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

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

5 25 18

2513

28

37 25

32	5	25
	27	13
	33
38

2 39 7

7

16 29

1536 8	22

27

5 25

5

25

9

NOTE: DRIVEMOTORCOVER(ITEM 9)

SHOWN HEREFORCLARITY.

101

103

201

102

6

25

31 18

25

13

3	7		23
					7
			30
		29	7			24
						4
					21	17
					1914
				12	26
			20
					14
			25
			5
			31

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

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

40 25 18

2513

304

311

308

310			37
302		39
32	40	25	25
		13
	27
	33

39 7

7

16 29

1536 8	22

27

40 25

4025

9

NOTE: DRIVEMOTORCOVER(ITEM 9)

SHOWN HEREFORCLARITY.

101

103

201 102

6

25

31 18

25

13

28

7		23		7
		30
	29	7			24
					4
				21	17
41				1914
				26
42			12
		20
				14
		25
		5
		31

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

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

19

13

4

19

22

13

19

12

				9
				17
		6		19
	16
				25
			8	14
				20
				3
		20	10	20
		5
				5
3
		18
26	15
	103	110
105	104
106		111
108
				21
			23	7
101				TORQUE
				35 FT. LBS.
109
107		102
DETAIL
OF ITEM 8

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

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

				103	110
			105	104
			106		111
			108
		3
			101
11			109
			107		102
		3A
3A			DETAIL
			OF ITEM 7
					18
4	14
16
	12				19 17
		7			6
		8	13
5			9
		15

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 -		C
			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

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

	22
	16
5	13
14
4
3	24
	25
	15
	18
	16
	22
	1
2

19

7 11

20

11 7

6

10

12

21

8

11

11

11

11

9

23

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

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1-19

SECTION 1 BASE

FIGURE 1-6. COVER INSTALLATION

10 110

4

104

10 110

A

6

117

8

108

5

105

15 12

115 112

2

102

12

15 112

115

2

102

13		B
113
2			11
102
			111
1
101
13
113	2	9
	102
		109
		13	2
		113
			102

	2	102
	15	115
	12	112
		7	6A
		107	7A
			107A
	6B
	7B
	113
	1314 2
	102
A	110 B			15
113	10		12	115
13				2
			112
				102

5

105

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	2
				Present)
	2902390			Fixed Standard Covers (Included Items 5 - 8) (S/N 6279 to	2
				Present)

3121137

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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 &	2
			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