JLG 20VP Parts Manual

Illustrated Parts Manual

Models

10VP 15VP 20VP

3120729

April 29, 2011

REVISION LOG

Note: This manual for use with VP Models built serial number 0130001577 to Present. For machines with serial numbers prior to 0130001577 refer to manual part number 3123001.

September 1997 - Original Issue (Manual edited to Final Assembly 0010548 Rev. 1)

November 1997 - Change 1 (Manual edited to Final Assembly 0010548 Rev. 4)

Pages Effected:

Cover

Effectivity Page a

Section 1 Pages: 1-2 to 1-5, 1-10, 1-11

Section 2 Pages: 3-2, 3-6, 3-10, 3-13

Section 3 Pages: 1-2 to 1-5, 1-10, 1-11

Section 4 Pages: 4-2 to 4-13

Section 6 Pages: 6-3

Section 8 Pages: 8-2 to 8-5

Section 9 Pages: 9-1

Section 10 Pages: 10-1

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

3120729 A

REVISION LOG

B 312 0729

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 REAR DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-3 WHEEL DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-4 JLG POTHOLE PROTECTION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

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

2-1 GROUND CONTROL/POWER PACK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 PLATFORM CONTROLS AND CABLES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4 PUMP/MOTOR/TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-5 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-6 OPTION INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

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 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

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

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

7-1 ELECTRICAL SCHEMATIC (PRIOR TO S/N 01491) . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 ELECTRICAL SCHEMATIC (S/N 01491 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . .7-3

7-3 ELECTRICAL SCHEMATIC (UL/EE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-4 HARNESS AND CABLES INSTALLATION (STANDARD MACHINES) . . . . . . . . . . . . .7-6

7-5 HARNESS AND CABLES INSTALLATION (EE MACHINES) (S/N 03094 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

3120729 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

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

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

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

ii 3120729

SECTION 1 BASE

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 BASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 REAR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 WHEEL DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 JLG POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

E C T

I O N

B A S E

3120729 1-1

SECTION 1 BASE

14 15

31 32 33

115 103 104 105 109

117 104

105 116 118

102

11 13

27 28 13

106

111

112

110

103

104

105

108

107

101

112

113

383637

201103019201

204

206

203

202

201

208

209

9 10

9 10 35

119 120 121

NOTE: REPLACEMENT DECALS

MUST BE ORDERED SEPARATELY

- SECTION 8.

FIGURE 1-1. BASE ASSEMBLY

E C T

I O N

A S E

1- 2 31 20729

SECTION 1 BASE

FIGURE 1-1. BASE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BASE ASSEMBLY OPTIONS: Ref. 0257230 10VP (Standard & CSA Machines) Ref. 8 0257229 15VP (Standard Machines) Ref. 8 0257237 15VP (CSA Machines) Ref. 8 0257228 20VP (Standard Machines) Ref. 8 0257239 20VP (CSA Machines) (Prior to S/N 02348) Ref. 4 0258693 20VP (CSA Machines) (S/N 02348 to Present) Ref. 4/B

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

4in/10cm

S E

I O N

A S E

3120729 1-3

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-1. BASE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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

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 (Prior to S/N 02369) 2

4845879 15VP (S/N 02369 to Present) 2

4845261 20VP (Prior to S/N 02369) 2

4845876 20VP (S/N 02369 to Present) 2 27 0641408 Bolt 1/4”-20NC x 1” (Prior to S/N 02369) A/R 28 3311405 Locknut 1/4”-20NC (Prior to S/N 02369) A/R 29 Counterweight Bracket Options: A/R

Not Required 10VP & 20VP 0

0902256 15VP (Standard Machines) 2

0902256 15VP (CSA Machines) (Prior to S/N 02369) 1

Not Required 15VP (CSA Machines) (S/N 02369 to Present) 0

30 Counterweight Weldment Options: A/R

Not Required 10VP & 15VP 0

4845291 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 Counterweight Bracket Options: A/R

Not Required 10VP, 15VP & 20VP (Standard Machines) 0 Not Required 10VP & 20VP (CSA Machines) 0

4845401 15VP (CSA Machines) 1 35 0630512 Bolt, Carriage A/R 36 3910620 Screw #6-32NC x (S/N 03094 to Present) 4 37 3310601 Nut #6-32NC (S/N 03094 to Present) 8 38 4750600 Flatwasher #6 (S/N 03094 to Present) 4 39 4711600 Flatwasher 3/8” (Standard Machines) (S/N 03609 to

Present)

1- 4 31 20729

SECTION 1 BASE

FIGURE 1-1. BASE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

MAST SUPPORT INSTALLATION OPTIONS: Ref. 0256197 STANDARD MACHINES (Prior to S/N 02289) Ref. 4/C 0258582 STANDARD MACHINES (S/N 02289 to Present) Ref. 1/A 0256793 CSA MACHINES (Prior to S/N 02289) Ref. 3/C 0258583 CSA MACHINES (S/N 02289 to Present) Ref. 2/B

101 Channel, Lift Cylinder Mounting Options: 1

4845478 Prior to S/N 02289 4845804 S/N 02289 to Present

102 Brace, Mast Options: 2

0880124 Standard Machines 0880125 CSA Machines

103 0641609 Bolt 3/8”-16NC x 1 1/8” A/R 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 115 Shim - .03 Options: A/R

Not Required Standard Machines 0

4700952 CSA Machines 1

116 Shim - .03 Options: A/R

Not Required Standard Machines 0

4700953 CSA Machines 2

117 0641612 Bolt 3/8”-16NC x 1 1/2” 2 118 Shim - .06 Options: A/R

Not Required Standard Machines 0

4700954 CSA Machines 6

119 Plate, Hood Mount Options: A/R

Not Required Standard Machines 0

3570094 CSA Machines 1

120 Flatwasher 1/4” Options: A/R

Not Required Standard Machines 0

4751400 CSA Machines 1

121 Bolt 1/4”-20NC x 3/4” Options: A/R

Not Required Standard Machines 0

0641406 CSA Machines 1

S E

I O N

A S E

3120729 1-5

SECTION 1 BASE

S E

I O N

A S E

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 1 209 1060662 Cable, Brake 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

1- 6 31 20729

SECTION 1 BASE

FIGURE 1-1. BASE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

A S E

3120729 1-7

SECTION 1 BASE

EXPLODED VIEW RIGHT SIDE

DRIVE MOTOR.

(NOT SHOWN)

11A

3 2

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

S E

I O N

A S E

FIGURE 1-2. REAR DRIVE ASSEMBLY

1- 8 31 20729

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

I O N

A S E

3120729 1-9

SECTION 1 BASE

S E

I O N

A S E

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- 10 31 20729

SECTION 1 BASE

FIGURE 1-2. REAR DRIVE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

A S E

3120729 1-11

SECTION 1 BASE

S E

I O N

A S E

FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY

1- 12 31 20729

SECTION 1 BASE

FIGURE 1-3. WHEEL DRIVE MOTOR ASSEMBLY

S E

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

I O N

A S E

3120729 1-13

SECTION 1 BASE

16 17

202222

(RIGHT SIDE)

(LEFT SIDE)

FRAME REF.

S E

I O N

A S E

FIGURE 1-4. JLG POTHOLE PROTECTION INSTALLATION

1- 14 31 20729

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

I O N

A S E

3120729 1-15

SECTION 1 BASE

S E

I O N

A S E

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1- 16 31 20729

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 PUMP/MOTOR/TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 OPTION INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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3120729 2-1

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SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

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SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

GROUND CONTROL/POWER PACK INSTALLATIONS Ref. 0256143 Machines With Wet Batteries Ref. 15 0258008 Machines With Dry Batteries Ref. 7 0256928 CSA Spec Machines (Additional Components) Ref. 0270167 (EE) Spec Machines (S/N 03094 to Present) Ref. 5

1 Bracket, Ground Controls Options: 1

0902248 (Standard) (Prior to S/N 03094) 0902643 (Standard) (S/N 03094 to Present) 0902649 (EE) (S/N 03094 to Present) 3570094 Plate, Hood Mounting (CSA Only) (Not Shown - Located on

Top of Item #1) 2 0641406 Bolt 1/4”-20NC x 3/4” 9 3 4751400 Flatwasher 1/4” Wide 19 4 3311405 Locknut 1/4”-20NC 2 5 Ground Control Assembly (See Items 101-105 For

Breakdown) Options:

0861039 Prior to S/N 02862 0861291 S/N 02862 to S/N 03094 0861355 S/N 03094 to S/N 03905 0861291 S/N 03905 to Present

6 Screw, Machine Options: 4

3910812 Prior to S/N 03094 - #8-32NC x 3/4” 0721006 S/N 03094 to Present - #10-24NC x 3/4”

7 Flatwasher Options: A/R

4750800 Prior to S/N 03094 - Flatwasher #8 4751000 S/N 03094 to Present - Flatwasher #10

8 Locknut Options: A/R

3310805 Locknut #8-32NC (Prior to S/N 02315) 3300392 Locknut #8-32NC (Brass) (S/N 02315 to S/N 03094) 3311005 Locknut #10-24NC (S/N 03094 to Present)

9 Not Used

10 0741407 Screw, Flathead 1/4”-20NC x 7/8” 4 11 0181857 Angle, Controller Mount 1 12 3311601 Nut 3/8”-16NC (EE Machines Only) 2 13 3311501 Nut 5/16”-18NC (EE Machines Only) 2 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

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3120729 2-3

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SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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 (Wet) 2

0400144 Battery (Dry) 2 24 3300202 Wingnut (Not Required On (EE) Machines) 4 25 0630504 Bolt, Battery Hold Down (Not Required On (EE) Machines) 4 26 0362658 Bar, Battery Hold Down (Not Required On (EE) Machines) 2 27 Not Used 28 4845266 Bracket, Brake Release (Prior to S/N 01577) 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 Battery Box - Right Options: 1

4845875 Standard Machines (S/N 03094 to Present)

0270299 (EE) Machines (S/N 03094 to Present)

3572654 (EE) Machines (Battery Box Lid) 38 Battery Box - Left Options: 1

4845878 Standard Machines (S/N 03094 to Present)

0270298 (EE) Machines (S/N 03094 to Present)

3572653 (EE) Machines (Battery Box Lid) 39 0641508 Bolt 5/16-18NC x 1” 6 40 4751500 Flatwasher 5/16” 6 41 3380453 Panel, Breaker (EE Machines Only) 1 42 1704584 Decal - Breaker Panel (EE Machines Only) 1 43 0641512 Bolt 5/16”-18NC x 1 1/2” 2 44 3311505 Locknut 5/16”-18NC 2 45 4568103 Bar, Battery Hold Down (EE Machines Only) 2 46 0902657 Bracket, Battery Disconnect (EE Machines Only) 1 47 4360256 Switch, Master Disconnect (EE Machines Only) 1 48 4761500 Lockwasher 5/16” 2 49 4761600 Lockwasher 3/8” 2 50 2400044 Fuse Mounting Block (EE Machines Only) (Prior to S/N

03682)

51 0741008 Flathead Screw #10-24NC x 1” (EE Machines Only) (Prior

to S/N 03682)

52 0861381 Fuse Box Assembly (EE Machines Only) (S/N 03682 to

Present) 52A 0741006 Screw #10-24NC x 3/4” 2 52B 0861380 Box, Fuse (EE) 1 52C 1704713 Decal - Fuse 1 52D 2400044 Fuse Mounting Block 1

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SECTION 2 CONTROLS

FIGURE 2-1. GROUND CONTROL/POWER PACK INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

52E 2400045 Fuse, 80Amp 1 52F 2540040 Grommet, Rubber 2

52G 3311005 Locknut #10-24NC 2

53 0641408 Bolt 1/4”-20NC x 1” (EE Machines Only) (S/N 03682 to

Present)

54 3572651 Plate, Battery Access (EE Machines Only) (S/N 03682 to

Present) 55 1380138 Clip, Receptial (EE Machines Only) (S/N 03682 to Present) 8 56 3900174 Screw (EE Machines Only) (S/N 03682 to Present) 8 57 0962346 Bushing, Spacer (EE Machines Only) (S/N 03682 to

Present) 58 1704679 Decal - Battery Disconnect (EE Machines Only) (S/N 03887

to Present) 59 3820006 Pop Rivet (EE Machines Only) (S/N 03887 to Present) 4

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0861039 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 7017700 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

0861291 GROUND CONTROL ASSEMBLY (S/N 02862 TO S/N 03094) Ref. A

0861355 GROUND CONTROL ASSEMBLY (S/N 03094 TO S/N 03905) Ref. A

0861291 GROUND CONTROL ASSEMBLY (S/N 03905 TO PRESENT) Ref. A

201 7020078 Switch, Push-Turn to Reset (Emergency Stop) 1 202 4360471 Switch - Key (Lift) 1

202A 7020174 Key, Replacement 1 set

203 4460633 Strain Relief Connector 1 204 7020096 Nameplate - Emergency Stop 1 205 7020267 Nameplate - Select 1

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SECTION 2 CONTROLS

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

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SECTION 2 CONTROLS

FIGURE 2-2. PLATFORM CONTROLS AND CABLES INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PLATFORM CONTROLS AND CABLES INSTALLATIONS Ref. 0257619 10 VP (Standard) Ref. 9 0270166 10 VP (EE) Ref. 2 0257618 15 VP (Standard) Ref. 9 0270168 15 VP (EE) Ref. 2 0257617 20 VP (Standard) Ref. 10 0270169 20 VP (EE) Ref. 2

Note: For Platform Controls & Cables (Restricted Height) (See Section 10)

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 2-5

For Breakdown): 1600267 Console Box Assembly (Prior to S/N 02996) 1600304 Console Box Assembly (S/N 02996 to Present)

4 1060564 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

13.5ft/4m

19ft/5.8m

23ft/7m

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3120729 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.

24 4460566

25 3380441 Panel, Control 1 26 0860946 Box, Electrical 1 27 Receptacle, Electrical Options: 1

4460190 Standard Machines

4460347 (EE) Machines 28 4060092 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 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

Connector, Strain Relief - 90°

2901542 Controller Mounting Kit (Includes Items with * asterisk) 1

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