Jlg 20DVSP (3121137) Parts Manual- Manuals

Jlg 20DVSP (3121137) Parts Manual– User Manual in PDF format online.

Manuals:

User Manual

User Manual Jlg 20DVSP (3121137) Parts Manual

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Summary

Page 3 - REVISION LOG

3121137 15DVL 15DVSP 20DVL 20DVSP A 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 e...

Page 5 - TABLE OF CONTENTS; TITLE

3121137 15DVL 15DVSP 20DVL 20DVSP i 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 B...

Page 6 - ii

ii 15DVL 15DVSP 20DVL 20DVSP 3121137 FIGURE NO. TITLE PAGE NO. TABLE OF CONTENTS SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 S...

Page 8 - SECTION 1 BASE

1-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 1 BASE FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (PRIOR TO S/N 5271) 5 25 32 33 27 37 25 13 2 38 3 7 7 29 29 15 8 22 36 27 16 7 23 30 21 14 19 26 14 17 4 24 7 7 20 12 31 5 25 6 25 13 18 31 25 101 102 5 5 25 25 9 NOTE: DRIVE MOTOR COVER (ITEM 9)SHO...

Page 9 - PART NUMBER

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

Page 10 - BEACON LIGHT INSTALLATION

1-4 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 1 BASE 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 ...

Page 16 - DETAIL

1-10 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 1 BASE FIGURE 1-3.DRIVE ASSEMBLY (PRIOR TO S/N 5271) 19 13 22 13 19 9 6 4 19 12 16 8 14 20 3 17 19 25 20 5 20 5 10 3 15 26 18 23 21 TORQUE35 FT. LBS. 7 DETAIL OF ITEM 8 109 101 107 102 103 104 110 111 105 106 108

Page 18 - TORQUE LIMITER CLUTCH ASSEMBLY

1-12 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 1 BASE 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, Tab...

Page 30 - FIGURE 1-7. MAST AND BATTERY BOX INSTALLATION

1-24 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 1 BASE FIGURE 1-7. MAST AND BATTERY BOX INSTALLATION

Page 31 - FIGURE 1-7. MAST AND BATTERY BOX INSTALLATION

3121137 15DVL 15DVSP 20DVL 20DVSP 1-25 SECTION 1 BASE FIGURE 1-7. MAST AND BATTERY BOX INSTALLATION ITEM # PART NUMBER QTY. DESCRIPTION REV. Ref. MAST SUPPORT INSTALLATION 0271259 Ref. 15DVL/15DVSP D 0271260 Ref. 20DVL/20DVSP D 0273323 Ref. 15DVSP (No Lanyard Attach Point) A 0273322 Ref. 20DVSP (No ...

Page 34 - SECTION 2 CONTROLS

2-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 2 CONTROLS FIGURE 2-1. PUMP/MOTOR/GROUND CONTROL/HORN INSTALLATIONS 105 108 302 303 304 106 108 201 202 203 101 102 107 6 2 8 103 104 301 7 402 403 404 405

Page 36 - GROUND CONTROL MODULE COMPONENTS OPTIONS:

2-4 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 2 CONTROLS 302 2 Screw Options: 3911008 Hinged Cover 3911010 Fixed Cover 303 4751000 A/R Flatwasher #10 304 3311005 2 Locknut #10-24NC (Fixed Cover Only) Ref. GROUND CONTROL MODULE COMPONENTS OPTIONS: 1600322 Module with Key (Standard) 1600339 Module wit...

Page 44 - BATTERY CHARGER INSTALLATION

2-12 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 2 CONTROLS 123 Not Used 124 3311501 4 Nut 5/16-18NC 125 3311505 4 Locknut 5/16-18NC 126 3572511 1 Plate, Proximity Switch Mounting 127 3900205 2 Screw #10-24NC x 5/8” 128 3911020 2 Screw #10-24NC x 1 1/4” 129 Not Used 130 4071058 1 Shim 131 4240032 2 Ti...

Page 48 - FIGURE 2-6. PLATFORM CABLE AND CONTROLS INSTALLATION; PRIOR TO

2-16 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 2 CONTROLS FIGURE 2-6. PLATFORM CABLE AND CONTROLS INSTALLATION 10 108 9 107 15 14 17 18 19 20 TO MODULE 106 103 102 13 7 4 2 11 105 112 16 110 113 12 2 6 111 116 115 114 109 16 2 4 13 2 4 13 104 24 3 5 23 22 19 8 21 PRIOR TO S/N 7616 5 8 S/N 7616 TO PR...

Page 49 - FIGURE 2-6. PLATFORM CABLE AND CONTROLS INSTALLATION

3121137 15DVL 15DVSP 20DVL 20DVSP 2-17 SECTION 2 CONTROLS FIGURE 2-6. PLATFORM CABLE AND CONTROLS INSTALLATION ITEM # PART NUMBER QTY. DESCRIPTION REV. Ref. PLATFORM CONTROLS AND CABLES INSTALLATIONS 0271663 Ref. 15DVSP/20DVSP K 0271273 Ref. 15DVL/20DVL L 1 0100011 A/R Loctite #242 (Not Shown) 2 064...

Page 50 - ACCESSORY OUTLET INSTALLATION

2-18 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 2 CONTROLS 25 4923316 1 Harness, Platform Control (S/N 7616 to Present) Ref. ACCESSORY OUTLET INSTALLATION 0271295 Ref. 110V/120V (DVL) B 0271792 Ref. 110V/120V (DVSP) C 0271296 Ref. 220V/240V (DVL) B 0271793 Ref. 220V/240V (DVSP) C 0272769 Ref. 110V/12...

Page 58 - SECTION 3 MAST

3-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 3 MAST FIGURE 3-1. MAST ASSEMBLY

Page 64 - SECTION 4 PLATFORM

4-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 4 PLATFORM FIGURE 4-1. PLATFORM WITH FRONT SLIDE BAR ENTRY (DVL) 1 2 5 69 38 7 108 105106107 109 110 10 102 111 11 4 112 113 101 103 104105106 104105106 11 7

Page 84 - ENTRY GATE LOCK INSTALLATION

4-22 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 4 PLATFORM 119 4846325 1 Rail 120 2080040 4 Fastener, Huck 121 3520176 1 Plug 122 0962337 2 Bushing, Hinge 123 3422866 2 Pin, Hinge 124 3760448 2 Ring, Snap 125 3520072 2 Plug, Cap 126 4711800 2 Flatwasher 1/2” Narrow 127 4711600 2 Flatwasher 3/8” Narro...

Page 86 - BOTTOM

4-24 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 4 PLATFORM FIGURE 4-7. PLATFORM WITH SIDE ENTRY (15 DVSP) 410 9 8 12 3 TOP 2 BOTTOM 6 106107 113 124 11 111104 114 120109103119 108 1 7 122 117 116 117 121 101 118 115 5 123 203 210 206 206 210 209 207 207 126 129 127 128

Page 88 - BUMPERS INSTALLATION

4-26 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 4 PLATFORM 127 3300151 2 Acorn Nut 1/4”-20NC (S/N 6232 to Present) 128 0641422 2 Bolt 1/4”-20NC x 2 3/4” (S/N 6232 to Present) 129 4220225 2 Stop (S/N 6232 to Present) 0272825 Ref. BUMPERS INSTALLATION A 201 0100011 A/R Loctite #242 202 Not Used 203 064...

Page 96 - FIGURE 4-11. QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE BAR

4-34 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 4 PLATFORM FIGURE 4-11. QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE BAR

Page 97 - FIGURE 4-11. QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE BAR; PLATFORM ASSEMBLIES

3121137 15DVL 15DVSP 20DVL 20DVSP 4-35 SECTION 4 PLATFORM FIGURE 4-11. QUICK-CHANGE PLATFORM INSTALLATION WITH SLIDE BAR ITEM # PART NUMBER QTY. DESCRIPTION REV. 0274343 Ref. PLATFORM INSTALLATION - 26” x 49” (66cm x 126.5cm) A 1 0641408 8 Bolt, 1/4”-20NC x 1” 2 0860520 1 Box, Manual Storage 3 10603...

Page 100 - SECTION 5 CYLINDER

5-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 5 CYLINDER FIGURE 5-1. LIFT CYLINDER ASSEMBLY 1 2 3 4 5 6 8 9 1 5 1 7 2 0 1 6 10 11 12 13 51

Page 104 - SECTION 6 HYDRAULIC

6-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 6 HYDRAULIC FIGURE 6-1. HYDRAULIC DIAGRAM

Page 108 - SECTION 7 ELECTRICAL

7-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL SCHEMATIC

Page 110 - FIGURE 7-2. ELECTRICAL COMPONENTS INSTALLATION

7-4 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL COMPONENTS INSTALLATION PUMP/ MOTOR SECURITY LOCK GROUND CONTROL STATION BATTERIES FUSE ALARM HORN LEFTDRIVEMOTOR LEFTDRIVEMOTORHARNESSREVERSER RIGHTDRIVEMOTOR BEACONLIGHT (BASE) BEACON LIGHT(MAST) TRACTIONMODULE AUX 1...

Page 112 - FIGURE 7-2. ELECTRICAL COMPONENTS INSTALLATION

7-6 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL COMPONENTS INSTALLATION ITEM # PART NUMBER QTY. DESCRIPTION REV. 0271263 Ref. ELECTRICAL SYSTEM INSTALLATION E 1 Not Used 2 0100048 A/R Grease, Dialectric (Not Shown) (Prior to S/N 4660) 3 0100051 A/R Grease, Battery T...

Page 114 - OPTIONAL HARNESS ASSEMBLIES

7-8 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 7 ELECTRICAL 209H 7024302 1 Connector - 4 Position (15DVSP) (Clipper CL1M1102) 70001799 3 Pin, Male (Clipper CM16PC10MQ) 209I 4460424 1 Connector - 2 Position 4460227 2 Pin, Male 209J 7027739 1 Junction Box 7020093 4 Screw, Countersunk M3 x 25 210 Not Av...

Page 115 - TOOLS

3121137 15DVL 15DVSP 20DVL 20DVSP 7-9 SECTION 7 ELECTRICAL 307C 1 Cover, Receptacle Options: 4060700 120V 4060092 240V 307D 4460023 1 Connector, Strain Relief 307E 1 Receptacle, Female Options: 4460346 120V 4460125 240V 307F 1 Plug, Male Options: 4460549 120V 4460205 240V 307G 4460566 1 Connector, 9...

Page 118 - SECTION 8 DECALS

8-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 8 DECALS FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC)

Page 124 - Brazilian Language

8-8 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 8 DECALS Ref. 20DVL: 0271285 Ref. Brazilian Language C 0271287 Ref. Chinese Language C 0271276 Ref. CSA Language C 0271286 Ref. Japanese Language (Prior to S/N 6121) C 0273850 Ref. Japanese Language (S/N 6121 to Present) A 0271284 Ref. Latin American Lan...

Page 127 - Part Number; STANDARD PARTS

3121137 15DVL 15DVSP 20DVL 20DVSP 9-1 SECTION 9 RECOMMENDED SERVICE PARTS STOCK DVL/DVSP SERIES The following list will service one machine (built to current production per date on the front cover) with emergency repairparts which can be installed in the field. Parts from the list should be replaced...

Page 129 - SECTION 10 SPECIAL OPTIONS

3121137 15DVL 15DVSP 20DVL 20DVSP 10-1 SECTION 10 SPECIAL OPTIONS Note: This list is to accomodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER QTY. DESCRIPTION REV...

Page 130 - SPECIAL OPTIONS

10-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 10 SPECIAL OPTIONS Ref. Tools 0100048 A/R Compound, Silicone (Use on Connectors/Receptacles) 7002821 1 Crimper (For Wire to Pin/Socket Connections) Not Used 7002828 1 Stripper, Wire 7024361 1 Calibration Tool 7002842 1 Brake Crimp Removal Tool (Not Show...

Page 131 - SECTION 11 PART NUMBER INDEX

Page Part Number Page Part Number Page Part Number Page Part Number 3121137 15DVL 15DVSP 20DVL 20DVSP 11-1 SECTION 11 PART NUMBER INDEX 0100011 1-3, 1-7, 1-8, 1-11, 1-15, 1-25, 2-3, 2-17, 2-23, 3-3, 4-10, 4-13, 4-17, 4-21, 4-25, 4-26, 4-29, 4-31, 4-35 0100019 ..... 1-11, 1-25, 4-180100035 1-4, 1-8, ...

Page 132 - PART NUMBER INDEX

Page Part Number Page Part Number Page Part Number Page Part Number 11-2 15DVL 15DVSP 20DVL 20DVSP 3121137 SECTION 11 PART NUMBER INDEX 0861519 ....................... 2-110861693 .............. 2-17, 2-230861767 ....................... 2-230902047 ......................... 3-30902297 .................

Page 138 - JLG Worldwide Locations

Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda.Rua Eng. Carlo...