JLG 20VP Parts Manual

0 (0)

Illustrated Parts Manual

Model

10VP

15VP

20VP

3120850

April 29, 2011

REVISION LOG

3120850 A

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

REVISION LOG

B 312 0850

3120850 i

FIGURE NO. TITLE PAGE NO.

TABLE OF CONTENTS

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-

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

ii 3120850

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

3120850 1-1

SECTION 1 BASE

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

1- 2 31 20850

SECTION 1 BASE

FIGURE 1-1. BASE ASSEMBLY

103

104

105

109

104

105

102

106

111

112

110

103

104

105

108

107

101

112

113

201

204

206

203

202

201

208

209

301

NOTE: REPLACEMENT DECALS

MUST BE ORDERED SEPARATELY

- SECTION 8.

3120850 1-3

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

4in/10cm

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- 4 31 20850

SECTION 1 BASE

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

FIGURE 1-1. BASE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3120850 1-5

SECTION 1 BASE

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

FIGURE 1-1. BASE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1- 6 31 20850

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY

EXPLODED VIEW RIGHT SIDE

DRIVE MOTOR.

(NOT SHOWN)

11A

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

3120850 1-7

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY

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

1- 8 31 20850

SECTION 1 BASE

1400126 TORQUE LIMITER CLUTCH ASSEMBLY (DALTON

BRAND) (PRIOR TO SEPTEMBER 1999)

Ref. A

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)

Ref. C

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

FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3120850 1-9

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1- 10 31 20850

SECTION 1 BASE

FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY

3120850 1-11

SECTION 1 BASE

FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY

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

1- 12 31 20850

SECTION 1 BASE

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

(RIGHT SIDE)

(LEFT SIDE)

FRAME REF.

3120850 1-13

SECTION 1 BASE

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

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

1- 14 31 20850

SECTION 1 BASE

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3120850 2-1

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

2-2 3120850

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

3120850 2-3

SECTION 2 CONTROLS

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

2-4 3120850

SECTION 2 CONTROLS

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

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

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3120850 2-5

SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-6 3120850

SECTION 2 CONTROLS

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

3120850 2-7

SECTION 2 CONTROLS

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

13.2ft/4m

15 VP

18.7ft/5.7m

20 VP

22.3ft/6.8m

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

Connector, Strain Relief - 90

25 3380441 Panel, Control 1

26 0860946 Box, Electrical 1

27 Supply Locally Receptacle, Electrical 1

2-8 3120850

SECTION 2 CONTROLS

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

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3120850 2-9

SECTION 2 CONTROLS

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-10 3120850

SECTION 2 CONTROLS

FIGURE 2-3. BATTERY CHARGER ASSEMBLIES (EUROPE AND AUSTRALIAN)

+ 90 hidden pages