gcironparts

Disassembly
1. Place the drive motor vertically in a vice with the output
shaft pointing downwards.
2. Using a 17mm spanner wrench loosen the 7 cover
bolts. remove the cover with the bolts.
3. Lift off the displacer and the intermediate disk.
4. Remove the cardan shaft.
5. Remove the control sleeve.
6. Remove the check valves consisting of ball, limit,
stop and filler (filler only when one valve is installed).
7. Turn the drive around in the vise so that the output
shaft is facing up. Remove the keyed shaft.
Assembly
1. The output shaft with pressed on and adjusted
tapered roller bearing and cylindrical shaft is to be
centrically positioned onto the housing edge. Press
the complete assembly into the housing to the limit
stop with the help of the press.

NOTE: Do not jam.

2. Before mounting the flange, put a mounting sleeve
onto the shaft.

NOTE: Be sure that the seal is thoroughly oiled.

3. Position the flange with slight pressure into the
housing. Take care to avoid damage to the seals.
4. Screw in the 8 socket head cap screws. Using a
Torque wrench, tighten to 80 in lb (8 Nm).
5. After turning the motor around introduce the control
sleeve. Make sure that the cylindrical roll of the output
shaft clicks into the groove of the control sleeve.
6. Insert the O-ring into the housing.
7. Installation of the check valves:
Insert 2 ball valves and carefully drive them in using
a mandrel.
8. Insert the limit stop and put the filler into position for
the lower valve.
9. Put the cardan shaft into position. Note that the
marked tooth must comply with the marking on the
control sleeve.
10. Position the intermediate disk.
11. Insert the O-ring into the recess of the displacer.
12. Place the displacer so that the tooth marking on the
cardan shaft on the displacer side meshes with the
tooth base of the rotor gearwheel that is located
centrally at the lowest point in the outer profile of the
rotor gearwheel. This is only possible at 6 positions.
13. Insert O-ring.
14. Insert spacer.
15. Remount cover, tighten the 7 hexagon bolts using a
torque wrench (torque to 60Nm 43 ft lb). The output
shaft should turn easily.

Labels: 2646E2, drive motor, JLG, repair, troubleshooting

General

The throttle control system on the Deutz engine includes the positional controller and the actuator. Four LEDs are incorporated in the controller. They are as follows:
• Red - failure: signals a problem with the system -
needs service or adjustment
• Green - clutch engaged; operation normal while system is powered.
• Amber - motor extend
• Amber - motor retract

The controller is designed so that when the system voltage reaches 10.5 volts, the actuator clutch will be released and the motor drive turned off in order to prevent unpredictable operation from occurring. When a failure condition occurs (i.e. position time-out) the controller will release the clutch and turn off the actuator motor. This will prevent unnecessary motor wear.

Note: Never run fuel tank dry. Diesel engines cannot be restarted after running out of fuel until fuel system has been air-vented or bled of air. See Deutz Instruction Manual for procedure.

1. Power the ignition switch at the ground control panel. Set the idle rpm.
2. Supply 12 volts of power to the white wire on the controller. Set the mid engine rpm.
3. Supply 12 volts of power to the white & green wires on the controller. Set the high engine rpm.

Note: Actuator rod travel must stop slightly before lever makes contact with throttle lever stop. Failure to do so will burn out actuator.

Controller Status
Clutch engaged no actuator movement

Clutch engaged actuator extending

Clutch engaged actuator retracting

Controller Fault - clutch disengaged and no actuator movement

Failure Modes
Immediate Red Light

Action:
1. Recycle power to determine if the problem is intermittent.
2. The input voltage must be greater than 10.5 Vdc.
3. Check wiring for any damage and correct.
4. Disconnect engine harness and actuator connnections.
5. If problem reoccurs return unit.
Green and either Amber light followed by a red light

Action:
1. Inspect and clean wiring connections.
2. Examine throttle linkage for any damage or bent components and correct.
3. With linkage disconnected, check each potentiometer for operation.
4. Reconnect linkage and reset each potentiometer for correct operation.
5. If failure continues to occur, replace unit.
Only green light on and no actuator movement

Action:
1. Adjust trim potentiometers.
2. If problem continues, replace unit.

To purchase this throttle actuator click here

This blog is designed to provide service technicians with information on the maintenance and repair of the equipment designated. This blog is no substitute for an appropriate education, skill development that comes through experience alone, safety, wise and judicious discernment, and ultimately proper performance of service procedures. You should read and understand the manuals, obey all locally approved safety practices, procedures, rules, codes, regulations and laws.
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Copyright © 2008 JLG Industries -Manual 3120788

Disassembly
IMPORTANT
DISSASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
WARNING
DO NOT FULLY EXTEND CYLINDER TO END OF STOKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
1. Place the cylinder barrel into a suitable holding fixture.
2. Using a suitable hammer, tap around the outside of the cylinder barrel and guide to shatter the Loctite.
3. Using a suitable spanner wrench, carefully remove the guide from the rod clevis end of the cylinder barrel.
4. Attach a suitable pulling device to the clevis end of cylinder rod section one.
IMPORTANT
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, GUIDE, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
5. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod Assembly from the cylinder barrel.
6. Using a suitable hammer, tap around the outside of the cylinder barrel and guide to shatter the Loctite.
7. Using a suitable spanner wrench, carefully remove the remaining guide from the cylinder barrel. Remove and discard the wiper ring, rod seal, backup ring and o-ring.
8. Using suitable protection, clamp cylinder rod section two in a vise or similar holding fixture.
9. Carefully remove cylinder rod section one from cylinder rod section two and carefully remove the piston from the cylinder rod. Remove and discard the piston seal and o-ring.
10. Carefully remove the guide from cylinder rod section one. Remove and discard the o-ring, back-up ring, rod seal, and wiper ring.
11. Remove the cylinder rod from the holding fixture.

If you would like more details or parts on the above photo click here.
If you would like to purchase the seal kit for the steer cylinder 1532E2 & 1932E2 (prior to Serial Number 67287), 2032E2, 2632E2, 2646E2 & 3246E2 (prior to Serial Number 66990) click here.
If you would like to purchase the seal kit for the steer cylinder 1532E2 & 1932E2 (Serial Number 67287 to present), 2032E2, 2632E2, 2646E2, 3246E2 (Serial Number 66990 to present) click here.

Cleaning and Inspection
1. Clean all parts thoroughly in an approved cleaning solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.
5. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.
6. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.
7. Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.
8. Inspect seal and o-ring grooves in guide for burrs and sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.
10. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

Assembly
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. Refer to the Illustrated Parts
Manual.
Apply a light film of hydraulic oil to all components
prior to assembly.
1. Using suitable protection, clamp the cylinder rod section one in a vise or similar holding fixture.
2. Place a new wiper ring, rod seal, o-ring, and back-up ring into the cylinder rod guide grooves.
3. Carefully install the cylinder rod guide on rod section one, ensuring that the wiper ring and rod seal are not damaged or dislodged. Push the guide onto the rod section.
4. Place a new piston ring on the piston and a new oring on the threaded end of cylinder rod section two.
5. Carefully place the piston on the threaded end of cylinder rod section two, ensuring that the o-ring is not damaged or dislodged. Push the piston onto the rod as far as it will go.
6. Attach cylinder rod section one to the threaded end of cylinder rod section two and assemble.
7. Remove the cylinder rod assembly from the holding fixture.
8. Position the cylinder barrel in a suitable holding fixture.

IMPORTANT
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, CYLINDER ROD GUIDE, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
9. With the barrel clamped securely, and while adequately supporting the cylinder rod assembly, insert the piston end of the rod assembly into the cylinder barrel. Ensure that the piston ring and o-ring are not damaged or dislodged.
10. Continue pushing the rod into the barrel until the cylinder rod guide can be inserted into the end of the cylinder barrel.
11. Coat the threads of the cylinder rod guide with Loctite #271 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench.
12. On the remaining cylinder rod guide place a new wiper ring, rod seal, o-ring, and back-up ring into the cylinder rod guide grooves.
13. Carefully install the cylinder rod guide onto rod section two and slide the guide into the end of the cylinder barrel.
14. Coat the threads of the cylinder rod guide with Loctite #271 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench.
Reconnect the hydraulic hoses to the applicable cylinder ports.

NOTE: The machine is equipped with a tilt alarm switch factory set to activate at 5° and will sound an alarm and illuminate a warning light on the platform control console. Consult factory for tilt switch adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs. There are two methods of adjustment, a manual adjustment and an adjustment using a voltmeter.1. Park the machine on a flat, level surface and ensure machine is level.
NOTE: Ensure switch mounting bracket is level and securely attached.

2. Level the base of the indicator by tightening the three flange nuts. Tighten each nut through approximately one half of it’s spring’s travel. DO NOT ADJUST THE “X” NUT DURING THE REMAINDER OF THE PROCEDURE.
3. With the electrical connections complete, slowly tighten one of the “Y” nuts until the circuit is closed and the light on the Platform Control Console illuminates.
4. Slowly back off the nut, counting the number of turns, until the circuit is again closed and the light again illuminates.
5. Divide the number of turns determined in step (4) in half. Tighten the nut this many turns. The line determined by this nut and the “X” nut is now parallel to the ground.
6. Repeat steps (3) through (5) for the remaining “Y” nut. The switch is now level.
7. Individually push down on one corner at a time; there should be enough travel to cause the switch to trip. If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the “X” nut and repeat steps (3) through (7).