JLG 15ELI Parts Manual

Illustrated Parts Manual

Model

15ELI

3120780

May 23, 2006

REVISION LOG

February 26, 1999 - Original Issue Of Manual

November 1, 1999 - Revised (Manual edited to 0010560 Revision 3)

June 15, 2000 - Revised

March 1, 2001 - Revised (Manual edited to 0010560 Revision 9)

August 1, 2002 - Revised (Manual edited to 0010560 Revision 15)

February 27, 2003 - Revised (Manual edited to 0010560 Revision 17)

July 31, 2003 - Revised (Manual edited to 0010560 Revision 21)

September 2, 2004 - Revised (Manual edited to 0010560 Revision 25)

March 30, 2005 - Revised (Manual edited to 0010560 Revision 29)

May 23, 2006 - Revised (Manual edited to 0010560 Revision 31)

3120780 15ELI A

REVISION LOG

B 15ELI 3120780

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 AC POWER COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 AC JUNCTION BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 AC MOTOR/PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 DC POWER COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 DC POWER PACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-6 BATTERY CHARGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-7 DC MOTOR/PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-8 CABLES AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 MAST ASSEMBLY (CHAIN & CABLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAST MOUNTED COMPONENTS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

4-1 PLATFORM INSTALLATION (GULLWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

5-1 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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

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

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

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

7-2 ELECTRICAL DIAGRAM - 12VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 ELECTRICAL DIAGRAM - 115VAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4 ELECTRICAL DIAGRAM - AC BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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

3120780 15ELI i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii 15ELI 3120780

SECTION 1

BASE

3120780 15ELI 1-1

SECTION 1 BASE

104

102

109

108

106 108

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

108

106

107

102 106 108

301

305

302

304

303

3 5 6 8

210 211

204

202

206

204

214

212

208

203

209

207

201

213

203

1-2 15ELI 3120780

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BASE ASSEMBLY OPTIONS: 0259070 Ref. Prior to S/N 19526 B 0272230 Ref. S/N 19526 to Present C

1 0641607 8 Bolt 3/8”-16NC x 7/8” 2 3311605 8 Locknut 3/8”-16NC 3 3760348 2 Ring, Retainer 4 4711600 16 Flatwasher 3/8” 5 2 Washer Options:

4712200 Prior to S/N 19526 4740415 S/N 19526 to Present

6 4740456 4 Washer, Shim 7 1 Base Weldment Options:

4845885 Prior to S/N 19526 4846613 S/N 19526 to Present

8 2 Wheel Assembly Options: (Stationary)

4860183 Wheel Assembly (Prior to S/N 13429) A 7020083 2 Wheel, Replacement 7020084 4 Bearing (2 Per Wheel) 4860202 Wheel Assembly (S/N 13429 to S/N 20796) B

2 Bearing Options: (1 Per Wheel) 7020209 S/N 13429 to S/N 13607 7024561 S/N 13607 to Present 7020074 4 Retainer (2 Per Wheel) 7012631 2 Spanner (1 Per Wheel) 4860246 Wheel Assembly (S/N 20796 to Present)

(No Service Parts Available)

9 Wheel Assembly Options:

2 Wheel Assembly - (Non-Locking) Options: 4860184 Wheel Assembly (Prior to S/N 20877)

(Non-Locking Gray Tire & Wheel)

4860245 Wheel Assembly (S/N 20877 to Present)

(Non-Locking Charcoal Gray Tire & Gray Wheel)

7020017 2 Swivel Rig for 4860184 (1 Per Assembly)

Not Available 2 Swivel Rig for 4860245 (1 Per Assembly)

7020086 2 Wheel, Replacement for 4860184 (1 Per Assembly)

Not Available 2 Wheel, Replacement for 4860245 (1 Per Assembly)

7020084 4 Bearing for 4860184 (2 Per Wheel)

Not Available 4 Bearing for 4860245 (2 Per Wheel)

7012631 2 Bushing, Axle Spanner for 4860184 (1 Per Assembly)

Not Available 2 Bushing, Axle Spanner for 4860245 (1 Per Assembly)

7012630 2 Axle Kit for 4860184 (1 Per Assembly)

Not Available 2 Axle Kit for 4860245 (1 Per Assembly) 10 3020017 A/R Lubricant (Not Shown) (Used Prior to S/N 20796) 11 4240032 A/R Tie, Wire (Not Shown - 4in Long) 12 4460234 A/R Mount, Wire Tie (Not Shown)

3120780 15ELI 1-3

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MAST SUPPORT INSTALLATION OPTIONS: 0259071 Ref. Prior to S/N 19526 A 0272232 Ref. S/N 19526 to Present A

101 0100001 A/R Adhesive (Not Shown) 102 0641609 12 Bolt 3/8”-16NC x 1 1/8” 103 Not Used 104 2420140 1 Gauge, Circular Level 105 2560088 2 Handle 106 3311605 12 Locknut 3/8”-16NC 107 4567824 2 Tube, Mast Brace 108 4711600 24 Flatwasher 3/8” 109 4845715 1 Support Weldment 110 1704582 1 Decal - Manual Descent (Not Shown - Located at bottom of

Mast) (S/N 19526 to Present Only)

0259104 Ref. FLOOR STOP INSTALLATION 4/C

201 0920114 1 Stop, Floor 202 1 Limit Switch Options:

Use 4360456 Prior to S/N 13474 (Was p/n 4360397)

4360456 S/N 13474 to Present

203 0641808 4 Bolt 1/2”-13NC x 1” 204 3311805 4 Locknut 1/2”-13NC 205 4711800 2 Flatwasher 1/2” 206 3911020 2 Screw #10-24NC x 1 1/4” 207 3311001 2 Nut #10-24NC 208 4751000 2 Flatwasher #10 209 4761000 2 Lockwasher #10 210 3539920 A/R Spacer - 11ga. 211 3539921 A/R Spacer - 14ga. 212 4460662 1 Strain Relief 213 0902523 1 Bracket, Limit Switch 214 4922561 1 Harness, Brake 215 4460234 A/R Mount, Wire Tie (Not Shown) 216 4240033 A/R Tie, Wire (Not Shown)

0256808 Ref. DESCENT ALARM INSTALLATION (OPTIONAL) C

301 0140033 1 Alarm 302 0641406 2 Bolt 1/4”-20NC x 3/4” 303 4751400 4 Flatwasher 1/4” 304 3311405 4 Nut 1/4”-20NC 305 4922805 1 Harness, Alarm (S/N 23815 to Present)

1-4 15ELI 3120780

SECTION 2

CONTROLS

3120780 15ELI 2-1

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

2-2 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. POWER PACK ASSEMBLY 0259206 Ref. 110 VOLT (Prior to S/N 19526) A 0272238 Ref. 110 VOLT (S/N 19526 to Present) B

1 0630486 4 Screw, Counter Sunk 2 0641406 4 Bolt 1/4”-20NC x 3/4” 3 0721006 2 Screw 4 Not Used 5 0860933 1 Junction Box Assembly (See Figure 2-2 for Breakdown) 6 1 Ground Control Box Assembly Options:

0861212 Prior to S/N 20166 0861305 S/N 20166 to Present 7020095 1 Switch, Push-Pull (Stop) 7020096 1 Legend Plate, “Stop” 7020097 1 Legend Plate, “Power/Off/On” 7020098 1 Switch, Key 7016339 1 Key, Replacement

1 Connector, Strain Relief Options: 7020090 1 Prior to S/N 20166 4460633 1 S/N 20166 to S/N 23612 7027787 1 S/N 23612 to Present 7020093 4 Screw 3m x 25 7020094 1 Lid

7 3311005 A/R Locknut #10-24NC 8 3311405 4 Locknut 1/4”-20NC 9 3311505 4 Locknut 5/16”-18NC

10 1 Pump/Motor Assembly Options: (See Figure 2-3 for Break-

down) 3600264 Prior to S/N 19526 3600353 S/N 19526 to Present

11 Not Used 12 4460566 1 Terminal, 90 Degrees 13 4751000 A/R Flatwasher #10 14 4751400 8 Flatwasher 1/4” 15 4751500 4 Flatwasher 5/16” 16 4845712 1 Plate, Mounting

Ref. POWER PACK INSTALLATION 0259294 Ref. Prior to S/N 19526 A 0272235 Ref. S/N 19526 to Present A

101 Not Used 102 0641404 4 Bolt 1/4”-20NC x 1/2” 103 0641614 4 Bolt 3/8”-16NC x 1 3/4” 104 1702353 1 Decal - Manual Descent (Prior to S/N 19526 Only)

105 to 108 Not Used

109 3311605 4 Locknut 3/8”-16NC

3120780 15ELI 2-3

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

110 1 Shield, Pump Cover Options:

4060875 Prior to S/N 19526

4061024 S/N 19526 to Present 110A 1704582 Decal (S/N 19688 to Present Only) 110B 9984088 Cover (S/N 19688 to Present Only)

111 to 113 Not Used

114 4711400 4 Flatwasher 1/4” Narrow 115 4711600 8 Flatwasher 3/8” Narrow 116 4070984 2 Shim, Pump Spacer

2-4 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-1. AC POWER COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120780 15ELI 2-5

SECTION 2 CONTROLS

FIGURE 2-2. AC JUNCTION BOX ASSEMBLY

2-6 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-2. AC JUNCTION BOX ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

JUNCTION BOX ASSEMBLY

0860933 Ref. 110 VOLT 10/I

1 1 Box with Lid Options:

0860911 Prior to S/N 13477

0860943 S/N 13477 to Present 2 7017440 2 Relay, Starter 12 VDC 3 3740093 1 Relay, Starter 4 3910808 12 Screw #8-32NF x 1/2” 5 4460565 1 Strip, Terminal

6 to 8 Not Used

9 4460633 A/R Connector, Strain Relief

10 to 15 Not Used

16 4360161 1 Circuit Breaker - 20 Amp 17 4360376 1 Rectifier 18 3740049 1 Relay 19 1 Transformer Options:

Use 4530013 Prior to S/N 14643 (Was p/n 4530010)

4530013 S/N 14643 to Present

20 Not Used 21 1 Harness Options:

4921663 Prior to S/N 23728

4923034 S/N 23728 to Present

22 1702569 1 Decal - 110 Volts (Not Shown) 23 1702120 1 Decal - Wire Size (Not Shown - Located on Front Cover) 24 1702365 1 Decal - JLG (Not Shown - Located on Front Cover) 25 3520028 1 Plug (S/N 13477 to Present Only) 26 3520034 4 Plug (S/N 19636 to Present Only) 27 4923131 1 Harness, AC Box (Not Shown) (S/N 20166 to Present) 28 4933305 1 Wiring Diagram, AC Box (Not Shown - See Section 7) (S/N

20166 to Present)

3120780 15ELI 2-7

SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY

2-8 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MOTOR/PUMP ASSEMBLY 3600264 Ref. 110 Volt (Prior to S/N 19526) A 3600353 Ref. 110 Volt (S/N 19526 to Present) C

1 7013713 2 Bolt 5/16”-24NF x 2 3/4” 2 7016735 1 Coupling 3 7013714 1 Plug 4 Kit 1 Ball (Was p/n 7013715) 5 7013716 1 Seal (Part of Pump Seal Kit p/n 7013701) 6 7013717 1 Washer 7 Not Used 8 7013722 1 Magnet

9 7013723 1 Filter 10 7013727 1 Cover 11 7013728 2 Screw 12 1 Gasket Options:

7016764 Prior to S/N 19526

7022225 S/N 19526 to Present 13 Not Used 14 7016765 1 Motor 15 1 Cover, Switch Box Options:

7013787 Prior to S/N 19526

7022226 S/N 19526 to Present 16 7013708 1 Cartridge, Valve - Check 17 3931516 1 Bolt 5/16”-18NC x 1” 18 7016756 1 Pipe, Plumbing 19 7016757 4 Bolt M6-1.0 35MM 20 7016758 4 Lockwasher 1/4” 21 7016721 4 Bolt #12-24NC x 1/2” 22 7016722 1 Pipe Nut (Not Shown) 23 Not Used 24 A/R Tank Options:

24A 7016760 1 Tank Used Prior to S/N 19526

24B 7013748 1 Decal - Caution (Prior to S/N 19526) 24C 7016759 1 Plug (Prior to S/N 19526) 24D 7022219 1 Tank Used S/N 19526 to Present 24E 7013748 1 Decal - Caution (S/N 19526 to Present) 24F 7013722 1 Plug, Magnetic (S/N 19526 to Present)

25 7016761 1 Tube, Return 26 7013792 1 Nut, Tube Compression 27 7013793 1 Sleeve, Tube Compression 28 Kit 1 Spring, Green (Was p/n 7016762) 29 1 Cartridge, Valve - Manual Descent Options:

7013764 Prior to S/N 19526

Not Required S/N 19526 to Present (Moved to Lift Cylinder) 30 7016751 1 Coil, Solenoid 31 7013743 1 O-Ring

3120780 15ELI 2-9

SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

32 1 End Head Options:

7016753 Prior to S/N 19526 7022220 S/N 19526 to Present

33 7016717 1 Pump Assembly

33A 7013701 Seal Kit - Pump (Includes Gasket for Item #10 Cover,

O-Ring & #5 Seal) 34 Kit 1 Cap, Relief (Was p/n 7013750) 35 1 Breather Options:

35A 7013794 Prior to S/N 19526 35B 7016714 S/N 19526 to Present 35C 7013748 1 Decal - Caution

36 2 Plug Options:

7013720 Prior to S/N 19526

Not Required S/N 19526 to Present

37 1 Tube, Return Options:

7013763 Prior to S/N 19526

7022224 S/N 19526 to Present 38 7016755 1 Valve 39 Kit 1 Screw, Adjustment (Was p/n 7013770) 40 7013745 1 Decal, Motor 50/60 Hertz (Not Shown)

— — — — — — — — — —

7013779 1 Relief Valve Kit (Includes Items 4, 28, 34 & 39)

2-10 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-3. AC MOTOR/PUMP ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120780 15ELI 2-11

SECTION 2 CONTROLS

FIGURE 2-4. DC POWER COMPONENTS INSTALLATION

2-12 15ELI 3120780

SECTION 2 CONTROLS

FIGURE 2-4. DC POWER COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. POWER PACK ASSEMBLY 0259205 Ref. 12 VOLT (Prior to S/N 19526) A 0272237 Ref. 12 VOLT (S/N 19526 to Present) D

1 0100011 A/R Loctite, #242 (Not Shown) 2 0630486 4 Screw, Countersunk 3 0641403 3 Bolt 1/4”-20NC x 3/8” 4 Hardware Options:

0641608 2 Prior to S/N 19526 (Bolt 3/8”-16NC x 1”) 0641606 S/N 19526 to S/N 20835 (Bolt 3/8”-16NC x 3/4”) 0791605 S/N 20835 to Present (Screw 3/8”-16NC x 5/8”)

5 0721006 2 Screw 6 0721014 1 Screw (Prior to S/N 19526 Only) 7 1 Ground Control Box Assembly Options:

0861212 Prior to S/N 20166 0861305 S/N 20166 to Present 7020078 1 Switch, Push-Pull (Stop) 7020096 1 Legend Plate, “Stop” 7020097 1 Legend Plate, “Power/Off/On”

1 Switch, Key Options: 7020098 Prior to S/N 20166 4360467 S/N 20166 to Present

1 Key, Replacement Options: 7016339 Prior to S/N 20166 2860030 S/N 20166 to Present 7020090 1 Connector, Strain Relief 7020093 4 Screw M3 x 25 7020094 1 Lid

8 0902054 1 Plate, Mounting

9 1060518 1 Cable, Solenoid (Prior to S/N 19526 Only) 10 1060571 1 Cable Assembly - Battery 11 3311005 3 Locknut #10-24NC 12 3311505 4 Locknut 5/16”-18NC 13 1 DC Motor/Pump Assembly (See Figure 2-7 for Breakdown)

3600291 Prior to S/N 19526

3600355 S/N 19526 to Present 14 3740013 1 Solenoid (Prior to S/N 19526 Only) 15 1 Relay Options:

3740080 Prior to S/N 19526

3740049 S/N 19526 to Present 16 3740113 1 Relay, Timer (Prior to S/N 19526 Only) 17 4567605 2 Tube, Butyrate (Not Shown) 18 4711400 3 Flatwasher 1/4” 19 4751000 6 Flatwasher #10 20 4751500 4 Flatwasher 5/16” 21 4751600 2 Flatwasher 3/8” (Prior to S/N 20835Only) 22 4845714 1 Bracket, Pump Mounting 23 0641404 1 Bolt 1/4”-20NC x 1/2” (Not Shown) (S/N 19526 to Present Only) 24 4751400 1 Flatwasher 1/4” (Not Shown) (S/N 19526 to Present Only)

3120780 15ELI 2-13

+ 53 hidden pages