Jlg 19AMI (3120875) Service Manual User Manual

Service and Maintenance ManualModel15AMIP/N - 3120875February 21, 2008

iv – JLG Lift – 3120875TABLE OF CONTENTSLIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of

SECTION 1 - SPECIFICATIONS3120875 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil ReservoirAC Models – 4.7 ltr. (5 qts. U.S.)DC

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31208751.4 TORQUE REQUIREMENTSWhen maintenance becomes necessary or a fastener hasloosened, refer to the To

SECTION 1 - SPECIFICATIONS3120875 – JLG Lift – 1-3Figure 1-2. Lubrication Locations (See Table below).Table 1-4. Lubrication Intervals for Various Co

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120875 Figure 1-3. Torque Chart. (ANSI Spec.)

SECTION 1 - SPECIFICATIONS3120875 – JLG Lift – 1-5Figure 1-4. Torque Chart. (ANSI to METRIC Conversion)SAE GRADE 5SAE GRADE 8Note: These torque v

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120875VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS 8.8 METRIC BOLTS &CLASS 8 METRIC NU

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis se

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 31208752.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-3Table 2-2. 9MP - Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALPRE-STA

NOTES:

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120875Footnotes:(1) Prior to use each day; or at each Operator change(2) Prior to each sale, lease,

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-52.3 GENERALThis section provides general information to assist in theperformance of maintenance

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120875Bolt Usage and Torque ApplicationUse bolts of proper length. A bolt which is too long willbottom

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-7inside “walking” plates inward; if “walking” persists,replace the chain. This type of problem is

SECTION 2 - SERVICE PROCEDURES2-8 – JLG Lift – 31208752.5 LUBRICATION INFORMATIONHydraulic SystemThe primary enemy of a hydraulic system is contamina-

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-92.6 AC JUNCTION BOX COMPONENTS(AC POWERED MACHINES ONLY)HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONN

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 31208752.7 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY - (DC POWERED MACHINES ONLY)General InformationD

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-11Transformer Replacement1. Disconnect the wiring connecting the transformer toother components w

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 3120875AC Iput Circuit Breaker and Voltage Selection Switch Replacement1. Remove the wiring from the A

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-132.8 HYDRAULIC LIFT PUMP - SERVICINGRemove hydraulic pump from machine.FENNER BRAND PUMP - Brush

FOREWORDThe purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its in

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120875Once brush housing has been removed, inspect the rotorcommutator for excessive wear before inst

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-15MONARCH BRAND PUMP - Brush ReplacementMotor Assembly - Remove/Install - Reference MarksMotor/Br

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120875Brush Carrier Assembly - Remove/InstallBrush Assembly - Remove/InstallBrush Carrier Assembly -

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-17TANK AND PUMP REMOVAL - (All Pumps)Tank InstallationFilter Screen InstallationPump Installation

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 3120875Pressure Adjust Valve Installation Pressure Check Valve InstallationPressure Adjust Valve Insta

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-192.9 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 3120875event that an unacceptable condition occurs, the headshould be replaced.PistonVisually inspect

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-21Cylinder Assembly(See Figure 2-2.)1. Rinse the inside of the tube with hydraulic fluid andallow

SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 31208752.10 MAST ASSEMBLY AND DISASSEMBLY PROCEDURESThe AM Series personnel lift mast sections are con

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-235. Carefully slide short mast section-4 out BOTTOM ofmast section-3 rails. Disassemble slide pa

NOTES:

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 31208752.11 MAST ASSEMBLY(See Figure 2-4., Figure 2-4., and Figure 2-5.)Mast Section 1 - Assembly1. Pl

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-25ft. lbs. Align the hole in the mounting journal with thehole in the cylinder and Install the (1

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 3120875Figure 2-4. 15AMI Mast Assembly Components. (4 Section - Chain/Cable or All Cable)MASTSECTION-

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-27Figure 2-5. 15AMI Mast Assembly Components. (4 Section - All Chain w/Equalizers)MASTSECTION-1M

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 3120875Figure 2-6. Mast Chain/Cable Routing Diagram.

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-29washer under head of each bolt, through holes inoutside rail, on top of mast section-2 and into

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 31208752.12 MAST TO BASE FRAME INSTALLATION1. Using an overhead crane or suitable lifting devicecapabl

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-312.13 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENTMast Chain/Cable AdjustmentThe intentio

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 3120875Figure 2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)SECTION-1FIXEDTO B

SECTION 2 - SERVICE PROCEDURES3120875 – JLG Lift – 2-332.14 SEQUENCE CABLE REPLACEMENT KITA sequence cable replacement kit is available from theJLG Pa

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120875 – JLG Lift – aINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSGENERALThis section contains the gene

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 31208753. Use a suitable tool and cut the cable as shown in theillustration following. For 1/8 in. cab

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120875PolarityFinding a negative voltage or current reading whenexpecting a positive reading frequently m

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-3 Voltage Measurement Resistance MeasurementFigure 3-1. Voltage Measurement (DC) Figure 3-2. Res

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120875 Continuity Measurement Current MeasurementFigure 3-3. Continuity Measurement Figure 3-4. Curr

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-53.5 ELECTRICAL SWITCH TESTINGBasic CheckThe following check determines if the switch is functioning

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120875Table 3-1. AC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM DOES NOT RISE.Power sour

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-7Table 3-2. DC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM DOES NOT RISE.Power sour

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120875NOTES:

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-9 Figure 3-5. Hydraulic Schematic. (AM Series) (2792491)2792491_A

EFFECTIVITY CHANGESb – JLG Lift – 3120875EFFECTIVITY CHANGESFebruary 1, 1999 - Original Issue of Manual (Correctionwas 1998)November 22, 2000 - Manu

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120875 Figure 3-6. Electrical Diagram. (AMI - 12V-DC)4933258_C

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-11 Figure 3-2. Electrical Diagram. (AMI - 12V-DC)4933258_C

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120875 Figure 3-7. Electrical Diagram. (AMI - 120V-AC)4933259_G

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-13 Figure 3-3. Electrical Diagram. (AMI - 120V-AC)4933259_G

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120875 Figure 3-8. Electrical Diagram. (AMI - 240V-AC)

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-15 Figure 3-4. Electrical Diagram. (AMI - 240V-AC)

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120875Figure 3-9. Electrical Diagram. (AMI - 100V-AC)

SECTION 3 - TROUBLESHOOTING3120875 – JLG Lift – 3-17 Figure 3-4. Electrical Diagram. (AMI - 100V-AC)

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120875NOTES:

3120875 – JLG Lift – iTABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONSGeneral. .

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

ii – JLG Lift – 3120875TABLE OF CONTENTSBearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120875 – JLG Lift – iiiTABLE OF CONTENTSMast Section 3 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .