JLG 15SP Parts Manual

Illustrated Parts Manual

Models

12SP

15SP

3120776

December 30, 2013

REVISION LOG

June 30,1999 - Original Issue Of Manual

November 1, 1999 - Updated Section 1

May 1, 2000 - Revised Manual (Edited to 0010563 Revision 11)

September 1, 2000 - Revised Manual (Edited to 0010563 Revision15)

March 15, 2001 - Revised Manual (Edited to 0010563 Revision 18)

January 15, 2002 - Revised Manual (Revised Pump and Lift Cylinders)

February 1, 2002 - Revised Manual (Edited to 0010563 Revision 30)

March 31, 2003 - Revised Manual (Edited to 0010563 Revision 35)

June 30, 2003 - Revised Manual (Edited to 0010563 Revision 40)

August 15, 2004 - Revised Manual (Edited to 0010563 Revision 47)

October 16, 2006 - Revised Manual (Edited to 0010563 Revision 62)

June 5, 2007 - Revised Manual (Edited to 0010563 Revision 70)

November 12, 2007 - Revised Manual (Edited to 0010563 Revision 71)

May 15, 2009 - Revised Manual (Edited to 0010563 Revision 76)

August 1, 2010 - Revised Manual (Edited to 0010563 Revision 78)

February 1, 2011 - Revised Manual (Edited to 0010563 Revision 80)

May 20, 2011 - Revised Manual (Edited to 0010563 Revision 80)

August 9, 2011 - Revised Manual (Edited to 0010563 Revision 80)

November 21, 2011 - Revised Manual (Edited to 0010563 Revision 80)

March 2, 2012 - Revised Manual (Edited to 0010563 Revision 80)

July 6, 2012 - Revised Manual (Edited to 0010563 Revision 80)

October 3, 2012 - Revised Manual (Edited to 0010563 Revision 80)

February 7, 2013 - Revised Manual (Edited to 0010563 Revision 80)

June 1, 2013 - Revised Manual (Edited to 0010563 Revision 80)

September 1, 2013 - Revised Manual (Edited to 0010563 Revision 80)

December 30, 2013 - Revised Manual (Edited to 0010563 Revision 80)

3120776 12SP & 15SP A

REVISION LOG

B 12SP & 15SP 3120776

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 DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449). . . . . . . . . . . . . . . . 2-2

2-2 DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT) . . . . . . . . . . . . . 2-8

2-3 DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449) . . . . . . . . . 2-12

2-4 DC MOTOR/PUMP ASSEMBLY (MONARCH) (S/N 0900027449 TO PRESENT). . . . . 2-16

2-5 BATTERY & CHARGER INSTALLATION (PRIOR TO S/N 0900031592) . . . . . . . . . . . . 2-18

2-6 BATTERY & CHARGER INSTALLATION (S/N 0900031592 TO PRESENT) . . . . . . . . . 2-22

2-7 BATTERY CHARGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-8 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 4 SECTION

MAST (S/N 0900015116 TO S/N 0900028704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-9 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 4 SECTION

MAST (S/N 0900028704 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-10 CABLE & PLATFORM CONTROLS INSTALLATION - 12SP WITH 5 SECTION MAST (

PRIOR TO S/N 0900015116) & ALL 15SP (PRIOR TO S/N 0900028704) . . . . . . . . 2-34

2-11 CABLE & PLATFORM CONTROLS INSTALLATION - 15SP WITH 5 SECTION

MAST (S/N 0900028704 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

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

3-1 MAST ASSEMBLY - 12SP WITH 4 SECTION MAST (S/N 0900015116 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAST ASSEMBLY - 12SP WITH 5 SECTION MAST (PRIOR TO S/N 0900015116) . . . 3-8

3-3 MAST ASSEMBLY - 15SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-4 MAST MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

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

4-1 STEEL BASE PLATFORM INSTALLATION (PRIOR TO S/N 0900018610) . . . . . . . . . . 4-2

4-2 STEEL BASE PLATFORM INSTALLATION (S/N 0900018610 TO PRESENT) . . . . . . . 4-6

4-3 STEEL BASE PLATFORM INSTALLATION WITH EXTENSION . . . . . . . . . . . . . . . . . . 4-10

4-4 MOLDED BASE PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 SIDE ENTRY PLATFORM WITH FOLDING TRAY INSTALLATION . . . . . . . . . . . . . . . . 4-16

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

5-1 LIFT CYLINDER ASSEMBLY (PRIOR TO S/N 0900018391) . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LIFT CYLINDER ASSEMBLY (S/N 0900018391 TO S/N 0900029975). . . . . . . . . . . . . 5-4

5-3 LIFT CYLINDER ASSEMBLY (S/N 0900029975 TO PRESENT) . . . . . . . . . . . . . . . . . . 5-6

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

6-1 HYDRAULIC DIAGRAM (PRIOR TO S/N 0900027449) . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM (S/N 0900027449 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . 6-4

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

7-1 ELECTRICAL DIAGRAM (PRIOR TO S/N 0900017472) . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL DIAGRAM (S/N 0900017472 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . 7-4

3120776 12SP & 15SP i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

ii 12SP & 15SP 3120776

SECTION 1

BASE

3120776 12SP & 15SP 1-1

SECTION 1 BASE

1 3

509

511

512

8 1

201

106

109

111

107

101

102

110

102

110

112

110

108

114

108

103

104

105

402

401

301

302

303

304

405

403

506

500

15 21 20 17

508

507

510

NOTE: REPLACEMENT DECALS MUST BE

ORDERED SEPARATELY – SEE SECTION 8.

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

1-2 12SP & 15SP 3120776

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BASE ASSEMBLY 0259472 Ref. Prior to S/N 0900018391 J 0271922 Ref. S/N 0900018391 to Present C

1 0100019 A/R Compound, Locking 2 0641607 8 Bolt 3/8in-16NC x 7/8in 3 0641812 8 Bolt 1/2in-13NC x 1-1/2in 4Not Used 5 0920114 2 Stop, Floor 6 3760348 2 Ring, Retaining 7Not Used 8 4711600 8 Flatwasher 3/8in Thin

9 4711800 4 Flatwasher 1/2in Thin 10 4740456 4 Shim 11 1 Base Options:

4846025 Prior to S/N 0900018391 4846534 S/N 0900018391 to Present

12 2 Wheel, Rear Options:

Use 4860202 Prior to S/N 0900013574 (was p/n 4860183) (Gray Wheel)

4860202 S/N 0900013574 to S/N 0900013653 (Gray Wheel) 4860208 S/N 0900013653 to S/N 0900020797 (Black Wheel) 4860211 S/N 0900013653 to S/N 0900020797 (Red Wheel) 4860244 S/N 0900020797 to Present (Gray Wheel)

Replacement Wheel Parts: 7020209 2 Bearing for 4860202 Wheel (1 Per Wheel) 7020237 2 Bearing for 4860208 & 4860211 Wheel(1 Per Wheel)

See Note 2 Bearing for 4860244 Wheel (1 Per Wheel)

(Note: Not Available for Purchase - Use 4860244)

7020074 4 Retainer for 4860202 Wheel (2 Per Assembly)

See Note 0 Retainer for 4860208, 4860211 & 4860244 Wheel

(Note: Not Required)

7012631 2 Spanner for 4860202 Wheel (1 Per Assembly)

See Note 0 Spanner for 4860208, 4860211 & 4860244 Wheel

(Note: Not Required)

13 Not Used 14 0721005 2 Screw #10-24NC x 5/8in 15 1320043 2 Clamp, Cable (S/N 0900014145 to Present Only) 16 Not Used 17 3311005 2 Locknut #10-24NC 18 Not Used 19 Not Used 20 4751000 4 Flatwasher #10 Regular 21 4761000 4 Lockwasher #10 22 4240032 5 Tie-Strap (Not Shown) 23 4460234 2 Tie-Strap (Not Shown) 24 4740415 2 Flatwasher, Special

3120776 12SP & 15SP 1-3

SECTION 1 BASE

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MAST SUPPORT INSTALLATIONS 0270399 Ref. 12SP with 5 Section Mast (Prior to S/N 0900015116) A 0270491 Ref. 12SP with 4 Section Mast (S/N 0900015116 - S/N 0900018391) A 0271924 Ref. 12SP with 4 Section Mast (S/N 0900018391 to Present) B 0259357 Ref. 15SP (Prior to S/N 0900018391) B 0271923 Ref. 15SP (S/N 0900018391 to Present) B

101 0100001 A/R Adhesive 102 0641609 4 Bolt 3/8in-16NC x 1-1/8in 103 A/R Bolt 3/8in-16NC Options:

0641610 Bolt 3/8in-16NC x 1-1/4in 0641612 Bolt 3/8in-16NC x 1-1/2in

104 1 Mast Assembly Options (Not Shown - See Section 3 for

Breakdown): 0801255 12SP with 5 Section Mast (Prior to S/N 0900015116) 0801257 12SP with 4 Section Mast (S/N 0900015116 to

S/N 0900018391) 0801324 12SP with 4 Section Mast (S/N 0900018391 to Present) 0801195 15SP Prior to S/N 0900018391 0801323 15SP S/N 0900018391 to Present

105 1704582 1 Decal - Manual Descent (S/N 0900018391 to Present Only) 106 2420140 1 Gauge, Level 107 2560088 2 Handle 108 3311605 A/R Locknut 3/8in-16NC 109 2 Tube, Mast Brace Options:

4567911 Prior to S/N 0900031592

1001110174 S/N 0900031592 to Present 110 4711600 A/R Flatwasher 3/8in Thin 111 4845715 1 Support, Mast 112 0100011 A/R Compound, Locking 113 Not Used 114 Use 3311608 4 Nut, Flanged 3/8in-16NC

201 2 FRONT WHEEL OPTIONS:

4860184 Wheel Assembly (Prior to S/N 0900013653)

(Non-Locking Gray Tire & Wheel)

4860194 Wheel Assembly (Prior to S/N 0900013653)

(Locking Gray Tire & Wheel)

4860209 Wheel Assembly (S/N 0900013653 to S/N 20797)

(Non-Locking Black Tire & Gray Wheel)

4860245 Wheel Assembly (S/N 0900020797 to Present)

(Non-Locking Charcoal Gray Tire & Gray Wheel)

Replacement Wheel Parts: 7020017 2 Swivel Rig for 4860184 & 4860194 (1 Per Assembly) 7020240 2 Swivel Rig for 4860209 (1 Per Assembly)

See Note 2 Swivel Rig for 4860245 (1 Per Assembly)

(Note: Not Available for Purchase - Use 4860245)

7020086 2 Wheel, Replacement for 4860184 & 4860194

(1 Per Assembly)

7020243 2 Wheel, Replacement for 4860209 (1 Per Assembly)

1-4 12SP & 15SP 3120776

SECTION 1 BASE

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

201 cont’d See Note 2 Wheel, Replacement for 4860245 (1 Per Assembly)

(Note: Not Available for Purchase - Use 4860245)

7020084 4 Bearing for 4860184, 4860194 & 4860209 (2 Per Wheel)

See Note 4 Bearing for 4860245 (2 Per Wheel)

7012631 2 Bushing, Axle Spanner for 4860184 & 4860194

(1 Per Assembly)

7020241 2 Bushing, Axle Spanner for 4860209 (1 Per Assembly)

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

(Note: Not Available for Purchase - Use 4860245)

7012630 2 Axle Kit for 4860184 & 4860194 (1 Per Assembly) 7020242 2 Axle Kit for 4860209 (1 Per Assembly)

See Note 2 Axle Kit for 4860245 (1 Per Assembly)

(Note: Not Available for Purchase - Use 4860245)

Ref. DESCENT ALARM INSTALLATION

0256808 Ref. Prior to S/N 0900018391 (Optional) —

0259472/0271922 Ref. S/N 0900018391 to Present (Standard Equipment) J/C

301 0140033 1 Alarm 302 0641406 2 Bolt 1/4in-20NC x 3/4in 303 4751400 4 Flatwasher 1/4in Regular 304 3311405 4 Nut 1/4in-20NC

Ref. BEACON ASSEMBLY

0259447 Ref. Prior to S/N 0900018391 (Optional) —

0259472/0271922 Ref. S/N 0900018391 to Present (Standard Equipment) J/C

401 0721008 2 Screw #10-24NC x 1in 402 2920146 1 Lamp, Beacon

7016319 1 Bulb, Replacement

7016372 1 Lens, Replacement 403 3311005 2 Locknut #10-24NC 404 Not Used 405 4751000 4 Flatwasher #10 Regular

Ref. ELECTRICAL COMPONENTS (BASE MOUNTED)

4933103 Ref. Prior to S/N 0900018391 B

0259472/0271922 Ref. S/N 0900018391 to Present J/C

500 4922416 1 Limit Switch/Beacon Light/Alarm Harness

(Includes Items 501-518)

501 to 505 Not Used

506 4460662 2 Connector, Strain Relief (Prior to S/N 0900027811) 507 2 Switch, Limit Options

4360397 Prior to S/N 0900013465

4360456 S/N 0900013465 to S/N 0900027811

4360702 S/N 0900027811 to Present 508 3911024 4 Screw #10-24NC x 3in 509 3311001 4 Nut #10-24NC 510 4751000 4 Flatwasher #10 Regular

3120776 12SP & 15SP 1-5

SECTION 1 BASE

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

511 4761000 4 Lockwasher #10 512 0902523 2 Bracket, Limit Switch

513 to 517 Not Used

518 3730099 1 Resistor (Not Shown)

1-6 12SP & 15SP 3120776

SECTION 2

CONTROLS

3120776 12SP & 15SP 2-1

SECTION 2 CONTROLS

116

103 115 109

701

703

702

201

203

204

606

613

613 608

602

306

611

307

604

302

609

303

610

309

614

11 19

31815

5 11 19

302

305

308

301

501

304

601

605

612

60323143189404

405

407

401

401 402 403

104

110

102

114

110A

406

110B

615

616

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449)

2-2 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MOTOR/PUMP & GROUND CONTROL INSTALLATIONS 0259449 Ref. Key Control Prior to S/N 0900017472 B 0271307 Ref. Key Control S/N 0900017472 to S/N 0900018391 A 0271929 Ref. Key Control S/N 0900018391 to S/N 0900027449 E 0272172 Ref. Keyless Control D

1 0100011 A/R Compound, Locking 2 0630486 4 Screw, Countersunk 3 0641403 3 Bolt 1/4in-20NC x 3/8in 4 0791605 2 Screw 3/8in-16NC x 5/8in 5 0721006 2 Screw 6 0721014 1 Screw (Prior to S/N 0900017472 Only) 7 1 Ground Control Box Assembly Options:

0861305 Box with Key Control E 0861536 Box with Keyless Control A 7020078 1 Switch, Push-Pull (Stop) 7020096 1 Legend Plate, “Stop” 7020097 1 Legend Plate, “Power/Off/On”

1 Switch, On/Off Options: 4360467 Switch, Key 2860030 1 Key, Replacement 7024411 Switch, Keyless

1 Strain Relief Options: 4460633 Prior to S/N 0900023599 7027299 S/N 0900023599 to S/N 0900027449 7020093 4 Screw M3 x 25mm 3910804 3 Screw #8-32 x 1/4in (Use on Keyswitch Terminals) 7020094 1 Box

8 0902054 1 Plate, Mounting 9 1060518 1 Cable, Battery (Prior to S/N 0900017472 Only)

10 1060571 1 Cable Assembly - Battery

4460567 1 Connector, Anderson

11 3311005 3 Locknut #10-24NC 12 3311505 4 Locknut 5/16in-18NC 13 1 DC Motor/Pump Assembly Options (See Figure 2-3 for

Breakdown): 3600291 Prior to S/N 0900013731 3600306 S/N 0900013731 to S/N 0900018391

Use 2915259 S/N 0900018391 to S/N 0900027449 (was p/n 3600343)

Ref. (Note: Kit p/n 2915259 includes Pump/Motor and 1

Hydraulic Tube. Once kit has been added, machine will be updated to S/N 0900027449 to Present.)

14 3740013 1 Solenoid (Prior to S/N 0900017472 Only) 15 A/R Relay Options:

3740080 2 Prior to S/N 0900017472 3740049 1 S/N 0900017472 to S/N 0900027449

16 3740113 1 Relay, Timer (Prior to S/N 0900017472 Only) 17 4567605 2 Tube, Butyrate (Not Shown) 18 4711400 3 Flatwasher 1/4in Thin (Prior to S/N 0900020824 Only)

3120776 12SP & 15SP 2-3

SECTION 2 CONTROLS

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

19 4751000 6 Flatwasher #10 Regular 20 4751500 4 Flatwasher 5/16in Regular 21 4751600 2 Flatwasher 3/8in Regular (Prior to S/N 0900020824 Only) 22 4845714 1 Bracket, Pump Mounting 23 1320224 1 Clamp, Cable 24 4791500 1 Starwasher 5/16in

Ref. MOTOR/PUMP COVER INSTALLATIONS 0270117 Ref. 12SP Prior to S/N 0900015116 B 0259294 Ref. 12SP S/N 0900015116 to S/N 0900018391 A 0271928 Ref. 12SP S/N 0900018391 to S/N 0900027449 D 0259294 Ref. 15SP Prior to S/N13653 A 0258478 Ref. 15SP S/N 0900013653 to S/N 0900013872 B 0270117 Ref. 15SP S/N 0900013872 to S/N 0900018391 C 0271927 Ref. 15SP S/N 0900018391 to S/N 0900027449 E

101 Not Used 102 0641404 4 Bolt 1/4in-20NC x 1/2in 103 0641614 4 Bolt 3/8in-16NC x 1-3/4in 104 1702353 1 Decal, Manual Decent (Prior to S/N 0900018391 Only)

105 to 108 Not Used

109 3311605 4 Locknut 3/8in-16NC 110 1 Shield, Pump Cover Options:

4060875 Prior to S/N 0900018485 9981089 S/N 0900018485 to S/N 0900019088 4061024 S/N 0900019088 to S/N 0900027449

110A 1704582 Decal (S/N 0900018485 to S/N 0900027449 Only) 110B 9984088 Cover (S/N 0900018485 to S/N 0900027449 Only)

111 to 113 Not Used

114 4711400 4 Flatwasher 1/4in Thin 115 4711600 8 Flatwasher 3/8in Thin 116 4070984 2 Shim, Pump Spacer (12 SP S/N 0900015116 to S/N

0900027449 Only and 15SP Prior to S/N13653 Only)

117 2820035

118 4240032 1 Tie Wire (S/N 0900016317 to S/N 0900027449) (Not Shown) 119 4240033 8 Tie Wire (7 inch) (S/N 0900016317 to S/N 0900027449) (Not

7.3ft/2.24m

1/4 Expandable Loom (15SP S/N 0900016317 to S/N

0900025179) (Not Shown)

Shown)

0259450 Ref. AUXILIARY LOWERING INSTALLATION (OPTIONAL) A

201 0861213 1 Box, Power Down

0400181 2 Battery 4460320 1 Connector, Amp 4460267 2 Pin, Amp

202 Not Used 203 4420064 .3ft/.09m Velcro, Loop 204 4420065 .3ft/.09m Velcro, Hook

2-4 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0270020 Ref. CYCLE COUNTER INSTALLATION (OPTIONAL) B

301 2420193 1 Gauge, Counter 302 3311001 4 Nut #10-24NC 303 3520166 1 Plug 304 3572158 1 Bracket, Gauge Mounting 305 3911010 2 Screw #10-24NC x 5/8in 306 3911024 2 Screw #10-24NC x 1-1/2in 307 4360437 1 Switch, Limit 308 4761000 2 Lockwasher #10 309 4622377 1 Harness, Counter

Ref. HARNESS INSTALLATION 4933103 Ref. Prior to S/N 0900017472 (Key Control) 2/B 0271307 Ref. S/N 0900017472 to S/N 0900018391 (Key Control) A 0271929 Ref. S/N 0900018391 to S/N 0900027449 (Key Control) E 0272172 Ref. (Keyless Control) D

1 Harness, Pump Options: 4922412 Prior to S/N 0900017472 (Key Control) 1/A 4922558 S/N 0900017472 to S/N 0900018391 (Key Control) 1/A 4922605 S/N 0900018391 to S/N 0900019088 (Key Control) 2/B 4922740 S/N 0900019088 to S/N 0900027449 (Key Control) 2/B 4922605 (Keyless Control) 2/B 2400006 1 Fuse 4460044 1 Fuseholder 3990010 2 Diode - 6 Amp (Prior to S/N 0900018391 Only) 4922420 1 Harness, Jumper (Prior to S/N 0900018391 Only) 1/A 3990010 1 Diode - 6 Amp

2910307 Ref. LIMIT SWITCH INSTALLATION (HOME DEPOT SPEC ONLY)

4460259 1 Terminal (Not Shown) 4460260 1 Terminal (Not Shown) 4460035 1 Terminal (Not Shown) 7016397 A/R Silicone (Not Shown)

401 3900205 4 Screw #10-24NC 402 4761000 2 Lockwasher #10 403 4751000 2 Flatwasher #10 Regular 404 3311005 2 Locknut #10-24NC 405 3572525 1 Bracket 406 3572511 1 Plate 407 4360496 1 Switch, Limit

0273365 Ref. HOURMETER INSTALLATION D

501 2420172 1 Hourmeter

3311001 2 Nut #10-24NC 3572158 1 Plate, Mounting

3120776 12SP & 15SP 2-5

SECTION 2 CONTROLS

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3911010 2 Screw #10-24NC x 5/8in 4761000 2 Lockwasher #10 4922935 1 Harness, Hourmeter

0271373 Ref. FLOOR BRAKE ALARM INSTALLATION (OPTIONAL) D 0275424 Ref. FLOOR BRAKE & GATE ALARM INSTALLATION (OPTIONAL) A

601 0100011 A/R Compound, Locking 602 1 Alarm, Horn Options:

0140022 Prior to S/N 0900023939 0140001 S/N 0900023939 to S/N 0900027449

603 A/R Relay Options:

3740080 1 Floor Brake Alarm (Prior to S/N 0900023632) 3740049 1 Floor Brake Alarm (S/N 0900023632 to S/N 0900027449)

3740080 2 Floor Brake & Gate Alarm 604 4360437 1 Switch, Limit 605 0641403 A/R Bolt 1/4in-20NC x 3/8in 606 0641507 1 Bolt 5/16in-18NC x 7/8in 607 Not Used 608 3311505 1 Locknut 5/16in-18NC 609 3311001 2 Nut #10-24NC 610 A/R Plug

3520166 1 Floor Brake Alarm

Not Required 0 Floor Brake & Gate Alarm 611 3911024 2 Screw #10-24NC x 1-1/2in 612 4711400 1 Flatwasher 1/4in Thin 613 4711500 2 Flatwasher 5/16in Thin 614 1 Harness Options (Not Shown):

4922583 Harness, Brake Alarm 4923528 Harness, Brake & Gate Alarm 4460267 2 Pin, Male

4460320 1 Plug, Male - 2 Position 615 3576779 1 Plate, Limit Switch (Floor Brake & Gate Alarm Installation Only) 616 3820034 4 Rivet, Pop (Floor Brake & Gate Alarm Installation Only)

617-620 Not Used

0272181 Ref. PROGRAMMABLE SECURITY LOCK INSTALLATION

(OPTIONAL)

701 See Note 1 Lock, Electronic (Note: Purchase p/n 0272181 as pre-wired

service replacement) 702 3911008 2 Screw 703 4751000 2 Flatwasher #10 Regular

2-6 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-1. DC POWER PACK INSTALLATION (PRIOR TO S/N 0900027449) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120776 12SP & 15SP 2-7

SECTION 2 CONTROLS

304

611

305

604

302

609

303

610

309

614

401

402

403

406

615

616

307

621

201

203

204

606

608

602

107

101 102

110

404

405

407

40127213

3 8

603

605

601

501 502

301 306

S/N 27449

TO S/N 30665

09000

103 106

351

302 311 312

301

306

310

S/N 30665

TO PRESENT

09000

313

702

S/N 0900027449

S/N 3159209000

703

S/N 31592

PRESENT

09000

702

703

FIGURE 2-2. DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT)

2-8 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-2. DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MOTOR/PUMP & GROUND CONTROL INSTALLATIONS 0275885 Ref. Key Control C 0275886 Ref. Keyless Control C

1 0100011 A/R Compound, Locking 2 0641404 2 Bolt 1/4in-20NC x 1/2in 3 0721006 2 Screw #10-24NC x 3/4in 4 0791608 2 Screw 3/8in-16NC x 1in 5 1 Ground Control Box Assembly Options:

0861305 Box with Key Control D 0861536 Box with Keyless Control A 7020078 1 Switch, Push-Pull (Stop) 7020096 1 Legend Plate, “Stop” 7020097 1 Legend Plate, “Power/Off/On”

1 Switch, On/Off Options: 4360467 Switch, Key 2860030 1 Key, Replacement 7024411 Switch, Keyless

1 Strain Relief Options: 4460633 S/N 0900027449 to S/N 0900023599 7027299 S/N 0900023599 to Present 7020093 4 Screw M3 x 25mm 3910804 3 Screw #8-32 x 1/4in (Use on Keyswitch Terminals) 7020094 1 Box

6 1060571 1 Cable Assembly - Battery

4460567 1 Connector, Anderson

7 1320224 1 Clamp, Cable 8 3311005 2 Locknut #10-24NC 9 3600462 1 DC Motor/Pump Assembly Options (See Figure 2-4 for

Breakdown): 10 3740049 A/R Relay Options: 11 4341432 1 Plate, Mounting 12 4751000 2 Flatwasher #10 Regular 13 4922740 1 Harness, Pump 14 4567605 2 Tube, Butyrate (Not Shown - Located on Battery Hanger Bar)

(Prior to S/N 0900033901 Only)

0275939 Ref MOTOR/PUMP COVER INSTALLATION B

101 0100011 A/R Compound, Locking 102 0641404 4 Bolt 1/4in-20NC x 1/2in 103 0641609 4 Bolt 3/8in-16NC x 1-1/8in

104 to 105 Not Used

106 3311608 4 Nut 3/8in-16NC 107 4061024 1 Shield, Pump Cover

108 to 109 Not Used

110 4711400 4 Flatwasher 1/4in Thin

3120776 12SP & 15SP 2-9

SECTION 2 CONTROLS

FIGURE 2-2. DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0259450 Ref. AUXILIARY LOWERING INSTALLATION (OPTIONAL) A

201 0861213 1 Box, Power Down

0400181 2 Battery 4460320 1 Connector, Amp

4460267 2 Pin, Amp 202 Not Used 203 4420064 .3ft/.09m Velcro, Loop 204 4420065 .3ft/.09m Velcro, Hook

0270020 Ref. CYCLE COUNTER INSTALLATION (OPTIONAL) E 301 2420193 1 Gauge, Counter 302 3311001 4 Nut #10-24NC 303 3520166 1 Plug 304 3911024 2 Screw #10-24NC x 1-1/2in 305 1 Switch, Limit

4360437 S/N 0900027449 to S/N 0900028112

1001092205 S/N 0900028112 to Present 306 4622377 1 Harness, Counter 307 4751000 6 Flatwasher #10 Regular

308 to 309 Not Used

310 3572158 1 Bracket, Gauge Mounting (S/N 0900030665 to Present Only) 311 3911010 2 Screw #10-24NC x 5/8in (S/N 0900030665 to Present Only) 312 4761000 2 Lockwasher #10 (S/N 0900030665 to Present Only) 313 0641504 1 Bolt 5/16in-18NC x 1/2in (Ground Screw) (S/N 0900030665 to

Present Only)

Ref. HARNESS INSTALLATION 0275885 Ref. Key Control B 0275886 Ref. Keyless Control B

351 4922740 1 Harness, Pump

2400006 1 Fuse 4460044 1 Fuseholder

2910307 Ref. LIMIT SWITCH INSTALLATION (HOME DEPOT SPEC ONLY) 4460259 1 Terminal (Not Shown) 4460260 1 Terminal (Not Shown) 4460035 1 Terminal (Not Shown) 7016397 A/R Silicone (Not Shown)

401 3900205 4 Screw #10-24NC 402 4761000 2 Lockwasher #10 403 4751000 2 Flatwasher #10 Regular 404 3311005 2 Locknut #10-24NC 405 3572525 1 Bracket 406 3572511 1 Plate 407 4360496 1 Switch, Limit

0275697 Ref. HOURMETER INSTALLATION C

501 2420172 1 Hourmeter 502 4922935 1 Harness, Hourmeter

2-10 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-2. DC POWER PACK INSTALLATION (S/N 0900027449 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271373 Ref. FLOOR BRAKE ALARM INSTALLATION (OPTIONAL) E 0275424 Ref. FLOOR BRAKE & GATE ALARM INSTALLATION (OPTIONAL) D

601 0100011 A/R Compound, Locking 602 0140001 1 Alarm, Horn 603 A/R Relay Options:

3740049 1 Floor Brake Alarm 3740080 2 Floor Brake & Gate Alarm

604 1 Switch, Limit

4360437 S/N 0900027449 to S/N 0900028112

1001092205 S/N 0900028112 to Present 605 0641403 1 Bolt 1/4in-20NC x 3/8in 606 0641507 1 Bolt 5/16in-18NC x 7/8in 607 Not Used 608 3311505 1 Locknut 5/16in-18NC 609 3311001 2 Nut #10-24NC 610 3520166 1 Plug (S/N 0900028112 to Present) 611 3911024 2 Screw #10-24NC x 1-1/2in

612 to 613 Not Used

614 1 Harness Options (Not Shown):

4922583 Harness, Brake Alarm 4923528 Harness, Brake & Gate Alarm 4460267 2 Pin, Male

4460320 1 Plug, Male - 2 Position 615 3576779 1 Plate, Limit Switch (Floor Brake & Gate Alarm Installation Only) 616 3820034 4 Rivet, Pop (Floor Brake & Gate Alarm Installation Only)

617 to 620 Not Used

621 4751000 6 Flatwasher #10 Regular (S/N 0900027811 to Present)

Ref. PROGRAMMABLE SECURITY LOCK INSTALLATION

(OPTIONAL)

0272181 Ref. S/N 0900027499 to S/N 0900031592 C

1001110217 Ref. S/N 0900031592 to Present B 701 2820035 702 2940132 1 Lock, Programmable

703 A/R Fastener Options:

3911008 Screw #10-24NC x 1/2in

3820032 Rivet 704 4460267 3 Pin, Male (Not Shown) (S/N 0900031622 to Present Only) 705 4460326 1 Plug, Male - 3 Position (Not Shown) (S/N31622 to Present Only) 706 1001114375 1 Harness, Security Lock (Not Shown) (S/N 0900031622 to Pres-

4460268 3 Socket, Female (Not Shown) (S/N 0900031622 to Present

4460445 1 Receptacle, Female - 3 Position (Not Shown) (S/N

8in/20cm

Sleeve, Insulation (Not Shown)

(Note: Does NOT include Items 404 & 405)

ent Only)

Only)

0900031622 to Present Only)

3120776 12SP & 15SP 2-11

SECTION 2 CONTROLS

212118

25A

25C

25B

312824273934533A372938242322117

33A

261115

NOTE: IF MOTOR/PUMP ASSEMBLY WAS REPLACED ON A MACHINE BUILT S/N 0900018391 TO S/N 0900027449, IT MAY HAVE AN UPDATE KIT INSTALLED ON IT. IF MACHINE IS EQUIPPED WITH A MONARCH MOTOR/PUMP REFER TO NEXT FIGURE FOR BREAKDOWN.

FIGURE 2-3. DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449)

2-12 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-3. DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. NOTE: IF MOTOR/PUMP ASSEMBLY WAS REPLACED ON A

MACHINES BUILT S/N 0900018391 TO S/N 0900027449, IT MAY HAVE AN UPDATE KIT INSTALLED ON IT. IF MACHINE IS EQUIPPED WITH A MONARCH MOTOR/PUMP REFER TO NEXT FIGURE FOR BREAKDOWN.

Ref. DC MOTOR/PUMP ASSEMBLIES 3600291 Ref. Prior to S/N 0900013731 A 3600306 Ref. S/N 0900013731 to S/N 0900018391 C 3600343 Ref. S/N 0900018391 to S/N 0900027449 C

1 7013713 2 Bolt 5/16in-24NF x 2-3/4in 2 7016735 1 Coupling 3 7013714 1 Plug 4 Use 7013779 1 Ball (was p/n 7013715) 5 7013716 1 Seal (Part of Pump Seal Kit p/n 7013701) 6 7013717 1 Washer 7Not Used 8 7013722 1 Magnet 9 7013710 1 Motor

7013757 1 Brush Kit

10 7013758 2 Screw 1/4in-20NC x 1/4in 11 7013728 2 Screw M6 x 1.0 - 12mm 12 Use 7013789 1 Solenoid (was p/n 7013760) 13 7016770 1 Cover 14 Not Used 15 7016771 1 Clamp 16 7013708 1 Cartridge, Valve - Check 17 Use 3931516 1 Bolt, Socket Head 5/16in-18NC x 1in (was p/n 7016720) 18 7016721 4 Bolt #12-24NC x 1/2in 19 7016772 1 Cable 20 Not Used 21 7016713 1 Decal - Fill Line 22 7013795 1 Tube, Return 23 7013792 1 Nut, Tube Compression 24 7013793 1 Sleeve, Tube Compression

25 Use 7022219 1 Tank (was p/n 7016775) 25A 7013748 1 Decal - Caution 25B 7016759 1 Plug

25C 7016777 1 Fitting, Coupling 25D 7016776 1 Decal - Maximum Torque (Not Shown)

26 7016773 1 Plumbing Assembly - Inlet

27 Use 7013779 1 Spring Options:

Prior to S/N 0900013731 (was p/n 7016762) S/N 0900013731 to S/N 0900027449 (was p/n 7013733)

28 1 Cartridge, Valve - Manual Descent

7013764 Prior to S/N 0900018391

Not Required S/N 0900018391 to S/N 0900027449 (Moved to Lift Cylinder)

3120776 12SP & 15SP 2-13

SECTION 2 CONTROLS

FIGURE 2-3. DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

29 1 Cartridge, Valve - Solenoid Options:

7016786 Prior to S/N 0900013731

7016751 S/N 0900013731 to S/N 0900027449 30 7013766 1 Pin 31 7013743 1 O-Ring 32 1 End Head Options:

See Note Prior to S/N 0900018391 (was p/n 7016753) (Note: No

Longer Available for Purchase)

7022220 S/N 0900018391 to S/N 0900027449 33 7016717 1 Pump Assembly

33A 7013701 1 Seal Kit - Pump (Includes Gasket for #13 Cover, O-Ring and

#5 Seal) 34 Use 7013779 1 Cap, Relief (was p/n 7013750) 35 7016714 1 Breather 36 7013720 2 Plug (Prior to S/N 0900018391) 37 7013726 1 Tube, Return 38 7016755 1 Valve 39 Use 7013779 1 Screw, Adjustment (was p/n 7013770)

40 to 41 Not Used

— — — — — — — — —

42 7013779 1 Relief Valve Kit (Includes Items 4, 27, 34 & 39)

2-14 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-3. DC MOTOR/PUMP ASSEMBLY (FENNER) (PRIOR TO S/N 0900027449)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120776 12SP & 15SP 2-15

SECTION 2 CONTROLS

01119

S/N 0900030948 TO PRESENT

0900027391

TOS/N 0

900030948

FIGURE 2-4. DC MOTOR/PUMP ASSEMBLY (MONARCH) (S/N 0900027449 TO PRESENT)

2-16 12SP & 15SP 3120776

SECTION 2 CONTROLS

FIGURE 2-4. DC MOTOR/PUMP ASSEMBLY (MONARCH) (S/N 0900027449 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600462 Ref. DC MOTOR/PUMP ASSEMBLY B

1 70000641 1 Base Assembly (Includes Items 14-18) 2 70000642 1 Cartridge 3 70000643 1 Coil 4 70001021 1 Pump 5 70001020 4 Screw 1/4in-20NC x 2-3/4in 6 7026165 1 Filter 7 70001029 1 Tube, Suction 8 70001030 1 Tube, Return

9 70000651 1 Reservoir 10 7026335 1 Clamp 11 70001025 1 Plug 12 70001031 1 Motor (Includes Motor Mounting Bolts & Item 24)

70001039 4 Brushes 13 70001032 1 Solenoid 14 70001033 2 Screw 15 70001027 1 Decal - Fill Line 16 70001034 1 Cable, Insulated 17 70001035 1 Control Wire Assembly 18 70001036 2 Boot, Terminal 19 Use 70000641 1 Valve, Relief

Use 70000641 1 Screw Use 70000641 1 Nut Use 70000641 1 Seal Use 70000641 1 Spring Use 70000641 1 Ball

20 Use 70000641 1 Valve, Check

Use 70000641 1 Plug Use 70000641 1 Spring Use 70000641 1 Poppet

Use 70000641 1 Ball 21 70003612 1 O-Ring (1/2in x 5/8in x 1/16in) 22 70003613 1 O-Ring (3-5/8in x 3-7/8in x 1/8in) 23 7026330 1 Seal 24 70002215 1 Bearing

3120776 12SP & 15SP 2-17

SECTION 2 CONTROLS

#101

INCLUDES

ITEMS 1-23

102

FIGURE 2-5. BATTERY & CHARGER INSTALLATION (PRIOR TO S/N 0900031592)

2-18 12SP & 15SP 3120776

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