JLG 24RS 24RSJ Parts Manual (3121288) – PDF DOWNLOAD (Eng)

Description

JLG 24RS 24RSJ Parts Manual (3121288) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 24RS 24RSJ Parts Manual (3121288) – PDF DOWNLOAD

TABLE OF CONTENTS
3121288 24RS_24RSJ 7
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 – 24RS …………………………………………………………………………………………………… 24
FIGURE 1-7. DRIVE VALVES INSTALLATION – 24RSJ …………………………………………………………………………………………………. 26
FIGURE 1-8. FLOW DIVIDER VALVE ASSEMBLY ……………………………………………………………………………………………………….. 28
FIGURE 1-9. FRAME SHIELDS INSTALLATION …………………………………………………………………………………………………………… 30
SECTION 2 – TURNTABLE ……………………………………………………………………………………………………………………………………………. 33
FIGURE 2-1. CONTROL VALVE AND HYDRAULIC FILTERS INSTALLATION – 24RS………………………………………………………. 34
FIGURE 2-2. CONTROL VALVE AND HYDRAULIC FILTERS INSTALLATION – 24RSJ …………………………………………………….. 36
FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY – 24RS ……………………………………………………………………………………………. 38
FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLY – 24RSJ ………………………………………………………………………………………….. 42
FIGURE 2-5. SWING COMPONENTS AND AUXILIARY PUMP INSTALLATIONS …………………………………………………………….. 46
FIGURE 2-6. SWING MOTOR/HUB ASSEMBLY …………………………………………………………………………………………………………… 48
FIGURE 2-7. SWING MOTOR ASSEMBLY ………………………………………………………………………………………………………………….. 52
FIGURE 2-8. AUXILIARY MOTOR/PUMP ASSEMBLY ………………………………………………………………………………………………….. 54
FIGURE 2-9. TURNTABLE BEARING INSTALLATION ………………………………………………………………………………………………….. 56
FIGURE 2-10. TURNTABLE LOCK INSTALLATION ………………………………………………………………………………………………………. 58
FIGURE 2-11. TANK INSTALLATIONS ………………………………………………………………………………………………………………………… 60
FIGURE 2-12. HYDRAULIC TANK ASSEMBLY…………………………………………………………………………………………………………….. 62
FIGURE 2-13. HYDRAULIC TANK LOCK INSTALLATION (SN B300002264 to Present) ……………………………………………………. 64
FIGURE 2-14. FUEL FILTER INSTALLATION (OPTIONAL) ……………………………………………………………………………………………. 66
FIGURE 2-15. WATER SEPARATOR FILTER ASSEMBLY (OPTIONAL) …………………………………………………………………………. 68
FIGURE 2-16. ELECTRICAL INSTALLATION – 24RS ……………………………………………………………………………………………………. 70
FIGURE 2-17. ELECTRICAL INSTALLATION – 24RSJ …………………………………………………………………………………………………… 72
FIGURE 2-18. GROUND CONTROL PANEL ASSEMBLY – 24RS……………………………………………………………………………………. 74
FIGURE 2-19. GROUND CONTROL PANEL ASSEMBLY – 24RSJ ………………………………………………………………………………….. 76
FIGURE 2-20. KEY SWITCH ASSEMBLY ……………………………………………………………………………………………………………………. 78
FIGURE 2-21. GROUND CONTROL DOOR INSTALLATION (OPTIONAL) ………………………………………………………………………. 80
FIGURE 2-22. ELECTRICAL PANEL ASSEMBLY …………………………………………………………………………………………………………. 82
FIGURE 2-23. LIMIT SWITCH INSTALLATION – 24RS ………………………………………………………………………………………………….. 84
FIGURE 2-24. LIMIT SWITCH INSTALLATION – 24RSJ ………………………………………………………………………………………………… 86
FIGURE 2-25. BEACON LIGHT INSTALLATION (OPTIONAL) ……………………………………………………………………………………….. 88
FIGURE 2-26. HOODS INSTALLATION ………………………………………………………………………………………………………………………. 90
FIGURE 2-27. CENTER HOOD ASSEMBLY (ENGINE SIDE) …………………………………………………………………………………………. 94
FIGURE 2-28. CENTER HOOD ASSEMBLY (TANK SIDE) …………………………………………………………………………………………….. 96
SECTION 3 – ENGINE ………………………………………………………………………………………………………………………………………………….. 99
FIGURE 3-1. DEUTZ ENGINE INSTALLATION …………………………………………………………………………………………………………… 100
FIGURE 3-2. ENGINE AND PUMP ASSEMBLY ………………………………………………………………………………………………………….. 102
FIGURE 3-3. ENGINE ASSEMBLY ……………………………………………………………………………………………………………………………. 104
FIGURE 3-4. ENGINE COMPONENTS (Prior to SN B300001631) ………………………………………………………………………………… 108
FIGURE 3-5. ENGINE COMPONENTS (SN B300001631 to Present) …………………………………………………………………………….. 112
FIGURE 3-6. PUMP COUPLING INSTALLATION………………………………………………………………………………………………………… 116
FIGURE 3-7. PISTON PUMP ASSEMBLY ………………………………………………………………………………………………………………….. 118
FIGURE 3-8. BATTERY INSTALLATION ……………………………………………………………………………………………………………………. 122
SECTION 4 – BOOM …………………………………………………………………………………………………………………………………………………… 125
FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION – 24RS …………………………………………………………………………………… 126
FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION – 24RSJ ………………………………………………………………………………….. 130
FIGURE 4-3. MAIN BOOM ASSEMBLY – 24RS …………………………………………………………………………………………………………… 134
FIGURE 4-4. MAIN BOOM ASSEMBLY – 24RSJ …………………………………………………………………………………………………………. 138
FIGURE 4-5. JIB ASSEMBLY – 24RSJ ……………………………………………………………………………………………………………………….. 142
FIGURE 4-6. POWER TRACK ASSEMBLY ………………………………………………………………………………………………………………… 144
FIGURE 4-7. PROXIMITY SWITCH INSTALLATION – 24RS …………………………………………………………………………………………. 146
FIGURE 4-8. PROXIMITY SWITCH INSTALLATION – 24RSJ ……………………………………………………………………………………….. 148
FIGURE 4-9. PLATFORM ROTATOR ASSEMBLY – 24RS ……………………………………………………………………………………………. 150
FIGURE 4-10. PLATFORM ROTATOR ASSEMBLY – 24RSJ ………………………………………………………………………………………… 152
TABLE OF CONTENTS
8 24RS_24RSJ 3121288
FIGURE 4-11. PLATFORM SUPPORT INSTALLATION – WITHOUT LSS – 24RS …………………………………………………………….. 154
FIGURE 4-12. PLATFORM SUPPORT INSTALLATION – WITHOUT LSS – 24RSJ …………………………………………………………… 156
FIGURE 4-13. PLATFORM SUPPORT INSTALLATION (24RS) – WITH LSS …………………………………………………………………… 158
FIGURE 4-14. CLAMPS INSTALLATION (BOOM) – 24RS …………………………………………………………………………………………….. 160
FIGURE 4-15. CLAMPS INSTALLATION (BOOM) – 24RSJ …………………………………………………………………………………………… 162
FIGURE 4-16. PLATFORM SUPPORT INSTALLATION (24RSJ) – WITH LSS …………………………………………………………………. 164
SECTION 5 – PLATFORM ……………………………………………………………………………………………………………………………………………. 167
FIGURE 5-1. PLATFORM ASSEMBLY ……………………………………………………………………………………………………………………….. 168
FIGURE 5-2. PLATFORM ASSEMBLY – 30IN X 3FT (76CM X .91M) – DROP BAR ENTRY (USA BUILT MACHINES)………….. 170
FIGURE 5-3. PLATFORM ASSEMBLY – 3FT X 6FT (91.5CM X 1.83M) WITH TRI-ENTRY (1 GATE / 2 DROP BARS) …………. 172
FIGURE 5-4. PLATFORM ASSEMBLY – 3FT X 6FT (91.5CM X 1.83M) WITH TRI-ENTRY (3 DROP BARS) ………………………. 174
FIGURE 5-5. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – 24RS…………………………………………………………. 176
FIGURE 5-6. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – 24RSJ (Prior to SN B300001777) ………………….. 178
FIGURE 5-7. PLATFORM CONSOLE ASSEMBLY – 24RS (Prior to SN B300001446) ………………………………………………………. 180
FIGURE 5-8. PLATFORM CONSOLE ASSEMBLY – 24RS (SN B300001446 to Present) ………………………………………………….. 184
FIGURE 5-9. PLATFORM CONSOLE ASSEMBLY – 24RSJ ………………………………………………………………………………………….. 188
FIGURE 5-10. CONSOLE BOX ASSEMBLY (Prior to SN B300001777) ………………………………………………………………………….. 192
FIGURE 5-11. CONSOLE BOX ASSEMBLY (SN B300001777 through B300002342) ………………………………………………………. 194
FIGURE 5-12. CONSOLE BOX ASSEMBLY (SN B300001540 to Present) ……………………………………………………………………… 196
FIGURE 5-13. CONSOLE BOX ASSEMBLY (SN B300002343 to Present) ……………………………………………………………………… 198
FIGURE 5-14. CONTROLLER ASSEMBLY (LIFT AND SWING) ……………………………………………………………………………………. 200
FIGURE 5-15. CONTROLLER ASSEMBLY (LIFT AND SWING) ……………………………………………………………………………………. 202
FIGURE 5-16. CONTROLLER ASSEMBLY (DRIVE AND STEER) …………………………………………………………………………………. 206
FIGURE 5-17. CONTROLLER ASSEMBLY (DRIVE AND STEER) …………………………………………………………………………………. 208
SECTION 6 – CYLINDER ……………………………………………………………………………………………………………………………………………… 211
FIGURE 6-1. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – 24RS ……………………………………………………………………. 212
FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – 24RSJ ………………………………………………………………….. 214
FIGURE 6-3. LIFT CYLINDER ASSEMBLY – JIB – 24RSJ (Prior to SN B300002343) ……………………………………………………….. 216
FIGURE 6-4. LIFT CYLINDER ASSEMBLY – JIB (SN B300002343 through B300002879)…………………………………………………. 218
FIGURE 6-5. LIFT CYLINDER ASSEMBLY – JIB (SN B300002880 to Present) ………………………………………………………………… 220
FIGURE 6-6. LIFT CYLINDER ASSEMBLY – MAIN BOOM ……………………………………………………………………………………………. 222
FIGURE 6-7. MASTER CYLINDER ASSEMBLY – 24RS ……………………………………………………………………………………………….. 224
FIGURE 6-8. MASTER CYLINDER ASSEMBLY – 24RSJ ……………………………………………………………………………………………… 226
FIGURE 6-9. STEER CYLINDER ASSEMBLY …………………………………………………………………………………………………………….. 228
FIGURE 6-10. TELESCOPE CYLINDER ASSEMBLY – 24RS ………………………………………………………………………………………… 230
FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY – 24RSJ ………………………………………………………………………………………. 232
FIGURE 6-12. VALVE BLOCK ASSEMBLY …………………………………………………………………………………………………………………. 234
SECTION 7 – HYDRAULIC …………………………………………………………………………………………………………………………………………… 237
FIGURE 7-1. HYDRAULIC INSTALLATION (FRONT AXLE) – 24RS……………………………………………………………………………….. 238
FIGURE 7-2. HYDRAULIC INSTALLATION (FRONT AXLE) – 24RSJ ……………………………………………………………………………… 242
FIGURE 7-3. HYDRAULIC INSTALLATION (REAR AXLE) – 24RS …………………………………………………………………………………. 246
FIGURE 7-4. HYDRAULIC INSTALLATION (REAR AXLE) – 24RSJ ……………………………………………………………………………….. 250
FIGURE 7-5. HYDRAULIC INSTALLATION (BOOM) – 24RS …………………………………………………………………………………………. 254
FIGURE 7-6. HYDRAULIC INSTALLATION (BOOM) – 24RSJ ……………………………………………………………………………………….. 258
FIGURE 7-7. HYDRAULIC INSTALLATION (DRIVE PUMP) – 24RS ……………………………………………………………………………….. 262
FIGURE 7-8. HYDRAULIC INSTALLATION (DRIVE PUMP) – 24RSJ ……………………………………………………………………………… 266
FIGURE 7-9. HYDRAULIC DIAGRAM LIST …………………………………………………………………………………………………………………. 270
SECTION 8 – ELECTRICAL ………………………………………………………………………………………………………………………………………….. 271
FIGURE 8-1. ELECTRICAL DIAGRAM LIST ……………………………………………………………………………………………………………….. 272
FIGURE 8-2. AC AT PLATFORM RECEPTACLE COMPONENTS – 110V GFI (ANSI EXPORT SPECS) …………………………….. 274
FIGURE 8-3. AC AT PLATFORM RECEPTACLE COMPONENTS – 220V (ANSI EXPORT SPECS) …………………………………… 276
FIGURE 8-4. AC AT PLATFORM RECEPTACLE COMPONENTS – DEALER/CUSTOMER SUPPLIED………………………………. 278
FIGURE 8-5. AC CABLE – MAIN BOOM (WITHOUT SKYPOWER) – 24RS ……………………………………………………………………… 280
FIGURE 8-6. AC CABLE – MAIN BOOM (WITH SKYPOWER) – 24RS (Prior to SN B300002343) ………………………………………. 282
FIGURE 8-7. AC CABLE – MAIN BOOM (WITH SKYPOWER) – 24RS (SN B300002343 to Present) …………………………………… 284
FIGURE 8-8. AC CABLE – MAIN BOOM (WITHOUT SKYPOWER) – 24RSJ ……………………………………………………………………. 286
FIGURE 8-9. AC CABLE – MAIN BOOM (WITH SKYPOWER) – 24RSJ (Prior to SN B300002343) ……………………………………… 288
FIGURE 8-10. AC CABLE – MAIN BOOM (WITH SKYPOWER) – 24RSJ (SN B300002343 to Present) ……………………………….. 290
FIGURE 8-11. AC CABLE – TOWER BOOM (WITHOUT SKYPOWER) …………………………………………………………………………… 292
TABLE OF CONTENTS
3121288 24RS_24RSJ 9
FIGURE 8-12. AC CABLE – TOWER BOOM (WITH SKYPOWER) (Prior to SN B300002343) ……………………………………………. 294
FIGURE 8-13. AC CABLE – TOWER BOOM (WITH SKYPOWER) (SN B300002343 to Present) ……………………………………….. 296
FIGURE 8-14. BEACON HARNESS …………………………………………………………………………………………………………………………… 298
FIGURE 8-15. BOOM CABLES INSTALLATION – 24RS WITHOUT SKYPOWER ……………………………………………………………. 300
FIGURE 8-16. BOOM CABLES INSTALLATION – 24RS WITH SKYPOWER …………………………………………………………………… 302
FIGURE 8-17. BOOM CABLES INSTALLATION – 24RSJ WITHOUT SKYPOWER ………………………………………………………….. 304
FIGURE 8-18. BOOM CABLES INSTALLATION – 24RSJ WITH SKYPOWER …………………………………………………………………. 306
FIGURE 8-19. BOOM HARNESS – MAIN BOOM – 24RS ………………………………………………………………………………………………. 308
FIGURE 8-20. BOOM HARNESS – MAIN BOOM – 24RSJ …………………………………………………………………………………………….. 310
FIGURE 8-21. BOOM HARNESS – TOWER BOOM …………………………………………………………………………………………………….. 312
FIGURE 8-22. CHASSIS HARNESS ………………………………………………………………………………………………………………………….. 314
FIGURE 8-23. EMR2 POWER HARNESS ………………………………………………………………………………………………………………….. 316
FIGURE 8-24. ENGINE HARNESS ……………………………………………………………………………………………………………………………. 318
FIGURE 8-25. GROUND CONTROL PANEL HARNESS – 24RS……………………………………………………………………………………. 320
FIGURE 8-26. GROUND CONTROL PANEL HARNESS – 24RSJ ………………………………………………………………………………….. 322
FIGURE 8-27. JIB HARNESS …………………………………………………………………………………………………………………………………… 324
FIGURE 8-28. LIFT DOWN HARNESS ………………………………………………………………………………………………………………………. 326
FIGURE 8-29. PLATFORM BOX HARNESS ASSEMBLY – 24RS (Prior to SN B300002343) …………………………………………….. 328
FIGURE 8-30. PLATFORM BOX HARNESS – 24RS (SN B300002343 to Present) …………………………………………………………… 330
FIGURE 8-31. PLATFORM BOX HARNESS ASSEMBLY – 24RSJ…………………………………………………………………………………. 332
FIGURE 8-32. PROXIMITY SENSOR HARNESS ………………………………………………………………………………………………………… 334
FIGURE 8-33. TELESCOPE HARNESS – MAIN BOOM – 24RSJ …………………………………………………………………………………… 336
FIGURE 8-34. TELESCOPE HARNESS – TOWER BOOM – 24RSJ ……………………………………………………………………………….. 338
FIGURE 8-35. TURNTABLE HARNESS …………………………………………………………………………………………………………………….. 340
FIGURE 8-36. VALVE HARNESS – 24RS …………………………………………………………………………………………………………………… 344
FIGURE 8-37. VALVE HARNESS – 24RSJ …………………………………………………………………………………………………………………. 346
SECTION 9 – DECALS ………………………………………………………………………………………………………………………………………………… 349
FIGURE 9-1. DECAL INSTALLATION – ANSI SPEC ……………………………………………………………………………………………………. 350
FIGURE 9-2. DECAL INSTALLATION – BRAZIL SPEC ………………………………………………………………………………………………… 354
FIGURE 9-3. DECAL INSTALLATION – CHINESE SPEC ……………………………………………………………………………………………… 358
FIGURE 9-4. DECAL INSTALLATION – JAPANESE SPEC …………………………………………………………………………………………… 362
FIGURE 9-5. DECAL INSTALLATION – KOREAN SPEC ………………………………………………………………………………………………. 366
FIGURE 9-6. DECAL INSTALLATION – LATIN AMERICAN SPEC …………………………………………………………………………………. 370
FIGURE 9-7. DECAL INSTALLATION – OPTIONS ………………………………………………………………………………………………………. 374
SECTION 10 – RECOMMENDED SERVICE PARTS STOCK …………………………………………………………………………………………… 377
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK ………………………………………………………………………………………… 378
SECTION 11 – SPECIAL OPTIONS ………………………………………………………………………………………………………………………………. 379
FIGURE 11-1. SPECIAL OPTIONS ……………………………………………………………………………………………………………………………. 380
PART NUMBER INDEX ………………………………………………………………………………………………………………………………………………. 383

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 PLEASE NOTE:

• 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.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]