JLG 3246ES Parts Manual

Illustrated Parts Manual

Models

1930ES, 2030ES 2630ES, 2646ES

& 3246ES

PRIOR TO S/N 0200135154

PRIOR TO S/N 1200004293

3121246

October 9, 2013

REVISION LOG

NOTES:

NOTE: The ES Scissor Lifts are manufactured by JLG Industries in the following countries: USA, Belgium or China.

Refer to the Serial Number Tag to identify the country of manufacture. The country of manufacture may be determined by the Serial Number. ES Scissors manufactured in the USA will have a serial number prefix of 02 (i.e. 02XXXXXXXX), ES Scissors manufactured in Belgium will have a prefix of 12 (i.e. 12XXXXXXXX) and ES Scissors manufactured in the China will have a serial number prefix of B2 (i.e. B2XXXXXXXX).

NOTE: 1930ES, 2030ES, 2630ES, 2646ES & 3246ES Global Illustrated Parts Manual P/N 3121167 has been replaced by multiple manuals. Review machine S/N and use the Global Illustrated Parts Manual for the correct serial number range: USA Built Machines Prior to S/N 0200135154 — Use manual p/n 3121246. USA Built Machines S/N 0200135154 to S/N 0200152825 — Use manual p/n 3121247. USA Built Machines S/N 0200152825 to S/N 0200198014 — Use manual p/n 3121248. USA Built Machines S/N 0200198014 to Present — Use manual p/n 3121275. Belgium Built Machines Prior to S/N 1200004293 — Use manual p/n 3121246. Belgium Built Machines S/N 1200004293 to S/N 1200008481— Use manual p/n 3121247. Belgium Built Machines S/N 1200008481 to Present — Use manual p/n 3121248. China Built Machines S/N B200000100 to Present — Use manual p/n 3121275.

MANUAL REVISION LOG:

May 31, 2008 - Original Issue of Manual (Edited to B/M 0010588 Revision 68)

August 1, 2008 - Revised Manual (Edited to B/M 0010588 Revision 69)

March 1, 2009 - Revised Manual

November 15, 2009 - Revised Manual

December 16, 2009 - Revised Manual

March 1, 2010 - Revised Manual

November 1, 2010 - Revised Manual

April 11, 2011 - Revised Manual

July 22, 2011 - Revised Manual

October 7, 2011 - Revised Manual

January 10, 2012 - Revised Manual

June 20, 2012 - Revised Manual

August 23, 2012 - Revised Manual

January 10, 2013 - Revised Manual

April 15, 2013 - Revised Manual

July 10, 2013 - Revised Manual

October 9, 2013 - Revised Manual

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES A

REVISION LOG

B 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 STEERING, DRIVE AND REAR AXLE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES PRIOR TO S/N 0200118041

& BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487) . . . . . . . . . . . . . . . 1-6

1-3 WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO

S/N 0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO

S/N 1200004293). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 FRAME MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-5 POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES) . . . . . . . . . . . . 1-20

1-6 POTHOLE PROTECTION INSTALLATION (2646ES/3246ES). . . . . . . . . . . . . . . . . . . 1-22

1-7 BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH

BREAKERS ON SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-8 BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH

BREAKERS ON END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1-9 BATTERY CHARGER WITH INVERTER ASSEMBLY AND INSTALLATION

(OPTIONAL ON ANSI SPEC MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

1-10 LADDERS, BEACON LIGHT & ROTARY SENSOR COVER INSTALLATIONS . . . . . . 1-32

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

2-1 BATTERIES AND COVERS INSTALLATION (USA BUILT MACHINES PRIOR TO

S/N 0200128413 & BELGIUM BUILT MACHINES PRIOR TO S/N 1200002974) . 2-2 2-2 BATTERIES AND COVERS INSTALLATION (USA BUILT MACHINES

S/N 0200128413 TO S/N 0200135154 & BELGIUM BUILT MACHINES

S/N 1200002974 TO S/N 1200004293). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 GROUND CONTROL ASSEMBLY & INSTALLATION (USA BUILT MACHINES

PRIOR TO S/N 0200117805 & BELGIUM BUILT MACHINES PRIOR TO

S/N 1200001367). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 GROUND CONTROL ASSEMBLY & INSTALLATION (USA BUILT MACHINES

S/N 0200117805 TO S/N 0200135154 & BELGIUM BUILT MACHINES

S/N 1200001367 TO S/N 1200004293). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-5 BRAKE DISCONNECT/RELEASE & MDI (MULTIFUNCTION DIGITAL

INDICATOR) GAUGE INSTALLATIONS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . 2-18

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

3-1 SCISSOR ARMS INSTALLATION - 1930ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 SCISSOR ARMS INSTALLATION - 2030ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 SCISSOR ARMS INSTALLATION - 2630ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4 SCISSOR ARMS INSTALLATION - 2646ES/3246ES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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

4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 RAIL (FIXED) INSTALLATION - 1930ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 RAIL (FOLD-DOWN) INSTALLATION - 1930ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 RAIL INSTALLATION - 2030ES/2630ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 RAIL INSTALLATION - 2646ES/3246ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-6 PLATFORM CONSOLE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-7 DRIVE/STEER CONTROLLER ASSEMBLY (ORIGINAL EQUIPMENT) . . . . . . . . . . . 4-26

4-8 DRIVE/STEER CONTROLLER ASSEMBLY (SERVICE REPLACEMENT) . . . . . . . . . 4-28

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

5-1 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

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

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

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

7-1 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

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

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATIONS (ANSI EXPORT SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-3 DECAL INSTALLATION (AUSTRALIAN & CE SPECS). . . . . . . . . . . . . . . . . . . . . . . . .8-14

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

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

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

ii 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1

FRAME

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-1

SECTION 1 FRAME

301

208

207

206

205

204

022012031031031

04104

115

114

112

102A

102

301

208

207

206

205

204

022012031031031

04104

115

114

112

102A

102

302

FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS

1-2 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. STEERING INSTALLATION 0272371 Ref. 1930ES F 0273227 Ref. 2030ES/2630ES C 0272372 Ref. 2646ES/3246ES G

1 0440259 2 Bearing, Flanged 2 4 Bolt M10 Options:

0701016 40mm Length 0701020 60mm Length

3 1380153 4 E-Clip 4 1 Steer Cylinder Assembly (See Section 5 for Breakdown):

1684237 1930ES/2030ES/2630ES 1684263 2646ES/3246ES

5 to 6 Not Used

7 3423037 4 Pin, Clevis 8 4812000 4 Flatwasher M10

9 4846757 2 Lug, Steer 10 0100011 A/R Compound, Locking 11 1320318 2 P-Clamp (Not Shown - Used with Steer Hoses) (USA Built

Machines Prior to S/N 0200124799 & Belgium Built Machines Prior to S/N 1200002594)

12 1380158 2 Clip (Not Shown - Used with Item 11) (USA Built Machines Prior

to S/N 0200124799 & Belgium Built Machines Prior to S/N 1200002594)

13 2110404 2 Fitting, Straight

Ref. DRIVE INSTALLATION 0272710 Ref. 1930ES L 0274224 Ref. 1930ES (UL SPEC) C 0272711 Ref. 2030ES/2630ES L 0274225 Ref. 2030ES/2630ES (UL SPEC) C 0273008 Ref. 2646ES/3246ES L 0274226 Ref. 2646ES/3246ES (UL SPEC) C

101 Not Used 102 2 Wheel Drive Assembly Options:

Ref. 1930ES

No Longer

Available - See

Note

Use 2915236 USA Built Machines S/N 0200118041 to S/N 0200135154

USA Built Machines Prior to S/N 0200118041 & Belgium Built Machines Prior to S/N 1200001487 (was p/n 0272305) (See Figure 1-2 for Breakdown) NOTE: To replace the complete unit both right & left Drive Assemblies must be upgraded at the same time. Order qty 2 of p/n 2915236.

& Belgium Built Machines S/N 1200001487 to S/N 1200004293 (See Figure 1-3 for Breakdown) (was p/n 3160306)

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-3

SECTION 1 FRAME

FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

102(cont’d) Ref. 2030ES/2630ES/2646ES/3246ES

No Longer

Available - See

Note

Use 1001100975 USA Built Machines S/N 0200118041 to S/N 0200135154

102A 3577112 2 Plate, Spacer (Used only on Machines with Kit

103 4 Wheel & Bolt Kit Options (includes Item 104):

Ref. Note: Must replace Tire & Wheel Assemblies in pairs per

2915012 1930ES (was p/n 0272699, 2915005, 4520277, 4520326 &

2915013 2030ES/2630ES/2646ES/3246ES

104 20 Bolt, Wheel Options:

0630579 36mm Length 0630580 22mm Length

105 to 107 Not Used

108 2780266 2 Hub Assembly (See Items 201-208 for Breakdown)

109 to 111 Not Used

112 3760463 2 Ring, Retaining 113 Not Used 114 4740523 4 Washer, Spindle Retaining 115 4740524 2 Thrustwasher M60

USA Built Machines Prior to S/N 0200118041 & Belgium Built Machines Prior to S/N 1200001487 (was p/n 0272306) (See Figure 1-2 for Breakdown) NOTE: To replace the complete unit both right & left Drive Assemblies must be upgraded at the same time. Order qty 2 of p/n 1001100975.

& Belgium Built Machines S/N 1200001487 to S/N 1200004293 (See Figure 1-3 for Breakdown) (was p/n 3160307)

p/n 2915236 installed)

axle.

4520565)

(was p/n 2915006, 4520278, 4520327 & 4520676)

2780266 Ref. HUB ASSEMBLY B

Ref. Note: Qtys shown for 1 Assembly. Two Assemblies required

per machine.

201 Use 1001102354 1 Cap, Dust (was p/n 7012524) 202 Use 3300423 1 Nut, Slotted (was p/n 7010641) 203 Use 3450406 1 Pin, Cotter 2” x 3/16” (was p/n 7010642) 204 Use 4740468 1 Washer (was p/n 7019697) 205 Use 1001102351 1 Bearing, Cone - Outer (was p/n 7026185) 206 Not Available 1 Hub (Purchase Complete Hub p/n 2780266) 207 Use 1001102353 1 Bearing, Cone - Inner (was p/n 7026183) 208 Use 1001102349 1 Seal (was p/n 7026184)

Ref. FRAME WELDMENTS

301 A/R Bushing Options:

0440264 2 1930ES 0440265 4 2030ES/2630ES/2646ES/3246ES

302 A/R Kingpin Rework Instruction Options (Provides rework procedure

for damaged kingpins): 3128601 1930ES/2030ES/2630ES 3128703 2646ES/3246ES

1-4 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-5

SECTION 1 FRAME

103

102

112

101

114

109 110

106 107 108 111 113

201A 201B

202 204 205 206

207

203

208 209 210 211 212

105

104

115

12132

25910

26A

25523

26A

GENUINE PARTS

26B

FIGURE 1-2.WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES PRIOR TO S/N 0200118041 &

BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487)

1-6 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES PRIOR TO S/N 0200118041 &

BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE ASSEMBLY (PEERLESS) 0272305 Ref. 1930ES F 0272306 Ref. 2030ES/2630ES/2646ES/3246ES F

Ref. HUB ASSEMBLY

1 1 Spindle

No Longer

Available

No Longer

Available

2 Use Item 210 1 Hub 3 Use Item 211 1 Ring, Input 4 Use Item 204 3 Gear, Input Sun 5 Use Item 204 3 Gear, Input Planet 6 Use Item 204 3 Pin, Planet Gear 7 Use Item 204 1 Carrier 8 Use Item 204 1 Gear, Output Sun

9 Use Item 205 3 Gear, Output Planet 10 Use Item 205 3 Pin, Output Planet 11 Use Item 202 1 Cover 12 7024757 1 Bushing Kit, Kingpin (includes 2 Bushings) 13 See Note 1 Motor, Electric (Note: Use Item 201A or 201B) 14 See Note 2 Bearing, Main (Note: Use Item 203, 205, 210 or 211) 15 Use Item 205 1 Bearing, Shaft 16 70001739 1 Seal, Lip 17 7024786 1 Seal, Lip 18 Use Item 204 3 Ring, Retaining 19 Use Item 202 1 Ring, Retaining 20 See Note 1 O-Ring (Note: Use Item 202, 203, 204, 205, 210 or 211) 21 Use Item 202 1 Thrustwasher 22 Not Used 23 Use Item 204 1 Plate, Thrust 24 Use Item 204 1 Ring, Retaining 25 See Note 9 Thrustwasher (Note: Use Item 204 or 205) 26 See Note A/R Bearing/Bushing Options (Note: Use Item 204 or 205):

26A 66 Bearing, Needle 26B 6 Bushing

27 See Note 1 Ring, Retaining (Note: Use Item 205, 210 or 211) 28 Use Item 205 1 Ring, Retaining 29 Use Item 202 2 Plug 30 Not Used 31 See Note 1 O-Ring (Note: Use Item 201A, 201B, 208 or 209) 32 Use Item 205 3 Washer, Tanged

Spindle 1930ES (was p/n 7024754)

Spindle 2030ES/2630ES/2646ES/3246ES (was p/n

7024761)

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-7

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES PRIOR TO S/N 0200118041 &

BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BRAKE & MOTOR COMPONENTS

101 See Note 3 Bolt (Note: Use Item 201A, 201B or 212) 102 See Note 3 Screw (Note: Use Item 201A, 201B or 206) 103 See Note 1 Cover, Brake (Note: Use Item 201A, 201B or 206) 104 Not Available 2 Bolt 105 See Note 1 O-Ring (Note: Use Item 201A, 201B, 206, 208, 209 or 212) 106 See Note 1 Cable, Electrical (Note: Use Item 201A, 201B or 207) 107 See Note 1 Tubing, Shrink (Note: Use Item 201A, 201B or 207) 108 See Note 4 Splice, Electrical (Note: Use Item 201A, 201B or 207) 109 See Note 4 Brush, Motor (Note: Use Item 201A, 201B or 208) 110 See Note 1 Bearing, Ball (Note: Use Item 201A, 201B or 209) 111 See Note 2 Splice, Electrical (Note: Use Item 201A, 201B or 207) 112 See Note 1 Connector (To Brake) (Note: Use Item 201A, 201B or 207) 113 See Note 1 Tubing, Shrink (Note: Use Item 201A, 201B or 207) 114 See Note 1 Brake Assembly (Note: Use Item 201A, 201B or 212) 115 7024785 1 Disc, Friction

Ref. KIT OPTIONS

201 1 Motor Kit Options (Includes Items 13,17,31,101-115 & New

Software):

Ref. Note: Both right AND left motors must be replaced at

the same time. Note: These kits upgrade only the motors from Peerless Motors to Advanced DC Motors used in the next figure. Kits include two motors. Note: If these Motor Kits have previously been installed on machine refer to next figure for replacement parts.

201A Use 2915042 1930ES Motor Kit (was Motor p/n 7024746.) 201B Use 2915043 2030ES/2630ES/2646ES/3246ES Motor Kit (was Motor p/n

7024760.) 202 7024747 1 Cover Kit (Includes Items 11,19,20,21 & 29) 203 7024748 1 Main Seal Kit (Includes Qty 1 each of Items 14,16 & 20) 204 7024749 1 Input Carrier Kit (Includes Items 4-8,18,20 & 23-26) 205 7024750 1 Output Planet Kit (Includes Items 9,10,15,20,25-28,32 &

Qty 1 of Item 14) 206 7024751 1 Brake Cover Kit (Includes 102,103 & 105) 207 No Longer

Available

208 7024753 1 Motor Brush Kit (Includes Items 31,105 & 109) 209 7024755 1 Motor Bearing Kit (Includes Items 31,105 & 110) 210 7024756 1 Hub Kit (Includes Items 2,16,20,27 & Qty 1 of Item 14) 211 7024758 1 Input Ring Kit (Includes Item 3,20,27 & Qty 1 of Item 14) 212 7024759 1 Brake Kit (Includes Items 101,105,114 & 115)

A/R Electrical Cable Kit Options (Includes Items 106-108 & 111-

113) (Were p/n’s 7024752 & 7024768):

Ref. Note: Electrical Cable Kits are no longer available.

Purchase Item 201A or 201B.

1-8 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES PRIOR TO S/N 0200118041 &

BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-9

SECTION 1 FRAME

255231820

191129

16227314

104

103

105

109

110

111

112

106

107

114

113

26A

26B

FIGURE 1-3.WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO

S/N 0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO S/N 1200004293)

1-10 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

127

125

128

126

STYLE “A”

151

153

154

152

STYLE “B”

108A

108B

202

201 203

204 205A 205B 205C 205D

206

GENUINE PARTS

207 208

209 210A 210B 211A 211B

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-11

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO S/N

0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO S/N 1200004293)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE ASSEMBLY (ADVANCED) 3160306 Ref. 1930ES E 3160307 Ref. 2030ES/2630ES/2646ES/3246ES E

Ref. Note: Due to service updates, drive motors may use any of

the various parts listed below. Visual identification will be required.

Ref. HUB ASSEMBLY

1 Not Available 1 Spindle 2 Use Item 206 1 Hub 3 Use Item 204 1 Ring, Input 4 Use Item 203 1 Gear, Input Sun 5 Use Item 203 3 Gear, Input Planet 6 Use Item 203 3 Pin, Planet Gear 7 Use Item 203 1 Carrier 8 Use Item 203 1 Gear, Output Sun

9 Use Item 207 3 Gear, Output Planet 10 Use Item 207 3 Pin, Output Planet 11 Use Item 201 1 Cover 12 7024757 1 Bushing Kit, Kingpin (Includes 2 Bushings) 13 See Note 1 Motor, Electric (Note: Use item 205A, 205B, 205C or 205D) 14 See Note 2 Bearing, Main (Note: Use Item 202, 204, 206 or 207) 15 Use Item 207 1 Bearing, Shaft 16 70001739 1 Seal, Lip 17 7024786 1 Seal, Lip 18 Use Item 203 3 Ring, Retaining 19 Use Item 201 1 Ring, Retaining 20 70000191 1 O-Ring 21 Use Item 201 1 Thrustwasher 22 Not Used 23 Use Item 203 1 Plate, Thrust 24 Use Item 203 1 Ring, Retaining 25 See Note 9 Thrustwasher (Note: Use Item 203 or 207) 26 See Note A/R Bearing/Bushing Options (Note: Use Item 203 or 207):

26A 66 Bearing, Needle 26B 6 Bushing

27 See Note 1 Ring, Retaining (Note: Use Item 204, 206 or 207) 28 Use Item 207 1 Ring, Retaining 29 Use Item 201 2 Plug

30 to 31 Not Used

32 Use Item 207 3 Washer, Tanged

Ref. BRAKE & MOTOR COMPONENTS

101 to 102 Not Used

103 Use Item 208 1 Brush & Terminal Assembly 104 70000790 2 Spring, Brush 105 70000791 1 Box, Brush

1-12 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO S/N

0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO S/N 1200004293)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

106 Use Item 208 1 Ring, Retaining 107 Use Item 208 1 Bearing 108 1 Harness, Electrical Cable Options:

108A Use 1001099628 1930ES (was p/n 7024770)

Use 1001099676 2030ES/2630ES/2646ES/3246ES

(was p/n 7024770 & 7024775)

108B 1001091502 1930ES

Use 1001134012 2030ES/2630ES/2646ES/3246ES (was p/n 1001091843) 109 70000792 1 Commutator 110 Use Item 209 1 Disc, Reaction 111 7024785 1 Disc, Friction 112 Use Item 209 1 Brake Assembly 113 See Note 2 Flatwasher (Note: Use Item 210A or 210B) 114 See Note 2 Bolt (Note: Use Item 210A or 210B)

115 to 124 Not Used

— — — — — — — — — —

Ref. Style “A” Brake Cover 125 See Note 1 Plate, Cover (Note: Use Item 211A or 211B) 126 See Note 1 O-Ring (Note: Use Item 210A, 210B, 211A or 211B) 127 70000383 1 Connector, Strain Relief 128 See Note 1 Cover (Note: Use Item 211A or 211B)

129 to 150 Not Used

— — — — — — — — — —

Ref. Style “B” Brake Cover 151 See Note 1 Plate, Cover (Note: Use Item 211A or 211B) 152 70001949 1 Gasket, Cover 153 See Note 1 Cover, Top (Note: Use Item 211A or 211B) 154 See Note 1 Cover, End (Note: Use Item 211A or 211B)

Ref. KIT OPTIONS

201 7024747 1 Cover Kit (Includes Items 11,19,20,21 & 29) 202 7024748 1 Main Seal Kit (Includes Qty 1 of Items 14,16 & 20) 203 7024749 1 Input Carrier Kit (Includes Items 4-8,18,20 & 23-26) 204 7024758 1 Input Ring Kit (Includes Item 3,20,27 & Qty 1 of Item 14) 205 1 Motor Kit Options (Includes Items 13,17,103-114 & 151-154):

Motors with Item #108A Style Electrical Cable 205A Use 1001100819 1930ES (was p/n 7024774) 205B Use 1001100820 2030ES/2630ES/2646ES/3246ES (was p/n 7024777)

Motors with Item #108B Style Electrical Cable 205C 70001263 1930ES 205D 70001345 2030ES/2630ES/2646ES/3246ES

206 7024756 1 Hub Kit (Includes Items 2,16,20,27 & Qty 1 of Item 14) 207 7024750 1 Output Planet Kit (Includes Items 9,10,15,20,25-28,32 & Qty 1

of Item 14) 208 7024771 1 Motor Brush & Bearing Kit (Includes Items 103, 106 & 107) 209 7024772 1 Brake Kit (Includes Items 110, 111 & 112)

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-13

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO S/N

0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO S/N 1200004293)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

210 1 Motor Hardware Kit (Includes 113 & 114) 210A 7024773 1930ES 210B 7024776 2030ES/2630ES/2646ES/3246ES

211 1 Brake Cover Kit Options: 211A 7024787 Style “A” (Includes Items 125 - 128) 211B 70001265 Style “B” (Includes Items 151 - 154)

1-14 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES S/N 0200118041 TO S/N

0200135154 & BELGIUM BUILT MACHINES S/N 1200001487 TO S/N 1200004293)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-15

SECTION 1 FRAME

FIGURE 1-4. FRAME MOUNTED COMPONENTS

1-16 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-4. FRAME MOUNTED COMPONENTS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONTROLLER INSTALLATION

Ref. 1930ES: 0272710 Ref. Non-UL Spec L 0274224 Ref. UL Spec C

Ref. 2030ES/2630ES: 0272711 Ref. Non-UL Spec L 0274225 Ref. UL Spec C

Ref. 2646ES/3246ES: 0273008 Ref. Non-UL Spec L 0274226 Ref. UL Spec C

1 0100083 A/R Grease, Heat Transfer

2 to 4 Not Used

5 4191706 A/R Bolt M6 x 12mm 6 1600346 1 Module, Control 7 1 Cover Options:

1930ES/2030ES/2630ES 1671132 Non-UL Spec (was p/n 1671090) 1671181 UL Spec

2646ES/3246ES 1671133 Non-UL Spec (was p/n 1671106) 1671182 UL Spec

8 to 10 Not Used

11 1 Relay Options:

3740130 USA Built Machines Prior to S/N 0200128698 & Belgium Built

Machines Prior to S/N 1200003300 0903069 1 Mounting Bracket Used on 3740130 Relay

USA Built Machines S/N 0200128698 to S/N 0200135154 &

Belgium Built Machines S/N 1200003300 to S/N 1200004293

Use 2915064 Non-UL Spec (was p/n 3740146)

3740146 UL Spec 0903098 1 Mounting Bracket Used on 3740146 on Relay

Ref. Note:

Relay p/n 3740130 Albright or Curtis brand has 4

terminals & no lead wires. Mounts with terminals to the

side.

Relay p/n 3740146 Albright or Curtis brand has 4

terminals & no lead wires. Mounts with terminals facing

up.

Relay p/n 3740150 is Trombetta brand has 2 terminals &

1 lead wire.

12 Not Used 13 4191708 A/R Bolt M6 x 20mm

14 to 15 Not Used

16 4811700 A/R Flatwasher M6 Narrow 17 Not Used 18 4240147 1 Strap, Anti-Static 19 4751400 A/R Flatwasher 1/4” Wide 20 0700819 1 Bolt M8 x 55mm

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-17

SECTION 1 FRAME

FIGURE 1-4. FRAME MOUNTED COMPONENTS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

21 A/R Clamp, Cable Options:

Ref. Note: Due to service updates, cable clamps may be any of

the various designs listed below. Visual identification will be required.

Non-UL Spec 21A 1320162 1 Clamp (Only Available on 1930ES) 21B 1320061 2 Clamp (Only Available on 2030ES/2630ES) 21C 3574714 1 Clamp (Available on All Models) 21D 1001091492 1 Clamp (Used as part of Service Update on 1930ES) 21E 1001094301 2 Clamp (Used as part of Service Update on 2030ES/

2630ES/2646ES/3246ES)

UL Spec 21F 1320162 1 Clamp (Available on All Models)

21G 1001091492 1 Clamp (Used as part of Service Update on 1930ES)

21H 1001094301 2 Clamp (Used as part of Service Update on 2030ES/

2630ES/2646ES/3246ES) 22 4191709 1 Bolt M6 x 25mm 23 4340751 A/R Mount, Cable Clamp Options:

A/R Non-UL Spec (1930ES Only)

1 UL Spec 24 4811900 1 Flatwasher M8 25 A/R Bolt M6 Options:

0760606 1 1930ES/2030ES/2630ES (12mm Length)

0700608 1 2646ES/3246ES(16mm Length) 26 3290605 A/R Locknut M6 27 1321283 A/R Clamp, Hose (2646ES/3246ES Only) 28 4811702 A/R Flatwasher M6 Wide (Non-UL Spec) 29 4831700 A/R Lockwasher M6 (Non-UL Spec)

30 to 50 Not Used

Ref. Items 51 - 56 may be used on machines with service update

kits.

51 1001094124 1 Block, Spacer (1930ES Only) 52 0700624 1 Bolt M6 x 80mm 53 0700619 2 Bolt M6 x 55mm 54 4751400 A/R Flatwasher 1/4” Wide 55 4811700 A/R Flatwasher M6 56 3290606 A/R Locknut M6

Ref. ALARM INSTALLATIONS 0272810 Ref. ANSI Spec F 0273443 Ref. Australian Spec B 0272811 Ref. CE Spec D 0272722 Ref. Descent Alarm A 0272913 Ref. Motion Alarm A

101 4922861 1 Harness, Chassis (Not Shown - Section 7 for Breakdown) (USA

Built Machines Prior to S/N 0200126538 & Belgium Built

Machines Prior to S/N 1200003119) 102 0140043 1 Alarm 103 4191706 2 Screw M6 x 12mm

1-18 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-4. FRAME MOUNTED COMPONENTS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-19

SECTION 1 FRAME

FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)

1-20 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. POTHOLE PROTECTION INSTALLATION 0272757 Ref. 1930ES K 0272758 Ref. 2030ES/2630ES K

1 4010415 4 Screw M4 x 35mm 2Not Used 3 0701014 4 Screw M10 x 30mm 4Not Used 5 3290405 4 Locknut M4 6Not Used 7 3291005 6 Locknut M10 8 3423045 8 Pin 9 Use 3423189 4 Pin (was p/n 3423046)

10 3574176 2 Link

0440263 4 Bushing

11 Not Used 12 3760348 20 Ring, Retaining 13 3860108 2 Roller 14 Not Used 15 Use 1001109345 2 Switch, Limit (was p/n 4360536 & 4360607) 16 4750800 8 Flatwasher (Wide) 17 4812000 4 Flatwasher M10 18 4740086 8 Thrustwasher 19 Not Used 20 4846774 2 Link 21 1 Support (Right) Options:

4846775 1930ES 4846816 2030ES/2630ES 0440263 4 Bushing

22 Not Used 23 1 Support (Left) Options:

4846861 1930ES 4846863 2030ES/2630ES 0440263 4 Bushing

24 0060083 1 Actuator Assembly A

4846773 1 Actuator

24A 1440333 1 Collar, Actuator

3760115 1 Ring, Retaining

24B 4160202 1 Spring

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-21

SECTION 1 FRAME

FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES)

1-22 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

SECTION 1 FRAME

FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0272759 Ref. POTHOLE PROTECTION INSTALLATION J

1 4010415 4 Screw M4 x 35mm 2Not Used 3 0701015 4 Screw M10 x 35mm 4 3290405 4 Locknut M4 5Not Used 6 3291005 6 Locknut M10 7 3423045 8 Pin 8 Use 3423189 4 Pin (was p/n 3423046) 9 3574176 2 Link

0440263 4 Bushing

10 Not Used 11 3760348 20 Ring, Retaining 12 3860108 2 Roller 13 Not Used 14 Use 1001109345 2 Switch, Limit (was p/n 4360536 & 4360607) 15 4750800 8 Flatwasher (Wide) 16 4812000 4 Flatwasher M10 17 4740086 8 Thrustwasher 18 4846774 2 Link

19 to 20 Not Used

21 4846811 1 Support (Right)

0440263 4 Bushing

22 Not Used 23 4846862 1 Support (Left)

0440263 4 Bushing

24 0060082 1 Actuator Assembly A

4846810 1 Actuator 0962292 4 Bushing, Garmax

24A 3760115 2 Ring, Retaining 24B 4160202 2 Spring

24C 4846788 2 Plunger

3121246 1930ES, 2030ES 2630ES, 2646ES & 3246ES 1-23

SECTION 1 FRAME

6 9

104

105

19 20

102

103

106

108

FIGURE 1-7. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH

BREAKERS ON SIDE)

1-24 1930ES, 2030ES 2630ES, 2646ES & 3246ES 3121246

+ 138 hidden pages

JLG 3246ES Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS

FIGURE 1-4. FRAME MOUNTED COMPONENTS

FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)

FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES)