JLG 15VPSP Parts Manual

Illustrated Parts Manual

Model

15VPSP

3120798

May 29, 2013

REVISION LOG

January 31, 2000 - Original Issue Of Manual

September 5, 2000 - Revised (Manual edited to 0010566 Revision 10)

March 27, 2003 - Revised (Manual edited to 0010566 Revision 22)

December 20, 2006 - Revised Manual

November 15, 2010 - Revised Manual

May 29, 2013 - Revised Manual

3120798 A

REVISION LOG

B 312 0 798

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 BASE MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 REAR DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 JLG POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SECTION 2 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 GROUND CONTROL/POWER PACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 PLATFORM CONTROLS AND CABLES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 BATTERY CHARGER ASSEMBLY (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 BATTERY CHARGER ASSEMBLY (ANSI EXPORT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 PUMP/MOTOR/TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-6 CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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

3-1 MAST ASSEMBLY - 15VPSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAST MOUNTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

4-1 PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS) . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM INSTALLATION (FIXED SIDE RAILS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 PLATFORM INSTALLATION (QUICK CHANGE GULLWING) . . . . . . . . . . . . . . . . . . . . 4-10

4-4 PLATFORM INSTALLATION (QUICK CHANGE MOLDED) . . . . . . . . . . . . . . . . . . . . . . 4-14

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

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

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

6-1 HYDRAULIC DIAGRAM (PRIOR TO S/N 03620) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

7-1 ELECTRICAL SCHEMATIC (PRIOR TO S/N 03620) . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL SCHEMATIC (S/N 03620 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATION (COUNTRY SPEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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

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

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

3120798 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii 3120798

SECTION 1 BASE

S

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 BASE MOUNTED COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 REAR DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 JLG POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

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1

B A S E

3120798 1-1

SECTION 1 BASE

9

202

205

204

203

201

118

10

107

27

105

115

110

116

25

7

23

5

8

12

14

13

16

17 25

26 15 4

11

19

21

20

112 113 109

114 113 109

113 109 102

209

208

114

102

117

103

114

120

111

102

114

102

109

303

302

301

304

208

209

208

209

208

209

24

28

18

26

6

29

32

31

30

22

108

114

206

207

112

101

REPLACEMENT DECALS MUST BE ORDERED

SEPARATELY - SEE SECTION 8

S E C T

I O N

1

B

A S E

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

1- 2 31 2 0798

SECTION 1 BASE

.

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

BASE ASSEMBLY Ref.

0259526 15VPSP Ref. C

1 0100011 Loctite #242 (Not Shown) A/R

2 to 3 Not Used

4 0630446 Bolt 3/8”-16NC x 1” (Carriage) 4 5 0641406 Bolt 1/4”-20NC x 3/4” 2 6 0641609 Bolt 3/8”-16NC x 1 1/8” 8 7 0721008 Screw 2 8 0902583 Bracket, Beacon 1 9 1060658 Cable, Brake Assembly (See Items for 201-211

Breakdown) 10 1702923 Decal - Manual Descent 1 11 2420165 Gauge, Hour Meter 1 12 2920146 Lamp, Beacon Assembly 1

7016319 Tube, Flash 1

7016372 Lens, Amber 1 13 3311005 Locknut #10-24NC 2 14 3311405 Locknut 1/4”-20NC 2 15 3311605 Locknut 3/8”-16NC 4 16 3740069 Relay, Power 24VDC 3 17 3911010 Screw 3 18 4160164 Spring, Compression 2 19 4300106 Stud, Grooved 4 20 4360314 Switch, Toggle 1 21 Switch, Tilt Options: 1

4360435 Prior to S/N 03863

4360465 S/N 03863 to Present 22 4460648 Receptacle - 2 Position 2 23 4711400 Flatwasher 1/4” Narrow 4 24 4740430 Washer, Fender 2 25 4751000 Flatwasher #10 Wide 7 26 4751600 Flatwasher 3/8” Wide 12 27 4846087 Base Weldment 1 28 4860175 Wheel, Rear Assembly 2

7019659 Steel Insert (1 Per Assembly) 2 29 4860177 Wheel, Caster Assembly 2

7019660 Axle 1/2” x 3 1/4” (1 Per Assembly) 2

7019661 Wheel, Replacement (1 Per Assembly) 2

7019662 Caster without Wheel (1 Per Assembly) 2

7019663 Bearing, Wheel (1 Per Assembly) 2 30 3310601 Nut #6-32 NC (S/N 13479 to Present) 8 31 3910620 Screw #6-32 NC x 1 1/4” (S/N 13479 to Present) 4 32 4750600 Flatwasher #6 (S/N 13479 to Present) 8

1

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1

B

A S E

3120798 1-3

SECTION 1 BASE

S E

C

T

I O N

1

B

A S E

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

MAST SUPPORT INSTALLATIONS Ref. 0259527 PRIOR TO S/N 03620 Ref. C 0271465 S/N 03620 TO PRESENT Ref. A

101 0641406 Bolt 1/4”-20NC x 3/4” 2 102 0641608 Bolt 3/8”-16NC x 1” 20 103 0641609 Bolt 3/8”-16NC x 1 1/8” 2 104 0641612 Bolt 3/8”-16NC x 1 1/2” 1 105 0641810 Bolt 1/2”-13NC x 1 1/4” 4 106 Not Used 107 0880139 Brace, Mast 2 108 2420140 Gauge, Level (Prior to S/N 03620) 1 109 3311605 Locknut 3/8”-16NC 18 110 3311805 Locknut 1/2”-13NC 4 111 3570172 Cover, Drive Motors 1 112 4711400 Flatwasher 1/4” Narrow 2 113 4711600 Flatwasher 3/8” Narrow 28 114 4751600 Flatwasher 3/8” Wide 13 115 4751800 Flatwasher 1/2” Wide 8 116 4845291 Weldment, Counterweight 1 117 4845474 Weldment, Rear Plate 1 118 4846173 Weldment, Ground Control 1 119 4240033 Wire, Tie (Not Shown) 2 120 1704582 Decal - Manual Descent (S/N 03620 to Present) 1

1060658 BRAKE CABLE ASSEMBLY Ref. 3/C

201 0641528 Bolt 5/16”-18NC x 3 1/2” 1 202 3311501 Nut 5/16”-18NC 1 203 4160166 Spring, Compression 1 204 0561284 Bar, Aluminum 1 205 3900248 Bolt 1/4”-20NC x 1/4” 2 206 2560150 Handle, Brake Cable 1 207 3570382 Bracket, Brake Cable 1 208 1060661 Cable, Brake 1 209 1060662 Cable, Brake 1 210 0100019 Loctite #271 (Not Shown) A/R 211 0100035 Loctite #222 (Not Shown) A/R

0270352 STATIC STRAP INSTALLATION Ref. A

301 0641608 Bolt 3/8”-16NC x 1” 1 302 3311605 Nut 3/8”-16NC 1 303 4751600 Flatwasher 3/8” 2 304 4240084 Strap, Static 1

1- 4 31 2 0798

SECTION 1 BASE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

1

B

A S E

3120798 1-5

SECTION 1 BASE

S E

C

T

I O N

1

B

A S E

FIGURE 1-2. REAR DRIVE ASSEMBLY

1- 6 31 2 0798

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258718 REAR DRIVE ASSEMBLY Ref. 1/B

1 4845473 Weldment, Drive 1 2 3570168 Plate, Motor Mount (Left) 1 3 3570169 Plate, Motor Mount (Right) 1 4 1400126 Clutch, Torque Limiting Options: 2

Dalton Brand Clutch, Torque Limiting (See Items 101-109 for Breakdown) (Prior to September 1999)

EPT Brand Clutch, Torque Limiting (See Items 201211 for Breakdown) (September 1999 to Present)

5 3160234 Wheel Drive Motor Assembly (See Figure 1-3 for

Breakdown) 6 4040268 Shaft, Drive 2 7 2860027 Key, Clutch 2 8 0741609 Bolt 3/8”-16NC x 1 1/8” 2 9 3440520 Pin, Roll 2

10 0440221 Bearing, Flange 4 11 0256851 Brake Assembly 2

7014117 Switch, Micro (1 Per Assembly) 2 7014118 Disc, Friction (1 Per Assembly) 2

11A 7014119 Gear (1 Per Assembly) 2

7014120 Setscrew (2 Per Assembly) 4 12 3930808 Bolt #8-32NC x 1/2” 8 13 4750800 Flatwasher #8 8 14 0100035 Loctite #222 (Not Shown) A/R 15 0100011 Loctite #242 (Not Shown) A/R 16 0100019 Loctite #272 (Not Shown) A/R 17 3900221 Bolt 5/16”-18NC x 3/4” 6 18 0641610 Bolt 3/8”-16NC x 1 1/4” 2 19 0641609 Bolt 3/8”-16NC x 1 1/8” 4 20 0641711 Bolt 7/16”-14NC x 1 3/8” 8 21 4751600 Flatwasher 3/8” 8 22 3311605 Locknut 3/8”-16NC 2 23 4711700 Flatwasher 7/16” 16 24 3311705 Locknut 7/16”-14NC 8 25 2860029 Key, Wheel 2 26 4740478 Washer, Wheel Retainer 2

2

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1

B

A S E

1400126 TORQUE LIMITER CLUTCH ASSEMBLY (DALTON

BRAND) (PRIOR TO SEPTEMBER 1999)

101 7016689 Hub 1 102 7016683 Nut, Adjusting 1 103 7016684 Spring 1 104 7016685 Bearing 1 105 7016691 Facing, Friction 2 106 7016690 Plate, Pressure 1 107 7016686 Sprocket 1 108 7016687 Coupling, Chain 1

3120798 1-7

Ref. A

SECTION 1 BASE

S E

C

T

I O N

1

B

A S E

FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

109 7016688 Sprocket 1

1400126 TORQUE LIMITER CLUTCH ASSEMBLY (EPT

BRAND) (SEPTEMBER 1999 TO PRESENT)

201 7023351 Hub 1 202 7023352 Chain 1 203 7023353 Sprocket 1 204 7023354 Bushing 1 205 7023355 Facing, Friction 2 206 7023356 Plate, Pressure 1 207 7023357 Disc, Spring 3 208 7023358 Lockwasher, Tabbed 1 209 7023359 Nut, Adjusting 1 210 7023360 Sprocket 1 211 7023361 Setscrew 1

Ref. C

1- 8 31 2 0798

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

1

B

A S E

3120798 1-9

SECTION 1 BASE

S E

C

T

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1

B

A S E

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

1- 1 0 31 2 0798

SECTION 1 BASE

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160234 DRIVE MOTOR ASSEMBLY Ref. B

1 7018000 Brush Kit 1 2 7018001 Key, Shaft 1 3 7018002 Gear and Pinion Assembly 1 4 7018005 Ring, Retaining 1 5 7018007 Key, Shaft 1 6 7018008 Bearing 1 7 7018009 Washer, Wave 1 8 7018010 Washer, Wave 1

9 7018011 Washer, Wave 1 10 7018012 Bearing 32mm x 12mm x 10mm 2 11 7018013 Bearing 47mm x 20mm x 14mm 1 12 7018014 Bearing 47mm x 25mm x 12mm 1 13 7018015 Shaft, Key 1 14 7018018 Seal, Lip 2 15 7018019 Gear and Drive Shaft 1 16 7018027 Bearing 1 17 7018028 O-Ring 1

C

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1

B

A S E

3120798 1-11

SECTION 1 BASE

3

5

2

1

9

10

8

13

7

14

16 17

21

202222

25

18

24

23

12

6

11

29

26

19

14

15

19

(RIGHT SIDE)

(LEFT SIDE)

FRAME REF.

S E

C

T

I O N

1

B

A S E

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

1- 1 2 31 2 0798

SECTION 1 BASE

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0257490 JLG POTHOLE PROTECTION INSTALLATION Ref. 2/B

1 4845507 Actuator Weldment 1 2 4567203 Tube, Sleeve 1 3 4160160 Spring, Compression 1 4 3020022 Grease, Lithium (with PTFE) (Not Shown) A/R 5 3841343 Rod, Actuator 1 6 3570230 Plate, Cable Attach 1 7 1060649 Cable 2 8 0641405 Bolt 1/4”-20NC x 5/8” 4

9 4750600 Flatwasher #6 4 10 4711400 Flatwasher 1/4” Narrow 4 11 3312002 Nut, Jam 5/8”-11NC 2 12 4712000 Flatwasher 5/8” Narrow 1 13 3440418 Rollpin 1/8” 1 1/8” 1 14 3900202 Screw, Shoulder 1/4”-20NC x 1/4” 4 15 3311005 Locknut #10-24NC 2 16 4845508 Bar, Pothole (Left Side) 1 17 4845509 Bar, Pothole (Right Side) 1 18 1100103 Cam 2 19 4160162 Spring, Torsion 4 20 3430630 Pin, Clevis 3/8” x 3 3/4” 2 21 3430638 Pin, Clevis 3/8” x 4 3/4” 2 22 4751600 Flatwasher 3/8” 4 23 3910620 Screw #6-32NC x 1 1/4” 4 24 3450403 Pin, Cotter 1/8” x 3/4” 4 25 3900249 Setscrew #10-32NC x 3/16” 4 26 4360456 Switch, Limit 2 27 0100035 Loctite #222 (Not Shown) A/R 28 0100011 Loctite #242 (Not Shown) A/R 29 4460662 Connector, Strain Relief 2

C

T

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1

B

A S E

3120798 1-13

SECTION 1 BASE

S E

C

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1

B

A S E

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1- 1 4 31 2 0798

SECTION 2 CONTROLS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

2-1 GROUND CONTROL/POWER PACK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 PLATFORM CONTROLS AND CABLES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 BATTERY CHARGER ASSEMBLY (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 BATTERY CHARGER ASSEMBLY (ANSI EXPORT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 PUMP/MOTOR/TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-6 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

S E C T

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T R O

L

S

3120798 2-1

S

28

23

19

27

13

20

8

33

38

39

40

33 21

6

12

14

3 33 8

10

16

36

5

9

34

35

7

4

18

33

31

22

37

101

25

1

24

30

2 29

20 26 32

8

15

21

30

8

32

11

8

17

33

17A

17B

17C

REPLACEMENT DECALS MUST BE ORDERED SEPARATELY - SEE SECTION 8

E

C

T

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATION

I O N

2

C O N

T R O

L S

2-2 312 0798

SECTION 2 CONTROLS

.

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATION

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

GROUND CONTROL/POWER PACK INSTALLATIONS: Ref. 0259528 GROUND CONTROL (STANDARD) Ref. D 0270719 GROUND CONTROL (KEYLESS) Ref. A

1 0140022 Alarm, Horn 1 2 0140033 Alarm 1 3 0181857 Angle, Controller Mount 1 4 Bar, Battery Hold Down Options: 2

0362604 Prior to S/N 3533 0362658 S/N 3533 to Present

5 0400122 Battery 2 6 0400164 Charger, Battery 120VAC (See Figure 2-3 for Breakdown) 1 7 0630504 Bolt, Battery Hold Down 4 8 0641406 Bolt 1/4”-20NC x 3/4” 13

9 0641508 Bolt 5/16”-18NC x 1” 6 10 0641609 Bolt 3/8”-16NC x 1 1/8” 2 11 0721006 Screw 2 12 0741407 Bolt 1/4”-20NC x 7/8” 4 13 Ground Control Box Options: 1

0861330 Standard 7020094 Lid 1 4360469 Switch, Key 1 2860030 Key, Replacement 1 7020078 Switch, Push-Pull (Stop) 1 7020093 Screw m3 x 25 4 7020097 Legend Plate, “Power/Off/On” 1 7020096 Legend Plate, “Stop” 1 4460633 Connector, Strain Relief 1 0861386 Keyless 7020094 Lid 1 7023273 Switch, Select 1 7020078 Switch, Push-Pull (Stop) 1 7020093 Screw m3 x 25 4 7020267 Legend Plate, “Power/Off/On” 1 7020096 Legend Plate, “Stop” 1

4460633 Connector, Strain Relief 1 14 0902250 Bracket, Charger/Controller 1 15 0902356 Bracket, Alarm 1 16 1600305 Controller 1 17 Hood Options: 1

2680432 Prior to S/N 3533

2680483 S/N 3533 to Present

17A 2700080 Hook 2 17B 7023342 Lid (Used on p/n 2680432) 1 17C 7023341 Lid (Used on p/n 2680432) 1

18 3300202 Wingnut 4 19 3311001 Nut #10-24NC 2 20 3311005 Locknut #10-24NC 3

S E

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L

S

3120798 2-3

S E C

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2

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R

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

21 3311405 Locknut 1/4”-20NC 6 22 3311605 Locknut 3/8”-16NC 2 23 3520166 Plug 1 24 3740069 Relay, Power 24VDC 1 25 3740130 Relay, 100Amp 1 26 3911010 Screw 1 27 3911024 Screw 2 28 4360437 Switch, Limit 1 29 4460685 Terminal, Stud Mount Tab 4 30 4711400 Flatwasher 1/4” Narrow 8 31 4711600 Flatwasher 3/8” Narrow 4 32 4751000 Flatwasher #10 Wide 6 33 4751400 Flatwasher 1/4” Wide 15 34 4751500 Flatwasher 5/16” Wide 6 35 4845875 Weldment, Battery Box (Left) 1 36 4845876 Weldment, Counterweight 2 37 4845878 Weldment, Battery Box (Right) 1 38 2940132 Lock, Programmable Security (Keyless Machines Only) 1 39 3900205 Screw #10-24NC x 5/8” (Keyless Machines Only) 2 40 4750800 Flatwasher #8 (Keyless Machines Only) 2

O

L

S

POWER PACK INSTALLATIONS Ref. 0259774 PRIOR TO S/N 3620 Ref. A 0271466 S/N 3620 TO PRESENT Ref. A

101 3600254 Pump/Motor 24VDC (See Figure 2-5 for Breakdown) 1

0641606 Bolt 3/8”-16NC x 3/4” 4 0741605 Bolt 3/8”-16NC x 5/8” 2 4751600 Flatwasher 3/8” Wide 4

2-4 312 0798

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

2

C O N

T R O

L

S

3120798 2-5

S E C

T

I O N

2

C O N

SECTION 2 CONTROLS

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

T R O

L S

2-6 312 0798

SECTION 2 CONTROLS

.

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

PLATFORM CONTROLS AND CABLES INSTALLATIONS Ref.

0259769 15 VPSP Ref. B

1 0641410 Bolt 1/4”-20NC x 1 1/4” 3 2 1060380 Cable, Lanyard 2 3 1320043 Clamp, Cable 2 4 1320149 Clamp, Hose 3 5 1380132 Clip, Gripper 1 6 1600304 Controller, Joystick 1 7 3300417 Nut, Acorn #8-32NC 4 8 3310801 Nut #8-32NC 8

9 3311405 Locknut 1/4”-20NC 2 10 3311605 Locknut 3/8”-16NC 1 11 3422657 Pin, Quick Release 1 12 3570680 Bracket, Joystick 1

12A Pad, Rubber Options: A/R

7020075 RH Side Pad 2

7020076 LH Side Pad 2 13 3570737 Bracket, Joystick 1 14 3580231 Pulley, Sheave 3 15 3760170 Ring, Split 1 16 3820024 Rivet 1 17 3900200 Screw, Shoulder 3 18 4160130 Spring, Extension 1 19 4711400 Flatwasher 1/4” Narrow 5 20 4750800 Flatwasher #8 Wide 5 21 4751000 Flatwasher #10 Wide 12 22 4751500 Flatwasher 5/16” Wide 3 23 4922203 Harness, Platform Control 1

S E

C

T

I O N

2

C O N

T R O

L

S

0271059 OPTIONAL 120V ACCESSORY OUTLET Ref. A

101 0100019 Loctite #271 (Not Shown) A/R 102 0721005 Screw 2 103 0860946 Box, Outlet 1 104 1060564 Cable Electrical 12/3 105 3252761 Decal - 120V 2 106 3300047 Locknut 1/2” Conduit 1 107 3311001 Nut #10-24NC 2 108 4060092 Cover 1 109 4460023 Connector 1 110 4460190 Receptacle 1 111 4460549 Plug 1 112 4460566 Terminal 90° 1 113 4761000 Lockwasher #10 2

3120798 2-7

23ft/7.0m

S

NOTE: COVER NOT SHOWN

FOR CLARITY

AC CIRCUIT BREAKER

BLACK

BLACK BLACK

BLACK

HEATSINK

CIRCUIT

BREAKER

DC POS RED

DC NEG BLACK

.001 OHM SHUNT

A

B

C

D

BLACK

SCR

BLUE

GREEN

WHITE

W

H

I

T

E

YELLOW

ORANGE

TRANSFORMER

7 7

7

14

14 12

12 13

13

12

15

6

16 17

6

8

4

3

2

5

2

11

1

10

TX PRI

RELAY

COM

N. C. N. O.

INTERLOCK

CONNECTOR

CIRCUIT

BOARD

AC BLACK

AC WHITE

AC GREEN

GROUND SCREW

9A

109A

3

103

9B

109B

9

109

110

10

4

104

6

106

7

107

8

108

111

11

101

1

102

2

105

5

E C

T

I O N

2

C O N

SECTION 2 CONTROLS

FIGURE 2-3. BATTERY CHARGER ASSEMBLY (ANSI)

T R O

L S

2-8 312 0798

SECTION 2 CONTROLS

.

FIGURE 2-3. BATTERY CHARGER ASSEMBLY (ANSI)

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

BATTERY CHARGER ASSEMBLIES Ref.

0400164 120 VOLT/60HZ Ref. B

1 7018550 Transformer 1 2 7018553 Card, Circuit 1 3 7018554 Shunt Assembly 1 4 7018506 Relay, Interlock 1 5 7018555 SCR Rectifier 2 6 7011596 Var ist o r 1 7 7018556 AC Cord Assembly 1 8 7011528 Connector, Strain Relief - 90° 1 9 7018567 DC Harness Assembly 1

9A 4460424 Connector, Male - 2 Position 1

4460267 Pin, Male 2 9B 7011528 Connector, Strain Relief 1 10 7018514 Breaker, Circuit - AC 1 11 7011509 Breaker, Circuit - DC 1

0400173 220 VOLT/60HZ W/INTERLOCK Ref. A

101 7018561 Transformer 1 102 7018553 Card, Circuit 1 103 7018554 Shunt Assembly 1 104 7018535 Relay, Interlock 1 105 7018555 SCR Rectifier 2 106 7018537 Var ist o r 1 107 7018565 AC Cord Assembly 1 108 7011528 Connector, Strain Relief - 90° 1 109 7018567 DC Harness Assembly 1

109A 4460424 Connector, Male - 2 Position 1

4460267 Pin, Male 2

109B 7011528 Connector, Strain Relief 1

110 7018557 Breaker, Circuit - AC 1 111 7011509 Breaker, Circuit - DC 1

S E

C

T

I O N

2

C O N

T R O

L

S

3120798 2-9

S

NOTE: COVER NOT SHOWN

FOR CLARITY

111

11

110

10

12

101

1

102

2

9A

109A

3

103

4

104

6

106

105

5

7

107

8

108

9B

109B

8

9

109

10

E

SECTION 2 CONTROLS

FIGURE 2-4. BATTERY CHARGER ASSEMBLY (ANSI EXPORT)

C

T

I O N

2

C O N

T R O

L S

2-10 3120798

SECTION 2 CONTROLS

.

FIGURE 2-4. BATTERY CHARGER ASSEMBLY (ANSI EXPORT)

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

BATTERY CHARGER ASSEMBLY Ref.

0400157 120/240 VOLT/50HZ Ref. B

1 7020620 Transformer (was p/n 7018551) 1 2 7018562 Card, Circuit 1 3 7018554 Shunt Assembly 1 4 7018564 Relay, Interlock 1 5 7018555 SCR Rectifier 2 6 7018589 Varistor (was p/n 7018537) 1 7 7018556 AC Cord Assembly 1 8 7011528 Connector, Strain Relief - 90° 1 9 7018567 DC Harness Assembly 1

9A 4460424 Connector, Male - 2 Position 1

4460267 Pin, Male 2 9B 7011528 Connector, Strain Relief 1 10 7018557 Breaker, Circuit - AC 2 11 7011509 Breaker, Circuit - DC 1 12 7018586 Switch, Selector 2 13 7011649 Relay (Not Shown) 1

0400166 240 VOLT/50HZ Ref. B

S E

C

T

I O N

2

C O N

T R O

101 7018551 Transformer 1 102 7018562 Card, Circuit 1 103 7018554 Shunt Assembly 1 104 7018563 Relay, Interlock 1 105 7018555 SCR Rectifier 2 106 7018537 Var ist o r 1 107 7018556 AC Cord Assembly 1 108 7011528 Connector, Strain Relief - 90° 1 109 7018567 DC Harness Assembly 1

109A 4460424 Connector, Male - 2 Position 1

4460267 Pin, Male 2

109B 7011528 Connector, Strain Relief 1

110 7018557 Breaker, Circuit - AC 1 111 7011509 Breaker, Circuit - DC 1

L

S

3120798 2-11

24

141822

23

8

10

21

28

11

30

16

2

33

7

4

27

40

35

3

5

37

34

29

26 25

19

1

12

6

17

13

9

20

32

31

15

SECTION 2 CONTROLS

FIGURE 2-5. PUMP/MOTOR/TANK ASSEMBLY

S E C

T

I O N

2

C O N

T R O

L S

2-12 3120798

SECTION 2 CONTROLS

.

FIGURE 2-5. PUMP/MOTOR/TANK ASSEMBLY

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

3600254 PUMP/MOTOR/TANK ASSEMBLY Ref. C

1 7013713 Bolt 5/16”-24NF x 2 3/4” 2 2 7016735 Coupling 1 3 7013714 Plug 1 4 7013715 Ball 1 5 7013716 Seal, Shaft 1 6 7013717 Washer 1 7 Not Serviced Plug, Shipping 1 8 7013722 Magnet 1 9 7013723 Filter - 149 Micron 1

10 7016710 Motor 1

7016718 Brush Kit 1 11 7013758 Screw 1/4”-20NC 2 12 7013727 Cover 1 13 7013728 Screw M6 x 1 2 14 Not Serviced Nameplate - Serial Number 1 15 7016719 Pipe, PCV 1 16 7013708 Valve, Check Cartridge 1 17 7016720 Bolt 5/16”-18NC x 1” 1 18 7016721 Bolt #12-24NC x 1/2” 4 19 7013791 Tube, Return 1 20 7016722 Nut 3/8” 1 21 7013759 Cable, Electrical 1 22 7016712 Tank, Plastic 1 23 7016713 Decal - Tank Fill Line 1 24 7016714 Breather 1 25 7013792 Nut, Compression 1 26 7013793 Sleeve, Compression 1 27 7013733 Spring 1 28 7016711 Solenoid, Start 1 29 7022205 Valve, Solenoid Cartridge 1

7022206 Coil 1 30 7016723 Valve, Manual Override Cartridge 1 31 7013766 Pin 1 32 7013743 O-Ring 1 33 Not Serviced Endhead 1 34 7017717 Pump Assembly 1

7013701 Seal Kit - Pump 1 35 7013750 Cap 1 36 7013720 Plug 1/16” 2 37 7016724 Tube 1

38 to 39 Not Used

40 7013770 Valve, Screw Adjustment 1

S E

C

T

I O N

2

C O N

T R O

L

S

3120798 2-13

S E C

T

I O N

2

C O N

SECTION 2 CONTROLS

FIGURE 2-6. CONTROL BOX ASSEMBLY

T R O

L S

2-14 3120798

SECTION 2 CONTROLS

.

FIGURE 2-6. CONTROL BOX ASSEMBLY

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

1600304 CONTROL BOX ASSEMBLY Ref. A

1 7020147 Printed Circuit Board 1 2 7023201 Joystick 1 3 7020144 Emergency Stop Actuator 1 4 7020145 Contact Block, Emergency Stop 1 5 7020143 Knob Potentiometer 1 6 7020142 Potentiometer 1 7 7023202 Membrane Keyboard Pad 1 8 7020139 Joystick Box W/Gasket 1 9 7026038 Connector, 12 Position 1

7026039 Pin 12

S E

C

T

I O N

2

C O N

T R O

L

S

3120798 2-15

S E C

T

I O N

2

C O N

SECTION 2 CONTROLS

FIGURE 2-6. CONTROL BOX ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

T R O

L S

2-16 3120798

SECTION 3 MAST

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

3-1 MAST ASSEMBLY - 15VPSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAST MOUNTING COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

S E

C

T

I O N

3

M

A S

T

3120798 3-1

S

50

12

50

53

52

48

3

2

35

45

47

61

35

60

90

28

63

75

29

74

21

66

509

511

508

505

66

92

83

20

62

305

308

311

34

69

38

11

6

17

4

76

39

27

40

65

10

25

58

86

57

73

43

44

72

9

69

18

23

22

54 55 56

32

33

204 504

203 205 207

63

7

1414

15

16

68

5 63

51

70

13

31

30

24

8

19

71

63

18

68

70

51

49

46

64

69

34

42

409

405

408

411

37

36

91

63

59

67

29

39

309

41

202 206

104

204

304

404

103

105

106

303

306

307

403

406

410

503 506 510

203

205

207

502

507

85

84

26

89

88

87

REPLACEMENT DECALS MUST BE ORDERED SEPARATELY - SEE SECTION 8

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP

E C T

I O N

3

M

A S T

3- 2 31 2 0798

SECTION 3 MAST

.

FIGURE 3-1. MAST ASSEMBLY - 15VPSP

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

0801211 MAST ASSEMBLY - 15VPSP (PRIOR TO S/N 3620) Ref. I 0801313 MAST ASSEMBLY - 15VPSP (S/N 3620 TO PRESENT) Ref. A

1 0100011 Loctite #242 (Not Shown) A/R 2 0362735 Bar, Sheave Pin Support 4 3 0362736 Bar, Sheave Pin Support 2 4 0561341 Block, Chain Anchor 1 5 0641406 Bolt 1/4”-20NC x 3/4” 33 6 0641407 Bolt 1/4”-20NC x 7/8” 6 7 0641410 Bolt 1/4”-20NC x 1 1/4” 8 8 0641508 Bolt 5/16”-18NC x 1” 1

9 0641510 Bolt 5/16”-18NC x 1 1/4” 4 10 0641812 Bolt 1/2”-13NC x 1 1/2” 4 11 0741006 Screw #10-24NC x 3/4” 2 12 0741606 Screw 3/8”-16NC x 3/4” 4 13 0902047 Bracket, Sequence Cable 1 14 0902422 Bracket, Bottom Chain Attach 1 15 0902423 Bracket, Bottom Chain Attach 1 16 0902424 Bracket, Bottom Chain Attach 1 17 0902431 Bracket, Sequence Cable 3 18 0902445 Bracket, Sequence Cable A/R 19 1060683 Cable, Sequence 3 20 1260343 Chain Assembly - #544 (See Items 101-107 for Breakdown)

(Prior to S/N 3529)

21 1260349 Chain Assembly - #444 (See Items 201-207 for Breakdown)

(Prior to S/N 3529) 22 1271392 Channel, Mast #6 1 23 1271419 Channel, Mast #3 1 24 1271421 Channel, Mast #2 1 25 1271455 Channel, Mast #1 1 26 Channel, Mast Header Options: 1

1271456 Prior to S/N 3620 1271471 S/N 3620 to Present

27 Lift Cylinder Assembly Options (See Section 5 for Break-

down):

1683808 Prior to S/N 3620

1684142 S/N 3620 to Present 28 2880310 Key 3 29 3311401 Nut 1/4”-20NC (S/N 12269 to Present) 6 30 3311601 Nut 3/8”-16 NC 8 31 3311801 Nut 1/2”-13NC 4 32 3340845 Pad, Slide Guide 14 33 3340858 Pad, Slide Guide 2 34 3422338 Pin, Chain Equalizer 6 35 3422717 Pin, Sheave 3 36 3422750 Pin, Chain Equalizer 2 37 3422752 Pin, Chain Equalizer 1 38 3422757 Pin, Keeper 2 39 3450304 Pin, Cotter 6

2

4

1

S E

C

T

I O N

3

M

A S

T

3120798 3-3

S E C T

I O N

3

M

A S T

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

40 3570893 Plate, Cylinder Mount 2 41 3571101 Plate, Chain Adjustment 2 42 3571103 Plate, Chain Adjustment 1 43 3571788 Plate, Acuator Support 1 44 3571790 Plate, Acuator Support 1 45 3580268 Sheave Assembly (Prior to S/N 3620) 2

0440225 Bearing 1 3580267 Sheave, Chain 1 3580286 Sheave Assembly (S/N 3620 to Present) 2 0440246 Bearing 1

3580285 Sheave, Chain 1 46 3580269 Sheave, Sequence Cable 3 47 3580274 Sheave Assembly (Prior to S/N 3608) 4

0440230 Bearing 1

3580275 Sheave, Chain 1

3580293 Sheave Assembly (S/N 3608 to Present) 4

0440294 Bearing 1

3580275 Sheave, Chain 1 48 3820034 Rivet 12 49 3900187 Screw, Shoulder 3 50 3900192 Screw, 3/8”-16NC x 1/2” 8 51 3900205 Bolt #10-24NC x 5/8” 8 52 4060960 Shield, Mast Cover 2 53 4060961 Shield, Mast Cover 1 54 4070860 Shim, Slide Pad 20 55 4070861 Shim, Slide Pad 20 56 4070862 Shim, Slide Pad 16 57 4070970 Shim, Cylinder Mount 2 58 4070971 Shim, Cylinder Mount 4 59 4160124 Spring 3 60 4567489 Tube, Spacer 2 61 4567492 Tube, Spacer 1 62 4567750 Tube, Spacer 1 63 4711400 Flatwasher 1/4” 59 64 4711500 Flatwasher 5/16” 3 65 4711800 Flatwasher 1/2” 4 66 4712600 Flatwasher 1” (Prior to S/N 3608) 16 67 4740414 Washer, Cup 6 68 4750800 Flatwasher #8 Wide 8 69 4751500 Flatwasher 5/16” Wide 10 70 4761000 Lockwasher #10 8 71 4761400 Lockwasher 1/4” 3 72 4761500 Lockwasher 5/16” 1 73 Mount, Cylinder Options: 1

4845731 Prior to S/N 3620

4846381 S/N 3620 to Present 74 0641408 Bolt 1/4”-20NC x 1” 3

3- 4 31 2 0798

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

75 Shied Options: 1

4060987 Prior to S/N 3617 4061006 S/N 3617 to Present

76 3760383 Ring, Retainer 1

77 to 82 Not Used

83 1260355 Chain Assembly - #544 (See Items 301-307 for Breakdown)

(S/N 3529 to Present)

84 1260356 Chain Assembly - #444 (See Items 401-407 for Breakdown)

(S/N 3529 to Present)

85 1260357 Chain Assembly - #444 (See Items 501-507 for Breakdown)

(S/N 3529 to Present) 86 0902698 Bracket, Sequence Cable (S/N 3608 to Present) 1 87 4070988 Shim, Slide Pad (S/N 3620 to Present) 2 88 4070989 Shim, Slide Pad (S/N 3620 to Present) 2 89 4070990 Shim, Slide Pad (S/N 3620 to Present) 2 90 4567749 Tube, Spacer (S/N 3620 to Present) 1 91 4567751 Tube, Spacer (S/N 3620 to Present) 1 92 4740007 Washer, Thrust (S/N 3620 to Present) 14

— — — — — — — — — —

Not Available Mast Kit (Not Available at Time of Printing) 1

1260343 CHAIN ASSEMBLY - #544 CHAIN (PRIOR TO S/N 3529) Rev. A

1

S E

C

T

I O N

3

M

A S

T

101 0100062 Loctite #RC/640 (Not Shown) A/R 102 0561308 Block, Chain Anchor 1 103 0561336 Block, Chain Anchor 1 104 Use 1260343 Chain 105 3422720 Pin, Chain Anchor 2 106 3450202 Pin, Cotter 4 107 4300129 Stud 1

1260349 CHAIN ASSEMBLY - #444 CHAIN (PRIOR TO S/N 3529) Rev. C

201 0100062 Loctite #RC/640 (Not Shown) A/R 202 0561149 Block, Chain Anchor 1 203 Block, Chain Anchor Options: 1

0561151 Prior to S/N 3218

0561408 S/N 3218 to Present 204 Use 1260349 Chain 205 3422346 Pin, Groove 1 206 3422355 Pin, Groove 1 207 4300111 Stud 1

1260355 CHAIN ASSEMBLY - #544 CHAIN (S/N 3529 TO PRESENT) Rev. C

301 0100062 Loctite #RC/640 (Not Shown) A/R 302 0561308 Block, Chain Anchor 2 303 0561336 Block, Chain Anchor 2 304 Use 1260355 Chain

71in/1.8m

11.8ft/3.6m

3120798 3-5

S E C T

I

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

305 3422338 Pin, Groove 2 306 3422720 Pin, Groove 4 307 3450202 Pin, Cotter 8 308 3450304 Pin, Cotter 2 309 3571101 Plate, Chain Adjustment 1 310 4300129 Stud 2 311 4751500 Flatwasher 5/16” 2

1260356 CHAIN ASSEMBLY - #444 CHAIN (S/N 3529 TO PRESENT) Rev. C

O N

3

M

A S T

401 0100062 Loctite #RC/640 (Not Shown) A/R 402 0561149 Block, Chain Anchor 2 403 0561408 Block, Chain Anchor 2 404 Use 1260356 Chain 405 3422338 Pin, Groove 2 406 3422346 Pin, Groove 2 407 3422355 Pin, Groove 2 408 3450304 Pin, Cotter 2 409 3571103 Plate, Chain Adjustment 1 410 4300111 Stud 2 411 4751500 Flatwasher 5/16” 2

1260357 CHAIN ASSEMBLY - #444 CHAIN (S/N 3529 TO PRESENT) Rev. C

501 0100062 Loctite #RC/640 (Not Shown) A/R 502 0561149 Block, Chain Anchor 2 503 0561408 Block, Chain Anchor 2 504 Use 1260357 Chain 505 3422338 Pin, Groove 2 506 3422346 Pin, Groove 2 507 3422355 Pin, Groove 2 508 3450304 Pin, Cotter 2 509 3571101 Plate, Chain Adjustment 1 510 4300111 Stud 2 511 4751500 Flatwasher 5/16” 2

11.8ft/3.6m

3- 6 31 2 0798

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

3

M

A S

T

3120798 3-7

S

14

2

3

6

177

180

181

179

180

178

182

E C T

I

SECTION 3 MAST

FIGURE 3-2. MAST MOUNTING COMPONENTS

O N

3

M

A S T

3- 8 31 2 0798

SECTION 3 MAST

.

FIGURE 3-2. MAST MOUNTING COMPONENTS

FIG & ITEM # PAR T N UMB E R DESCRIPTION QTY. REV.

0258448 OPTIONAL CRANE HOOK INSTALLATION Ref. C

1 0641612 Bolt 3/8”-16NC x 1 1/2” 4 2 3311605 Locknut 3/8”-16NC 4 3 3570976 Plate, Crane Hook 1 4 4711600 Flatwasher 3/8” 8 5 Not Used 6 1703455 Decal - Crane Hook 1

0801211 MAST ASSEMBLY - 15VPSP (SAFETY ATTACH) Ref. I

101 to 176 Not Used

177 0641812 Bolt 1/2”-13NC x 1 1/2” 2 178 3271805 Locknut 1/2”-13NC 2 179 3539814 Plate, Safety Attach Backing 1 180 4751800 Flatwasher 1/2” Wide 4 181 4845345 Weldment, Safety Attach 1 182 1704277 Decal - Lanyard Attach 1

S E

C

T

I O N

3

M

A S

T

3120798 3-9

S E C T

I O N

3

M

SECTION 3 MAST

FIGURE 3-2. MAST MOUNTING COMPONENTS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

A S T

3- 1 0 3120 7 98

SECTION 4 PLATFORM

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

4-1 PLATFORM INSTALLATION (FOLD-DOWN SIDE RAILS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM INSTALLATION (FIXED SIDE RAILS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 PLATFORM INSTALLATION (QUICK CHANGE GULLWING) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 PLATFORM INSTALLATION (QUICK CHANGE MOLDED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

S E

C

T

I O N

4

P L A T

F O R

M

3120798 4-1

S E C T

I O N

4

SECTION 4 PLATFORM

FIGURE 4-1.PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS)

P L A T

F O R

M

4-2 3120798

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259350 PLATFORM ASSEMBLY Ref. G

1 0100011 Loctite #242 (Not Shown) A/R 2 0721008 Screw 4 3 0940049 Stopper, Hood 2 4 2940074 Latch 1 5 3311001 Nut #10-24NC 4 6 3820032 Rivet 12 7 3311501 Nut 5/16”-18NC 4 8 3422744 Pin, Plunger 5 9 3571552 Plate, Platform Pan 1

10 to 11 Not Required

12 4280296 Strip, Wear 2ft/0.6m 13 4420039 Tape, Non Skid 10ft/3.0m 14 4751500 Flatwasher 5/16” Wide 4 15 4751000 Flatwasher #10 Wide 4 16 4761000 Lockwasher #10 4 17 Platform Options: 1

4846030 Prior to S/N 03571 4846323 S/N 03571 to S/N 03620 4846521 S/N 03620 to Present

18 Platform, Gate Options: 1

4846034 Prior to S/N 03571 4846324 S/N 03571 to Present

19 Rail, Platform Gate Options: 1

4846035 Prior to S/N 03571

4846325 S/N 03571 to Present 20 2080040 Fastener, Huck 4 21 3520176 Plug 1 22 0962337 Bushing, Hinge (S/N 03479 to Present) 2 23 3422866 Pin, Hinge (S/N 03479 to Present) 2 24 3760448 Ring, Snap (S/N 03479 to Present) 2

S E

C

T

I O N

4

P L A T

F O R

M

PLATFORM SUB ASSEMBLY Ref. 0259376 PRIOR TO S/N 03200 Ref. A 0270065 S/N 03200 TO PRESENT Ref. A

101 Not Required 102 3311605 Locknut 3/8”-16NC 1 103 3422744 Pin, Plunger 1 104 3900270 Bolt, Shoulder 1/2”-16NC x 1/2” 1 105 4711600 Flatwasher 3/8” Narrow 1 106 4846129 Rail, Top 1

3120798 4-3

S E

C

T

I O N

4

P L

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PLATFORM INSTALLATIONS Ref.

0259775 Standard Ref. D 0271387 Chinese Ref. A

201 Not Required 202 0641616 Bolt 3/8”-16NC x 2” 2 203 0641620 Bolt 3/8”-16NC x 2 1/2” 4 204 3311605 Locknut 3/8”-16NC 6 205 4711600 Flatwasher 3/8” 12 206 1703681 Decal - JLG 5 207 1704277 Decal - Lanyard Attach 1 208 Decal - JLG Manufacturing Options: 1

1704458 Standard

1704971 Chinese 209 1704467 Decal - Model Designation 1 210 Decal - Close Gate Options: 1

1704469 Standard

1704976 Chinese 211 Decal - Fall Hazard Options: 1

1704366 Standard

1704970 Chinese

A T

F O R

M

4-4 3120798

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

4

P L A T

F O R

M

3120798 4-5

S

2

15

17

10

103

207

106

211

203 204 205

4

18

23

24

13

9

6

19

206

210

12

20

3 7

14

5

16

8

203 204 205

102 104 105

202

204

205

22

209

208

E

C

T

SECTION 4 PLATFORM

FIGURE 4-2.PLATFORM INSTALLATION (FIXED SIDE RAILS)

O N

4

P L A T

F O R

M

I

4-6 3120798

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM INSTALLATION (FIXED SIDE RAILS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0270438 PLATFORM ASSEMBLY Ref. C

1 0100011 Loctite #242 (Not Shown) A/R 2 0721008 Screw 4 3 0940049 Stopper, Hood 2 4 2940074 Latch 1 5 3311001 Nut #10-24NC 4 6 0630545 Bolt 5/8”-18NC 2 7 3311501 Nut 5/16”-18NC 4 8 3520176 Plug 1 9 3571552 Plate, Platform Pan 1

10 3820032 Rivet 12

11 Not Required

12 4280296 Strip, Wear 13 4420039 Tape, Non Skid 10ft/6.1m 14 4751500 Flatwasher 5/16” Wide 4 15 4751000 Flatwasher #10 Wide 4 16 4761000 Lockwasher #10 4 17 4846323 Platform 1 18 4846324 Platform, Gate 1 19 4846325 Rail, Platform Gate 1 20 2080040 Fastener, Huck 4 22 0962337 Bushing, Hinge 2 23 3422866 Pin, Hinge 2 24 3760448 Ring, Snap 2

0270440 PLATFORM SUB ASSEMBLY Ref. A

20in/51cm

S E

C

T

I O N

4

P L A T F

O

101 Not Required 102 3311605 Locknut 3/8”-16NC 1 103 3422744 Pin, Plunger 1 104 3900270 Bolt, Shoulder 1/2”-16NC x 1/2” 1 105 4711600 Flatwasher 3/8” Narrow 1 106 4846129 Rail, Top 1

PLATFORM INSTALLATIONS Ref. 0270441 Standard Ref. B 0271388 Chinese Ref. A

201 Not Required 202 0641616 Bolt 3/8”-16NC x 2” 2 203 0641620 Bolt 3/8”-16NC x 2 1/2” 4 204 3311605 Locknut 3/8”-16NC 6 205 4711600 Flatwasher 3/8” 12 206 1703681 Decal - JLG 5 207 1704277 Decal - Lanyard Attach 1

3120798 4-7

R

M

S E

C

T

I O N

4

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM INSTALLATION (FIXED SIDE RAILS) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

208 Decal - Warning Options: 1

1704366 Standard 1704970 Chinese

209 Decal - JLG Manufacturing Options: 2

1704458 Standard

1704971 Chinese 210 1704467 Decal - Model Designation 1 211 Decal - Close Gate Options: 1

1704469 Standard

1704976 Chinese

P L A T

F O R

M

4-8 3120798

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM INSTALLATION (FIXED SIDE RAILS) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

4

P L A T

F O R

M

3120798 4-9

S

114

130

120

112

110

129

131

108

116

102

120

122

123

120 122 123

128

5

145

127

128

4

106

104

111

112

121

144

105

107

124

139

138

120 122 136 137

127

135

132 133 134

1

101

9

3

7

2 6 8

3

9

7

115

126

141

126

117

118

119

109

119

113

142

124

103

114

E

SECTION 4 PLATFORM

FIGURE 4-3.PLATFORM INSTALLATION (QUICK CHANGE GULLWING)

C

T

I O N

4

P L A T

F O R

M

4-10 3120798

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM INSTALLATION (QUICK CHANGE GULLWING)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PLATFORM INSTALLATIONS Ref.

0270513 Standard Ref. A 0271389 Chinese Ref. A

1 Not Required 2 0641408 Bolt 1/4”-20NC x 1” 8 3 1060380 Cable, Lanyard 4 4 Decal - JLG Manufacturing Options: 2

1704458 Standard

1704971 Chinese 5 1704467 Decal - Model Designation 1 6 3311405 Locknut 1/4”-20NC 8 7 3422657 Pin, Quick Release 4 8 4711400 Flatwasher 1/4” Narrow 16 9 4846021 Bracket 2

S E

C

T

I O N

0258586 PLATFORM ASSEMBLY Ref. 5

101 4845810 Weldment, Platform Rail (Stationary) 1 102 4845811 Weldment, Platform Rail (Extension) 1 103 4845812 Weldment, Gate 1 104 2020005 Glides, Extension 1 Pair 105 3570362 Pan, Floor (Stationary) 1 106 3570274 Pan, Floor (Extension) 1 107 3340829 Pad, Slide 2 108 4845614 Handle 2 109 2600225 Hinge, Gate 4 110 3900200 Bolt, Shoulder 2 111 3311005 Locknut #10-24NC 64 112 4751000 Flatwasher #10 66 113 3311505 Locknut 5/16”-18NC 2 114 3520072 Cap-Plug 4 115 2940074 Latch 1 116 2560154 Grip, Handle 2 117 0721006 Bolt #10-24NC x 3/4” 4 118 3900032 Bolt, Shoulder 2 119 4711600 Flatwasher 3/8” (Narrow) 4 120 3311405 Locknut 1/4”-20NC 22 121 3900252 Screw, Button Head 1/4”-20NC 64 122 4711400 Flatwasher 1/4” (Narrow) 40 123 0641414 Bolt 1/4”-20NC x 1 3/4” 16 124 3900258 Screw, Button Head 1/4”-20NC x 3/4” 8 125 0100011 Loctite #242 (Not Shown) A/R 126 4751000 Flatwasher #10 8 127 4420039 Tape, Non Skid 11ft/3.4m 128 1703681 Decal - JLG 3 129 4160165 Spring, Gas Shock (Note: Not Include Brackets) 1

0902877 Bracket, Mounting 2

4

P L A T

F O R

M

3120798 4-11

S E

C

T

I O N

4

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM INSTALLATION (QUICK CHANGE GULLWING) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

130 4711500 Flatwasher 5/16” (Narrow) 4 131 3250030 Plug, Hole 2 132 0720805 Screw #8-32NC x 5/8” 4 133 4750800 Flatwasher #8 8 134 3310805 Locknut #8-32NC 4 135 1380132 Clip, Gripper 4 136 0641416 Bolt 1/4”-20NC x 2” 4 137 3570653 Plate, Shim 2 138 3570654 Plate, Backing 2 139 4845657 Weldment, Stop 2 140 Not Used 141 3311005 Locknut #10-24NC 4 142 3300356 Nut, Acorn 5/16”-18NC 2 143 Not Used 144 4280296 Strip, Wear 145 4060803 Shield, Flex-Trim

10in/25cm

2.2ft/0.67m

P L A T

F O R

M

4-12 3120798

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM INSTALLATION (QUICK CHANGE GULLWING) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

C

T

I O N

4

P L A T

F O R

M

3120798 4-13

SECTION 4 PLATFORM

103

122

105 106 108

104

120 121

118

130 133 134

112

123 124 125

110

109 113 114

102

105

106

128

106 107 126 127

118

116

115 120

117 119

107

7

2

6

5

4

3

1

101

111

131

7

FIGURE 4-4.PLATFORM INSTALLATION (QUICK CHANGE MOLDED)

S E

C

T

I O N

4

P L A T

F O R

M

4-14 3120798

SECTION 4 PLATFORM

FIGURE 4-4. PLATFORM INSTALLATION (QUICK CHANGE MOLDED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0270512 MOLDED PLATFORM INSTALLATION Ref. A

1 Not Used 2 0641408 Bolt 1/4”-20NC x 1” 8 3 1060380 Cable, Lanyard 4 4 3311405 Locknut 1/4”-20NC 8 5 3422657 Pin, Ball Detent 4 6 4711400 Flatwasher 1/4” 16 7 4846021 Weldment, Platform Mount 2

S E

C

0258672 PLATFORM ASSEMBLY Ref. 1/A

101 4845822 Rail 1 102 3510676 Basket 1 103 4060882 Cover 1 104 4845831 Weldment, Bottom Mount 1 105 0641416 Bolt 1/4”-20NC x 2” 10 106 4751400 Flatwasher 1/4” 22 107 3520072 Cap 4 108 3311405 Locknut 1/4”-20NC 12 109 4160125 Spring, Gas 1 110 0362347 Link, Gate 1 111 3640924 Rail, Gate (Top) 1 112 3640990 Rail, Gate (Bottom) 1 113 4751500 Flatwasher 5/16” 1 114 3311505 Locknut 5/16”-18NC 1 115 3340746 Pad, Gate Rest 1 116 3911032 Screw, Machine #10-24NC x 2” 4 117 4751000 Flatwasher #10 8 118 4060803 Flex-Trim 2ft/0.6m 119 3311001 Nut #10-24NC 4 120 4070890 Shim, Gate Stop 2 121 3340754 Pad, Gate Latch 1 122 3900177 Screw, Plastite 6 123 3900202 Bolt, Shoulder 2 124 4740429 Washer, Nylon 4 125 3311005 Locknut #10-24NC 2 126 3900203 Bolt, Shoulder 2 127 4740428 Washer, Nylon 4 128 3300151 Nut, Acorn 1/4”-20NC 2 129 0100011 Loctite #242 (Not Shown) A/R 130 2940082 Latch, Gate 1 131 3520028 Plug 4 132 Not Used 133 3820024 Rivet 2 134 4070894 Shim, Gate Latch 1

T

I O N

4

P L A T

F O R

M

3120798 4-15

S E

C

T

I O N

4

SECTION 4 PLATFORM

FIGURE 4-4. PLATFORM INSTALLATION (QUICK CHANGE MOLDED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

P L A T

F O R

M

4-16 3120798

SECTION 5 CYLINDER

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

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

S E

C

T

I O N

5

C

Y L

I N D

E

R

3120798 5-1

S E

C

T

I O N

SECTION 5 CYLINDER

FIGURE 5-1.LIFT CYLINDER ASSEMBLY

5

C

Y L

I N D

E

R

5-2 312 0798

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LIFT CYLINDER ASSEMBLIES Ref.

1683808 PRIOR TO S/N 03620 Ref. A 1684142 S/N 03620 TO PRESENT Ref. G

1 Kit O-Ring 1 2 Kit Wiper 1 3 Kit Seal 1 4 Kit O-Ring 1 5 Kit Seal 1 6 Kit Ring, Wear 1 7 Not Used 8 Locknut Options: 1

7003246 Prior to S/N 03620 7023391 S/N 03620 to Present

9 Not Used

10 Barrel Options: 1

7019839 Prior to S/N 03620

Not Available S/N 03620 to Present

11 Rod Options: 1

7019838 Prior to S/N 03620 7023393 S/N 03620 to Present

12 Piston Options: 1

7019835 Prior to S/N 03620 7023392 S/N 03620 to Present

13 Head Options: 1

7019834 Prior to S/N 03620 7023394 S/N 03620 to Present

14 Spacer Options: 1

7019872 Prior to S/N 03620

Not Required S/N 03620 to Present

15 Poppet, Solenoid Valve

(S/N 03620 to Present Only) 7024354 Poppet, Solenoid Valve - 20 Volt Coil 7012958 20 Volt Coil Only 7012998 Seal Kit

16 7023397 Spring (S/N 03620 to Present Only) 1 17 7023398 Control Valve (S/N 03620 to Present Only) 1 18 7023399 Knob-Red 1

— — — — — — — — — — 7019865 Seal Kit - 1683808 (Includes Items 1-6) 1 7023395 Seal Kit - 1684142 (Includes Items 1-6) 1

1

S E

C

T

I O N

5

C

Y L

I N D

E

R

3120798 5-3

S E

C

T

I O N

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

5

C

Y L

I N D

E

R

5-4 312 0798

SECTION 6 HYDRAULIC

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

6-1 HYDRAULIC DIAGRAM (PRIOR TO S/N 03620) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

S E

C

T

I O N

6

H

Y D R

A U

L

I

C

3120798 6-1

S E

C

T

I

SECTION 6 HYDRAULIC

FIGURE 6-1.HYDRAULIC DIAGRAM (PRIOR TO S/N 03620)

O N

6

H

Y D R

A U

L

I

C

6-2 31207 98

SECTION 6 HYDRAULIC

FIGURE 6-1. HYDRAULIC DIAGRAM (PRIOR TO S/N 03620)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259774/

2792403

1 0100020 Sealant, Pipe (Not Shown) A/R

2 to 3 Not Used

4 2220416 Fitting 1 5 2220472 Fitting 1 6 2220473 Fitting 1 7 2220507 Fitting, 90° 1 8 2220603 Fitting 1 9 2220875 Fitting 1

10 to 11 Not Used

12 4568026 Tu b e, Re t u r n 1 13 4568027 Tube, Extension 1 14 4640956 Valve, Flow 1

HYDRAULIC DIAGRAM Ref. A

S E

C

T

I O N

6

H

Y D R

A U

L

I

C

3120798 6-3

S E

C

T

I

SECTION 6 HYDRAULIC

FIGURE 6-2. HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT)

O N

6

H

Y D R

A U

L

I

C

6-4 31207 98

SECTION 6 HYDRAULIC

FIGURE 6-2. HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0271466/

2792491

1 0100020 Sealant, Pipe (Not Shown) A/R

2 to 3 Not Used

4 2220415 Fitting 1 5 2220472 Fitting 1 6 2220473 Fitting 1 7 2220603 Fitting 1

8 to 9 Not Used

10 4568285 Tu b e, Re t u r n 1 11 4568286 Tube, Extension 1

HYDRAULIC DIAGRAM Ref. A

S E

C

T

I O N

6

H

Y D R

A U

L

I

C

3120798 6-5

S E

C

T

I

SECTION 6 HYDRAULIC

FIGURE 6-2. HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

O N

6

H

Y D R

A U

L

I

C

6-6 31207 98

SECTION 7 ELECTRICAL

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

7-1 ELECTRICAL SCHEMATIC (PRIOR TO S/N 03620) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL SCHEMATIC (S/N 03620 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

S E

C

T

I O N

7

E L E

C

T

R

I C

A

L

3120798 7-1

S E

C

SECTION 7 ELECTRICAL

FIGURE 7-1.ELECTRICAL SCHEMATIC (PRIOR TO S/N 03620)

T

I

O

N

7

E L E

C

T

R

I C A

L

7-2 3120798

SECTION 7 ELECTRICAL

FIGURE 7-2.ELECTRICAL SCHEMATIC (S/N 03620 TO PRESENT)

S E

C

T

I O N

7

E

L

E

C

T

R

I C

A

L

3120798 7-3

SECTION 7 ELECTRICAL

TO PUMP MOTOR SOLENOID

TO BATTERY TERMINAL

BEACON

BATTERY (LEFT SIDE)

(–

)

(–

)

(+

)

(+

)

BATTERY

(RIGHT SIDE)

HORN

ALARM

HOURMETER

GROUND CONTROL BOX

MAIN CONTACTOR RELAY

PUMP/MOTOR ASSEMBLY

POT-HOLE

PROTECTION

LIMIT SWITCHES

13

13C

13

16

17

14

2

3

1

15A

15

104

15

13

3

FIGURE 7-3. ELECTRICAL COMPONENTS INSTALLATION

C

O

N

C

R

C A

S E

T

I

7

E L E

T

I

L

7-4 3120798

SECTION 7 ELECTRICAL

+

TO

BATTERY

TERMINAL

TO

BATTERY

TERMINAL

MOTOR/BRAKE

ASSEMBLY

(RIGHT SIDE)

MOTOR/BRAKE

ASSEMBLY

(LEFT SIDE)

MAIN CONTROLLER

ELEVATION

LIMIT

SWITCH

TILT SENSOR SWITCH

PLATFORM

CONTROL

BOX

16

14

14A

14

204

105

101M

101N

101J

101K

101L

101E

101F

101G

201

14

14B

12B

12

12A

13

13A

13

11

11A

103B

11C

11B

13B

12C

102

103B

103

103A

101

106

101H

101I

101

101A

106A

101B 101C 101D

GROUND

CONTROLS

SWITCH

GROUND

CONTROLS

RELAY

EXTERNAL

DRIVE/HORN

RELAY

CONTACTOR

RELAY

S E

C

T

I O N

7

E

L

E

C

T

R

I C

A

L

3120798 7-5

S E

C

T

I

O

N

7

E L E

C

T

R

I C A

L

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

ELECTRICAL SYSTEM INSTALLATIONS Ref.

0259776 Prior to S/N 03620 Ref. E 0271478 S/N 03620 to Present Ref. A

1 1060618 Cable, Battery - 40” 1 2 1060619 Cable, Battery - 24” 1 3 1060620 Cable, Battery - 21” 2

4 to10 Not Used

11 4921963 Harness, Right Motor 1

11A 4460644 Receptacle - 5 Pin 1

4460645 Shell, Receptacle 2 11B 4460648 Receptacle - 2 Position 1 11C 4460320 Connector, Female - 2 Position 1

4460267 Pin 1

4460268 Socket 2

12 4921964 Harness, Left Motor 1

12A 4460644 Receptacle - 5 Pin 1

4460645 Pin 2 12B 4460648 Receptacle - 2 Position 1 12C 4460320 Connector, Female - 2 Position 1

4460267 Pin 1

4460268 Socket 2

13 4921965 Harness, Valve & Limit Switch (Prior to S/N 03083) 1

4922492 Harness, Valve & Limit Switch (S/N 03083 to S/N

03620)

4922617 Harness, Valve & Limit Switch (S/N 03620 to Pres-

ent)

3990010 Diode A/R 13A 4460681 Receptacle - 15 Pin 1

4460643 Shell, Receptacle 1

4460684 Socket 8 13B 4460424 Connector, Male - 2 Position 2

4460267 Pin 2

4460268 Socket 2 13C 2400006 Fuse - 5 Amp 1

4460044 Fuseholder 1

14 4921966 Harness, Controller Power 1

3990010 Diode 2 14A 4460646 Receptacle - 5 Pin 1

4460647 Shell, Receptacle 2 14B 4460320 Connector, Female - 2 Position 1

4460268 Socket 2

15 4921967 Harness, Key Switch Power 1

15A 2400006 Fuse - 5 Amp 1

4460044 Fuseholder 1

16 4921968 Harness, Main Contactor 1

3990010 Diode - 6 Amp 2

17 4921969 Harness, E-Stop (Located Inside Control Box) 1 18 4460234 Strap, Tie (Not Shown) 2

1

7-6 3120798

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

19 4240032 Strap, Tie (Not Shown) 6 20 4240033 Strap, Tie (Not Shown) 4

STANDARD HARNESS ASSEMBLIES Ref.

101 4922203 Harness, Ground to Platform 1 101A 1060616 Cable, Shielded A/R 101B 4460682 Terminal, 15 Pin 1 101C 4460643 Terminal, 15 Pin 1 101D 4460683 Te r m i n a l , P i n 8 101E 4460771 Terminal Plug, Male 1 101F 4460773 Backshell 1 101G 4460775 Pin, Male 9 101H 4460774 Cap, Dust 1

101I 7020216 Harness, Connector (Includes Items 101J, 101K,

101L, 101M & 101N)

101J 4460772 Terminal Plug, Female 1

101K 4460773 Backshell 1

101L 4460776 Pin, Female 9 101M 4460671 Terminal, 12 Pin 1 101N 4460672 Terminal, Female 9

102 4460648 Terminal (Harness Supplied with Drive Motor Only) 2 103 Not Available Harness Assembly - Brake 2

103A 4460320 Connector, Female - 2 Position 2

4460268 Socket 1 4460267 Pin 1

103B 4460424 Connector, Male - 2 Position 1

4460268 Socket 1

4460267 Pin 1 104 Not Available Beacon Light Harness Assembly 1 105 4460445 Receptacle - 3 Position (Attach to #14 for Tilt Sensor) 1

4460227 Pin 3 106 7018567 DC Battery Charger Harness Assembly 1

106A 7011621 Connector, Male - 2 Position 1

4460267 Pin, Male 2

TOOLS Ref.

0100048 Compound, Silicone (Use on Connectors/

Receptacles) 201 7002821 Crimper (For Wire to Pin/Socket Connections) 1 202 7002830 Extractor (For Removal of Pin/Socket from

Connectors) (Not Shown) 203 Not Used 204 7002828 Stripper, Wire 1

1

A/R

1

S E

C

T

I O N

7

E

L

E

C

T

R

I C

A

L

3120798 7-7

S E

C

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

T

I

O

N

7

E L E

C

T

R

I C A

L

7-8 3120798

SECTION 8 DECALS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATION (COUNTRY SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

S E

C

T

I O N

8

D

E

C

A L S

3120798 8-1

SECTION 8 DECALS

20

16

10

28

27

17

11

2

20

1 35

3

33 37

26

42

S/N 03620 TO

PRESENT

5

12

29

101

6

22

30

23

4

9

8

21

7

13 34

15

4

32 36

31

24

25

18

19

38

39

16

39

101

FIGURE 8-1.DECALS INSTALLATION

S E

C

T

I O N

8

D

E

C

A L S

8- 2 31 2 0798

SECTION 8 DECALS

FIGURE 8-1. DECALS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259770 DECAL INSTALLATION - STANDARD Ref. E

1 0860520 Box, Manual Storage 1 2 1702110 Decal - Read Instructions 1 3 1702282 Decal - Warning 1 4 1702300 Decal - Tie Down 2 5 1702361 Decal - Electrical Hazard (Prior to S/N 03620) 1 6 Decal - Crushing Options: 2

1702364 Prior to S/N 03620 1703786 S/N 03620 to Present

7 Decal - Explosion/Fire Hazard 1

1702437 Prior to S/N 03620

1703785 S/N 03620 to Present 8 Not Available Decal - Bar Code 1 9 1702885 Decal - Daily Checklist 1

10 1702886 Decal - Leveling 1 11 1702887 Decal - Operation (Prior to S/N 03620) 1 12 1702905 Decal - Joystick (Prior to S/N 03620) 1 13 1702922 Decal - Manual Decent (Prior to S/N 03620) 1 14 1703072 Decal - No Forklift 2 15 1703073 Decal - Fork Pockets 2 16 1703625 Decal - JLG 2 17 1703635 Decal - Brakes (Prior to S/N 03620) 1 18 1703636 Decal - Brakes 1 19 1704527 Decal - Operation 1 20 1703681 Decal - JLG 1 21 1703682 Decal - Charger Cord Location 1 22 1703684 Decal - Control Box Location 1 23 1703687 Decal - Arrow 2 24 1703688 Decal - Arrow 2 25 1703708 Decal - Towing/Winching 1 26 1704277 Decal - Lanyard Attach (Prior to S/N 03608) 1 27 Decal - Maximum Capacity Options: 1

1704538 Prior to S/N 03608

1704749 S/N 03608 to S/N 03620

28 1704366 Decal - Warning (Prior to S/N 03620) 1 29 1704467 Decal - Model Designation 2 30 1704469 Decal - Close Gate (Prior to S/N 03608) 1 31 3251813 Decal - USA 1 32 Not Available Nameplate, Serial Number 1 33 3380441 Panel, Control 1 34 3820006 Rivet (Prior to S/N 03620) 4 35 3820024 Rivet 4 36 3820031 Rivet 4 37 3820032 Rivet 4 38 4420051 Tape, Safety A/R 39 1704539 Decal - Wheel Load 4

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3120798 8-3

S

SECTION 8 DECALS

FIGURE 8-1. DECALS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

40 Not Used 41 1700584 Decal - Patent 1 42 1704888 Decal - Warning/Instruction (S/N 03620 to Present) 1

0270641 DECAL INSTALLATION (WAL*MART SPEC ONLY) Ref. A 0271256 DECAL INSTALLATION (HOUSE 2 HOME SPEC

ONLY)

0270873 DECAL INSTALLATION W/FIX SIDERAILS (HOME

DEPOT SPEC ONLY)

0270875 DECAL INSTALLATION W/MOLDED PLATFORM/

MATERIAL TRAY (HOME DEPOT SPEC ONLY)

101 Decal Options: 5

1704706 Associates Only (WAL*MART SPEC ONLY) 1704960 Team Members (HOUSE 2 HOME SPEC ONLY) 1704423 Employees Only (HOME DEPOT SPEC ONLY)

Ref. A

Ref. B

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8- 4 31 2 0798

SECTION 8 DECALS

FIGURE 8-1. DECALS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

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3120798 8-5

13

16

7

17

18

3

1 30

28 32

24

12

21

22

23

11

9

23

19

15

30 16

4

6

14

5

8 29

10

4

27 31

20 31

25

2

SECTION 8 DECALS

FIGURE 8-2.DECALS INSTALLATION (COUNTRY SPEC)

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8- 6 31 2 0798

SECTION 8 DECALS

FIGURE 8-2. DECALS INSTALLATION (COUNTRY SPEC)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DECAL INSTALLATION - STANDARD Ref.

0259790 CSA SPEC Ref. B 0271365 CHINESE Ref. B

1 0860520 Box, Manual Storage 1 2 1700584 Decal - Patent 1 3 Decal - Read Instructions Options: 1

1702110 CSA

1703741 Chinese 4 1702300 Decal - Tie Down 2 5 Decal - Explosion/Fire Hazard Options: 1

1702437 CSA

1703747 Chinese 6 Not Available Decal - Bar Code 1 7 Decal - Leveling Options: 1

1702437 CSA

1703745 Chinese 8 1702922 Decal - Manual Decent (Prior to S/N 03620) 1 9 1703072 Decal - No Forklift 2

10 1703073 Decal - Fork Pockets 2 11 1703625 Decal - JLG 2 12 Decal - Brakes Options: 1

1703636 CSA

1703749 Chinese

13 1703681 Decal - JLG 1 14 1703682 Decal - Charger Cord Location 1 15 Decal - Control Box Location Options: 1

1703684 CSA

1703751 Chinese

16 1703687 Decal - Arrow 2 17 1703688 Decal - Arrow 2 18 Decal - Towing/Winching Options: 1

1703708 CSA

1703752 Chinese

19 Decal - Crushing Hazard Options: 2

1703786 CSA

1704081 Chinese

20 Decal - JLG Manufacturing Options: 1

1704458 CSA

1704971 Chinese

21 1704467 Decal - Model Designation 2 22 Decal - Operation Options: 1

1704527 CSA

1704973 Chinese

23 Decal - Wheel Load Options: 4

1704539 CSA

1704974 Chinese

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3120798 8-7

S

SECTION 8 DECALS

FIGURE 8-2. DECALS INSTALLATION (COUNTRY SPEC) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

24 Decal - Warning/Instruction Options: 1

1704889 CSA 1704975 Chinese

25 Decal - USA Options: 1

3251813 CSA

Not Required Chinese

26 Nameplate, CSA 1

3252191 CSA

Not Required Chinese 27 Not Available Nameplate, Serial Number 1 28 3380441 Panel, Control 1 29 3820006 Rivet (Prior to S/N 03620) 4 30 3820024 Rivet 4 31 3820031 Rivet 8 32 3820032 Rivet 4 33 4420051 Tape, Safety A/R

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8- 8 31 2 0798

SECTION 9 RECOMMENDED SERVICE PARTS STOCK

VPSP SERIES The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.

JLG PART

NUMBER

DESCRIPTION

STANDARD PARTS

QTY PER FLEET

1-10 10-20 20 OR MORE

S

E

C

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I O N

9

3740069 Relay, Power 24 VDC (Figure 1-1 & 2-1) 1 1 1 4360314 Switch, Toggle (Figure 1-1) 1 1 1 4360465 Switch, Tilt (Figure 1-1) 1 1 1 7014117 Switch, Micro (Figure 1-2) 1 1 1 4360456 Switch, Limit (Figure 1-4) 1 1 1 0861330 Ground Control Box (Figure 2-1) 1 1 1 0861386 Ground Control Box (Keyless) (Figure 2-1) 1 1 1 1600305 Controller (Figure 2-1) 1 1 1 3740130 Relay 100-Amp (Figure 2-1) 1 1 1 4360437 Switch, Limit (Figure 2-1) 1 1 1 1600304 Controller, Joystick (Figure 2-2) 1 1 1 7018550 Transformer (Figure 2-3) 1 1 1 7018506 Relay, Interlock (Figure 2-3) 1 1 1 7018514 Breaker, Circuit - AC (Figure 2-3) 1 1 1 7011509 Breaker, Circuit - DC (Figure 2-3) 1 1 1 7016735 Coupling (Figure 2-5) 1 1 1 7013723 Filter - 149 Micron (Figure 2-5) 1 1 1 7016714 Breather (Figure 2-5) 1 1 1 7016711 Solenoid, Start (Figure 2-5) 1 1 1 3990010 Diode (Figure 7-3) 2 2 2 2400006 Fuse - 5 Amp (Figure 7-3) 2 2 2

R

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3120798 9-1

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SECTION 9 RECOMMENDED SERVICE PARTS

E

C

T

I O N

9

R

E C O

M M

E N D

VPSP SERIES The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.

JLG PART

NUMBER

DESCRIPTION

QTY PER FLEET

1-10 10-20 20 OR MORE

E

D S

E

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E

P A R

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T O C K

9-2 312 0798

SECTION 10 SPECIAL OPTIONS

Note: This list is to accommodate machines ordered with special equipment. Options may not

be applicable to all models. For more specific parts information contact JLG Parts Department.

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0220008 ARRESTER, SAFETY BELT Ref.

0220007 ARRESTER, STATIC LANYARD Ref.

S E

0271685 CHAIN & SHEAVE COVERS INSTALLATION Ref.

0272004 CYCLE COUNTER Ref.

ELECTRICAL CONNECTOR KITS Ref. 1001148902 Amp/Tyco Electrical Connector Kit Ref. 1001148903 Deutsch DT Electrical Connector Kit Ref. 1001148904 Deutsch HD Electrical Connector Kit Ref. 1001148905 Packard Electrical Connector Kit Ref. 1001148906 Various Electrical Connectors Kit Ref.

0255040 FLUORESCENT TUBE CADDY Ref.

0271809 LIMTER 12FT Ref.

0258799 MATERIAL TRAY Ref.

0271198 RUG CARRIER Ref.

TOOLS Ref.

0100048 Compound, Silicone (Use on Connectors/

Receptacles) 7002821 Crimper (For Wire to Pin/Socket Connections) 1 7002830 Extractor (For Removal of Pin/Socket from

Connectors) 7002828 Stripper, Wire 1

1001137005 Cable Kit, Software (Not Shown) 1

A/R

1

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3120798 10-1

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S P

SECTION 10 SPECIAL OPTIONS

Note: This list is to accommodate machines ordered with special equipment. Options may not

be applicable to all models. For more specific parts information contact JLG Parts Department.

FIG & ITEM # DESCRIPTION QTY. REV.

E C

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10-2 3120798

SECTION 11 PART NUMBER INDEX

PagePart Number PagePart Number PagePart Number

0100011 1-3, 1-7, 1-13, 3-3,

4-3, 4-7, 4-11, 4-

15

0100019 ...........1-4, 1-7, 2-7

0100020 ..................6-3, 6-5

0100035 .........1-4, 1-7, 1-13

0100048 ................7-7, 10-1

0100062 ..................3-5, 3-6

0140022 ......................... 2-3

0140033 ......................... 2-3

0181857 ......................... 2-3

0220007 ....................... 10-1

0220008 ....................... 10-1

0255040 ....................... 10-1

0256851 ......................... 1-7

0257490 ....................... 1-13

0258448 ......................... 3-9

0258586 ....................... 4-11

0258672 ....................... 4-15

0258718 ......................... 1-7

0258799 ....................... 10-1

0259350 ......................... 4-3

0259376 ......................... 4-3

0259526 ......................... 1-3

0259527 ......................... 1-4

0259528 ......................... 2-3

0259769 ......................... 2-7

0259770 ......................... 8-3

0259774 ..................2-4, 6-3

0259775 ......................... 4-4

0259776 ......................... 7-6

0259790 ......................... 8-7

0270065 ......................... 4-3

0270352 ......................... 1-4

0270438 ......................... 4-7

0270440 ......................... 4-7

0270441 ......................... 4-7

0270512 ....................... 4-15

0270513 ....................... 4-11

0270641 ......................... 8-4

0270719 ......................... 2-3

0270873 ......................... 8-4

0270875 ......................... 8-4

0271059 ......................... 2-7

0271198 ....................... 10-1

0271256 ......................... 8-4

0271365 ......................... 8-7

0271387 ......................... 4-4

0271388 ......................... 4-7

0271389 ....................... 4-11

0271465 ......................... 1-4

0271466 ..................2-4, 6-5

0271478 ......................... 7-6

0271685 ....................... 10-1

0271809 ....................... 10-1

0272004 ....................... 10-1

0362347 ....................... 4-15

0362604 ......................... 2-3

0362658 ......................... 2-3

0362735 ......................... 3-3

0362736 ......................... 3-3

0400122 ......................... 2-3

0400157 ....................... 2-11

0400164 .................. 2-3, 2-9

0400166 ....................... 2-11

0400173 ......................... 2-9

0440221 ......................... 1-7

0440225 ......................... 3-4

0440230 ......................... 3-4

0440246 ......................... 3-4

0440294 ......................... 3-4

0561149 .................. 3-5, 3-6

0561151 ......................... 3-5

0561284 ......................... 1-4

0561308 ......................... 3-5

0561336 ......................... 3-5

0561341 ......................... 3-3

0561408 .................. 3-5, 3-6

0630446 ......................... 1-3

0630504 ......................... 2-3

0630545 ......................... 4-7

0641405 ....................... 1-13

0641406 .... 1-3, 1-4, 2-3, 3-3

0641407 ......................... 3-3

0641408 ....... 3-4, 4-11, 4-15

0641410 .................. 2-7, 3-3

0641414 ....................... 4-11

0641416 .............. 4-12, 4-15

0641508 .................. 2-3, 3-3

0641510 ......................... 3-3

0641528 ......................... 1-4

0641606 ......................... 2-4

0641608 ......................... 1-4

0641609 .... 1-3, 1-4, 1-7, 2-3

0641610 ......................... 1-7

0641612 .................. 1-4, 3-9

0641616 .................. 4-4, 4-7

0641620 .................. 4-4, 4-7

0641711 ......................... 1-7

0641810 ......................... 1-4

0641812 .................. 3-3, 3-9

0720805 ....................... 4-12

0721005 ......................... 2-7

0721006 ................ 2-3, 4-11

0721008 ........... 1-3, 4-3, 4-7

0741006 ......................... 3-3

0741407 ......................... 2-3

0741605 ......................... 2-4

0741606 ......................... 3-3

0741609 ......................... 1-7

0801211 .................. 3-3, 3-9

0801313 ......................... 3-3

0860520 .................. 8-3, 8-7

0860946 ......................... 2-7

0861330 .................. 2-3, 9-1

0861386 .................. 2-3, 9-1

0880139 ......................... 1-4

0902047 ......................... 3-3

0902250 .........................2-3

0902356 .........................2-3

0902422 .........................3-3

0902423 .........................3-3

0902424 .........................3-3

0902431 .........................3-3

0902445 .........................3-3

0902583 .........................1-3

0902698 .........................3-5

0902877 .......................4-11

0940049 ..................4-3, 4-7

0962337 ..................4-3, 4-7

1060380 ...... 2-7, 4-11, 4-15

1060564 .........................2-7

1060616 .........................7-7

1060618 .........................7-6

1060619 .........................7-6

1060620 .........................7-6

1060649 .......................1-13

1060658 ..................1-3, 1-4

1060661 .........................1-4

1060662 .........................1-4

1060683 .........................3-3

1100103 .......................1-13

1260343 ..................3-3, 3-5

1260349 ..................3-3, 3-5

1260355 .........................3-5

1260356 ..................3-5, 3-6

1260357 ..................3-5, 3-6

1271392 .........................3-3

1271419 .........................3-3

1271421 .........................3-3

1271455 .........................3-3

1271456 .........................3-3

1271471 .........................3-3

1320043 .........................2-7

1320149 .........................2-7

1380132 ................2-7, 4-12

1400126 ..................1-7, 1-8

1600304 ........ 2-7, 2-15, 9-1

1600305 ..................2-3, 9-1

1683808 ..................3-3, 5-3

1684142 ..................3-3, 5-3

1700584 ..................8-4, 8-7

1702110 ..................8-3, 8-7

1702282 .........................8-3

1702300 ..................8-3, 8-7

1702361 .........................8-3

1702364 .........................8-3

1702437 ..................8-3, 8-7

1702885 .........................8-3

1702886 .........................8-3

1702887 .........................8-3

1702905 .........................8-3

1702922 ..................8-3, 8-7

1702923 .........................1-3

1703072 ..................8-3, 8-7

1703073 ..................8-3, 8-7

1703455 .........................3-9

Part Number

1703625 .................. 8-3, 8-7

1703635 ......................... 8-3

1703636 .................. 8-3, 8-7

1703681 .4-4, 4-7, 4-11, 8-3,

8-7

1703682 .................. 8-3, 8-7

1703684 .................. 8-3, 8-7

1703687 .................. 8-3, 8-7

1703688 .................. 8-3, 8-7

1703708 .................. 8-3, 8-7

1703741 ......................... 8-7

1703745 ......................... 8-7

1703747 ......................... 8-7

1703749 ......................... 8-7

1703751 ......................... 8-7

1703752 ......................... 8-7

1703785 ......................... 8-3

1703786 .................. 8-3, 8-7

1704081 ......................... 8-7

1704277 ....3-9, 4-4, 4-7, 8-3

1704366 ...........4-4, 4-8, 8-3

1704423 ......................... 8-4

1704458 ..4-4, 4-8, 4-11, 8-7 1704467 .4-4, 4-8, 4-11, 8-3,

8-7

1704469 ...........4-4, 4-8, 8-3

1704527 .................. 8-3, 8-7

1704538 ......................... 8-3

1704539 .................. 8-3, 8-7

1704582 ......................... 1-4

1704706 ......................... 8-4

1704749 ......................... 8-3

1704888 ......................... 8-4

1704889 ......................... 8-8

1704960 ......................... 8-4

1704970 .................. 4-4, 4-8

1704971 ..4-4, 4-8, 4-11, 8-7

1704973 ......................... 8-7

1704974 ......................... 8-7

1704975 ......................... 8-8

1704976 .................. 4-4, 4-8

2020005 ....................... 4-11

2080040 .................. 4-3, 4-7

2220415 ......................... 6-5

2220416 ......................... 6-3

2220472 .................. 6-3, 6-5

2220473 .................. 6-3, 6-5

2220507 ......................... 6-3

2220603 .................. 6-3, 6-5

2220875 ......................... 6-3

2400006 .................. 7-6, 9-1

2420140 ......................... 1-4

2420165 ......................... 1-3

2560150 ......................... 1-4

2560154 ....................... 4-11

2600225 ....................... 4-11

2680432 ......................... 2-3

2680483 ......................... 2-3

2700080 ......................... 2-3

Page

3120798 11-1

SECTION 11 PART NUMBER INDEX

PagePart Number PagePart Number PagePart Number

2792403 ......................... 6-3

2792491 ......................... 6-5

2860027 ......................... 1-7

2860029 ......................... 1-7

2860030 ......................... 2-3

2880310 ......................... 3-3

2920146 ......................... 1-3

2940074 .........4-3, 4-7, 4-11

2940082 ....................... 4-15

2940132 ......................... 2-4

3020022 ....................... 1-13

3160234 ................1-7, 1-11

3250030 ....................... 4-12

3251813 ..................8-3, 8-8

3252191 ......................... 8-8

3252761 ......................... 2-7

3271805 ......................... 3-9

3300047 ......................... 2-7

3300151 ....................... 4-15

3300202 ......................... 2-3

3300356 ....................... 4-12

3300417 ......................... 2-7

3310601 ......................... 1-3

3310801 ......................... 2-7

3310805 ....................... 4-12

3311001 2-3, 2-7, 4-3, 4-7, 4-

15

3311005 1-3, 1-13, 2-3, 4-11,

4-12, 4-15

3311401 ......................... 3-3

3311405 .1-3, 2-4, 2-7, 4-11,

4-15

3311501 ...........1-4, 4-3, 4-7

3311505 .............. 4-11, 4-15

3311601 ......................... 3-3

3311605 1-3, 1-4, 1-7, 2-4, 2-

7, 3-9, 4-3, 4-4,

4-7

3311705 ......................... 1-7

3311801 ......................... 3-3

3311805 ......................... 1-4

3312002 ....................... 1-13

3340746 ....................... 4-15

3340754 ....................... 4-15

3340829 ....................... 4-11

3340845 ......................... 3-3

3340858 ......................... 3-3

3380441 ..................8-3, 8-8

3422338 ..................3-3, 3-6

3422346 ..................3-5, 3-6

3422355 ..................3-5, 3-6

3422657 .......2-7, 4-11, 4-15

3422717 ......................... 3-3

3422720 ..................3-5, 3-6

3422744 ..................4-3, 4-7

3422750 ......................... 3-3

3422752 ......................... 3-3

3422757 ......................... 3-3

3422866 ..................4-3, 4-7

3430630 ........................1-13

3430638 ........................1-13

3440418 ........................1-13

3440520 ..........................1-7

3450202 .................. 3-5, 3-6

3450304 .................. 3-3, 3-6

3450403 ........................1-13

3510676 ........................4-15

3520028 ........................4-15

3520072 .............. 4-11, 4-15

3520166 ..........................2-4

3520176 .................. 4-3, 4-7

3539814 ..........................3-9

3570168 ..........................1-7

3570169 ..........................1-7

3570172 ..........................1-4

3570230 ........................1-13

3570274 ........................4-11

3570362 ........................4-11

3570382 ..........................1-4

3570653 ........................4-12

3570654 ........................4-12

3570680 ..........................2-7

3570737 ..........................2-7

3570893 ..........................3-4

3570976 ..........................3-9

3571101 .................. 3-4, 3-6

3571103 .................. 3-4, 3-6

3571552 .................. 4-3, 4-7

3571788 ..........................3-4

3571790 ..........................3-4

3580231 ..........................2-7

3580267 ..........................3-4

3580268 ..........................3-4

3580269 ..........................3-4

3580274 ..........................3-4

3580275 ..........................3-4

3580285 ..........................3-4

3580286 ..........................3-4

3580293 ..........................3-4

3600254 ................ 2-4, 2-13

3640924 ........................4-15

3640990 ........................4-15

3740069 ........... 1-3, 2-4, 9-1

3740130 .................. 2-4, 9-1

3760170 ..........................2-7

3760383 ..........................3-5

3760448 .................. 4-3, 4-7

3820006 .................. 8-3, 8-8

3820024 .. 2-7, 4-15, 8-3, 8-8

3820031 .................. 8-3, 8-8

3820032 .... 4-3, 4-7, 8-3, 8-8

3820034 ..........................3-4

3841343 ........................1-13

3900032 ........................4-11

3900177 ........................4-15

3900187 ..........................3-4

3900192 ..........................3-4

3900200 ................ 2-7, 4-11

3900202 ..............1-13, 4-15

3900203 .......................4-15

3900205 ..................2-4, 3-4

3900221 .........................1-7

3900248 .........................1-4

3900249 .......................1-13

3900252 .......................4-11

3900258 .......................4-11

3900270 ..................4-3, 4-7

3910620 ................1-3, 1-13

3911010 ..................1-3, 2-4

3911024 .........................2-4

3911032 .......................4-15

3930808 .........................1-7

3990010 ..................7-6, 9-1

4040268 .........................1-7

4060092 .........................2-7

4060803 ..............4-12, 4-15

4060882 .......................4-15

4060960 .........................3-4

4060961 .........................3-4

4060987 .........................3-5

4061006 .........................3-5

4070860 .........................3-4

4070861 .........................3-4

4070862 .........................3-4

4070890 .......................4-15

4070894 .......................4-15

4070970 .........................3-4

4070971 .........................3-4

4070988 .........................3-5

4070989 .........................3-5

4070990 .........................3-5

4160124 .........................3-4

4160125 .......................4-15

4160130 .........................2-7

4160160 .......................1-13

4160162 .......................1-13

4160164 .........................1-3

4160165 .......................4-11

4160166 .........................1-4

4240032 .........................7-7

4240033 ..................1-4, 7-7

4240084 .........................1-4

4280296 .........4-3, 4-7, 4-12

4300106 .........................1-3

4300111 ..................3-5, 3-6

4300129 ..................3-5, 3-6

4360314 ..................1-3, 9-1

4360435 .........................1-3

4360437 ..................2-4, 9-1

4360456 ................1-13, 9-1

4360465 ..................1-3, 9-1

4360469 .........................2-3

4420039 .........4-3, 4-7, 4-11

4420051 ..................8-3, 8-8

4460023 .........................2-7

4460044 .........................7-6

4460190 .........................2-7

Part Number

4460227 ......................... 7-7

4460234 ......................... 7-6

4460267 .. 2-9, 2-11, 7-6, 7-7

4460268 .................. 7-6, 7-7

4460320 .................. 7-6, 7-7

4460424 .. 2-9, 2-11, 7-6, 7-7

4460445 ......................... 7-7

4460549 ......................... 2-7

4460566 ......................... 2-7

4460633 ......................... 2-3

4460643 .................. 7-6, 7-7

4460644 ......................... 7-6

4460645 ......................... 7-6

4460646 ......................... 7-6

4460647 ......................... 7-6

4460648 ........... 1-3, 7-6, 7-7

4460662 ....................... 1-13

4460671 ......................... 7-7

4460672 ......................... 7-7

4460681 ......................... 7-6

4460682 ......................... 7-7

4460683 ......................... 7-7

4460684 ......................... 7-6

4460685 ......................... 2-4

4460771 ......................... 7-7

4460772 ......................... 7-7

4460773 ......................... 7-7

4460774 ......................... 7-7

4460775 ......................... 7-7

4460776 ......................... 7-7

4567203 ....................... 1-13

4567489 ......................... 3-4

4567492 ......................... 3-4

4567749 ......................... 3-5

4567750 ......................... 3-4

4567751 ......................... 3-5

4568026 ......................... 6-3

4568027 ......................... 6-3

4568285 ......................... 6-5

4568286 ......................... 6-5

4640956 ......................... 6-3

4711400 . 1-3, 1-4, 1-13, 2-4,

2-7, 3-4, 4-11, 4-

15

4711500 ................ 3-4, 4-12

4711600 1-4, 2-4, 3-9, 4-3, 4-

4, 4-7, 4-11

4711700 ......................... 1-7

4711800 ......................... 3-4

4712000 ....................... 1-13

4712600 ......................... 3-4

4740007 ......................... 3-5

4740414 ......................... 3-4

4740428 ....................... 4-15

4740429 ....................... 4-15

4740430 ......................... 1-3

4740478 ......................... 1-7

4750600 ................ 1-3, 1-13

4750800 1-7, 2-4, 2-7, 3-4, 4-

Page

11-2 3120798

SECTION 11 PART NUMBER INDEX

PagePart Number PagePart Number PagePart Number

12

4751000 1-3, 2-4, 2-7, 4-3, 4-

7, 4-11, 4-15

4751400 ................2-4, 4-15

4751500 2-4, 2-7, 3-4, 3-6, 4-

3, 4-7, 4-15 4751600 1-3, 1-4, 1-7, 1-13,

2-4

4751800 ..................1-4, 3-9

4761000 ... 2-7, 3-4, 4-3, 4-7

4761400 ......................... 3-4

4761500 ......................... 3-4

4845291 ......................... 1-4

4845345 ......................... 3-9

4845473 ......................... 1-7

4845474 ......................... 1-4

4845507 ....................... 1-13

4845508 ....................... 1-13

4845509 ....................... 1-13

4845614 ....................... 4-11

4845657 ....................... 4-12

4845731 ......................... 3-4

4845810 ....................... 4-11

4845811 ....................... 4-11

4845812 ....................... 4-11

4845822 ....................... 4-15

4845831 ....................... 4-15

4845875 ......................... 2-4

4845876 ......................... 2-4

4845878 ......................... 2-4

4846021 ..............4-11, 4-15

4846030 ......................... 4-3

4846034 ......................... 4-3

4846035 ......................... 4-3

4846087 ......................... 1-3

4846129 ..................4-3, 4-7

4846173 ......................... 1-4

4846323 ..................4-3, 4-7

4846324 ..................4-3, 4-7

4846325 ..................4-3, 4-7

4846381 ......................... 3-4

4846521 ......................... 4-3

4860175 ......................... 1-3

4860177 ......................... 1-3

4921963 ......................... 7-6

4921964 ......................... 7-6

4921965 ......................... 7-6

4921966 ......................... 7-6

4921967 ......................... 7-6

4921968 ......................... 7-6

4921969 ......................... 7-6

4922203 ..................2-7, 7-7

4922492 ......................... 7-6

4922617 ......................... 7-6

7002821 ................7-7, 10-1

7002828 ................7-7, 10-1

7002830 ................7-7, 10-1

7003246 ......................... 5-3

7011509 .........2-9, 2-11, 9-1

7011528 ................ 2-9, 2-11

7011596 ......................... 2-9

7011621 ......................... 7-7

7011649 ....................... 2-11

7012958 ......................... 5-3

7012998 ......................... 5-3

7013701 ....................... 2-13

7013708 ....................... 2-13

7013713 ....................... 2-13

7013714 ....................... 2-13

7013715 ....................... 2-13

7013716 ....................... 2-13

7013717 ....................... 2-13

7013720 ....................... 2-13

7013722 ....................... 2-13

7013723 ................ 2-13, 9-1

7013727 ....................... 2-13

7013728 ....................... 2-13

7013733 ....................... 2-13

7013743 ....................... 2-13

7013750 ....................... 2-13

7013758 ....................... 2-13

7013759 ....................... 2-13

7013766 ....................... 2-13

7013770 ....................... 2-13

7013791 ....................... 2-13

7013792 ....................... 2-13

7013793 ....................... 2-13

7014117 .................. 1-7, 9-1

7014118 ......................... 1-7

7014119 ......................... 1-7

7014120 ......................... 1-7

7016319 ......................... 1-3

7016372 ......................... 1-3

7016683 ......................... 1-7

7016684 ......................... 1-7

7016685 ......................... 1-7

7016686 ......................... 1-7

7016687 ......................... 1-7

7016688 ......................... 1-8

7016689 ......................... 1-7

7016690 ......................... 1-7

7016691 ......................... 1-7

7016710 ....................... 2-13

7016711 ................ 2-13, 9-1

7016712 ....................... 2-13

7016713 ....................... 2-13

7016714 ................ 2-13, 9-1

7016718 ....................... 2-13

7016719 ....................... 2-13

7016720 ....................... 2-13

7016721 ....................... 2-13

7016722 ....................... 2-13

7016723 ....................... 2-13

7016724 ....................... 2-13

7016735 ................ 2-13, 9-1

7017717 ....................... 2-13

7018000 ....................... 1-11

7018001 ....................... 1-11

7018002 .......................1-11

7018005 .......................1-11

7018007 .......................1-11

7018008 .......................1-11

7018009 .......................1-11

7018010 .......................1-11

7018011 .......................1-11

7018012 .......................1-11

7018013 .......................1-11

7018014 .......................1-11

7018015 .......................1-11

7018018 .......................1-11

7018019 .......................1-11

7018027 .......................1-11

7018028 .......................1-11

7018506 ..................2-9, 9-1

7018514 ..................2-9, 9-1

7018535 .........................2-9

7018537 ................2-9, 2-11

7018550 ..................2-9, 9-1

7018551 .......................2-11

7018553 .........................2-9

7018554 ................2-9, 2-11

7018555 ................2-9, 2-11

7018556 ................2-9, 2-11

7018557 ................2-9, 2-11

7018561 .........................2-9

7018562 .......................2-11

7018563 .......................2-11

7018564 .......................2-11

7018565 .........................2-9

7018567 ........ 2-9, 2-11, 7-7

7018586 .......................2-11

7018589 .......................2-11

7019659 .........................1-3

7019660 .........................1-3

7019661 .........................1-3

7019662 .........................1-3

7019663 .........................1-3

7019834 .........................5-3

7019835 .........................5-3

7019838 .........................5-3

7019839 .........................5-3

7019865 .........................5-3

7019872 .........................5-3

7020075 .........................2-7

7020076 .........................2-7

7020078 .........................2-3

7020093 .........................2-3

7020094 .........................2-3

7020096 .........................2-3

7020097 .........................2-3

7020139 .......................2-15

7020142 .......................2-15

7020143 .......................2-15

7020144 .......................2-15

7020145 .......................2-15

7020147 .......................2-15

7020216 .........................7-7

Part Number

7020267 ......................... 2-3

7020620 ....................... 2-11

7022205 ....................... 2-13

7022206 ....................... 2-13

7023201 ....................... 2-15

7023202 ....................... 2-15

7023273 ......................... 2-3

7023341 ......................... 2-3

7023342 ......................... 2-3

7023351 ......................... 1-8

7023352 ......................... 1-8

7023353 ......................... 1-8

7023354 ......................... 1-8

7023355 ......................... 1-8

7023356 ......................... 1-8

7023357 ......................... 1-8

7023358 ......................... 1-8

7023359 ......................... 1-8

7023360 ......................... 1-8

7023361 ......................... 1-8

7023391 ......................... 5-3

7023392 ......................... 5-3

7023393 ......................... 5-3

7023394 ......................... 5-3

7023395 ......................... 5-3

7023397 ......................... 5-3

7023398 ......................... 5-3

7023399 ......................... 5-3

7024354 ......................... 5-3

7026038 ....................... 2-15

7026039 ....................... 2-15

Page

3120798 11-3

SECTION 11 PART NUMBER INDEX

PagePart Number PagePart Number PagePart Number

Part Number

Page

11-4 3120798

McConnellsburg PA. 17233-9533

3120798

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

(717) 485-5161 (717) 485-6417

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia

+61 2 65 811111

+61 2 65 813058

JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755 Castellbisbal, Barcelona Spain

+34 93 772 4700

+34 93 771 1762

JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil

+55 19 3295 0407

+55 19 3295 1025

JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N. T. Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG Industries (Italia) s.r.l. Via Po. 22 20010 Pregnana Milanese - MI Italy

+39 029 359 5210

+39 029 359 5845

JLG France SAS Z.I. de Baulieu 47400 Fauillet France

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

Oshkosh-JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4, Jurong Industrial Estate Singapore, 639379

+65-6591 9030

+65-6591 9031

JLG 15VPSP Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION

FIGURE 1-2. REAR DRIVE ASSEMBLY

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATION

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

FIGURE 2-3. BATTERY CHARGER ASSEMBLY (ANSI)

FIGURE 2-4. BATTERY CHARGER ASSEMBLY (ANSI EXPORT)

FIGURE 2-5. PUMP/MOTOR/TANK ASSEMBLY

FIGURE 2-6. CONTROL BOX ASSEMBLY

SECTION 3 MAST

FIGURE 3-1. MAST ASSEMBLY - 15VPSP

FIGURE 3-2. MAST MOUNTING COMPONENTS

SECTION 4 PLATFORM

FIGURE 4-1.PLATFORM INSTALLATION (FOLD DOWN SIDE RAILS)

FIGURE 4-2.PLATFORM INSTALLATION (FIXED SIDE RAILS)

FIGURE 4-3.PLATFORM INSTALLATION (QUICK CHANGE GULLWING)

FIGURE 4-4.PLATFORM INSTALLATION (QUICK CHANGE MOLDED)

SECTION 5 CYLINDER

FIGURE 5-1.LIFT CYLINDER ASSEMBLY

SECTION 6 HYDRAULIC

FIGURE 6-1.HYDRAULIC DIAGRAM (PRIOR TO S/N 03620)

FIGURE 6-2. HYDRAULIC DIAGRAM (S/N 03620 TO PRESENT)

SECTION 7 ELECTRICAL

FIGURE 7-1.ELECTRICAL SCHEMATIC (PRIOR TO S/N 03620)

FIGURE 7-2.ELECTRICAL SCHEMATIC (S/N 03620 TO PRESENT)

FIGURE 7-3. ELECTRICAL COMPONENTS INSTALLATION

SECTION 8 DECALS

FIGURE 8-1.DECALS INSTALLATION

FIGURE 8-2.DECALS INSTALLATION (COUNTRY SPEC)

SECTION 9 RECOMMENDED SERVICE PARTS STOCK

SECTION 10 SPECIAL OPTIONS

SECTION 11 PART NUMBER INDEX

8-7

8-7

4-12, 4-15

4-15

7, 4-11, 4-15

2-4