JLG 41AM Parts Manual

0 (0)

3120873

20AM/25AM/30AM/36AM/41AM

3

4

20AM/25AM/30AM/36AM/41AM

3120873

3120873

20AM/25AM/30AM/36AM/41AM

5

JLG 41AM Parts Manual

6

20AM/25AM/30AM/36AM/41AM

3120873

TABLE OF CONTENTS

SECTION 1 - BASE..............................................................................................................................................................................

 

9

FIGURE 1-1. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE)

............................................ 10

FIGURE 1-2. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE) ............................................

16

FIGURE 1-3. OUTRIGGER COMPONENTS INSTALLATION .......................................................................................................

20

FIGURE 1-4. MAST SUPPORT INSTALLATION ...........................................................................................................................

24

FIGURE 1-5. TILTBACK AND LOADING HARDWARE (FRAME MOUNTED) COMPONENTS (SEE PARTS LIST FOR USAGE)

........................................................................................................................................................................................................

 

28

FIGURE 1-6. TILTBACK AND LOADING HARDWARE (FRAME MOUNTED) COMPONENTS (SEE PARTS LIST FOR USAGE)

........................................................................................................................................................................................................

 

32

SECTION 2 - CONTROLS .................................................................................................................................................................

 

35

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION (Prior to SN 0900026490)................................................................

36

FIGURE 2-2. AC POWER COMPONENTS INSTALLATION (SN 0900026490 to Present) ...........................................................

40

FIGURE 2-3. AC JUNCTION BOX ASSEMBLY

.............................................................................................................................

44

FIGURE 2-4. AC MOTOR/PUMP ASSEMBLY (FENNER) (Prior to SN 0900026490) ...................................................................

46

FIGURE 2-5. AC MOTOR/PUMP ASSEMBLY (MONARCH) (SN 0900026490 to Present)...........................................................

50

FIGURE 2-6. DC POWER COMPONENTS INSTALLATION .........................................................................................................

52

FIGURE 2-7. DC MOTOR/PUMP ASSEMBLY (FENNER) (Prior to SN 0900027922) ...................................................................

58

FIGURE 2-8. DC MOTOR/PUMP ASSEMBLY (MONARCH) (SN 0900027922 to Present)...........................................................

62

FIGURE 2-9. DC POWER PACK INSTALLATION (SEE PARTS LIST FOR USAGE) ...................................................................

64

FIGURE 2-10. DC POWER PACK INSTALLATION (SEE PARTS LIST FOR USAGE) .................................................................

68

FIGURE 2-11. BATTERY CHARGER ASSEMBLY ........................................................................................................................

70

FIGURE 2-12. CABLES AND CONTROLS INSTALLATION (Prior to SN 0900028703) ................................................................

72

FIGURE 2-13. CABLES AND CONTROLS INSTALLATION (SN 0900028703 to Present)............................................................

78

SECTION 3 - MAST ...........................................................................................................................................................................

 

85

FIGURE 3-1. MAST ASSEMBLY - 20AM .......................................................................................................................................

 

86

FIGURE 3-2. MAST ASSEMBLY - 25AM & 36AM..........................................................................................................................

92

FIGURE 3-3. MAST ASSEMBLY - 30AM & 41AM........................................................................................................................

100

FIGURE 3-4. MAST MOUNTED COMPONENTS INSTALLATIONS............................................................................................

108

SECTION 4 - PLATFORM................................................................................................................................................................

 

113

FIGURE 4-1. STEP-IN MOLDED PLATFORM INSTALLATION...................................................................................................

114

FIGURE 4-2. QUICK-CHANGE PLATFORM 26IN X 26IN (66CM X 66CM) INSTALLATION ......................................................

116

FIGURE 4-3. QUICK-CHANGE PLATFORM 22IN X 25IN(56CM X 68.5CM) INSTALLATION ....................................................

120

FIGURE 4-4. QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATE ............................................................

122

FIGURE 4-5. OPTIONAL PLATFORM COMPONENTS INSTALLATIONS ..................................................................................

126

SECTION 5 - CYLINDER .................................................................................................................................................................

 

129

FIGURE 5-1. LIFT CYLINDER ASSEMBLY (Prior to SN 0900017519)........................................................................................

130

FIGURE 5-2. LIFT CYLINDER ASSEMBLY (SN 0900017519 through 0900029961) ..................................................................

132

FIGURE 5-3. LIFT CYLINDER ASSEMBLY (SN 0900029962 to Present)...................................................................................

134

SECTION 6 - HYDRAULIC ..............................................................................................................................................................

 

137

FIGURE 6-1. HYDRAULIC DIAGRAM..........................................................................................................................................

 

138

SECTION 7 - ELECTRICAL .............................................................................................................................................................

 

141

FIGURE 7-1. ELECTRICAL DIAGRAM LIST................................................................................................................................

 

142

FIGURE 7-2. ELECTRICAL DIAGRAM - 12VDC (Prior to SN 0900028703)................................................................................

144

FIGURE 7-3. ELECTRICAL DIAGRAM - 12VDC (SN 0900028703 to Present) ...........................................................................

146

FIGURE 7-4. ELECTRICAL DIAGRAM - 240VAC........................................................................................................................

148

SECTION 8 - DECALS.....................................................................................................................................................................

 

151

FIGURE 8-1. DECAL INSTALLATION (SEE PARTS LIST FOR USAGE CHART) ......................................................................

152

FIGURE 8-2. DECAL INSTALLATION (SEE PARTS LIST FOR USAGE CHART) ......................................................................

156

FIGURE 8-3. DECAL INSTALLATION (SEE PARTS LIST FOR USAGE CHART) ......................................................................

160

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ...........................................................................................................

163

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7

TABLE OF CONTENTS

 

FIGURE 9-1. AM SERIES STANDARD PARTS ...........................................................................................................................

164

FIGURE 9-2. AM SERIES VARIABLE PARTS..............................................................................................................................

166

SECTION 10 - SPECIAL OPTIONS .................................................................................................................................................

167

FIGURE 10-1. SPECIAL OPTIONS LIST......................................................................................................................................

168

FIGURE 10-2. STRADDLE INSTALLATION .................................................................................................................................

170

PART NUMBER INDEX....................................................................................................................................................................

175

8

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

SECTION 1 - BASE

3120873

20AM/25AM/30AM/36AM/41AM

9

SECTION 1 - BASE

FIGURE 1-1. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE)

10

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-1. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE)

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

 

 

Ref

USAGE CHART

 

 

 

 

 

Ref

Machines Built Prior to SN 0900031574 - Note: Use this figure.

 

 

 

 

 

Ref

Machines Built SN 0900031575 through SN 0900031617 - No

 

 

 

 

 

 

exact SN break exists, contact the JLG Parts Dept to confirm

 

 

 

 

 

 

design before ordering parts.

 

 

 

 

 

Ref

Machines Built SN 0900031618 to Present - Note: Use next

 

 

 

 

 

 

figure.

 

 

 

 

 

Ref

BASE ASSEMBLIES

 

 

 

 

 

Ref

Base Assemblies 20AM/25AM

 

 

 

 

0258180

Ref

Base Assemblies (Prior to SN 0900017519)

J

 

 

 

0271423

Ref

Base Assemblies (SN 0900017519 through 0900031574)

K

 

 

 

0271423

Ref

See Usage Chart for (SN 0900031575 through 0900031617)

K

 

 

 

 

Ref

Base Assemblies 30AM

 

 

 

 

0258809

Ref

Base Assemblies (Prior to SN 0900017519)

H

 

 

 

0271427

Ref

Base Assemblies (SN 0900017519 through 0900031574)

K

 

 

 

0271427

Ref

See Usage Chart for (SN 0900031575 through 0900031617)

K

 

 

 

 

Ref

Base Assemblies 36AM/41AM

 

 

 

 

0258810

Ref

Base Assemblies (Prior to SN 0900017519)

J

 

 

 

0271428

Ref

Base Assemblies (SN 0900017519 through 0900031574)

K

 

 

 

0271428

Ref

See Usage Chart for (SN 0900031575 through 0900031617)

K

 

 

1

0100011

AR

Compound, Locking

 

 

 

2

0100019

AR

Compound, Locking

 

 

 

3

0641406

2

Bolt 1/4in-20NC x 3/4in

 

 

 

4

0641606

6

Bolt 3/8in-16NC x 3/4in

 

 

 

5

0641607

2

Bolt 3/8in-16NC x 7/8in

 

 

 

6

0641830

2

Bolt 1/2in-13NC x 3-3/4in

 

 

 

7

0720805

6

Screw #8-24NC x 5/8in (Prior to SN 0900019233)

 

 

 

8

0721005

AR

Screw #10-24NC

 

 

 

9

1320043

6

Clamp (Prior to SN 0900027722)

 

 

 

12

2560088

2

Grip

 

 

 

13

2920151

4

Light, Indicator

 

 

 

14

3020022

AR

Lithium, White

 

 

 

17

3310805

6

Locknut #8-32NC (Prior to SN 0900019233)

 

 

 

18

3311005

AR

Locknut #10-24NC

 

 

 

19

3311405

2

Locknut 1/4in-20NC

 

 

 

20

3311605

2

Locknut 3/8in-16NC

 

 

 

21

3311805

2

Locknut 1/2in-13NC

 

 

 

22

3312001

2

Nut 5/8in-11NC (Use p/n 3312002)

 

 

 

23

 

Ref

Pin, Plunger Options:

 

 

 

23

3422369

4

Pin, Plunger (Prior to SN 0900012037)

 

 

 

23

3422744

4

Pin, Plunger (SN 0900012037 through 0900031617)

 

 

 

26

3570973

2

Plate, Cover

 

 

 

27

3740106

1

Relay (Note: Part of p/n 4922421 Harness after S/N

 

 

 

 

 

 

0900014544)

 

 

 

29

3900212

8

Screw, Button #4-40NC

 

 

 

30

3900255

2

Screw, Shoulder

 

 

 

32

4460234

AR

Base, Tie-Strap

 

 

 

33

4711600

14

Flatwasher 3/8in

 

 

 

34

4711800

4

Flatwasher 1/2in (Prior to SN 0900029419)

 

 

 

35

4740525

4

Flatwasher 3/4in Hardened

 

 

3120873

 

 

20AM/25AM/30AM/36AM/41AM

11

SECTION 1 - BASE

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

37

4750800

12

Flatwasher #8 (Prior to SN 0900019233)

 

 

 

38

4751000

AR

Flatwasher #10

 

 

 

39

 

Ref

Base Weldment Options:

 

 

 

39

4845705

1

Base Weldment (Prior to SN 0900017519)

 

 

 

39

4846388

1

Base Weldment (SN 0900017519 through 0900031574)

 

 

 

39

4846388

1

See Usage Chart for (SN 0900031575 through 0900031617)

 

 

 

40

 

Ref

Wheel Assembly - Stationary Options:

 

 

 

40

4860183

2

Stationary Wheel (Used) (Prior to SN 0900020788)

 

 

 

40

7020083

2

Wheel, Replacement (1 Per Wheel)

 

 

 

40

7020084

4

Bearing (2 Per Wheel)

 

 

 

40

7012631

2

Bushing, Axle Spanner (1 Per Wheel)

 

 

 

40

4860246

2

Stationary Wheel (Used) (No Service Parts Available) (SN

 

 

 

 

 

 

0900020788 through 0900031574)

 

 

 

40

4860246

2

Stationary Wheel (See Usage Chart for) (No Service Parts

 

 

 

 

 

 

Available) (SN 0900031575 through 0900031617)

 

 

 

42

 

Ref

Wheel Assembly - 4in Options:

 

 

 

42

4860185

2

4in Wheel (Prior to SN 0900020788)

 

 

 

42

7020087

2

Wheel, Replacement (1 Per Wheel)

 

 

 

42

7020084

4

Bearing (2 Per Wheel)

 

 

 

42

7012631

2

Bushing, Axle Spanner (1 Per Wheel)

 

 

 

42

4860247

2

4in Wheel (No Service Parts Available) (SN 0900020788

 

 

 

 

 

 

through 0900029418)

 

 

 

42

1001100945

2

4in Wheel (No Service Parts Available) (SN 0900029419

 

 

 

 

 

 

through 0900031574)

 

 

 

42

1001100945

2

4in Wheel (See Usage Chart for) (No Service Parts Available)

 

 

 

 

 

 

(SN 0900031575 through 0900031617)

 

 

 

43

3571150

1

Plate, Wheel Spacer

 

 

 

44

0630530

3

Bolt 3/8in-16NC x 2-1/2in (30AM/36AM/41AM Only)

 

 

 

45

3311601

3

Nut 3/8in-16NC (30AM/36AM/41AM Only)

 

 

 

46

4891600

3

Flatwasher 3/8in Hardened (30AM/36AM/41AM Only)

 

 

 

47

4845883

1

Counterweight (30AM/36AM/41AM Only)

 

 

 

48

3020017

AR

Lubricant (Prior to SN 0900020788)

 

 

 

49

4240032

AR

Tie-Strap

 

 

 

50

2820086

5.84

Loom, Wire (Not Shown)

 

 

 

 

 

ft/1.8m

 

 

 

 

51

4922421

1

Harness, Potted Relay (Use p/n 4922752) (See ELECTRICAL

 

 

 

 

 

 

SECTION for Breakdown) (Prior to SN 0900019239)

 

 

 

52

3539660

AR

Shim, Caster (20AM/25AM Only)

 

 

 

53

1001093778

6

Mount, Tie Strap

 

 

 

 

 

Ref

FRONT WHEEL ASSEMBLIES

 

 

 

101

 

Ref

Wheel Assembly Options:

 

 

 

101

4860184

2

Swivel Non-Locking Wheel (Prior to SN 0900020788)

 

 

 

101

7020017

2

Swivel Rig (1 Per Assembly)

 

 

 

101

7020086

2

Wheel, Replacement (1 Per Assembly)

 

 

 

101

7020084

4

Bearing (2 Per Wheel)

 

 

 

101

7012631

2

Bushing, Axle Spanner (1 Per Assembly)

 

 

 

101

7012630

2

Axle Kit (1 Per Assembly)

 

 

 

101

4860245

2

Swivel Non-Locking Wheel (No Service Parts Available) (SN

 

 

 

 

 

 

0900020788 through 0900031574)

 

 

 

101

4860245

2

Swivel Non-Locking Wheel (See Usage Chart for) (No

 

 

 

 

 

 

Service Parts Available) (SN 0900031575 through

 

 

 

 

 

 

0900031617)

 

 

 

101

4860194

2

Swivel Locking Wheel (Prior to SN 0900020788)

 

 

 

101

7020017

2

Swivel Rig (1 Per Assembly)

 

 

12

 

 

 

20AM/25AM/30AM/36AM/41AM

3120873

 

 

 

 

SECTION 1 - BASE

 

 

 

 

 

 

 

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

101

7020086

2

Wheel, Replacement (1 Per Assembly)

 

 

 

101

7020084

4

Bearing (2 Per Wheel)

 

 

 

101

7012631

2

Bushing, Axle Spanner (1 Per Assembly)

 

 

 

101

7012630

2

Axle Kit (1 Per Assembly)

 

 

 

101

0272943

2

Swivel Locking Wheel (SN 0900020788 through 0900031574)

 

 

 

101

2940150

2

Latch, Lock (1 Per Assembly)

 

 

 

101

0272943

2

Swivel Locking Wheel (See Usage Chart for) (SN 0900031575

 

 

 

 

 

 

through 0900031617)

 

 

 

101

2940150

2

Latch, Lock (1 Per Assembly)

 

 

 

101

4860200

2

Swivel Braking Wheel (Required on Australian Spec

 

 

 

 

 

 

Machines) (Prior to SN 0900020788)

 

 

 

101

7020211

2

Swivel Rig (1 Per Assembly)

 

 

 

101

7020212

2

Wheel, Replacement (1 Per Assembly)

 

 

 

101

7020214

2

Bushing, Axle Spanner (1 Per Assembly)

 

 

 

101

7020213

2

Axle/Brake Kit (1 Per Assembly)

 

 

 

101

4860248

2

Swivel Braking Wheel (Required on Australian Spec

 

 

 

 

 

 

Machines) (No Service Parts Available) (SN 0900020788

 

 

 

 

 

 

through 0900031574)

 

 

 

101

4860248

2

Swivel Braking Wheel (See Usage Chart for) (Required on

 

 

 

 

 

 

Australian Spec Machines) (No Service Parts Available) (SN

 

 

 

 

 

 

0900031575 through 0900031617)

 

 

 

 

0271253

Ref

STROBE LIGHT ONLY INSTALLATION (OPTIONAL)

E

 

 

201

2920146

1

Lamp, Beacon

 

 

 

202

2820035

2 ft/.6m

1/4in Expandable Loom (Not Shown Only) (Prior to SN

 

 

 

 

 

 

0900019636)

 

 

 

203

0721006

2

Screw, #10-24NC x 3/4in

 

 

 

204

3311005

2

Nut #10-24NC

 

 

 

205

4751000

4

Flatwasher #10 Wide

 

 

 

206

 

Ref

Plate, Mounting Options:

 

 

 

206

3572959

1

Plate, Mounting (Prior to SN 0900027722)

 

 

 

206

1001093322

1

Plate, Mounting (SN 0900027722 through 0900031617)

 

 

 

207

4922837

1

Harness, Strobe Light (Not Shown)

 

 

 

 

0271252

Ref

DESCENT ALARM ONLY INSTALLATION (OPTIONAL)

D

 

 

301

0140033

1

Alarm

 

 

 

302

0721006

2

Screw, #10-24NC x 3/4in

 

 

 

303

3311005

2

Nut #10-24NC

 

 

 

304

4751000

4

Flatwasher #10 Wide

 

 

 

305

 

Ref

Plate, Mounting Options:

 

 

 

305

3572959

1

Plate, Mounting (Prior to SN 0900027722)

 

 

 

305

1001093322

1

Plate, Mounting (SN 0900027722 through 0900031617)

 

 

 

306

 

Ref

Harness, Alarm Options (Not Shown):

 

 

 

306

4922511

1

Harness, Alarm (Prior to SN 0900019636)

 

 

 

306

4922805

1

Harness, Alarm (SN 0900019636 through 0900031617)

 

 

 

 

1001093343

Ref

STROBE LIGHT AND DESCENT ALARM INSTALLATION (WHEN

A

 

 

 

 

 

EQUIPPED WITH BOTH OPTIONS ON) (OPTIONAL) (SN

 

 

 

 

 

 

0900027722 to Present)

 

 

 

401

0140033

1

Alarm

 

 

 

402

0721006

2

Screw #10-24NC x 3/4in

 

 

 

403

2920146

1

Lamp, Beacon

 

 

 

404

3311005

2

Nut #10-24NC

 

 

 

407

4751000

4

Flatwasher #10 Wide

 

 

 

408

4922805

1

Harness, Alarm (Not Shown)

 

 

 

409

4922837

1

Harness, Strobe Light (Not Shown)

 

 

3120873

 

 

20AM/25AM/30AM/36AM/41AM

13

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

410

1001093322

1

Plate, Mounting (Not Shown)

 

14

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-2. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE)

16

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-2. FRAME, STROBE AND ALARM INSTALLATIONS (SEE PARTS LIST FOR USAGE)

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

 

 

Ref

USAGE CHART

 

 

 

 

 

Ref

Machines Built Prior to SN 0900031574 - Note: Use previous

 

 

 

 

 

 

figure.

 

 

 

 

 

Ref

Machines Built SN 0900031575 through SN 0900031617 - No

 

 

 

 

 

 

exact SN break exists, contact the JLG Parts Dept to confirm

 

 

 

 

 

 

design before ordering parts.

 

 

 

 

 

Ref

Machines Built SN 0900031618 to Present - Note: Use this

 

 

 

 

 

 

figure.

 

 

 

 

1001103370

Ref

BASE ASSEMBLY

B

 

 

1

0100011

AR

Compound, Locking

 

 

 

2

0641406

2

Bolt 1/4in-20NC x 3/4in

 

 

 

3

0641606

6

Bolt 3/8in-16NC x 3/4in

 

 

 

4

0641828

2

Bolt 1/2in-13NC x 3-1/2in

 

 

 

6

3020022

AR

Lithium, White

 

 

 

8

3311405

2

Locknut 1/4in-20NC

 

 

 

9

3311805

4

Locknut 1/2in-13NC

 

 

 

10

3422744

5

Pin, Plunger

 

 

 

11

3539660

AR

Plate, Caster Spacer

 

 

 

14

4240032

1

Tie-Strap

 

 

 

15

4711600

6

Flatwasher 3/8in Narrow

 

 

 

17

4751800

12

Flatwasher 1/2in Wide

 

 

 

19

1001093778

6

Tie-Strap, Push Mount

 

 

 

20

1001100945

2

Wheel - 4in (No Service Parts Available)

 

 

 

21

1001102618

1

Frame Weldment

 

 

 

22

1001103214

1

Harness, Frame (See ELECTRICAL SECTION for Breakdown)

 

 

 

23

1001103416

2

Wheel Assembly - 8in Stationary (No Service Parts Available)

 

 

 

 

 

Ref

FRONT WHEEL ASSEMBLIES

 

 

 

101

 

Ref

Wheel Assembly Options:

 

 

 

101

1001103417

2

Swivel Non-Locking Wheel (No Service Parts Available)

 

 

 

101

1001115956

2

Swivel Locking Wheel (No Service Parts Available)

 

 

 

101

1001115505

2

Swivel Braking Wheel (No Service Parts Available) (Required on

 

 

 

 

 

 

Australian Spec Machines)

 

 

 

 

0271253

Ref

STROBE LIGHT ONLY INSTALLATION (OPTIONAL)

E

 

 

201

2920146

1

Lamp, Beacon

 

 

 

203

0721006

2

Screw, #10-24NC x 3/4in

 

 

 

204

3311005

2

Nut #10-24NC

 

 

 

205

4751000

4

Flatwasher #10 Wide

 

 

 

206

1001093322

1

Plate, Mounting

 

 

 

207

4922837

1

Harness, Strobe Light (Not Shown)

 

 

 

 

0271252

Ref

DESCENT ALARM ONLY INSTALLATION (OPTIONAL)

D

 

 

301

0140033

1

Alarm

 

 

 

302

0721006

2

Screw, #10-24NC x 3/4in

 

 

 

303

3311005

2

Nut #10-24NC

 

 

 

304

4751000

4

Flatwasher #10 Wide

 

 

 

305

1001093322

1

Plate, Mounting

 

 

 

306

4922805

1

Harness, Alarm (Not Shown)

 

 

 

 

1001093343

Ref

STROBE LIGHT AND DESCENT ALARM INSTALLATION (WHEN

A

 

 

 

 

 

EQUIPPED WITH BOTH) (OPTIONAL)

 

 

 

401

0140033

1

Alarm

 

 

 

402

0721006

2

Screw #10-24NC x 3/4in

 

 

 

403

2920146

1

Lamp, Beacon

 

 

3120873

 

 

20AM/25AM/30AM/36AM/41AM

17

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

404

3311005

2

Nut #10-24NC

 

407

4751000

4

Flatwasher #10 Wide

 

408

4922805

1

Harness, Alarm (Not Shown)

 

409

4922837

1

Harness, Strobe Light (Not Shown)

 

410

1001093322

1

Plate, Mounting

 

18

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-3. OUTRIGGER COMPONENTS INSTALLATION

20

20AM/25AM/30AM/36AM/41AM

3120873

 

 

 

 

SECTION 1 - BASE

 

 

FIGURE 1-3. OUTRIGGER COMPONENTS INSTALLATION

 

 

 

 

 

 

 

 

 

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

 

 

Ref

OUTRIGGER ASSEMBLIES

 

 

 

 

0258814

Ref

Outrigger Assemblies 20AM/25AM

G

 

 

 

0258815

Ref

Outrigger Assemblies 30AM

H

 

 

 

0258821

Ref

Outrigger Assemblies 30AM (Australian Spec Machines with

G

 

 

 

 

 

Outdoor Wind Spec Requirements Built) (Prior to SN

 

 

 

 

 

 

0900030915)

 

 

 

 

0258816

Ref

Outrigger Assemblies 36AM/41AM

G

 

 

 

 

Ref

Note: Qty shown is for one outrigger jack. Complete

 

 

 

 

 

 

machine requires 4x the qty listed.

 

 

 

1

0100011

AR

Compound, Locking

 

 

 

2

0100035

AR

Compound, Locking

 

 

 

3

0641410

1

Bolt 1/4in-20NC x 1-1/4in

 

 

 

4

0641624

1

Bolt 3/8in-16NC x 3in (Prior to SN 0900012074)

 

 

 

4

0641622

1

Bolt 3/8in-16NC x 2-3/4in (SN 0900012074 to Present)

 

 

 

5

2540024

2

Grommet (Prior to SN 0900016557)

 

 

 

5

0962288

2

Bushing, Molded Nylon Insulator (SN 0900016557 to Present)

 

 

 

6

1220015

1

Cap, End

 

 

 

7

2560127

1

Handle

 

 

 

8

2840019

1

Screw, Jack

 

 

 

9

3020035

AR

Lubricant, Silicone

 

 

 

10

3300380

1

Locknut, Flanged (Prior to SN 0900031663)

 

 

 

11

 

Ref

Locknut #8-32NC Options:

 

 

 

11

3300392

2

Locknut #8-32NC (Prior to SN 0900016557)

 

 

 

11

3300440

2

Locknut #8-32NC (SN 0900016557 to Present)

 

 

 

12

3311405

1

Locknut 1/4in-20NC

 

 

 

13

3311605

1

Locknut 3/8in-16NC

 

 

 

14

3340712

1

Pad, Jack

 

 

 

15

3780200

3

O-Ring (SN 0900016557 to Present)

 

 

 

16

3900193

2

Screw, Countersunk #8-32NC x 3/4in

 

 

 

17

4280291

1

Pad, Contact

 

 

 

18

 

Ref

Beam, Outrigger Options:

 

 

 

18

4567732

1

Beam, Outrigger 20AM/25AM

 

 

 

18

4567733

1

Beam, Outrigger 30AM (Indoor Use)

 

 

 

18

4567736

1

Beam, Outrigger 30AM (Australian Spec Machines with

 

 

 

 

 

 

Outdoor Wind Spec Requirements Built) (Prior to SN

 

 

 

 

 

 

0900030915)

 

 

 

18

4567734

1

Beam, Outrigger 36AM/41AM

 

 

 

19

4711600

2

Washer 3/8in (Narrow)

 

 

 

20

4740434

5

Washer, Nylon #8

 

 

 

21

4751400

2

Flatwasher 1/4in Wide

 

 

 

22

4751600

AR

Flatwasher 3/8in Wide (Prior to SN 0900031663)

 

 

 

23

4891800

1

Flatwasher 1/2in Hardened (Prior to SN 0900031663)

 

 

 

24

0741407

2

Screw, Countersunk 1/4in-20NC x 7/8in

 

 

 

25

4220178

1

Stop, Outrigger

 

 

 

26

Not Available

1

Nameplate - Outrigger

 

 

 

27

3820006

4

Rivet

 

 

 

28

1001116824

1

Outrigger Jack Kit (Includes Items 3, 6, 7, 8, 9, 12, 14, 21 & 28A -

C

 

 

 

 

 

28G) (SN 0900031663 to Present)

 

 

 

28

1001133151

1

Kit, Jack Pad (Includes Items 28A - 28G)

A

 

 

28A

1001129756

1

Ball Pivot, Outrigger

 

 

 

28B

1001129757

1

Bushing, Flange Bearing

 

 

3120873

 

 

20AM/25AM/30AM/36AM/41AM

21

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

28C

1001129758

1

Spacer

 

28D

1001129761

1

Pad, Jack

 

28E

1001129763

1

Plate, Jack Ball Cover

 

28F

1001129764

4

Bolt 1/4in - 20NC x 3/4in

 

28G

1001129779

1

Nut 3/8in -16NC, Flange

 

 

 

Ref

BASE MOUNTED COMPONENTS

 

 

 

Ref

Base Mounted Components 20AM/25AM

 

 

0258180

Ref

Base Mounted Components (Prior to SN 0900017519)

J

 

0271423

Ref

Base Mounted Components (SN 0900017519 through

K

 

 

 

0900031574)

 

 

0271423 or

Ref

Base Mounted Components (SN 0900031575 through

K/B

 

1001103370

 

0900031617)

 

 

1001103370

Ref

Base Mounted Components (SN 0900031618 to Present)

B

 

 

Ref

Base Mounted Components 30AM

 

 

0258809

Ref

Base Mounted Components (Prior to SN 0900017519)

H

 

0271427

Ref

Base Mounted Components (SN 0900017519 through

K

 

 

 

0900031574)

 

 

0271427 or

Ref

Base Mounted Components (SN 0900031575 through

K/B

 

1001103370

 

0900031617)

 

 

1001103370

Ref

Base Mounted Components (SN 0900031618 to Present)

B

 

 

Ref

Base Mounted Components 36AM/41AM

 

 

0258810

Ref

Base Mounted Components (Prior to SN 0900017519)

J

 

0271428

Ref

Base Mounted Components (SN 0900017519 through

K

 

 

 

0900031574)

 

 

0271428 or

Ref

Base Mounted Components (SN 0900031575 through

K/B

 

1001103370

 

0900031617)

 

 

1001103370

Ref

Base Mounted Components (SN 0900031618 to Present)

B

101

0100011

AR

Compound, Locking

 

105

2540024

8

Grommet (Prior to SN 0900016557)

 

105

2540024

8

Bushing, Molded Nylon Insulator - Use p/n 0962288 Grommet

 

107

3300379

16

Locknut, Brass #8-32NC

 

110

 

Ref

Pin, Plunger Options:

 

110

3422369

4

Pin, Plunger (Prior to SN 0900012037)

 

110

3422744

4

Pin, Plunger (SN 0900012037 to Present)

 

112

3900194

8

Screw, Brass #8-32NC x 5/8in

 

113

3900212

8

Screw, Button #4-40NC

 

116

4740434

16

Washer, Nylon #8

 

118

10701650

8

Locknut #4-40NC (SN 0900031618 to Present)

 

22

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-4. MAST SUPPORT INSTALLATION

24

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

3120873

20AM/25AM/30AM/36AM/41AM

25

SECTION 1 - BASE

FIGURE 1-4. MAST SUPPORT INSTALLATION

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

 

 

 

 

Ref

USAGE CHART

 

 

 

 

Items 1-19

Ref

Machines Built (Prior to SN 0900031574)

 

 

 

 

See Note

Ref

Machines Built (Note: No exact SN break exist, contact the

 

 

 

 

 

 

JLG Parts Dept to confirm design before ordering parts.) (SN

 

 

 

 

 

 

0900031575 through 0900031617)

 

 

 

 

Items 101-114

Ref

Machines Built (SN 0900031618 to Present)

 

 

 

 

 

Ref

MAST SUPPORT INSTALLATIONS

 

 

 

 

0258548

Ref

Mast Support Installations 20AM (Prior to SN 0900017519)

A

 

 

 

0271434

Ref

Mast Support Installations 20AM (SN 0900017519 through

E

 

 

 

 

 

0900031574)

 

 

 

 

0258549

Ref

Mast Support Installations 25AM (Prior to SN 0900017519)

A

 

 

 

0271435

Ref

Mast Support Installations 25AM (SN 0900017519 through

E

 

 

 

 

 

0900031574)

 

 

 

 

0258550

Ref

Mast Support Installations 30AM (Prior to SN 0900017519)

A

 

 

 

0271436

Ref

Mast Support Installations 30AM (SN 0900017519 through

E

 

 

 

 

 

0900031574)

 

 

 

 

0258551

Ref

Mast Support Installations 36AM (Prior to SN 0900017519)

B

 

 

 

0271437

Ref

Mast Support Installations 36AM (SN 0900017519 through

E

 

 

 

 

 

0900031574)

 

 

 

 

0258552

Ref

Mast Support Installations 41AM (Prior to SN 0900017519)

B

 

 

 

0271438

Ref

Mast Support Installations 41AM (SN 0900017519 through

E

 

 

 

 

 

0900031574)

 

 

 

 

 

Ref

Note: See Usage Chart for SN 0900031575 to SN 0900031617.

 

 

 

1

 

Ref

Bolt Options:

 

 

 

1

0641608

AR

Bolt 3/8in-16NC x 1in

 

 

 

1

0641609

AR

Bolt 3/8in-16NC x 1-1/8in

 

 

 

3

2420140

1

Gauge, Level

 

 

 

4

2560088

2

Grip, Handle (20AM/25AM/30AM Only)

 

 

 

5

 

Ref

Nut Options:

 

 

 

5

3311605

AR

Locknut 3/8in-16NC

 

 

 

5

3311608

AR

Flanged Nut 3/8in-16NC

 

 

 

6

3570971

1

Plate, Cover (Prior to SN 0900017519)

 

 

 

7

4567508

2

Brace

 

 

 

8

4711600

AR

Flatwasher 3/8in

 

 

 

9

 

Ref

Support Weldment Options:

 

 

 

9A

4845715

1

Support Weldment 20AM/25AM/30AM

 

 

 

9B

4845763

1

Support Weldment 36AM/41AM

 

 

 

10

0100001

AR

Adhesive (20AM/25AM/30AM Only)

 

 

 

14

1704582

1

Decal, Manual Descent

 

 

 

15

0641408

4

Screw 1/4in

 

 

 

16

3311405

4

Lock Nut 1/4in

 

 

 

17

4568433

1

Tube, Valve Protection (SN 0900017519 through 0900031574)

 

 

 

18

4751400

8

Flatwasher 1/4in

 

 

 

19

0100011

AR

Compound, Locking

 

 

 

 

 

Ref

MAST SUPPORT INSTALLATIONS

 

 

 

 

1001108565

Ref

Mast Support Installations 20AM (SN 0900031618 to Present)

A

 

 

 

1001108566

Ref

Mast Support Installations 25AM (SN 0900031618 to Present)

A

 

 

 

1001108567

Ref

Mast Support Installations 30AM (SN 0900031618 to Present)

A

 

 

 

1001108568

Ref

Mast Support Installations 36AM (SN 0900031618 to Present)

A

 

 

 

1001108569

Ref

Mast Support Installations 41AM (SN 0900031618 to Present)

A

 

 

 

 

Ref

Note: See Usage Chart for SN 0900031575 to SN 0900031617.

 

 

26

 

 

 

20AM/25AM/30AM/36AM/41AM

3120873

 

 

 

 

SECTION 1 - BASE

 

 

 

 

 

 

 

ITEM

PART NUMBER

QTY

DESCRIPTION

 

REV

 

 

 

 

 

 

 

 

101

0100011

AR

Compound, Locking

 

 

 

102

0630550

2

Capscrew 1/4in-20NC x 3/4in

 

 

 

103

0641608

8

Bolt 3/8in-16NC x 1in

 

 

 

104

0641609

4

Bolt 3/8in-16NC x 1-1/8in

 

 

 

104

0641611

4

Bolt 3/8in-16NC x 1-3/8in

 

 

 

106

2420140

1

Gauge, Level

 

 

 

107

2560088

2

Grip, Handle (20AM/25AM/30AM Only)

 

 

 

108

3311605

8

Locknut 3/8in-16NC

 

 

 

109

3311608

4

Nut, Flanged 3/8in-16NC

 

 

 

110

4711600

8

Flatwasher 3/8in Narrow

 

 

 

111

1001102616

1

Shield, Lift Down Valve

 

 

 

112

1001107441

2

Brace

 

 

 

113

 

Ref

Support Weldment Options:

 

 

 

113

1001107459

1

Support Weldment 20AM/25AM/30AM

 

 

 

113

1001108178

1

Support Weldment 36AM/41AM

 

 

 

114

1001107451

2

Mount, Tiltback Shock (36AM/41AM)

 

 

 

3120873

20AM/25AM/30AM/36AM/41AM

27

SECTION 1 - BASE

FIGURE 1-5. TILTBACK AND LOADING HARDWARE (FRAME MOUNTED) COMPONENTS (SEE

PARTS LIST FOR USAGE)

28

20AM/25AM/30AM/36AM/41AM

3120873

SECTION 1 - BASE

FIGURE 1-5. TILTBACK AND LOADING HARDWARE (FRAME MOUNTED) COMPONENTS (SEE

PARTS LIST FOR USAGE)

 

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

Ref

USAGE CHART

 

 

 

 

 

Ref

Machines Built Prior to SN 0900031574 - Note: Use this figure.

 

 

 

 

 

Ref

Machines Built SN 0900031575 through SN 0900031617 - No

 

 

 

 

 

 

exact SN break exists, contact the JLG Parts Dept to confirm

 

 

 

 

 

 

design before ordering parts.

 

 

 

 

 

Ref

Machines Built SN 0900031618 to Present - Note: Use next

 

 

 

 

 

 

figure.

 

 

 

 

0258406

Ref

TILTBACK INSTALLATION (36AM/41AM ONLY)

H

 

 

1

0100019

AR

Compound, Locking

 

 

 

2

0630383

4

Carriage Bolt, 5/16in-18NC

 

 

 

3

0641518

2

Bolt 5/16in-18NC x 2-1/4in

 

 

 

4

0641608

10

Bolt 3/8in-16NC x 1in

 

 

 

5

0962195

2

Bushing, Tiltstop

 

 

 

6

0962196

2

Bushing, Shock Mount

 

 

 

7

0962197

2

Bushing, Shock Mount

 

 

 

8

1060380

2

Cable, Lanyard

 

 

 

9

1320215

2

Clamp, Stowage

 

 

 

10

2560088

2

Grip, Handle

 

 

 

11

3311505

10

Locknut 5/16in-18NC

 

 

 

12

3311605

10

Locknut 3/8in-16NC

 

 

 

13

3420934

2

Pin, Quick Release

 

 

 

14

3422369

1

Plunger Pin (Prior to SN 0900012209)

 

 

 

15

3422370

2

Pin, Grooved

 

 

 

16

3570927

2

Plate, Tilt Back Mount

 

 

 

17

3570949

1

Plate, Stop

 

 

 

18

3820024

2

Rivet

 

 

 

19

3900111

4

Screw, Shoulder

 

 

 

20

3941004

4

Screw, Self Tapper

 

 

 

21

 

Ref

Hardware Option:

 

 

 

21

4060805

2 ft

Shield, Flex Trim (Prior to SN 0900019171)

 

 

 

21

4060807

2 ft

Hardware (SN 0900019171 through 0900019854)

 

 

 

21

0940049

2

Hardware (Stopper, Rubber) (SN 0900019855 to Present)

 

 

 

22

4567599

2

Tube, Shock Cover

 

 

 

23

4711500

AR

Flatwasher 5/16in Narrow

 

 

 

24

4711600

24

Flatwasher 3/8in Narrow

 

 

 

25

4845706

1

T-Bar Weldment

 

 

 

26

4845762

1

Tiltback Weldment

 

 

 

27

 

Ref

Wheel, Caster Options:

 

 

 

27

4860187

2

4in Diameter (Prior to SN 0900019171)

 

 

 

27

4860143

2

5in Diameter (SN 0900019171 through 0900020847)

 

 

 

28

4160173

2

Spring, Gas Shock

 

 

 

29

3422744

1

Plunger Pin (SN 0900012209 to Present)

 

 

 

30

3520163

2

Cap, Tube

 

 

 

31

0641614

8

Bolt 3/8in-16NC x 1-3/4in (Prior to SN 0900019171)

 

 

 

32

 

Ref

Plate, Spacer Options:

 

 

 

32

3572370

4

Plate, Spacer (Prior to SN 0900019171)

 

 

 

32

Not Required

0

Plate, Spacer (SN 0900019171 to Present)

 

 

 

33

3311501

1

Nut 5/16in-18NC (SN 0900019855 to Present)

 

 

 

34

4860251

2

Wheel, Locking Caster (SN 0900020847 to Present)

 

 

3120873

 

 

20AM/25AM/30AM/36AM/41AM

29

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

 

 

 

 

 

 

 

Ref

LOADING HARDWARE (FRAME MOUNTED COMPONENTS)

 

 

 

 

(20AM/25AM/30AM)

 

 

0258741

Ref

Loading Hardware (Frame Mounted Components)

K

 

 

 

20AM/25AM/30AM

 

 

0258965

Ref

Loading Hardware (Frame Mounted Components) 36AM/41AM

I

103

 

Ref

Bolt Options:

 

103

0641608

AR

Bolt 3/8in-16NC x 1in

 

103

0641611

AR

Bolt 3/8in-16NC x 1-3/8in

 

105

2560088

2

Grip

 

108

3311605

4

Locknut 3/8in-16NC

 

111

3422744

1

Pin, Plunger

 

112

3450504

4

Pin, Cotter

 

113

3520163

2

End Cap, Tube

 

114

4070981

1

Shim .25 (Prior to SN 0900029419)

 

119

4711600

4

Flatwasher 3/8in Narrow

 

121

4712200

4

Flatwasher 3/4in Narrow

 

123

4845706

1

Weldment, T-Bar

 

124

4845727

1

Bracket, Mast Wheel (Prior to SN 0900029419)

 

128

 

Ref

Wheel 4in Options:

 

128

4860185

2

Wheel (Prior to SN 0900014095)

 

128

7020087

2

Wheel, Replacement (1 Per Wheel)

 

128

7020084

4

Bearing (2 Per Wheel)

 

128

7012631

2

Bushing, Axle Spanner (1 Per Wheel)

 

128

4860196

2

Wheel (SN 0900014095 through 0900020788)

 

128

See Note

2

Wheel, Replacement (1 Per Wheel) (Note: Not Available -

 

 

 

 

Purchase p/n 4860196)

 

128

7020084

4

Bearing (2 Per Wheel)

 

128

See Note

2

Bushing, Axle Spanner (1 Per Wheel) (Note: Not Available -

 

 

 

 

Purchase p/n 4860196)

 

128

4860250

2

Wheel (SN 0900020788 through 0900029419)

 

133

0641828

2

Bolt 1/2in-13NC x 3-1/2in

 

134

3311805

2

Locknut 1/2in-13NC

 

135

4711800

2

Flatwasher 1/2in Narrow

 

136

1001100905

1

Weldment, Mast Wheel Bracket (SN 0900029419 through

 

 

 

 

0900031574)

 

137

1001100945

2

Wheel 4in (SN 0900029419 through 0900031574)

 

30

20AM/25AM/30AM/36AM/41AM

3120873

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