JLG 12SP & 15SP Illustrated Parts Manual 3120776 – PDF DOWNLOAD

Illustrated Parts Manual

Models 12SP & 15SP 3120776 December 30, 2013

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REVISION LOG June 30,1999 - Original Issue Of Manual November 1, 1999 - Updated Section 1 May 1, 2000 - Revised Manual (Edited to 0010563 Revision 11) September 1, 2000 - Revised Manual (Edited to 0010563 Revision15) March 15, 2001 - Revised Manual (Edited to 0010563 Revision 18) January 15, 2002 - Revised Manual (Revised Pump and Lift Cylinders) February 1, 2002 - Revised Manual (Edited to 0010563 Revision 30) March 31, 2003 - Revised Manual (Edited to 0010563 Revision 35) June 30, 2003 - Revised Manual (Edited to 0010563 Revision 40) August 15, 2004 - Revised Manual (Edited to 0010563 Revision 47) October 16, 2006 - Revised Manual (Edited to 0010563 Revision 62) June 5, 2007 - Revised Manual (Edited to 0010563 Revision 70) November 12, 2007 - Revised Manual (Edited to 0010563 Revision 71) May 15, 2009 - Revised Manual (Edited to 0010563 Revision 76) August 1, 2010 - Revised Manual (Edited to 0010563 Revision 78) February 1, 2011 - Revised Manual (Edited to 0010563 Revision 80) May 20, 2011 - Revised Manual (Edited to 0010563 Revision 80) August 9, 2011 - Revised Manual (Edited to 0010563 Revision 80) November 21, 2011 - Revised Manual (Edited to 0010563 Revision 80) March 2, 2012 - Revised Manual (Edited to 0010563 Revision 80) July 6, 2012 - Revised Manual (Edited to 0010563 Revision 80) October 3, 2012 - Revised Manual (Edited to 0010563 Revision 80) February 7, 2013 - Revised Manual (Edited to 0010563 Revision 80) June 1, 2013 - Revised Manual (Edited to 0010563 Revision 80) September 1, 2013 - Revised Manual (Edited to 0010563 Revision 80) December 30, 2013 - Revised Manual (Edited to 0010563 Revision 80)

3120776

12SP & 15SP

A

REVISION LOG

B

12SP & 15SP

3120776

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

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

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

SECTION 2 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11

DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449) . . . . . . . . . . . . . . . . 2-2 DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT) . . . . . . . . . . . . . 2-8 DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449) . . . . . . . . . 2-12 DC MOTOR/PUMP ASSEMBLY (MONARCH) (S/N 0900027449 TO PRESENT). . . . . 2-16 BATTERY & CHARGER INSTALLATION (PRIOR TO S/N 0900031592) . . . . . . . . . . . . 2-18 BATTERY & CHARGER INSTALLATION (S/N 0900031592 TO PRESENT) . . . . . . . . . 2-22 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 4 SECTION MAST (S/N 0900015116 TO S/N 0900028704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 4 SECTION MAST (S/N 0900028704 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 5 SECTION MAST ( PRIOR TO S/N 0900015116) & ALL 15SP (PRIOR TO S/N 0900028704) . . . . . . . . 2-34 CABLE & PLATFORM CONTROLS INSTALLATION - 15SP WITH 5 SECTION MAST (S/N 0900028704 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4

MAST ASSEMBLY - 12SP WITH 4 SECTION MAST (S/N 0900015116 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAST ASSEMBLY - 12SP WITH 5 SECTION MAST (PRIOR TO S/N 0900015116). . . 3-8 MAST ASSEMBLY - 15SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 MAST MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5

STEEL BASE PLATFORM INSTALLATION (PRIOR TO S/N 0900018610) . . . . . . . . . . 4-2 STEEL BASE PLATFORM INSTALLATION (S/N 0900018610 TO PRESENT) . . . . . . . 4-6 STEEL BASE PLATFORM INSTALLATION WITH EXTENSION . . . . . . . . . . . . . . . . . . 4-10 MOLDED BASE PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 SIDE ENTRY PLATFORM WITH FOLDING TRAY INSTALLATION . . . . . . . . . . . . . . . . 4-16

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3

LIFT CYLINDER ASSEMBLY (PRIOR TO S/N 0900018391) . . . . . . . . . . . . . . . . . . . . . 5-2 LIFT CYLINDER ASSEMBLY (S/N 0900018391 TO S/N 0900029975) . . . . . . . . . . . . . 5-4 LIFT CYLINDER ASSEMBLY (S/N 0900029975 TO PRESENT) . . . . . . . . . . . . . . . . . . 5-6

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1 6-2

HYDRAULIC DIAGRAM (PRIOR TO S/N 0900027449) . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HYDRAULIC DIAGRAM (S/N 0900027449 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . 6-4

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2

3120776

ELECTRICAL DIAGRAM (PRIOR TO S/N 0900017472) . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL DIAGRAM (S/N 0900017472 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . 7-4

12SP & 15SP

i

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

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

DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii

12SP & 15SP

3120776

SECTION 1 BASE

3120776

12SP & 15SP

1-1

SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

NOTE: REPLACEMENT DECALS MUST BE ORDERED SEPARATELY – SEE SECTION 8.

104

101 107 111

102 110 109 110 110 108 103

108

109 103

102 112 105

110

108 110 114

110

301

304 303 302

401

12 402 403 405

101 106

14 11

10 6

15 21 20 17

5

512

8 1 2 201

500

509 511

506

9 1 3

1-2

507

510

508

12SP & 15SP

3120776

SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION ITEM #

1 2 3 4 5 6 7 8 9 10 11

PART NUMBER

QTY.

0259472 0271922

Ref. Ref. Ref.

BASE ASSEMBLY Prior to S/N 0900018391 S/N 0900018391 to Present

A/R 8 8

Compound, Locking Bolt 3/8in-16NC x 7/8in Bolt 1/2in-13NC x 1-1/2in

2 2

Stop, Floor Ring, Retaining

8 4 4 1

Flatwasher 3/8in Thin Flatwasher 1/2in Thin Shim Base Options: Prior to S/N 0900018391 S/N 0900018391 to Present Wheel, Rear Options: Prior to S/N 0900013574 (was p/n 4860183) (Gray Wheel) S/N 0900013574 to S/N 0900013653 (Gray Wheel) S/N 0900013653 to S/N 0900020797 (Black Wheel) S/N 0900013653 to S/N 0900020797 (Red Wheel) S/N 0900020797 to Present (Gray Wheel) Replacement Wheel Parts: Bearing for 4860202 Wheel (1 Per Wheel) Bearing for 4860208 & 4860211 Wheel(1 Per Wheel) Bearing for 4860244 Wheel (1 Per Wheel) (Note: Not Available for Purchase - Use 4860244) Retainer for 4860202 Wheel (2 Per Assembly) Retainer for 4860208, 4860211 & 4860244 Wheel (Note: Not Required) Spanner for 4860202 Wheel (1 Per Assembly) Spanner for 4860208, 4860211 & 4860244 Wheel (Note: Not Required)

0100019 0641607 0641812 Not Used 0920114 3760348 Not Used 4711600 4711800 4740456 4846025 4846534

12

2 Use 4860202 4860202 4860208 4860211 4860244

13 14 15 16 17 18 19 20 21 22 23 24

3120776

7020209 7020237 See Note

2 2 2

7020074 See Note

4 0

7012631 See Note

2 0

Not Used 0721005 1320043 Not Used 3311005 Not Used Not Used 4751000 4761000 4240032 4460234 4740415

DESCRIPTION

2 2

Screw #10-24NC x 5/8in Clamp, Cable (S/N 0900014145 to Present Only)

2

Locknut #10-24NC

4 4 5 2 2

Flatwasher #10 Regular Lockwasher #10 Tie-Strap (Not Shown) Tie-Strap (Not Shown) Flatwasher, Special

12SP & 15SP

REV. J C

1-3

SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED) ITEM #

101 102 103

PART NUMBER

QTY.

DESCRIPTION

REV.

0270399 0270491 0271924 0259357 0271923

Ref. Ref. Ref. Ref. Ref. Ref.

MAST SUPPORT INSTALLATIONS 12SP with 5 Section Mast (Prior to S/N 0900015116) 12SP with 4 Section Mast (S/N 0900015116 - S/N 0900018391) 12SP with 4 Section Mast (S/N 0900018391 to Present) 15SP (Prior to S/N 0900018391) 15SP (S/N 0900018391 to Present)

A A B B B

A/R 4 A/R

A/R 1 A/R

Adhesive Bolt 3/8in-16NC x 1-1/8in Bolt 3/8in-16NC Options: Bolt 3/8in-16NC x 1-1/4in Bolt 3/8in-16NC x 1-1/2in Mast Assembly Options (Not Shown - See Section 3 for Breakdown): 12SP with 5 Section Mast (Prior to S/N 0900015116) 12SP with 4 Section Mast (S/N 0900015116 to S/N 0900018391) 12SP with 4 Section Mast (S/N 0900018391 to Present) 15SP Prior to S/N 0900018391 15SP S/N 0900018391 to Present Decal - Manual Descent (S/N 0900018391 to Present Only) Gauge, Level Handle Locknut 3/8in-16NC Tube, Mast Brace Options: Prior to S/N 0900031592 S/N 0900031592 to Present Flatwasher 3/8in Thin Support, Mast Compound, Locking

4

Nut, Flanged 3/8in-16NC

2

FRONT WHEEL OPTIONS:

0100001 0641609 0641610 0641612

104

1 0801255 0801257

105 106 107 108 109

110 111 112 113 114

0801324 0801195 0801323 1704582 2420140 2560088 3311605 4567911 1001110174 4711600 4845715 0100011 Not Used Use 3311608

201

1 1 2 A/R 2

4860184 4860194 4860209 4860245

1-4

7020017 7020240 See Note

2 2 2

7020086

2

7020243

2

Wheel Assembly (Prior to S/N 0900013653) (Non-Locking Gray Tire & Wheel) Wheel Assembly (Prior to S/N 0900013653) (Locking Gray Tire & Wheel) Wheel Assembly (S/N 0900013653 to S/N 20797) (Non-Locking Black Tire & Gray Wheel) Wheel Assembly (S/N 0900020797 to Present) (Non-Locking Charcoal Gray Tire & Gray Wheel) Replacement Wheel Parts: Swivel Rig for 4860184 & 4860194 (1 Per Assembly) Swivel Rig for 4860209 (1 Per Assembly) Swivel Rig for 4860245 (1 Per Assembly) (Note: Not Available for Purchase - Use 4860245) Wheel, Replacement for 4860184 & 4860194 (1 Per Assembly) Wheel, Replacement for 4860209 (1 Per Assembly)

12SP & 15SP

3120776

SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED) ITEM #

PART NUMBER

QTY.

DESCRIPTION

201 cont’d

See Note

2

7020084 See Note 7012631

4 4 2

7020241 Not Available

2 2

7012630 7020242 See Note

2 2 2

Wheel, Replacement for 4860245 (1 Per Assembly) (Note: Not Available for Purchase - Use 4860245) Bearing for 4860184, 4860194 & 4860209 (2 Per Wheel) Bearing for 4860245 (2 Per Wheel) Bushing, Axle Spanner for 4860184 & 4860194 (1 Per Assembly) Bushing, Axle Spanner for 4860209 (1 Per Assembly) Bushing, Axle Spanner for 4860245 (1 Per Assembly) (Note: Not Available for Purchase - Use 4860245) Axle Kit for 4860184 & 4860194 (1 Per Assembly) Axle Kit for 4860209 (1 Per Assembly) Axle Kit for 4860245 (1 Per Assembly) (Note: Not Available for Purchase - Use 4860245)

Ref.

301 302 303 304

401 402

403 404 405

0256808 0259472/0271922

Ref. Ref.

0140033 0641406 4751400 3311405

1 2 4 4

0259447 0259472/0271922

Ref. Ref. Ref.

0721008 2920146 7016319 7016372 3311005 Not Used 4751000

DESCENT ALARM INSTALLATION Prior to S/N 0900018391 (Optional) S/N 0900018391 to Present (Standard Equipment)

BEACON ASSEMBLY Prior to S/N 0900018391 (Optional) S/N 0900018391 to Present (Standard Equipment) Screw #10-24NC x 1in Lamp, Beacon Bulb, Replacement Lens, Replacement Locknut #10-24NC

4

Flatwasher #10 Regular

4933103 0259472/0271922

Ref. Ref. Ref.

ELECTRICAL COMPONENTS (BASE MOUNTED) Prior to S/N 0900018391 S/N 0900018391 to Present

500

4922416

1

Limit Switch/Beacon Light/Alarm Harness (Includes Items 501-518)

501 to 505 506 507

Not Used 4460662

508 509 510

3120776

4360397 4360456 4360702 3911024 3311001 4751000

4 4 4

— J/C

Alarm Bolt 1/4in-20NC x 3/4in Flatwasher 1/4in Regular Nut 1/4in-20NC

2 1 1 1 2

2 2

REV.

— J/C

B J/C D

Connector, Strain Relief (Prior to S/N 0900027811) Switch, Limit Options Prior to S/N 0900013465 S/N 0900013465 to S/N 0900027811 S/N 0900027811 to Present Screw #10-24NC x 3in Nut #10-24NC Flatwasher #10 Regular

12SP & 15SP

1-5

SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED) ITEM #

PART NUMBER

QTY.

511 512 513 to 517 518

4761000 0902523 Not Used 3730099

4 2

Lockwasher #10 Bracket, Limit Switch

1

Resistor (Not Shown)

1-6

DESCRIPTION

12SP & 15SP

REV.

3120776

SECTION 2 CONTROLS

3120776

12SP & 15SP

2-1

CLICK HERE TO

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