JLG 20DVSP Parts Manual

Illustrated Parts Manual

Models

15DVL

15DVSP

20DVL

20DVSP

P/N

3121137

June 24, 2011

REVISION LOG

September 1, 2001 - Original Issue Of Manual (Manual edited to B/M 0010581)

October 15, 2001 - Revised Manual (Manual edited to B/M 0010581)

March 15, 2002 - Revised Manual (Manual edited to B/M 0010581 - Rev 7)

May 30, 2002 - Revised Manual (Manual edited to B/M 0010581 - Rev 10)

January 8, 2003 - Added 20DVSP

February 13, 2003 - Revised Manual (Manual edited to B/M 0010581 - Rev 21)

May 8, 2003 - Revised Manual (Manual edited to B/M 0010581 - Rev 25)

September 19, 2003 - Revised Manual (Manual edited to B/M 0010581 - Rev 29)

February 26, 2004 - Revised Manual (Manual edited to B/M 0010581 - Rev 32)

August 11, 2004 - Revised Manual (Manual edited to B/M 0010581 - Rev 36)

May 5, 2005 - Revised Manual (Manual edited to B/M 0010581 - Rev 45)

February 15, 2006 - Revised Manual (Manual edited to B/M 0010581 - Rev 48)

June 30, 2006 - Revised Manual (Manual edited to B/M 0010581 - Rev 48)

June 29, 2007 - Revised Manual (Manual edited to B/M 0010581 - Rev 48)

June 24, 2011 - Revised Manual

3121137 15DVL 15DVSP 20DVL 20DVSP A

REVISION LOG

B 15DVL 15DVSP 20DVL 20DVSP 3121137

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271) . . . . . . . . . 1-2

1-2 BASE MOUNTED COMPONENTS INSTALLATION (S/N 5271 TO PRESENT) . . . . . . 1-6

1-3 DRIVE ASSEMBLY (PRIOR TO S/N 5271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE ASSEMBLY (S/N 5271 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 MAST AND BATTERY BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

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

2-1 PUMP/MOTOR/GROUND CONTROL/HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . 2-2

2-2 PUMP/MOTOR ASSEMBLY - FENNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 PUMP/MOTOR ASSEMBLY - MONARCH (SERVICE REPLACEMENT) . . . . . . . . . . . . 2-8

2-4 BATTERIES/CHARGER/SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 PLATFORM CABLE AND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7 CONTROLLER ASSEMBLY (PRIOR TO S/N 7616). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-8 CONTROLLER ASSEMBLY (S/N 7616 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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

3-1 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

4-1 PLATFORM WITH FRONT SLIDE BAR ENTRY (DVL). . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM WITH GULLWING GATE (DVL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3 PLATFORM WITH MOLDED SIDES (DVL & DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-4 PLATFORM WITH ROLLING EXTENSION (DVL & DVSP) . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 PLATFORM WITH FIXED SIDE RAILS (DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-6 PLATFORM WITH FOLDING SIDE RAILS (DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-7 PLATFORM WITH SIDE ENTRY (15 DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-8 PLATFORM/SIDE ENTRY WITH MATERIAL TRAY (20DVL) . . . . . . . . . . . . . . . . . . . . . 4-28

4-9 PLATFORM/SIDE ENTRY WITH FOLDING TRAY (15DVSP/20DVSP) . . . . . . . . . . . . . 4-30

4-10 OBSTRUCTION SENSOR INSTALLATION (DVSP) (OPTIONAL) . . . . . . . . . . . . . . . . . 4-32

4-11 QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE BAR . . . . . . . . . . . . . . . . 4-34

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

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

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

6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

7-1 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI EXPORT SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

3121137 15DVL 15DVSP 20DVL 20DVSP i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

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

ii 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1

BASE

3121137 15DVL 15DVSP 20DVL 20DVSP 1-1

SECTION 1 BASE

292915

211419

261417

62513183125101

102

NOTE: DRIVE MOTOR COVER (ITEM 9)

SHOWN HERE FOR CLARITY.

201

103

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271)

1-2 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BASE ASSEMBLY OPTIONS: 0271258 Ref. Base Assembly - (Standard) J 0272776 Ref. Base Assembly - (Rubber Tires) A 0272981 Ref. Base Assembly - (Rubber Tires - Rear Only) B

1 0100011 A/R Loctite #242 (Not Shown) 2 1 Drive Assembly (Right Side) Options: (See Figure 1-3 for

Breakdown) 0271460 (Standard) 0272775 (Rubber Tires / Rubber Tires - Rear Only)

3 1 Drive Assembly (Left Side) Options: (See Figure 1-3 for Break-

down) 0271461 (Standard) 0272774 (Rubber Tires / Rubber Tires - Rear Only)

4 0641406 4 Bolt 1/4”-20NC x 3/4” 5 0641607 14 Bolt 3/8”-16NC x 7/8” 6 0641614 2 Bolt 3/8”-16NC x 1 3/4” 7 1060649 2 Cable, Pothole Protection 8 1100103 2 Cam

9 1671020 1 Cover, Drive Motor 10 3020017 A/R Lubricant (Not Shown) 11 3020022 A/R Grease, White Lithium (Not Shown) 12 3311005 2 Locknut #10-24NC 13 3311605 4 Locknut 3/8”-16NC 14 3312002 2 Locknut 5/8”-11NC 15 3430638 4 Pin, Clevis 16 3450403 4 Pin, Cotter 1/8” x 3/4” 17 3573093 1 Plate, Cable Mounting 18 3760365 2 Ring, Tie Down 19 3841343 1 Rod, Actuator 20 3900202 4 Screw, Socket Head Shoulder 21 4160160 1 Spring, Compression 22 4160162 4 Spring, Compression 23 4567203 1 Tube, Plunger 24 4711400 4 Flatwasher 1/4” Narrow 25 4711600 20 Flatwasher 3/8” Narrow 26 4712000 1 Flatwasher 5/8” Narrow 27 4751600 5 Flatwasher 3/8” Wide 28 4846436 1 Base Weldment 29 4846437 2 Bar, Pothole Protection 30 4846446 1 Actuator 31 2 Wheel, Caster Assembly Options:

4860235 Standard / Rubber Tires - Rear Only 4860239 Rubber Tires

32 1 Strap, Static Options:

4240084 (Prior to S/N 4184)

4240147 (S/N 4184 to S/N 5271) 33 0641606 1 Bolt 3/8”-16NC x 3/4” 34 4240127 2 Tie-Strap (Not Shown - Located at Motors)

3121137 15DVL 15DVSP 20DVL 20DVSP 1-3

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

35 0100035 A/R Loctite #222 (Not Shown) 36 3900249 4 Setscrew 37 4300154 2 Stud 3/8”-16NC x 2” 38 Plate, Shim Options:

4070547 4 Standard / Rubber Tires

Not Used 0 Rubber Tires - Rear Only

39 Shim, Caster Options:

Not Used Standard / Rubber Tires - Rear Only

4071064 Rubber Tires

40 Bolt Options: (Not Shown)

Not Used 0 Standard

0641610 2 Rubber Tires (3/8 - 16NC x 1/1/4”) 0641609 6 Rubber Tires - Rear Only (3/8 - 16NC x 1/1/8”)

0271946 Ref. BEACON LIGHT INSTALLATION B

101 2920155 1 Light, Beacon - Amber Options:

Preco Model 3970

Preco Model 3971 7026196 1 Bulb, Replacement 7026195 1 Lens, Replacement

102 3820032 2 Rivet 103 3520033 1 Plug, Hole 1” (S/N 5521 to S/N 5271)

0272061 Ref. BEACON HOLE PLUG INSTALLATION B

201 3520033 2 Plug, Hole 1”

1-4 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121137 15DVL 15DVSP 20DVL 20DVSP 1-5

SECTION 1 BASE

101

NOTE: DRI VE MOTOR COVER (I TEM 9)

SHOWN HERE FOR CLARITY.

305

310 302

62513183125102

201

15822

1672330211419

261417

20414212315253939

311

308

304

103

FIGURE 1-2. BASE MOUNTED COMPONENTS INSTALLATION (S/N 5271 TO PRESENT)

1-6 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-2. BASE MOUNTED COMPONENTS INSTALLATION (S/N 5271 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BASE ASSEMBLY OPTIONS: 0271258 Ref. Base Assembly - (Standard) P 0272776 Ref. Base Assembly - (Rubber Tires) I 0272981 Ref. Base Assembly - (Rubber Tires - Rear Only) H 0273083 Ref. Base Assembly - (30:1 Gear Ratio) E

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

2 to 3 Not Used

4 0641406 4 Bolt 1/4”-20NC x 3/4” 5 8 Bolt Options: 3/8”-16NC x 7/8”

0641607 (Standard / Rubber Tires - Rear Only) (Prior to S/N 5271)

Not Used (Rubber Tires) 6 0641614 2 Bolt 3/8”-16NC x 1 3/4” 7 1060649 2 Cable, Pothole Protection 8 1100103 2 Cam 9 1671020 1 Cover, Drive Motor

10 3020017 A/R Lubricant (Not Shown) 11 3020022 A/R Grease, White Lithium (Not Shown) 12 2 Hardware Options:

3311005 Locknut #10-24NC (Prior to S/N 6320)

3311402 Jam Nut 1/4”-20NC (S/N 6320 to Present) 13 3311605 4 Locknut 3/8”-16NC 14 3312002 2 Locknut 5/8”-11NC 15 3430638 4 Pin, Clevis 16 3450403 4 Pin, Cotter 1/8” x 3/4” 17 1 Plate, Cable Mounting Options:

3573093 1 Prior to S/N 6320

3575698 1 S/N 6320 to Present 18 3760365 2 Ring, Tie Down 19 3841343 1 Rod, Actuator 20 4 Hardware Options:

3900202 Screw, Socket Head Shoulder (Prior to S/N 6320)

0630590 Bolt 1/4”-20NC x 3/4” (S/N 6320 to Present) 21 4160160 1 Spring, Compression 22 4160162 4 Spring, Compression 23 4567203 1 Tube, Plunger 24 4711400 4 Flatwasher 1/4” Narrow 25 4711600 6 Flatwasher 3/8” Narrow 26 4712000 1 Flatwasher 5/8” Narrow 27 4751600 19 Flatwasher 3/8” Wide 28 4846436 1 Base Weldment 29 A/R Bar, Pothole Protection Options:

4846437 2 Prior to S/N 5470

4846869 1 Right Side (S/N 5470 to Present)

4846870 1 Left Side (S/N 5470 to Present) 30 4846446 1 Actuator 31 2 Wheel, Caster Assembly Options:

4860235 Standard / Rubber Tires - Rear Only

4860239 Rubber Tires

3121137 15DVL 15DVSP 20DVL 20DVSP 1-7

SECTION 1 BASE

FIGURE 1-2. BASE MOUNTED COMPONENTS INSTALLATION (S/N 5271 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

32 4240147 1 Strap, Static 33 0641606 1 Bolt 3/8”-16NC x 3/4” 34 4240127 2 Tie-Strap (Not Shown - Located at Motors) 35 0100035 A/R Loctite #222 (Not Shown) 36 3900249 4 Setscrew 37 4300154 2 Stud 3/8”-16NC x 2” 38 Not Used 39 1 Drive Motor Frame Assembly Options:

(See Figure 1-4 for Breakdown) 0272584 Standard 0272830 Rubber Tires / Rubber Tires - Rear Only 0273084 30:1 Gear Ratio

40 0641609 14 Bolt 3/8”-16NC x 1 1/8” 41 4071077 A/R Shims - .015 (S/N 5470 to Present) 42 4071078 A/R Shims - .036 (S/N 5470 to Present)

0271946 Ref. BEACON LIGHT INSTALLATION B

101 2920178 1 Light, Beacon - Amber Options: (was p/n 2920155)

Preco Model 3970

Preco Model 3971 7026196 1 Bulb, Replacement 7026195 1 Lens, Replacement

102 3820032 2 Rivet 103 3520033 1 Plug, Hole 1” (S/N 5521 to Present)

0272061 Ref. BEACON HOLE PLUG INSTALLATION B

201 3520033 2 Plug, Hole 1”

0272825 Ref. BUMPER INSTALLATION (15 DVSP OPTION ONLY) A

301 0100011 A/R Loctite #242 (Not Shown) 302 0641407 6 Bolt, 1/4-20 x 7/8” 303 Not Used 304 0641814 4 Bolt, 1/2-13NC x 1 3/4” 305 0940105 2 Bumper, Side Base

306 to 307 Not Used

308 0940108 2 Bumper, Base 309 Not Used 310 4711400 26 Flatwasher 1/4” 311 4751800 4 Flatwasher 1/2” Wide

1-8 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-2. BASE MOUNTED COMPONENTS INSTALLATION (S/N 5271 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121137 15DVL 15DVSP 20DVL 20DVSP 1-9

SECTION 1 BASE

TORQUE

35 FT. LBS.

DETAIL

OF ITEM 8

109

101

107

102

103 104

110

111

105

106

108

FIGURE 1-3.DRIVE ASSEMBLY (PRIOR TO S/N 5271)

1-10 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-3. DRIVE ASSEMBLY (PRIOR TO S/N 5271)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE ASSEMBLY OPTIONS: Ref. Note: Quanities shown are for one side.

Ref. (Standard) F 0271460 Ref. Right Side 0271461 Ref. Left Side

Ref. (Rubber Tires / Rubber Tires - Rear Only) A 0272775 Ref. Right Side 0272774 Ref. Left Side

1 0100011 A/R Loctite #242 (Not Shown) 2 0100019 A/R Loctite #271 (Not Shown) 3 0440221 2 Bearing, Axle 4 0641609 A/R Bolt 3/8”-16NC x 1 1/8” 5 0641816 A/R Bolt 1/2”-13NC x 2” 6 0741506 3 Screw, Countersunk 5/16”-18NC x 3/4” 7 0741609 1 Screw, Countersunk 3/8”-16NC x 1 1/4” 8 1400126 1 Clutch, Torque Limiting (See Items 101-111 for Breakdown)

9 2860027 1 Key, Clutch 10 2860029 1 Key, Wheel 11 3020017 A/R Lubricant (Not Shown) 12 3160282 1 Drive Motor Assembly (See Figure 1-5 for Breakdown) 13 3311605 4 Locknut 3/8”-16NC 14 3311801 A/R Nut 1/2”-13NC 15 3440520 1 Rollpin 16 1 Plate, Motor Mounting Options:

3573070 Right Side

3573077 Left Side 17 3573071 1 Plate, Bearing Mounting 18 4040268 1 Shaft, Drive 19 4711600 8 Flatwasher 3/8” Narrow 20 4711800 A/R Flatwasher 1/2” 21 4740478 1 Washer, Wheel Retainer 22 1 Frame Options:

4846440 Right Side

4846441 Left Side 23 1 Wheel Options:

4860232 Standard

4860240 Rubber Tires / Rubber Tires - Rear Only

1705981 Decal - This Side In (Not Shown) 24 0100038 A/R Primer #7471 (Not Shown) 25 0641611 2 Bolt 3/8-16NC x 1 3/8 26 1 Rollpin Options:

Not Used Standard

3440320 Rubber Tires / Rubber Tires - Rear Only

3121137 15DVL 15DVSP 20DVL 20DVSP 1-11

SECTION 1 BASE

FIGURE 1-3. DRIVE ASSEMBLY (PRIOR TO S/N 5271) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1400126 Ref. TORQUE LIMITER CLUTCH ASSEMBLY C

101 7023351 1 Hub 102 7023352 1 Chain 103 7023353 1 Sprocket 104 7023354 1 Bushing 105 7023355 2 Facing, Friction 106 7023356 1 Plate, Pressure 107 7023357 3 Disc, Spring 108 7023358 1 Lockwasher, Tabbed 109 7023359 1 Nut, Adjusting 110 7023360 1 Sprocket 111 7023361 1 Setscrew

1-12 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-3. DRIVE ASSEMBLY (PRIOR TO S/N 5271) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121137 15DVL 15DVSP 20DVL 20DVSP 1-13

SECTION 1 BASE

DETAIL

OF ITEM 7

109

101

107

102

103

104

110

111

105

106

108

181719

161514

131211

FIGURE 1-4.DRIVE ASSEMBLY (S/N 5271 TO PRESENT)

1-14 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-4. DRIVE ASSEMBLY (S/N 5271 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE ASSEMBLY OPTIONS:

Ref. Note: Quanities shown are for one side. 0272584 Ref. (Standard) F 0272830 Ref. (Rubber Tires / Rubber Tires - Rear Only) F 0273084 Ref. (30:1 Gear Ratio) E

1 0100011 A/R Loctite #242 (Not Shown) 2 0100038 A/R Loctite #7471 (Not Shown) 3 0272595 1 Drive Motor Frame Assembly

3A 0440258 4 Bearing

4 0641609 4 Bolt, 3/8 - 16NC x 1 1/8” 5 0741506 6 Screw, 5/16 - 18NC x 3/4” 6 0741609 2 Screw, 3/8 - 16NC x 1 1/8” 7 2 Clutch, Torque Limiting Options:

1400126 Prior to S/N 6340 (See Items 101-111 for Breakdown)

Use 1400126 S/N 6340 to S/N 6398 (was p/n 1400128. No Serviceable

Parts Available for P/N 1400128)

1400126 S/N 6398 to Present

8 2860027 2 Key, Clutch

9 2860031 2 Key, Wheel 10 3020039 A/R Lubricant, Loctite Moly Paste #51049 (Not Shown) 11 2 Drive Motor Assembly Options:

3160282 (Standard & Rubber Tires / Rubber Tires - Rear Only) (See

Figure 1-5 for Breakdown) (Prior to S/N 6340)

3160312 (Standard & Rubber Tires / Rubber Tires - Rear Only) (No

Serviceable Parts) (S/N 6340 to Present)

3160283 (30:1 Gear Ratio) (See Figure 1-5 for Breakdown) (Prior to S/

N 6340)

3160311 (30:1 Gear Ratio) (No Serviceable Parts) (S/N 6340 to

Present) 12 3311605 4 Nut, 3/8-16NC 13 3423050 2 Pin, Spiral Spring 14 3573986 2 Plate, Drive Motor Mount 15 4040268 2 Shaft, Drive 16 4711600 8 Flatwasher 3/8” Narrow 17 4740478 2 Washer, Wheel Retainer 18 2 Wheel, Rear Options:

4860232 Standard 4860240 Rubber Tires / Rubber Tires - Rear Only) 1705981 Decal - This Side In (Not Shown)

19 4812000 2 Flatwasher 10mm (Prior to S/N 6183)

Ref. TORQUE LIMITER CLUTCH ASSEMBLY 1400126 Ref. Prior to S/N 6340 C 1400128 Ref. S/N 6340 to S/N 6398 (No Serviceable Parts Available -

Replaced with P/N 1400126)

1400126 Ref. S/N 6398 to Present C

101 7023351 1 Hub 102 7023352 1 Chain

3121137 15DVL 15DVSP 20DVL 20DVSP 1-15

SECTION 1 BASE

FIGURE 1-4. DRIVE ASSEMBLY (S/N 5271 TO PRESENT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

103 7023353 1 Sprocket 104 7023354 1 Bushing 105 7023355 2 Facing, Friction 106 7023356 1 Plate, Pressure 107 7023357 3 Disc, Spring 108 7023358 1 Lockwasher, Tabbed 109 7023359 1 Nut, Adjusting 110 7023360 1 Sprocket 111 7023361 1 Setscrew

1-16 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-4. DRIVE ASSEMBLY (S/N 5271 TO PRESENT) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121137 15DVL 15DVSP 20DVL 20DVSP 1-17

SECTION 1 BASE

112112

112011719

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

1-18 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE MOTOR ASSEMBLY OPTIONS: 3160282 Ref. 24 Volt (Standard) (Prior to S/N 6340) G 3160312 Ref. 24 Volt (Standard) (S/N 6340 to Present) A 3160283 Ref. 24 Volt (UPS Spec) (Prior to S/N 6340) G 3160311 Ref. 24 Volt (UPS Spec) (S/N 6340 to Present) A

1 7018030 1 Boot, Terminal

7018031 1 Housing, Terminal 7018032 2 Terminal, Motor Lead

Not Available 2 Terminal, Brake Lead 2 7018033 1 Clamp 3 1 Boot Options:

7018034 Prior to S/N 6340

7028062 S/N 6340 to Present 4 7018035 1 Clamp 5 7018001 1 Key 6 7018009 2 Washer, Wave (Motor p/n 3160282 Only) 7 1 Bearing, Gear & Pinion Assembly Options:

7018040 Motor p/n 3160282

7018046 Motor p/n 3160283 8 1 Shield Options:

7018041 Motor p/n 3160282

7018047 Motor p/n 3160283 9 7018010 1 Washer, Wave

10 1 O-Ring Options:

7018028 Motor p/n 3160282

Not Available Motor p/n 3160283

11 1 Bearing, Gear & Driveshaft Assembly Options:

7018042 Motor p/n 3160282

7018048 Motor p/n 3160283

12 7018043 1 Housing, Gear (Motor p/n 3160282 Only) 13 7018000 1 Spring & Brush Kit (Includes (Qty.2 Each) of Brushes, Caps,

Springs & Screws) 14 7018036 1 Brake Assembly 15 7018011 1 Washer, Wave

Not Available 1 Bearing 16 7018037 2 O-Ring 17 7018038 1 Ring Assembly 18 7018039 1 Armature 19 7018021 1 Key 20 7018026 1 Seal 21 70000933 1 Seal

Not Available 1 Bearing 22 7018045 2 Cap, Brush 23 0641408 4 Bolt 24 7018049 1 Bolt (Motor p/n 3160283 Only) 25 7018050 1 Shield (Motor p/n 3160283 Only)

3121137 15DVL 15DVSP 20DVL 20DVSP 1-19

SECTION 1 BASE

5676A7A6B7B

101

102

104

113

110

113

111

109

113

102

117

108

107

107A

105

102 115

112

113

102

110

115

102

112

10512112

FIGURE 1-6. COVER INSTALLATION

1-20 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-6. COVER INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. COVER INSTALLATIONS 0271264 Ref. HINGED E 0272161 Ref. HINGED LOCKABLE C 0272276 Ref. FIXED STANDARD (S/N 4365 TO PRESENT) C 0272330 Ref. FIXED/SECURITY LOCK (S/N 4365 TO PRESENT) A

1 0120006 2 Adjuster, Hood 2 0641405 A/R Bolt 1/4”-20NC x 5/8” 3 0641408 2 Bolt 1/4”-20NC x 1” (Not Required On Fixed Cover) 4 A/R Bracket, Hood Support Options:

0902737 2 Hinged Cover (Prior to S/N 5597) 0902836 2 Hinged Cover (S/N 5597 to Present) 0902836 4 Fixed Cover

5 1671014 2 Cover, Counterweight 6 1 Cover, Left Options:

1671073 Fixed 1671015 Hinged 1671065 Hinged Lockable

6A 7023493 1 Latch 6B 2600258 2 Hinge

7 1 Cover, Right Options:

1671074 Fixed 1671077 Fixed/Security Lock 1671016 Hinged 1671066 Hinged Lockable

7A 7023493 1 Latch 7B 2600258 2 Hinge

8 1 Cover, Ground Station Options:

1671017 Hinged 1671072 Fixed

9 1671026 1 Cover, Charger 10 3311405 A/R Locknut 1/4”-20NC 11 3820032 3 Rivet 12 4711400 A/R Flatwasher 1/4” Narrow (Prior to S/N 5597) 13 4751400 A/R Flatwasher 1/4” 14 4761400 8 Lockwasher 1/4” (Not Required On Fixed Cover) 15 3900258 18 Button Head Screw 1/4-20NC x 3/4 (Fixed Cover Only)

1 Kit, Covers Options: 2902387 Hinged, Covers (Included Items 5 - 8) (S/N 6279 to Present) 2 2902388 Hinged Lockable, Covers (Included Items 5 - 8) (S/N 6279 to

Present)

2902390 Fixed Standard Covers (Included Items 5 - 8) (S/N 6279 to

Present)

3121137 15DVL 15DVSP 20DVL 20DVSP 1-21

SECTION 1 BASE

FIGURE 1-6. COVER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. COVER INSTALLATIONS (UL SPEC)

0272768 Ref. FIXED STANDARD (S/N 4987 TO PRESENT) C 0272785 Ref. FIXED/SECURITY LOCK (S/N 4987 TO S/N 5597) A

101 0120006 2 Adjuster, Hood 102 0641405 A/R Bolt 1/4”-20NC x 5/8” 103 Not Used 104 0902836 4 Bracket, Hood Support 105 1671014 2 Cover, Counterweight 106 Not Used 107 1 Cover, Right Options:

1671074 Fixed 1671077 Fixed/Security Lock

107A 7023493 1 Latch

108 1671072 1 Cover, Ground Station 109 1671026 1 Cover, Charger 110 3311405 A/R Locknut 1/4”-20NC 111 3820032 3 Rivet 112 4711400 A/R Flatwasher 1/4” Narrow (Prior to S/N 5597) 113 4751400 A/R Flatwasher 1/4” 114 Not Used 115 3900258 18 Button Head Screw 1/4-20NC x 3/4 116 0641403 A/R Bolt 1/4”-20NC x 3/8” 117 1671095 1 Cover, Left

2902389 1 Kit, Covers - Fixed Standard (Included Items 105, 107, 108 &

117) (S/N 6279 to Present)

1-22 15DVL 15DVSP 20DVL 20DVSP 3121137

SECTION 1 BASE

FIGURE 1-6. COVER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121137 15DVL 15DVSP 20DVL 20DVSP 1-23

SECTION 1 BASE

FIGURE 1-7. MAST AND BATTERY BOX INSTALLATION

1-24 15DVL 15DVSP 20DVL 20DVSP 3121137

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