JLG 20VP Parts Manual
Illustrated Parts Manual
Model
10VP
15VP
20VP
3120850
April 29, 2011
REVISION LOG
Note: This manual for use with VP Models built serial number 0130001711 to Present. For machines with serial numbers prior
to 0130001711 refer to manual part number 3120837.
December 1997 - Original Issue (Manual edited to Final Assembly 0010548 Rev. 4)
March 17, 2000 - Revised (Manual edited to Final Assembly 0010548 Rev. 20)
September 12, 2000 - Revised (Manual edited to Final Assembly 0010548 Rev. 25)
March 19, 2003 - Revised (Manual edited to Final Assembly 0010548 Rev. 30)
November 1, 2006 - Revised
April 29, 2011 - Revised
3120850 A
REVISION LOG
B 312 0850
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - BASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 REAR DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3 WHEEL DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-4 JLG POTHOLE PROTECTION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
SECTION 2 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 GROUND CONTROL/POWER PACK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM CONTROLS AND CABLES INSTALLATIONS2-6
2-3 BATTERY CHARGER ASSEMBLIES (EUROPE AND AUSTRALIAN) . . . . . . . . . . . . . . .2-10
2-4 BATTERY CHARGER ASSEMBLY (UK ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-5 PUMP/MOTOR/TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2-6 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-7 OPTION INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 MAST ASSEMBLY - 10VP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 MAST ASSEMBLY - 15VP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-3 MAST ASSEMBLY - 20VP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-4 MAST MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 MOLDED PLATFORM INSTALLATION (PRIOR TO S/N 02370) . . . . . . . . . . . . . . . . . . .4-2
4-2 MOLDED PLATFORM INSTALLATION (S/N 02370 TO PRESENT) . . . . . . . . . . . . . . . .4-6
4-3 QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE RAIL ENTRY . . . . . . . . . . .4-10
4-4 QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATE (PRIOR TO S/N 02256)
4-12
4-5 QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATE (S/N 02256 TO
PRESENT)4-16
4-6 QUICK-CHANGE PLATFORM INSTALLATION WITH EXTENSION (PRIOR TO S/N 02256) 4-
20
4-7 QUICK-CHANGE PLATFORM INSTALLATION WITH EXTENSION (S/N 02256 TO PRESENT)
4-24
4-8 OPTIONAL PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .4-28
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 HARNESS AND CABLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
3120850 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 3120850
SECTION 1 BASE
S
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
1-1 BASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 REAR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 WHEEL DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4 JLG POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
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3120850 1-1
SECTION 1 BASE
30
31
32
33
103
104
105
109
104
105
102
2
11
13
27
28
13
29
8
106
26
16
111
112
110
103
104
105
108
107
101
112
113
6
6
34
6
17
24
4
3
3
23
22
38
10
7
9
21
12
21
9
9
25
12
9
9
10
2019201
204
206
203
202
201
208
209
18
37
35
36
301
10
1
10
14
15
9
21
5
NOTE: REPLACEMENT DECALS
MUST BE ORDERED SEPARATELY
- SECTION 8.
S
FIGURE 1-1. BASE ASSEMBLY
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1- 2 31 20850
SECTION 1 BASE
.
FIGURE 1-1. BASE ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
BASE ASSEMBLY OPTIONS: Ref.
0257235 10VP Ref. 8
0257236 15VP Ref. 8
0257238 20VP Ref. 8
1 Base Weldment Options: 1
4845561 Prior to S/N 02369
4845877 S/N 02369 to Present
2 Battery Box Weldment Options: 1
4845258 Prior to S/N 02369
4845875 S/N 02369 to S/N 03094
3 4860175 Wheel, Rear Assembly 2
7019659 Steel Insert (1 Per Assembly) 2
4 Drive Assembly - Rear (See Figure 1-2 for Breakdown)
Options:
0257241 Prior to S/N 02363
0258718 S/N 02363 to Present
5 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
6 1060658 Cable, Brake Assembly (See Items for 201-211
Breakdown)
7 4845474 Rear Plate Weldment 1
8 0630446 Bolt 3/8”-16NC x 1” (Carriage) 4
9 4751600 Flatwasher 3/8” Wide A/R
10 3311605 Locknut 3/8”-16NC 16
11 Bolt Options: A/R
0641406 Bolt 1/4”-20NC x 3/4” (Prior to S/N 02369)
0641508 Bolt 5/16”-18NC x 1” (S/N 02369 to S/N 03094)
12 0641609 Bolt 3/8”-16NC x 1 1/8” 12
13 Flatwasher Options: A/R
4751400 Flatwasher 1/4” Wide (Prior to S/N 02369)
4751500 Flatwasher 5/16” Wide (S/N 02369 to S/N 03094)
14 3539659 Plate, Spacer 1/8” 1
15 3539660 Plate, Spacer 5/64” 1
16 2820086 Loom, Wire
17 4160164 Spring, Compression 2
18 4460648 Connector, Terminal 2
19 3020017 Grease, Multi-Purpose (Not Shown) A/R
20 0100011 Compound, Locking (Not Shown) A/R
21 0641608 Bolt 3/8”-16NC x 1” 5
22 Options: A/R
3760393 Ring, Retainer (Prior to S/N 02363) 2
4845878 Battery Box Cover - Right (S/N 02369 to S/N 03094) 1
1
1
4in/10cm
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3120850 1-3
SECTION 1 BASE
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FIGURE 1-1. BASE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
23 Options: A/R
2860026 Key, Wheel (Prior to S/N 02363) 2
3311505 Locking Nut 5/16”-18NC (S/N 02369 to S/N 03094) 6
24 Options: A/R
4751000 Flatwasher #10 Wide (Prior to S/N 01703) 2
4740430 Flatwasher, Fender (S/N 01703 to Present) 2
25 3570172 Cover, Motor 1
26 Counterweight Weldment Options: A/R
Not Required 10VP 0
4845260 15VP 2
4845261 20VP 2
27 0641408 Bolt 1/4”-20NC x 1” A/R
28 3311405 Locknut 1/4”-20NC A/R
29 Counterweight Bracket Options: A/R
Not Required 10VP & 20VP 0
0902256 15VP (Standard Machines) 2
30 Counterweight Weldment Options: A/R
Not Required 10VP & 15VP 0
4845377 20VP 1
31 0641810 Bolt 1/2”-13NC x 1 1/4” A/R
32 3311805 Locknut 1/2”-13NC A/R
33 4751800 Flatwasher 1/2” A/R
34 2820085 Block, Insulated 2
35 3910620 Screw #6-32NC x (S/N 03094 to Present) 4
36 3310601 Nut #6-32NC (S/N 03094 to Present) 8
37 4750600 Flatwasher #6 (S/N 03094 to Present) 4
38 4711600 Flatwasher 3/8” (S/N 03609 to Present) 8
MAST SUPPORT INSTALLATION OPTIONS: Ref.
0256197 Prior to S/N 02289 Ref. 4/C
0258582 S/N 02289 to Present Ref. 1/A
101 Channel, Lift Cylinder Mounting Options: 1
4845478 Prior to S/N 02289
4845804 S/N 02289 to Present
102 0880124 Brace, Mast 2
103 0641609 Bolt 3/8”-16NC x 1 1/8” 11
104 4751600 Flatwasher 3/8” Wide 24
105 3311605 Locknut 3/8”-16NC 12
106 2420140 Gauge, Level 1
107 0641505 Bolt 5/16”-18NC x 5/8” 1
108 4711500 Flatwasher 5/16” Narrow 1
109 0641612 Bolt 3/8”-16NC x 1 1/2” 1
110 1320041 Clamp 1
111 0641404 Bolt 1/4”-20NC x 1/2” 1
112 4711400 Flatwasher 1/4” Narrow 2
113 3311401 Nut 1/4”-20NC 1
114 0100011 Compound, Locking (Not Shown) A/R
1- 4 31 20850
SECTION 1 BASE
FIGURE 1-1. BASE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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 (55in/139.7cm) 1
209 1060662 Cable, Brake (69in/175.3cm) 1
210 0100019 Compound, Locking (Not Shown) A/R
211 0100035 Compound, Locking (Not Shown) A/R
0270352 STATIC STRAP INSTALLATION Ref. 1/A
301 0641608 Bolt 3/8”-16NC x 1” 1
3311605 Locknut 3/8”-16NC 1
4751600 Flatwasher 3/8” 2
4240084 Strap, Static 1
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3120850 1-5
SECTION 1 BASE
EXPLODED VIEW RIGHT SIDE
DRIVE MOTOR.
(NOT SHOWN)
5
11A
12
13
11
5
22
21
18
4
10
17
3
2
1
21
19
24
23
7
9
25
10
26
8
20
23
DETAIL
OF ITEM 4
(PRIOR TO
SEPTEMBER 1999)
109
101
102
107
104
105
106
103
108
DETAIL
OF ITEM 4
(SEPTEMBER 1999
TO PRESENT)
209
201
207
202
203
204
210
211
205
206
208
6
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FIGURE 1-2. REAR DRIVE ASSEMBLY
1- 6 31 20850
SECTION 1 BASE
FIGURE 1-2. REAR DRIVE ASSEMBLY
S
E
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
REAR DRIVE ASSEMBLY OPTIONS: Ref.
0257241 Prior to S/N 02363 Ref. 3/C
0258718 S/N 02363 to Present 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
201-211 for Breakdown) (September 1999 to
Present)
5 Wheel Drive Motor Assembly (See Figure 1-3 for
Breakdown) Options:
3160217 Prior to S/N 02363
3160234 S/N 02363 to Present
6 Shaft, Drive Options: 2
4040259 Prior to S/N 02363
4040268 S/N 02363 to Present
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 Compound, Locking (Not Shown) A/R
15 0100011 Compound, Locking (Not Shown) A/R
16 0100019 Compound, Locking (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
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3120850 1-7
SECTION 1 BASE
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FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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
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. A
Ref. C
1- 8 31 20850
SECTION 1 BASE
FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120850 1-9
SECTION 1 BASE
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FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY
1- 10 31 20850
SECTION 1 BASE
FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY
S
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FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
DRIVE MOTOR ASSEMBLY OPTIONS: Ref.
3160217 Prior to S/N 02363 Ref. D
3160234 S/N 02363 to Present Ref. C
1 7018000 Brush Kit 1
7018044 Holder, Brush 1
2 7018001 Key, Shaft 1
3 7018002 Gear and Pinion Assembly 1
4 7018019 Gear and Drive Shaft 1
4A 7018007 Key, Shaft 1
5 7018018 Seal, Lip 1
6 7018005 Ring, Retaining 1
7 2860028 Shaft, Key 1
8 7018008 Bearing 2
9 7018009 Washer, Wave 1
10 7018010 Washer, Wave 1
11 7018011 Washer, Wave 1
12 7018012 Bearing 32mm x 12mm x 10mm 2
13 7018013 Bearing 47mm x 20mm x 14mm 1
14 7018014 Bearing 47mm x 25mm x 12mm 1
15 7018027 Bearing 1
16 7018015 Shaft, Key 1
17 7018026 Seal, Lip 1
18 O-Ring Options: 1
Not Required Prior to S/N 02363
7018028 S/N 02363 to Present
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3120850 1-11
SECTION 1 BASE
3
5
2
1
9
10
8
13
7
14
16
17
21
20
22
22
25
25
18
24
24
23
12
6
11
11
29
26
19
14
15
19
(RIGHT SIDE)
(LEFT SIDE)
FRAME REF.
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FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION
1- 12 31 20850
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 Compound, Locking (Not Shown) A/R
28 0100011 Compound, Locking (Not Shown) A/R
29 4460662 Connector, Strain Relief 2
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3120850 1-13
SECTION 1 BASE
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FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
1- 14 31 20850
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 ASSEMBLIES (EUROPE AND AUSTRALIAN). . . . . . . . . . . . . . . . . . . . 2-10
2-4 BATTERY CHARGER ASSEMBLIES (UK ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-5 PUMP/MOTOR/TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-6 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-7 OPTION INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
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3120850 2-1
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SECTION 2 CONTROLS
FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS
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SECTION 2 CONTROLS
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FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0256599 GROUND CONTROL/POWER PACK INSTALLATIONS Ref. 10
1 Bracket, Ground Controls Options: 1
0902248 Prior to S/N 03136
0902643 S/N 03136 to Present
2 0641406 Bolt 1/4”-20NC x 3/4” 9
3 4751400 Flatwasher 1/4” Wide 15
4 3311405 Locknut 1/4”-20NC 2
5 Ground Control Assembly (See Items 101-105 For Break-
down) Options:
0861053 Prior to S/N 02862
0861292 S/N 02862 to S/N 03136
0861356 S/N 03136 to S/N 03905
0861292 S/N 03905 to Present
6 Screw Options: A/R
3910812 Screw, Machine #8-32NC x 3/4” (Prior to S/N 03136) 4
0721006 Screw, Machine #10-24NC x 3/4” (S/N 03136 to Present) 2
7 Flatwasher Options: A/R
4750600 Flatwasher #8 (Prior to S/N 03136) 8
4751000 Flatwasher #10 (S/N 03136 to Present) 2
8 Locknut Options: A/R
3310805 Locknut #8-32NC (Prior to S/N 02315) 4
3300392 Locknut #8-32NC (Brass) (S/N 02315 to S/N 03136) 4
3311005 Locknut #10-24NC (S/N 03136 to Present) 2
9 Not Used
10 0741407 Screw, Flathead 1/4”-20NC x 7/8” 4
11 0181857 Angle, Controller Mount 1
12 0641406 Bolt 1/4”-20NC x 3/4” 4
13 4711400 Flatwasher 1/4” Narrow 4
14 0100011 Compound, Locking(Not Shown) A/R
15 1600238 Controller Assembly (Prior to S/N 02996) 1
2900868 Controller Configuration Kit 1
1600305 Controller Assembly (S/N 02996 to Present) 1
2900868 Controller Configuration Kit 1
16 0902250 Bracket, Battery Charger 1
17 0641608 Bolt 3/8”-16NC x 1” 10
18 4751600 Flatwasher 3/8” 20
19 3311605 Locknut 3/8”-16NC 10
20 Relay, 100Amp Options: 1
3740120 Prior to S/N 02315
3740130 S/N 02315 to Present
21 3539565 Plate, Pump Mounting 1
22 2680432 Hood 1
22A 2700080 Hook 2
22B 7023342 Lid 1
22C 7023341 Lid 1
23 0400122 Battery 2
24 3300202 Wingnut 4
1
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3120850 2-3
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SECTION 2 CONTROLS
FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
25 0630504 Bolt, Battery Hold Down 4
26 0362658 Bar, Battery Hold Down 2
27 Not Used
28 4845266 Bracket, Brake Release 1
29 4360314 Switch, Ground 1
30 3740069 Relay, Power 24VDC 2
31 3911010 Screw 2
32 3311001 Nut #10-24NC 2
33 4751000 Flatwasher #10 Wide 4
34 0741605 Screw, Countersunk 3/8”-16NC x 5/8” 2
35 0100051 Grease Battery (Not Shown) A/R
36 4761000 Lockwasher #10 2
37 4845875 Weldment, Battery Box (Right Side) 1
38 4845878 Weldment, Battery Box (Left Side) 1
39 0641508 Bolt 5/16”-18NC x 1” 6
40 4751500 Flatwasher 5/16 6
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0861053 GROUND CONTROL ASSEMBLY (PRIOR TO S/N 02862) Ref. A
101 7017701 Switch, Push-Turn to Reset (Emergency Stop) 1
7017703 Block, Contact - N.C. 2
7017715 Button - Red 1
102 7017714 Switch - Key (Lift) 1
7017702 Block, Contact - N.C. 2
102A 7017704 Key, Replacement 1 set
103 Strain Relief Connector Options: 1
7012637 Connector, Strain Relief (CG16)
7017713 Connector, Strain Relief (CG20)
104 7017706 Nameplate - Emergency Stop 1
105 7017705 Nameplate - Select 1
0861292 GROUND CONTROL ASSEMBLY (S/N 02862 TO S/N 03136) Ref. A
0861356 GROUND CONTROL ASSEMBLY (S/N 03136 TO S/N 03905) Ref. A
0861292 GROUND CONTROL ASSEMBLY (S/N 03905 TO PRESENT) Ref. A
201 7020078 Switch, Push-Turn to Reset (Emergency Stop) 1
202 4360433 Switch - Key (Prior to S/N 03136) 1
4360472 Switch - Key (S/N 03136 to S/N 0390) 1
4360433 Switch - Key (S/N 03905 to Present) 1
202A 7016339 Key, Replacement (Used with Switch p/n 4360433) 1 set
2860030 Key, Replacement (Used with Switch p/n 4360472) 1 set
203 4460633 Strain Relief Connector 1
204 7020096 Nameplate - Emergency Stop 1
205 7020267 Nameplate - Select 1
2-4 3120850
SECTION 2 CONTROLS
FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120850 2-5
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SECTION 2 CONTROLS
FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS
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SECTION 2 CONTROLS
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FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PLATFORM CONTROLS AND CABLES INSTALLATIONS Ref.
0257624 10 VP Ref. 11
0257610 15 VP Ref. 10
0257601 20 VP Ref. 12
1 3570680* Plate, Control Mounting 1
1A Pad, Rubber Options: A/R
7020075 RH Side Pad 2
7020076 LH Side Pad 2
2 Not Used
3 Platform Console Box Assembly Options (See Figure 2-6
for Breakdown):
1600267 Console Box Assembly (Prior to S/N 02996)
1600304 Console Box Assembly (S/N 02996 to Present)
4 1060663 Cable, Electrical A/R
10 VP
15 VP
20 VP
5 Platform Harness Assembly Options: (See Section 7 for
Breakdown)
4922027 10 VP (Prior to S/N 02445)
4922201 10 VP(S/N 02445 to Present)
4922028 15 VP (Prior to S/N 02445)
4922202 15 VP(S/N 02445 to Present)
4922029 20 VP (Prior to S/N 02445)
4922203 20 VP(S/N 02445 to Present)
6 3422657* Pin, Quick Release 1
7 1060380* Cable, Lanyard 2
8 1320043* Clamp, Cable 1
9 3310801* Nut #8-32NC A/R
10 4750800* Flatwasher #8 Wide A/R
11 3300416* Nut, Acorn #8-32NC 4
12 0100035 Compound, Locking (Not Shown) A/R
13 4160130 Spring, Extension 1
14 3311605 Locknut 3/8”-16NC 1
15 1320149 Clamp 3
16 0641412 Bolt 1/4”-20NC x 1 1/2” 3
17 0100019 Compound, Locking (Not Shown) A/R
18 3311405 Locknut 1/4”-20NC 7
19 3580231 Pulley, Sheave A/R
20 3900200 Screw, Shoulder 5/16”-18NC x 1 1/4” A/R
21 4751500 Flatwasher 5/16” Wide A/R
22 0641406 Bolt 1/4”-20NC x 3/4” 4
23 4711400 Flatwasher 1/4” Narrow A/R
24 4460566
25 3380441 Panel, Control 1
26 0860946 Box, Electrical 1
27 Supply Locally Receptacle, Electrical 1
Connector, Strain Relief - 90
°
1
13.2ft/4m
18.7ft/5.7m
22.3ft/6.8m
1
1
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3120850 2-7
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SECTION 2 CONTROLS
FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
28 Supply Locally Cover, Weatherproof 1
29 0721005 Screw, Machine #10-24NC x 5/8” 2
30 4761000 Lockwasher #10 2
31 3311001 Nut #10-24NC 2
32 4460023 Connector, Strain Relief 1
33 Clamp, Cable Options: A/R
1320227 Prior to S/N 01966 7
1320043 S/N 01966 to Present 4
34 Hardware Options: A/R
1020008 Button, Nylon (Prior to S/N 01966) 7
1380132 Clip, Gripper (S/N 01966 to Present) 4
35 4460549 Plug, Electrical (Prior to S/N 02970) 1
36 0960407 Bushing (Prior to S/N 02535) 1
37 4751000 Flatwasher #10 Wide A/R
38 3300047 Nut, Conduit 1
39 Carrier Options: A/R
Not Required 10VP & 20VP 0
1180344 15VP 1
40 Plate, Spacer Options: A/R
Not Required 10VP & 20VP 0
3539617 15VP 2
41 0641409 Bolt 1/4”-20NC x 1” A/R
42 0641416 Bolt 1/4”-20NC x 2” A/R
43 0641414 Bolt 1/4”-20NC x 1 3/4” A/R
44 3760170 Ring, Split 1
45 0100048 Compound, Silicone #661 (Not Shown) A/R
46 3570737 Bracket, Protector 1
47 Hardware Options: 4
4750800 Flatwasher #8 Wide (Prior to S/N 02535)
3820024 Pop Rivet (S/N 02535 to Present)
48 4760800 Lockwasher #8 (Prior to S/N 02535) 4
49 3310801 Nut #8-32NC (Prior to S/N 02535) 4
50 3910806 Screw #8-32NC x 3/8” (Prior to S/N 02535) 4
51 4740120 Washer, Nylon (S/N 03629 to Present) 4
2901542* Controller Mounting Kit (Includes Items with * asterisk) 1
2-8 3120850
SECTION 2 CONTROLS
FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120850 2-9
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SECTION 2 CONTROLS
FIGURE 2-3. BATTERY CHARGER ASSEMBLIES (EUROPE AND AUSTRALIAN)
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