Jlg 19AMI (3120875) Service Manual- Manuals

Jlg 19AMI (3120875) Service Manual– User Manual in PDF format online.

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User Manual

User Manual Jlg 19AMI (3120875) Service Manual

Summary

Page 3 - FOREWORD; READ; UNDERSTOOD; before any attempt is made to operate the; YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL; and; NOTE; are defined as follows:

FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its intended purpose. It is important to over-stress proper machine usage. Allinformation in this manual should be READ and UNDERSTOOD before any attempt i...

Page 5 - – JLG Lift –; INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS; GENERAL

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS 3120875 – JLG Lift – a INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL T h i s s e c t i o n c o n t a i n s t h e g e n e r a l sa f e t y p r e c a u ti on swhich must be observed during maintenance of the aerialplatform. It is of utmost importan...

Page 6 - EFFECTIVITY CHANGES

EFFECTIVITY CHANGES b – JLG Lift – 3120875 EFFECTIVITY CHANGES February 1, 1999 - Original Issue of Manual (Correctionwas 1998) November 22, 2000 - Manual Revised - Pages Affected;Section 2 - Pages 2-12 through 2-15. August 5, 2002 – Manual Revised March 31, 2005 – Manual Revised August 3, 2006 – Ma...

Page 7 - TABLE OF CONTENTS; SECTION 1 - SPECIFICATIONS

3120875 – JLG Lift – i TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aHydraulic Sy...

Page 9 - SECTION 3 - TROUBLESHOOTING

3120875 – JLG Lift – iii TABLE OF CONTENTS Mast Section 3 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Platform Mounting Section - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2.1...

Page 10 - LIST OF FIGURES; LIST OF TABLES; TITLE

iv – JLG Lift – 3120875 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . . 1-2 1-2. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 11 - SECTION 1. SPECIFICATIONS; WET

SECTION 1 - SPECIFICATIONS 3120875 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Reservoir AC Models – 4.7 ltr. (5 qts. U.S.) DC Models – 4.7 ltr. (5 qts. U.S.) 1.2 COMPONENT DATA Hydraulic Pump/Electric Motor Assembly DC Models - 12 Volt DC Motor/Pump Motor - 12v - DC Stan...

Page 12 - TORQUE REQUIREMENTS; Lubrication Specifications; HYDRAULIC PRESSURE ADJUSTMENT; clockwise, increases system; CYLINDER SPECIFICATIONS; Screw Located at Base of Pump Motor

SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3120875 1.4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener hasloosened, refer to the Torque Charts, Figures 1-3., 1-4. or1-5., to determine proper torque value. 1.5 LUBRICATION Hydraulic Oil Hydraulic oils must have anti-wear qualitie...

Page 16 - CLASS 8 METRIC NUTS

SECTION 1 - SPECIFICATIONS 1-6 – JLG Lift – 3120875 VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY CLASS 8.8 METRIC BOLTS & CLASS 8 METRIC NUTS CLASS 10.9 METRIC BOLTS & CLASS 10 METRIC NUTS SIZE PITCH TENSILE STRESS AREA CLAMP LOAD TORQUE CLAMP LOAD TORQUE DRY OR LOCTITE 263 LUB LO...

Page 17 - SECTION 2 - SERVICE PROCEDURES; SECTION 2. SERVICE PROCEDURES; AND MAINTENANCE; General

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-1 SECTION 2. SERVICE PROCEDURES 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby those personnel that are responsible to place themachine in operation readiness and maintain its...

Page 18 - PREVENTIVE MAINTENANCE AND

SECTION 2 - SERVICE PROCEDURES 2-2 – JLG Lift – 3120875 2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE (See Table 2-2.) The preventive maintenance and inspection checks arelisted and de fined in the fo llowing tabl e. This table isdivided into two basic parts, the “AREA” to be inspectedand the “...

Page 19 - INTERVAL

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-3 Table 2-2. 9MP - Preventive Maintenance & Inspection Schedule. AREA ON MACHINE INTERVAL PRE-START (1) INSPECTION 3 MONTH PREVENTATIVE MAINTENANCE 6 MONTH PREVENTATIVE MAINTENANCE PRE-DELIVERY (2)OR FREQUENT (3) INSPECTION ANNUAL (4) (YEARLY...

Page 21 - SERVICING AND MAINTENANCE

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-5 2.3 GENERAL This section provides general information to assist in thep e r f o r m a n c e o f m a i n t e n a n c e o n t h e p e r s o n n e l l i f t .Descriptions, techniques and specific procedures aredesigned to provide the safest and mo...

Page 23 - Chain Anchors and Sheaves:; Mast Cable Inspection Procedure

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-7 i n s i d e “ w a l k i n g ” p l a t e s i n w a r d ; i f “ wa l k i n g ” p e r s i s t s ,replace the chain. This type of problem is accelerated bypoor lubrication maintenance practice, and most tightjoint chains have been operated with lit...

Page 24 - LUBRICATION INFORMATION; Hydraulic System

SECTION 2 - SERVICE PROCEDURES 2-8 – JLG Lift – 3120875 2.5 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina-tion. Contaminants enter the system by various means,e.g., using inadequate hydraulic oil, allowing moisture,grease, filings, sealing components, ...

Page 25 - AC JUNCTION BOX COMPONENTS

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-9 2.6 AC JUNCTION BOX COMPONENTS (AC POWERED MACHINES ONLY) HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELEC-TRICAL POWER TO THE JUNCTION BOX BEFORE ATTEMPTINGTO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPO-NENTS. WHEN TESTING CIRCUITS WITH ELE...

Page 26 - General Information

SECTION 2 - SERVICE PROCEDURES 2-10 – JLG Lift – 3120875 2.7 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY - (DC POWERED MACHINES ONLY) General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGERIF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-TE RY CHARGER WH ILE TH E MACH INE IS UNDER WA...

Page 27 - Transformer Replacement; Printed Circuit Board Replacement; DC Circuit Breaker Replacement

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-11 Transformer Replacement 1. Disconnect the wiring connecting the transformer toother components within the charger assembly. 2. Remove the four nuts from the cap screws securingthe transformer brackets to the base of the chargerchassis. 3. Remo...

Page 29 - FENNER BRAND PUMP - Brush Replacement; Motor Cap Installation

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-13 2.8 HYDRAULIC LIFT PUMP - SERVICING Remove hydraulic pump from machine. FENNER BRAND PUMP - Brush Replacement Motor Cap/Motor Installation Motor Brush Installation Motor Cap Installation 1. Cap Assembly Screws 2. Cap Assembly Motor Installatio...

Page 30 - Brush Housing Final Assembly Tips; New Brush Installation; Brush Final Positioning

SECTION 2 - SERVICE PROCEDURES 2-14 – JLG Lift – 3120875 Once brush housing has been removed, inspect the rotorcommutator for excessive wear before installing a newbrush set. The rotor commutator surface when new, is approximately1/8 in. (3mm) in thickness. Brush Housing Final Assembly Tips It is ea...

Page 31 - MONARCH BRAND PUMP - Brush Replacement

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-15 MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks Motor/Brush Cover - Remove/Install Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and va...

Page 33 - Tank Installation

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-17 TANK AND PUMP REMOVAL - (All Pumps) Tank Installation Filter Screen Installation Pump Installation Tank Installation 1. Tank Assembly 3. O-Ring Seal 2. Tank Screws (4) 4. Use Screwdriver to pry tank away from pump head. Filter Screen Installat...

Page 34 - Pressure Adjust Valve Installation; Pressure Check Valve Installation

SECTION 2 - SERVICE PROCEDURES 2-18 – JLG Lift – 3120875 Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation 1. Adjust Valve Cap 4. Valve Ball 2. Adjustment Screw 5. Adjust Valve Por t 3. Valve Spring 6. Extend (Pressure) Por t (Shown Plugged) Note...

Page 35 - INSPECTION AND REBUILD; Cylinder Disassembly; Cylinder Rod

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-19 2.9 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULICFLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATEMEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE INTHE CYLINDER BEFORE DISCONNECTI...

Page 36 - Piston

SECTION 2 - SERVICE PROCEDURES 2-20 – JLG Lift – 3120875 event that an unacceptable condition occurs, the headshould be replaced. Piston Visually inspect the outside surface for scratches or pol-ishing. Deep scratches are unacceptable. Polishing indi-cates uneven loading and when this occurs, the di...

Page 37 - Cylinder Assembly

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-21 Cylinder Assembly (See Figure 2-2.) 1. Rinse the inside of the tube with hydraulic fluid andallow to drain. A high-pressure rinse followed by awipe with a lint-free rag is preferable. Clean all inter-nal components of any foreign material. 2. ...

Page 38 - MAST ASSEMBLY AND DISASSEMBLY; Mast Disassembly Procedure; Model; TOP

SECTION 2 - SERVICE PROCEDURES 2-22 – JLG Lift – 3120875 2.10 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The AM Series personnel lift mast sections are contructedof extruded aluminum, protected with an anodized surfacefinish. The mast sections rails are interlocked into eachothe r when asse mbl e d an...

Page 39 - Mast Section 3 – Removal; Mast Section 2 – Removal

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-23 5. Carefully slide short mast section-4 out BOTTOM ofmast section-3 rails. Disassemble slide pads, shimsand cable anchor plate from mast section-4, if nec-essary. Mast Section 3 – Removal 6. Remove chain adjust nuts from threaded ends ofchain ...

Page 40 - Mast Section 1 - Assembly; Mast Section 2 - Assembly

SECTION 2 - SERVICE PROCEDURES 2-24 – JLG Lift – 3120875 2.11 MAST ASSEMBLY (See Figure 2-4., Figure 2-4., and Figure 2-5.) Mast Section 1 - Assembly 1. Place mast section-1, rail (open) side up (See Figure 2-3.) on a clean, flat surface (preferably a table or work bench capable of supporting the we...

Page 41 - Mast Section 3 - Assembly

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-25 ft. lbs. Align the hole in the mounting journal with thehole in the cylinder and Install the (1) 5/16" bolt. 16. New Design Cylinder: Install the mounting pin through the side mounting brackets and the cylindervalve body and through the mo...

Page 45 - Platform Mounting Section - Assembly

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-29 washer under head of each bolt, through holes inoutside rail, on top of mast section-2 and into theslide pad inserts. Thread in enough to hold pad inplace. 31. Shim per instructions in step 7, Mast Section 2 -Assembly. 32. Insert slide pads in...

Page 46 - MAST TO BASE FRAME INSTALLATION

SECTION 2 - SERVICE PROCEDURES 2-30 – JLG Lift – 3120875 2.12 MAST TO BASE FRAME INSTALLATION 1. Using an overhead crane or suitable lifting devicecapable of supporting the weight of base frame,attach a sling strap or chain to the front crossmem-ber of the base frame, raise base frame. 2. Extend hyd...

Page 47 - SEQUENCING CABLES ADJUSTMENT; Mast Chain/Cable Adjustment; Sequencing Cable Adjustment

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-31 2.13 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT Mast Chain/Cable Adjustment The intention of this procedure is to assure equal load dis-tribution between the individual chains/cables of a mastsection chain/cable set. Adjust using the ...

Page 48 - MAST SIDE PROFILE

SECTION 2 - SERVICE PROCEDURES 2-32 – JLG Lift – 3120875 Figure 2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) SECTION-1 FIXED TO BASE SEQUENCE CABLE ADJUST NUT CHECK IF OVERALL HEIGHT OF MACHINE FROM FLOOR TO TOP OF MAST IS WITHIN SPECIFICATION SECTION-2 EXTENDED BY CYLINDER ...

Page 49 - SEQUENCE CABLE REPLACEMENT KIT; Remove Old Cable

SECTION 2 - SERVICE PROCEDURES 3120875 – JLG Lift – 2-33 2.14 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from theJLG Parts Department to service broken or wornsequence cables. This kit consists of a replacementsequence cable with the threaded (top) end attached same...

Page 51 - SECTION 3. TROUBLESHOOTING; TROUBLESHOOTING INFORMATION; HYDRAULIC CIRCUIT CHECKS; Grounding

SECTION 3 - TROUBLESHOOTING 3120875 – JLG Lift – 3-1 SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presente...

Page 52 - Polarity; Procedure

SECTION 3 - TROUBLESHOOTING 3-2 – JLG Lift – 3120875 Polarity F i n d i n g a n e g a t i v e v o l t a g e o r c u r r e n t r e a d i n g w h e nexpecting a positive reading frequently means the leadsare reversed. Check what reading is expected, the loca-tion of the signal and that the leads are c...

Page 53 - Voltage Measurement

SECTION 3 - TROUBLESHOOTING 3120875 – JLG Lift – 3-3 Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads ...

Page 54 - Continuity Measurement

SECTION 3 - TROUBLESHOOTING 3-4 – JLG Lift – 3120875 Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4. Current Measurement (DC) • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing...

Page 55 - ELECTRICAL SWITCH TESTING

SECTION 3 - TROUBLESHOOTING 3120875 – JLG Lift – 3-5 3.5 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioningproperly, not the circuit in which the switch is placed. Aswitch is functioning properly when there is continuitybetwee n th e correct terminals o...

Page 70 - JLG Worldwide Locations

Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda.Rua Eng. Carlo...