JLG 3246ES Parts Manual
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3
TABLE OF CONTENTS
SECTION 1 - FRAME ........................................................................................................................................................................... 7
FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS .......................................................................................... 8
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (Prior to SN
0200118041, Prior to SN 1200001487) .......................................................................................................................................... 12
FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0200118041
through 0200135154, SN 1200001487 through 1200004293) ........................................................................................................ 16
FIGURE 1-4. FRAME MOUNTED COMPONENTS ........................................................................................................................ 20
FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)................................................................... 24
FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES) ................................................................................ 26
FIGURE 1-7. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH BREAKERS ON SIDE) ........... 28
FIGURE 1-8. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH BREAKERS ON END) ............ 30
FIGURE 1-9. BATTERY CHARGER WITH INVERTER ASSEMBLY AND INSTALLATION (OPTIONAL ON ANSI SPEC
MACHINES) ................................................................................................................................................................................... 34
FIGURE 1-10. LADDERS, BEACON LIGHT AND ROTARY SENSOR COVER INSTALLATIONS ............................................... 36
SECTION 2 - GROUND COMPONENTS ........................................................................................................................................... 39
FIGURE 2-1. BATTERIES AND COVERS INSTALLATION (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (Prior to
SN 0200128413, Prior to SN 1200002974) .................................................................................................................................... 40
FIGURE 2-2. BATTERIES AND COVERS INSTALLATION (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN
0200128413 through 0200135154, SN 1200002974 through 1200004293) ................................................................................... 44
FIGURE 2-3. GROUND CONTROL ASSEMBLY AND INSTALLATION (USA BUILT MACHINES AND BELGIUM BUILT
MACHINES) (Prior to SN 0200117805, Prior to SN 1200001367).................................................................................................. 48
FIGURE 2-4. GROUND CONTROL ASSEMBLY AND INSTALLATION (USA BUILT MACHINES AND BELGIUM BUILT
MACHINES) (SN 0200117805 through 0200135154, SN 1200001367 through 1200004293) ....................................................... 52
FIGURE 2-5. BRAKE DISCONNECT/RELEASE AND MDI (MULTIFUNCTION DIGITAL INDICATOR) GAUGE INSTALLATIONS
(OPTIONAL) ................................................................................................................................................................................... 56
SECTION 3 - SCISSORS ARMS ....................................................................................................................................................... 59
FIGURE 3-1. SCISSOR ARMS INSTALLATION - 1930ES ............................................................................................................ 60
FIGURE 3-2. SCISSOR ARMS INSTALLATION - 2030ES ............................................................................................................ 64
FIGURE 3-3. SCISSOR ARMS INSTALLATION - 2630ES ............................................................................................................ 66
FIGURE 3-4. SCISSOR ARMS INSTALLATION - 2646ES/3246ES ............................................................................................... 70
SECTION 4 - PLATFORM .................................................................................................................................................................. 73
FIGURE 4-1. PLATFORM INSTALLATION .................................................................................................................................... 74
FIGURE 4-2. RAIL (FIXED) INSTALLATION - 1930ES .................................................................................................................. 78
FIGURE 4-3. RAIL (FOLD-DOWN) INSTALLATION - 1930ES ...................................................................................................... 82
FIGURE 4-4. RAIL INSTALLATION - 2030ES/2630ES .................................................................................................................. 86
FIGURE 4-5. RAIL INSTALLATION - 2646ES/3246ES .................................................................................................................. 90
FIGURE 4-6. PLATFORM CONSOLE BOX INSTALLATION ......................................................................................................... 94
FIGURE 4-7. DRIVE/STEER CONTROLLER ASSEMBLY (ORIGINAL EQUIPMENT) .................................................................. 98
FIGURE 4-8. DRIVE/STEER CONTROLLER ASSEMBLY (SERVICE REPLACEMENT) ............................................................ 100
SECTION 5 - CYLINDER ................................................................................................................................................................. 103
FIGURE 5-1. LIFT CYLINDER ASSEMBLY ................................................................................................................................. 104
FIGURE 5-2. STEER CYLINDER ASSEMBLY ............................................................................................................................. 110
SECTION 6 - HYDRAULIC .............................................................................................................................................................. 113
FIGURE 6-1. HYDRAULIC DIAGRAM .......................................................................................................................................... 114
SECTION 7 - ELECTRICAL ............................................................................................................................................................. 117
FIGURE 7-1. ELECTRICAL SCHEMATIC .................................................................................................................................... 118
FIGURE 7-2. ELECTRICAL COMPONENTS INSTALLATION ..................................................................................................... 120
SECTION 8 - DECALS ..................................................................................................................................................................... 131
FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) ................................................................................................................... 132
FIGURE 8-2. DECALS INSTALLATIONS (ANSI EXPORT SPEC) ............................................................................................... 138
FIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN AND CE SPECS) .................................................................................... 144
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 5
TABLE OF CONTENTS
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ............................................................................................................ 149
FIGURE 9-1. MODEL ES STANDARD PARTS ............................................................................................................................ 150
FIGURE 9-2. MODEL ES VARIABLE PARTS ............................................................................................................................... 152
FIGURE 9-3. MODEL ES MAINTENANCE KITS ................................................................................................ .......................... 154
SECTION 10 - SPECIAL OPTIONS ................................................................................................................................................. 155
FIGURE 10-1. SPECIAL OPTIONS LIST ...................................................................................................................................... 156
PART NUMBER INDEX .................................................................................................................................................................... 161
6 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
SECTION 1 - FRAME
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 7
SECTION 1 - FRAME
FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS
8 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
STEERING INSTALLATION
0272371
Ref
Steering Installation 1930ES
F 0273227
Ref
Steering Installation 2030ES/2630ES
C 0272372
Ref
Steering Installation 2646ES/3246ES
G 1 0440259
2
Bearing, Flanged
2 Ref
Bolt M10 Options:
2 0701016
4
Bolt 40mm Length
2 0701020
4
Bolt 60mm Length
3 1380153
4
E-Clip
4 Ref
Steer Cylinder Assembly (See CYLINDER SECTION for
Breakdown):
4
1684237
1
Steer Cylinder Assembly 1930ES/2030ES/2630ES
4 1684263
1
Steer Cylinder Assembly 2646ES/3246ES
7 3423037
4
Pin, Clevis
8 4812000
4
Flatwasher M10
9 4846757
2
Lug, Steer
10
0100011
AR
Compound, Locking
11
1320318
2
P-Clamp (Not Shown - Used with Steer Hoses) (USA Built
Machines) (Prior to SN 0200124799)
11
1320318
2
P-Clamp (Not Shown - Used with Steer Hoses) (Belgium Built
Machines) (Prior to SN 1200002594)
12
1380158
2
Clip (Not Shown - Used with Item 11) (USA Built Machines)
(Prior to SN 0200124799)
12
1380158
2
Clip (Not Shown - Used with Item 11) (Belgium Built Machines)
(Prior to SN 1200002594)
13
2110404
2
Fitting, Straight
Ref
DRIVE INSTALLATION
0272710
Ref
Drive Installation 1930ES
L 0274224
Ref
Drive Installation 1930ES (UL SPEC)
C 0272711
Ref
Drive Installation 2030ES/2630ES
L 0274225
Ref
Drive Installation 2030ES/2630ES (UL SPEC)
C 0273008
Ref
Drive Installation 2646ES/3246ES
L 0274226
Ref
Drive Installation 2646ES/3246ES (UL SPEC)
C
102
Ref
Wheel Drive Assembly Options:
102
Ref
Wheel Drive Assembly Options 1930ES
102
No Longer
Available - See
Note
NLA
Wheel Drive Assembly USA Built Machines (was p/n
0272305) (See WHEEL DRIVE ASSEMBLY for Breakdown)
(NOTE: To replace the complete unit both right and left Drive
Assemblies must be upgraded at the same time. Order qty 2
of p/n 2915236.) (Prior to SN 0200118041)
102
No Longer
Available - See
Note
NLA
Wheel Drive Assembly Belgium Built Machines (was p/n
0272305) (See WHEEL DRIVE ASSEMBLY for Breakdown)
(NOTE: To replace the complete unit both right and left Drive
Assemblies must be upgraded at the same time. Order qty 2
of p/n 2915236.) (Prior to SN 1200001487)
102
2915236
Ref
Wheel Drive Assembly USA Built Machines (See WHEEL
DRIVE ASSEMBLY for Breakdown) (was p/n 3160306) (SN
0200118041 through 0200135154)
102
2915236
Ref
Wheel Drive Assembly Belgium Built Machines (See WHEEL
DRIVE ASSEMBLY for Breakdown) (was p/n 3160306) (SN
1200001487 through 1200004293)
102
Ref
Wheel Drive Assembly 2030ES/2630ES/2646ES/3246ES
102
No Longer
NLA
Wheel Drive Assembly USA Built Machines (was p/n
FIGURE 1-1. STEERING, DRIVE AND REAR AXLE INSTALLATIONS
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 9
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Available - See
Note
0272306) (See WHEEL DRIVE ASSEMBLY for Breakdown)
(NOTE: To replace the complete unit both right and left Drive
Assemblies must be upgraded at the same time. Order qty 2
of p/n 1001100975.) (Prior to SN 0200118041)
102
No Longer
Available - See
Note
NLA
Wheel Drive Assembly Belgium Built Machines (was p/n
0272306) (See WHEEL DRIVE ASSEMBLY for Breakdown)
(NOTE: To replace the complete unit both right and left Drive
Assemblies must be upgraded at the same time. Order qty 2
of p/n 1001100975.) (Prior to SN 1200001487)
102
1001100975
Ref
Wheel Drive Assembly USA Built Machines (See WHEEL
DRIVE ASSEMBLY for Breakdown) (was p/n 3160307) (SN
0200118041 through 0200135154)
102
1001100975
Ref
Wheel Drive Assembly Belgium Built Machines (See WHEEL
DRIVE ASSEMBLY for Breakdown) (was p/n 3160307) (SN
1200001487 through 1200004293)
102A
3577112
2
Plate, Spacer (Used only on Machines with Kit P/N 2915236
installed)
103
Ref
Wheel and Bolt Kit Options (includes Item 104):
Ref
Note: Must replace Tire and Wheel Assemblies in pairs per
axle.
103
2915012
4
Wheel and Bolt Kit 1930ES (was p/n 0272699, 2915005,
4520277, 4520326 & 4520565)
103
2915013
4
Wheel and Bolt Kit 2030ES/ 2630ES/ 2646ES/ 3246ES (was
p/n 2915006, 4520278,4520327 AND 4520676)
104
Ref
Bolt, Wheel Options:
104
0630579
20
Bolt, Wheel 36mm Length
104
0630580
20
Bolt, Wheel 22mm Length
108
2780266
2
Hub Assembly (See Items 201-208 for Breakdown)
112
3760463
2
Ring, Retaining
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
1001102354
1
Cap, Dust (was p/n 7012524)
202
3300423
1
Nut, Slotted (was p/n 7010641)
203
3450406
1
Pin, Cotter 2in x 3/16in (was p/n 7010642)
204
4740468
1
Washer (was p/n 7019697)
205
1001102351
1
Bearing, Cone - Outer (was p/n 7026185)
206
Not Available
1
Hub (Purchase Complete Hub p/n 2780266)
207
1001102353
1
Bearing, Cone - Inner (was p/n 7026183)
208
1001102349
1
Seal (was p/n 7026184)
Ref
FRAME WELDMENTS
301
Ref
Bushing Options:
301
0440264
2
Bushing 1930ES
301
0440265
4
Bushing 2030ES/2630ES/2646ES/3246ES
302
Ref
Kingpin Rework Instruction Options (Provides rework procedure
for damaged kingpins):
302
3128601
AR
Kingpin Rework Instruction 1930ES/2030ES/2630ES
302
3128703
AR
Kingpin Rework Instruction 2646ES/3246ES
SECTION 1 - FRAME
10 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES)
(Prior to SN 0200118041, Prior to SN 1200001487)
12 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
WHEEL DRIVE ASSEMBLY (PEERLESS)
0272305
Ref
Wheel Drive Assembly 1930ES
F 0272306
Ref
Wheel Drive Assembly 2030ES/2630ES/2646ES/3246ES
F
Ref
HUB ASSEMBLY
1 Ref
Spindle
1
No Longer
Available
NLA
Spindle 1930ES (was p/n 7024754)
1
No Longer
Available
NLA
Spindle 2030ES/ 2630ES/ 2646ES/ 3246ES (was p/n
7024761)
2
Item 210
1
Hub 3
Item 211
1
Ring, Input
4 Item 204
3
Gear, Input Sun
5 Item 204
3
Gear, Input Planet
6
Item 204
3
Pin, Planet Gear
7 Item 204
1
Carrier
8 Item 204
1
Gear, Output Sun
9 Item 205
3
Gear, Output Planet
10
Item 205
3
Pin, Output Planet
11
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
Item 205
1
Bearing, Shaft
16
70001739
1
Seal, Lip
17
7024786
1
Seal, Lip
18
Item 204
3
Ring, Retaining
19
Item 202
1
Ring, Retaining
20
See Note
1
O-Ring (Note: Use Item 202, 203, 204, 205, 210 or 211)
21
Item 202
1
Thrustwasher
23
Item 204
1
Plate, Thrust
24
Item 204
1
Ring, Retaining
25
See Note
9
Thrustwasher (Note: Use Item 204 or 205)
26
See Note
AR
Bearing/Bushing Options: (Note: Use Item 204 or 205)
26A
See Note
66
Bearing, Needle
26B
See Note
6
Bushing
27
See Note
1
Ring, Retaining (Note: Use Item 205, 210 or 211)
28
Item 205
1
Ring, Retaining
29
Item 202
2
Plug
31
See Note
1
O-Ring (Note: Use Item 201A, 201B, 208 or 209)
32
Item 205
3
Washer, Tanged
Ref
BRAKE AND 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)
FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES)
(Prior to SN 0200118041, Prior to SN 1200001487)
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 13
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
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
Ref
Motor Kit Options (Includes Items 13, 17, 31, 101-115 and New
Software):
Ref
Note: Both right AND left motors must be replaced at the
same time.
Ref
Note: These kits upgrade only the motors from Peerless
Motors to Advanced DC Motors used in the next figure.
Kits include two motors.
Ref
Note: If these Motor Kits have previously been installed
on machine refer to next figure for replacement parts.
201A
2915042
1
Motor Kit 1930ES Motor Kit (was Motor p/n 7024746.)
201B
2915043
1
Motor Kit 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
NLA
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.
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)
SECTION 1 - FRAME
14 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES)
(SN 0200118041 through 0200135154, SN 1200001487 through 1200004293)
16 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 17
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
WHEEL DRIVE ASSEMBLY (ADVANCED)
3160306
Ref
Wheel Drive Assembly 1930ES
E 3160307
Ref
Wheel Drive Assembly 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 Item 206
1
Hub 3
Item 204
1
Ring, Input
4 Item 203
1
Gear, Input Sun
5 Item 203
3
Gear, Input Planet
6 Item 203
3
Pin, Planet Gear
7
Item 203
1
Carrier
8 Item 203
1
Gear, Output Sun
9 Item 207
3
Gear, Output Planet
10
Item 207
3
Pin, Output Planet
11
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
Item 207
1
Bearing, Shaft
16
70001739
1
Seal, Lip
17
7024786
1
Seal, Lip
18
Item 203
3
Ring, Retaining
19
Item 201
1
Ring, Retaining
20
70000191
1
O-Ring
21
Item 201
1
Thrustwasher
23
Item 203
1
Plate, Thrust
24
Item 203
1
Ring, Retaining
25
See Note
9
Thrustwasher (Note: Use Item 203 or 207)
26
See Note
AR
Bearing/Bushing Options (Note: Use Item 203 or 207)
26A
See Note
66
Bearing, Needle
26B
See Note
6
Bushing
27
See Note
1
Ring, Retaining (Note: Use Item 204, 206 or 207)
28
Item 207
1
Ring, Retaining
29
Item 201
2
Plug 32
Item 207
3
Washer, Tanged
Ref
BRAKE AND MOTOR COMPONENTS
103
Item 208
1
Brush and Terminal Assembly
104
70000790
2
Spring, Brush
105
70000791
1
Box, Brush
106
Item 208
1
Ring, Retaining
107
Item 208
1
Bearing
108
Ref
Harness, Electrical Cable Options:
108A
1001099628
1
Harness, Electrical Cable 1930ES (was p/n 7024770)
108A
1001099676
1
Harness, Electrical Cable 2030ES/2630ES/2646ES/3246ES
(was p/n 7024770 & 7024775)
108B
1001091502
1
Harness, Electrical Cable 1930ES
SECTION 1 - FRAME
FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES)
(SN 0200118041 through 0200135154, SN 1200001487 through 1200004293)
18 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
108B
1001134012
1
Harness, Electrical Cable 2030ES/2630ES/2646ES/3246ES
(was p/n 1001091843)
109
70000792
1
Commutator
110
Item 209
1
Disc, Reaction
111
7024785
1
Disc, Friction
112
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)
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)
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
Ref
Motor Kit Options (Includes Items 13, 17, 103-114 & 151-154):
205
Ref
Motors with Item #108A Style Electrical Cable
205A
1001100819
1
Motor Kit 1930ES (was p/n 7024774)
205B
1001100820
1
Motor Kit 2030ES/2630ES/2646ES/3246ES (was p/n
7024777)
205
Ref
Motors with Item #108B Style Electrical Cable
205C
70001263
1
Motor Kit 1930ES
205D
70001345
1
Motor Kit 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 and Bearing Kit (Includes Items 103, 106 & 107)
209
7024772
1
Brake Kit (Includes Items 110, 111 & 112)
210
Ref
Motor Hardware Kit (Includes 113 & 114)
210A
7024773
1
Motor Hardware Kit 1930ES
210B
7024776
1
Motor Hardware Kit 2030ES/2630ES/2646ES/3246ES
211
Ref
Brake Cover Kit Options:
211A
7024787
1
Style "A" (Includes Items 125 - 128)
211B
70001265
1
Style "B" (Includes Items 151 - 154)
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 19
SECTION 1 - FRAME
FIGURE 1-4. FRAME MOUNTED COMPONENTS
20 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
FIGURE 1-4. FRAME MOUNTED COMPONENTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
CONTROLLER INSTALLATION
Ref
Controller Installation 1930ES:
0272710
Ref
Non-UL Spec
L 0274224
Ref
UL Spec
C
Ref
Controller Installation 2030ES/2630ES:
0272711
Ref
Non-UL Spec
L 0274225
Ref
UL Spec
C
Ref
Controller Installation 2646ES/3246ES:
0273008
Ref
Non-UL Spec
L 0274226
Ref
UL Spec
C 1 0100083
AR
Grease, Heat Transfer
5 4191706
AR
Bolt M6 x 12mm
6 1600346
1
Module, Control
7 Ref
Cover Options:
7 Ref
Cover 1930ES/2030ES/2630ES
7 1671132
1
Cover - Non-UL Spec (was p/n 1671090)
7 1671181
1
Cover - UL Spec
7 Ref
Cover 2646ES/3246ES
7 1671133
1
Cover - Non-UL Spec (was p/n 1671106)
7 1671182
1
Cover - UL Spec
11 Ref
Relay Options:
11
3740130
1
Relay - USA Built Machines (Prior to SN 0200128698)
11
3740130
1
Relay - Belgium Built Machines (Prior to SN 1200003300)
11
0903069
1
Mounting Bracket Used on 3740130 Relay
11 Ref
USA Built Machines (SN 0200128698 through 0200135154)
11 Ref
Belgium Built Machines (SN 1200003300 through
1200004293)
11
2915064
1
Relay - Non-UL Spec (was p/n 3740146)
11
3740146
1
Relay - UL Spec
11
0903098
1
Mounting Bracket Used on 3740146 on Relay
Ref
Note: Relay p/n 3740130 Albright or Curtis brand has 4
terminals and no lead wires. Mounts with terminals to the
side.
Ref
Relay p/n 3740146 Albright or Curtis brand has 4 terminals
and no lead wires. Mounts with terminals facing up.
Ref
Relay p/n 3740150 is Trombetta brand has 2 terminals and
1 lead wire.
13
4191708
AR
Bolt M6 x 20mm
16
4811700
AR
Flatwasher M6 Narrow
18
4240147
1
Strap, Anti-Static
19
4751400
AR
Flatwasher 1/4in Wide
20
0700819
1
Bolt M8 x 55mm
21 Ref
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.
21 Ref
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)
SECTION 1 - FRAME
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 21
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
21E
1001094301
2
Clamp (Used as part of Service Update on
2030ES/2630ES/2646ES/3246ES)
21 Ref
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
Ref
Mount, Cable Clamp Options:
23
4340751
AR
Mount, Cable Clamp - Non-UL Spec (1930ES Only)
23
4340751
1
Mount, Cable Clamp - UL Spec
24
4811900
1
Flatwasher M8
25 Ref
Bolt M6 Options:
25
0760606
1
Bolt M6 1930ES/2030ES/2630ES (12mm Length)
25
0700608
1
Bolt M6 2646ES/3246ES (16mm Length)
26
3290605
AR
Locknut M6
27
1321283
AR
Clamp, Hose (2646ES/3246ES Only)
28
4811702
AR
Flatwasher M6 Wide(Non-UL Spec)
29
4831700
AR
Lockwasher M6 (Non-UL Spec)
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
AR
Flatwasher 1/4in Wide
55
4811700
AR
Flatwasher M6
56
3290606
AR
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 - ELECTRICAL SECTION for
Breakdown) (USA Built Machines) (Prior to SN 0200126538)
101
4922861
1
Harness, Chassis (Not Shown - ELECTRICAL SECTION for
Breakdown) (Belgium Built Machines) (Prior to SN 1200003119)
102
0140043
1
Alarm
103
4191706
2
Screw M6 x 12mm
SECTION 1 - FRAME
22 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)
24 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
POTHOLE PROTECTION INSTALLATION
0272757
Ref
Pothole Protection Installation 1930ES
K 0272758
Ref
Pothole Protection Installation 2030ES/2630ES
K 1 4010415
4
Screw M4 x 35mm
3 0701014
4
Screw M10 x 30mm
5 3290405
4
Locknut M4
7 3291005
6
Locknut M10
8 3423045
8
Pin 9
3423189
4
Pin (was p/n 3423046)
10
3574176
2
Link 10
0440263
4
Bushing
12
3760348
20
Ring, Retaining
13
3860108
2
Roller 15
1001109345
2
Switch, Limit(was p/n 4360536 & 4360607)
16
4750800
8
Flatwasher (Wide)
17
4812000
4
Flatwasher M10
18
4740086
8
Thrustwasher
20
4846774
2
Link 21 Ref
Support (Right) Options:
21
4846775
1
Support (Right) 1930ES
21
4846816
1
Support (Right) 2030ES/2630ES
21
0440263
4
Bushing
23 Ref
Support (Left) Options:
23
4846861
1
Support (Left) 1930ES
23
4846863
1
Support (Left) 2030ES/2630ES
23
0440263
4
Bushing
24
0060083
1
Actuator Assembly
A
24
4846773
1
Actuator
24A
1440333
1
Collar, Actuator
24A
3760115
1
Ring, Retaining
24B
4160202
1
Spring
FIGURE 1-5. POTHOLE PROTECTION INSTALLATION (1930ES/2030ES/2630ES)
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 25
SECTION 1 - FRAME
FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES)
26 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
0272759
Ref
POTHOLE PROTECTION INSTALLATION
J 1 4010415
4
Screw M4 x 35mm
3 0701015
4
Screw M10 x 35mm
4 3290405
4
Locknut M4
6 3291005
6
Locknut M10
7 3423045
8
Pin 8
3423189
4
Pin (was p/n 3423046)
9 3574176
2
Link 9
0440263
4
Bushing
11
3760348
20
Ring, Retaining
12
3860108
2
Roller 14
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 21
4846811
1
Support (Right)
21
0440263
4
Bushing
23
4846862
1
Support (Left)
23
0440263
4
Bushing
24
0060082
1
Actuator Assembly
A
24
4846810
1
Actuator
24
0962292
4
Bushing, Garmax
24A
3760115
2
Ring, Retaining
24B
4160202
2
Spring
24C
4846788
2
Plunger
FIGURE 1-6. POTHOLE PROTECTION INSTALLATION (2646ES/3246ES)
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 27
SECTION 1 - FRAME
FIGURE 1-7. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH
BREAKERS ON SIDE)
28 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
0400218
Ref
BATTERY CHARGER ASSEMBLY
1 7018514
2
Breaker, Circuit - AC
2 7011509
1
Breaker, Circuit - DC
3 7018577
2
Capacitor
4 7022944
1
Card, Circuit
5 7022947
1
Connector, Strain Relief
6 Not Available
1
Cord Set - AC
7 7022945
1
Cord Set - DC
8 Not Available
1
Cover 9
7018583
1
Plug, AC Inlet
10
4460648
1
Plug, Anderson Battery Cable
11
4460424
1
Connector, Female - 2 Position
11
4460227
2
Pin, Male
12
7022946
1
Harness with Connector
12
4460899
1
Connector, Female - 6 Position
12
4460464
6
Pin, Male
13
7020613
1
Rectifier Assembly with Heatsink and Rectifiers
14
7020673
1
Rectifier
15
7018564
1
Relay 16
7020674
1
Shunt Assembly
17
7018586
1
Switch, Slide
18
7022948
1
Transformer
19
7018589
1
Varistor Assembly
20
7020663
1
Varistor
Ref
BATTERY CHARGER INSTALLATION
0272874
Ref
AC Cable Has Factory Supplied Plug
E 0272875
Ref
AC Cable Has Locally Supplied Plug
E
101
0400218
1
Battery Charger Assembly (See Items 1-20 for Breakdown)
102
Ref
Cable, AC Options:
102
1060688
1
Factory Supplied Plug
102
1060689
1
Locally Supplied Plug
103
1320043
1
Clamp
104
4191707
3
Screw M6 x 16mm
105
3900267
1
Capscrew
106
4811700
3
Flatwasher M6
107
0751006
2
Screw, Pan Head (Thread Forming) (Not Shown)
108
3574843
1
Plate, Charger Cover
FIGURE 1-7. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH
BREAKERS ON SIDE)
3121246 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 29
SECTION 1 - FRAME
FIGURE 1-8. BATTERY CHARGER ASSEMBLY AND INSTALLATION (MAC CHARGER WITH
BREAKERS ON END)
30 1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154 3121246
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