JLG Telehandler 919 Parts Manual 3122243500

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JLG Telehandler 919 Parts Manual 3122243500
Size: 38.26 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Parts Manual
Model: JLG 919 Telehandler
Part Number: 3122243500
Publication Date: 2025
Number of Pages: 584 Pages

Contents:
SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME COMPONENTS INSTALLATION​

FIGURE 1-2. FRAME COVERS ASSEMBLY​

FIGURE 1-3. ENCLOSURE INSTALLATION​

FIGURE 1-4. FUEL TANK INSTALLATION​

FIGURE 1-5. HOOD INSTALLATION​

FIGURE 1-6. HYDRAULIC TANK INSTALLATION​

FIGURE 1-7. TANK ASSEMBLY - FUEL​

FIGURE 1-8. TANK ASSEMBLY - HYDRAULIC​

SECTION 2 - BOOM

FIGURE 2-1. BOOM INSTALLATION​

FIGURE 2-2. BOOM ASSEMBLY​

FIGURE 2-3. BOOM BASE ASSEMBLY​

FIGURE 2-4. BOOM FLY ASSEMBLY​

FIGURE 2-5. BOOM ANGLE INDICATOR INSTALLATION​

FIGURE 2-6. BOOM PROP INSTALLATION​

FIGURE 2-7. COUPLER INSTALLATION (HYDRAULIC)​

FIGURE 2-8. COUPLER INSTALLATION - UNIVERSAL (HYDRAULIC)​

FIGURE 2-9. COUPLER ASSEMBLY - UNIVERSAL​

FIGURE 2-10. COUPLER INSTALLATION (MANUAL)​

FIGURE 2-11. COUPLER INSTALLATION, UNIVERSAL (MANUAL)​

FIGURE 2-12. FORK LOCKING CYLINDER KIT​

FIGURE 2-13. TELESCOPE CYLINDER INSTALLATION​

SECTION 3 - ATTACHMENTS

FIGURE 3-1. BASKET, PERSONNEL (1.2MX2.4M) (DOMESTIC)​

FIGURE 3-2. BASKET, PERSONNEL (1.2MX2.4M) (ISO)​

FIGURE 3-3. BASKET, PERSONNEL (1.2MX2.4M) (FRENCH)​

FIGURE 3-4. BOLT-ON EDGE ASSEMBLY, 72"​

FIGURE 3-5. CARRIAGE, SIDE TILT, (48IN)​

FIGURE 3-6. CARRIAGE, SIDE TILT, UNIVERSAL QUICK ATTACH, (48IN)​

FIGURE 3-7. CARRIAGE, SIDE SHIFT (48IN)​

FIGURE 3-8. CARRIAGE, SIDE SHIFT, UNIVERSAL QUICK ATTACH, (48IN)​

FIGURE 3-9. CARRIAGE ASSEMBLY - 48IN STANDARD​

FIGURE 3-10. CARRIAGE ASSEMBLY - 48IN UNIVERSAL​

FIGURE 3-11. CARRIAGE ASSEMBLY - FORK POSITIONING STANDARD (48IN)​

FIGURE 3-12. CARRIAGE ASSEMBLY - FORK POSITIONING UNIVERSAL (48IN)​

FIGURE 3-13. FORK MOUNTED HOOK (4 TON)​

FIGURE 3-14. FORK MOUNTED PLATFORM​

FIGURE 3-15. FORK 2.00X4X48 / 3800# CAPACITY​

FIGURE 3-16. FORK 2.00X5X60 / 6850# CAPACITY (SN 0160140396 to Present)​

FIGURE 3-17. FORK 2.36 X5X72 / 6850# CAPACITY (SN 0160140396 to Present)​

FIGURE 3-18. LIFTING HOOK ASSEMBLY, STANDARD​

FIGURE 3-19. LIFTING HOOK ASSEMBLY, UNIVERSAL​

FIGURE 3-20. LIGHT MATERIAL BUCKET, (72INCH) (1.7 YD³/1.29 M³)​

FIGURE 3-21. LIGHT MATERIAL BUCKET, (72INCH) (1.0 YD³/0.76 M³)​

FIGURE 3-22. MULTI-PURPOSE GRAPPLE BUCKET (1850MM)​

FIGURE 3-23. UNIVERSAL HITCH ATTACHMENT​

FIGURE 3-24. QUICK SWITCH ASSEMBLY​

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE ASSEMBLY (HRC)​

FIGURE 4-2. ENGINE ASSEMBLY (LRC)​

FIGURE 4-3. ENGINE MOUNTS INSTALLATION​

FIGURE 4-4. ENGINE WIRING INSTALLATION​

FIGURE 4-5. ENGINE AIR INTAKE INSTALLATION​

FIGURE 4-6. ENGINE FUEL LINES INSTALLATION​

FIGURE 4-7. ENGINE PUMP ADAPTOR INSTALLATION​

FIGURE 4-8. ENGINE PUMP INSTALLATION​

FIGURE 4-9. ENGINE MODULE INSTALLATION​

FIGURE 4-10. ENGINE COOLING INSTALLATION​

FIGURE 4-11. ENGINE EXHAUST INSTALLATION​

FIGURE 4-12. ENGINE HEATER INSTALLATION​

FIGURE 4-13. AIR CLEANER ASSEMBLY​

FIGURE 4-14. AC LINES INSTALLATION​

FIGURE 4-15. AC PUMP INSTALLATION​

FIGURE 4-16. COOLANT EXPANSION TANK INSTALLATION​

FIGURE 4-17. COOLANT LINES INSTALLATION​

FIGURE 4-18. FAN GUARD INSTALLATION​

FIGURE 4-19. FAN INSTALLATION - COOLING​

FIGURE 4-20. HEATER HOSE INSTALLATION​

FIGURE 4-21. RADIATOR ASSEMBLY​

FIGURE 4-22. QUICKFIT OIL CHANGE ASSEMBLY​

SECTION 5 - DRIVE TRAIN

FIGURE 5-1. FRONT AXLE ASSEMBLY​

FIGURE 5-2. FRONT AXLE ASSEMBLY - CENTER HOUSING​

FIGURE 5-3. FRONT AXLE ASSEMBLY - DIFFERENTIAL​

FIGURE 5-4. FRONT AXLE ASSEMBLY - HUB REDUCTION (LH)​

FIGURE 5-5. FRONT AXLE ASSEMBLY - HUB REDUCTION (RH)​

FIGURE 5-6. FRONT AXLE ASSEMBLY - BRAKES​

FIGURE 5-7. FRONT AXLE ASSEMBLY - STEERING​

FIGURE 5-8. AXLE ASSEMBLY - REAR​

FIGURE 5-9. REAR AXLE ASSEMBLY - CENTER HOUSING​

FIGURE 5-10. REAR AXLE ASSEMBLY - DIFFERENTIAL​

FIGURE 5-11. REAR AXLE ASSEMBLY - HUB REDUCTION (LH)​

FIGURE 5-12. REAR AXLE ASSEMBLY - HUB REDUCTION (RH)​

FIGURE 5-13. REAR AXLE ASSEMBLY - STEERING​

FIGURE 5-14. REAR AXLE ASSEMBLY - TRUNION​

FIGURE 5-15. DRIVE TRAIN INSTALLATION​

FIGURE 5-16. DRIVE MOTER INSTALLATION​

FIGURE 5-17. FENDER INSTALLATION​

FIGURE 5-18. FENDER INSTALLATION (CAB)​

FIGURE 5-19. FENDER ASSEMBLY (Prior to SN 0160141665)​

FIGURE 5-20. FENDER ASSEMBLY (SN 0160141666 to Present)​

FIGURE 5-21. TIRE SET - 12 X 16.5 PHUEMATIC​

FIGURE 5-22. TIRE SET - 12 X 16.5 FOAM-FILLED​

FIGURE 5-23. TIRE SET - 33 X 12-20 NON MARKING​

FIGURE 5-24. TIRE SET - 33 X 16 TURF​

FIGURE 5-25. TIRE SET - 33 X 16 AG​

FIGURE 5-26. RIGHT TIRE/WHEEL ASSEMBLY, CAMSO (AIR 12-16.5 - 12 PLY)​

FIGURE 5-27. LEFT TIRE/WHEEL ASSEMBLY, CAMSO (AIR 12-16.5 - 12 PLY)​

SECTION 6 - CAB

FIGURE 6-1. CAB TRIM INSTALLATION - OPEN CAB (Prior to SN 0160139500)​

FIGURE 6-2. CAB TRIM INSTALLATION - OPEN CAB (SN 0160139501 to Present)​

FIGURE 6-3. CAB TRIM INSTALLATION - CLOSED CAB (Prior to SN 0160139500)​

FIGURE 6-4. CAB TRIM INSTALLATION - CLOSED CAB (SN 0160139501 to Present)​

FIGURE 6-5. CAB ASSEMBLY - OPEN CAB​

FIGURE 6-6. CAB ASSEMBLY - CLOSED CAB (Prior to SN 0160145681)​

FIGURE 6-7. CAB ASSEMBLY - CLOSED CAB (SN 0160145682 to Present)​

FIGURE 6-8. CAB NO HEAT INSTALLATION​

FIGURE 6-9. CAB HEATER INSTALLATION​

FIGURE 6-10. CAB HEATER/AC INSTALLATION​

FIGURE 6-11. CAB MAT INSTALLATION​

FIGURE 6-12. CAB MOUNTS INSTALLATION​

FIGURE 6-13. CAB DUCT INSTALLATION​

FIGURE 6-14. CAB GUARD INSTALLATION (TOP)​

FIGURE 6-15. CAB GUARD INSTALLATION (FRONT)​

FIGURE 6-16. AC CONDENSER INSTALLATION​

FIGURE 6-17. A/C RECEIVER DRIER​

FIGURE 6-18. ARMREST/CONSOLE INSTALLATION​

FIGURE 6-19. COLUMN SHIFT INSTALLATION​

FIGURE 6-20. CONDENSER​

FIGURE 6-21. DECAL INSTALLATION - EMERGENCY EXIT​

FIGURE 6-22. DOOR ASSEMBLY - CAB​

FIGURE 6-23. FIRE EXTINGUISHER INSTALLATION​

FIGURE 6-24. HEADLINER INSTALLATION (Prior to SN 0160142888)​

FIGURE 6-25. HEADLINER INSTALLATION (SN 0160142889 to Present)​

FIGURE 6-26. HEATER INSTALLATION - HEAT/AC​

FIGURE 6-27. HEATER INSTALLATION - HEAT ONLY​

FIGURE 6-28. HEATER ASSEMBLY - HEAT ONLY​

FIGURE 6-29. HEATER ASSEMBLY - HEAT/AC​

FIGURE 6-30. LEVEL INDICATOR INSTALLATION​

FIGURE 6-31. MIRROR INSTALLATION​

FIGURE 6-32. MIRRORS INSTALLATION​

FIGURE 6-33. MOTOR ASSEMBLY - WIPER​

FIGURE 6-34. NO ENGINE SPEED SET SWITCH INSTALLATION​

FIGURE 6-35. SEAT INSTALLATION - STANDARD​

FIGURE 6-36. SEAT INSTALLATION - SEAOP​

FIGURE 6-37. SEAT ASSEMBLY - STANDARD​

FIGURE 6-38. SEAT ASSEMBLY - VINYL​

FIGURE 6-39. SEAT BELT INSTALLATION (2IN) (Prior to SN 0160146763)​

FIGURE 6-40. SEAT BELT INSTALLATION (3IN)​

FIGURE 6-41. SECONDARY EXIT INSTALLATION (CA SPECS)​

FIGURE 6-42. SECONDARY EXIT INSTALLATION (ANSI SPECS)​

FIGURE 6-43. SECONDARY EXIT INSTALLATION (ISO SPECS)​

FIGURE 6-44. SECONDARY EXIT INSTALLATION (ENGLISH/SPANISH LANGUAGES)​

FIGURE 6-45. STEERING COLUMN INSTALLATION - FIXED​

FIGURE 6-46. STEERING COLUMN ASSEMBLY - FIXED​

FIGURE 6-47. STEERING COLUMN INSTALLATION - TILT​

FIGURE 6-48. STEERING COLUMN ASSEMBLY - TILT​

FIGURE 6-49. STEERING WHEEL INSTALLATION​

FIGURE 6-50. WASHER HOSE PASS THROUGH INSTALLATION​

FIGURE 6-51. WINDOW WASHER INSTALLATION​

FIGURE 6-52. WINDOW ASSEMBLY - REAR​

FIGURE 6-53. WIPER INSTALLATION - FRONT​

FIGURE 6-54. WIPER INSTALLATION - REAR WINDOW​

FIGURE 6-55. WIPER INSTALLATION - ROOF​

SECTION 7 - CONTROLS

FIGURE 7-1. JOYSTICK INSTALLATION​

FIGURE 7-2. PEDAL INSTALLATION - ACCELERATOR​

FIGURE 7-3. BRAKE PEDAL INSTALLATION​

FIGURE 7-4. BRAKE PEDAL ASSEMBLY​

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. BOOM HYDRAULIC INSTALLATION​

FIGURE 8-2. HOSE INSTALLATION - BOOM​

FIGURE 8-3. HOSE INSTALLATION - CAB​

FIGURE 8-4. HOSE INSTALLATION - ENGINE BAY​

FIGURE 8-5. HOSE INSTALLATION - FRAME​

SECTION 9 - HYDRAULIC COMPONENTS

FIGURE 9-1. BOOM AUX HYDRAULIC INSTALLATION (MANUAL - SINGLE)​

FIGURE 9-2. BOOM AUX HYDRAULIC INSTALLATION (HYDRAULIC - TWIN)​

FIGURE 9-3. BOOM AUX HYDRAULIC INSTALLATION (FLAT FACE)​

FIGURE 9-4. BOOM AUX HYDRAULIC INSTALLATION (UNIVERSAL COUPLER)​

FIGURE 9-5. BOOM AUXILIARY HYDRAULIC VALVE INSTALLATION​

FIGURE 9-6. CYLINDERS INSTALLATION (Prior to SN 0160142888)​

FIGURE 9-7. CYLINDERS INSTALLATION (SN 0160142889 to Present)​

FIGURE 9-8. CYLINDER ASSEMBLY - COMP (Prior to SN 0160142888)​

FIGURE 9-9. CYLINDER ASSEMBLY - COMP (SN 0160142889 to Present)​

FIGURE 9-10. CYLINDER ASSEMBLY - EXTEND/RETRACT​

FIGURE 9-11. CYLINDER ASSEMBLY - FORK LOCKING​

FIGURE 9-12. CYLINDER ASSEMBLY - FORK POSITIONING​

FIGURE 9-13. CYLINDER ASSEMBLY - LIFT (Prior to SN 0160142888)​

FIGURE 9-14. CYLINDER ASSEMBLY - LIFT (SN 0160142889 to Present)​

FIGURE 9-15. CYLINDER ASSEMBLY - SIDE TILT CARRIAGE​

FIGURE 9-16. CYLINDER ASSEMBLY - TILT​

FIGURE 9-17. CYLINDER ASSEMBLY - UNIVERSAL SIDE SHIFT​

FIGURE 9-18. DIVERTOR VALVE​

FIGURE 9-19. DRIVE MOTOR ASSEMBLY​

FIGURE 9-20. MAIN CONTROL VALVE INSTALLATION​

FIGURE 9-21. MAIN CONTROL VALVE ASSEMBLY (Prior to SN 0160141920)​

FIGURE 9-22. MAIN CONTROL VALVE ASSEMBLY (SN 0160141921 to Present)​

FIGURE 9-23. PRIORITY VALVE INSTALLATION​

FIGURE 9-24. PRIORITY VALVE ASSEMBLY​

FIGURE 9-25. PUMP ASSEMBLY​

FIGURE 9-26. PUMP ASSEMBLY​

FIGURE 9-27. REMOTE GREASE INSTALLATION​

FIGURE 9-28. SAHR BRAKE VALVE INSTALLATION​

FIGURE 9-29. SAHR VALVE INSTALLATION​

FIGURE 9-30. SAHR BRAKE VALVE AND FITTING ASSEMBLY​

FIGURE 9-31. STEERING SELECT VALVE INSTALLATION​

FIGURE 9-32. STEERING SELECT VALVE ASSEMBLY​

FIGURE 9-33. STEER VALVE ASSEMBLY​

FIGURE 9-34. WATCH DOG VALVE INSTALLATION​

FIGURE 9-35. WATCH DOG VALVE AND FITTING ASSEMBLY​

FIGURE 9-36. VALVE AUX HYDRAULIC INSTALLATION​

FIGURE 9-37. VALVE ASSEMBLY - MAIN CONTROL VALVE (Prior to SN 0160141920)​

FIGURE 9-38. MAIN CONTROL VALVE ASSEMBLY (SN 0160141921 to Present)​

FIGURE 9-39. VALVE ASSEMBLY - STEERING SELECT​

FIGURE 9-40. VALVE ASSEMBLY - WATCHDOG​

FIGURE 9-41. VALVE ASSEMBLY, - BLOCK​

SECTION 10 - ELECTRICAL

FIGURE 10-1. A/C OPTION HARNESS​

FIGURE 10-2. ALARM INSTALLATION - BACK UP​

FIGURE 10-3. ALARM INSTALLATION - WHITE NOISE​

FIGURE 10-4. BATTERY INSTALLATION​

FIGURE 10-5. BATTERY DISCONNECT INSTALLATION​

FIGURE 10-6. BATTERY DISCONNECT INSTALLATION (SWITCH NONE)​

FIGURE 10-7. CLEARSKY CS550 BEACON INSTALLATION (WITHOUT A/C)​

FIGURE 10-8. CLEARSKY CS550 BEACON INSTALLATION (WITH A/C)​

FIGURE 10-9. CLEARSKY HARNESS - CS550 BEACON​

FIGURE 10-10. BEACON WORKLIGHT HARNESS​

FIGURE 10-11. BOOM WORKLIGHT JUMPER HARNESS​

FIGURE 10-12. BOOM AUX HARNESS​

FIGURE 10-13. CAB ELECTRICAL INSTALLATION​

FIGURE 10-14. CAB HARNESS​

FIGURE 10-15. CAB HARNESS (ENCLOSED CAB)​

FIGURE 10-16. CAB HARNESS - OPTION​

FIGURE 10-17. CAMERA INSTALLATION - REVERSE​

FIGURE 10-18. DASH SWITCHES INSTALLATION​

FIGURE 10-19. ENGINE HARNESS​

FIGURE 10-20. FRAME ELECTRICAL COMPONENTS INSTALLATION​

FIGURE 10-21. FRAME HARNESS INSTALLATION​

FIGURE 10-22. FRAME HARNESS​

FIGURE 10-23. FRAME HARNESS​

FIGURE 10-24. FUSEBOX ASSEMBLY - FRAME​

FIGURE 10-25. HEADLIGHTS HARNESS​

FIGURE 10-26. HEADLIGHT/WORKLIGHT OPTIONAL HARNESS​

FIGURE 10-27. LIGHTS - ROADLIGHTS INSTALLATION​

FIGURE 10-28. LIGHTS - WORKLIGHTS INSTALLATION​

FIGURE 10-29. LSI INSTALLATION - OPEN CAB​

FIGURE 10-30. LSI INSTALLATION - ENCLOSED CAB​

FIGURE 10-31. LSI SENSOR INSTALLATION​

FIGURE 10-32. LSI OVERRIDE HARNESS (SN 0160146255 to Present)​

FIGURE 10-33. LSI PIGTAIL HARNESS​

FIGURE 10-34. REVERSE SENSING INSTALLATION​

FIGURE 10-35. REVERSE SENSOR HARNESS​

FIGURE 10-36. SEAT BELT ALARM HARNESS​

FIGURE 10-37. TAILLIGHTS HARNESS​

FIGURE 10-38. VALVE JUMPER HARNESS​

SECTION 11 - DECALS

FIGURE 11-1. DECALS INSTALLATION - INFO (ANSI SPECS)​

FIGURE 11-2. DECALS INSTALLATION - INFO (ISO SPECS)​

FIGURE 11-3. DECALS INSTALLATION - INFO (ENGLISH/FRENCH LANGUAGES)​

FIGURE 11-4. DECALS INSTALLATION - INFO (ENGLISH/SPANISH LANGUAGES)​

FIGURE 11-5. DECALS INSTALLATION - BRAND (OPEN CAB)​

FIGURE 11-6. DECALS INSTALLATION - BRAND (CLOSED CAB)​

FIGURE 11-7. DECAL INSTALLATION - CLEARSKY CS550 BEACON​

FIGURE 11-8. LOAD CHART (ANSI SPECS)​

FIGURE 11-9. LOAD CHART (METRIC SPECS)​

FIGURE 11-10. REVERSE SENSOR SYSTEM DECAL (ENGLISH)​

FIGURE 11-11. REVERSE SENSOR SYSTEM DECAL (ISO)​

FIGURE 11-12. REVERSE SENSING SYSTEM DECAL, (ENGLISH/FRENCH)​

FIGURE 11-13. REVERSE SENSOR SYSTEM DECAL (ENGLISH/SPANISH)​

SECTION 12 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 12-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 13 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 13-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX