Jlg 15SP Service Manual User Manual

Service and Maintenance ManualModel12SP15SP3120775March 17, 2008

iv – JLG Lift – 3120775TABLE OF CONTENTS NOTES:

SECTION 1 - SPECIFICATIONS3120775 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil ReservoirDC Models - 5 qts. U.S. (4.7 ltr.)1

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31207751.5 LUBRICATIONHydraulic OilHydraulic oils must have anti-wear qualities at least to APIService Clas

SECTION 1 - SPECIFICATIONS3120775 – JLG Lift – 1-3123Table 1-4. Lubrication Intervals for Various ComponentsITEM COMPONENTNO/TYPELUBE POINTSLUBE/METHO

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120775Figure 1-2. Torque Chart.

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis se

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 31207752.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-3Table 2-2. Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALPRE-START (1

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120775Footnotes:1. Prior to use each day; or at each Operator change2. Prior to each sale, lease, or d

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-52.3 SERVICING AND MAINTENANCE GUIDELINESGeneralThe following information is provided to assist y

NOTES:

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120775Bolt Usage and Torque ApplicationUse bolts of proper length. A bolt which is too long willbottom

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-7are on the verge of cracking. Fatigue and ultimatestrength failures on JLG Lifts are incurred as

SECTION 2 - SERVICE PROCEDURES2-8 – JLG Lift – 3120775shall be noted, and then a determination made if furtheruse would constitute a hazard.Mast cable

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-92.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLYGeneral InformationDO NOT ATTEMPT TO DISASSEMBLE T

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 3120775Transformer Replacement1. Disconnect the wiring connecting the transformer toother components w

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-11AC Circuit Breaker and Voltage Selection Switch Replacement1. Remove the wiring from the AC bre

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 31207752.6 HYDRAULIC LIFT PUMP - SERVICINGRemove hydraulic pump from machine.FENNER BRAND PUMP - Brush

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-13Once brush housing has been removed, inspect the rotorcommutator for excessive wear before inst

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120775MONARCH BRAND PUMP - Brush ReplacementMotor Assembly - Remove/Install - Reference MarksMotor/Br

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-15Brush Carrier Assembly - Remove/InstallBrush Assembly - Remove/InstallBrush Carrier Assembly -

FOREWORDThe purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its in

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120775TANK AND PUMP REMOVAL - (All Pumps)Tank InstallationFilter Screen InstallationPump Installation

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-17Pressure Adjust Valve Installation Pressure Check Valve InstallationPressure Adjust Valve Insta

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 31207752.7 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-19event that an unacceptable condition occurs, the headshould be replaced.PistonVisually inspect

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 3120775Cylinder Assembly(See Figure 2-1.)1. Rinse the inside of the tube with hydraulic fluid andallow

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-212.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURESThe SP Series personnel lift mast sections are cont

SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 3120775NOTE: When sliding mast sections apart, be careful not toscratch or score the anodized finish i

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-232.9 MAST ASSEMBLY(See Figure 2-3., Figure 2-4. & Figure 2-5.)Mast Section 1 - Assembly1. Pl

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 3120775Figure 2-3. 15SP Mast Assembly Components. (5 Section)MASTSECTION-1MASTSECTION-2MASTSECTION-3M

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-25Figure 2-4. 12SP Mast Assembly Components. (4 Section)LIFTCYLINDERMASTSECTION 1MASTSECTION 4MA

NOTES:

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 3120775Figure 2-5. Mast Chain Routing Diagram.

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-27ft. lbs. Align the hole in the mounting journal with thehole in the cylinder and Install the (1

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 3120775NOTE: Before fastening and shimming the slide pad on thetop left side of the mast, install a se

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-2946. Shim per instructions in step 7, Mast Section 2 -Assembly.Platform Mounting Section - Assem

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 31207754. Slide port end of hydraulic cylinder through hole inbase frame cylinder mounting channel. (R

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-31one side or the other.The threaded end of the chain/cable may need to berestrained while tighte

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 3120775Sequencing Cable Adjustment1. Retract mast completely, and check each sequenc-ing cable on outs

SECTION 2 - SERVICE PROCEDURES3120775 – JLG Lift – 2-33Clamp Installation (Drum/Socket Type)THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-MENDS THE

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 31207756. Reclamp the assembly in the vise on the flats of thesleeve. Using the plug driver, a metal t

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

MAINTENANCE SAFETY PRECAUTIONS3120775 – JLG Lift – aMAINTENANCE SAFETY PRECAUTIONSGENERALThis section contains the general safety precautionswhich mus

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120775PolarityFinding a negative voltage or current reading whenexpecting a positive reading frequently m

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-3 Voltage Measurement Resistance MeasurementFigure 3-1. Voltage Measurement (DC) Figure 3-2. Res

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120775 Continuity Measurement Current MeasurementFigure 3-3. Continuity Measurement Figure 3-4. Curr

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-53.5 ELECTRICAL SWITCH TESTINGBasic CheckThe following check determines if the switch is functioning

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120775Table 3-1. DC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPlatform does not rise.Power sou

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-7Figure 3-5. Hydraulic Schematic. (SP Series)2792491_A

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120775Figure 3-6. Electrical Diagram (Standard)

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-9 Figure 3-6., Electrical Diagram (Standard)

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120775Figure 3-7. Electrical Diagram (With Floor Brake/Gate Alarm Option)

SECTION 3 - TROUBLESHOOTING3120775 – JLG Lift – 3-11Figure 3-7., Electrical Diagram (With Floor Brake/Gate Alarm Option)

EFFECTIVITY PAGEb – JLG Lift – 3120775EFFECTIVITY CHANGESJune 2, 1999 - Original Issue of ManualMarch 7, 2000 - Manual Revised (added CSA/Latin Amer

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120775NOTES:

CALIFORNIAN PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of C

JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Australia)P.O. B

3120775 – JLG Lift – i TABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . .

ii – JLG Lift – 3120775TABLE OF CONTENTS 2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120775 – JLG Lift – iii TABLE OF CONTENTSSECTION 3 - TROUBLESHOOTING3.1 General . . . . . . . . . . . . . . . . . . . . . . .