JLG 19BD Parts Manual
3121155 15BD/19BD 3
4 15BD/19BD 3121155
3121155 15BD/19BD 5
TABLE OF CONTENTS
SECTION 1 - BASE.............................................................................................................................................................................. 9
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION ................................................................................................ 10
SECTION 2 - CONTROLS ................................................................................................................................................................. 13
FIGURE 2-1. POWER COMPONENTS INSTALLATION ............................................................................................................... 14
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748) .......................................................... 18
FIGURE 2-3. MOTOR/PUMP ASSEMBLY (Including SN 0130005748) ......................................................................................... 20
FIGURE 2-4. AC JUNCTION BOX ASSEMBLY ............................................................................................................................. 22
FIGURE 2-5. CABLES AND CONTROLS INSTALLATION (15BD WITH PUSH BUTTON CONTROLS) ...................................... 26
FIGURE 2-6. CABLES AND CONTROLS INSTALLATION (15BD WITH FOOT CONTROLS) ...................................................... 30
FIGURE 2-7. CABLES AND CONTROLS INSTALLATION (19BD WITH FOOT CONTROLS) ...................................................... 34
SECTION 3 - MAST ........................................................................................................................................................................... 37
FIGURE 3-1. MAST ASSEMBLY (15BD) ....................................................................................................................................... 38
FIGURE 3-2. MAST ASSEMBLY (19BD) ....................................................................................................................................... 42
SECTION 4 - PLATFORM .................................................................................................................................................................. 47
FIGURE 4-1. PLATFORM WITH GULLWING GATE (15BD ONLY)............................................................................................... 48
FIGURE 4-2. PLATFORM (27IN/69CM X 23IN/58.5CM) WITH SWING GATE .............................................................................. 50
FIGURE 4-3. PLATFORM (26IN/66CM X 25IN/63.5CM) WITH SWING GATE .............................................................................. 52
FIGURE 4-4. PLATFORM OPTIONS ............................................................................................................................................. 54
FIGURE 4-5. PLATFORM GATE INTERLOCK INSTALLATION .................................................................................................... 56
SECTION 5 - CYLINDER ................................................................................................................................................................... 59
FIGURE 5-1. LIFT CYLINDER ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748) ........................................................ 60
FIGURE 5-2. LIFT CYLINDER ASSEMBLY (Including SN 0130005748) ....................................................................................... 62
SECTION 6 - HYDRAULIC ................................................................................................................................................................ 65
FIGURE 6-1. HYDRAULIC DIAGRAM ............................................................................................................................................ 66
SECTION 7 - ELECTRICAL ............................................................................................................................................................... 69
FIGURE 7-1. ELECTRICAL SCHEMATIC - 120VAC, 60HZ ........................................................................................................... 70
FIGURE 7-2. ELECTRICAL SCHEMATIC - 120VAC, 60HZ (CORNING SPEC) ............................................................................ 72
FIGURE 7-3. ELECTRICAL SCHEMATIC - 120VAC, 50-60HZ (CORNING SPEC)....................................................................... 74
FIGURE 7-4. ELECTRICAL SCHEMATIC - 220VAC, 50-60HZ (CORNING SPEC)....................................................................... 76
SECTION 8 - DECALS ....................................................................................................................................................................... 79
FIGURE 8-1. DECAL INSTALLATION ............................................................................................................................................ 80
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ............................................................................................................. 83
FIGURE 9-1. 15BD STANDARD PARTS ....................................................................................................................................... 84
FIGURE 9-2. 15BD VARIABLE PARTS .......................................................................................................................................... 86
SECTION 10 - SPECIAL OPTIONS ................................................................................................................................................... 87
FIGURE 10-1. SPECIAL OPTIONS ................................................................................................................................................ 88
PART NUMBER INDEX ..................................................................................................................................................................... 89
3121155 15BD/19BD 7
SECTION 1 - BASE
SECTION 1 - BASE
3121155 15BD/19BD 9
SECTION 1 - BASE
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION
10 15BD/19BD 3121155
SECTION 1 - BASE
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
MAST SUPPORT INSTALLATIONS
0271828
Ref
Mast Support Installations 15BD (Excluding SN 0130005748)
C 0272127
Ref
Mast Support Installations 15BD (Including SN 0130005748)
B 1001128982
Ref
Mast Support Installations 19BD
B 1
Ref
Bolt Options:
1 0641609
AR
Bolt 3/8in-16NC x 1-1/8in
1 0641610
AR
Bolt 3/8in-16NC x 1-1/4in
2 Ref
Mast Assembly Options (See MAST SECTION for Breakdown):
2 0801321
1
Mast Assembly 15BD (Excluding SN 0130005748)
2 0801328
1
Mast Assembly 15BD (Including SN 0130005748)
2 0801409
1
Mast Assembly 19BD
3 1705636
AR
Decal - Manual Descent (Including SN 0130005748)
4 Ref
Nut Options:
4 3311605
AR
Locknut 3/8in-16NC
4 3311608
AR
Flanged Nut 3/8in-16NC
5 4568473
2
Brace Tube, Mast
6 4711600
24
Flatwasher 3/8in Thin
7 4845914
1
Support, Mast
Ref
Base Weldment
4846589
Ref
18 x 33 Bolt Pattern
1001126088
Ref
20 x 24 Bolt Pattern
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION
3121155 15BD/19BD 11
SECTION 2 - CONTROLS
SECTION 2 - CONTROLS
3121155 15BD/19BD 13
SECTION 2 - CONTROLS
FIGURE 2-1. POWER COMPONENTS INSTALLATION
14 15BD/19BD 3121155
SECTION 2 - CONTROLS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
PUMP/MOTOR AND JUNCTION BOX ASSEMBLY
1001111734
Ref
120 VAC, 60Hz (15BD) (All Machines) (Excluding SN
0130005748)
A
See Note
Ref
120 VAC, 60Hz (Note: Uses Installation p/n 0271128 with Kit
p/n 2915246 installed.) (15BD) (Including SN 0130005748)
1001167245
Ref
120VAC, 60Hz (19BD)
A 1001147216
Ref
120 VAC, 50-60Hz (with AC Outlet)
A 1001144708
Ref
220 VAC, 50-60Hz
A 1 0630550
2
Capscrew 1/4in-20NC x 3/4in
2 0641406
4
Bolt 1/4in-20NC x 3/4in
3 0721006
2
Screw #10-24NC x 3/4in
4 0791608
2
Screw 3/8in-16NC x 3/4in
5 0861305
1
Ground Control Box Assembly
E 5 7020078
1
Switch, Push-Pull (Stop)
5 7020096
1
Legend Plate, "Stop"
5 7020097
2
Legend Plate, "Power/Off/On"
5 4360467
1
Switch, Key
5 2860030
1
Key, Replacement
5 7027299
1
Connector, Strain Relief
5 7020093
1
Screw M3 x 25mm (Box Lid Hardware)
5 3910804
2
Screw #8-32NC x 1/4in (Keyswitch Terminals)
5 7020094
1
Lid 6
3311005
AR
Locknut #10-24NC
7 3311405
4
Locknut 1/4in-20NC
8 Ref
Pump/Motor Assembly Options:
8
3600467
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown) (Excluding SN
0130005748)
8
3600453
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown) (Including SN
0130005748)
8
3600453
1
Pump/Motor Assembly - 19BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown)
8
3600453
1
Pump/Motor Assembly - All Machines with 120VAC, 50-60Hz
Motor & AC Outlet (See MOTOR/PUMP ASSEMBLY for
Breakdown)
8
3600453
1
Pump/Motor Assembly - All Machines with 220VAC, 50-60Hz
Motor (See MOTOR/PUMP ASSEMBLY for Breakdown)
9
4341431
1
Bracket, Junction Box Mounting Options
10
4341432
1
Bracket, Pump/Motor Mounting Options:
11
4460566
1
Connector, 90 Strain Relief
12
4751000
2
Flatwasher #10 Regular
13
4751400
8
Flatwasher 1/4in Regular
14
1001105113
2
Insulation, Heatshrink (Not Shown)
15 Ref
Junction Box Assembly (See AC JUNCTION BOX ASSEMBLY
for Breakdown)
15
1001111733
1
120 VAC, 60Hz (All Machines) (Excluding SN 0130005748)
15
0861476
1
120 VAC, 60Hz (Including SN 0130005748)
15
1001147215
1
120 VAC,50- 60Hz
15
1001144703
1
220 VAC,50- 60Hz
16
0100011
AR
Compound, Locking
17
3740154
1
Relay, Timer (Used on 120 VAC, 50-60Hz Only)
FIGURE 2-1. POWER COMPONENTS INSTALLATION
3121155 15BD/19BD 15
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
18
3911024
1
Screw #10-24NC x 1-1/2in (Used on 120 VAC, 50-60Hz Only)
Ref
PUMP/MOTOR AND JUNCTION BOX INSTALLATION
B
0275939
Ref
All Machines with Gullwing or Right Side Entry Platforms
(Excluding SN 0130005748)
A
1001126224
Ref
All Machines with Left Side Entry Platforms (Not Shown)
(Excluding SN 0130005748)
A
Ref
Note: Right/Left Side Gate Entry determined by operator's
position when facing push button controls.
101
0100011
AR
Compound, Locking
102
0641404
4
Bolt 1/4in-20NC x 1/2in
103
0791609
4
Bolt 3/8in-16NC x 1-1/8in
106
3311608
4
Nut, Flanged 3/8in-16NC
107
4061024
1
Shield, Pump Cover
110
4711400
4
Flatwasher 1/4in Thin
0275697
Ref
HOURMETER INSTALLATION (OPTIONAL)
C
203
2420172
1
Hourmeter
205
4922935
1
Harness, Hourmeter (Not Shown)
A
SECTION 2 - CONTROLS
16 15BD/19BD 3121155
SECTION 2 - CONTROLS
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748)
18 15BD/19BD 3121155
SECTION 2 - CONTROLS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
USAGE CHART:
3600467
Ref
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor
without AC Outlet (Shown in This Figure) (Excluding SN
0130005748)
3600453
Ref
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
Next Figure) (Including SN 0130005748)
3600453
Ref
Pump/Motor Assembly - 19BD with 120VAC, 60Hz Motor (See
Next Figure)
3600453
Ref
Pump/Motor Assembly - All Machines with 120VAC, 50-60Hz
Motor & AC Outlet (See Next Figure)
3600453
Ref
Pump/Motor Assembly - All Machines with 220VAC, 50-60Hz
Motor (See Next Figure)
3600467
Ref
MOTOR/PUMP ASSEMBLY
C 1 70000641
1
Base Assembly (Includes Items 14-18)
2 70001021
1
Pump (Includes Item 3)
3 70001020
4
Screw 1/4in-20NC x 2-3/4in
4 70001042
1
Tube, Suction
5 7026165
1
Filter 6
70001044
1
Tube, Return
7 70001045
1
Motor (Includes Item 19 and Motor Bolts)
8 70000642
1
Cartridge
9 70000643
1
Coil 10
70000651
1
Reservoir
11
70001025
1
Plug 12
7026335
1
Clamp 13
70001027
1
Decal - Fill Line
14
70000641
1
Valve, Relief (Note: Part of Item 1)
14
70000641
1
Screw
14
70000641
1
Nut 14
70000641
1
Seal 14
70000641
1
Spring
14
70000641
1
Ball 15
70000641
1
Valve, Check (Note: Part of Item 1)
15
70000641
1
Plug 15
70000641
1
Spring
15
70000641
1
Poppet
15
70000641
1
Ball 16
70003612
1
O-Ring (1/2in x 5/8in x 1/16in)
17
70003613
1
O-Ring (3-5/8in x 3-7/8in x 1/8in)
18
7026330
1
Seal 19
70002215
1
Bearing
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748)
3121155 15BD/19BD 19
SECTION 2 - CONTROLS
FIGURE 2-3. MOTOR/PUMP ASSEMBLY (Including SN 0130005748)
20 15BD/19BD 3121155
SECTION 2 - CONTROLS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
USAGE CHART:
3600467
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor
without AC Outlet (See Previous Figure) (Excluding SN
0130005748)
3600453
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor
(Shown in This Figure)
3600453
1
Pump/Motor Assembly - 19BD with 120VAC, 60Hz Motor
(Shown in This Figure)
3600453
1
Pump/Motor Assembly - All Machines with 120VAC, 50-60Hz
Motor & AC Outlet (Shown in This Figure)
3600453
1
Pump/Motor Assembly - All Machines with 220VAC, 50-60Hz
Motor (Shown in This Figure)
3600453
Ref
MOTOR/PUMP ASSEMBLY
B 1 70000641
1
Adapter, Motor/Pump/Tank (Includes Items 17 & 18)
2 70000642
1
Cartridge
3 70000643
1
Coil 5
70000644
1
Pump 6
3931420
4
Screw 1/4in-20NC x 1- 1/4in
7 70000645
1
Tube, Suction
8 7026165
1
Filter 9
70000646
1
Tube, Return
10
70000647
1
Plate, Motor Adapter
11
70000648
4
Screw 1/4in-20NC x 3/4in
12
70000649
1
Shaft, Intermediate
13
70000650
1
Motor 14
70000651
1
Reservoir
15
7026160
1
Plug 16
7026335
1
Clamp 17
70000641
1
Valve, Relief (Note: Part of Item 1)
17
70000641
1
Screw
17
70000641
1
Nut 17
70000641
1
Seal 17
70000641
1
Spring
17
70000641
1
Ball 18
70000641
1
Valve, Check (Note: Part of Item 1)
18
70000641
1
Plug 18
70000641
1
Spring
18
70000641
1
Poppet
18
70000641
1
Ball
FIGURE 2-3. MOTOR/PUMP ASSEMBLY (Including SN 0130005748)
3121155 15BD/19BD 21
SECTION 2 - CONTROLS
FIGURE 2-4. AC JUNCTION BOX ASSEMBLY
22 15BD/19BD 3121155
SECTION 2 - CONTROLS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
JUNCTION BOX ASSEMBLY
1001111733
Ref
120 VAC, 60Hz (All Machines) (Excluding SN 0130005748)
B 0861476
Ref
120 VAC, 60Hz (Including SN 0130005748)
2/B 1001147215
Ref
120 VAC, 50-60Hz
A 1001144703
Ref
220 VAC, 50-60Hz
A 1 0860943
1
Box with Lid Options:
2 Ref
Decal Options:
2 1702102
1
Decal - 115V-1PH-50/60Hz
2 1702569
1
Decal - 115V-1PH-60Hz
2 1702103
1
Decal - 230V-1PH-50/60Hz
3 1702120
1
Decal - Wire Size
4 Ref
Decal - JLG Options:
4 1703681
1
Decal - JLG All Machines (Excluding SN 0130005748)
4 1702365
1
Decal - JLG (use p/n 1703681) (Including SN 0130005748)
5 3520028
1
Plug (115V Only)
6 3520034
4
Plug 7
3740049
1
Relay 8 Ref
Relay, Starter Options:
8 3740093
1
115V 8
3740105
1
230V 9
3740094
1
Relay, Starter 12 VDC
10
3910808
AR
Screw #8-32NF x 1/2in
11 Ref
Circuit Breaker Options:
11
4360161
1
115V
11
4360070
2
230V
12
4360376
1
Rectifier
13
4460565
1
Strip, Terminal
14
4460633
3
Connector, Strain Relief
15 Ref
Transformer Options:
15
4530010
1
120 VAC, 60Hz (All Machines) (Excluding SN 0130005748)
15
1702365
1
120 VAC, 60Hz (use p/n 4530013) (Including SN 0130005748)
15
4530023
1
120 VAC, 50-60Hz
15
4530010
1
220 VAC, 50-60Hz
16
4922546
1
Harness, Ground Controls
I
16A
4460633
1
Connector, Strain Relief
16B
4460424
1
Receptacle, Female - 2 Position
16B
4460268
2
Socket, Female
17 Ref
Harness, Junction Box Options (Not Shown):
17
4923131
1
120 VAC, 60Hz
B
17
4923150
1
120 VAC, 50-60Hz
B
17
4923151
1
220 VAC, 50-60Hz
B
17
2400006
1
Fuse - 5 Amp
17
4460044
1
Fuseholder
18
4933305
1
Diagram, Junction Box (Not Shown - See ELECTRICAL
SECTION)
19
1001093646
1
Harness, Capacitor
A
20
1001096586
1
Harness, 16/5 (See ELECTRICAL SECTION for Breakdown)
A
21
1001096587
1
Harness, 12/3 (See ELECTRICAL SECTION for Breakdown)
A
22 Ref
Harness, AC Plug Options:
22
1001111735
1
Harness, AC for All Machines (Excluding SN 0130005748)
A
FIGURE 2-4. AC JUNCTION BOX ASSEMBLY
3121155 15BD/19BD 23
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
22
Not Available
1
Plug (Purchase Locally)
22
4922645
1
Harness, AC (Including SN 0130005748)
A
22A
4460549
1
Plug (Including SN 0130005748)
SECTION 2 - CONTROLS
24 15BD/19BD 3121155
SECTION 2 - CONTROLS
FIGURE 2-5. CABLES AND CONTROLS INSTALLATION (15BD WITH PUSH BUTTON CONTROLS)
26 15BD/19BD 3121155
SECTION 2 - CONTROLS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
CABLES AND CONTROLS INSTALLATION
0270490
Ref
Cables and Controls Installation All Machines (Excluding SN
0130005748)
F
0270489
Ref
Cables and Controls Installation (Including SN 0130005748)
C 1 0100011
AR
Compound, Locking
2 0641410
1
Bolt 1/4in-20NC x 1-1/4in
3 0641612
1
Bolt 3/8in-16NC x 1-1/2in
4 0860945
1
Box, Junction
5 0861207
1
Control Box Assembly
E 5 7020078
1
Switch, Push-Pull (Red)
5 7020088
2
Switch, Push Button (White)
5 7020089
1
Switch, Push Button (Green)
5 7020091
1
Plug 5
7027299
1
Connector, Strain Relief
5 7020093
4
Screw M3 x 25mm
7 Ref
Cable, Electrical - 16/5 Options:
7
1060922
1
Cable, Electrical - 16/5 All Machines (Excluding SN
0130005748)
C 7 1060687
1
Cable, Electrical - 16/5 (use p/n 4923163) (Including SN
0130005748)
A
8 Ref
Cable, Retractile - 16/5 Options:
8
4922652
1
Cable, Retractile - 16/5 All Machines (Excluding SN
0130005748)
C
8
1060694
1
Cable, Retractile - 16/5 (Including SN 0130005748)
D
9
1320149
1
Clamp
10
1670603
1
Cover, Junction Box
12
3311405
3
Locknut 1/4in-20NC
13
3311605
2
Locknut 3/8in-16NC
14
3570923
1
Plate, Decal Mounting
15 Ref
Sheave, Control Cable Options:
15
3580344
1
Sheave, Control Cable All Machines (Excluding SN
0130005748)
15
3580231
1
Sheave, Control Cable (Including SN 0130005748)
16
3820032
4
Rivet 17
3900191
2
Screw, Panhead
18 Ref
Screw, Shoulder Options:
18
3900373
1
Screw, Shoulder All Machines (Excluding SN 0130005748)
18
3900200
1
Screw, Shoulder (Including SN 0130005748)
19
4160130
1
Spring, Extension
20
4460023
3
Connector, Strain Relief
21
4460566
2
Connector, Strain Relief - 90
22
4711400
2
Flatwasher 1/4in Thin
23
4711600
2
Flatwasher 3/8in Thin
25
4751000
5
Flatwasher #10 Regular
26
4751500
1
Flatwasher 5/16in Regular
27
4761000
3
Lockwasher #10
29
4922420
1
Harness, Jumper (Control Box)
1/A
29
3990010
1
Diode 6 Amp
30
3520034
2
Plug, 5/16in Hole
32
1320041
1
Clamp, 1/2in
33
1001096054
1
Plate, AC Box Mounting
FIGURE 2-5. CABLES AND CONTROLS INSTALLATION (15BD WITH PUSH BUTTON CONTROLS)
3121155 15BD/19BD 27
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
34
3311001
1
Nut, #10-24NC
35
3900205
1
Screw, #10-24NC x 5/8in
36
0641407
2
Screw, 1/4in-20NC x 7/8in
37 Ref
Cable, Accessory - 12/3
37
1060924
1
12/3 Cable (All Machines) (Excluding SN 0130005748)
D
37
1060564
1
12/4 Cable (Including SN 0130005748)
-
38 Ref
Cable, Retractile Options:
38
4922653
1
16/4 Cable (All Machines) (Excluding SN 0130005748)
C
38
1060565
1
16/4 Cable (Including SN 0130005748)
B
Ref
ACCESSORY OUTLET INSTALLATIONS
1001097212
Ref
120V GFI (AC) (All Machines) (Excluding SN 0130005748)
A 0270972
Ref
120V (AC) (Including SN 0130005748)
A 1001144987
Ref
220V (AC)
A
101
Ref
Decal Options:
101
3252761
1
Decal - 120V
101
3252760
1
Decal - 220V
102
3311001
4
Nut #10-24NC
103
Ref
Screw Options: #10-24NC x 1/4in
103
3900205
4
Screw #10-24NC x 1/4in
103
0721006
4
Screw #10-24NC x 3/4in
104
4460023
1
Terminal, Connector
105
4761000
4
Lockwasher #10
106
Ref
Box, Plug and Receptacle Assembly Options:
106
1001096767
1
120V GFI (AC) (All Machines) (Excluding SN 0130005748)
106
Not Available
120V (AC) (Purchase Individual Components) (Including SN
0130005748)
106
Not Available
220V (AC) (Purchase Individual Components)
106A
Ref
Receptacle, Box Options:
106A
0861731
1
Receptacle, Box All Machines (Excluding SN 0130005748)
106A
0860946
1
Receptacle, Box (Including SN 0130005748)
106B
Ref
Receptacle, Cover Options:
106B
4060700
1
120V GFI (AC) Cover (Side Hinged) (Prior to SN
0130013095)
106B
1001110873
1
120V GFI (AC) Cover (Top Hinged) (SN 0130013095 to
Present)
106B
4060092
1
120V (AC) Cover (Including SN 0130005748)
106B
1001145894
1
220V (AC)
106C
Ref
Receptacle Options:
106C
4460346
1
120V GFI (AC) (All Machines) (Excluding SN 0130005748)
106C
4460190
1
120V (AC) (Including SN 0130005748)
106C
1001145893
1
220V (AC)
106D
Ref
Plug Options:
106D
4460549
1
120V
106D
1001145887
1
220V
SECTION 2 - CONTROLS
28 15BD/19BD 3121155
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