JLG 12SP Service And Maintenance Manual
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JLG 12SP Service And Maintenance Manual

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Service and Maintenance Manual
Model
12SP
15SP
3120775
June 29, 2018 - Rev K
ANSI

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Summary of Contents for JLG 12SP

  • Page 1 Service and Maintenance Manual Model 12SP 15SP 3120775 June 29, 2018 - Rev K ANSI...
  • Page 3 TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE- TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.
  • Page 4 NOTES:...
  • Page 5 OFF ALL POWER CONTROLS. • BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO- NENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACH- MENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. 3120775 – JLG Lift –...
  • Page 6 June 2, 1999 - A - Original Issue of Manual March 7, 2000 - B - Manual Revised (added CSA/Latin America Specifications) April 13, 2000 - C - Manual Revised (added 12SP Model) April 25, 2000 - D - Manual Revised (corrected Mast Disassembly/Assembly - Section-2.) November 22, 2000 - E - Manual Revised - Pages Affected;Section 2 - Pages 2-4 through 2-19.
  • Page 7 Mast Cable Inspection Procedure ......... . . 2-6 3120775 – JLG Lift –...

  • Page 8: Table Of Contents

    Clamp Installation (Drum/Socket Type) ........2-32 – JLG Lift –...
  • Page 9 12SP Mast Assembly Components. (4 Section)........
  • Page 10 TABLE OF CONTENTS NOTES: – JLG Lift – 3120775...
  • Page 11 Machine Overall Width And Length (Stowed) Selectable Voltage 12SP - 34 in.(W) x 73 in.(L) (86 cm x 185 cm) NOTE: A high output - 12Volt DC, 20 Amp output - SCR 15SP - 34 in.(W) x 75.5 in.(L) (86 cm x 192 cm) charger is supplied with the AGM battery option.

  • Page 12: Hydraulic Pressure Setting - Adjustment Screw Located At Base Of Pump Motor

    +20°F (–7°C) JLG recom- mends using Mobil DTE 13 hydraulic oil. PRESSURE ADJUSTMENT Aside from JLG recommendations, it is not advisable to ADJUSTMENT SCREW mix oils of different brands or types, as they may not con- SCREW CAP...
  • Page 13 4. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir. 3120775 – JLG Lift –...

  • Page 14: Torque Chart

    SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart. – JLG Lift – 3120775...
  • Page 15 The Annual Machine Inspection must be performed by a machine into service. qualified JLG equipment mechanic on an annual basis, no Preparation, Inspection, and Maintenance later than thirteen (13) months from the date of the prior Annual Machine Inspection.
  • Page 16 Owner, Dealer, or User Qualified JLG Service and Maintenance Man- Inspection rental delivery. Mechanic ual and applicable JLG inspec- tion form. Frequent In service for 3 months or 150 hours, Owner, Dealer, or User Qualified JLG Service and Maintenance Man- Inspection whichever comes first;...
  • Page 17 Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2 Hydraulic Hoses, Lines, and Fittings 1, 9 1, 9 Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7 Hydraulic Filter Hydraulic Fluid * Electrical Connections Instruments, Gauges, Switches, Lights, Horn 3120775 – JLG Lift –...
  • Page 18 Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership * Drain and Refill with fresh hydraulic fluid every two years. Footnotes: 11. Check for proper fluid level.
  • Page 19 New parts and thickness. Be sure to cut holes in the right location, as should remain in their containers until they are ready to be blank gaskets can cause serious system damage. used. 3120775 – JLG Lift –...
  • Page 20 (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are dis- covered, replace all chains, as seemingly sound plates – JLG Lift – 3120775...
  • Page 21 Fatigue and ultimate Also, more then one crack can often appear on a link strength failures on JLG Lifts are incurred as a result of plate. In addition to rusting, this condition can be caused...

  • Page 22: 2.4 Lubrication Information

    Additional inspection of this sec- Hydraulic Oil tion is required. For best performance, JLG recommends the use of ISO- 3. Wear of one-third the original diameter of outside Vg grade 32, 46 oil with a viscosity range between 15-250 individual wires.

  • Page 23: Battery Charger - Assembly And Disassembly

    The AM Series dual AC input battery charger allows for replacement of the following internal components. Con- sult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department: • Transformer • Printed Circuit Board •...

  • Page 24: Transformer Replacement

    3. Remove transformer. DC Circuit Breaker Replacement 1. Remove the wiring from the breaker terminals. 2. Remove the bolt, nut and washer from each side of the breaker, remove the breaker from the housing. 2-10 – JLG Lift – 3120775...

  • Page 25: Ac Circuit Breaker And Voltage Selection Switch Replacement

    (see illustration below). One through the rear panel of the base with a short white spacer and one at the long white insulator attaching the shunt assembly to the bracket. 2. Remove the varistor from it’s mount. 3120775 – JLG Lift – 2-11...

  • Page 26: 2.6 Hydraulic Lift Pump - Servicing

    1. Motor Assembly 3. Pump End Head 2. Positive (+) Post 4. Spring Washer 2. Motor Assembly Screws 4. Motor to Pump Coupler Note: Length of wires to brush assemblies shown exaggerated for illustrative purposes. 2-12 – JLG Lift – 3120775...

  • Page 27: Brush Housing Final Assembly Tips

    Clean the rotor commutator with a non-conductive electrical CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT cleaner before assembling the brush housing to the motor hous- AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF ing. THE BRUSH. 3120775 – JLG Lift – 2-13...

  • Page 28: Monarch Brand Pump - Brush Replacement

    NOTE: (a) Once cover screws are removed, you may need to tap lightly around the edge of the top cover to separate it from the motor housing. Read the important note above before attempting to remove the cover. (b) These steel screws are threaded into the aluminum valve body, do not overtighten. 2-14 – JLG Lift – 3120775...

  • Page 29: Brush Carrier Assembly - Remove/Install

    1. Brush Assembly (a) 4. Brush Terminal Screw 2. Brush Carrier Socket 5. Brush Attach Terminal 3. Brush Tab Slot NOTE: (a) Slide brush assembly into socket until tab is in slot at rear of socket. 3120775 – JLG Lift – 2-15...

  • Page 30: Tank And Pump Removal - (All Pumps)

    4. Use Screwdriver to pry tank away from pump head. Filter Screen Installation Filter Screen Installation 1. Filter Screen 2. Pump Pick-Up Tube Pump O-Ring Installation 1. Pump Assembly 2. O-Ring Seal 3. O-Ring Seal 2-16 – JLG Lift – 3120775...

  • Page 31: Pressure Adjust Valve Installation

    6. Extend (Pressure) Port 3. O-Ring Seal 7. Return Port (Shown Plugged) 4. Backing Ring Note: Adjust pressure per specification shown in Section-1 of this Note: Extend (Pressure) and Return Ports Shown Plugged Service Manual. 3120775 – JLG Lift – 2-17...

  • Page 32: Hydraulic Lift Cylinder - Removal, Inspection And Rebuild

    Remove the rod seal, static o-ring and 11. Pull the mast cylinder out of the mast. backup and rod wiper. Damage to the seal grooves, par- ticularly on the sealing surfaces, is unacceptable. In the 2-18 – JLG Lift – 3120775...

  • Page 33: Lift Cylinder Internal Component Assembly Cross-Section

    Remove the seals and bearings. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the piston should be replaced. 3120775 – JLG Lift – 2-19...

  • Page 34: Cylinder Assembly

    14. Install the ground station (pump) cover. 15. Set-up machine for operation and cycle mast (up and down) approximately 3 ft. to 4 ft. a few times. 16. Check the hydraulic oil reservoir again, add oil to the fill line. 2-20 – JLG Lift – 3120775...

  • Page 35: Mast Assembly And Disassembly Procedures

    ATTACHED) BOTTOM (REFERS TO BOTTOM END OF MAST SECTION - END WHICH SETS AT CLOSED RAIL MACHINES BASE FRAME) (REFERS TO CLOSED RAIL BACK OF MAST SECTION) Figure 2-2. Mast Section - Assembly/Disassembly Reference. 3120775 – JLG Lift – 2-21...

  • Page 36: Mast Section 4 Removal

    14. Remove countersunk-flathead screws securing Mast disassembly should now be complete. chain sheave wheel assembly attach bars on both side rails at top of mast section-6 and remove sheave wheel assembly. 2-22 – JLG Lift – 3120775...

  • Page 37: Mast Assembly

    Apply Loc- be sure there are no air gaps between shims, tite #242 to the journal bolt threads and torque to 85 shim and mast or shim and slide pad when tight- ened. 3120775 – JLG Lift – 2-23...

  • Page 38: 15Sp Mast Assembly Components. (5 Section)

    SECTION 2 - SERVICE PROCEDURES MAST SECTION-1 MAST SECTION-2 MAST SECTION-3 MAST MAST SECTION-4 SECTION-5 LIFT CYLINDER ORIGINAL DESIGN LIFT CYLINDER MOUNT NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2-3. 15SP Mast Assembly Components. (5 Section) 2-24 – JLG Lift – 3120775...

  • Page 39: 12Sp Mast Assembly Components. (4 Section)

    SECTION 2 - SERVICE PROCEDURES MAST SECTION 4 MAST SECTION 1 MAST SECTION 2 MAST SECTION 3 LIFT CYLINDER ORIGINAL DESIGN LIFT CYLINDER MOUNT NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2-4. 12SP Mast Assembly Components. (4 Section) 3120775 – JLG Lift – 2-25...

  • Page 40: Mast Chain Routing Diagram

    SECTION 2 - SERVICE PROCEDURES Figure 2-5. Mast Chain Routing Diagram. 2-26 – JLG Lift – 3120775...

  • Page 41: Mast Section 3 - Assembly

    -3, (one on each side of the mast), together until ends are even. with beveled surface facing inward towards section- 22. Locate one (1) of the chain bottom anchor plates (one with threaded holes horizontally aligned to out- 3120775 – JLG Lift – 2-27...

  • Page 42: Mast Section 4 - Assembly

    Assembly. (narrow chains) are seating properly in chain anchor block chain sheave wheels attached to mast sec- NOTE: If assembling the 12SP (4 Section) mast, skip the fol- tion-3. lowing Mast Section 4 - Assembly steps and go directly to Platform Mounting Section - Assembly, 41.

  • Page 43: Platform Mounting Section - Assembly

    3. Bring base frame into position in front of mast 4 until BOTTOM ends of mast sections are even. assembly, (base frame and mast assembly must be held at 90° angle to each other). 3120775 – JLG Lift – 2-29...

  • Page 44: Mast Chains/Cables And Sequencing Cables Adjustment

    The chain equalizers will always Mast installation should now be complete. assure equal tension, but if the adjustment isn’t equal as described, the chains may tend to pull to 2-30 – JLG Lift – 3120775...

  • Page 45: Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)

    8. Repeat steps (1) through (7) for remaining mast sec- above the base frame when it is lowered and empty. tions. 9. Once mast section adjustment is completed, apply loctite #242 to the threads under the (jam) nuts that 3120775 – JLG Lift – 2-31...

  • Page 46: Sequencing Cable Adjustment

    A sequence cable replacement kit is available from the 1. Retract mast completely, and check each sequenc- JLG Parts Department to service broken or worn ing cable on outside of masts for excessive slack. sequence cables. This kit consists of a replacement Adjust only to remove slack from cable.

  • Page 47: Clamp Installation (Drum/Socket Type)

    5/8 in. past the end of the sleeve. THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM- MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN...
  • Page 48 NOTE: The end of the rope may not be visible in the inspec- tion hole after loading. 9. Install cable on machine and adjust per instructions shown previously in Section 2.11, MAST CHAINS/ CABLES AND SEQUENCING CABLES ADJUST- MENT 2-34 – JLG Lift – 3120775...

  • Page 49: Section 3 - Troubleshooting

    For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down. 3120775 – JLG Lift –...

  • Page 50: Polarity

    1 through 4. If there is a prob- harness. lem the third wire is used to troubleshoot the other wires. • Meter that can measure resistance or continuity. To find the problem, start at step 1 and use the entire pro- cedure. – JLG Lift – 3120775...

  • Page 51: Resistance Measurement

    • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads 3120775 – JLG Lift –...
  • Page 52 (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity – JLG Lift – 3120775...

  • Page 53: 3.5 Electrical Switch Testing

    This voltage can be seen if the measurement Another type of limit switch used by JLG is the inductive is taken with one test lead on the load and the other on proximity switch, also referred to as a "prox switch".
  • Page 54 Breather cap on tank is saturated or clogged Replace breather cap on tank. with oil. Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick. Unit lowers very slowly . Flow control valve not functioning. Replace flow control valve. – JLG Lift – 3120775...

  • Page 55: Hydraulic Schematic. (Sp Series)

    SECTION 3 - TROUBLESHOOTING 2792491_A Figure 3-5. Hydraulic Schematic. (SP Series) 3120775 – JLG Lift –...

  • Page 56: Electrical Diagram (Standard)

    SECTION 3 - TROUBLESHOOTING Figure 3-6. Electrical Diagram (Standard) – JLG Lift – 3120775...
  • Page 57 SECTION 3 - TROUBLESHOOTING Figure 3-6., Electrical Diagram (Standard) 3120775 – JLG Lift –...
  • Page 58 SECTION 3 - TROUBLESHOOTING Figure 3-7. Electrical Diagram (With Floor Brake/Gate Alarm Option) 3-10 – JLG Lift – 3120775...
  • Page 59 SECTION 3 - TROUBLESHOOTING Figure 3-7., Electrical Diagram (With Floor Brake/Gate Alarm Option) 3120775 – JLG Lift – 3-11...
  • Page 60 SECTION 3 - TROUBLESHOOTING NOTES: 3-12 – JLG Lift – 3120775...
  • Page 62 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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