JLG 10MSP Parts Manual

3121229 10MSP 3

TABLE OF CONTENTS

SECTION 1 - BASE.............................................................................................................................................................................. 7

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION .................................................................................................. 8

FIGURE 1-2. DRIVE ASSEMBLY ................................................................................................................................................... 12

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION .......................................................................................................... 14

SECTION 2 - CONTROLS ................................................................................................................................................................. 17

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION .................................................................................................. 18

FIGURE 2-2. BATTERY CHARGER AND PLUG INSTALLATION (Prior to SN 0130010886) ....................................................... 22

FIGURE 2-3. BATTERY CHARGER AND PLUG INSTALLATION (SN 0130010886 to Present) .................................................. 24

FIGURE 2-4. BATTERIES, SWITCHES, HORN AND BEACON LIGHT INSTALLATION .............................................................. 28

FIGURE 2-5. GROUND COMPONENTS INSTALLATIONS ........................................................................................................... 32

FIGURE 2-6. PLATFORM CABLES AND CONTROLS INSTALLATION ........................................................................................ 34

FIGURE 2-7. CONTROL BOX ASSEMBLY .................................................................................................................................... 36

SECTION 3 - MAST ........................................................................................................................................................................... 39

FIGURE 3-1. MAST ASSEMBLY AND INSTALLATION ................................................................................................................. 40

SECTION 4 - PLATFORM .................................................................................................................................................................. 43

FIGURE 4-1. PLATFORM INSTALLATION (ALL SPECS TO PRESENT AND AUSTRALIAN SPEC) (Prior to SN 0130018678) . 44

FIGURE 4-2. PLATFORM INSTALLATION (AUSTRALIAN SPEC ONLY) (SN 0130018678 to Present) ...................................... 46

FIGURE 4-3. MATERIAL TRAY INSTALLATION ........................................................................................................................... 48

FIGURE 4-4. OPTIONAL BICYCLE CARRIERS INSTALLATION .................................................................................................. 50

FIGURE 4-5. OPTIONAL RUG CARRIER INSTALLATION ........................................................................................................... 52

FIGURE 4-6. OPTIONAL FLUORESCENT TUBE CADDY ASSEMBLY ........................................................................................ 54

SECTION 5 - CYLINDER ................................................................................................................................................................... 57

FIGURE 5-1. LIFT CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) (Prior to SN 0130011099) ............................................... 58

FIGURE 5-2. LIFT CYLINDER ASSEMBLY (SERVICE REPLACEMENT) (SN 0130011099 to Present) ...................................... 60

SECTION 6 - HYDRAULIC ................................................................................................................................................................ 63

FIGURE 6-1. HYDRAULIC DIAGRAM ............................................................................................................................................ 64

SECTION 7 - ELECTRICAL ............................................................................................................................................................... 67

FIGURE 7-1. ELECTRICAL COMPONENTS INSTALLATION ....................................................................................................... 68

SECTION 8 - DECALS ....................................................................................................................................................................... 75

FIGURE 8-1. DECAL INSTALLATION ............................................................................................................................................ 76

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ............................................................................................................. 81

FIGURE 9-1. 10MSP STANDARD PARTS ..................................................................................................................................... 82

FIGURE 9-2. 10MSP VARIABLE PARTS ....................................................................................................................................... 84

SECTION 10 - SPECIAL OPTIONS ................................................................................................................................................... 85

FIGURE 10-1. SPECIAL OPTIONS ................................................................................................................................................ 86

PART NUMBER INDEX ..................................................................................................................................................................... 87

3121229 10MSP 5

SECTION 1 - BASE

3121229 10MSP 7

SECTION 1 - BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

8 10MSP 3121229

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

0274893

Ref

BASE ASSEMBLY

F 1 0100081

AR

Compound, Locking

2 0274904

1

Frame Assembly (See Items 101-111 for Breakdown)

3 0630580

10

Bolt, Wheel

4 0641609

13

Bolt 3/8in-16NC x 1-1/8in

5 0940132

1

Bumper, Chassis

6 3020039

AR

Lubricant Loctite #51049

7 3160323

2

Drive Motor Assembly (See DRIVE ASSEMBLY for Breakdown)

8 3311605

1

Locknut 3/8in-16NC

9 3760115

2

Ring, Retaining

10

3760496

2

Ring, Retaining

11

4071113

AR

Shim .015in

12

4071114

AR

Shim .036in

13

4240147

1

Strap, Static

14 Ref

Tire and Wheel Assembly Options:

14

1001098810

2

Tire and Wheel Assembly (was p/n 4520281) (Prior to SN

0130011864)

14

1001098810

2

Tire and Wheel Assembly (SN 0130011864 to Present)

15

4520342

1

Spindle (Left Side)

16

4520343

1

Spindle (Right Side)

17 Ref

Tire and Wheel Assembly Options:

17

1001114467

2

Tire and Wheel Assembly (Was p/n 4520326) (Prior to SN

0130008686)

17

See Note

1

Tire and Wheel Assembly (Note: Tire and Wheel Assemblies used in this range of SNs vary between old and new style - Use p/n 1001114467 as replacement.) (SN 0130008685 through

0130009365)

17

1001114467

2

Tire and Wheel Assembly (was p/n 4520565) (SN 0130009366 through 0130011758)

17

1001114467

1

Tire and Wheel Assembly (was p/n 1001100840) (SN 0130011759 through 0130013969)

17

1001114467

2

Tire and Wheel Assembly (SN 0130013970 to Present)

18

4711600

1

Flatwasher 3/8in Narrow

19

8882970

AR

Coating, Clear

20

0100011

AR

Locking Compound

0274904

Ref

FRAME ASSEMBLY

I

101

0440306

2

Bearing, Ball

102

0440307

2

Bearing, Roller

103

0440308

2

Bearing, Race

104

0641413

6

Bolt 1/4in-20NC x 1-5/8in

105

2360750

1

Frame 106

3020029

AR

Grease (Not Shown)

107

3271405

6

Locknut 1/4in-20NC

108

3960590

2

Seal 110

4341155

2

Mount, Caster

111

4711400

6

Flatwasher 1/4in Narrow

0274078

Ref

BUMPERS INSTALLATION (OPTIONAL)

C

201

0641408

13

Bolt 1/4in-20NC x 1in

202

0940152

2

Bumper, Side

203

0940153

1

Bumper, Front

204

3311405

13

Locknut 1/4in-20NC

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

3121229 10MSP 9

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

205

4751400

26

Flatwasher 1/4in Wide

0240103

Ref

GUIDE ROLLER ATTACHMENT (OPTIONAL)

B

301

0100011

AR

Locking Compound

302

0641606

10

Bolt 3/8in-16NC x 3/4in

303

0641617

4

Bolt 3/8in-16NC x 2-1/8in

304

0903120

4

Bracket, Top Roller

305

0903121

4

Bracket, Bottom Roller

306

3311605

8

Locknut 3/8in-16NC

307

4520352

4

Wheel 308

Ref

Hardware Options:

308

0641606

4

Bolt 3/8in-16NC x 3/4in (Prior to SN 0130015906)

308

3900283

4

Screw Button Head 3/8in-16NC x 3/4in (SN 0130015906 to Present)

309

Ref

Bolt Options:

309

0641606

2

Bolt 3/8in-16NC x 3/4in (Prior to SN 0130015906)

309

0641609

2

Bolt 3/8in-16NC x 1-1/8in (SN 0130015906 to Present)

SECTION 1 - BASE

10 10MSP 3121229

SECTION 1 - BASE

FIGURE 1-2. DRIVE ASSEMBLY

12 10MSP 3121229

FIGURE 1-2. DRIVE ASSEMBLY

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

3160323

Ref

SPINDLE/HUB ASSEMBLY

1 3160323

1

Spindle 2

7024756

1

Hub 3

7024758

1

Ring, Input

4 70000210

1

Gear, Input Sun

5 70000210

3

Gear, Input Planet

6 70000210

3

Pin, Input Planet

7 70000210

1

Carrier 8

70000210

1

Gear, Output Sun

9 70000212

3

Gear, Output Planet

10

70000212

3

Pin, Output Planet

11

7024747

1

Cover 14

See Note

2

Bearing (Note: Use Items 201, 203, 205 & 206)

16

See Note

1

Seal, Lip (Note: Use Items 201 & 205)

17

70000215

1

Seal, Lip

18

70000210

3

Ring, Retaining

19

7024747

1

Ring, Retaining

20

70000191

1

O-Ring 21

7024747

1

Thrustwasher

23

70000210

1

Plate, Thrust

24

70000210

1

Ring, Retaining

25

See Note

6

Thrustwasher (Note: Use Items 202 & 206)

26

See Note

3

Bushing, Planet (Note: Use Items 202 & 206)

27

See Note

1

Ring, Retaining (Note: Use Items 203 & 205)

29

7024747

2

Plug

32

70000212

3

Thrustwasher, Tanged

3160323

Ref

DRIVE MOTOR ASSEMBLY

B

101

3160323

1

Hub/Spindle Assembly (Includes Items 1-32)

102

70000211

1

Electric Motor Assembly

102A

70000213

4

Brush

102B

70000213

1

Indicator, Wear (Not Shown)

102C

70000213

4

Spring, Brush

102D

70000213

1

Bearing (Not Shown)

103

70000214

1

Brake Assembly

103A

70000935

1

Disc, Brake (Part of Kit)

106

70000211

2

Bolt 107

70000214

3

Bolt Ref

KIT OPTIONS:

Ref

Repair Kit Options:

200

7024747

1

Cover Kit (Includes Items 11, 19-21 & 29)

201

7024748

1

Main Seal and Bearing Kit (Includes Items 14, 16 & 20)

202

70000210

1

Input Carrier Kit (Includes Items 4-8, 18, 20 & 23-26)

203

7024758

1

Input Ring Kit (Includes Items 3, 14, 20 & 27)

204

70000211

1

Motor Kit (Includes Items 17, 102 & 106)

205

7024756

1

Hub Kit (Includes Items 2, 14, 16, 20 & 27)

206

70000212

1

Output Planet Kit (Includes Items 9, 10, 14, 20, 25, 26 & 32)

207

70000213

1

Brush and Bearing Kit (Includes Items 102A-102D)

208

70000214

1

Brake Kit (Includes Items 103 & 107)

SECTION 1 - BASE

3121229 10MSP 13

SECTION 1 - BASE

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION

14 10MSP 3121229

SECTION 1 - BASE

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

0274901

Ref

COVER INSTALLATION

C 1 0100011

AR

Locking Compound

3 0641616

4

Bolt 3/8in-16NC x 2in (Prior to SN 0130015319)

4 0903222

1

Brace 5

0940049

2

Stopper, Hood

6 Ref

Cover, Battery and Frame Options:

6

1001120531

1

Cover, Battery and Frame (was p/n 1671141) (Prior to SN

0130015319)

6

1001120531

1

Cover, Battery and Frame (SN 0130015319 to Present)

7 1671143

1

Cover, Mast

8 1671146

1

Cover, Rear Bumper

9 1671298

1

Cover, Front Hood

11

3300454

9

Nut 1/4in-20NC

12

3900258

22

Screw Button Head 1/4in-20NC x 3/4in

13 Ref

Support Options:

13A

4341067

1

Support (Prior to SN 0130015319)

13B

1001121648

1

Support (SN 0130015319 to Present)

14

4711600

4

Flatwasher 3/8in Narrow

15

4751400

19

Flatwasher 1/4in (Wide)

16

4751500

4

Flatwasher 5/16in (Wide)

17

1380169

1

Clip 18

3900174

1

Screw, Thumb

19

3760308

1

Retainer

20

0641617

2

Bolt 3/8in-16NC x 2-1/8in (SN 0130015319 to Present)

21

3311605

2

Locknut 3/8in-16NC (SN 0130015319 to Present)

0240114

Ref

TIE-DOWNS INSTALLATION

A

101

0811610

4

Screw 3/8in-16NC x 1-1/4in

102

3311605

4

Locknut 3/8in-16NC

103

3760365

2

Tie-Ring

104

4711600

4

Flatwasher 3/8in Narrow

FIGURE 1-3. COVERS AND TIE-DOWNS INSTALLATION

3121229 10MSP 15

SECTION 2 - CONTROLS

3121229 10MSP 17

SECTION 2 - CONTROLS

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION

18 10MSP 3121229

SECTION 2 - CONTROLS

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

3600392

1

PUMP/MOTOR ASSEMBLY

D 1 7027943

Ref

Pump Components Kit

1A

7027943

1

Pump 1B

7027943

1

Seal 1C

7011021

1

Seal 1D

7027943

1

Seal 1E

7010928

4

Screw

1F

7011033

1

Screw

1G

7027943

1

Lockwasher

1H

7027943

1

Retainer

1J

7011016

1

Coupler

2 7027944

Ref

Adaptor Components Kit

2A

7011025

1

Seal 2B

7011011

2

Screw

2C

7027944

1

Plug 2D

7027944

1

Adaptor

2E

7011013

1

Retainer

2F

7027944

1

Plug, Plastic (Not Shown)

2G

7027944

1

Plug, Steel

2H

7027944

1

Seat Assembly

2J

7027944

1

Plug 3

7027945

Ref

Relief Valve Components Kit

3A

7011008

1

Spring

3B

7011017

1

Spring

3C

7011009

1

Screw, Adjustment

3D

7027945

1

Gasket

3E

7011004

1

Cap 3F

7027945

1

Ball 4

7027946

Ref

Tube Components Kit

4A

7011024

1

Seal 4B

7027946

1

Seal 4C

7027946

1

Washer

4D

7011031

1

Ring, Retaining

4E

7011032

1

Ring, Retaining

4G

7027946

1

Tube 4H

7027946

1

Tube 4J

7027946

1

Tube 4K

7011029

1

Strainer

4L

7011034

1

Spacer

5 7027947

Ref

Tank Components Kit

5A

7027947

1

Tank 5B

7027947

4

Screw

5C

7011027

1

Magnet

5D

7027947

1

Label 5E

7011069

1

Breather/Dipstick

6 See Note

1

Label (Not Shown) (Note: Not Available for Purchase)

7 7027948

1

Motor Assembly

7 7027948

1

Brush Kit

8 7027949

Ref

Return Port Components Kit

8A

7027949

1

Seal

FIGURE 2-1. PUMP MOTOR ASSEMBLY AND INSTALLATION

3121229 10MSP 19

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

8B

7027949

1

Seal 8C

7027949

1

Washer

8D

7027949

1

Body, Return Port

9 2221185

1

Fitting, 90

10

2110606

1

Fitting, Straight

Ref

PUMP/MOTOR INSTALLATIONS

0273546

Ref

Standard Hydraulic Oil

E 0274181

Ref

Fire Resistant Hydraulic Oil

A

101

0100011

Locking Compound

102

0641606

Bolt 3/8in-16NC x 3/4in

107

3600392

1

Pump/Motor Assembly (See Items 1-10 for Breakdown)

108

1704412

1

Decal - Hydraulic Oil (Stamp Appropriately)

109

Ref

Oil, Hydraulic Options (Not Shown):

109

2300021

1.2 gals

Standard Hydraulic Oil

109

2300014

1.2 gals

Fire Resistant Hydraulic Oil

SECTION 2 - CONTROLS

20 10MSP 3121229

SECTION 2 - CONTROLS

FIGURE 2-2. BATTERY CHARGER AND PLUG INSTALLATION (Prior to SN 0130010886)

22 10MSP 3121229

SECTION 2 - CONTROLS

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

Ref

BATTERY CHARGER INSTALLATIONS

0274897

Ref

ANSI - Charger with Plug

C 0274898

Ref

Australian - Charger without Plug

B 0274899

Ref

ANSI - Charger without Plug

C 0274900

Ref

ANSI - Charger with Plug/Cord Reel

C 1 0100011

AR

Locking Compound

2 0400241

1

Battery Charger Assembly (No Serviceable Parts Available)

3 0610131

1

LED Board

4 1060689

1

Cord, Electrical

5 3911016

4

Screw #10-24NC x 1in

5 3311001

2

Nut #10-24NC (Charger with Australian Plug Only)

6 4191706

4

Screw 6mm x 12mm

7 Ref

Cover, Terminal Options:

7 4460802

1

Charger with Plug

7 4460802

1

Charger without Plug

7 Not Required

0

Charger with Plug/Cord Reel

8 Ref

Terminal, Inlet Options:

8A

4460803

1

Charger with ANSI Plug

8A

4460940

1

Charger with Australian Plug

8A

Not Required

0

Charger without Plug

8B

4120046

1

Socket, Cord Reel Stop (Charger with ANSI Plug/Cord Reel Only)

Ref

Note: Items 20-23 used with Charger with Plug/Cord Reel only.

20

3680057

1

Reel, Charger Cord

20A

0791508

1

Screw 5/16in-18NC x 1in

21

4751500

1

Flatwasher 5/16in Wide

22

0791406

1

Screw 1/4in-20NC x 3/4in

23

3575423

1

Angle, Mounting

101

2915230

1

BATTERY CHARGER REPROGRAM CONTROLLER KIT (was p/n 1600466)

FIGURE 2-2. BATTERY CHARGER AND PLUG INSTALLATION (Prior to SN 0130010886)

3121229 10MSP 23

SECTION 2 - CONTROLS

FIGURE 2-3. BATTERY CHARGER AND PLUG INSTALLATION (SN 0130010886 to Present)

24 10MSP 3121229

SECTION 2 - CONTROLS

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

Ref

BATTERY CHARGER INSTALLATIONS

0274898

Ref

ANSI/ANSI Export - Charger without Plug

F 0274900

Ref

ANSI - Charger with Plug/Cord Reel

F 1 0100011

AR

Locking Compound

2 Ref

Battery Charger Assembly Options (No Serviceable Parts Available):

2

1001110117

1

Battery Charger Assembly (was p/n 0400241) (SN 0130010886 through 0130013544)

2 1001102932

1

Battery Charger Assembly (SN 0130013545 through

0130016979)

2

1001136381

1

Battery Charger Assembly (SN 0130016980 to Present)

3 0610131

1

LED Board

4 1060689

1

Cord, Electrical

6 4191706

4

Screw 6mm x 12mm

8

4120046

1

Terminal, Inlet Socket, Cord Reel Stop (Charger with ANSI Plug/Cord Reel Only)

Ref

Note: Items 9-12 used with Charger with Plug/Cord Reel only.

9

3680057

1

Reel, Charger Cord

9A

0791508

1

Screw 5/16in-18NC x 1in

10

4751500

1

Flatwasher 5/16in Wide

11

0791406

1

Screw 1/4in-20NC x 3/4in

12

3575423

1

Angle, Mounting

Ref

CHARGER PLUG INSTALLATIONS (ANSI/ ANSI EXPORT/ AUSTRALIAN SPECS)

1001097449

Ref

Charger Plug 110V (ANSI/ ANSI Export/ CSA/ Japanese Spec)

B 1001097455

Ref

Charger Plug 220V (Australian Spec)

C 1001097456

Ref

Charger Plug No Plug (ANSI Export Spec)

A

101

0100011

AR

Locking Compound

102

3911016

AR

Screw #10-24NC x 1in

103

4460802

1

Cover, Terminal

104

Ref

Terminal, Inlet Options:

104

4460803

1

1001097449 Installation

104

4460940

1

1001097455 Installation

104

Not Required

0

1001097456 Installation

105

3311001

2

Nut #10-24NC (1001097455 Installation Only)

106

4761000

2

Lockwasher #10 (1001097455 Installation Only)

Ref

CHARGER PLUG INSTALLATIONS (CE SPECS ONLY)

1001097450

Ref

Charger Plug 220V Post Ground

B 1001097451

Ref

Charger Plug 220V Side Ground

B 1001097452

Ref

Charger Plug 220V Keyed Ground

B 1001097453

Ref

Charger Plug 110V IEC 60309 Yellow

B 1001097454

Ref

Charger Plug 110V IEC 60309 Blue

B 1001097456

Ref

Charger Plug No Plug

A

201

0100011

AR

Locking Compound

202

0721004

4

Screw #10-24NC x 1/2in

203

3571584

1

Plate, Plug Inlet

204

4460428

1

Connector, Strain Relief

205

Ref

Terminal, Male Options:

205

4461202

1

1001097450 Installation

205

4461205

1

1001097451 Installation

FIGURE 2-3. BATTERY CHARGER AND PLUG INSTALLATION (SN 0130010886 to Present)

3121229 10MSP 25

ITEM

PART NUMBER

QTY

DESCRIPTION

REV

205

4461249

1

1001097452 Installation

205

4461196

1

1001097453 Installation

205

4461199

1

1001097454 Installation

205

Not Required

0

1001097456 Installation

206

4711000

4

Flatwasher #10

207

3911016

AR

Screw #10-24NC x 1in (1001097456 Installation Only)

208

4460802

1

Cover, Terminal (1001097456 Installation Only)

301

2915230

1

BATTERY CHARGER REPROGRAM CONTROLLER KIT (was p/n 1600466)

SECTION 2 - CONTROLS

26 10MSP 3121229

SECTION 2 - CONTROLS

FIGURE 2-4. BATTERIES, SWITCHES, HORN AND BEACON LIGHT INSTALLATION

28 10MSP 3121229