JLG 1500SJ Parts Manual

Illustrated Parts Manual

Model

1500SJ

3121263

January 20, 2014

REVISION LOG

March 15, 2011 - Original Issue of Manual (Edited to B/M 1001118886 Revision 5)

May 9, 2011 - Revised Manual (Edited to B/M 1001118886 Revision 6)

August 3, 2011 - Revised Manual (Edited to B/M 1001118886 Revision C)

November 11, 2011 - Revised Manual (Edited to B/M 1001118886 Revision G)

January 27, 2012 - Revised Manual (Edited to B/M 1001118886 Revision H)

June 25, 2012 - Revised Manual (Edited to B/M 1001118886 Revision I)

August 17, 2012 - Revised Manual (Edited to B/M 1001118886 Revision I)

January 8, 2013 - Revised Manual (Edited to B/M 1001118886 Revision I)

April 23, 2013 - Revised Manual (Edited to B/M 1001118886 Revision K)

July 19, 2013 - Revised Manual (Edited to B/M 1001118886 Revision M)

October 15, 2013 - Revised Manual (Edited to B/M 1001118886 Revision M)

January 20, 2014 - Revised Manual (Edited to B/M 1001118886 Revision AE & B/M 1001160120 Revision D)

3121263 1500SJ A

REVISION LOG

B 1500SJ 3121263

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 DRIVE HUB ASSEMBLY - BONFIGLIOLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 TRACTION VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . . . 2-2

2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 TURNTABLE SWING DRIVE AND BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . 2-10

2-4 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 CATERPILLAR ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-6 DEUTZ TD2011 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-7 DEUTZ TCD2.9L4 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2-8 PUMP ASSEMBLY (REXROTH) (CATERPILLAR ENGINE MACHINES) . . . . . . . . . . . 2-46

2-9 PUMP ASSEMBLY (REXROTH) (DEUTZ ENGINE MACHINES) . . . . . . . . . . . . . . . . . 2-52

2-10 PUMP ASSEMBLY (SAUER TANDEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2-11 PUMP ASSEMBLY (SAUER PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-12 PUMP ASSEMBLY (SAUER GEAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-13 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

2-14 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . . 2-72

2-15 HYDRAULIC OIL COOLER INSTALLATION - CATERPILLAR & DEUTZ TD2011

ENGINES (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2-16 HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES

(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

2-17 GROUND CONTROLS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

2-18 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

2-19 ENGINE TRAY JACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

2-20 HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

2-21 2500W GENERATOR INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

2-22 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES. . . . 2-100

2-23 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES. . . . . . . . . . 2-106

2-24 CLEARSKY TELEMATICS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 2-112

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 JIB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4 ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-5 POWER TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-6 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-7 PLATFORM SUPPORT & VALVES (BOOM MOUNTED) INSTALLATIONS . . . . . . . . . 3-28

3-8 PLATFORM VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-9 JIB VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-10 ENCLOSURE BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3121263 1500SJ i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM) . . . . . . . . . 4-8

4-3 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 CONTROLLER ASSEMBLY (LIFT & SWING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-6 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVEL (JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 LEVEL (PLATFORM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 LIFT (BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 LIFT (JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 LOCK (JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-9 TELESCOPE (JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-10 TELESCOPE (MAIN BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

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

6-1 HYDRAULIC DIAGRAM - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 HYDRAULIC DIAGRAM - OSCILLATING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-6 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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

7-1 ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

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

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI EXPORT SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-3 DECAL INSTALLATION (AUSTRALIAN & CE SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii 1500SJ 3121263

SECTION 1

FRAME

3121263 1500SJ 1-1

SECTION 1 FRAME

324747

4747503940474747472341

41 42

246

231

217

47 13

105

254

144

14546292817482

225

220

212

226

5041332921451171

17262626

4241424141

4225564343

1 7

213940

252626

1 9

1 8

37 38

25253

115201

FIGURE 1-1. AXLE INSTALLATIONS

1-2 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref AXLE INSTALLATIONS - COMMON PARTS 0271934 Ref Fixed Axle K 0271521 Ref Oscillating Axle K

1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0100081 AR Adhesive #454 4 0363037 4 Bar, Stop 5Not Used 6 0641606 40 Bolt 3/8-16NC x 3/4 7 0641608 48 Bolt 3/8-16NC x 1 8 0641609 32 Bolt 3/8-16NC x 1-1/8

9 0641611 16 Bolt 3/8-16NC x 1-3/8 10 Not Used 11 0641613 8 Bolt 3/8-16NC x 1-5/8 12 Not Used 13 4 Bolt Options:

0641620 Bolt 3/8-16NC x 2-1/2

0641624 Bolt 3/8-16NC x 3 14 0641808 8 Bolt 1/2-13NC x 1 15 Not Used 16 0642214 1 Bolt 3/4-10NC x 1-3/4 17 0962033 2 Bushing 18 1180358 4 Carrier

7024365 AR 24 in Section Repair Kit (Includes Inner & Outer Links, Joining

Bars & Rollers, and Assembling Hardware)

7024366 1 Mounting Bracket Kit (Includes Mounting Brackets for Both

Ends, 1 Roller Assembly and Assembling Hardware) 19 1320263 4 Clamp, Cable 20 1320298 4 Clamp, Hose 21 1684102 4 Axle Extension Cylinder Assembly (See CYLINDER SECTION

for Breakdown) 22 3310805 8 Locknut #8-32NC 23 3340881 8 Pad, Wear 24 Use 1001161401 2 Pad, Axle (was p/n 3340907) 25 Use 1001161402 8 Pad, Wear (was p/n 3340946) 26 Use 1001161403 32 Pad, Wear (was p/n 3340932) 27 3340939 8 Pad, Rubber 28 3422918 1 Pin 29 3422960 4 Pin 30 3573294 4 Plate 31 3573335 8 Plate 32 3841287 1 Keeper, Pin 33 3900270 4 Bolt, Shoulder 1/2 -13NC x 1-1/2 34 3930820 8 Capscrew #8-32NC x 1-1/4

35 to 36 Not Used

37 4071035 2 Shim #18 Gauge 38 4071036 4 Shim #11 Gauge 39 4071054 8 Shim #18 Gauge 40 4071055 12 Shim #11 Gauge

3121263 1500SJ 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

41 4071039 24 Shim #18 Gauge 42 4071040 36 Shim #11 Gauge 43 4071042 24 Shim #16 Gauge

44 to 45 Not Used

46 4360578 4 Switch, Limit 47 4711600 140 Flatwasher 3/8 Thin 48 4740461 1 Thrustwasher 49 4750800 8 Flatwasher #8 Regular 50 4846637 4 Extension, Axle 51 4846383 1 Box, Axle Pivot 52 0681813 12 Bolt 1/2-13NC x 1-5/8 (Grade 8) 53 0681814 18 Bolt 1/2-13NC x 1-3/4 (Grade 8) 54 0681815 12 Bolt 1/2-13NC x 1-7/8 (Grade 8) 55 0681816 6 Bolt 1/2-13NC x 2 (Grade 8) 56 4711800 48 Flatwasher 1/2 Thin 57 4460968 4 Connector, Strain Relief (Not Shown)

Ref AXLE INSTALLATION - OPTIONAL PARTS

0271934 Ref Fixed Axle J

101 to 104 Not Used

105 0363076 2 Bar, Stop

106 to 114 Not Used

115 0641814 4 Bolt 1/2-13NC x 1-3/4

116 to 143 Not Used

144 4071049 6 Shim 11 Gauge 145 4071050 4 Shim 16 Gauge

0271521 Ref Oscillating Axle J

201 to 211

212 0642020 4 Bolt 5/8-11NC x 2-1/2

213 to 216 Not Used

217 1684081 2 Oscillating Axle Cylinder Assembly (See CYLINDER SECTION

for Breakdown)

218 to 219 Not Used

220 3312005 4 Locknut 5/8-11NC

221 to 224 Not Used

225 3422833 2 Pin 226 3422915 2 Pin

227 to 230 Not Used

231 3841258 4 Keeper, Pin

232 to 245 Not Used

246 4712000 4 Flatwasher 5/8 Thin

247 to 253 Not Used

254 3520054 4 Plug

1-4 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121263 1500SJ 1-5

SECTION 1 FRAME

3 5

41 43

193633

133537

FIGURE 1-2. STEER INSTALLATION

1-6 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271520 Ref STEER INSTALLATION J

1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0100035 AR Compound, Locking 4Not Used 5 0630464 4 Screw, Button Head #10-24NC x 1/2 6 0641505 4 Bolt 5/16-18NC x 5/8 7 0641511 4 Bolt 5/16-18NC x 1-3/8 8Not Used

9 0641634 4 Bolt 3/8-16NC x 4-1/4 10 0642016 4 Bolt 5/8-11NC x 2 11 0962423 8 Bushing 12 1671040 4 Cover, Sensor 13 1684314 4 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 14 3311505 4 Locknut 5/16-18NC 15 3300464 4 Nut, Slotted 16 Not Used 17 3422917 4 Kingpin 18 3422940 4 Pin, Steer Cylinder (Outer) 19 3422941 4 Pin, Steer Cylinder (Inner) 20 3423256 4 Pin, Sensor 21 3451214 4 Pin, Cotter 3/8 x 3-1/2 22 3760383 4 Ring, Retaining 23 3841258 4 Keeper, Pin 24 Not Used 25 3931020 8 Capscrew #10-24NC x 1-1/4 26 3931412 16 Capscrew 1/4-20NC x 3/4 27 3932024 8 Capscrew 5/8-11NC x 1-1/2 28 1001099632 4 Spindle 29 4360505 4 Switch, Rotary Angle Sensor (Steer) 30 4460914 4 Terminal 31 4711500 12 Flatwasher 5/16 Thin 32 4711800 4 Flatwasher 1/2 Thin 33 4740181 4 Thrustwasher 34 4740229 4 Thrustwasher 35 4740505 8 Thrustwasher 36 4751600 4 Flatwasher 3/8 Regular 37 4755000 4 Flatwasher 2 1/2 Regular 38 0200833 4 Arm, Steer 39 0741606 8 Screw, Countersunk 3/8-16NC x 3/4 40 1120549 4 Cap, Seal (Outer) 41 1120550 4 Cap, Seal (Inner) 42 3960551 4 Seal (Outer) 43 3960552 4 Seal (Inner) 44 0080277 4 Adapter, Angle Sensor Pilot 45 4750800 8 Flatwasher M8

3121263 1500SJ 1-7

SECTION 1 FRAME

301

302

101

SPINDLE

REF.

204

102

202 LH201 R

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

1-8 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref WHEEL DRIVE INSTALLATION

0275685 Ref With Bonfiglioli Drive Hub B

1001104324 Ref With Reggiana Riduttori Drive Hub A

1 0100019 AR Compound, Locking 2Not Used 3 0701617 48 Bolt M16 x 45 (12 Per Wheel) 4 4892000 48 Flatwasher 5/8 Hardened (12 Per Wheel)

Ref HUB AND MOTOR ASSEMBLY

2780286 Ref With Bonfiglioli Drive Hub C

1001104315 Ref With Reggiana Riduttori Drive Hub A

101 4 Drive Hub Assembly Options:

Ref Note: Various brands used. When replacing complete hub,

note that all 4 hubs must be the same brand.

Ref Note: Various brands used. Identify brand before ordering

replacement parts.

1001093243 Bonfiglioli Hub (was p/n 2780290) (See DRIVE HUB ASSEM-

BLY - BONFIGLIOLI for Breakdown)

1001104325 Reggiana Riduttori Hub (See DRIVE HUB ASSEMBLY -

REGGIANA RIDUTTORI for Breakdown)

102 3160339 4 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

Breakdown)

Ref TIRE AND WHEEL INSTALLATIONS

0271852 Ref Foam-Filled Tires B

1001115961 Ref Solid Tires A

Ref Note: Assemblies may require ballast/foam filling to manu-

facturer’s specifications prior to installing on a machine.

Refer to Operation & Safety or Service &Maintenance

Manuals. Purchase individual tire and/or rim only if able to

foam fill tire & wheel assembly, otherwise, purchase com-

plete assembly.

201 2 Right Side Tire & Wheel Assembly Options (See Items 301-302

for Breakdown):

0272055 Foam-Filled Tire and Wheel Assembly

1001112716 Solid Tire and Wheel Assembly

202 2 Left Side Tire & Wheel Assembly Options (See Items 301-302

for Breakdown):

0272056 Foam-Filled Tire and Wheel Assembly

1001112669 Solid Tire and Wheel Assembly 203 0701619 64 Bolt M16 x 55 (16 Per Wheel) 204 4892000 64 Flatwasher 5/8 Hardened (16 Per Wheel)

Ref TIRE AND WHEEL ASSEMBLY COMPONENTS

301 4 Tire Only Options:

4520261 Tire 445/50D710 (For Foam Filling)

Not Available Tire 445/65-24 (Solid) (Purchase Items 201 or 202)

3121263 1500SJ 1-9

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

302 4 Rim Only Options:

4860236 Rim, Wheel (Foam-Filled Tires)

Not Available Rim (Solid Tires) (Purchase Items 201 or 202)

1-10 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121263 1500SJ 1-11

106

104

343536

102

3738394041

4445464748

109

101

108

105

103

12 11

5031151

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY - BONFIGLIOLI

1-12 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY - BONFIGLIOLI

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001093243 Ref DRIVE HUB ASSEMBLY WITH FITTINGS & HARDWARE D

Ref Note: Various brands used. Identify brand before ordering

replacement parts.

1001093242 1 Hub, Torque Less Fittings

1 70000810 10 Bolt M10 x 25 2 70000811 1 O-Ring 3 70000812 1 Pin 4 70000813 2 Bolt M8 x 16 5 70002393 1 Cap, Disconnect 6 Not Available 2 Plug 7 70002394 1 Cover Assembly (Includes Items 2-6 & 8) 8 70000816 1 Pad

9 70000817 1 O-Ring 10 70000818 1 Gear, Primary Sun 11 Use Item 151 1 Ring, Neoprene 12 Use Item 151 2 Washer 13 Use Item 151 1 Spring 14 Use Item 151 1 Shaft 15 Not Used 16 70000820 1 Reduction Assembly, Primary 17 70000821 1 Gear, Secondary Sun 18 70000822 1 Reduction Assembly, Secondary 19 70000823 5 Snap Ring 20 70000824 5 Gear Assembly, Planetary 21 70000825 5 Spacer 22 70000826 1 Nut 23 70002395 1 Housing, Hub (Includes Bearing) 24 Not Available 2 Bearing (Purchase Item 23)

25 to 30 Not Used

31 Not Available 1 Spindle 32 70000834 4 Disc, Steel 33 70000835 5 Disc, Lined 34 70000836 1 Spacer 35 70002398 1 Shaft, Brake 36 70000838 1 Snap Ring 37 70000839 1 Ring, Backup 38 70000840 1 O-Ring 39 70000841 1 Spacer 40 70000842 1 Ring, Backup 41 70000843 1 O-Ring 42 70000844 1 O-Ring 43 70000845 1 Ring, Backup 44 70000846 1 Piston, Brake 45 70000847 15 Spring 46 70000848 1 Plate, Spring Retainer 47 70000849 1 Snap Ring 48 Use 3790158 1 O-Ring (was p/n 70002399) 49 70002396 1 Circlip

3121263 1500SJ 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY - BONFIGLIOLI (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

50 70002397 1 Seal

51 to 100 Not Used

101 0761215 2 Bolt M12 x 35 102 2110404 1 Fitting, Adapter 103 2110808 1 Fitting, Adapter 104 2110812 1 Fitting, Adapter 105 2130406 1 Fitting, 90 Adapter 106 2130812 1 Fitting, 90 Adapter 107 Not Used 108 5241200 2 Flatwasher Hardened 109 0100011 AR Compound, Locking 110 Not Used 111 3020008 17oz Lubricant HD 80W-90 (Not Shown)

112 to 150 Not Used

— — — — — — — — — —

151 70000819 1 Brake Shaft Kit (Includes Items 11-14)

1-14 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY - BONFIGLIOLI (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121263 1500SJ 1-15

SECTION 1 FRAME

345715

102

161718

61110

8113

MOTOR SHOWN HERE

FOR CLARITY

101

108

105

103

104

106

110

1095253

FIGURE 1-5. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI

1-16 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001104325 Ref DRIVE HUB ASSEMBLY WITH FITTINGS & HARDWARE D

Ref Note: Various brands used. Identify brand before ordering

replacement parts.

1001101550 1 Hub, Torque Less Fittings 1 70002015 8 Bolt M8 x 25 2 70002016 1 Ring, Motor Support 3 Use Item 51 1 O-Ring 4 70002018 1 Snap Ring 5 70002019 1 Retainer, Spring 6 70002020 9 Spring 7Use 70002249 1 Piston (was p/n 70002021) 8 See Note 1 Ring, Backup (Note: Use Item 51 or 53.) 9 See Note 1 O-Ring (Note: Use Item 51 or 53.)

10 See Note 1 O-Ring (Note: Use Item 51 or 53.) 11 See Note 1 Ring, Backup (Note: Use Item 51 or 53.) 12 70002026 5 Disc, Friction 13 70002027 6 Disc, Steel 14 Not Used 15 70002029 1 Spindle 16 70002030 4 Gear, Planetary 17 70002031 4 Bearing 18 70002032 5 Snap Ring 19 70002033 1 Gear, Brake/Input 20 70002034 1 Bearing 21 Not Used 22 70002035 1 Ring, Wear 23 70002036 1 Spring 24 70002037 1 Shaft, Engagement 25 Use Item 51 1 Seal 26 70002039 2 Bearing Assembly 27 70002040 1 Support, Hub 28 70002041 1 Nut, Retaining 29 Use 70002674 4 Washer (was p/n 70002042) 30 Use 70002674 4 Screw (was p/n 70002043) 31 70002044 1 Gear, Planetary Sun 32 70002045 1 Reduction Assembly, Secondary 33 70002046 1 Snap Ring 34 70002047 1 Gear, Secondary Input Sun 35 70002048 1 Reduction Assembly, Primary 36 70002049 1 Snap Ring 37 70002050 1 Gear, Primary Input Sun 38 Use Item 51 1 O-Ring 39 Not Available 1 Housing, Hub 40 70002052 2 Screw, Countersunk 41 See Note 1 O-Ring (Note: Use Item 51 or 52.) 42 Use Item 52 1 Thrustwasher 43 See Note 1 O-Ring (Note: Use Item 51 or 52.) 44 Use Item 52 1 Cover, Hub

3121263 1500SJ 1-17

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

45 Use Item 52 3 Plug 46 Use Item 52 1 Snap Ring 47 Use Item 52 1 Pin, Engagement 48 See Note 1 Gasket (Note: Use Item 51 or 52.) 49 Use Item 52 1 Cover, Engagement 50 Use Item 52 2 Screw 51 70002248 1 Seal Kit (Includes Items 3, 8-11, 25, 38, 41, 43 & 48) 52 70002247 1 Cover Kit (Includes Items 41-50) 53 70002249 1 Brake Kit (Includes Items 4-13)

54 to 100 Not Used

101 0761214 2 Bolt M12 x 30 102 2110404 1 Fitting, Adapter 103 2110808 1 Fitting, Adapter 104 2110812 1 Fitting, Adapter 105 2130406 1 Fitting, 90 Adapter 106 2130812 1 Fitting, 90 Adapter 107 Not Used 108 5241200 2 Flatwasher 12 Hardened 109 0100011 AR Compound, Locking 110 3790158 1 O-Ring 111 3020008 17oz Lubricant HD 80W-90 (Not Shown)

1-18 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121263 1500SJ 1-19

SECTION 1 FRAME

151617

2831323335

3634345152

FIGURE 1-6. DRIVE MOTOR ASSEMBLY

1-20 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160339 Ref DRIVE MOTOR ASSEMBLY B

1 7022368 4 Bolt 2 70000859 1 End Cap, Motor 3 70003628 2 Locating Pin 4 Use Item 51 1 O-Ring 5 7007420 1 Plug (Includes Item 4) 6 7007446 1 Pin, Dowel 7 7021249 1 Bearing, Needle 8 70000854 1 Plate, Valve 9 7022311 1 Snap Ring

10 7022314 1 Retainer, Spring 11 7024867 1 Spring 12 7024868 1 Washer (was p/n 7022313) 13 70000855 1 Block, Cylinder 14 7021275 3 Pin, Slipper 15 70000856 1 Guide 16 70000857 1 Retainer, Slipper 17 7024865 9 Piston, Cylinder 18 Use Item 51 1 Ring, Piston 19 Use Item 51 1 O-Ring 20 70000860 1 Piston, Servo (Includes Items 18 & 19) 21 70000861 1 Spring 22 Not Available 1 Pin 23 70000853 1 Swashplate 24 70000852 1 Bearing Kit 25 Use Item 51 1 Gasket 26 Not Available 1 Plug 27 Use Item 51 1 O-Ring 28 7022321 1 Plug (Includes Item 29) 29 Use Item 51 1 O-Ring 30 Not Available 1 Housing 31 70000858 1 Shaft 32 7007437 1 Bearing 33 7007439 1 Snap Ring 34 7007438 2 Snap Ring 35 Use Item 51 1 Seal 36 7022371 1 Washer, Seal Support

37 to 50 Not Used

51 70000862 Motor Seal Kit (Includes Items 4,18,19,25,27,29 & 35) 52 7027740 Cylinder Block Kit (Includes Items 9 - 17)

3121263 1500SJ 1-21

SECTION 1 FRAME

323

272

716

101

106

104

105

101

103

102

103

102

101

104

106

105

304

202

304

203

30420330420230420

304

202

309

208

062

5308207

304

202

306

205

310

209

307

206

30720

309

208

304

322

304

301

302

314

311

318

316

319

317

320

303

321

314

312

304

301

304

204

211

201

210

202

FIGURE 1-7. FRAME VALVES AND COVERS INSTALLATION

1-22 1500SJ 3121263

SECTION 1 FRAME

FIGURE 1-7. FRAME VALVES AND COVERS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001119717 Ref VALVES & MODULE INSTALLATION - FRAME MOUNTED D

1 0100011 AR Compound, Locking 2Not Used 3 0641424 2 Bolt 1/4-20NC x 3 4 0641504 8 Bolt 5/16-18NC x 1/2 5Not Used 6 0641509 4 Bolt 5/16-18NC x 1-1/8 7Not Used 8 0641608 20 Bolt 3/8-16NC x 1 9 0641808 4 Bolt 1/2-13NC x 1

10 to 14 Not Used

15 3311405 2 Locknut 1/4-20NC 16 3311505 9 Locknut 5/16-18NC 17 3311605 4 Locknut 3/8-16NC 18 3841340 2 Loop, Hose

19 to 20 Not Used

21 4060808 22 4641155 1 Manifold, Junction 23 Not Used 24 4641268 2 Valve Assembly - Steer (See Items 101-106) 25 4641454 1 Valve Assembly - Traction 26 4711400 8 Flatwasher 1/4 Thin 27 4711500 31 Flatwasher 5/16 Thin 28 4711600 26 Flatwasher 3/8 Thin 29 4711800 4 Flatwasher 1/2 Thin 30 Not Used 31 1001112758 1 Module (Chassis) (Note: Control System must be recalibrated

124in/3.2m

Flex-Trim

when Module is replaced)

4641268 2 STEER VALVE ASSEMBLY B

101 7026028 12 Cartridge (6 Per Valve)

7011346 12 Seal Kit - Cartridge (1 Per Cartridge)

102 7024927 4 Valve (2 Per Valve)

7012773 4 Seal Kit - Cartridge (1 Per Cartridge) 7018991 8 Coil (2 Per Valve)

103 Use 70001976 2 Valve (1 Per Valve) (was p/n 7012770)

7012773 2 Seal Kit - Cartridge (1 Per Cartridge) 7018991 4 Coil (2 Per Valve)

70001939 1 Orifice 104 2221086 6 Check, Pressure 105 2110606 8 Fitting, Straight 106 2130810 2 Fitting, 90

3121263 1500SJ 1-23

SECTION 1 FRAME

FIGURE 1-7. FRAME VALVES AND COVERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271523 Ref FRAME COVERS INSTALLATION (PLASTIC) C

201 0100011 AR Compound, Locking 202 0791604 63 Screw 3/8-16NC x 1/2 203 0791607 42 Screw 3/8-16NC x 7/8 204 1670996 1 Cover (Frame Front) 205 1671045 4 Plate, Cover (Axle Side) 206 1671046 4 Plate, Cover (Axle Corner) 207 1671047 1 Plate, Cover (Rear) 208 1671048 2 Plate, Cover (Frame Top) 209 1671049 4 Plate, Cover (Frame Side) 210 3900283 7 Screw 3/8-16NC x 3/4 211 4751600 7 Flatwasher 3/8 Regular

1001110114 Ref FRAME COVERS INSTALLATION (STEEL) C

301 0100011 AR Compound, Locking 302 0641406 8 Screw 1/4-20NC x 3/4 303 0641414 4 Screw 1/4-20NC x 1-3/4 304 0791604 63 Screw 3/8-16NC x 1/2 305 Not Used 306 1671045 4 Plate, Cover (Axle Side) 307 1671046 4 Plate, Cover (Axle Corner) 308 1671047 1 Plate, Cover (Rear) 309 1671048 2 Plate, Cover (Frame Top) 310 1671049 3 Plate, Cover (Frame Side) 311 3300454 8 Nut, Retainer 1/4-20NC 312 3311405 4 Locknut 1/4-20NC 313 Not Used 314 4711400 12 Flatwasher 1/4 Thin 315 Not Used 316 1001110108 1 Cover - RH Side 317 1001110109 1 Cover - LH Side 318 1001110110 1 Cover - Center Side 319 1001110111 1 Shift - RH Side 320 1001110112 1 Shift - LH Side 321 1001110113 2 Plate 322 1001110513 51in/5.5m Seal 323 1001110877 1 Mount, Fire Extinguisher

1-24 1500SJ 3121263

+ 302 hidden pages

JLG 1500SJ Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. AXLE INSTALLATIONS

FIGURE 1-2. STEER INSTALLATION

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

FIGURE 1-4. DRIVE HUB ASSEMBLY - BONFIGLIOLI

FIGURE 1-5. DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI

FIGURE 1-6. DRIVE MOTOR ASSEMBLY

FIGURE 1-7. FRAME VALVES AND COVERS INSTALLATION