150 ft lb* (169-203 Nm) 600

Lubrication Specifications

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum drippi ng

point of 350 adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum

EPGL Extreme Pressure Gear Lube (oil) meetin g API

service classification GL-5 or MIL-Spec MIL-L2105

HO Hydraulic Oil. API service classification GL-3,e.g.

Mobilfluid 424 .

F. Excellent water resistance and

3120855 – JLG Sizzor – 1-3

SECTION 1 - SPECIFICATIONS

1.6 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. On 2032E2/2632E2/2646E2 and 3246E2 the plate is located on the front, center of the machine frame, on 1932E2 it is located above the right rear tire. The serial number will also be stamped on the front center of the machine frame.

1.7 LIMIT SWITCHES

The machines are equipped with the following limit switches:

Tilt Alarm - Illuminates a light on the platform and sounds an alarm when the machine is elevated and out of level in any direction 2° or more.

High Drive Cut-Out - High drive speed is cut out when the platform is raised above the preset height per model as follows.

1932E2 - 2.6 m

2032E2 - 2.1 m

2632E2 (Australian Only) - 2.9 m

2632E2/2646E2 - 2.6 m

3246E2 - 2.8 m

1.8 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), given in parenthe ses.

Table 1-4. Cylinder Specifications

Description Bore Stroke Rod Diameter

Lift Cylinder

(1932E2)

Lift Cylinder

(2032E2)

Lift Cylinder

(2632E2)

Lift Cylinder

(2646E2)

Lift Cylinder

(3246E2)

Steer Cylinder

(All Models)

Brake Cylinder

(All Models)

3.00 (7.6)

3.50 (8.9)

3.00 (7.6)

3.5

(8.9)

1.50 (3.8)

2.00 (5.1)

32.00 (81.2)

38.87 (98.7)

38.94 (99.0)

37.75 (95.8)

38.94 (99.0)

6.25

(15.9)

1.75 (4.4)

2.00 (5.1)

0.75 (1.9)

1.00 (2.5)

Figure 1-1. Serial Number Location

1-4 – JLG Sizzor– 3120855

SECTION 1 - SPECIFICATIONS

1.9 PRESSURE SETTINGS

Pressure Settings for Non Proportional Control Machines

Main Relief Max - 221 bar

Steer Relief Max - 138 bar

Lift Up Relief Max -

1932E2 - 159 bar

2033E2 - 152 bar

2632E2/2646E2/3246E2 - 165 bar

Pressure Settings for Proportional Control Machines

Main Relief Max - 207 bar +3.4/-0 bar (3000 psi +50/-0 psi)

Steer Relief Max - 145 bar (2100 psi)

Lift Up Relief Max - 145 bar (2100 psi)

1.11 MAJOR COMPONENT WEIGHTS

Table 1-6. Major Component Weights

COMPONENT KG LB

Platform (31 in. x 62 in.) - 1932E2 113 250

Platform (31 in. x84 in.) - 2032 E2/2632E2 176 388

Platform (46in. x 84 in.) - 2646 E2/3246E2 204 450

Manual Platform Extension -1932E 2 71 156

Manual Platform Extension -20 32E2/2632E2 71 156

Manual Platform Extension -26 46E2/3246E2 98 215

Arm Assembly - 1932E2 (Includes Lift Cylinder) 279 616

Arm Assembly - 2032E2 (Includes Lift Cylinder) 477 1,052

Arm Assembly - 2632E2 (Includes Lift Cylinder) 3,380 1,535

Arm Assembly - 2646E2 (Includes Lift Cylinder) 787 1,736

Arm Assembly - 3246E2 (Includes Lift Cylinder) 980 2,156

Chassis - 1932E2 w/Solid Tires 798 1,760

Chassis - 2032E2 w/Solid Tires (Includes 464 lb[211 kg] Counterweight)

Chassis - 2646E2 w/Solid Tires 876 1,932

Chassis - 3246E2 w/Solid Tires 1,022 2,253

1,054 2,324

1.10 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-5. Critical Stability Weights

Component 1932E2 2032E2/2632E2

Tires-Solid (each)

Tires-Solid-NonMarking (each)

Motor/Pump Assembly

Batteries - Std.- Each 63 lb

Batteries - Standard Combined

24lb

(11kg)

24lb

(11kg)

41 lb

(19 kg)

(29 kg)

252 lb

(114 kg)

31 lb

(14 kg)

30 lb

(14 kg)

41 lb

(19 kg)

63 lb

(29 kg)

252 lb

(114 kg)

2646E2/3246E2

31 lb

(14 kg)

30 lb

(14 kg)

41 lb

(19 kg)

63 lb

(29 kg)

252 lb

(114 kg)

3120855 – JLG Sizzor – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart.

1-6 – JLG Sizzor– 3120855

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

This section provides information necessary to perform maintenance on the scissor lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

NOTE: Maintenance procedures provided in this section

apply to all scissor lift models covered in this manual. Procedures that apply to a specific model will be so noted.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

The maintenance procedures included consist of servicing and component removal and installation, disassembly and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

items must be maintained on a scheduled basis in order to function properly.

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90°.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

Safety and Workmanship

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure Washing

It is a good practice to avoid pressure washing electronic components. Should pressure washing be utilized to wash areas containing electronic components, JLG Industries Inc. recommends a maximum pressure of 52 bar at a minimum distance of 30.5 cm. away. In addition, JLG Industries Inc. also recommends that these components are indirectly sprayed for brief time periods to avoid saturation.

3120855 – JLG Sizzor – 2-1

SECTION 2 - PROCEDURES

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3. If a bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Batteries

Clean batteries, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry batteries and coat terminals with an anti-corrosion compound.

Lubrication and Servicing

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices.

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Components and assemblies requiring lubrication and servicing are shown in Section 1.

2.3 LUBRICATION INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in Section 1. Always examine filters for evidence of metal particles.

2-2 – JLG Sizzor – 3120855

SECTION 2 - PROCEDURES

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, except as recommended, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity ranges.

2. JLG recommends Mobilfluid 424, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -26° C (-15° F). is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of

-26° C (-15° F).

3. The only exception to the above is to drain and fill the system with Mobil DTE 13M oil or its equivalent. This will allow start up at temperatures down to -29° C (-20° F). However, use of this oil will give poor performance at temperatures above 49° C (120° F). Systems using DTE 13M oil should not be operated at temperatures above 94° C (200° F) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils increases JLG’s recommended oil change interval to 800 hours. However, filter elements must be changed after the first 50 hours of operation and every 400 hours thereafter. When changing the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If you are unable to obtain the same type of oil supplied with the machine, consult your local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Table 1-2 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4 CYLINDERS - THEORY OF OPERATION

Cylinders are of the double acting type. The Steer systems incorporate double acting cylinders. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

A holding valve is used in the Lift circuit to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

2.5 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is

3120855 – JLG Sizzor – 2-3

SECTION 2 - PROCEDURES

released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Relief Valves

Relief valves are installed at various points within the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral reliefs are provided for each side of the circuit.

2.8 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is replaced or when improper system operation is suspected.

Cylinder w/o Holding Valves - Brake Cylinder and Steer Cylinder

OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

1. Using all applicable safety precautions, activate motor and fully extend cylinder to be checked. Shut down motor.

2. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the retract port.

2.6 COMPONENT FUNCTIONAL DESCRIPTION

Hydraulic Pump

The main hydraulic pump is an integral part of the electric motor/pump assembly, located at the rear of the battery and ground control tray on the frame of the machine. The pump is a single section pump that provides an output of

11.4 lpm.

2.7 WEAR PADS

Sliding Pads

The original thickness of the sliding pads is 47.6 mm. Replace sliding pads when they are worn to 42.7 mm.

3. Activate motor and activate cylinder extend function. Check retract port for leakage.

4. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to retract port and retract cylinder.

5. With cylinder fully retracted, shut down motor and carefully disconnect hydraulic hose from cylinder extend port.

6. Activate motor and activate cylinder retract function. Check extend port for leakage.

7. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks.

2-4 – JLG Sizzor – 3120855

SECTION 2 - PROCEDURES

Cylinders w/Single Holding Valves - Lift Cylinder

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLATFORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE.

DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Raise platform completely then retract cylinder slightly to avoid trapping pressure. Place a suitable overhead lifting device approximately 2.5 cm (1 in) below the platform.

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Carefully remove hydraulic hoses from cylinder port block.

4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the holding valve is defective and must be replaced.

5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

6. Remove lifting device from platform, activate hydraulic system and run cylinder through one complete cycle to check for leaks.

3. Retract the lift cylinder rod completely.

4. Tag and disconnect the hydraulic lines, then cap the lift cylinder hydraulic lines and ports.

5. Remove the bolts and locknuts securing the barrel end to the lower arm assembly.

6. Carefully remove the cylinder from the scissor lift and place in a suitable work area.

Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings, aligning barrel end in lower arm assembly cylinder saddle.

2. After the cylinder barrel is in place, Secure it with the bolts and locknuts.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. Extend the cylinder rod until the cylinder head aligns with upper inside cylinder saddle. Set the head of the cylinder in the saddle and replace the bolts and locknuts.

5. Lower platform to stowed position and shut down motor. Check hydraulic fluid level and adjust accordingly.

2.10 LIFT CYLINDER REPAIR

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. BE SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES FROM CYLINDER OPENINGS - PARTICULARY AT THE HEAD.

1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.

2.9 LIFT CYLINDER REMOVAL AND INSTALLATION

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

Lift Cylinder Removal

2. Operate the hydraulic power source and extend the

1. Place the machine on a flat and level surface. Raise the platform and attach a suitable lifting device to the platform.

2. Remove the bolts and locknuts securing the cylinder to the upper inner arm assembly. Drop the cylinder out of the saddle on the inner arm assembly.

3120855 – JLG Sizzor – 2-5

cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if necessary

3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

SECTION 2 - PROCEDURES

Figure 2-1. Lift Cylinder Assembly

4. Place the cylinder barrel into a suitable holding fixture

Figure 2-2. Barrel Support

5. If applicable, using a suitable spanner wrench, loosen the spanner nut retainer and remove the spanner nut from the cylinder barrel.

6. Secure a pull bar to the rod end with a 0.75 - 16 capscrew fastener.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

2-6 – JLG Sizzor – 3120855

Figure 2-3. Capscrew Removal

7. Using this as a handle, pull out the piston rod and extend until the piston bottoms out on the head

8. Gently tap the piston against the head to drive the rod assembly out.

9. Place the rod on a clean surface that will not damage the chrome.

10. Vise - up on the wrench flats on the end of the rod and remove the piston locknut.

SECTION 2 - PROCEDURES

face of the rod. In the event that an unacceptable condition occurs, the rod should be repaired or replaced.

3. Visually inspect the inside bore of the head for scratches or polishing. Deep scratches are unacceptable. If polishing occurs the bore should be checked for ovality.

4. If ovality occurs it is unacceptable. Check the condition of the seals looking particularly for metal particles embedded in the seal surface.

5. Damage to the seal grooves is unacceptable, particularly on the sealing surfaces. In the event that an unacceptable condition occurs, the piston should be replaced.

6. Visually inspect the bore on the inside tube assembly for pits and scratches. There should be no scratches or pits deep enough to catch the fingernail.

7. Inspect threaded portion of barrel for damage. Dress threads as necessary.

8. Inspect threaded portion of piston for damage. dress threads as necessary.

9. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

Figure 2-4. Rod Support

11. Break the piston free and separate from the rod.

12. Slide the spacer and head off the rod from the piston shoulder end.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. There should be no scratches or pits deep enough to catch the fingernail. Pits or scratches that go to the base metal are unacceptable. Chrome should be present over the entire sur-

10. Inspect threaded portion of head for damage. Dress threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

13. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

14. If applicable, inspect port block fittings and holding valve. Replace as necessary.

15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

16. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used.

Apply a light film of hydraulic oil to all components prior to assembly.

3120855 – JLG Sizzor – 2-7

SECTION 2 - PROCEDURES

1. Using a special tool, pictured in the following illustration, install a new rod seal into the applicable cylinder head gland groove.

Figure 2-5. Rod Seal Installation

WHEN INSTALLING NEW "PARKER" TYPE PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

2. Using a soft mallet, tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable head gland groove.

12. Thoroughly rinse the inside of the rod weldment and allow to drain. Wipe with a lint free rag.

13. Clean and visually inspect all parts for material defects and contamination.

14. Lubricate the head, piston, and all seals with hydraulic fluid prior to installation.

15. When the rod is ready to be installed in the rod weldment, liberally apply an anti-seize lubricant.

16. Cover the entire rod assembly with hydraulic fluid and with the rod weldment positioned in a suitable holding fixture insert the rod into the rod weldment.

17. Using a spanner wrench tighten the cylinder head.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

18. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

19. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applicable. For proper holding valve torque specifications refer to Table 2-2, Holding Valve Torque Specifications.

3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head.

4. Install a washer ring onto the rod, then carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer onto the rod.

6. If applicable, correctly place a new o-ring and backup rings in the inner piston diameter groove.

7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

8. Carefully place the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged.

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.

Table 2-1. Cylinder Component Torque Specifications.

Component Torque Value (w/Loctite)

Piston Nut - Lift Cylinder - 1932E2 375-450 ft lb

(508-610 Nm)

Piston Nut - Lift Cylinder - 2032E2/

2646E2/3246E2

Table 2-2. Holding Valve Torque Specifications.

Description Torque Value

1932E2, 2032E2 - Hydraforce -

1.25" hex 3/4 - 16 thds

2646E2/3246E2 - Hydraforce - 1"

hex 7/8 - 14 thds

800-1000 ft lb

(1085-1356 Nm)

20 ft lb (27.1 Nm)

25 ft lb (33.9Nm)

2-8 – JLG Sizzor – 3120855