JLG 41EL Parts Manual

Illustrated Parts Manual

Models

20EL 25EL 30EL 36EL 41EL

P/N - 3120783

November 11, 2004

REVISION LOG

May 10, 1999 - Original Issue Of Manual

November 15, 1999 - Revised (Manual edited to 0010555 Revision 19)

June 30, 2000 - Revised (Manual edited to 0010555 Revision 22)

July 1, 2000 - Updated (Changed Pages 3-6 and 3-12)

August 24, 2000 - Revised (Manual edited to 0010555 Revision 23)

April 12, 2001 - Revised (Manual edited to 0010555 Revision 27)

January 10, 2002 - Revised (Manual edited to 0010555 Revision 29)

March 1, 2002 - Revised (Manual edited to 0010555 Revision 31)

June 12, 2002 - Revised (Manual edited to 0010555 Revision 34)

October 31, 2002 - Revised (Manual edited to 0010555 Revision 36)

February 19, 2003 - Revised (Manual edited to 0010555 Revision 37)

July 15, 2003 - Revised (Manual edited to 0010555 Revision 43)

April 29, 2004 - Revised (Manual edited to 0010555 Revision 45)

November 11, 2004 - Revised (Manual edited to 0010555 Revision 47)

3120783 A

REVISION LOG

B 3120783

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 BASE MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 TILTBACK INSTALLATION 36EL/41EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

SECTION 2 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 AC POWER COMPONENTS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 AC JUNCTION BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 AC MOTOR/PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4 DC POWER COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-5 DC POWER PACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-5 BATTERY CHAGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-7 DC MOTOR/PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-8 CABLES AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 MAST ASSEMBLY - 20EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 MAST ASSEMBLY - 25EL & 36EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3 MAST ASSEMBLY - 30EL & 41EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-4 MAST MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 STEP-IN MOLDED PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 QUICK-CHANGE PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATE . . . . . . . . . . . .4-8

4-4 OPTIONAL PLATFORM COMPONENT INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . .4-12

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 LIFT CYLINDER ASSEMBLY (PRIOR TO S/N 17519) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 LIFT CYLINDER ASSEMBLY (S/N 17519 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . .5-4

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 ELECTRICAL DIAGRAM - 12VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 ELECTRICAL DIAGRAM - 120VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

3120783 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii 3120783

SECTION 1 BASE

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 BASE MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 TILT BACK INSTALLATION (36EL/41EL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

E C T

I O N

B A S E

3120783 1-1

SECTION 1 BASE

S E C T

I O N

A S E

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

1-2 3120783

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BASE ASSEMBLIES Ref. 0258180 20EL/25EL (PRIOR TO S/N 17519) Ref. J 0271423 20EL/25EL (S/N 17519 TO PRESENT) Ref. F 0258469 30EL (PRIOR TO S/N 17519) Ref. H 0271424 30EL (S/N 17519 TO PRESENT) Ref. G 0258470 36EL/41EL (PRIOR TO S/N 17519) Ref. H 0271425 36EL/41EL (S/N 17519 TO PRESENT) Ref. G

1 0100011 Loctite #242 A/R 2 0100019 Loctite #272 A/R 3 0641406 Bolt 1/4”-20NC x 3/4” 2 4 0641606 Bolt 3/8”-16NC x 3/4” 6 5 0641607 Bolt 3/8”-16NC x 7/8” 2 6 0641830 Bolt 1/2”-13NC x 3/4” 2 7 0720805 Screw #8-24NC x 5/8” 6 8 0721005 Screw #10-24NC 2 9 1320043 Clamp 6

10 Use 0962288 Bushing, Molded Nylon Insulator (S/N 16557 to Present)

(Prior to S/N 16557 - Was P/N 2540024 - Grommet) 11 2540025 Grommet 2 12 2560088 Handle 2 13 2920151 Light, Indicator 4 14 3020022 Lithium, White A/R 15 3300379 Locknut, Brass #8-32NC 16 16 3310405 Locknut #4-40NC A/R 17 3310805 Locknut #8-32NC (Prior to S/N 19233) 6 18 3311005 Locknut #10-24NC 2 19 3311405 Locknut 1/4”-20NC 2 20 3311605 Locknut 3/8”-16NC 2 21 3311805 Locknut 1/2”-13NC 2 22 Use 3312002 Locknut 5/8”-11NC (Prior to S/N 12331) 2

3312002 Nut 5/8”-11NC (S/N 12331 to Present) 2

23 Pin, Plunger Options: 4

3422369 Prior to S/N 12037

3422744 S/N 12037 to Present 24 3570946 Plate, Cover 2 25 3570947 Plate, Cover 2 26 3570973 Plate, Cover 2 27 3740106 Relay (Note: Part of p/n 4922421 Harness after S/N 14544) 1 28 3900194 Screw, Brass #8-32NC x 5/8” 8 29 3900212 Screw, Button #4-40NC A/R 30 3900255 Screw, Shoulder 2 31 3941405 Screw, Self-Tapping 8 32 4460234 Tie, Wire A/R 33 4711600 Flatwasher 3/8” 14 34 4711800 Flatwasher 1/2” 4 35 Use 4740525 Flatwasher 3/4” (S/N 20143 to Present)

(Prior to S/N 20143 - Was P/N 4712200)

S E

I O N

A S E

3120783 1-3

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

36 4740434 Washer, Nylon #8 24 37 4750800 Flatwasher #8 (Prior to S/N 19233) 12 38 4751000 Flatwasher #10 8 39 Base Weldment Options: 1

4845705 Prior to S/N 17519 4846388 S/N 17519 to Present

40 Wheel Assembly - Stationary Options: A/R

4860183 Stationary Wheel Used Prior to S/N 20788 2 7020083 Wheel, Replacement (1 Per Wheel) 2 7020084 Bearing (2 Per Wheel) 4 7012631 Bushing, Axle Spanner (1 Per Wheel) 2 4860246 Stationary Wheel Used S/N 20788 to Present

(No Service Parts Available) 41 Not Used 42 Wheel Assembly - 4” Options: A/R

4860185 4” Wheel Used Prior to S/N 20788 2 7020087 Wheel, Replacement (1 Per Wheel) 2 7020084 Bearing (2 Per Wheel) 4 7012631 Bushing, Axle Spanner (1 Per Wheel) 2 4860247 4” Wheel Used S/N 20788 to Present

(No Service Parts Available) 43 3571150 Plate, Wheel Spacer (S/N 12331 to Present) 1 44 3020017 Lubricant (Used Prior to S/N 20788) A/R 45 4240032 Tie, Wire (Not Shown) (S/N 16285 to Present) 18 46 2820086 Loom, Wire (Not Shown) (S/N 16285 to Present)

47 Use 4922752 Harness, Potted Relay (Not Shown) (Was P/N 4922421)

(Prior to S/N 19239)

5.84ft/

1.8m

OUTRIGGER ASSEMBLIES Ref. 0258466 20EL/25EL Ref. E 0258467 30EL Ref. E 0258468 36EL/41EL Ref. E

101 0100011 Loctite #242 (Not Shown) A/R 102 3300380 Locknut 1 103 0641410 Bolt 1/4”-20NC x 1 1/4” 1 104 0641624 3/8”-16NC x 3” (Prior to S/N 12074) 1

0641622 3/8”-16NC x 2 3/4” (S/N 12074 to Present) 1

105 1220015 Cap, End 1 106 Use 0962288 Bushing, Molded Nylon Insulator (S/N 16557 to Present)

(Prior to S/N 16557 - Was 2540024 (Grommet)) 107 2560127 Handle 1 108 2840019 Screw, Jack 1 109 3020035 Lubricant, Silicone A/R 110 3300392 Locknut Brass #8-32NC 2 111 3311405 Locknut 1/4”-20NC 1 112 3311605 Locknut 3/8”-16NC 1 113 3340712 Pad, Jack 1

1-4 3120783

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

114 3900193 Screw, Countersunk #8-32NC x 3/4” 2 115 4280291 Pad, Contact 1 116 Beam, Outrigger Options: 1

4567601 20EL/25EL 4567602 30EL

4567603 36EL/41EL 117 Not Used 118 4740434 Washer, Nylon #8 5 119 4751400 Flatwasher 1/4” 2 120 4751600 Flatwasher 3/8” A/R 121 4891800 Flatwasher 1/2” 1 122 3780200 O-Ring (S/N 16557 to Present) 2 123 0100035 Loctite #222 A/R

MAST SUPPORT INSTALLATIONS Ref. 0258543 20EL (Prior to S/N 17519) Ref. B 0271429 20EL (S/N 17519 to Present) Ref. C 0258544 25EL (Prior to S/N 17519) Ref. B 0271430 25EL (S/N 17519 to Present) Ref. C 0258545 30EL (Prior to S/N 17519) Ref. B 0271431 30EL (S/N 17519 to Present) Ref. C 0258546 36EL (Prior to S/N 17519) Ref. A 0271432 36EL (S/N 17519 to Present) Ref. C 0258547 41EL (Prior to S/N 17519) Ref. A 0271433 41EL (S/N 17519 to Present) Ref. C

S E

I O N

A S E

201 0641609 Bolt 3/8”-16NC x 1 1/8” A/R 202 Not Used 203 2420140 Gauge, Level 1 204 2560088 Handle (Models 20EL/25EL/30EL Only) 2 205 3311605 Locknut 3/8”-16NC 14 206 3570971 Plate, Cover 1 207 4567508 Brace 2 208 4711600 Flatwasher 3/8” 28 209 Support Weldment Options:

4845715 20EL/25EL/30EL 1 4845763 36EL/41EL 1

210 0100001 Adhesive (Models 20EL/25EL/30EL Only)

(S/N 12074 to Present)

211 to 213 Not Used

214 1704582 Decal, Manual Descent 1 215 0641408 Screw 1/4” 4 216 3311405 Locknut 1/4” 4 217 4568433 Tube, Valve Protection 1 218 4751400 Flatwasher 1/4” 8

A/R

3120783 1-5

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRONT WHEEL ASSEMBLIES Ref.

301 Wheel Assembly Options: 2

4860184 Swivel Non-Locking Wheel Used Prior to S/N 20788 2 7020017 Swivel Rig (1 Per Assembly) 2 7020086 Wheel, Replacement (1 Per Assembly) 2 7020084 Bearing (2 Per Wheel) 4 7012631 Bushing, Axle Spanner (1 Per Assembly) 2 7012630 Axle Kit (1 Per Assembly) 2 4860245 Swivel Non-Locking Wheel Used S/N 20788 to Present

(No Service Parts Available)

1-6 3120783

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

A S E

3120783 1-7

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-2. TILTBACK INSTALLATION (36EL/41EL)

1-8 3120783

SECTION 1 BASE

FIGURE 1-2. TILTBACK INSTALLATION (36EL/41EL)

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258406 TILTBACK INSTALLATION 36AM/41AM Ref. G

1 0100019 Loctite #272 (Not Shown) A/R 2 0630383 Carriage Bolt, 5/16”-18NC 4 3 0641518 Bolt 5/16”-18NC x 2 1/4” 2 4 0641608 Bolt 3/8”-16NC x 1” 10 5 0962195 Bushing, Tiltstop 2 6 0962196 Bushing, Shock Mount 2 7 0962197 Bushing, Shock Mount 2 8 1060380 Cable, Lantard 2

9 1320215 Clamp, Stowage 2 10 2560088 Grip, Handle 2 11 3311505 Locknut, 5/16”-18NC 10 12 3311605 Locknut, 3/8”-16NC 10 13 3420934 Pin, Quick Release 2 14 3422369 Plunger Pin (Prior to S/N 12209) 1 15 3422370 Pin, Grooved 2 16 3570927 Plate, Tilt Back Mount 2 17 3570949 Plate, Stop 1 18 3820024 Rivet 2 19 3900111 Screw , Shou lde r 4 20 3941004 Screw, Self Tapper 4 21 Hardware Option:

Use 4060807 Shield, Flex Trim (Was P/N 4060805)

(Prior to S/N 19171) 4060807 (S/N 19171 to S/N 19855) 2ft 0940049 (S/N 19855 to Present) (Stopper, Rubber) 2

22 4567599 Tube, Shock Cover 2 23 4711500 Flatwasher, 5/16” Narrow A/R 24 4711600 Flatwasher, 3/8” Narrow 24 25 4845706 T-Bar Weldment 1 26 4845762 Tiltback Weldment 1 27 Use 4860143 Wheel, Caster (Was P/N 4860187 ) (Prio r to S/N 19 171 ) 2

4860143 (S/N 19171 to Present)

28 4160173 Spring, Gas Shock 2 29 3422744 Plunger Pin (S/N 12209 to Present) 1 30 3520163 Cap, Tube 2 31 0641614 Bolt 3/8”-16NC x 1 3/4” (Prior to S/N 19171) 8 32 Plate, Spacer Options: 4

3572370 (Prior to S/N 19171)

Not Used (S/N 19171 to Present)

33 3311501 Nut 5/16-18NC (S/N 19855 to Present) 1

2ft

I O N

A S E

3120783 1-9

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-2. TILTBACK INSTALLATION (36EL/41EL) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-10 3120783

SECTION 2 CONTROLS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

2-1 AC POWER COMPONENTS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 AC JUNCTION BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 AC MOTOR/PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 DC POWER COMPONENTS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 DC POWER PACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-6 BATTERY CHARGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-7 DC MOTOR/PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-8 CABLES AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

S E C T

I O N

C O N

T R O

3120783 2-1

S E

I O N

C O N

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

T R O

L S

2-2 3120783

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

POWERPACK ASSEMBLY OPTIONS: Ref. 0258434 120 VOLT (Prior to S/N 17519) Ref. C 0271131 120 VOLT (S/N 17519 to Present) Ref. B

1 0630486 Screw, Counter Sunk 4 2 0641406 Bolt 1/4”-20NC x 3/4” 4 3 0721006 Screw 2 4 0721014 Screw (Prior to S/N 12076) 1 5 0860933 Junction Box Assembly (See Figure 2-2 for Breakdown) 1 6 Ground Control Box Assembly Options: 1

0861212 Prior to S/N 20143 0861305 S/N 20143 to Present 7020078 Switch, Push-Pull (Stop) 1 7020096 Legend Plate, “Stop” 1 7020097 Legend Plate, “Power/Off/On” 1

Switch, Key Options: 1 7020098 Prior to S/N 20143 4360467 S/N 20143 to Present

Key, Replacement Options: 1 7016339 Prior to S/N 20143 2860030 S/N 20143 to Present 7020090 Connector, Strain Relief 1 7020093 Screw m3 x 25 4 7020094 Lid 1

7 3311005 Locknut #10-24NC A/R 8 3311405 Locknut 1/4”-20NC 4 9 3311505 Locknut 5/16”-18NC 4

10 Pump/Motor Assembly Options (See Figure 2-3 for

Breakdown): 3600281 Prior to S/N 12829 3600292 S/N 12829 to S/N 17519 3600322 S/N 17519 to Present

11 3740113 Relay, Timer (Prior to S/N 12076 Only) 1 12 4460566 Terminal, 90 Degrees 1 13 4751000 Flatwasher #10 A/R 14 4751400 Flatwasher 1/4” 8 15 4751500 Flatwasher 5/16” 4 16 4845712 Plate, Mounting 1

S E

I O N

C O N

T R O

POWERPACK INSTALLATION OPTIONS: Ref. 0258683 20EL (Prior to S/N 17519) Ref. C 0271139 20EL (S/N 17519 to Present) Ref. E 0258478 25EL/30EL/36EL/41EL (Prior to S/N 17519) Ref. B 0271137 25EL/30EL/36EL/41EL (S/N 17519 to Present) Ref. D

101 Not Used 102 0641404 Bolt 1/4”-20NC x 1/2” 4 103 Bolt Options: 4

0641610 Bolt 3/8”-16NC x 1 1/4” (20EL)

3120783 2-3

I O N

C O N

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0641608 Bolt 3/8”-16NC x 1” (25EL/30EL/36EL/41EL)

104 1702353 Decal - Manual Descent (Prior to S/N 17519 Only) 1

105 to 108 Not Used

109 3311605 Locknut 3/8”-16NC 4 1 10 Shield, Pump Cover 1

4060875 (Prior to S/N 19688)

4061024 (S/N 19688 to Present) 110A 1704582 Decal (S/N 19688 to Present Only) 110B 9984088 Cover (S/N 19688 to Present Only)

111 to 113 Not Used

114 4711400 Flatwasher 1/4” 4 115 4711600 Flatwasher 3/8” 8 116 Flatwasher Options: A/R

4751600 Flatwasher 3/8” Wide (20EL Only) (Prior to S/N 15553) A/R

Not Required (25EL/30EL/36EL/41EL) 0 117 Not Used 118 Shim Options (S/N 15553 to Present): 2

4070984 20EL

Not Required 25EL/30EL/36EL/41EL

0258482 AUXILIARY LOWERING INSTALLATION Ref. A

201 to 300 Not Used

301 0861213 Box, Power Down 1

0400181 Battery 2 4460320 Connector, Amp 1

4460267 Pin, Amp 2 302 Not Used 303 4420064 Velcro, Loop .3ft/.09m 304 4420065 Velcro, Hook .3ft/.09m

0271373 FLOOR BRAKE ALARM INSTALLATION Ref. A

401 0100011 Loctite #242 (Not Shown) A/R 402 0140022 Alarm, Horn 1 403 4922583 Harness, Brake Alarm (Not Shown) 1

2-4 3120783

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

C O N

T R O

3120783 2-5

I O N

C O N

SECTION 2 CONTROLS

FIGURE 2-2. AC JUNCTION BOX ASSEMBLY

T R O

L S

2-6 3120783

SECTION 2 CONTROLS

FIGURE 2-2. AC JUNCTION BOX ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

JUNCTION BOX ASSEMBLY OPTIONS: Ref.

0860933 120 VOLT Ref. 9/H

1 Box with Lid Options: 1

0860911 Prior to S/N 13463

0860943 S/N 13463 to Present 2 3740094 Relay, Starter 12 VDC 1 3 3740093 Relay, Starter 115VAC 1 4 3910808 Screw #8-32NF x 1/2” 10 5 4460565 Strip, Terminal 1 6Not Used 7Not Used 8Not Used 9 4460633 Connector, Strain Relief A/R

10 Not Used 11 Not Used 12 Not Used 13 Not Used 14 Not Used 15 Not Used 16 4360161 Circuit Breaker 110 Volt - 20 Amp 1 17 4360376 Rectifier 1 18 3740049 Relay 1 19 Transformer Options: 1

Use 4530013 Prior to S/N 14485

(Was P/N 4530010 115/230VAC to 12VDC Transformer)

4530013 S/N 14485 to Present

(115/230VAC to 16VDC Transformer) 20 Not Used 21 4921663 Harness, Wiring 1 22 1702569 Decal - 110 Volt (Not Shown) 1 23 1702120 Decal - Wire Size 1 24 1702365 Decal - JLG 1 25 3520028 Plug 1/2” 1 26 3520034 Plug, Hole 4

S E

I O N

C O N

T R O

3120783 2-7

I O N

C O N

SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY

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SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

MOTOR/PUMP ASSEMBLY OPTIONS: Ref. 3600281 Prior to S/N 12829 Ref. A 3600292 S/N 12829 to 17519 Ref. C 3600322 S/N 17519 to Present Ref. C

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1 Bolt Options: 2

7013713 5/16”-24NF x 2 3/4” (Prior to S/N 17519)

3600281/3600292 Assemblies

7022222 5/16”-24NF x 2 1/2” (S/N 17519 to Present)

3600322 Assemblies 2 7016735 Coupling 1 3 7013714 Plug 1 4 7013715 Ball 1 5 7013716 Seal 1 6 Washer Options: 1

7013717 3600281/3600292 Assemblies (Prior to S/N 17519)

7022217 3600322 Assemblies (S/N 17519 to Present) 7Not Used 8 7013722 Magnet 1 9 7016713 Decal - Fill Line 1

10 Screw Options: 2

7013728 3600281/3600292 Assemblies (Prior to S/N 17519)

Not Required 3600322 (S/N 17519 to Present)

11 Cover Options: 1

7016770 3600281/3600292 Assemblies (Prior to S/N 17519)

Not Required 3600322 (S/N 17519 to Present)

12 Gasket Options: A/R

7016764 3600281 Assemblies (Prior to S/N 12829) 1

7016793 3600292 Assemblies (S/N 12829 to 17519) 1

Not Required 3600322 Assemblies (S/N 17519 to Present) 13 Not Used 14 7016771 Clamp 1 15 7016774 Motor 1 16 Cover, Switch Box Options: A/R

7013787 3600281 Assemblies (Prior to S/N 12829) 1 7016787 3600292 Assemblies (S/N 12829 to 17519) 1

7016787 3600322 Assemblies (S/N 17519 to Present) 17 7013708 Cartridge, Valve - Check 1 18 7016720 Bolt 5/16”-18NC x 1” (Prior to S/N 17519) 1 19 7016757 Bolt M6-1.0 35MM 4 20 7016758 Lockwasher 1/4” 4 21 7016721 Bolt #12-24NC x 1/2” 4 22 7013795 Tube, Return 1 23 7016773 Plumbing Assembly - Inlet 1 24 Not Used 25 Not Used 26 Not Used

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SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

27 Tank Options: 1

7016775 3600281/3600292 Assemblies (Prior to S/N 17519)

7022219 3600322 (S/N 17519 to Present) 27A 7016776 Decal - Caution 1 27B 7016759 Plug 1

28 7013792 Nut, Tube Compression 1 29 7013793 Sleeve, Tube Compression 1 30 7013733 Spring 1 31 Valve, Manual Descent Options: 1

7013764 3600281/3600292 Assemblies (Prior to S/N 17519)

Not Required 3600322 (S/N 17519 to Present) 32 7016751 Cartridge, Valve - Solenoid 1 33 7013743 O-Ring 1 34 End Head Options: 1

7016753 3600281/3600292 Assemblies (Prior to S/N 17519) 7022220 3600322 (S/N 17519 to Present)

35 Pump Assembly Options: 1

7013747 3600281/3600292 Assemblies (Prior to S/N 17519)

7022221 3600322 (S/N 17519 to Present) 36 7013779 Cap, Relief 1 37 7016714 Breather 1 38 7013720 Plug 2 39 7013726 Tube, Return A/R 40 7016755 Valve 1 41 7013770 Screw, Adjustment 1

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SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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SECTION 2 CONTROLS

FIGURE 2-4. DC POWER COMPONENTS INSTALLATION

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SECTION 2 CONTROLS

FIGURE 2-4. DC POWER COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

POWER PACK ASSEMBLY OPTIONS: Ref. 0258438 Prior to S/N 17519 Ref. A 0271130 S/N 17519 to Present Ref. D

1 0100011 Loctite, #242 (Not Shown) A/R 2 0630486 Screw, Countersunk 4 3 0641403 Bolt 1/4”-20NC x 3/8” 3 4 Bolt Options: 2

0641608 3/8”-16NC x 1” (Prior to S/N 17519) 0641606 3/8”-16NC x 3/4” (S/N 17519 to Present)

5 0721006 Screw 2 6 0721014 Screw (Prior to S/N 17519) 1 7 Ground Control Box Assembly Options: 1

0861212 Prior to S/N 20143 0861305 S/N 20143 to Present 7020078 Switch, Push-Pull (Stop) 1 7020096 Legend Plate, “Stop” 1 7020097 Legend Plate, “Power/Off/On” 1

Switch, Key Options: 1 7020098 Prior to S/N 20143 4360467 S/N 20143 to Present

Key, Replacement Options: 1 7016339 Prior to S/N 20143 2860030 S/N 20143 to Present 7020090 Connector, Strain Relief 1 7020093 Screw m3 x 25 4 7020094 Lid 1

8 0902054 Plate, Mounting 1

9 1060518 Cable, Battery (Prior to S/N 17519 Only) 1 10 1060571 Cable Assembly - Battery 1 11 3311005 Locknut #10-24NC A/R 12 3311505 Locknut 5/16”-18NC 4 13 DC Motor/Pump Assembly Options:

(See Figure 2-7 for Breakdown) 3600273 Prior to S/N 17519 3600320 S/N 17519 to Present

14 3740013 Solenoid (Prior to S/N 17519) 1 15 Relay Options: A/R

3740080 Relay, Bosch (Prior to S/N 17519) 3740049 (Skirted typ e) S/N 17519 to Prese nt

16 3740113 Relay, Timer (Prior to S/N 17519) 1 17 4567605 Tube, Butyrate (Not Shown) (Prior to S/N 17519) 2 18 Washer 1/4” Options:

4711400 Prior to S/N 17519 3 4751400 S/N 17519 to Present 1

19 4751000 Washer #10 A/R 20 4751500 Washer 5/16” 4 21 4751600 Washer 3/8” 2 22 4845714 Bracket, Pump Mounting 1

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FIGURE 2-4. DC POWER COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

23 0641404 Bolt 1/4”-20NC x 1/2” (S/N 17519 to Present) (Not Shown) 1 24 1320224 Clamp, Cable (S/N 17519 to Present) (Not Shown) 1 25 Harness, Pump 12V DC Options: (Not Shown) 1

4922605 S/N 17519 to S/N 19378 4922740 S/N 19378 to Present

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101 Not Used 102 0641404 Bolt 1/4”-20NC x 1/2” 4 103 Bolt Options: 4

0641610 Bolt 3/8”-16NC x 1 1/4” (20EL) 0641608 Bolt 3/8”-16NC x 1” (25EL/30EL/36EL/ 41EL )

104 1702353 Decal - Manual Descent (Prior to S/N 17519 Only) 1

105 to 108 Not Used

109 3311605 Locknut 3/8”-16NC 4

1 10 Shield, Pump Cover 1

4060875 (Prior to S/N 19688)

4061024 (S/N 19688 to Present) 110A 1704582 Decal (S/N 19688 to Present Only) 110B 9984088 Cover (S/N 19688 to Present Only)

111 to 113 Not Used

114 4711400 Flatwasher 1/4” 4 115 4711600 Flatwasher 3/8” 8 116 Flatwasher Options: A/R

4751600 Flatwasher 3/8” Wide (20EL Only) (Prior to S/N 15553) A/R

Not Required (25EL/30EL/36EL/41EL) 0 117 Not Used 118 Shim Options (S/N 15553 to Present): 2

4070984 20EL

Not Required 25EL/30EL/36EL/41EL

0258482 AUXILIARY LOWERING INSTALLATION Ref. A

201 to 300 Not Used

301 0861213 Box, Power Down 1

0400181 Battery 2 4460320 Connector, Amp 1

4460267 Pin, Amp 2 302 Not Used 303 4420064 Velcro, Loop .3ft/.09m 304 4420065 Velcro, Hook .3ft/.09m

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