JLG 3246ES Parts Manual

0 (0)
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

 

 

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

 

 

 

 

 

 

 

 

 

 

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

NLA

Wheel Drive Assembly USA Built Machines (was p/n

 

 

 

 

Available - See

 

0272305) (See WHEEL DRIVE ASSEMBLY for Breakdown)

 

 

 

 

Note

 

(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

NLA

Wheel Drive Assembly Belgium Built Machines (was p/n

 

 

 

 

Available - See

 

0272305) (See WHEEL DRIVE ASSEMBLY for Breakdown)

 

 

 

 

Note

 

(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

 

 

3121246

1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154

9

SECTION 1 - FRAME

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

Available - See

 

0272306) (See WHEEL DRIVE ASSEMBLY for Breakdown)

 

 

Note

 

(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

NLA

Wheel Drive Assembly Belgium Built Machines (was p/n

 

 

Available - See

 

0272306) (See WHEEL DRIVE ASSEMBLY for Breakdown)

 

 

Note

 

(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

 

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

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (Prior to SN 0200118041, Prior to SN 1200001487)

 

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

NLA

Spindle 1930ES (was p/n 7024754)

 

 

 

 

Available

 

 

 

 

 

1

No Longer

NLA

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

 

 

 

 

Available

 

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)

 

 

3121246

1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154

13

SECTION 1 - FRAME

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

NLA

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)

 

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

SECTION 1 - FRAME

FIGURE 1-3. WHEEL DRIVE ASSEMBLY (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0200118041 through 0200135154, SN 1200001487 through 1200004293)

 

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

 

 

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

 

 

 

 

SECTION 1 - FRAME

 

 

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)

 

 

3121246

1930ES,2030ES,2630ES,2646ES,3246ES,PRIOR TO SN 0200135154

21

SECTION 1 - FRAME

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

 

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

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

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

 

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

 

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

 

 

 

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

 

 

 

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

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

BREAKERS ON SIDE)

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

 

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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