Api technologies corp. 7608AE Series Service Manual

Models1532E21932E22032E22632E22646E23246E23120855May 10, 2006SERVICE & MAINTENANCE

SECTION 1 - SPECIFICATIONS1-4 – JLG Sizzor– 31208551.6 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the machi

SECTION 1 - SPECIFICATIONS3120855 – JLG Sizzor – 1-51.9 PRESSURE SETTINGSPressure Settings for Non Proportional Control MachinesMain Relief Max - 221

SECTION 1 - SPECIFICATIONS1-6 – JLG Sizzor– 3120855Figure 1-2. Torque Chart.

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on

SECTION 2 - PROCEDURES2-2 – JLG Sizzor – 3120855Pressure-Fit PartsWhen assembling pressure-fit parts, use an anti-seize ormolybdenum disulfide base co

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-33. Cloudy oils indicate a high moisture content whichpermits organic growth, resulting in oxidation or

SECTION 2 - PROCEDURES2-4 – JLG Sizzor – 3120855released, the spool automatically returns to neutral, pro-hibiting any flow through the circuit.Relief

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-5Cylinders w/Single Holding Valves - Lift CylinderOPERATE ALL FUNCTIONS FROM GROUND CONTROL STATIONONLY

SECTION 2 - PROCEDURES2-6 – JLG Sizzor – 31208554. Place the cylinder barrel into a suitable holding fix-ture5. If applicable, using a suitable spanne

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-77. Using this as a handle, pull out the piston rod andextend until the piston bottoms out on the head8

SECTION 2 - PROCEDURES2-8 – JLG Sizzor – 31208551. Using a special tool, pictured in the following illustra-tion, install a new rod seal into the appl

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-92.11 BRAKE CYLINDER REPAIRDisassemblyDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ONA CLEAN WORK SU

SECTION 2 - PROCEDURES2-10 – JLG Sizzor – 3120855Cleaning and Inspection1. Clean all parts thoroughly in an approved cleaningsolvent.2. Inspect the cy

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-11EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-INDER ROD, GUIDE, AND PISTON. AVOID PULLING THE RO

SECTION 2 - PROCEDURES2-12 – JLG Sizzor – 31208558. Inspect seal and o-ring grooves in guide for burrsand sharp edges. Dress applicable surfaces as ne

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-134. Slowly back off the nut, counting the number ofturns, until the circuit is closed again5. Divide t

SECTION 2 - PROCEDURES2-14 – JLG Sizzor – 31208552.14 PRESSURE SETTING PROCEDURES NOTE: Make all pressure adjustments with motor operatingand hydrauli

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-15Main Relief Pressure Switch for Non Proportional Control Machines1. Install a pressure gauge at gauge

SECTION 2 - PROCEDURES2-16 – JLG Sizzor – 3120855 Figure 2-12. Control Valve Components (3246E2 w/Proportional Control)

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-17WELDERTERMINALCONNECTORFIREEXTINGUISHERFigure 2-13. Quick Welder™ Installation

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120855 – JLG Sizzor – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section

SECTION 2 - PROCEDURES2-18 – JLG Sizzor – 31208552.15 DRIVE MOTOR (SAUER DANFOSS)Dismantling1. Place motor in proper holding device that allowsaccess

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-19AssemblyNOTE: Before assembly, inspect all parts and replace if nec-essary.Before assembly, lubricate

SECTION 2 - PROCEDURES2-20 – JLG Sizzor – 31208554. Screw in the 8 socket head cap screws. Using aTorque wrench, tighten to 80 in lb (8 Nm).5. After t

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-21.4. Remove end cover assembly (2) and seal ring (4).Discard seal ring.NOTE: Refer to the appropriate

SECTION 2 - PROCEDURES2-22 – JLG Sizzor – 31208555. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previously loosene

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-236. Thoroughly wash end cover (2) in proper solventand blow dry. Be sure the end cover valve apertures

SECTION 2 - PROCEDURES2-24 – JLG Sizzor – 312085510. Remove rotor set (8) and warplane (9), together toretain the rotor set in its assembled form, mai

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-2513. Remove thrust bearing (11) from top of couplingshaft (12). Inspect for wear, brinelling, corrosio

SECTION 2 - PROCEDURES2-26 – JLG Sizzor – 312085519. Remove housing (18) from vise, invert it and removeand discard seal (20). A blind hole bearing or

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-27NOTE: The depth or location of bearing/bushing (13) in rela-tion to the housing wear plate surface an

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Sizzor – 3120855REVISON LOGOriginal Issue - June 1998Revised - March 5, 1999 (Added 3246E2)Revise

SECTION 2 - PROCEDURES2-28 – JLG Sizzor – 3120855NOTE: Bearing mandrel must be pressed against the let-tered end of bearing shell. Take care that the

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-29The Torqlink™ dirt and water seal (20) must be pressed inuntil its’ flange is flush against the housi

SECTION 2 - PROCEDURES2-30 – JLG Sizzor – 31208557. Apply masking tape around splines or keyway onshaft (12) to prevent damage to seal. 8. Be sure tha

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-3110. Install drive link (10) the long splined end down intothe coupling shaft (12) and engage the driv

SECTION 2 - PROCEDURES2-32 – JLG Sizzor – 312085515. Assemble the manifold (7) over the alignment studsand drive link (10) and onto the rotor set. Be

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-33NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previously scribed o

SECTION 2 - PROCEDURES2-34 – JLG Sizzor – 3120855lbs.(61-75 N m) if cover is so equipped.One Piece Stator ConstructionA disassembled rotor (8A) stator

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-35the seventh or full complement of seven vanes.Assemble the seven vanes using minimum force.Remove the

SECTION 2 - PROCEDURES2-36 – JLG Sizzor – 3120855INTRODUCTIONThe JLG designed SMART System™ is a 24 Volt multiplexmotor control unit installed on the

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-371: STARTUP (2/1)At this point, the analyzer will display the current fault, ifany are present. You ma

3120855 – JLG Sizzor – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE

SECTION 2 - PROCEDURES2-38 – JLG Sizzor – 3120855NOTE: Refer to the appropriate Machine Personality Set-tings Table, and the Machine Setup Table in th

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-39Figure 2-17. Organizational Chart

SECTION 2 - PROCEDURES2-40 – JLG Sizzor – 31208552.21 MACHINE PERSONALITY SETTINGS Table 2-4. Machine Personality SettingsPERSONALITY MIN MAXDRIVE-AC

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-412.22 MACHINE MODEL DEFAULT SETTINGS Table 2-5. Machine Model Default Settings Chart Adjustment 3246E

SECTION 2 - PROCEDURES2-42 – JLG Sizzor – 31208552.23 MACHINE CONFIGURATION INFORMATIONNOTE: The following information is to be used when workingwith

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-435(FUNCTION CUTOUT)01No function cutout installed.Overload switch for French, Japanese machines. — Cut

SECTION 2 - PROCEDURES2-44 – JLG Sizzor – 31208552.24 JLG SMART SYSTEM™ HELP MESSAGES AND FLASH CODES Table 2-7. Help MessagesNO FLASH CODE IS I

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-45Table 2-8. JLG SMART System™ Flash Codes & Help MessagesCode Description2-1 - Indicates problems

SECTION 2 - PROCEDURES2-46 – JLG Sizzor – 31208553-3 - Indicates that a contactor coil is short-circuit SHORT-CIRCUIT LINE CONTACTOR COIL - The line c

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-472.25 ANALYZER MENU STRUCTURE In the following structure descriptions, an intended item isselected by

ii – JLG Sizzor – 3120855TABLE OF CONTENTS (Continued) LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Location. . . . . . . . . . .

SECTION 2 - PROCEDURES2-48 – JLG Sizzor – 3120855SYSTEMSBATTERYTEMPERATUREPUMP VOLTPUMP AMPELEVATIONDisplays measured battery voltageNOTE: Only accura

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-49DATALOGONDRIVELIFTDECKPUMPRENTALERASE RENTAL(YES:ENTER,NO ESC)MAX. TEMPMIN. TEMPMAX BATTERYDisplays t

SECTION 2 - PROCEDURES2-50 – JLG Sizzor – 3120855ACCESS LEVEL CODEDisplays the current access levelLevel 3 - Personalities cannot be changedLevel 2 -

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-51DECKACCELDECELCREEPMAX OUTMAX INDisplays/adjusts deck accelerationDisplays/adjusts deck decelerationD

SECTION 2 - PROCEDURES2-52 – JLG Sizzor – 3120855MACHINE SETUPCALIBRATIONSMODEL NUMBERTILT SWITCHPOWER DECKDECK EXT. LIMITFUNCTION CUTOUTGROUND ALARMD

SECTION 2 - PROCEDURES3120855 – JLG Sizzor – 2-532.26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks a

SECTION 2 - PROCEDURES2-54 – JLG Sizzor – 3120855Table 2-10. Preventive Maintenance and Inspection ScheduleDaily Weekly Monthly 3 Month 6 Month 1 Year

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused

SECTION 3 - TROUBLESHOOTING3-2 – JLG Sizzor – 3120855Table 3-1. Electricl Troubleshooting ChartTROUBLE PROBABLE CAUSE REMEDYAll machine functions do n

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-3Table 3-2. Hydraulic System Troubleshooting ChartTROUBLE PROBABLE CAUSE REMEDYHydraulic pump nois

SECTION 1 - SPECIFICATIONS3120855 – JLG Sizzor – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil Tank1932E211.4 liters at full mark on tank9.

SECTION 3 - TROUBLESHOOTING3-4 – JLG Sizzor – 3120855Figure 3-1. Electrical Schematic - Non Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-51870117 CFigure 3-2. Electrical Schematic - Non Proportional Control (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-6 – JLG Sizzor – 3120855 U3JLG SMART SYSTEMMICROPROCESSORFigure 3-3. Electrical

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-7U3JLG SMART SYSTEMMICROPROCESSOR1870107BFigure 3-4. Electrical Schematic - Proportional Control

SECTION 3 - TROUBLESHOOTING3-8 – JLG Sizzor – 3120855NOTE: CASE DRAIN IS ONLY FOR 3246E2;THEREFORE, 2646E2 LIFT CYL HOSES MUSTBE CONNECTED DIRECTLY TO

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-9 2792399 BFigure 3-6. Hydraulic Schematic - 3246E2 Proprtional Control

SECTION 3 - TROUBLESHOOTING3-10 – JLG Sizzor – 3120855Figure 3-7. Harness and Cable Assembly - Non Proportional Control (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120855 – JLG Sizzor – 3-11Figure 3-8. Harness and Cable Assembly - Non Proportional Control (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-12 – JLG Sizzor – 3120855This page left blank intentionally.

SECTION 1 - SPECIFICATIONS1-2 – JLG Sizzor– 3120855GradeabilityAll Models - 25%Inside Turning Radius1932E2 - 0.5 m2032E2/2632E2 - 1m2646E2 - 1 m3246E2

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

SECTION 1 - SPECIFICATIONS3120855 – JLG Sizzor – 1-3Ground ClearanceWith Platform LoweredAll Models - 8.0 cmWith Platform Elevated(Pothole Protection