JLG 3246ES Parts Manual

4.4 (5)

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NOTE: 1930ES, 2030ES, 2630ES, 2646ES & 3246ES Global Illustrated Parts Manual P/N 3121167 has been replaced by multiple manuals.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

REVISION LOG

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

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

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

3121246

SECTION 1

FRAME

3121246

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

1-1

SECTION 1 FRAME

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

108 206	206	203	205204 202 201	104
301			206
	208 207			103
				104
				103

102A

114

112

302

115

1		7	102
		7
2 10	8	1	3
2 10	8		3
			9

	13
2 10	8

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		USA Built Machines Prior to S/N 0200118041 & Belgium
	Available - See		Built Machines Prior to S/N 1200001487
	Note		(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.
	Use 2915236		USA Built Machines S/N 0200118041 to S/N 0200135154
			& 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		USA Built Machines Prior to S/N 0200118041 & Belgium
	Available - See		Built Machines Prior to S/N 1200001487
	Note		(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.
	Use 1001100975		USA Built Machines S/N 0200118041 to S/N 0200135154
			& Belgium Built Machines S/N 1200001487 to
			S/N 1200004293 (See Figure 1-3 for Breakdown)
			(was p/n 3160307)
102A	3577112	2	Plate, Spacer (Used only on Machines with Kit
			p/n 2915236 installed)
103		4	Wheel & Bolt Kit Options (includes Item 104):
		Ref.	Note: Must replace Tire & Wheel Assemblies in pairs per
			axle.
	2915012		1930ES (was p/n 0272699, 2915005, 4520277, 4520326 &
			4520565)
	2915013		2030ES/2630ES/2646ES/3246ES
			(was p/n 2915006, 4520278, 4520327 & 4520676)
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
	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

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

BELGIUM BUILT MACHINES PRIOR TO S/N 1200001487)

	106	31
	107	31
	107	13
	108	13
	108
	111
	113	109

	110	17
	112	17
	112

114 101

102

103

115

104

105

	26B
	24
8	OR
	26A
6
	7
	25
	5

OR 28

26A

26B

203

201A 207

201B 208

202 209

204 210

205 211

206 212

25	19
23	21
18	21

20	29

GENUINE PARTS

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		Spindle 1930ES (was p/n 7024754)
	Available
	No Longer		Spindle 2030ES/2630ES/2646ES/3246ES (was p/n
	Available		7024761)
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

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	A/R	Electrical Cable Kit Options (Includes Items 106-108 & 111-
	Available		113) (Were p/n’s 7024752 & 7024768):
		Ref.	Note: Electrical Cable Kits are no longer available.
			Purchase Item 201A or 201B.
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)

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

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)

13 103

		105
		109
12		110
		110
	104	111
	104

112

	1
			106	107
	9			107
	9
	32
	25	9		114
		9		114
			10	113
			14	113
			14
				16
9				2
	15			2
OR	15
OR	28
26A
26B
				14
	26B			27
24				27
24				3
8	OR
8
	26A
6		4
7
25
5
	25			19
	23	21
	18	21
	20			29
	20
		11

1-10

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

3121246

SECTION 1 FRAME

201	207
203	208	202
204	209	202
204	209
205A	210A
205B	210B
205C	211A
205D	211B
206
	GENUINE PARTS

108A	OR	108B
108A

151

153

154

152

STYLE “A”

STYLE “B”

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
2	Not Used
3	0701014	4	Screw M10 x 30mm
4	Not Used
5	3290405	4	Locknut M4
6	Not 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
2	Not Used
3	0701015	4	Screw M10 x 35mm
4	3290405	4	Locknut M4
5	Not 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