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

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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

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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

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SECTION 2 CONTROLS

FIGURE 2-3. BATTERY CHARGER ASSEMBLY (ANSI)

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2-8 312 0798

SECTION 2 CONTROLS

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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

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3120798 2-9

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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

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2-10 3120798