JLG 18RS 18RSJ Parts Manual (3121285)-PDF Download (Eng)

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JLG 18RS 18RSJ Parts Manual (3121285)-PDF Download

TABLE OF CONTENTS:

JLG 18RS 18RSJ Service & Maintenance Manual (3121284)-PDF Download

SECTION 1 – FRAME ……………………………………………………………………………………………………………………………………………………. 11
FIGURE 1-1. STEERING INSTALLATION ……………………………………………………………………………………………………………………. 12
FIGURE 1-2. WHEEL DRIVE INSTALLATION ………………………………………………………………………………………………………………. 14
FIGURE 1-3. DRIVE MOTOR ASSEMBLY …………………………………………………………………………………………………………………… 16
FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY …………………………………………………………………………………………………………….. 18
FIGURE 1-5. TIRE AND WHEEL INSTALLATION …………………………………………………………………………………………………………. 22
FIGURE 1-6. DRIVE VALVES INSTALLATION – 18RS …………………………………………………………………………………………………… 24
FIGURE 1-7. DRIVE VALVES INSTALLATION – 18RSJ …………………………………………………………………………………………………. 26
FIGURE 1-8. FLOW DIVIDER VALVE ASSEMBLY ……………………………………………………………………………………………………….. 28
FIGURE 1-9. FRAME SHIELDS INSTALLATIONS ………………………………………………………………………………………………………… 30
SECTION 2 – TURNTABLE ……………………………………………………………………………………………………………………………………………. 33
FIGURE 2-1. CONTROL VALVE AND HYDRAULIC FILTERS INSTALLATION – 18RS………………………………………………………. 34
FIGURE 2-2. CONTROL VALVE AND HYDRAULIC FILTERS INSTALLATION – 18RSJ …………………………………………………….. 36
FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY – 18RS ……………………………………………………………………………………………. 38
FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLY – 18RSJ ………………………………………………………………………………………….. 42
FIGURE 2-5. TURNTABLE BEARING AND SWING DRIVE INSTALLATION …………………………………………………………………….. 46
FIGURE 2-6. SWING MOTOR ASSEMBLY ………………………………………………………………………………………………………………….. 48
FIGURE 2-7. SWING BEARING AND ROTATION BOX ASSEMBLY ……………………………………………………………………………….. 50
FIGURE 2-8. TANK INSTALLATIONS ………………………………………………………………………………………………………………………….. 52
FIGURE 2-9. HYDRAULIC TANK ASSEMBLY………………………………………………………………………………………………………………. 54
FIGURE 2-10. HYDRAULIC TANK LOCK INSTALLATION (SN B300002264 to Present) ……………………………………………………. 56
FIGURE 2-11. FUEL FILTER INSTALLATION (OPTIONAL) ……………………………………………………………………………………………. 58
FIGURE 2-12. WATER SEPARATOR FILTER ASSEMBLY (OPTIONAL) …………………………………………………………………………. 60
FIGURE 2-13. ELECTRICAL INSTALLATION – 18RS ……………………………………………………………………………………………………. 62
FIGURE 2-14. ELECTRICAL INSTALLATION – 18RSJ …………………………………………………………………………………………………… 64
FIGURE 2-15. GROUND CONTROL PANEL ASSEMBLY – 18RS……………………………………………………………………………………. 66
FIGURE 2-16. GROUND CONTROL PANEL ASSEMBLY – 18RSJ ………………………………………………………………………………….. 68
FIGURE 2-17. KEY SWITCH ASSEMBLY ……………………………………………………………………………………………………………………. 70
FIGURE 2-18. GROUND CONTROL DOOR INSTALLATION (OPTIONAL) ………………………………………………………………………. 72
FIGURE 2-19. ELECTRICAL PANEL ASSEMBLY …………………………………………………………………………………………………………. 74
FIGURE 2-20. LIMIT SWITCH INSTALLATION …………………………………………………………………………………………………………….. 76
FIGURE 2-21. BEACON LIGHT INSTALLATION (OPTIONAL) ……………………………………………………………………………………….. 78
FIGURE 2-22. HOODS INSTALLATION ………………………………………………………………………………………………………………………. 80
FIGURE 2-23. CENTER HOOD ASSEMBLY (ENGINE SIDE) …………………………………………………………………………………………. 84
FIGURE 2-24. CENTER HOOD ASSEMBLY (TANK SIDE) …………………………………………………………………………………………….. 86
SECTION 3 – ENGINE ………………………………………………………………………………………………………………………………………………….. 89
FIGURE 3-1. DEUTZ ENGINE INSTALLATION …………………………………………………………………………………………………………….. 90
FIGURE 3-2. ENGINE AND PUMP ASSEMBLY ……………………………………………………………………………………………………………. 92
FIGURE 3-3. ENGINE ASSEMBLY ……………………………………………………………………………………………………………………………… 94
FIGURE 3-4. ENGINE COMPONENTS ………………………………………………………………………………………………………………………… 98
FIGURE 3-5. PUMP COUPLING INSTALLATION………………………………………………………………………………………………………… 102
FIGURE 3-6. PISTON PUMP ASSEMBLY ………………………………………………………………………………………………………………….. 104
FIGURE 3-7. BATTERY INSTALLATION ……………………………………………………………………………………………………………………. 108
SECTION 4 – BOOM …………………………………………………………………………………………………………………………………………………… 111
FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION – 18RS …………………………………………………………………………………… 112
FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION – 18RSJ ………………………………………………………………………………….. 116
FIGURE 4-3. MAIN BOOM ASSEMBLY – 18RS …………………………………………………………………………………………………………… 120
FIGURE 4-4. MAIN BOOM ASSEMBLY – 18RSJ …………………………………………………………………………………………………………. 124
FIGURE 4-5. JIB ASSEMBLY …………………………………………………………………………………………………………………………………… 128
FIGURE 4-6. POWER TRACK ASSEMBLY ………………………………………………………………………………………………………………… 130
FIGURE 4-7. PROXIMITY SWITCH INSTALLATION – 18RS …………………………………………………………………………………………. 132
FIGURE 4-8. PROXIMITY SWITCH INSTALLATION – 18RSJ ……………………………………………………………………………………….. 134
FIGURE 4-9. PLATFORM ROTATOR ASSEMBLY – 18RS ……………………………………………………………………………………………. 136
FIGURE 4-10. PLATFORM ROTATOR ASSEMBLY – 18RSJ ………………………………………………………………………………………… 138
FIGURE 4-11. PLATFORM SUPPORT INSTALLATION – WITHOUT LSS – 18RS ……………………………………………………………. 140
FIGURE 4-12. PLATFORM SUPPORT INSTALLATION – WITHOUT LSS – 18RSJ ………………………………………………………….. 142
FIGURE 4-13. PLATFORM SUPPORT INSTALLATION – WITH LSS ……………………………………………………………………………… 144
FIGURE 4-14. PLATFORM SUPPORT INSTALLATION (18RSJ) – WITH LSS …………………………………………………………………. 146
TABLE OF CONTENTS
8 18RS_18RSJ 3121285
SECTION 5 – PLATFORM ……………………………………………………………………………………………………………………………………………. 149
FIGURE 5-1. PLATFORM ASSEMBLY ……………………………………………………………………………………………………………………….. 150
FIGURE 5-2. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – 18RS…………………………………………………………. 152
FIGURE 5-3. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – 18RSJ (Prior to SN B300001836) ………………….. 154
FIGURE 5-4. PLATFORM CONSOLE ASSEMBLY – 18RS (Prior to SN B300001441) ………………………………………………………. 156
FIGURE 5-5. PLATFORM CONSOLE ASSEMBLY – 18RS (SN B300001441 to Present) ………………………………………………….. 160
FIGURE 5-6. PLATFORM CONSOLE ASSEMBLY – 18RSJ ………………………………………………………………………………………….. 164
FIGURE 5-7. PLATFORM ASSEMBLY – 30IN X 3FT (76CM X .91M) – DROP BAR ENTRY ………………………………………………. 168
FIGURE 5-8. PLATFORM ASSEMBLY – 3FT X 6FT (91.5CM X 1.83M) WITH TRI-ENTRY (1 GATE / 2 DROP BARS) …………. 170
FIGURE 5-9. PLATFORM ASSEMBLY – 3FT X 6FT (91.5CM X 1.83M) WITH TRI-ENTRY (3 DROP BARS) ………………………. 172
FIGURE 5-10. CONSOLE BOX ASSEMBLY (Prior to SN B300001540) ………………………………………………………………………….. 174
FIGURE 5-11. CONSOLE BOX ASSEMBLY (SN B300001540 to Present) ……………………………………………………………………… 176
FIGURE 5-12. CONSOLE BOX ASSEMBLY (SN B300001540 through B300001835) ………………………………………………………. 178
FIGURE 5-13. CONSOLE BOX ASSEMBLY (SN B300001836 to Present) ……………………………………………………………………… 180
FIGURE 5-14. CONTROLLER ASSEMBLY (LIFT AND SWING) ……………………………………………………………………………………. 182
FIGURE 5-15. CONTROLLER ASSEMBLY (LIFT AND SWING) ……………………………………………………………………………………. 184
FIGURE 5-16. CONTROLLER ASSEMBLY (DRIVE AND STEER) …………………………………………………………………………………. 188
FIGURE 5-17. CONTROLLER ASSEMBLY (DRIVE AND STEER) …………………………………………………………………………………. 190
SECTION 6 – CYLINDER ……………………………………………………………………………………………………………………………………………… 193
FIGURE 6-1. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – 18RS ……………………………………………………………………. 194
FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – 18RSJ ………………………………………………………………….. 196
FIGURE 6-3. LIFT CYLINDER ASSEMBLY – JIB – 18RSJ (Prior to SN B300003130) ……………………………………………………….. 198
FIGURE 6-4. LIFT CYLINDER ASSEMBLY – JIB – 18RSJ (SN B300003130 to Present) ……………………………………………………. 200
FIGURE 6-5. LIFT CYLINDER ASSEMBLY – MAIN BOOM – 18RS …………………………………………………………………………………. 202
FIGURE 6-6. LIFT CYLINDER ASSEMBLY – MAIN BOOM – 18RSJ ……………………………………………………………………………….. 204
FIGURE 6-7. MASTER CYLINDER ASSEMBLY – 18RS ……………………………………………………………………………………………….. 206
FIGURE 6-8. MASTER CYLINDER ASSEMBLY – 18RSJ ……………………………………………………………………………………………… 208
FIGURE 6-9. STEER CYLINDER ASSEMBLY …………………………………………………………………………………………………………….. 210
FIGURE 6-10. TELESCOPE CYLINDER ASSEMBLY – 18RS (Prior to SN B300001836)…………………………………………………… 212
FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY – 18RS (SN B300001836 to Present) ………………………………………………. 214
FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY – 18RSJ ………………………………………………………………………………………. 216
FIGURE 6-13. VALVE BLOCK ASSEMBLY …………………………………………………………………………………………………………………. 218
SECTION 7 – HYDRAULIC …………………………………………………………………………………………………………………………………………… 221
FIGURE 7-1. HYDRAULIC INSTALLATION (FRONT AXLE) – 18RS……………………………………………………………………………….. 222
FIGURE 7-2. HYDRAULIC INSTALLATION (FRONT AXLE) – 18RSJ ……………………………………………………………………………… 226
FIGURE 7-3. HYDRAULIC INSTALLATION (REAR AXLE) – 18RS …………………………………………………………………………………. 230
FIGURE 7-4. HYDRAULIC INSTALLATION (REAR AXLE) – 18RSJ ……………………………………………………………………………….. 234
FIGURE 7-5. HYDRAULIC INSTALLATION (BOOM) – 18RS …………………………………………………………………………………………. 238
FIGURE 7-6. HYDRAULIC INSTALLATION (BOOM) – 18RSJ ……………………………………………………………………………………….. 242
FIGURE 7-7. HYDRAULIC INSTALLATION (DRIVE PUMP) – 18RS ……………………………………………………………………………….. 246
FIGURE 7-8. HYDRAULIC INSTALLATION (DRIVE PUMP) – 18RSJ ……………………………………………………………………………… 250
FIGURE 7-9. HYDRAULIC FLUSHING LOOP INSTALLATION – 18RS …………………………………………………………………………… 254
FIGURE 7-10. HYDRAULIC FLUSHING LOOP INSTALLATION – 18RSJ ………………………………………………………………………… 256
FIGURE 7-11. HYDRAULIC DIAGRAM LIST ……………………………………………………………………………………………………………….. 258
SECTION 8 – ELECTRICAL ………………………………………………………………………………………………………………………………………….. 259
FIGURE 8-1. ELECTRICAL DIAGRAM LIST ……………………………………………………………………………………………………………….. 260
FIGURE 8-2. AC AT PLATFORM RECEPTACLE COMPONENTS – 110V GFI (ANSI EXPORT SPECS) …………………………….. 262
FIGURE 8-3. AC AT PLATFORM RECEPTACLE COMPONENTS – 220V (ANSI EXPORT SPECS) …………………………………… 264
FIGURE 8-4. AC AT PLATFORM RECEPTACLE COMPONENTS – DEALER/CUSTOMER SUPPLIED………………………………. 266
FIGURE 8-5. AC TO PLATFORM CABLE – MAIN BOOM (18RS WITHOUT SKYPOWER) ………………………………………………… 268
FIGURE 8-6. AC TO PLATFORM CABLE – MAIN BOOM (18RSJ WITHOUT SKYPOWER) ………………………………………………. 270
FIGURE 8-7. AC TO PLATFORM CABLE – MAIN BOOM (18RS WITH SKYPOWER) (Prior to SN B300001836) …………………. 272
FIGURE 8-8. AC TO PLATFORM CABLE – MAIN BOOM (18RS WITH SKYPOWER) (SN B300001836 to Present) …………….. 274
FIGURE 8-9. AC TO PLATFORM CABLE – MAIN BOOM (18RSJ WITH SKYPOWER) (Prior to SN B300001836) ……………….. 276
FIGURE 8-10. AC TO PLATFORM CABLE – MAIN BOOM (18RSJ WITH SKYPOWER) (SN B300001836 to Present) ………….. 278
FIGURE 8-11. AC TO PLATFORM CABLE – TOWER BOOM (WITHOUT SKYPOWER) …………………………………………………… 280
FIGURE 8-12. AC TO PLATFORM CABLE – TOWER BOOM (WITH SKYPOWER) (Prior to SN B300001836) …………………….. 282
FIGURE 8-13. AC TO PLATFORM CABLE – TOWER BOOM (WITH SKYPOWER) (SN B300001836 to Present) ………………… 284
FIGURE 8-14. BEACON HARNESS …………………………………………………………………………………………………………………………… 286
FIGURE 8-15. BOOM CABLES INSTALLATION – 18RS WITHOUT SKYPOWER …………………………………………………………….. 288
TABLE OF CONTENTS
3121285 18RS_18RSJ 9
FIGURE 8-16. BOOM CABLES INSTALLATION – 18RS WITH SKYPOWER …………………………………………………………………… 290
FIGURE 8-17. BOOM CABLES INSTALLATION – 18RSJ WITHOUT SKYPOWER ………………………………………………………….. 292
FIGURE 8-18. BOOM CABLES INSTALLATION – 18RSJ WITH SKYPOWER …………………………………………………………………. 294
FIGURE 8-19. BOOM HARNESS – MAIN BOOM – 18RS ………………………………………………………………………………………………. 296
FIGURE 8-20. BOOM HARNESS – MAIN BOOM – 18RSJ …………………………………………………………………………………………….. 298
FIGURE 8-21. BOOM HARNESS – TOWER BOOM …………………………………………………………………………………………………….. 300
FIGURE 8-22. CHASSIS HARNESS ………………………………………………………………………………………………………………………….. 302
FIGURE 8-23. EMR2 POWER HARNESS ………………………………………………………………………………………………………………….. 304
FIGURE 8-24. ENGINE HARNESS ……………………………………………………………………………………………………………………………. 306
FIGURE 8-25. GROUND CONTROL PANEL HARNESS – 18RS……………………………………………………………………………………. 308
FIGURE 8-26. GROUND CONTROL PANEL HARNESS – 18RSJ ………………………………………………………………………………….. 310
FIGURE 8-27. JIB HARNESS …………………………………………………………………………………………………………………………………… 312
FIGURE 8-28. LIFT DOWN HARNESS ………………………………………………………………………………………………………………………. 314
FIGURE 8-29. PLATFORM BOX HARNESS – 18RS (Prior to SN B300001836) ………………………………………………………………. 316
FIGURE 8-30. PLATFORM BOX HARNESS – 18RS (SN B300001836 to Present) …………………………………………………………… 318
FIGURE 8-31. PLATFORM BOX HARNESS – 18RSJ …………………………………………………………………………………………………… 320
FIGURE 8-32. PROXIMITY SENSOR HARNESS ………………………………………………………………………………………………………… 322
FIGURE 8-33. TURNTABLE HARNESS …………………………………………………………………………………………………………………….. 324
FIGURE 8-34. VALVE HARNESS – 18RS …………………………………………………………………………………………………………………… 328
FIGURE 8-35. VALVE HARNESS – 18RSJ …………………………………………………………………………………………………………………. 330
SECTION 9 – DECALS ………………………………………………………………………………………………………………………………………………… 333
FIGURE 9-1. DECAL INSTALLATION – ANSI SPEC ……………………………………………………………………………………………………. 334
FIGURE 9-2. DECAL INSTALLATION – BRAZIL SPEC ………………………………………………………………………………………………… 338
FIGURE 9-3. DECAL INSTALLATION – CHINESE SPEC ……………………………………………………………………………………………… 342
FIGURE 9-4. DECAL INSTALLATION – JAPANESE SPEC …………………………………………………………………………………………… 346
FIGURE 9-5. DECAL INSTALLATION – KOREAN SPEC ………………………………………………………………………………………………. 350
FIGURE 9-6. DECAL INSTALLATION – LATIN AMERICAN SPEC …………………………………………………………………………………. 354
FIGURE 9-7. DECAL INSTALLATION – OPTIONS ………………………………………………………………………………………………………. 358
SECTION 10 – RECOMMENDED SERVICE PARTS STOCK …………………………………………………………………………………………… 361
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK ………………………………………………………………………………………… 362
SECTION 11 – SPECIAL OPTIONS ………………………………………………………………………………………………………………………………. 363
FIGURE 11-1. SPECIAL OPTIONS ……………………………………………………………………………………………………………………………. 364
PART NUMBER INDEX ………………………………………………………………………………………………………………………………………………. 367

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• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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