Oshkosh Corporation JLG 15BD Setup guide

3121155 15BD/19BD 3

4 15BD/19BD 3121155

3121155 15BD/19BD 5

TABLE OF CONTENTS
3121155 15BD/19BD 7
SECTION 1 - BASE.............................................................................................................................................................................. 9
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION................................................................................................ 10
SECTION 2 - CONTROLS ................................................................................................................................................................. 13
FIGURE 2-1. POWER COMPONENTS INSTALLATION ............................................................................................................... 14
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748).......................................................... 18
FIGURE 2-3. MOTOR/PUMP ASSEMBLY (Including SN 0130005748)......................................................................................... 20
FIGURE 2-4. AC JUNCTION BOX ASSEMBLY............................................................................................................................. 22
FIGURE 2-5. CABLES AND CONTROLS INSTALLATION (15BD WITH PUSH BUTTON CONTROLS) ...................................... 26
FIGURE 2-6. CABLES AND CONTROLS INSTALLATION (15BD WITH FOOT CONTROLS)...................................................... 30
FIGURE 2-7. CABLES AND CONTROLS INSTALLATION (19BD WITH FOOT CONTROLS)...................................................... 34
SECTION 3 - MAST........................................................................................................................................................................... 37
FIGURE 3-1. MAST ASSEMBLY (15BD) ....................................................................................................................................... 38
FIGURE 3-2. MAST ASSEMBLY (19BD) ....................................................................................................................................... 42
SECTION 4 - PLATFORM.................................................................................................................................................................. 47
FIGURE 4-1. PLATFORM WITH GULLWING GATE (15BD ONLY)............................................................................................... 48
FIGURE 4-2. PLATFORM (27IN/69CM X 23IN/58.5CM) WITH SWING GATE.............................................................................. 50
FIGURE 4-3. PLATFORM (26IN/66CM X 25IN/63.5CM) WITH SWING GATE.............................................................................. 52
FIGURE 4-4. PLATFORM OPTIONS ............................................................................................................................................. 54
FIGURE 4-5. PLATFORM GATE INTERLOCK INSTALLATION.................................................................................................... 56
SECTION 5 - CYLINDER................................................................................................................................................................... 59
FIGURE 5-1. LIFT CYLINDER ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748)........................................................ 60
FIGURE 5-2. LIFT CYLINDER ASSEMBLY (Including SN 0130005748)....................................................................................... 62
SECTION 6 - HYDRAULIC ................................................................................................................................................................ 65
FIGURE 6-1. HYDRAULIC DIAGRAM............................................................................................................................................ 66
SECTION 7 - ELECTRICAL............................................................................................................................................................... 69
FIGURE 7-1. ELECTRICAL SCHEMATIC - 120VAC, 60HZ........................................................................................................... 70
FIGURE 7-2. ELECTRICAL SCHEMATIC - 120VAC, 60HZ (CORNING SPEC)............................................................................ 72
FIGURE 7-3. ELECTRICAL SCHEMATIC - 120VAC, 50-60HZ (CORNING SPEC)....................................................................... 74
FIGURE 7-4. ELECTRICAL SCHEMATIC - 220VAC, 50-60HZ (CORNING SPEC)....................................................................... 76
SECTION 8 - DECALS....................................................................................................................................................................... 79
FIGURE 8-1. DECAL INSTALLATION............................................................................................................................................ 80
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ............................................................................................................. 83
FIGURE 9-1. 15BD STANDARD PARTS ....................................................................................................................................... 84
FIGURE 9-2. 15BD VARIABLE PARTS.......................................................................................................................................... 86
SECTION 10 - SPECIAL OPTIONS................................................................................................................................................... 87
FIGURE 10-1. SPECIAL OPTIONS................................................................................................................................................ 88
PART NUMBER INDEX ..................................................................................................................................................................... 89

SECTION 1 - BASE
3121155 15BD/19BD 9
SECTION 1 - BASE

SECTION 1 - BASE
10 15BD/19BD 3121155
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION

SECTION 1 - BASE
3121155 15BD/19BD 11
FIGURE 1-1. BASE COMPONENTS AND MAST INSTALLATION
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
MAST SUPPORT INSTALLATIONS
0271828
Ref
Mast Support Installations 15BD (Excluding SN 0130005748)
D
0272127
Ref
Mast Support Installations 15BD (Including SN 0130005748)
B
1001128982
Ref
Mast Support Installations 19BD
B
1
Ref
Bolt Options:
1
0641609
AR
Bolt 3/8in-16NC x 1-1/8in
1
0641610
AR
Bolt 3/8in-16NC x 1-1/4in
2
Ref
Mast Assembly Options (See MAST SECTION for Breakdown):
2
0801321
1
Mast Assembly 15BD (Excluding SN 0130005748)
2
0801328
1
Mast Assembly 15BD (Including SN 0130005748)
2
0801409
1
Mast Assembly 19BD
3
1705636
AR
Decal - Manual Descent (Including SN 0130005748)
4
Ref
Nut Options:
4
3311605
AR
Locknut 3/8in-16NC
4
3311608
AR
Flanged Nut 3/8in-16NC
5
4568473
2
Brace Tube, Mast
6
4711600
24
Flatwasher 3/8in Thin
7
4845914
1
Support, Mast
Ref
Base Weldment
4846589
Ref
18 x 33 Bolt Pattern
1001126088
Ref
20 x 24 Bolt Pattern

SECTION 2 - CONTROLS
3121155 15BD/19BD 13
SECTION 2 - CONTROLS

SECTION 2 - CONTROLS
14 15BD/19BD 3121155
FIGURE 2-1. POWER COMPONENTS INSTALLATION

SECTION 2 - CONTROLS
3121155 15BD/19BD 15
FIGURE 2-1. POWER COMPONENTS INSTALLATION
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
PUMP/MOTOR AND JUNCTION BOX ASSEMBLY
1001111734
Ref
120 VAC, 60Hz (15BD) (All Machines) (Excluding SN
0130005748)
A
See Note
Ref
120 VAC, 60Hz (Note: Uses Installation p/n 0271128 with Kit
p/n 2915246 installed.) (15BD) (Including SN 0130005748)
1001167245
Ref
120VAC, 60Hz (19BD)
A
1001147216
Ref
120 VAC, 50-60Hz (with AC Outlet)
A
1001144708
Ref
220 VAC, 50-60Hz
A
1
0630550
2
Capscrew 1/4in-20NC x 3/4in
2
0641406
4
Bolt 1/4in-20NC x 3/4in
3
0721006
2
Screw #10-24NC x 3/4in
4
0791608
2
Screw 3/8in-16NC x 3/4in
5
0861305
1
Ground Control Box Assembly
E
5
7020078
1
Switch, Push-Pull (Stop)
5
7020096
1
Legend Plate, "Stop"
5
7020097
2
Legend Plate, "Power/Off/On"
5
4360467
1
Switch, Key
5
2860030
1
Key, Replacement
5
7027299
1
Connector, Strain Relief
5
7020093
1
Screw M3 x 25mm (Box Lid Hardware)
5
3910804
2
Screw #8-32NC x 1/4in (Keyswitch Terminals)
5
7020094
1
Lid
6
3311005
AR
Locknut #10-24NC
7
3311405
4
Locknut 1/4in-20NC
8
Ref
Pump/Motor Assembly Options:
8
3600467
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown) (Excluding SN
0130005748)
8
3600453
1
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown) (Including SN
0130005748)
8
3600453
1
Pump/Motor Assembly - 19BD with 120VAC, 60Hz Motor (See
MOTOR/PUMP ASSEMBLY for Breakdown)
8
3600453
1
Pump/Motor Assembly - All Machines with 120VAC, 50-60Hz
Motor & AC Outlet (See MOTOR/PUMP ASSEMBLY for
Breakdown)
8
3600453
1
Pump/Motor Assembly - All Machines with 220VAC, 50-60Hz
Motor (See MOTOR/PUMP ASSEMBLY for Breakdown)
9
4341431
1
Bracket, Junction Box Mounting Options
10
4341432
1
Bracket, Pump/Motor Mounting Options:
11
4460566
1
Connector, 90 Strain Relief
12
4751000
2
Flatwasher #10 Regular
13
4751400
8
Flatwasher 1/4in Regular
14
1001105113
2
Insulation, Heatshrink (Not Shown)
15
Ref
Junction Box Assembly (See AC JUNCTION BOX ASSEMBLY
for Breakdown)
15
1001111733
1
120 VAC, 60Hz (All Machines) (Excluding SN 0130005748)
15
0861476
1
120 VAC, 60Hz (Including SN 0130005748)
15
1001147215
1
120 VAC,50- 60Hz
15
1001144703
1
220 VAC,50- 60Hz
16
0100011
AR
Compound, Locking
17
3740154
1
Relay, Timer (Used on 120 VAC, 50-60Hz Only)

SECTION 2 - CONTROLS
16 15BD/19BD 3121155
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
18
3911024
1
Screw #10-24NC x 1-1/2in (Used on 120 VAC, 50-60Hz Only)
Ref
PUMP/MOTOR AND JUNCTION BOX INSTALLATION
B
0275939
Ref
All Machines with Gullwing or Right Side Entry Platforms
(Excluding SN 0130005748)
A
1001126224
Ref
All Machines with Left Side Entry Platforms (Not Shown)
(Excluding SN 0130005748)
A
Ref
Note: Right/Left Side Gate Entry determined by operator's
position when facing push button controls.
101
0100011
AR
Compound, Locking
102
0641404
4
Bolt 1/4in-20NC x 1/2in
103
0791609
4
Bolt 3/8in-16NC x 1-1/8in
106
3311608
4
Nut, Flanged 3/8in-16NC
107
4061024
1
Shield, Pump Cover
110
4711400
4
Flatwasher 1/4in Thin
0275697
Ref
HOURMETER INSTALLATION (OPTIONAL)
C
203
2420172
1
Hourmeter
205
4922935
1
Harness, Hourmeter (Not Shown)
A

SECTION 2 - CONTROLS
18 15BD/19BD 3121155
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748)

SECTION 2 - CONTROLS
3121155 15BD/19BD 19
FIGURE 2-2. MOTOR/PUMP ASSEMBLY (ALL MACHINES) (Excluding SN 0130005748)
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
Ref
USAGE CHART:
3600467
Ref
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor
without AC Outlet (Shown in This Figure) (Excluding SN
0130005748)
3600453
Ref
Pump/Motor Assembly - 15BD with 120VAC, 60Hz Motor (See
Next Figure) (Including SN 0130005748)
3600453
Ref
Pump/Motor Assembly - 19BD with 120VAC, 60Hz Motor (See
Next Figure)
3600453
Ref
Pump/Motor Assembly - All Machines with 120VAC, 50-60Hz
Motor & AC Outlet (See Next Figure)
3600453
Ref
Pump/Motor Assembly - All Machines with 220VAC, 50-60Hz
Motor (See Next Figure)
3600467
Ref
MOTOR/PUMP ASSEMBLY
C
1
70000641
1
Base Assembly (Includes Items 14-18)
2
70001021
1
Pump (Includes Item 3)
3
70001020
4
Screw 1/4in-20NC x 2-3/4in
4
70001042
1
Tube, Suction
5
7026165
1
Filter
6
70001044
1
Tube, Return
7
70001045
1
Motor (Includes Item 19 and Motor Bolts)
8
70000642
1
Cartridge
9
70000643
1
Coil
10
70000651
1
Reservoir
11
70001025
1
Plug
12
7026335
1
Clamp
13
70001027
1
Decal - Fill Line
14
70000641
1
Valve, Relief (Note: Part of Item 1)
14
70000641
1
Screw
14
70000641
1
Nut
14
70000641
1
Seal
14
70000641
1
Spring
14
70000641
1
Ball
15
70000641
1
Valve, Check (Note: Part of Item 1)
15
70000641
1
Plug
15
70000641
1
Spring
15
70000641
1
Poppet
15
70000641
1
Ball
16
70003612
1
O-Ring (1/2in x 5/8in x 1/16in)
17
70003613
1
O-Ring (3-5/8in x 3-7/8in x 1/8in)
18
7026330
1
Seal
19
70002215
1
Bearing

SECTION 2 - CONTROLS
20 15BD/19BD 3121155
FIGURE 2-3. MOTOR/PUMP ASSEMBLY (Including SN 0130005748)