JLG AM-19 Operators And Safety Manual Service & Maintenance Manual Illustrated Parts Manual Download

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Operators and Safety Manual

Service & Maintenance Manual

Illustrated Parts Manual

Models

AM-19
AM-24
AM-30
AM-36

AC & DC Models

3120596

January 1, 1998

ANSI

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Summary of Contents for AM-19

Page 1: ...afety Manual Service Maintenance Manual Illustrated Parts Manual Models AM 19 AM 24 AM 30 AM 36 AC DC Models 3120596 January 1 1998 ANSI G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 3: ...OSHA REGULATIONS W THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS L WHICH MAY LEAD TO DEATH OR SERIOUS INJURY IF IGNORED Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAUTION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows A DANGER DANGER INDICATES AN IMMINENT...

Page 4: ...ating condition 5 Load limits specified by the manufacturer shall not be exceeded 6 Instruction and warning placards must be leg ible 7 Aerial lifts may be field modified for uses other than those intended by the manufacturer only if certified in writing by the manufacturer or an equivalent entity such as a nationally recog nized testing lab to be in conformity to applica ble OSHA safety regulatio...

Page 5: ...OR B HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the ma chines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or re moving any portion of the system 2 Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line...

Page 6: ...n 10 2 Pages 10 2 2 10 2 3 10 2 9 10 2 11 to 10 2 13 and 10 2 17 Section 10 3 Pages 10 3 3 10 3 8 and 10 3 11 Section 10 4 Pages 10 4 2 10 4 3 and 10 4 5 Section 10 7 Pages 10 7 2 to 10 7 4 Section 10 8 Pages 10 8 3 and 10 8 4 Section 10 9 Page 10 9 1 Section 10 1 0 Page 10 1 0 3 Pages Affected Cover Revision Log Page c Section 10 Illustrated Parts Table of Contents Page 10 0 1 Section 10 1 Pages ...

Page 7: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 8: ... 5 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3 1 General 3 1 3 2 Personnel Training 3 1 3 3 Operating Characteristics and Limitations 3 2 3 4 Controls and Indicators 3 2 SECTION 4 MACHINE OPERATION 4 1 Machine Description 4 1 4 2 General 4 1 4 3 Machine Set Up and Operation 4 2 4 4 Stowing Machine 4 3 4 5 Transporting and Lifting 4 4 SECTION 5 OPTIONAL EQUIPMENT 5 1 Optional Equipment 5...

Page 9: ...alled Pushing Machine on a Smooth Firm Surface Pushing Machine on a Slope Tilt Back Assembly Set Up Loading Machine onto Pickup Truck for Transport Straddle Adaptor Wiring Harness Installation Straddle Adaptor AC Control Box Wiring Connections Straddle Adaptor DC Ground Control Station Wiring Connections Straddle Extension Component Assembly Lowering AccessMaster on Straddle Unit Side Lifting Rail...

Page 10: ...CTRICALLY CHARGED CONDUCTOR MAIN TAIN A CLEARANCE OF AT LEAST 10 FEET 3M BETWEEN ANY PART OF THE MACHINE AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50 000 VOLTS ONE FOOT 0 3 M ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDI TIONAL 30 000 VOLTS OR LESS ALLOW FOR PLATFORM SWAY ROCK OR SAG AND ELECTRI CAL LINE SWAYING SEE FOLLOWING TABLE Table 1 1 Minimum Safe Approach Distance to energized ...

Page 11: ...ILS NEVER POSITION THE UNIT SIDEWAYS ON A SLOPE KEEP CLEAR FROM BEHIND AND IN FRONT OF UNIT SEE FIGURE 1 1 1 2 USE CAUTION AND CHECK CLEARANCES WHEN MOVING MACHINE IN RESTRICTED OR CLOSE QUARTERS ALWAYS USE AN ASSISTANT WHEN MOVING MACHINE IN AREAS WHERE VISION IS OB STRUCTED KEEP NON OPERATING PERSONNEL AT LEAST 6 FEET 1 8 M AWAY FROM MACHINE DURING TRANSPORTING OPERATIONS CORRECT way to push on ...

Page 12: ...TIONS TO AVOID ALL KNOWN HAZ ARDS IN THE WORK AREA MUST BE TAKEN BY THE OPERATOR AND HIS SUPERVISOR BEFORE STARTING THE WORK DO NOT OPERATE THIS MACHINE UNLESS IT HAS BEEN SERVICED AND MAINTAINED AC CORDING TO THE MANUFACTURERS SPECI FICATIONS AND SCHEDULE ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION HAVE AUTHOR IZED PERSONNEL TAKE ANY NECESSARY C...

Page 13: ...E PLAT FORM SIZE WITH UNAUTHORIZED DECK EX TENSIONS OR ATTACHMENTS DO NOT TIE OFF MACHINE TO ANY ADJA CENT STRUCTURE NEVER ATTACH WIRE CABLE OR ANY SIMILAR ITEMS TO PLAT FORM TO AVOID FALLING USE EXTREME CAU TION WHEN ENTERING OR LEAVING PLAT FORM ABOVE GROUND ENTER OR EXIT THRU GATE ONLY PLATFORM MUST BE WITHIN 1 FOOT 0 3 M OF ADJACENT SAFE AND SECURE STRUCTURE ALLOW FOR ANY VERTICAL MOVEMENT OF ...

Page 14: ... be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service 2 3 DELIVERY AND FREQUENT INSPECTION The following check list provides a systematic inspec tion to assist in detecting defective damaged or improperly installed parts The check list denotes the items to be inspected and conditions to examine ...

Page 15: ...IL ALL MALFUNCTIONS HAVE BEEN COR RECTED USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND IN SPECTION Note Do not overlook visual inspection of chassis under side Checking this area often results in discovery of conditions which could cause extensive machine damage 1 Wheels and Casters Properly secured wheels and casters...

Page 16: ... lubricated Sequencing cables prop erly secured and undamaged 12 Handrail Installation All railings securely attached no visible damage no missing parts sliding entry bar in proper working order Plat form gate working properly no visible sign of damage if so equipped Daily Walk Around Inspection Items 1 Wheels and Casters 2 Base Frame 3 Tilt Back Base Assembly 4 Battery Box Charger 5 Outrigger Int...

Page 17: ...ERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN COR RECTED USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION Once the walk around inspection is complete a func tional check of all systems should be performed in an area free of overhead and ground level obstructions Perform a functional check in accordance with the following procedures 1 Set up machine for operation according to instructions i...

Page 18: ...the end of the work day the batteries should be charged for the next days work Check the electrolyte level of the batteries and adjust accordingly cells should be completely covered but DO NOT OVERFILL allow for electrolyte expansion or battery will overflow while charging Add only distilled water to batteries Connect the battery charger to a properly grounded receptacle using a suitable extension...

Page 19: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 20: ...be permitted to operate the machine Operator Training Operator training must include instruction in the following 1 Use and limitations of the platform controls ground controls and emergency controls 2 Knowledge and understanding of this manual and of the control markings instructions and warnings on the machine itself 3 Knowledge and understanding of all safety work rules of the employer and Fede...

Page 21: ...roperly installed and locked in place as indi cated by the outrigger interlock LED s on the base frame This machine as originally manufactured by JLG and operated within its rated capacity on a smooth firm and level supporting surface pro vides a stable aerial platform for all platform posi tions 3 4 CONTROLS AND INDICATORS See Figure 3 1 Note When the machine is shut down for overnight park ing o...

Page 22: ...terrupted power to the platform controls On AM DC Models a 5 Amp fuse is provided to interrupt power to the platform controls in the event of an electrical overload See Rgure 3 2 1 EMERGENCY STOP SHUT OFF Button An EMERGENCY STOP RED button is pro vided in order to turn machine power on and off in the platform and also to turn off machine power in the event of an emergency Power is on when the swi...

Page 23: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 24: ...nd regulations As with any type of machinery the operator is very important to efficient and safe opera tion It is absolutely necessary that the JLG lift be regularly maintained in accordance with this manual Any evidence of lack of maintenance malfunction excessive wear damage or modification to the ma chine must be reported immediately to the machine owner the jobsite supervisor or safety manage...

Page 25: ...ing Outrigger Installation See Figure 4 1 1 Start on either side of machine and remove an outrigger beam from the stowage sockets on either side of mast behind platform 2 Insert outrigger beam into an outrigger socket on base frame with outrigger interlock con tacts on bottom i e with jackscrew foot pad down and jack handle up Insert each outrig ger beam in socket until locking pin snaps into outr...

Page 26: ...nel simul taneously Upon reaching desired elevation level release UP and FUNCTION ENABLE buttons A WARNING ENSURE AREA BENEATH PLATFORM IS FREE OF PERSONNEL AND OBSTRUCTIONS PRIOR TO LOWERING PLATFORM 3 To lower platform depress FUNCTION EN ABLE BUTION green and platform DOWN button bottom white button on control panel simultaneously Upon reaching desired eleva tion level release DOWN and FUNCTION...

Page 27: ...NG note to ensure safe transport of unit when pushing A WARNING FAILURE TO HEED THE FOLLOWING INSTRUC TIONS COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING MOVED WHICH COULD RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNED OR CRUSHED BY UNIT KEEP CLEAR FROM BEHIND AND IN FRONT OF THE UNIT FIG 4 2 WALK BESIDE THE UNIT AND HOLD ONTO THE SIDE OF THE PLATFORM FIG 4 2 ON A LEVEL ...

Page 28: ... pin located on the mast support crossbar see Fig 4 4 from the mast support bracket on the back of mast 3 Carefully lower the tilt back assembly as far as it will go 4 Grasp either of the gas spring assemblys on the tilt back assembly and and pull upward out of spring clip s Guide the groove pins on the unattached end of the gas spring assy into the slot on the mast crossbar support bracket attach...

Page 29: ...ove Release Pin While Holding Base Attach Gas Cylinders to Support Brackets and Secure with Safety Pins Pull Out T Handle Lifting Bar On Base Lift Unit Into Tilt Back Position Figure 4 4 Tilt Back Assembly Set up 4 6 JLG Lift G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 30: ...it sets at approximately 2 to 3 inches above tailgate height Adjust by pulling out on the spring loaded locking pin and raising or lower ing the load bar slide pad assembly BE CER TAIN THE LOAD BAR SLIDE PAD ASSEM BLY IS LOCKED IN PLACE AT PROPER HEIGHT 4 STEP 1 Push machine in against tailgate until snug 5 STEP 2 On platform end of machine extend T handle load lifting bar out from under base fram...

Page 31: ...r out from under front of unit 4 8 STEP3 Start lifting machine onto tailgate STEPS Push all the way into truck bed STEP4 Continue lifting and pushing onto truck bed STEPS With machine completely in bed tie down machine Figure 4 58 Loading Machine onto Truck for Transport JLG Lift G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 32: ...ow the coupled con figuration to be easily maneuvered The unit can be quickly disassembled for compact storage The straddle extension provides clearance of up to 48 inches 1 2m and the length for caster spacing is adjustable from 104 to 128 inches 2 6m to 3 3 m The AccessMaster AM models are fully operational at full rated capacity when used in combination with the straddle extension Straddle Adap...

Page 33: ...RKING AROUND ELECTRICAL COMPONENTS 4 Press the two 2 three 3 prong connector ends into the spring clips mounted on the base frame and route the wiring harness through the base frame and up hydraulic lines on side of mast Tie wiring harness to the hydraulic lines and route to either the AC Control Box on AC voltage models or the Ground Control Station on DC models as shown in Figure 5 1 AC MODELS O...

Page 34: ...rlock relay at top to right of ground controls butt splice the WHITE 16 GA wire with butt splice end from the straddle adaptor wiring harness to STRADDLE HARNESS WIRE BUTT SPLICE 71 STRADDLE HARNESS WIRE I LL IW a w TO BATTERY POWER 1 RELAY 1 ffi ww T 1 1 11 I t l f I L J I w w a _ I YELLOW REF I TO GROUND CONTROL SWITCHES TO MOTOR Figure 5 3 Straddle Adaptor DC Ground Control Station wiring conne...

Page 35: ...IDE LIFT RAIL INTERLOCK CABLE RETRACT REEL AM UNIT OUTRIGGERS s On the same side lifting rail install the remain ing pup outrigger beam into the side lifting rail socket and align with the AccessMaster base outrigger socket Push pup beam in until the locking pin in the AccessMaster base secures the pup beam in place 6 Mount the remaining side lifting rail by repeat ing the instructions in steps 4 ...

Page 36: ...t can now be rolled into position where needed Make any neccessary adjusts to the Straddle Extension i e extend side rails or lifting side rails with winch enough to raise the AccessMaster unit over any obstacles i e seat rows etc before setting in position Use the following steps to lift the AccessMas ter Unit Note When raisin or lowering side rails keep rails and AccessMasterR Unit as level as p...

Page 37: ... the quick release pins installed through the side rail adjust bracket and the straddle end support vertical rails 4 Remove ONLY the two 2 side rail quick re lease pins installed through each side lifting rail adjust bracket and the straddle end support vertical rails at all four 4 corners of the strad dle extension See Figure 5 5 A WARNING DO NOT REMOVE THE END CAP PIN FROM THE ADJUST BRACKET UNT...

Page 38: ...ve The platform will be lowered unpowered using gravity 6 3 EMERGENCY OPERATION Use of Ground Controls IMPORTANT KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION A DANGER BEFORE TOUCHING ANY PART OF THE MACHINE IN AN EMERGENCY SITUATION FIRST DETERMINE IF MACHINE IS IN CONTACT WITH OR CLOSE PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR THIS MACHINE DOES NOT PRO VIDE PROTECTION FROM C...

Page 39: ...d carefully lift the ma chine to an upright postion Post Incident Inspection Following any incident thoroughly inspect the machine and test all functions Do not lift platform above 10 feet 3 meters until you are sure that all damage has been repaired and that all controls and machine components are operating cor rectly 6 4 INCIDENT NOTIFICATION It is imperative that JLG Industries Inc be notified ...

Page 40: ...M36 AC 300 lb 136 kg AM36 DC 300 lb 136 kg JLG Lift Machine Weight AM 19 AC 660 lbs 299 kg AM 19 DC 725 lbs 329 kg AM 24 AC 700 lbs 318 kg AM 24 DC 765 lbs 347 kg AM 30 AC 850 lbs 386 kg AM 30 DC 915 lbs 415 kg AM 36 AC 955 lbs 433 kg AM 36 DC 1 020 lbs 463 kg Machine Height Platform Lowered AM19 AC 6ft 5 in 1 95 m AM19 DC 6ft 5 in 1 95 m AM24 AC 6ft 5 in 1 95 m AM24 DC 6ft 5 in 1 95 m AM30 AC 7ft...

Page 41: ...46 Texaco Inc Rando Oil Hd 32 46 Union 76 XCel aw 46 200 Lubrication Specifications Table7 2 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL ...

Page 42: ...170 0 6250 16300 18 0 2560 170 130 190 23000 240 180 0 3340 21300 260 200 285 30100 380 280 0 7500 11 n 7 n Ann nn n n l nn A n n Note Tensile strength for bolt size 4 thru 1 120 000 min PSI size 1 1 8 thru 1 1 2 105 000 min PSI Torque Multiplier Torque Specifications are usually given in foot pounds lower ranges in inch pounds or inch ounces ou 55 80 90 120 135 165 190 240 265 420 AI I co SAE Gra...

Page 43: ...rush or Spray 500 Key To Lubricants MPG Multi Purpose Grease HO Hydraulic Oil See Table 7 1 Notes 1 Be sure to lubricate like items on each side of machine 2 Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions user must adjust lubricating requirements accordingly 3 Lubricating intervals are calculated on 50 hours of machine operation per...

Page 44: ...nt areas as well as the openings and fittings themselves As soon as a line or JLG Lift component is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or maintenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should...

Page 45: ...ean all metal parts with non flammable cleaning solvent Lubricate compo nents as required to aid assembly Lubrication and Servicing Components and assemblies requiring lubrica tion and servicing are shown in the Lubrication Chart Figure 7 2 Service applicable compo nents with the amount type and grade of lubri cant recommended in this manual at the speci fied intervals When recommended lubricants ...

Page 46: ... or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated 5 Protruding or Turned Pins Chains operating with inadequate lube generate tremendous friction between the pin and plates pin and bushing on roller chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Insp...

Page 47: ...em by various means e g using inadequate hy draulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign mat...

Page 48: ... The 24 30 and 36 ft models use six 6 mast sections whereas the 19ft mast assembly contains only 5 mast sections 1 After the platform has been removed from the mast and mast has been removed from ma chine lay mast assembly down with the short est mast section 5 6 on top and facing up 2 Remove sequencing cables from sides of mast assembly Also remove the latch bar assem bly from BOTTOM of mast sect...

Page 49: ...chor plate 18 At TOP of mast section 3 pull chains out and allow to hang loose be certain floor surface is clean and free ofany metal chips or debris which may stick to lubricated chains 19 Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly 20 Remove countersunk flathead screws secur ing chain sheave wheel assembly attach bars on both side ...

Page 50: ...RES 2 Q 0 w N 2 0 F M JLG Lift en l en E LL 0 E 0 I 0 m o r 2 0 ii en en l en E LL 0 a 0 1 Figure 8 1 AccessMaster Mast Components JLG Lift 8 7 c 0 o a l 0 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 51: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 52: ...ts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place 7 Shim slide pads using the following steps Note Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels ...

Page 53: ... attach bar rectangular plate with threaded holes on each side ofpin bore hole d Slide the whole anchor block assembly with sheave pin wheels and pin attach bars into top of mast section 2 Position anchorblock with narrow chains facing mast section 3 e Attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head coun tersunk flathead cap screws each side Coat threads with Loctite 1...

Page 54: ...rrow chain as sembly 444 to top of mast section 3 as fol lows a Locate the two 2 narrow chain sheave wheels and slide onto sheave pin b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin attach bars one each end of sheave pin to outside of space tubes d Holding complete sheave wheel assembly slide assembly into top of mast...

Page 55: ...s in step 7 The following steps 46 through 55 apply to 24 30 and 36 ft masts only These masts contain one mast section more than a 19ft mast If assembling a 19ft mast jump to step 56 Note When sliding mast sections together be careful not to scratch or score the lubricating graphokote coat ing in the slide pad channels 46 Locate mast section S carefully slide section S closed rail into section 4 o...

Page 56: ...lat stable surface 57 Attach the remaining chain cable anchor plate one with threaded holes vertically aligned in center of bracket Attach through inner verti cal set of holes in bottom of mast section 5 6 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 58 Complete the following steps to determine shim stock thickness required for section 5 6 Note Always use the an...

Page 57: ...position in front of mast JLG Lift assembly base frame andmastassemblymust be held at goo angle to each other 4 Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel Return port tube side of cylinder must be on right side facing bottom of base and mast s Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting c...

Page 58: ... are listed and defined in the following table See Table 8 2 this chapter This table is divided into two basic parts the AREA to be inspected and the INTER VAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the v...

Page 59: ... SECTION 8 SERVICE PROCEDURES 0 0 0 0 0 CABLEASSY S CHAIN CABLE ANCHOR PLATES Figure 8 2 Mast Chain Cable Routing Diagram JLG Lift JLG Lift 8 15 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 60: ...2 15 Placards and Decals 1 2 16 Wheels and Casters 1 8 9 12 17 Wheel Bearings 8 12 18 Power Switch Ground Control 1 11 19 Control Tags 1 2 20 Placards and Decals 1 2 21 Hoses and Cables 1 8 Inspection and Maintenance Code 10 to be performed annually The inspection and maintenance code numbers are as follows 1 Check for proper and secure installation 2 Check for visible damage and legibility 3 Chec...

Page 61: ...lly so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 9 3 HYDRAULIC CIRCUIT CHECKS See Figure 9 2 The first reference for improper function of a hydrau lic system where the cause is not immediately appar ent should be the Troubleshooting Chart The best place to begin the...

Page 62: ... oil Unit lowers very slowly Red emergency button is engaged PUSHED IN on either ground control station or on platform Control relay not functioning Motor start relay not functioning Unit wiring not properly grounded Manual descent valve open Hydraulic hose and or fittings loose causing a hydraulic pressure leak Lift DOWN solenoid valve not functioning Hydraulic hose and or fittings loose Valve an...

Page 63: ... oil Unit lowers very slowly Red emergency button is engaged PUSHED IN on either ground control station or on platform Control relay not functioning Motor start relay not functioning Unit wiring not properly grounded Manual descent valve open Hydraulic hose and or fittings loose causing a hydraulic pressure leak Lift DOWN solenoid valve not functioning Hydraulic hose and or fittings loose Valve an...

Page 64: ... On outside of outrigger beam slide threads of brass screws of contactor plate assembly through insulating grommets in outrigger beams until nylon washers rest against grom mets and hold in place if necessary 4 Install one 1 nylon washer on each screw inside of outrigger beam against insulating grommet s Thread a brass 8 32UNC locknut onto each screw inside outrigger beam tighten screws until 175 ...

Page 65: ...E FILTER SCREEN I RETURN TUBE SOLENOID WITH MANUAL OVERRIDE FILTER SCREEN CHECK If VALVE ADJ RELIEF i VALVE I I 1 I I I I I 7 TANK FILTER SCREEN JLG Lift 2792298 Rev Figure 9 2 Hydraulic Schematic AC DC Machines 9 5 JLGLitt Updated 5 97 9 6 Blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 66: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 67: ... 2 Platform Component Installations Fiberglass Platform Installation SECTION 10 5 CYLINDERS 10 5 1 Uft Cylinder Assembly Standard Parts SECTION 10 6 HYDRAULICS 10 6 1 Hydraulic Diagram SECTION 10 7 ELECTRICAL 10 7 1 10 7 2 10 7 3 Electrical Diagrams and Components Ust Electrical Diagram 115VAC 60HZ Electrical Diagram 12VDC SECTION 10 8 DECALS 10 8 1 Decals Installation SECTION 10 9 RECOMMENDED SER...

Page 68: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 69: ...10 1 2 SECTION 10 1 BASE Base Mounted Components Installation Tilt Back Installation 30Ft and 36Ft Machines 10 1 2 10 1 6 10 1 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 70: ... C N TT C c XI m 9 I en m i 0 c c 0 cg z C m 0 1 0 z 0 I z m 1 C m 0 z G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 71: ... Handle Loading 1 13 3422369 Piin Lock 5 14 2540024 Grommet 8 15 3900194 Screw Brass 8 32NC x 5 8 8 16 4740434 Washer Nylon 8 24 17 3300379 Locknut Brass 8 32NC 16 18 3900212 Screw Button 4 40NC NR 19 Not Used 20 3310405 Locknut 4 40NC NR 21 4844697 Mount Cylinder 1 22 2560088 Grip Handle 2 23 4751600 Flatwasher 3 8 8 24 2540025 Grommet 3 25 3740106 Relay 1 26 0641406 Bolt 1 4 20NC x 3 4 2 27 4751...

Page 72: ...641410 Bolt 1 4 20NC x 1 1 4 1 Per Assembly 4 117 4740430 Washer Fender 1 Per Assembly 4 118 3311405 Locknut 1 4 20NC 1 Per Assembly 4 119 4740434 Washer Nylon 8 6 Per Assembly 24 120 0100019 Loctite 271 Not Shown NR 121 3020035 Lubricant Silicone NR 0254803 OUTRIGGER ASSEMBLY 19FT AND 24FT MACHINES Ref D VARIABLE PARTS 151 4566510 Beam Outrigger 1 Per Assembly 4 0254802 OUTRIGGER ASSEMBLY 30 FT M...

Page 73: ...309 4844873 Socket Weldment 2 0255074 OPTIONAL FOUR WHEEL SWIVEL INSTALLATION Ref NB VARIABLE PARTS 351 4860143 Caster Wheel Assembly 2 7012641 Wheel Replacement 1 Per Assembly 2 7012630 Axle Kit 1 Per Assembly 2 7012642 Bearing Roller 1 Per Assembly 2 7012631 Bushing Spanner 1 Per Assembly 2 7012628 Retainer 1 Per Assembly 2 7012643 Spacer 2 Per Assembly 4 0257051 OPTIONAL FOUR WHEEL SWIVEL INSTA...

Page 74: ...SECTION 10 1 BASE FIGURE 10 1 2 TILT BACK INSTALLATION 30FT AND 36FT MACHINES 10 1 6 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 75: ...d 3 8 16NC 10 17 3420934 Pin Quick Release 2 18 1060380 Cable Lanyard 3 19 3941404 Screw Self Tapping 1 4 x 1 2 1 20 3538059 Plate Stop 1 21 4060804 Flex Trim Prior to S N 1141 0 1 ft 3m 4060805 Flex Trim S N 11410 to Present 1 ft 3m 22 4751600 Flatwasher 3 8 2 23 3420166 Pin Quick Release 1 0254959 TILT BACK INSTALLATION 30 FT MACHINE Ref 5 VARIABLE PARTS 51 4160131 Spring Assembly 2 52 3900196 B...

Page 76: ... 25 2 53 3311502 Nut 312 18 2 54 0100011 Loctite NR 55 4860156 Wheel Assembly Swivel 2 7012642 Bearing Roller 1 Per Assembly 2 7012628 Retainer Bearing 2 Per Assembly 4 7012643 Spacer 2 Per Assembly 4 7012629 Wheel Replacement With Bearing 1 Per Assembly 2 7012631 Bushing Spanner 1 Per Assembly 2 7012630 Axle Kit 1 Per Assembly 2 Not Available Lock Swivel 1 Per Assembly 2 0257052 TILT BACK INSTALL...

Page 77: ... 0 DC Power Components Installations 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Battery Charger Assembly 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DC Motor Pump Assembly 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Cables and Controls Installation 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ...

Page 78: ...SECTION 10 2 CONTROLS FIGURE 10 2 1 AC POWER COMPONENTS INSTALLATION 107 109 r 11 II I V 10 2 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 79: ...18NC 4 10 4460566 Connector Terminal 90Q 1 11 Not Used 12 Not Used 13 Not Used 14 Not Used 15 3600239 Pump Motor Assembly 115VAC 60HZ See Figure 1 10 2 3 for Breakdown 16 3911010 Screw Machine 1 0 24NC x 5 8 2 17 4751000 Flatwasher 1 0 2 18 Not Used 19 3311001 Nut 10 24NC 2 POWERPACK INSTALLATION STANDARD PARTS Ref 101 0641608 Bolt 3 8 16NC x 1 4 102 4751600 Flatwasher 3 8 8 103 Not Used 104 33116...

Page 80: ...SECTION 10 2 CONTROLS FIGURE 10 2 2 AC JUNCTION BOX ASSEMBLY 10 2 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 81: ...Relief S N 10998 to Present 4 10 Not Used 11 Not Used 12 Not Used 13 Not Used 14 Not Used 15 Not Used 16 4360161 Breaker Circuit 20 Amp 1 17 4360376 Rectifier 1 18 3740049 Relay 1 19 4530010 Transformer 115 230VAC to 12VDC 1 20 3740098 Relay Thermal Overload Prior to SIN 10216 1 21 4921663 Harness 1 22 Decal 115V Options Not Shown Located on Front 1 Cover 1702102 Prior to May 1995 1702569 May 1995...

Page 82: ...SECTION 10 2 CONTROLS FIGURE 10 2 3 AC MOTOR PUMP ASSEMBLY 10 2 6 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 83: ...Ring Kit For Item 16 1 12 7013726 Tube Return 1 13 7013791 Tube Return 90Q 1 14 7013784 Inlet Plumbing Kit Includes Item 15 1 15 7013723 Filter Part of Item 14 1 16 7013747 Pump Assembly See Item 11 for 0 Ring Kit 1 17 7013713 Bolt 2 18 7013785 Reservoir Assembly Includes Items 19 21 and 22 1 19 7013740 Screw Part of Item 18 4 20 7013779 Valve Assembly 1 21 7013794 Breather Dipstick Assembly Part ...

Page 84: ...SECTION 10 2 CONTROLS FIGURE 10 2 4 AC POWER COMPONENTS INSTALLATION 24 22 105 107 106 G 12 26 7106 kD 10 2 8 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 85: ...lief 1 12 4751500 Flatwasher 5 16 1 13 0902054 Plate Mounting 1 14 Not Used 15 Not Used 16 3740080 Relay Bosch 1 17 Not Used 18 Not Used 19 Not Used 20 3740013 Solenoid 1 21 3911010 Screw 1 0 24NC x 5 8 2 22 4761000 Lockwasher 1 0 2 23 Not Used 24 3311001 Nut 1 0 24NC 2 25 Not Used 26 3311505 Locknut 5 16 18NC 4 27 Not Used 28 1060571 Cable Assembly Battery 1 29 1060518 Cable Battery 1 POWERPACK I...

Page 86: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 87: ...Flatwasher 1 0 8 208 3311001 Nut 1 0 24NC Prior to S N 11 049 8 3300408 Nut 1 0 24NC S N 11049 to Present 8 209 0641410 Bolt 1 4 20NC x 1 1 4 2 210 4751400 Flatwasher 1 4 8 211 3311401 Nut 1 4 20NC 2 212 0641405 Bolt 1 4 20NC x 5 8 4 213 0100011 Loctite 242 Prior to S N 11027 NR 0100019 Loctite 271 S N 11 027 to Present NR 0254960 BATTERY BOX AND CHARGER INSTALLATION Ref 4 VARIABLE PARTS Ref 251 0...

Page 88: ... 5 BAlTERY CHARGER ASSEMBLY __ 10 POWER TRANSFORMER FINISH WHITE POWER TRANSFORMER START TX PRJ FINISH WHITE 10 HEATSJNK 6 7 5 0 NEEDLE CIRCUIT AMMETER BREAKER HEATSJNK 5 I r o CIRCUIT AMMETER BREAKER DCPOS RED DC NEG BLK DCPOS RED DC NEG BLK G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 89: ...Dial 1 10 Consult Factory Transformer 1 Note Battery Charger Serial Number Naneplate Located on right side of charger First line is the Charger Spec and Date Code Prior to Mid February 1996 Example BA515 Spec AP Date Code First Letter in the Date Code indicates Month A January 8 February C March etc with exception of Letter I which is not used Second Letter indicates Year N 1992 0 1993 P 1994 S 19...

Page 90: ...SECTION 10 2 CONTROLS FIGURE 10 2 6 DC MOTOR PUMP ASSEMBLY 10 2 14 Updated 4 98 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 91: ... Used 20 7013708 Valve Cartridge Check 1 21 7016720 Bolt Torx 5 16 18NC x 1 1 22 7016750 Plug 1 23 Not Used 24 Not Used 25 4640900 Spring 1 26 7016755 Cartridge 1 27 7013764 Cartridge 1 28 Not Used 29 7013740 Bolt Washerhead 4 30 7013766 Pin 1 31 7013743 0 Ring 1 32 Not Used 33 7016753 Endhead 1 34 7013747 Pump Assembly 1 35 7016754 Tank 1 36 7013750 Cap Relief 1 37 7013794 Breather Dipstick 1 38 ...

Page 92: ...3 10 2 16 SECTION 10 2 CONTROLS FIGURE 10 2 7 CABLES AND CONTROLS INSTALLATION 7 20 19 18 s2 16 7 13 12 0 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 93: ...1406 Bolt 1 4 20NC x 3 4 4 13 4711400 Flatwasher 1 4 Narrow 19 14 Not Used 15 4460566 Connector Strain Relief 90 NR 16 4460023 Connector Strain Relief Prior to S N 10321 NR 4460633 Connector Strain Relief S N 10321 to Present NR 17 0960407 Bushing Prior to S N 10321 1 18 0860946 Box Receptacle 1 19 4460190 Receptacle 1 20 4060092 Cover Box 1 21 Not Used 22 0721006 Screw Machine 1 0 24NC x 3 4 NR 2...

Page 94: ...ef 6 MACHINES VARIABLE PARTS 0254922 CABLES AND CONTROLS INSTALLATION 30 FT Ref 6 MACHINES VARIABLE PARTS 0254923 CABLES AND CONTROLS INSTALLATION 36 FT Ref E MACHINES VARIABLE PARTS 51 0860945 Box Junction 1 52 1060565 Cable Electrical 16 4 NR 53 1670603 Cover Box 1 54 Not Required 10 2 18 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 95: ... NO I DESCRIPTION I PAGE NO 10 3 1 Mast Assemblies 19 Ft and 24 Ft 10 3 2 10 3 2 Mast Assemblies 30 Ft and 36 Ft 10 3 6 10 3 3 Mast Mounted Components 10 3 10 10 3 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 96: ... 1 0 en z m i Ill 0 c I m w en I IIIII II I I I II lllllll II Ill IIIII II I I I II 2s 1h I 1111 II o l1 I j_JJ __ I 3 4 CD I J z 1 c N j o I 46 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 97: ...605 Locknut 3 8 16NC 6 8 15 3422361 Pin Sheave 3 4 16 4070860 Shim 075 16 20 17 0901992 Bracket Chain Attach Bottom 2 2 18 0901993 Bracket Chain Attach Bottom 1 2 19 0641410 Bolt 1 4 20NC x 1 1 4 10 10 20 0902047 Bracket Cable 3 4 21 4566486 Tube Spacer 1 1 22 4566487 Tube Spacer 2 4 23 4712600 Flatwasher 1 Narrow 2 2 24 0362378 Bar Latch 1 1 25 3340704 Pad Wear 14 18 26 4070861 Shim 036 2 2 27 40...

Page 98: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 99: ...028 Lubricant Graphkote Not Shown NR NR 60 3900205 Screw 10 24NC x 112 6 8 1260305 CHAIN ASSEMBLY 466 CHAIN Ref Ref B 101 0561156 Block 1 1 102 1260299 Chain 68in 68 in 103 3422346 Pin Grooved Prior to May 1995 2 2 3422265 Pin May 1995 to Present 2 2 3450201 Pin Cotter 1116 x 112 May 1995 to Present 4 4 104 0561150 Block 1 1 105 4300111 Stud 1 1 106 0100019 Loctite 271 Not Shown Prior to SIN 10998...

Page 100: ... 23 6 87 87 1 t I 9 h 293eda I 39 42 50 37 38 r A 83 25 I I 46 G c 0 m 0 I Co a l en m 0 1 en o en Z en m a Ill 0 c I m w en I 31 l en z 1 c G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 101: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 102: ...641410 Bolt 1 4 20NC x 1 1 4 10 20 0902047 Bracket Cable 4 21 4566486 Tube Spacer 1 22 4566487 Tube Spacer 4 23 4712600 Flatwasher 1 Narrow 2 24 0362378 Bar Latch 1 25 3340704 Pad Wear 18 26 4070861 Shim 036 2 27 4070862 Shim 015 9 28 4751600 Flatwasher 3 8 12 29 4761400 Lockwasher 1 4 4 30 Not Used 31 3900192 Screw Countersunk 3 8 16NC x 1 2 16 32 3900206 Bolt 1 4 28NF x 5 8 1 33 3311405 Locknut ...

Page 103: ... Ref 8 81 1271233 Channel Mast 1 1 82 1271234 Channel Mast 2 1 83 1271235 Channel Mast 3 and 4 2 84 1271236 Channel Mast 5 1 85 1260303 Chain Assembly 466 Chain See Items 101 1 06 2 for Breakdown 86 1260304 Chain Assembly 444 Chain See Items 201 208 1 for Breakdown 87 1060547 Cable Assembly Prior to S N 11459 4 1060654 Cable Assembly SIN 11459 to Present 4 88 1683200 Uft Cylinder Assembly See Sect...

Page 104: ...tud 1 106 0100019 Loctite 271 Not Shown Prior to S N 10998 NR 0100062 Loctite RC680 Not Shown SIN 10998 to Present NR 1260304 CHAIN ASSEMBLY 444 CHAIN 30 FT MAST Ref B 1260301 CHAIN ASSEMBLY 444 CHAIN 36 FT MAST Ref B 201 0561159 Block 1 202 1260298 Chain NR 30Ft Mast 14Ft 36Ft Mast 16 25A 203 3422346 Pin Grooved 2 204 0561151 Block 2 205 4300111 Stud 2 206 0100019 Loctite 271 Not Shown Prior to S...

Page 105: ...1 10 3 10 SECTION 10 3 MAST FIGURE 10 3 3 MAST MOUNTED COMPONENTS 202 204 205 10 26 21 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 106: ...Used 18 Not Used 19 3020035 Lubricant Silicone Not Shown NR 0254842 LOADING HARDWARE INSTALLATION 19FT AND Ref 5 24FT MACHINES VARIABLE PARTS 20 4844921 Load Axle Weldment 1 21 4860152 Wheel Assembly 2 7012633 Bearing Roller 1 Per Assembly 2 7012634 Retainer Bearing 2 Per Assembly 4 22 0641608 Bolt3 8 16NCx 1 2 23 4711400 Flatwasher 1 4 Narrow 8 24 3311605 Nut 3 8 16NC 2 25 3450504 Rollpin 5 32 x ...

Page 107: ...x 1 3 8 2 203 Not Used 204 4711600 Flatwasher 3 8 Narrow 2 205 3311601 Nut 3 8 16NC 2 206 1701500 Decal Prior to S N 10781 1 1703455 Decal S N 10781 to Present 1 0255019 OPTIONAL CRANE HOOK INSTALLATION 30 FT Ref c AND 36 FT MACHINES 201 3538591 Plate Crane Hook 1 202 Not Used 2 203 0641609 Bolt 3 8 16NC x 1 1 8 4 204 4711600 Flatwasher 3 8 Narrow 4 205 3311601 Nut 3 8 16NC 4 206 1701500 Decal Pri...

Page 108: ...10 4 1 10 4 2 SECTION 10 4 PLATFORM Platform Component Installations Fiberglass Platform Installation 10 4 2 10 4 4 10 4 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 109: ...10 4 2 SECTION 10 4 PLATFORM FIGURE 10 4 1 PLATFORM COMPONENT INSTALLATIONS r w 201F 201A 2018 201C 2010 201E 202 202C G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 110: ... 3900215 Screw Socket Head 1 4 20NC x 1 2 53 4751400 Flatwasher 1 4 2 54 3311401 Nut 1 4 20NC 2 0254879 ALUMINUM PLATFORM INSTALLATION 26 x 26 Ref C 3 VARIABLE PARTS 51 3510471 Platform Weldment 26 x 26 1 52 0640486 Screw Socket Head 5 16 18NC x 1 2 53 4751500 Flatwasher 5 16 2 54 3311505 Nut 5 16 18NC 2 PLATFORM ASSEMBLIES STANDARD PARTS Ref 101 Not Used 102 Not Used 103 0641414 Bolt 1 4 20NC x 1...

Page 111: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 112: ...Pin Snap 2 203B 3422551 Pin Hitch 2 204 Decal Caddy Placement Options Not Shown 1 1703088 English 1703123 Japanese 1703117 Latin America Spanish 1703643 Brazil 205 Decal Capacity Options Not Shown 1 1703087 English 1703122 Japanese 1703116 Latin America Spanish 1703642 Brazil 0255584 LASER LOCATOR INSTALLATION PRIOR TOMAY 1995 Ref 301 2920127 Pointer Laser 1 4845016 Mounting Weldment 1 1320218 Cla...

Page 113: ...SECTION 10 4 PLATFORM FIGURE 10 4 2 FIBERGLASS PLATFORM INSTALLATION 02 10 4 6 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 114: ...62347 Unk Gate 1 111 3640924 Rail Gate Top 1 112 3640990 Rail Gate Bottom 1 113 4751500 Flatwasher 5 16 1 114 3311501 Nut 5 16 18NC Prior to S N 11313 1 3311505 Locknut 5 16 18NC SIN 11313 to Present 1 115 3340746 Pad Gate Rest 1 116 3911032 Screw Machine 1 0 24NC x 2 4 117 4751000 Flatwasher 1 0 8 118 4060804 Flex Trim Prior to S N 11313 2Ft 4060803 Flex Trim S N 11313 to Present 2Ft 119 3311001 ...

Page 115: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 116: ...SECTION 10 5 CYLINDERS 10 5 1 Uft Cylinder Assembly Standard Parts 10 5 2 10 5 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 117: ...SECTION 10 5 CYLINDERS FIGURE 10 5 1 LIFT CYLINDER ASSEMBLY STANDARD PARTS 10 5 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 118: ...Ring Back up 1 10 Kit 0 Ring 1 11 Kit Seal Piston 1 12 Kit Ring Wear 1 13 Kit 0 Ring 1 7003245 Seal Kit Includes Items 7 13 1 1683201 LIFT CYLINDER ASSEMBLY 19FT AND 24FT Ref MACHINES VARIABLE PARTS 51 7003250 Rod 1 1683200 LIFT CYLINDER ASSEMBLY 30 FT MACHINES Ref VARIABLE PARTS 51 7003251 Rod 1 1683175 LIFT CYLINDER ASSEMBLY 36 FT MACHINES Ref VARIABLE PARTS 51 7003252 Rod 1 10 5 3 10 5 4 Blank ...

Page 119: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 120: ...SECTION 10 6 HYDRAULICS FIGURE NO DESCRIPTION 10 6 1 Hydraulic Diagram 10 6 2 10 6 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 121: ...10 6 2 EXTEND PORT RETURN PORT SECTION 10 6 HYDRAULICS FIGURE 1o 1 HYDRAULIC DIAGRAM G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 122: ... 19 Ref N2 10 2220875 Fitting 90Q 1 11 4640900 Valve Flow Control 1 12 2220416 Fitting 90Q 1 13 4566559 Tube 1 14 2220472 Fitting 90Q 1 15 2220603 Fitting 1 16 4566558 Tube 1 17 2220507 Fitting 90Q 1 18 2220473 Fitting 1 19 0100020 Sealant Pipe Not Shown NR 10 6 3 10 6 4 Blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 123: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 124: ...CTION 10 7 ELECTRICAL Electrical Diagrams and Components Ust Electrical Diagram 115VAC 60HZ Electrical Diagram 12VDC 10 7 2 10 7 3 10 7 4 10 7 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 125: ...NING MACHINES 4921663 Harness Ground Control 1 4460044 Fuseholder 1 2400006 Fuse 5Amp 1 4932809 ELECTRICAL DIAGRAM 115VAC 60HZ WITH FOOT Ref A SWITCH MACHINE WITH S O s 26730 AND 26820 26824 4921661 Harness Ground Control 1 4460044 Fuseholder 1 2400006 Fuse 5Amp 1 4932716 ELECTRICAL DIAGRAM 12VDC Ref F 1320210 Clamp 1 4460044 Fuseholder 1 2400006 Fuse 5Amp 1 0255569 ELECTRICAL DIAGRAM DESCENT Ref ...

Page 126: ... e G a i5 w w a e u IPi ATFORM CONTROLl I ENABI E LIFT EIE Y I I t I L __ _j GRO ID ccrmKJ SCI eB RECTIFIER I I II l1 A CttAJr II S va rs J j t t l i l w II j G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 127: ...L 12 J Wtt6tE m PiATFORM CONTROz i 7 L __d 0 A SET I ED t ft E OIR SET Lm 0104 SET l 0 u r W _ f P LIFT _ L _ OIR S T Lm I A C II PUr u5 vrx rs IIII 12VDC BATTERY 1 I 1 1 j J PUM STARTER MOTOR RELAY II LL co G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 128: ...SECTION 10 8 DECALS 8 1 Decals Installation 10 8 2 10 8 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 129: ...SECTION 10 8 DECALS FIGURE 10 8 1 DECALS INSTALLATION N 10 8 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 130: ...iction NR 22 1702109 Decal Leveling 1 23 1702364 Decal Crushing 2 24 Not Used 25 1702412 Decal AccessMaster 1 26 Not Used 27 3820031 Rivet 4 28 1702631 Decal Barcode S N 10251 to Present 1 29 1703073 Decal Forklift S N 11386 to Present 2 0255562 DECAL INSTALLATION LATIN AMERICA Ref 5 1 1702365 Decal JLG 3 2 Not Used 3 1701612 Decal JLG 1 4 3252440 Decal Tipping 1 5 Not Used 6 1702446 Decal Caution...

Page 131: ... Used 19 1703597 Decal Checklist 1 20 Consult Factory Nameplate Serial Number 1 21 4420039 Tape Friction NR 22 1703591 Decal Leveling 1 23 1703598 Decal Crushing 2 24 Not Used 25 1702412 Decal AccessMaster 1 26 Not Used 27 3820031 Rivet 4 28 1702631 Decal Barcode S N 10251 to Present 1 29 1703073 Decal Forklift S N 11386 to Present 2 DECAL INSTALLATION VARIABLE Ref 51 Decal Capacity Options 1 Alum...

Page 132: ... AM 24 1702410 AM 30 1702411 AM 36 53 Decal Tilt Back Crushing 30 Ft and 36 Ft Machines 1 1702415 U S A CSA 1702519 Latin America 1702521 Japanese 1703600 Brazil 54 Decal Explosion D C Units Only 1 1702437 U S A CSA 1702524 Latin America 1702527 Japanese 1703601 Brazil 10 8 5 10 8 6 Blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 133: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 134: ... Figure 10 2 3 and 10 2 6 1 1 1 7012638 Switch Push Button White Figure 10 2 7 1 1 1 7012639 Switch Push Button Green Figure 10 2 7 1 1 1 2400006 Fuse 5 Amp Figure 10 7 1 4 4 4 VARIABLE PARTS 3740094 Relay Starter AC Units Figure 10 2 2 1 1 1 3740093 Relay Starter AC Units Figure 10 2 2 1 1 1 4360161 Breaker Circuit 20 Amp AC Units Figure 10 2 2 1 1 1 4360376 Rectifier AC Units Figure 10 2 2 1 1 1...

Page 135: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 136: ...ssembly Kit Extra Reserve Pack Ref 0256789 Camera Mount Assembly Ref 1670815 Cover Travel Storage Ref Japan Spec Installations Ref 0255268 1282302 Decal Installation Ref 1702057 Decal Capacity 1 1702527 Decal Explosion 1703166 Decal Foot Pedal 1702521 Decal Tilt Back Crushing 0255401 Power Unit Assembly Ref 0860977 Junction Box Assembly 1 3600244 Pump Motor Assmbly 4932784 Wiring Diagram Ref Logan...

Page 137: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 138: ...nectors 1 4460467 Extractor 16 18 Gauge For Wire to Pin Socket from Deutsch 1 Connectors 4460510 Extractor 12 14 Gauge For Wire to Pin Socket from Deutsch 1 Connectors 7016654 Screwdriver Magnetic 1 7004275 Seal Tool 1 1 7004276 Seal Tool 1 1 2 1 7002826 Seal Tool 2 1 8896941 Stipper Wire 1 10 10 3 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 139: ... C f 1 en m 0 TI 1 0 z 0 _ 0 cr _ t 0 en g a hi m z 0 1 i r r 0 0 a z 1 0 z en G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 140: ...g Roller 1 7012631 Bearing Spanner 1 7012628 Retainer 1 7012643 Spacers 2 17 3422369 Pin Locking 4 18 Not Used 19 2560120 Knob Locking 6 20 3520071 Plug Square 2 4 21 3421060 Pin Quick Release 3 8 x 4 12 22 4711500 Flatwasher 5 16 4 23 3680052 Reel Cord 2 24 4460205 Connector Plug 2 25 2920121 Ught L E D 4 26 3520162 Plug LED Mounting 4 27 1320041 Clamp 2 28 3900194 Screw 8 32NC x 5 8 Brass 16 29 ...

Page 141: ...995 to Present 55 4070891 Shim 8 56 3311605 Locknut 3 8 16NC 6 57 3315805 Locknut 5 16 18NC 4 58 4860143 Caster 5 Swivel Locking 4 7012641 Wheel Replacement 1 7012630 Kit Axle 1 7012642 Bearing Roller 1 7012631 Bearing Spanner 1 7012628 Retainer 1 7012643 Spacers 2 0255831 STRADDLE EXTENSION ASSEMBLY PHENOLIC Ref 2 CASTERS VARIABLE PARTS AUGUST 1995 TO PRESENl 51 4845021 Base Tube Weldment 1 52 48...

Page 142: ...LG 2 105 Consult Factory Nameplate Manufacturers 1 106 3820001 Rivet Pop 4 0257110 DECAL INSTALLATION JAPANESE Ref 101 1703426 Decal Caution 2 102 1703434 Decal Warning 2 103 1703441 Decal Danger Extension 2 104 1702365 Decal JLG 2 105 Consult Factory Nameplate Manufacturers 1 106 3820001 Rivet Pop 4 0257112 DECAL INSTALLATION LATIN AMERICA Ref 101 1703428 Decal Caution 2 102 1703435 Decal Warning...

Page 143: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

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JLG AM-19, Operators And Safety Manual Service & Maintenance Manual Illustrated Parts Manual

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