Jlg 15SP Service Manual- Manuals

Jlg 15SP Service Manual– User Manual in PDF format online.

Manuals:

User Manual

User Manual Jlg 15SP Service Manual

Summary

Page 3 - FOREWORD; READ; UNDERSTOOD; before any attempt is made to operate the; YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL; and; NOTE; are defined as follows:

FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its intended purpose. It is important to over-stress proper machine usage. Allinformation in this manual should be READ and UNDERSTOOD before any attempt i...

Page 5 - – JLG Lift –; MAINTENANCE SAFETY PRECAUTIONS; GENERAL

MAINTENANCE SAFETY PRECAUTIONS 3120775 – JLG Lift – a MAINTENANCE SAFETY PRECAUTIONS GENERAL T h i s s e c t i o n c o n t a i n s t h e g e n e r a l sa f e t y p r e c a u ti on swhich must be observed during maintenance of the aerialplatform. It is of utmost importance that maintenance per-sonnel...

Page 6 - EFFECTIVITY PAGE; EFFECTIVITY CHANGES

EFFECTIVITY PAGE b – JLG Lift – 3120775 EFFECTIVITY CHANGES June 2, 1999 - Original Issue of Manual March 7, 2000 - Manual Revised (added CSA/Latin America Specifications) April 13, 2000 - Manual Revised (added 12SP Model) April 25, 2000 - Manual Revised (corrected Mast Disassembly/Assembly - Sectio...

Page 7 - TABLE OF CONTENTS; SECTION 1 - SPECIFICATIONS

3120775 – JLG Lift – i TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 9 - SECTION 3 - TROUBLESHOOTING

3120775 – JLG Lift – iii TABLE OF CONTENTS SECTION 3 - TROUBLESHOOTING 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . ....

Page 11 - SECTION 1 - SPECIFICATIONS; SECTION 1. SPECIFICATIONS; TORQUE REQUIREMENTS

SECTION 1 - SPECIFICATIONS 3120775 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Reservoir DC Models - 5 qts. U.S. (4.7 ltr.) 1.2 COMPONENT DATA Hydraulic Pump/Electric Motor Assembly DC MODELS - 12 VOLT DC MOTOR/PUMP Motor - 12v - DC Standard Duty Pump Displacement - .098 ...

Page 12 - Hydraulic Oil; HYDRAULIC PRESSURE ADJUSTMENT; clockwise, increases system; CYLINDER SPECIFICATIONS; Screw Located at Base of Pump Motor

SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3120775 1.5 LUBRICATION Hydraulic Oil Hydraulic oils must have anti-wear qualities at least to APIService Classification GL-3, and sufficient chemical stabil-ity for mobile hydraulic system service. JLG Industries,recommends Mobilfluid 424 hydraulic oil, w...

Page 13 - MPG

SECTION 1 - SPECIFICATIONS 3120775 – JLG Lift – 1-3 1 2 3 Table 1-4. Lubrication Intervals for Various Components ITEM COMPONENT NO/TYPE LUBE POINTS LUBE/METHOD INTERVAL HOURS COMMENTS 3 MOS. or 150 Hrs. 6 MOS. or 300 Hrs. 1 YR. or 600 Hrs. 2 YRS. or 1200 Hrs. 1 Hydraulic Oil Fill To Lineon Reservoi...

Page 15 - SECTION 2 - SERVICE PROCEDURES; SECTION 2. SERVICE PROCEDURES; AND MAINTENANCE

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-1 SECTION 2. SERVICE PROCEDURES 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby those personnel that are responsible to place themachine in operation readiness and maintain its...

Page 16 - PREVENTIVE MAINTENANCE AND

SECTION 2 - SERVICE PROCEDURES 2-2 – JLG Lift – 3120775 2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE (See Table 2-2.) The preventive maintenance and inspection checks arelisted and defined in the following table. This table isdivided into two basic parts, the “AREA” to be inspectedand the “INT...

Page 17 - INTERVAL; MAST ASSEMBLY

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-3 Table 2-2. Preventive Maintenance & Inspection Schedule. AREA ON MACHINE INTERVAL PRE-START (1) INSPECTION 3 MONTH PREVENTATIVE MAINTENANCE 6 MONTH PREVENTATIVE MAINTENANCE PRE-DELIVERY (2)OR FREQUENT (3) INSPECTION ANNUAL (4) (YEARLY) INSP...

Page 20 - Chain Size

SECTION 2 - SERVICE PROCEDURES 2-6 – JLG Lift – 3120775 Bolt Usage and Torque Application Use bolts of proper length. A bolt which is too long willbottom before the head is tight against its related part. If abolt is too short, there will not be enough thread area toengage and hold the part properly...

Page 21 - Mast Cable Inspection Procedure; TIGHT JOINTS

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-7 a r e o n t h e v e r g e o f c r a c k i n g . F a t i g u e a n d u l t i m a t estrength failures on JLG Lifts are incurred as a result ofsevere abuse as design specs are well within the rated lift-ing capacity of these chains. Tight Joints:...

Page 22 - LUBRICATION INFORMATION

SECTION 2 - SERVICE PROCEDURES 2-8 – JLG Lift – 3120775 shall be noted, and then a determination made if furtheruse would constitute a hazard. Mast cables must be replaced after machine has been inservice for five (5) years, regardless of cable condition, orsooner if conditions dictate. Conditions s...

Page 23 - DISASSEMBLY

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-9 2.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGERIF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-TE RY CHARGER WH ILE TH E MACH INE IS UNDER WA RRANTYWILL VOID THE CHARGER W...

Page 24 - Transformer Replacement; Printed Circuit Board Replacement; DC Circuit Breaker Replacement

SECTION 2 - SERVICE PROCEDURES 2-10 – JLG Lift – 3120775 Transformer Replacement 1. Disconnect the wiring connecting the transformer toother components within the charger assembly. 2. Remove the four nuts from the cap screws securingthe transformer brackets to the base of the chargerchassis. 3. Remo...

Page 26 - FENNER BRAND PUMP - Brush Replacement; Motor Cap Installation

SECTION 2 - SERVICE PROCEDURES 2-12 – JLG Lift – 3120775 2.6 HYDRAULIC LIFT PUMP - SERVICING Remove hydraulic pump from machine. FENNER BRAND PUMP - Brush Replacement Motor Cap/Motor Installation Motor Brush Installation Motor Cap Installation 1. Cap Assembly Screws 2. Cap Assembly Motor Installatio...

Page 27 - Brush Housing Final Assembly Tips; New Brush Installation; Brush Final Positioning

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-13 Once brush housing has been removed, inspect the rotorcommutator for excessive wear before installing a newbrush set. The rotor commutator surface when new, is approximately1/8 in. (3mm) in thickness. Brush Housing Final Assembly Tips It is ea...

Page 28 - MONARCH BRAND PUMP - Brush Replacement

SECTION 2 - SERVICE PROCEDURES 2-14 – JLG Lift – 3120775 MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks Motor/Brush Cover - Remove/Install Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and va...

Page 30 - Tank Installation

SECTION 2 - SERVICE PROCEDURES 2-16 – JLG Lift – 3120775 TANK AND PUMP REMOVAL - (All Pumps) Tank Installation Filter Screen Installation Pump Installation Tank Installation 1. Tank Assembly 3. O-Ring Seal 2. Tank Screws (4) 4. Use Screwdriver to pry tank away from pump head. Filter Screen Installat...

Page 31 - Pressure Adjust Valve Installation; Pressure Check Valve Installation

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-17 Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation 1. Adjust Valve Cap 4. Valve Ball 2. Adjustment Screw 5. Adjust Valve Por t 3. Valve Spring 6. Extend (Pressure) Por t (Shown Plugged) Note...

Page 32 - INSPECTION AND REBUILD; Cylinder Disassembly; Cylinder Rod

SECTION 2 - SERVICE PROCEDURES 2-18 – JLG Lift – 3120775 2.7 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULICFLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATEMEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE INTHE CYLINDER BEFORE DISCONNECTI...

Page 33 - Piston

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-19 event that an unacceptable condition occurs, the headshould be replaced. Piston Visually inspect the outside surface for scratches or pol-ishing. Deep scratches are unacceptable. Polishing indi-cates uneven loading and when this occurs, the di...

Page 34 - Cylinder Assembly

SECTION 2 - SERVICE PROCEDURES 2-20 – JLG Lift – 3120775 Cylinder Assembly (See Figure 2-1.) 1. Rinse the inside of the tube with hydraulic fluid andallow to drain. A high-pressure rinse followed by awipe with a lint-free rag is preferable. Clean all inter-nal components of any foreign material. 2. ...

Page 35 - MAST ASSEMBLY AND DISASSEMBLY; Mast Disassembly Procedure; Model; TOP

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-21 2.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The SP Series personnel lift mast sections are contructedof extruded aluminum, protected with an anodized surfacefinish. The mast sections rails are interlocked into eachother when assembled and are...

Page 36 - Mast Section 4 Removal; Mast Section 3 Removal

SECTION 2 - SERVICE PROCEDURES 2-22 – JLG Lift – 3120775 NOTE: When sliding mast sections apart, be careful not toscratch or score the anodized finish in the slide padchannels. 5. Carefully slide short mast section-4/5 out BOTTOMof mast section-3/4 rails. Disassemble slide pads,shims and cable ancho...

Page 37 - Mast Section 1 - Assembly; Mast Section 2 - Assembly

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-23 2.9 MAST ASSEMBLY (See Figure 2-3., Figure 2-4. & Figure 2-5.) Mast Section 1 - Assembly 1. Place mast section-1, rail (open) side up (See Figure 2-1.) on a clean, flat surface (preferably a table or work bench capable of supporting the we...

Page 41 - Mast Section 3 - Assembly

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-27 ft. lbs. Align the hole in the mounting journal with thehole in the cylinder and Install the (1) 5/16" bolt. 15. New Design Cylinder: Install the mounting pin through the side mounting brackets and the cylindervalve body and through the mo...

Page 42 - Mast Section 4 - Assembly

SECTION 2 - SERVICE PROCEDURES 2-28 – JLG Lift – 3120775 NOTE: Before fastening and shimming the slide pad on thetop left side of the mast, install a sequence cablebracket against the mast under the flatwasher. 30. Thread slide pad attaching bolts, two (2) 1/4"-20UNC x 3/8" long hex head bol...

Page 43 - Platform Mounting Section - Assembly; MAST TO BASE FRAME INSTALLATION

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-29 46. Shim per instructions in step 7, Mast Section 2 -Assembly. Platform Mounting Section - Assembly 47. Locate the remaing mast section-4/5 (platform mounting - mast section). Lay mast section on flat stable surface. 48. Attach the remaining c...

Page 44 - SEQUENCING CABLES ADJUSTMENT

SECTION 2 - SERVICE PROCEDURES 2-30 – JLG Lift – 3120775 4. Slide port end of hydraulic cylinder through hole inbase frame cylinder mounting channel. (Return port (tube side) of cylinder must be on right side facingbottom of base and mast) . 5. Align threaded hole in side of hydraulic cylinderhead w...

Page 45 - MAST SIDE PROFILE

SECTION 2 - SERVICE PROCEDURES 3120775 – JLG Lift – 2-31 one side or the other.The threaded end of the chain/cable may need to berestrained while tightening the adjust nut to keep thechain/cable from twisting. 7. Retract the mast all the way and check if the top ofthe mast sections appear as shown i...

Page 46 - Sequencing Cable Adjustment

SECTION 2 - SERVICE PROCEDURES 2-32 – JLG Lift – 3120775 Sequencing Cable Adjustment 1. Retract mast completely, and check each sequenc-ing cable on outside of masts for excessive slack.Adjust only to remove slack from cable. 2. Tighten nylock-nut just enough to remove excessiveslack from sequencing...

Page 49 - SECTION 3 - TROUBLESHOOTING; SECTION 3. TROUBLESHOOTING; TROUBLESHOOTING INFORMATION; HYDRAULIC CIRCUIT CHECKS; BASICS

SECTION 3 - TROUBLESHOOTING 3120775 – JLG Lift – 3-1 SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presente...

Page 50 - Polarity; Procedure

SECTION 3 - TROUBLESHOOTING 3-2 – JLG Lift – 3120775 Polarity F i n d i n g a n e g a t i v e v o l t a g e o r c u r r e n t r e a d i n g w h e nexpecting a positive reading frequently means the leadsare reversed. Check what reading is expected, the loca-tion of the signal and that the leads are c...

Page 51 - Voltage Measurement

SECTION 3 - TROUBLESHOOTING 3120775 – JLG Lift – 3-3 Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads ...

Page 52 - Continuity Measurement

SECTION 3 - TROUBLESHOOTING 3-4 – JLG Lift – 3120775 Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4. Current Measurement (DC) • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing...

Page 53 - ELECTRICAL SWITCH TESTING

SECTION 3 - TROUBLESHOOTING 3120775 – JLG Lift – 3-5 3.5 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioningproperly, not the circuit in which the switch is placed. Aswitch is functioning properly when there is continuitybetwee n th e correct terminals o...

Page 61 - CALIFORNIAN PROPOSITION 65; BATTERY WARNING; WASH HANDS

CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!

Page 62 - JLG Worldwide Locations

JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Su...