JLG 100Hx 110Hx 100HX+10 Parts Manual (3120801) - PDF DOWNLOAD

Illustrated Parts Manual

Models 100HX 110HX 100HX+10 3120801 July 29, 2011

REVISION LOG January 1991 - Original Issue Of Manual February 1997 - Revised (New Format) September 1997 - Change 1 October 29, 1999 - Revised (Manual edited to 0010375 Revision 41) March 1, 2000 - Revised (Manual edited to 0010375 Revision 41) October 1, 2000 - Revised (Manual edited to 0010375 Revision 42) February 12, 2004 - Revised January 2, 2008 - Revised July 29, 2011 - Revised

3120801

A

REVISION LOG

B

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TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8

STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . .1-2 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 DRIVE BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 DRIVE BRAKE ASSEMBLY - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 DRIVE MOTOR ASSEMBLY - VICKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20 VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED). . . . . . . . . . . . . . . . .1-22 TOW PACKAGE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27

TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 CONTROL VALVES AND TILT INDICATOR INSTALLATIONS . . . . . . . . . . . . . . . . . . . .2-10 CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) . . . . . . . . . .2-14 CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) . . . . . . .2-18 CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989) . . .2-30 ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT) . . . . . . . . .2-32 CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 SWING DRIVE, BEARING AND LOCK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2-36 SWING MOTOR ASSEMBLY - NICHOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992). . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 SWING BRAKE ASSEMBLY (APRIL 1992 to PRESENT). . . . . . . . . . . . . . . . . . . . . . . . .2-44 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . .2-50 DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54 DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES . .2-68 GENERATOR INSTALLATIONS - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . .2-70 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72 MAIN PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86 HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE) . . . .2-88 HOODS AND ALARM INSTALLATION (MACHINES WITH 4620078 TURNTABLE) . . . .2-92

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-1 3-2

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BOOM ASSEMBLY COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 2 OF 2). . . . . . . . . . . . . .3-3 CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

i

TABLE OF CONTENTS

FIGURE NO. 3-3 3-4 3-5 3-6 3-7

TITLE

PAGE NO.

EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 EXTEND-A-REACH INSTALLATIONS (MAY 1992 TO PRESENT) (100HX+10 & 110HXER ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION . . . . . . . . . . . . . 3-24 BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN SPECS BUILT PRIOR TO S/N 28224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

SECTION 4 - PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8

PLATFORM COMPONENTS INSTALLATION - 100HX/110HX . . . . . . . . . . . . . . . . . . . . 4-2 PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991) . . . . . . . . . . . . . . . . . . . . 4-16 CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) . . . . . . . . . . . . . . . . . 4-20 CONTROLLER ASSEMBLIES - OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . 4-28

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14

AXLE EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 AXLE LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992) . . . . . . 5-6 LEVEL CYLINDER ASSEMBLY (100HX & 110HX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992) 5-10 LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER) . . . . . . . . . . . . . . . . . . . . . . . 5-12 LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO MAY 1992) . . . . . . . . . . . . . . . . . . . . 5-14 LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT) . . . . . . . . . . . . . . . . . 5-16 LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE). . . . . . . . . . . . . . . . . . . . 5-18 LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (100HX+10 & 110HXER ONLY) . . . 5-20 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 TELESCOPE CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 CYLINDER BELLOWS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SECTION 6 - HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11

ii

HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HYDRAULIC DIAGRAM - DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER) . . . . . . . . . . 6-12 HYDRAULIC DIAGRAM - LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 HYDRAULIC DIAGRAM - LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 HYDRAULIC DIAGRAM - PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 HYDRAULIC DIAGRAM - ROTATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 HYDRAULIC DIAGRAM - SEQUENCE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 HYDRAULIC DIAGRAM - SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

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TABLE OF CONTENTS FIGURE NO. 6-12

TITLE

PAGE NO.

HYDRAULIC DIAGRAM - TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2 7-3

ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 WIRING SCHEMATIC - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 WIRING SCHEMATIC - STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1 8-2

DECALS INSTALLATION - BROWN DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 DECALS INSTALLATION - BLACK DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

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TABLE OF CONTENTS

FIGURE NO.

iv

TITLE

PAGE NO.

3120801

SECTION 1 FRAME

S E C T I O N

TABLE OF CONTENTS FIGURE

1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8

3120801

DESCRIPTION

STEERING AND AXLE/WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE ASSEMBLY - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE MOTOR ASSEMBLY - VICKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) . . . . . . . . . . . . . . . . . . . . . .

TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 1-6 1-10 1-12 1-16 1-20 1-21 1-28

1 F R A M E

1-1

S E C T I O N

SECTION 1 FRAME FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS

1 F R A M E

1-2

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SECTION 1 FRAME FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS FIG & ITEM #

PART NUMBER

1281982 0239122

STEERING INSTALLATION Standard Standard (Machines with Tow Bar Package) (S/N 47309 to Present)

Ref. Ref.

F 5

Ref.

1

1681934

2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

4843050 3420620 3421553 4740314 3960243 3300007 0630078 2780159 1120347 0721003 4761000 4740347 3323803 3324203 0440190 0440191 3451012 3421524 3312602 4740111 2160002 0642644 0560605 3323002 0641507 4761500 3532561 4130206 4130370 0960821 3421330 3422635 See Note

33

3120801

REV.

Ref.

1

30 31 32

QTY.

FRAME WELDMENT

0259555

28A 29

DESCRIPTION

2360280

3420158 4712600 4130205 0960821 0100011

Steer Cylinder Assembly (See Section 5 for Breakdown) Tie-Rod Assembly Pin, Quick Release Kingpin Washer, Thrust Seal, Hub Nut, Wheel Stud, Wheel Hub Assembly (Includes Item 7) Cap, Hub Bolt #10-24NC x 3/8” Lockwasher #10 Washer, Hardened Nut, Slotted 1 3/4”-12NF Nut, Slotted 2"-12NF Cup, Bearing Cone, Bearing Pin, Cotter 5/16” x 3" Pin, Steer Cylinder Nut, Jam 1"- 8NC Washer, Thrust Fitting, Grease Bolt 1"-8NCx 5 1/2” Block Nut, Jam 1 1/4” - 12 NF Bolt 5/16”-18NC x 7/8” Lockwasher 5/16” Plate, Retainer Spindle (Left Side) Options: Standard Standard (Machines With Tow Bar Package) Bushing, Bronze Pin, Clevis (Prior to S/N 33256) Pin, Clevis (S/N 33256 to Present) 3421330 Pin (Prior to S/N 33256) (Note Recommend using 3422635 in place of original 3421330) Hairpin Flatwasher 1" Spindle (Right Side) Bushing, Bronze Loctite #242 (Not Shown)

S E C T I O N 1

1 1 1 2 2 2 24 24 2 2 8 8 2 2 2 4 4 4 1 2 5 3 2 2 2 2 2 1 1

F R A M E

2 1 1

1 1 1 2 A/R

1-3

S E C T I O N

SECTION 1 FRAME FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM #

PART NUMBER

34 35 36 37

3760170 1260017 2160001 2160003 0239089

1 F R A M E

1-4

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121

4843031 4843030 3972218 3312202 0361632 4070576 4070577 0642008 4712000 3311505 4300032 4761400 4843032 3760106 1260017 3421546 3421565 3760170 3340527 0560674 0560673

122

1681964

123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142

3760140 3421549 0560675 0641406 4751400 0100011 0361631 4070574 4070575 3421548 3532592 0641403 3532590 3532591 3300151 4843028 4843023 0641505 4761500 4070670

DESCRIPTION Ring, Quick Release Chain Fitting, Grease - 90° Fitting, Grease - 45° AXLES INSTALLATION Inner Axle Weldment (Front Right Side) Inner Axle Weldment (Front Left Side) Setscrew 3/4”-10NC x 2 1/4” Nut, Jam 3/4”-10NC Bar Shim 1/32” Shim 1/16” Bolt 5/8”-11NC x 1" Flatwasher 5/8” Locknut 5/16”-18NC Stud (Welded on Part) Lockwasher 1/4” Bushing Weldment D-Ring Chain #3 Pin, Axle Lock Snap-Pin Ring, Quick Release Wear Pad Block, Axle Shim Block, Axle Shim Axle Extension Cylinder Assembly Options (See Section 5 for Breakdown) Ring, Retaining Pin, Attaching (Front Axle Cylinder) Block, Axle Shim Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Loctite #242 (Not Shown) Bar, Wear Shim 1/16” Shim 1/32” Pin, Attaching (Rear Axle Cylinder) Plate, Cover Bolt 1/4”-20NC x 5/8” Plate, Cover Plate, Cover Nut, Acorn Inner Axle Weldment (Rear Right Side) Inner Axle Weldment (Rear Left Side) Bolt 5/16”-18NC x 5/8” Lockwasher 5/16” Shim 1/8”

QTY.

REV.

2 8in/20cm 2 1 Ref.

9

1 1 16 16 2 2 2 8 8 12 4 8 4 4 64in/1.6m 4 4 4 4 8 2 2 8 2 2 8 12 A/R 2 2 2 2 1 4 2 2 4 1 1 16 16 A/R

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SECTION 1 FRAME FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM #

PART NUMBER

143 144

4070672 4070674 0239152

201 202

2780155 0920072 0920084 0920110 0920119

203 Use 1001096405 1001096405 204 205 206 207 208 209 210

4300092 4751800 4761800 3311801 0642216 4762200 3300007

DESCRIPTION Shim 1/32” Shim 1/16” WHEEL DRIVE INSTALLATION Hub Assembly (See Figure 1-2 for Breakdown) Brake Assembly Options: Prior to March 1992 (See Figure 1-3 for Breakdown) March 1992 to S/N 33476 (See Figure 1-4 for Breakdown) S/N 33476 to Present (See Figure 1-4 for Breakdown) Optional Replacement (Note: Can be used as suitable replacement. Requires P/N 4300097 5-1/8” long Stud) (was p/n 0920117) Note: Repair Kit p/n 7018612 & Mounting Face Gasket p/n 7000731 are only Service Parts available for Brake p/ns 0920119 & 0920117.

Motor Assembly Options: Original Equipment (was p/n 3160132 - See Figure 1-5 for Breakdown) Service Replacement Kit (See Figure 1-6 for Breakdown) Stud 1/2”-13NC x 5 1/2” Flatwasher 1/2” Lockwasher 1/2” Nut 1/2”-13NC Bolt 3/4”-10NC x 2" Lockwasher 3/4” Narrow Lugnut 3/4”-16NF TIRE AND WHEEL INSTALLATIONS Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/ or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

301

0239344 0253929 0259456 0259442

3120801

Tire and Wheel Assembly - 15 x 22.5 Foam-Filled (Prior to April 1993) Tire and Wheel Assembly - 385/65R22.5 Foam-Filled (April 1993 to S/N 44997) Tire and Wheel Assembly - 385/65R22.5 Foam-Filled L.H. (S/N 44997 to Present) Tire and Wheel Assembly - 385/65R22.5 Foam-Filled R.H. (S/N 44997 to Present)

QTY.

REV.

A/R A/R Ref.

3/B

2 2

S E C T I O N 1 F R A M E

2

4 4 4 4 24 24 24 Ref.

A/R A/R 2 2

1-5

S E C T I O N

SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY

1 F R A M E

1-6

3120801

SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY FIG & ITEM #

PART NUMBER 2780155

1 2 3

7001974 7001975 7001976

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

7001965 7001966 7001928 7000243 7001967 Kit 7001968 Kit 7000231 7000220 7001963 Kit 7001972 7001973 7001971 7001970 7000285 7001919 7007657

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

3120801

7001910 7001955 7001959 7001956 7001962 7001961 7017003 7001957 7001958 7007698 7007699 Kit 7001948 7001947 7001949 7001950 7001951 7001928 7001952 7000265 7001977 7000284 7000282

DESCRIPTION DRIVE HUB ASSEMBLY Bolt, Hex Head Bolt, Hex Head Shoulder Lockwasher —————————— Cover Assembly Cover Plug, Pipe Plug, Pipe Cap, Cover O-Ring Rod, Disconnect O-Ring Cap, Disconnect Bolt Gear, Ring O-Ring Thrustwasher Bearing, Thrust Gear, Input (Sun Gear) Spacer, Thrust Ring, Retaining Shaft, Input Gear, Internal —————————— Carrier Assembly Carrier Shaft, Planet Pin, Roll Ring, Retaining Spacer Gear, Cluster Cup, Bearing Cone, Bearing Hub and Spindle Assembly Spindle Seal Cup, Bearing Cone, Bearing Shim, Bearing Ring, Retaining Hub Plug, Pipe Plug, Magnetic Stud Ring, Keeper Ring, Retaining Washer

QTY.

REV.

Ref. 16 4 20 1 1 1 1 1 1 1 1 1 4 1 2 4 2 1 1 1 1 1

S E C T I O N 1 F R A M E

1 1 3 3 3 3 3 6 6 1 1 1 2 2 1 1 1 2 1 12 1 1 2

1-7

S E C T I O N

SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER

43 44 45

7000283 Not Used 7000290 2900560

DESCRIPTION

QTY.

Spring

1

Coupling, Input —————————— Seal Kit (Includes Items 8, 10, 14 and 31)

1

REV.

1 F R A M E

1-8

3120801

SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 1 F R A M E

3120801

1-9

S E C T I O N

SECTION 1 FRAME FIGURE 1-3. DRIVE BRAKE ASSEMBLY - AUSCO

1 F R A M E

1-10

3120801

SECTION 1 FRAME FIGURE 1-3. DRIVE BRAKE ASSEMBLY - AUSCO FIG & ITEM #

PART NUMBER 0920072

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

7003047 Kit 7003049 Kit 7003051 7003052 7003070 7000717 7003054 7003006 7003055 7003056 7003057 Kit Kit Kit Kit 7000760 7000796 7003071 7003007 7003059 7000728 Kit 2900662 7003069

3120801

DESCRIPTION DRIVE BRAKE ASSEMBLY - AUSCO Housing Gasket Bearing Seal, Oil Retainer, Spring Spring, Compression Shaft, Splined Pin, Torque Disc, Primary Spring, Separator Disc, Rotating Disc, Stationary Piston Ring, Backup O-Ring Ring, Backup O-Ring Bearing Screw, Bleeder Plate, Power Screw Valve, Pressure Plug Gasket —————————— Seal Kit (Includes Items 2,4,14,15,16, 17 and 24) Gasket Kit (Includes Item 24)

QTY.

REV.

Ref.

D

1 1 1 1 1 8 1 2 1 6 3 3 1 1 1 1 1 1 1 1 4 1 1 2

S E C T I O N 1 F R A M E

1 1

1-11

S E C T I O N

SECTION 1 FRAME FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO

1 F R A M E

1-12

3120801

SECTION 1 FRAME FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO FIG & ITEM #

PART NUMBER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 and 27 28 29

Kit Kit 7007977 Not Used Not Used Not Used Not Used Not Used Not Used Not Used Kit Not Used 7007986 Not Used 7011716 Not Used 7007987 Kit Kit Kit Kit Kit Kit Not Used 7007924 Not Used Kit 7007933 2900766 2900768

0920084 0920110 51 52

7011712 7007979 7007980 Not Required

53 Not Required 7007970 7018602 54 7011713 7018605

3120801

DESCRIPTION Seal, Oil Bearing Ring, Retaining

QTY.

REV.

1 1 1

S E C T I O N 1

Seal, Case

1

Cover

1

Ring, Retainer

1

Pin, Dowel Ring, Back-up O-Ring Ring, Back-up O-Ring Rotor Stator

2 1 1 1 1 2 2

Plug, Pipe

1

O-Ring Gasket —————————— Seal Kit (Includes Items 1,11,18,19,20,21,28 and 29) Bearing Kit (Includes Items 1,2,11,28 and 29)

2 2

DRIVE BRAKE ASSY - MICO (VARIABLE PARTS) Prior To S/N 33476 S/N 33476 To Present Shaft Spring Options: Inner Spring - Prior To S/N 33476 Outer Spring - Prior To S/N 33476 S/N 33476 To Present Spring Options: Prior To S/N 33476 Spring (Red) - S/N 33476 To Present Spring (Blue) - S/N 33476 To Present Housing Options: Prior To S/N 33476 S/N 33476 To Present

F R A M E

1 1

Ref. Ref.

A B

1 A/R 6 6 0 A/R 0 6 3 1

1-13

S E C T I O N

SECTION 1 FRAME FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO (CONTINUED) FIG & ITEM #

PART NUMBER

55

7007914 7018609

Bolt, Washer Head Options: Prior To S/N 33476 S/N 33476 To Present Guide, Spring Options: Prior To S/N 33476 S/N 33476 To Present Piston Options: Prior To S/N 33476 S/N 33476 To Present Plate, Return/Separator Assembly Options: Prior To S/N 33476 Components: Plate, Return Separator Assembly Pin Separator S/N 33476 To Present Components: Plate, Return Plug Options: Bleeder Screw - Prior To S/N 33476 Plug - S/N 33476 To Present

2900767 7018608

Lining Kit Options (Includes Items 58, 11, 22, 23, 28 and 29): Prior To S/N 33476 S/N 33476 To Present

7007985 7018607 56 7011717 7018606 57

1

7007923 7018603 58

F R A M E

7007923 Kit 7011715 7011714 7007983 7018603 Kit 59

1-14

DESCRIPTION

QTY.

REV.

4

1

1

1 1 2 4 2 1 1

1

3120801

SECTION 1 FRAME FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 1 F R A M E

3120801

1-15

S E C T I O N

SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS

1 F R A M E

1-16

3120801

SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS FIG & ITEM #

PART NUMBER 3160132

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

3120801

7006766 7006767 7006768 7006769 7006774 7006776 Kit 7006786 7006787 7006788 7006789 7006721 7006796 7006791 7006792 Kit 7006794 7006795 7006719 7006797 7006798 7006703 Kit 7009300 7009301 Kit Kit Kit 7009305 7009306 7006706 7009307 7009308 7006717 7006716 7006715 7006714 7006713 7006712 7006711 7006710 7006709 7009309 7006707 7009310 7006704

DESCRIPTION DRIVE MOTOR ASSEMBLY - VICKERS Yoke Roll Pin Spherical Seat Spring Seat Yoke Spring Yoke Stop Gasket Housing Washer Screw Screw Shim (Included with Item 18) Retaining Ring Shaft Bearing Pintle Bearing O-Ring Shim Kit (Includes Item 12) Cover Bearing Piston Piston Rod Plug O-Ring Screw Control Block Gasket O-Ring Back-up Ring Retaining Ring Valve Block Pin Pin Shaft Piston and Shoes Shoe Plate Spherical Washer Pin, Retainer Pin Cylinder, Block Spring Washer Spring Spring Washer Retaining Ring Bearing Spacer Kit Wafer Plate Bearing S/A

QTY.

REV.

Ref.

B

1 1 1 1 1 1 1 1 6 6 4 1 1 1 2 2 2 1 2 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 9 1 1 1 3 1 1 1 1 1 1 1 1

S E C T I O N 1 F R A M E

1-17

S E C T I O N

SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED) FIG & ITEM #

PART NUMBER 2900659

DESCRIPTION —————————— Seal Kit (Includes 7,14,17,24,27,28 and 29)

QTY.

REV.

1

1 F R A M E

1-18

3120801

SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 1 F R A M E

3120801

1-19

S E C T I O N

SECTION 1 FRAME FIGURE 1-6. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS 27

28 24

29

25

39

26

37 36

5 23

1

35

6

2

21

F R A M E

8 20

5

22

14 17 15 16 9 11 10

13 12

4

7

1

31

31 32

1 32 33 34 30

18

38 19

3 40 41 3

100

1-20

3120801

SECTION 1 FRAME FIGURE 1-6. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS FIG & ITEM #

PART NUMBER 1001096405

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 100

201 202

3120801

1001096406 7022302 7007446 7007438 70000794 Not Available Use Item 100 7027740 7024862 Use Item 7 70000856 7021275 7024865 70000857 7022311 7024867 7024868 7022314 7023910 7007439 70000795 7022368 7021249 7022321 7022322 7007420 7021256 7007419 7007418 Not Available Not Available 7007420 7021256 7022321 7022322 7022324 7022325 7024871 7007437 7022326 7007459 7022371 7022328

70001098 70001099

DESCRIPTION DRIVE MOTOR ASSEMBLY KIT - SAUER-DANFOSS Drive Motor Assembly - Sauer-Danfoss Bearing, Journal Pin Ring, Retaining Swashplate Pin Gasket Cylinder Block Kit (Includes Items 9-17) Plate, Valve Block, Cylinder Guide, Slipper Retainer Pin, Slipper Hold Down Piston Assembly Retainer, Slipper Ring, Retaining Spring Washer Retainer, Spring Shaft Ring, Retaining Cap, End - Axial Screw Bearing, Needle Plug (Includes Item 24) O-Ring Plug (Includes Item 26) O-Ring Plug (Includes Item 28) O-Ring Seat, Spring Housing Plug (Items Item 32) O-Ring Plug (Items Item 34) O-Ring O-Ring Ring, Seal Piston, Servo Bearing Spring Seal, Lip Washer, Support Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40) Adapter Options: Adapter 12x16 (Not Shown) Adapter 8x10 (Not Shown)

QTY.

REV.

Ref.

2

Ref. 2 1 2 1 2 1 1 1 1 1 3 9 1 1 1 1 1 1 1 1 5 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1

A

S E C T I O N 1 F R A M E

Ref. 1 1

1-21

S E C T I O N

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED)

1 F R A M E

1-22

3120801

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) FIG & ITEM #

PART NUMBER 0239072

1 2 3 4 5 to 6 7 8

4640039 7006851 0641626 4751600 4761600 3311601 Not Used 2980089 4751400

0256611

51 51A 51B 51C 51D 52 53 54 55

4640986 7012995 7012518 7000645 7017409 7012518 7011336 2900770 0641506 4751500 0100011 3539843 0239046

101

102

103 104 105 106 107 108

3120801

4640451 7010630 7011317 4640260 Not Available 7009379 7007321 7007323 2220061 2180134 0641626 4761600 3311601 4640123 7012518 7000558 7004368 7006075

DESCRIPTION SELECTOR VALVE INSTALLATION (USED WITHOUT AXLE JACK OR WITH SINGLE AXLE JACK)

QTY.

REV.

Ref.

B

Valve, Selector O-Ring (Valve Seals) Bolt 3/8”-16NC x 3 1/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC

1 2 2 2 2 2

Lever Flatwasher 1/4"

1 6

SELECTOR VALVE INSTALLATION (USED WITH DUAL JACKS) Valve, Selector Cartridge Less Coil Seal Kit - 7012995 Cartridge (1 Per Cartridge) Coil Cartridge, Directional Seal Kit - 7017409 Cartridge (1 Per Cartridge) Cartridge (Sun) Seal Kit - 7011336 Cartridge (1 Per Cartridge) Bolt 5/16"-18NC x 3/4" Flatwasher 5/16" Loctite (Not Shown) Plate, Mounting VALVES INSTALLATION Valve, Counterbalance Cartridge Seal Kit - 7010630 Cartridge Valve, Flow Divider Cartridge (Vickers/Modular Controls Version) Seal Kit (Vickers/Modular Controls Version) Cartridge (Fluid Controls Version) Seal Kit (Fluid Controls Version) Fitting, Adapter Fitting, Straight Bolt 3/8"-16NC x 3 1/4" Lockwasher 3/8" Nut 3/8"-16NC Valve, 2 Speed Seal Kit (Hydraforce Version) Seal Kit (FPS Version) Coil (Hydraforce Version) Coil (FPS Version)

Ref.

1

2

1 2 2 2 2 2 2 2 2 2 A/R 1 Ref.

S E C T I O N

5

1 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1

1-23

F R A M E

S E C T I O N

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) (CONTINUED) FIG & ITEM #

PART NUMBER

109 110 111

0641518 4761500 3311501 0250993

201 202 203 204 205 206 207 208 209 210

1 F R A M E

211 to 215 216 217

Not Used 3534395 4360277 4360236 3900168 4920140 4360237 4360278 4460049 0860037 3500812 4460023 3311401 4761400 Not Used 1100049 4564974 0239126

301 302 303 304 305 306

4060681 4060682 Not Used 4761400 3300151 0100011

0256602

401 402

403 404 405

4843122 1681991 1683596 3421584 3450508 0641809 0641844

406 4761800 3311805

1-24

DESCRIPTION Bolt 5/16"-18NC x 2 1/4" Lockwasher 5/16" Nut 5/16"-18NC

QTY. 2 2 2

AXLE LIMIT SWITCHES INSTALLATION

Ref.

Plate, Switch Mounting Switch, Limit Head, Switch Actuator Bolt, Drilled Head #10-24NC x 1 3/4" Lockwire Arm and Roller Arm and Roller Connector, Strain Relief Box, Electrical Cover, Electrical Box Connector, Strain Relief Nut 1/4"-20NC Lockwasher 1/4"

4 4 4 8 4 2 2 4 1 1 5 2 2

Cam Tube, Cable Carrier

4 2

FRAME SHIELDS INSTALLATION Shield (Front) Shield (Rear) Lockwasher 1/4" Nut, Acorn 1/4"-20NC Loctite #242 (Not Shown) AXLE LIFT CYLINDER INSTALLATION (WITH DUAL AXLE JACK) Bracket Weldment Axle Lift Cylinder Assembly Options: Prior to S/N 34133 (See Section 5 for Breakdown) S/N 34133 to Present (See Section 5 for Breakdown) Pin Pin, Cotter Bolt Options: Bolt 1/2"-13NC x 1 1/8" (Prior to S/N 34133) Bolt 1/2"-13NC x 5 1/8" (S/N 34133 to Present) Hardware Options: Lockwasher 1/2" (Prior to S/N 34133) Locknut 1/2"-13NC (S/N 34133 to Present)

REV.

Ref.

3

C

1 1 8 8 A/R

Ref.

6

2 2

2 4 4

4

3120801

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) (CONTINUED) FIG & ITEM #

PART NUMBER

407

408 409 410 411 to 417 418 418A 418B 418C 418D 418E 419 419A 419B 420 421 422 423 424 425 426 427 428 429 430

3532839 3340831 Use 4713400 0100011 3539843 Not used 4640987 7012995 7012518 7000645 7017408 7012967 7012539 7012912 7012998 4640967 7012995 7012518 7000645 0641414 4711400 3311405 0641506 4751500 3539631 4360314 0641409 4761400 3311401 1703083

0239291

501 502

4843122 1681991

503 504 505 506 507 508 509 510

3421584 3450508 0641809 4761800 3532839 4740243 0100011 4640039 7006851 0641632 4761600 3311601

511 512 513

3120801

DESCRIPTION Options: Plate, Base (Prior to S/N 34133) Weldment, Jack Pad (S/N 34133 to Present) Washer, Spacer (Was P/N 4740243) Loctite #242 (Not Shown) (Prior to S/N 34133) Plate, Valve Mounting Valve, Select Cartridge Less Coil Seal Kit (1 Per Assembly) Coil (1 Per Assembly) Cartridge Less Coil Seal Kit (1 Per Assembly) Coil (1 Per Assembly) Cartridge, Relief Seal Kit (1 Per Assembly) Valve, 3 Way Cartridge Less Coil Seal Kit (1 Per Assembly) Coil (1 Per Assembly) Bolt 1/4"-20NC x 1 3/4" Flatwasher 1/4" Narrow Locknut 1/4"-20NC Bolt 5/16"-18NC x 3/4" Flatwasher 5/16" Plate, Switch Mounting Switch, Toggle Bolt 1/4"-20NC x 1 1/8" Lockwasher 1/4" Nut 1/4"-20NC Decal AXLE LIFT CYLINDER INSTALLATION (WITH SINGLE AXLE JACK) Bracket Weldment Axle Lift Cylinder Assembly (See Section 5 for Breakdown) Pin Pin, Cotter Bolt 1/2"-13NC x 1 1/8" Lockwasher 1/2" Plate, Base Washer, Spacer Loctite #242 (Not Shown) Valve, Control O-Ring (Valve Seals) Bolt 3/8"-16NC x 4" Lockwasher 3/8" Nut 3/8"-16NC

QTY.

REV.

2

4 A/R 1

1

1 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 2 2 2 4 4 4 4 2

Ref.

S E C T I O N

F R A M E

9

1 1 1 2 4 4 1 2 A/R 1 2 2 2 2

1-25

S E C T I O N

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) (CONTINUED) FIG & ITEM #

PART NUMBER

514 515

3252453 2980089 4751400 4565166

516

DESCRIPTION Nameplate Lever Flatwasher 1/4" Tube, Spacer

QTY.

REV.

1 1 6 2

1 F R A M E

1-26

3120801

SECTION 1 FRAME FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 1 F R A M E

3120801

1-27

S E C T I O N

SECTION 1 FRAME FIGURE 1-8. TOW PACKAGE INSTALLATIONS

1 F R A M E

1-28

3120801

SECTION 1 FRAME FIGURE 1-8. TOW PACKAGE INSTALLATIONS FIG & ITEM #

PART NUMBER 0252787

1 2 3 4 5 6 7 8 9 10

11 12 13

14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32

101 102 103

3120801

0252788 3536023 3536028 3536024 3536025 3536026 3536027 0251221 Not Used 2620022 2620043 0630439 4712600 3312601 3312602 3420860 2880410 4753000 3323002 0961668 0561022 4841055 3420292 1260017 3250840 1702305 3250872 3820001 4640261 0900479 0641507 4751500 4761500 3421892 0642644 0630439 3900146

DESCRIPTION TOW PACKAGE INSTALLATION

QTY.

REV.

Ref.

9/G

Steering Link Assembly (Includes Items 201-212) Lug, Steering - Plain (Prior to S/N 47309) Lug, Steering - Tapped (Prior to S/N 47309) Plate, Stop Gusset - Right Gusset - Left Lug - Center Tow Bar Assembly (Includes Items 101-103)

1 1 1 4 1 1 2 1

Hitch Options: Prior to S/N 31729 S/N 31729 to Present Bolt 1"- 8NC x 5" (Grade 8) Flatwasher 1" Nut 1"- 8NC Options: Prior to S/N 33983 S/N 33983 to Present Pin Key Flatwasher 1 1/4" Nut, Jam 1 1/4"- 12NF Bushing (Prior to S/N 47309) Block, Stop Mount, Tow Bar Pin, Quick Release Chain Decal - Caution Options: Prior to May 1994 May 1994 to Present Nameplate - Tow Select Rivet Valve, Select Bracket Bolt 5/16"-18NC x 7/8" Flatwasher 5/16" Lockwasher 5/16" Pin, Clevis Bolt 1"- 8NC x 5 1/2" (Prior to S/N 33983) Bolt 1"- 8NC x 5 (S/N 33983 to S/N 44508) Bolt 1"- 8NC x 5 (S/N 44508 to Present)

1

1 F R A M E

1 2 2

1 1 2 2 3 2 2 2 16in/41cm

1

1 4 1 1 2 2 2 1 1 1 1

0232121

TOW BAR ASSEMBLY

Ref.

3420447 4740036 3420372

Pin, Tow Flatwasher, Special Pin, Cotter

1 1 1

S E C T I O N

1-29

S E C T I O N

SECTION 1 FRAME FIGURE 1-8. TOW PACKAGE INSTALLATIONS (CONTINUED) FIG & ITEM #

PART NUMBER 0252788

201 202 203 204 205 206 207 208 209 210 211 212

1 F R A M E

1-30

4844277 4844276 Not Used Not Used 3323002 0560605 3420620 Not Used 4761400 1260017 3311401 2160003

DESCRIPTION STEERING LINK ASSEMBLY

QTY.

REV.

Ref.

A

Tube, Steer Link - Outer Tube, Steer Link - Inner

1 1

Nut, Jam 1 1/4"-12NF Block, Tie Rod Pin

2 2 1

Lockwasher 1/4" Chain Nut 1/4"-20NC Fitting, Grease - 45°

1 6in/15cm 1 2

3120801

SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27

3120801

DESCRIPTION

TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 Turntable Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 Turntable Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL VALVES AND TILT INDICATOR INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL VALVE ASSEMBLY - VICKERS (Prior to October 1994) . . . . . . . . . . . . . . . . . . . . .

CONTROL VALVE ASSEMBLY - VICKERS (October 1994 to Present) . . . . . . . . . . . . . . . . . . .

CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (Prior to June 1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (June 1995to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORY VALVE ASSEMBLY (Miller) (Machines Built Through 1989) . . . . . . . . . . . . . . . .

ACCESSORY VALVE ASSEMBLY (Machines Built 1990 to Present). . . . . . . . . . . . . . . . . . . . .

CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING DRIVE, BEARING AND LOCK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING MOTOR ASSEMBLY - Nichols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING BRAKE ASSEMBLY (Prior to April 1992). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING BRAKE ASSEMBLY (April 1992 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . . . . . . .

DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (Built Prior to February 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (Built February 1992 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES . . . . . . .

GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TANKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOODS AND ALARM INSTALLATION (Machines with 4620044 Turntable) . . . . . . . . . . . . . . .

HOODS AND ALARM INSTALLATION (Machines with 4620078 Turntable) . . . . . . . . . . . . . . .

PAGE

2-2 2-6 2-10 2-14 2-18

S E C T I O N 2 T U R N T A B L E

2-22 2-26 2-30 2-32 2-34 2-36 2-38 2-40 2-44 2-48 2-50 2-54 2-60 2-68 2-70 2-72 2-74 2-76 2-80 2-86 2-88 2-92

2-1

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES)

2 T U R N T A B L E

2-2

3120801

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) FIG & ITEM #

PART NUMBER 4620044

1 2

0252852 0960594 0961392

DESCRIPTION TURNTABLE Note: Used on machines built through May 1992 Boom Pivot Assembly Bushing, Self-Aligning (1 Per Assembly) Bushing, Bronze (Base Pivot) BOOM AND CYLINDERS INSTALLATION

101 102

1682034 1682587

103 104 105 106 107 108 109 110 111 112 113 to 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133

3120801

Not Used 3951814 3311802 2160002 0681812 4740171 0100019 1120368 Not Used 3421555 Not Used 4300038 4751500 4761500 3311501 Not Used Not Used 3421676 4712200 4762200 0682213 3421678 4740361 3900159 0641840 3311805 2160001 4740040

Boom Assembly (See Section 3 for Breakdown) Lift Cylinder Assembly (See Section 5 for Breakdown) (Prior to May 1992) Lift Cylinder Assembly (See Section 5 for Breakdown) (May 1992 to Present) Setscrew 1/2"-13NC x 1 3/4" Nut, Jam 1/2"-13NC Fitting, Grease Bolt 1/2"-13NC Washer, Special Hardened Loctite #271 (Not Shown) Cap, Boom Pivot

QTY.

REV.

1

2 2 2

S E C T I O N 2

Ref.

T U R N T A B L E

1 1 1

2 2 3 4 4 A/R 2

Pin, Boom Pivot

1

Stud (Welded on Part) Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC

1 1 1 1

Pin, Bottom Lift Cylinder Flatwasher 3/4" Lockwasher 3/4" Bolt 3/4"-10NC x 1 5/8" (Grade 8) Pin, Top Lift Cylinder Washer, Special Screw, Countersunk 1/2"-13NC x 3/4" Bolt 1/2"-13NC x 5" Locknut 1/2"-13NC Fitting, Grease - 90° Flatwasher, Special

1 2 2 2 1 2 4 1 1 1 2

2-3

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM #

PART NUMBER 0250612 0251019 0239863 0251018

2

151 1681978 1681580

T U R N T A B L E

152 3421586 0236548 153 Not Required 4740006 154 Not Required 0641608 155 Not Required 4761600 156 3421561 3420085 157 Not Required 3450610 0251007

201 202 203 204 205 206 207 208 209 210 211 212 213 214

4360277 4360236 4360278 0560984 3900168 4920140 4460052 1100048 1120372 0681812 4740171 Not Used 0641408 4761400 0100019

2-4

DESCRIPTION BOOM INSTALLATION (VARIABLE PARTS) 110HX Prior To Early 1990 110HX Early 1990 To May 1992 110HXER Prior To Early 1990 110HXER Early1990 To May 1992 Master Cylinder Assembly Options (See Section 5 for Breakdown): 110HX 110HXER Pin Options: 110HX 110HXER Flatwasher, Special Options: 110HX 110HXER Bolt 3/8"-16NC x 1" Options: 110HX 110HXER Lockwasher 3/8" Options: 110HX 110HXER Pin Options: 110HX 110HXER Pin, Cotter 3/16" x 2 1/2" Options: 110HX 110HXER HORIZONTAL CUTOUT LIMIT SWITCH INSTALLATION (RIGHT SIDE)

QTY.

REV.

Ref. Ref. Ref. Ref. Ref.

— D D C

1

1

A/R 0 1 1

3

1

2

Ref.

Switch, Limit Head, Actuator Roller and Arm Block, Switch Mounting Bolt, Socket Head #10-24NC Special Lockwire Connector, Strain Relief Cam Cap Bolt 1/2"-13NC x 1 1/2" (Grade 8) Washer, Special Hardened

1 1 1 1 2 1 1 1 1 2 2

Bolt 1/4"-20NC x 1" Lockwasher 1/4" —————————— Loctite #271

2 2

2/B

A/R

3120801

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM #

301 302 303 304 305 306 307 308 309 310 311 312 313 314

401 402 403 to 404 405 406 407 408 409 410 411 412 413 to 450 451

PART NUMBER

DESCRIPTION

QTY.

REV.

0251006

8 METER CUTOUT LIMIT SWITCH INSTALLATION (DUTCH AND GERMAN SPECS PRIOR TO S/N 28224) (LEFT SIDE)

Ref.

B

4360277 4360236 4360278 0560984 3900168 4920140 4460052 1100047 1120372 0681812 4740171 Not Used 0641408 4761400

Switch, Limit Head, Actuator Roller and Arm Block, Switch Mounting Bolt, Socket Head #10-24NC Special Lockwire Connector, Strain Relief Cam Cap Bolt 1/2"-13NC x 1 1/2" (Grade 8) Washer, Special Hardened

1 1 1 1 2 1 1 1 1 2 2 2 2

0100019

Bolt 1/4"-20NC x 1" Lockwasher 1/4" —————————— Loctite #271

A/R

0239843 0239844

LUBE LINES INSTALLATION 110HX & 100HX 110HXER

Ref. Ref. Ref.

2160002 2220001 Not Used 2750807 2200261 2750527 2220063 4300031 4761400 3311401 1320040 Not Used 2750528 2751032

452 2750529 2750528

3120801

Fitting, Grease Fitting

3 3

Hose Fitting, Nipple Hose Fitting Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Clamp, Insulated

1 2 2 3 1 1 1 1

Hose Options: 110HX & 100HX 110HXER Hose Options: 110HX & 100HX 110HXER

1

S E C T I O N 2 T U R N T A B L E

A 3

1

2-5

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES)

2 T U R N T A B L E

2-6

3120801

SECTION 2 TURNTABLE FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) FIG & ITEM #

1 2

PART NUMBER

DESCRIPTION

QTY.

4620078

TURNTABLE Note: Used on machines built May 1992 to Present.

1

0252852 0960594 0961392

0252921 0252923 0252916 0252919 0252855/0252857 0252934/0252930

101 102

1682630

103 104 105 106 107 108 109 110 111 112 113 to 116 117 118 119 120 121 to 122 123 124 125 126 127 128 129 130 131 132 133 134 to 150

Not Used 3952014 3312002 2160002 0681812 4740171 0100019 1120368 Not Used 3421555 Not Used 4300034 4751600 4761600 3311601 Not Used 3421676 4712200 4762200 0682213 3421678 4740361 3900159 0641840 3311805 2160001 4740040 Not Used

3120801

Boom Pivot Assembly Bushing, Self-Aligning (1 Per Assembly) Bushing, Bronze (Base Pivot) BOOM AND CYLINDERS INSTALLATIONS 100HX Standard Machine 100HX Machine with Chip Covers 110HX Standard Machine 110HX Machine with Chip Covers 110HXER & 110HX+10 Standard Machine 110HXER & 110HX+10 Machine withChip Covers Boom Assembly (See Section 3 for Breakdown) Lift Cylinder Assembly (See Section 5 for Breakdown) Setscrew 5/8"-11NC x 1 3/4" Nut, Jam 5/8"-11NC Fitting, Grease Bolt 1/2"-13NC Washer, Special Hardened Loctite #271 (Not Shown) Cap, Boom Pivot

REV.

2 2 2 Ref. Ref. Ref. Ref. Ref. Ref. Ref.

2 5 5 4 4 2/C 2/C

T U R N T A B L E

1 1

2 2 3 4 4 A/R 2

Pin, Boom Pivot

1

Stud (Welded on Part) Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC

1 1 1 1

Pin, Bottom Lift Cylinder Flatwasher 3/4" Lockwasher 3/4" Bolt 3/4"-10NC x 1 5/8" (Grade 8) Pin, Top Lift Cylinder Washer, Special Screw, Countersunk 1/2"-13NC x 3/4" Bolt 1/2"-13NC x 5" Locknut 1/2"-13NC Fitting, Grease - 90° Flatwasher, Special

1 2 2 2 1 2 4 1 1 1 2

S E C T I O N

2-7

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM #

PART NUMBER

151 1681978 1681580 152 3421586 0236548

2

153 Not Required 4740006

T U R N T A B L E

154 Not Required 0641608 155 Not Required 4761600 156 3422068 3420085 157 Not Required 3450610

201 202 203 204 205 206 207 208 209 210 211 212 213 214

Master Cylinder Assembly Options (See Section 5 for Breakdown): 100HX & 110HX 110HX+10 & 110HXER Pin Options: 100HX & 110HX 110HX+10 & 110HXER Flatwasher, Special Options: 100HX & 110HX 110HX+10 & 110HXER Bolt 3/8"-16NC x 1" Options: 100HX & 110HX 110HX+10 & 110HXER Lockwasher 3/8" Options: 100HX & 110HX 110HX+10 & 110HXER Pin Options: 100HX & 110HX 110HX+10 & 110HXER Pin, Cotter 3/16" x 2 1/2" Options: 100HX & 110HX 110HX+10 & 110HXER

QTY.

REV.

1

1

A/R 0 1 1

3

1

2

0251007

HORIZONTAL CUTOUT LIMIT SWITCH INSTALLATION (RIGHT SIDE)

Ref.

4360277 4360236 4360278 0560984 3900168 4920140 4460052 1100048 1120372 0681812 4740171 Not Used 0641408 4761400

Switch, Limit Head, Actuator Roller and Arm Block, Switch Mounting Bolt, Socket Head #10-24NC Special Lockwire Connector, Strain Relief Cam Cap Bolt 1/2"-13NC x 1 1/2" (Grade 8) Washer, Special Hardened

1 1 1 1 2 1 1 1 1 2 2

Bolt 1/4"-20NC x 1" Lockwasher 1/4" —————————— Loctite #271

2 2

0100019

2-8

DESCRIPTION

2

A/R

3120801

SECTION 2 TURNTABLE FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM #

301 302 303 304 305 306 307 308 309 310 311 312 313 314

401 402 403 to 404 405 406 407 408 409 410 411 412 413 to 450 451

PART NUMBER

DESCRIPTION

QTY.

0251006

8 METER CUTOUT LIMIT SWITCH INSTALLATION (DUTCH AND GERMAN SPECS PRIOR TO S/N 28224) (LEFT SIDE)

Ref.

4360277 4360236 4360278 0560984 3900168 4920140 4460052 1100047 1120372 0681812 4740171 Not Used 0641408 4761400

Switch, Limit Head, Actuator Roller and Arm Block, Switch Mounting Bolt, Socket Head #10-24NC Special Lockwire Connector, Strain Relief Cam Cap Bolt 1/2"-13NC x 1 1/2" (Grade 8) Washer, Special Hardened

1 1 1 1 2 1 1 1 1 2 2 2 2

0100019

Bolt 1/4"-20NC x 1" Lockwasher 1/4" —————————— Loctite #271

A/R

0239843 0239844

LUBE LINES INSTALLATION 110HX & 100HX 110HXER

Ref. Ref. Ref.

2160002 2220001 Not Used 2750807 2200261 2750527 2220063 4300031 4761400 3311401 1320040 Not Used 2750528 2751032

452 2750529 2750528

3120801

Fitting, Grease Fitting

3 3

Hose Fitting, Nipple Hose Fitting Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Clamp, Insulated

1 2 2 3 1 1 1 1

Hose Options: 110HX & 100HX 110HXER Hose Options: 110HX & 100HX 110HXER

1

REV.

S E C T I O N 2 T U R N T A B L E

A 3

1

2-9

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS

2 T U R N T A B L E

2-10

3120801

SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS FIG & ITEM #

PART NUMBER 0239913 0251093 0254061

1 4640524 4640914 2 2A

4640535

2B

4640580

2B

4640716

3

4640360 7009745 7004289 7003635 7004368 7012910 7010635 7009798

4 4640246 4640941 5 6 7 8 9 10 11

3120801

Not Used 0641708 4761700 4300033 4751400 4761400 3311401

DESCRIPTION

QTY.

REV.

CONTROL VALVES INSTALLATION 4620044 Turntable Machines Built Prior To May 1990 4620044 Turntable Machines Built May 1990 To May 1992 4620078 Turntable Machines

Ref. Ref.

E

Ref.

C

Ref.

6

Control Valve Assembly (Vickers) Options: Prior to October 1994 (See Figure 2-4 for Breakdown) October 1994 to Present (See Figure 2-5 for Breakdown) Accessory Valve Options: Accessory Valve Assembly (Machines Built Through 1989) (See Figure 2-8 for Breakdown) Note: 4640535 Accessory Valve is no longer available as a complete assembly. See Figure 2-8 for Individual parts.

Accessory Valve Assembly (Machines built 1990 to September 1991) (See Figure 2-9 for Breakdown) Note: 4640580 Accessory Valve is no longer available as a complete assembly. See Figure 2-9 for Individual parts.

Accessory Valve Assembly (Machines Built September 1991 to Present) (See Figure 2-9 for Breakdown) Note: Complete 4640716 Valves are available.

See Figure 2-9 for Individual parts.

Dump Valve Assembly Coil (Vickers/Modular Controls Version) Solenoid Cartridge Less Coil (Vickers/Modular Controls Version) Check Valve Cartridge (Vickers/Modular Controls Version) Coil (Hydraforce Version) Solenoid Cartridge Less Coil (1989 to Present) (Hydraforce Version) Solenoid Cartridge Less Coil (Prior to 1989) (Hydraforce Version) Check Valve Cartridge (Hydraforce Version) Control Valve Assembly (Bang-Bang) Options: Prior to June 1995 (See Figure 2-6 for Breakdown) June 1995 to Present (See Figure 2-7 for Breakdown) Bolt 7/16"-14NC x 1" Lockwasher 7/16" Stud (Welded on Part) Flatwasher 1/4" Lockwasher 1/4" Nut 1/4"-20NC

S E C T I O N 2

1

T U R N T A B L E

1

1

1

1 1 1 1 1 1 1 1 1

3 3 2 A/R A/R A/R

2-11

S E C T I O N 2 T U R N T A B L E

SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS (CONTINUED) FIG & ITEM #

PART NUMBER

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 to 50 51

0641526 4300038 4751500 3311501 0901399 4761500 0641616 4751600 4761600 3311601 0140001 0641418 4751600 1320041 0641408 4060808 Not Used 4300042 Not Used

4640513 7003640 7004289 2900503 7000645 7012910 2900756 7022390

4640543 7009745 7004368 4640543 7009745 7004368 52 Not Required 4640839 7012945

2-12

DESCRIPTION Bolt 5/16"-18NC x 3 1/4" Stud (Welded on Part) Flatwasher 5/16" Nut 5/16"-18NC Bracket Lockwasher 5/16" Bolt 3/8"-16NC x 2" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Horn Bolt 1/4"-20NC x 2 1/4" Flatwasher 3/8" Clamp Bolt 1/4"-20NC x 1" Flex-Guard Stud (Welded on Part) Dump Valve Assembly Options: 4620044 Turntable Machine Built Prior to May 1990 Components: Dump Valve Assembly Coil (Modular Controls Version) Cartridge Less Coil (Modular Controls Version) Seal Kit (Modular Controls Version) Coil (Hydraforce Version) Cartridge Less Coil (Hydraforce Version) Seal Kit (Hydraforce Version) Nut (Attachs Coil to Cartridge) 4620044 Turntable Machine Built May 1990 to May 1992 Components: Dump Valve Assembly Coil (Modular Controls Version) Coil (Hydraforce Version) 4620078 Turntable Machine Components: Dump Valve Assembly Coil (Modular Controls Version) Coil (Hydraforce Version) Relief Valve Assembly Options: 4620044 Turntable Machines 4620078 Turntable Machines Cartridge, Replacement

QTY.

REV.

2 5 9 11 1 9 4 4 4 4 1 2 3 1 1 7.5ft/2.3m A/R 1

1 A/R A/R A/R A/R A/R A/R 1

1 A/R A/R 1 A/R A/R 1

2

3120801

SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY. Ref.

0239155 0250618

EXTEND-A-REACH VALVE INSTALLATION (110HXER & 100HX+10 ONLY) Prior To December 1989 December 1989 To Present

101

4640519

102 103 104 105 106

4300038 4761500 3311501 4300070 4751500 0251088

201 202 203 204

3120801

4360280 2820022 4360171 4300106

Control Valve Assembly (See Figure 2-10 for Breakdown) Stud (Welded on Part) Lockwasher 5/16" Nut 5/16"-18NC Stud (Welded on Part) Flatwasher 5/16" TILT INDICATOR INSTALLATION Sensor, Level (3°) Tubing, Vinyl (Not Shown) Sensor, Level (5°) Stud, Grooved (Not Shown)

Ref. Ref.

REV.

— 3

S E C T I O N

1

2

2 4 6 2 6 Ref.

4

1 A/R 1 2

2-13

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994)

2 T U R N T A B L E

2-14

3120801

SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) FIG & ITEM #

PART NUMBER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

7006747 7006725 7006733 Kit Kit Kit 7009350 7006762 7009351 7006763 Use 7012325 Kit 7009316 7009315 7009319 Kit 7006744 7006726 Kit 7006728 7006729 7006730 7006731 7006745

39 40 41 42 43 44 45

3120801

7006746 Kit 7009323 Kit 7009324 7009325 7006757 Kit Kit 7006732 7006737 7009321 7009363 Not Required Kit 7006752 Kit Kit 7006773 7006756 7006771 Kit

DESCRIPTION Inlet Body Setscrew Plug O-Ring O-Ring O-Ring Working Section - Complete (Drive) (4 Section) Working Section - Complete (Lift) Working Section - Complete (Telescope) Working Section - Complete (Swing) Nut, Retaining (was p/n 7009317) O-Ring Core Tube (Includes O-Ring) Coil and Frame Pin O-Ring Spool Plug, Torque O-Ring Shim Kit Spring Poppet Ball Screw Cap, End (Not Sold Separately) Ball O-Ring Plug Gasket Spring Retainer Spool (Not Sold Separately) Seat Ring, Back-Up O-Ring Servo Stem Assembly Poppet Retainer (13/16"-2.1cm Length) (Design A) Retainer (1 3/16"-3cm Length) (Design B) Retainer (Design C) O-Ring Retainer Ring, Back-Up O-Ring Spring Poppet Plug, Torque O-Ring

QTY.

REV.

1 1 1 5 5 5 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 8 2 2 2 2 2 2 2 1 2 2 2 2 2 1 1

S E C T I O N 2 T U R N T A B L E

1 2 2 2 2 2 1 1

2-15

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) (CONTINUED) FIG & ITEM #

PART NUMBER

46

7006761 7006761 7006761 7009369 7009368 7006777 Not Required 7006780 7006778 Kit 7009329 7006782

47

2

48 49 50 51 52

T U R N T A B L E

7009330 7009395

2-16

DESCRIPTION

QTY.

Ball (Design A - All Sections Except Swing) Ball (Design A - Swing Section) Ball (Design B - All Sections) Poppet (Design C - All Sections) Spring (Design C - All Sections) Pin, Solid (Design A - Swing Section Only) Pin, Solid (Design B and Design C) Cover End Plug, Torque O-Ring Rod, Tie Nut

2 1 2 2 1 1

Seal Kit (Includes Items 4, 5, 6, 12, 16, 27, 34, 35, 38, 40,41,45, 50 and Servo Stem O-Rings) Seal Kit - Valve Face (Includes Items 4,5 and 6)

4

REV.

1 1 1 3 6

5

3120801

SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-17

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT)

2 T U R N T A B L E

2-18

3120801

SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM #

PART NUMBER 4640914

1 2 3 4 5 6

7006724 7006733 Kit Kit Kit 7006725

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138

Kit 7012319 Kit Kit Kit 7012322 Kit Kit 7006730 7012325 7012339 7009319 7012326 7012327 7006745 7006731 7006748 7006746 7009323 7012330 7012329 7012328 7009324 7009320 7006737 7006757 Not Used 7006773 Kit Kit 7009398 Kit Kit 7012333 Kit Kit Kit Kit Not Serviced

3120801

DESCRIPTION VICKERS VALVE ASSEMBLY - 4 SECTION Inlet Section Inlet Body Plug O-Ring O-Ring O-Ring Setscrew Working Sections (Standard Parts) Cap (2 Per Section) Screw (2 Per Section) Nut (2 Per Section) Plug (2 Per Section) Packing (2 Per Section) Packing (2 Per Section) Piston (2 Per Section) Spring (2 Per Section) Poppet (2 Per Section) Nut, Retaining (2 Per Section) Coil (2 Per Section) Pin (2 Per Section) Core Tube Sub Assembly (2 Per Section) Spool Screw (8 Per Section) Ball Gasket Ball Plug (2 Per Section) Shim (A/R Per Section) Retainer (2 Per Section) Shim (A/R Per Section) Spring (2 Per Section) Stem Servo Sub Assembly (2 Per Section) Poppet (2 Per Section) Seat (2 Per Section) Spring (2 Per Section) O-Ring (2 Per Section) Back-up (2 Per Section) Retainer (2 Per Section) Back-up Ring (2 Per Section) O-Ring (2 per Section) Load Sense (2 Per Section) O-Ring (2 Per Section) O-Ring (2 Per Section) O-Ring (5 Per Section) O-Ring (2 Per Section) Cap, End (2 Per Section)

QTY.

REV.

Ref. Ref. 1 1 1 1 1 1

—

S E C T I O N 2

Ref. A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R

T U R N T A B L E

A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R

2-19

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM #

PART NUMBER 7009330 7012383

150 7012332 7012334 7012335

2 T U R N T A B L E

151 7012331 7012331 7012335 152 7009399 7009397 7009399 153 Not Required Not Required 7012300

DESCRIPTION —————————— Seal Kit (1 Per Section) Piston/Spring Kit (Includes 1 each of 100, 102, 103, 106 and 107) (2 per Section) WORKING SECTION (VARIABLE PARTS) Drive Section Lift & Telescope Section Swing Section Spool Options: Drive Section Lift & Telescope Section Swing Section Poppet Options: Drive Section Lift & Telescope Section (2 Per Spool) Swing Section Piston Options: Drive Section Lift & Telescope Section (2 Per Spool) Swing Section OUTLET SECTION

201 202 203 204 205 206 207 208 209

2-20

7006782 7009361 7012337 Kit 7006778 7012338 Kit 7012336 7006770

Nut Rod, Tie Cover End O-Ring Plug Setscrew Orifice Sub-Assembly O-Ring Plug O-Ring

QTY.

REV.

A/R A/R

Ref. Ref. Ref. 1

A/R 2 A/R 2 A/R 2 A/R 2 Ref. 6 3 1 2 2 1 1 1 1

3120801

SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-21

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995)

2 T U R N T A B L E

2-22

3120801

SECTION 2 TURNTABLE FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) FIG & ITEM #

PART NUMBER 4640246

1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25

7002304

7004823 7002378 7002229 7004822 7004840 7002346 7004839 7004838 7004841 7002342 7002340 7002337 7004834 7002334 7004835 7000417 7004836 7002338 7002327 7004837 7002322 7004826 7002321 7002328 7002294 7002320 7004842 7002329 7002323 7000102 7002326 7002324

DESCRIPTION

QTY.

REV.

VALVE ASSEMBLY - 3 SECTION

Ref.

A

DUMP SECTION Solenoid Assembly Seat O-Ring Ball Guide Tube Assembly Cone, Female O-Ring Pin, Push Plunger Tube, Guide Pin, Push O-Ring Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Nameplate Screw Seat O-Ring Main Relief (Poppet) Valve Case, Poppet Spring Poppet Seat, Adjustable O-Ring Spring Plug O-Ring Orifice Plug WORKING SECTIONS (STANDARD PARTS)

40

7004859

41

7002274

42

7003825 7002348

3120801

Solenoid Assembly (2 Per Section) (Includes Items 43-56) Washer (7002315,7002316,7002317 Sections) (2 Per Section) Washer (7003855 Sections) (2 Per Section) Spring (2 Per Section)

Ref.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1

S E C T I O N 2 T U R N T A B L E

Ref. A/R A/R A/R A/R

2-23

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) (CONTINUED) FIG & ITEM #

PART NUMBER

43

7002305

44

49

7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340

50 51 52 53 54 55 56

Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002339

45 46 47 48

2 T U R N T A B L E

101 102 103 104 105

7002315 7002316 7002315 Not Required 7000468

7002262

7000414 7000413

2-24

DESCRIPTION Guide Tube Assembly (1 Per Solenoid Assembly) Cone, Female (1 Per Solenoid Assembly) O-Ring (1 Per Solenoid Assembly) O-Ring (1 Per Solenoid Assembly) Pin, Push (1 Per Solenoid Assembly) Plunger (1 Per Solenoid Assembly) Tube, Guide (1 Per Solenoid Assembly) Pin, Actuator (1 Per Solenoid Assembly) Ring, Quad (1 Per Solenoid Assembly) Guide, External Push Pin (1 Per Solenoid Assembly) O-Ring (1 Per Solenoid Assembly) Sleeve, Inner Flux (1 Per Solenoid Assembly) Spring (1 Per Solenoid Assembly) Sleeve, Outer Flux (1 Per Solenoid Assembly) Coil (1 Per Solenoid Assembly) Case, Solenoid (1 Per Solenoid Assembly) Plate, End (1 Per Solenoid Assembly) Screw (4 Per Solenoid Assembly)

QTY.

REV.

A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R

WORKING SECTION (VARIABLE PARTS) Note: Complete Sections listed below include items 40-56 and relief valve assembly when equipped

Ref.

Section #1 - Steer/Tele Section #2 - Level Section #3 - Steer/Tele Section #4 Relief Valve Options: Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) Dual Pilot Check Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) —————————— Seal Kit - Working Section Seal Kit - Dump Section

1 1 1 0 A/R

A/R

4 1

3120801

SECTION 2 TURNTABLE FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-25

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT)

2 T U R N T A B L E

2-26

3120801

SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) FIG & ITEM #

PART NUMBER 4640941

1 2 3 4

7002447 7002448 7002449 7002450 7002451 7011118 7000448

101 102 103 104 105

106 107 108 109 110 111 112 113 114 115 116 117

7004859 7003825 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002327 7002339 7000414

151 152

7002315 7002316 7011183

153

3120801

7002315

QTY.

REV.

VALVE ASSEMBLY - 3 SECTION

DESCRIPTION

Ref.

B

DUMP SECTION ASSEMBLY

Ref.

Dump Section - Complete Cartridge Seal Kit - 7002448 Cartridge Coil Cartridge Without Coil Seal Kit - 7002451 Cartridge —————————— O-Ring (Between Sections)

1 1 1 1 1 1

Ref. 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4

WORKING SECTIONS - COMPLETE (INCLUDES ITEMS 101-117 AND RELIEF VALVE ASSEMBLY WHEN EQUIPPED)

Ref.

Section #1 - Steer Section #2 Options: Level Section (4640941 Valve) (Prior to S/N 27357) Level Section (4640941 Valve) (S/N 27357 to Present) Section #3 - Tele

2 T U R N T A B L E

2

WORKING SECTIONS (STANDARD PARTS) Solenoid Assembly Washer Spring Guide Tube Assembly Cone, Female O-Ring O-Ring Pin, Push Plunger Tube, Guide Pin Actuator Ring, Quad Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Nameplate Screw —————————— Seal Kit - Working Section (1 Per Section)

S E C T I O N

2

1 1

1

2-27

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

154 155

Not Required

Section #4 Options: Relief Valve Options: Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) Dual Pilot Check Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) (Prior to S/N 27357) Dual Pilot Check Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) (S/N 27357 to Present)

0 A/R

7000468

7002262

2 7011183

T U R N T A B L E

2-28

REV.

3120801

SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-29

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-8. ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989)

2 T U R N T A B L E

2-30

3120801

SECTION 2 TURNTABLE FIGURE 2-8. ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989) FIG & ITEM #

PART NUMBER 4640535

1 2 3 4 5 6 7 8 9 10 11 12 13 14

3120801

7009755 7009759 7007760 3790015 7009761 3790014 7009756 3790118 3790211 3790016 7009762 7009757 7009758

QTY.

REV.

ACCESSORY VALVE ASSEMBLY Note: Not sold as a complete assembly.

DESCRIPTION

Ref.

A

Body (Not Sold Separately) Cartridge, Pressure Reducing/Relieving O-Ring Ring, Back-Up O-Ring Ring, Back-Up O-Ring Cartridge, Sequence O-Ring O-Ring O-Ring Ring, Back-Up Cartridge, 2-Position Coil (Includes Nut and Washer)

1 1 1 2 1 2 1 1 1 2 2 2 1 1

S E C T I O N 2 T U R N T A B L E

2-31

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-9. ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT)

2 T U R N T A B L E

2-32

3120801

SECTION 2 TURNTABLE FIGURE 2-9. ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT) FIG & ITEM #

PART NUMBER 4640580

1 2 3 4 5

7004365 7004366 7004367 7004369 7004368

DESCRIPTION ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO SEPTEMBER 1991) Note: Not sold as a complete assembly.

Cartridge - Sequence Cartridge - Pressure Reducing Cartridge - Main Relief Cartridge Less Coil - Dump Coil

QTY.

REV.

Ref.

—

1 1 1 1 1

2900707 2900708 2900709

Seal Kit (Sequence and Pressure Reducing) Seal Kit (Main Relief) Seal Kit (Dump)

4640716

ACCESSORY VALVE ASSEMBLY (MACHINES BUILT SEPTEMBER 1991 TO PRESENT) Note: Refer to P/N stamped on cartridge hex nut for identification.

Ref.

101

7012506 7010552

1 1

102

7012505

Cartridge - Sequence (Hydraforce PS10-34A) Cartridge - Sequence (Vickers/Modular Controls PSV7-10V) Cartridge - Pressure Reducing (Hydraforce PR1032A) Cartridge - Pressure Reducing (Vickers/Modular Controls PRV1-10V) Cartridge - Main Relief (Hydraforce RV50-26A) Cartridge - Main Relief (Vickers/Modular Controls RV5-10V) Cartridge Less Coil - Dump (Hydraforce SV16-21) Coil (Hydraforce 6352012) Cartridge w/Coil - Dump (Vickers/Modular Controls SV3-16V) Coil (Vickers/Modular Controls 565966)

7010553 103

7012507 7010554

104 105 104

7004369 7004368 7010556

105

7010555 7012509 7010557 7012510 7010558 7012511 7010559 2900709 7010560

3120801

Seal Kit (Sequence) (Hydraforce Version) Seal Kit (Sequence) (Vickers/Modular Controls Version) Seal Kit (Pressure Reducing) (Hydraforce Version) Seal Kit (Pressure Reducing) (Vickers/Modular Controls Version) Seal Kit (Main Relief) (Hydraforce Version) Seal Kit (Main Relief) (Vickers/Modular Controls Version) Seal Kit (Dump) (Hydraforce Version) Seal Kit (Dump) (Vickers/Modular Controls Version)

S E C T I O N 2

2 1 1 —

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2-33

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-10. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER MACHINES)

2 T U R N T A B L E

2-34

3120801

SECTION 2 TURNTABLE FIGURE 2-10. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER MACHINES) FIG & ITEM #

PART NUMBER

1 2 3 4 5 6

7002315 7004859 7002274 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002327 7002339 7000468

7 8 9 10 11 12 13 14 15 16 17 18 19

7000414

3120801

DESCRIPTION Telescope Section - Complete Solenoid Assembly Washer Spring Guide Tube Assembly Cone, Female O-Ring O-Ring Pin, Push Plunger Tube, Guide Pin, Actuator Ring, Quad Tuide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Nameplate Screw Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) —————————— Seal Kit - Working Section

QTY.

REV.

1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1

S E C T I O N 2 T U R N T A B L E

1

2-35

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-11. SWING DRIVE, BEARING AND LOCK INSTALLATIONS

2 T U R N T A B L E

2-36

3120801

SECTION 2 TURNTABLE FIGURE 2-11. SWING DRIVE, BEARING AND LOCK INSTALLATIONS FIG & ITEM #

PART NUMBER 0239786

1

3160127

2 0920032 0920083 0920109 3 4

5 6 7 8 9 10 11 12 13 14 15

2780116 4843302 4844109 2440058 3533337 0100019 3900164 0642216 0641810 4761800 3931864 4740189 0100009 4740171 0250348

101 102 103 104 105

106

0440193 0682016 0682026 4740004 0100019 0682016 0682018 0100004

0239842 201 202 203 204 205

3120801

4843318 3421565 1260017 3760170 3421563

DESCRIPTION SWING DRIVE INSTALLATION Swing Motor Assembly (See Figure 2-12 for Breakdown) Swing Brake Options: Brake - Prior to April 1992 (See Figure 2-13 for Breakdown) Brake - April 1992 to S/N 33476 (See FIgure 2-14 for Breakdown) Brake - S/N 33476 to Present (See FIgure 2-14 for Breakdown) Swing Hub Assembly (See Figure 2-15 for Breakdown) Mounting Plate Options: Prior to June 1992 June 1992 to Present Gear, Pinion Plate, Retaining Loctite #271 (Not Shown) Screw, Countersunk 1/2"-20NF x 1" Bolt 3/4"-10NC x 1 1/4" Bolt 1/2"-13NC x 1 1/4" Lockwasher 1/2" Bolt, Socket 1/2"-13NC x 4" (Grade 8) Washer, Special Sealant, RTV #738 (Not Shown) Washer, Hardened TURNTABLE BEARING INSTALLATION Bearing, Turntable Bolt 5/8”-11NC x 2” (Grade 8) Bolt 5/8” -11NC x 3 1/4” (Grade 8) Washer, Special Loctite #271 (Not Shown) Bolt Options: Bolt 5/8”-11NC x 2” (Grade 8) Bolt 5/8”-11NC x 2 1/4” (Grade 8)(Use with item 106) Devcon (Required Prior to December 1992) (Not Shown) TURNTABLE LOCK INSTALLATION Bushing Weldment Pin, Snap Chain Ring, Quick Release Pin, Locking

QTY.

REV.

Ref.

6/E

1 1

S E C T I O N 2 T U R N T A B L E

1 1

1 1 A/R 2 8 2 2 2 2 A/R A/R Ref.

7

1 40 40 80 A/R 40

A/R

Ref.

2

1 1 9in/23cm 2 1

2-37

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-12. SWING MOTOR ASSEMBLY - NICHOLS

2 T U R N T A B L E

2-38

3120801

SECTION 2 TURNTABLE FIGURE 2-12. SWING MOTOR ASSEMBLY - NICHOLS FIG & ITEM #

PART NUMBER 3160127

1 2 3 4 5 6

7 8 9 10

Kit Kit Kit 7004196 7004167 7004179 7010791 7004191 Kit 7004171 7004197 7010792

11 7010700 7010793 12

13

7004198 7010794 7004192 7004177 7010790

3120801

DESCRIPTION

QTY.

SWING MOTOR ASSEMBLY Seal Dust Ring, Back-up Seal, Quad Ring Valve, Rotary Ball, Check Valve IGR Assembly Options: Prior to S/N 38344 S/N 38344 to Present Ring, Retaining Seal, Ring Plug, Vent (Includes O-Ring) Bolt Options: Prior to S/N 38344 S/N 38344 to Present Shaft, Spline Options: Prior to S/N 46431 S/N 46431 to Present Body/Bearing Assembly Options: Prior to S/N 38344 S/N 38344 to Present Cover/Bearing Assembly Seal Kit (Includes of items 1, 2, 3, 8, and O-Ring on #9) (Prior to S/N 38344) Seal Kit (Includes of items 1, 2, 3, 8, and O-Ring on #9) (S/N 38344 to Present)

REV. D

1 1 1 1 2 1

S E C T I O N 2 T U R N T A B L E

1 2 1 8

1

1

1 1 1

2-39

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-13. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992)

2 T U R N T A B L E

2-40

3120801

SECTION 2 TURNTABLE FIGURE 2-13. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

0920032 0920032

SWING BRAKE ASSEMBLY - AUSCO (MODEL 28653) SWING BRAKE ASSEMBLY - AUSCO (MODEL 37265V)

Ref. Ref.

— C

Note: Refer to Model Number stamped on the front of the Housing item 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

3120801

Kit 7000730 7003007 7000729 7003012 7003091 7000796 7000760 Kit Kit Kit Kit 7000721 7003057 7000720 7003056 7003006 7000732 7003055 7000718 7003054 7000717 7003013 7003053 7000798 7003052 7003051 Kit 7000713 7003049 Kit 7000714 7003090 7000712 7000711 Kit 7003059 Not Used Not Used Not Used 2900131

Gasket Bolt (Model 38653) Bolt, Flanged (Model 37265V) Lockwasher (Model 28653 Only) Plate, Power (Model 38653) Plate, Power (Model 37265V) Bleeder Bearing, Ball (Model 37265V Only) O-Ring Ring, Back-up O-Ring Ring, Back-up Piston (Model 28653) Piston (Model 37265V) Disc, Stationary (Model 28653) Disc, Stationary (Model 37265V) Spring, Compression Disc, Rotating (Model 28653) Disc, Rotating (Model 37265V) Disc, Primary (Model 28653) Disc, Primary (Model 37265V) Pin, Torque Shaft, Splined (Model 28653) Shaft, Splined (Model 37265V) Spring, Compression (Model 28653) Spring, Compression (Model 37265V) Retainer, Spring (Model 37265V Only) Seal, Oil Bearing, Ball (Model 28653) Bearing, Ball (Model 37265V) Gasket (Model 37265V Only) Housing (Model 28653) Housing (Model 37265V) Ring, Retaining (Model 28653 Only) Ring, Retaining (Model 28653 Only) Gasket Valve, Pressure Relief (Model 37265V Only)

S E C T I O N 2

1 4 4 4 1 1 1 1 1 1 1 1 1 1 3 3 6 3 3 1 1 2 1 1 8 8 1 1 1 1 1 1 1 1 1 1 1

T U R N T A B L E

Seal Kit (Includes Items 1,7,8,9,10,20,22 and 26)

2-41

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-13. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) (CONTINUED) FIG & ITEM #

PART NUMBER 0920032

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

2 T U R N T A B L E

SWING BRAKE ASSEMBLY - MICO

QTY.

REV.

Ref.

B

7007913 7007912 7007924 7007928 Kit Kit Kit Kit Kit 7007923 Kit Kit 7007914 Kit 7007926 7007908 7007916 7007909 7007902 7007907 7007906 7007905 7007915 Kit Kit 7007930 7007901 7007933 7007934

Capscrew Lockwasher Plug Cover Ring, Square O-Ring Bearing O-Ring Ring, Back-Up Piston O-Ring Ring, Back-Up Bleeder Ring, Retaining Shaft Disc Spring Disc, Friction Separator Disc Spring Spring Pin, Dowel Bearing O-Ring Housing Pin, Spiral Gasket Gasket

4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 3 6 3 2 1 8 8 2 1 1 1 4 1 1

2900642

Seal Kit (Includes Items 35,36,38,39,41,42,55 and 58 Gaskets) Bearing Kit (Includes Items 36,37,44,54,55 and 58 Gasket)

1

7007927

2-42

DESCRIPTION

1

3120801

SECTION 2 TURNTABLE FIGURE 2-13. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-43

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-14. SWING BRAKE ASSEMBLY (APRIL 1992 to PRESENT)

2 T U R N T A B L E

2-44

3120801

SECTION 2 TURNTABLE FIGURE 2-14. SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT) FIG & ITEM #

PART NUMBER

DESCRIPTION SWING BRAKE ASSEMBLIES (STANDARD PARTS)

1 2 3 4 to 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Kit Kit 7007977 Not Used Kit Not Used 7011719 Not Used Not Used Not Used 7007987 Kit Kit Kit Kit Kit Kit Not Used Not Used Kit 7007934 2900766 2900768

0920083 0920083 0920109 51 7011718 7011720 52 7007979 7007980 Not Required 53 Not Required 7007970 7018602 54 7007981 7011713 7018605

3120801

QTY.

Seal, Oil Bearing Ring, Retaining

1 1 1

Seal, Case

1

Cover

1

Pin, Dowel Ring, Back-up (Inner) O-Ring (Inner) Ring, Back-up (Outer) O-Ring (Outer) Rotor Stator

2 1 1 2 2

O-Ring Gasket

2 2

Seal Kit (Includes Items 1,11,16,17,18,19,26 and 27) Bearing Kit (Includes Items 1,2,11,26 and 27)

1 1

SWING BRAKE ASSEMBLY (VARIABLE PARTS) Machines Built Through 1992 Machines Built 1993 to S/N 33476 Machines Built S/N 33476 to Present Shaft Options: Machines Built Through 1992 Machines Built Through 1993 to Present Spring Options: 0920083 Brake Components: Spring (Small) Spring (Large) 0920109 Brake Spring Options: 0920083 Brake 0920109 Brake Components: Spring (Red) Spring (Blue) Housing Options: Machines Built Through 1992 Machines Built Through 1993 to S/N 33476 Machines Built S/N 33476 to Present

REV.

Ref.

Ref. Ref. Ref.

S E C T I O N 2 T U R N T A B L E

— A B

1

A/R 6 6 0 A/R 0 6 3 1

2-45

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-14. SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

55 7007985 7018607 56

2

57

T U R N T A B L E

Not Required 7011717 7018606 7007923 7007923 7018603

58 Kit 7011715 7011714 7007983 7018604 59 7007914 7018609 60 Not Required 7011716

2900767 7018608

2-46

DESCRIPTION Bolt, Washer Head 0920083 Brake 0920109 Brake Guide, Spring Machines Built Through 1992 Machines Built Through 1993 to S/N 33476 Machines Built S/N 33476 to Present Piston 0920083 Brake 0920109 Brake Return Plate/Separator Assembly Options: 0920083 Brake Components: Plate, Return Separator Assembly Pin Separator 0920109 Brake (1 Welded Component) Screw, Bleeder/Plug Options: 0920083 Brake (Screw, Bleeder) 0920109 Brake (Plug) Ring, Retaining Options: Machines Built Through 1992 Machines Built Through 1993 to Present —————————— Lining Kit Options (Includes Items 11,20,21,26, 27 & 58): 0920083 Brake 0920109 Brake

QTY.

REV.

4

1

1

A/R 1 2 4 2 1 1

A/R

1

3120801

SECTION 2 TURNTABLE FIGURE 2-14. SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-47

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-15. SWING HUB ASSEMBLY

2 T U R N T A B L E

2-48

3120801

SECTION 2 TURNTABLE FIGURE 2-15. SWING HUB ASSEMBLY FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

Ref.

—

2780116

SWING HUB ASSEMBLY

1

7001916

2 3 4 5 6 7 8 9 to 12 13 14 15 16 17 18 19 20

7001917 7001918 7000279 Kit 7001920 Not Used 7001922 Not Used 7001921 Not Used 7000287 7000288 7001923 7001924 7001929 7001926

Hub and Spindle Assembly (See Items 101-111 for Breakdown) Gear, Internal Carrier Assembly (See items 201-207 for Breakdown) Gear, Ring O-Ring Cover

1 1 1 2 1

Washer, Thrust

1

Gear, Input

1

Washer, Thrust Bearing, Thrust Bolt Bolt, Shoulder Lockwasher Plug, Pipe

4 2 8 4 4 1

7001916 101 102 103 104 105 106 107 108 109 110 111

7001982 Kit 7000272 7000273 7000274 7000275 Not Available Kit Kit 7001928 7001926 7001918

201 202 203 204 205 206 207

Not Available Kit 7001902 Kit 7001904 Kit Kit 2900202 7001927

3120801

HUB AND SPINDLE ASSEMBLY Shaft, Output Seal, Lip Cup, Bearing Cone, Bearing Cup, Bearing Cone, Bearing Hub Spacer Ring, Retaining Plug, Pipe Plug, Pipe CARRIER ASSEMBLY Housing, Carrier Washer, Thrust Bearing, Needle Spacer Shaft, Planet Gear, Cluster Rollpin Seal Kit (Includes Items 5, 102, 108 and 109) Cluster Gear Kit (Includes Items 202, 204,206 and 207)

1

S E C T I O N 2 T U R N T A B L E

Ref. 1 1 1 1 1 1 1 1 1 1 2 Ref. 1 6 84 3 3 3 3 1 1

2-49

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-16. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION

2 T U R N T A B L E

2-50

3120801

SECTION 2 TURNTABLE FIGURE 2-16. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION FIG & ITEM #

1 2 3 4 5 6 7 8 9 10

PART NUMBER

Not Used 3530403 3951820 0641807 4761800 1440154 0641514 4761500 0100011 0100019

0238032 0251852 0254882 51

52

1660160 1660213 2200222 2200222 Not Required Not Required

101 0620058 Not Available 102

103 104 105

2760091 Not Available Kit 3760004 Kit

2901146 Use 1660213EX

3120801

DESCRIPTION

QTY.

ROTARY OIL COUPLING INSTALLATION (STANDARD PARTS)

Ref.

Plate, Retaining Setscrew 1/2"-13NC x 2 1/2" Bolt 1/2"-13NC x 7/8" Lockwasher 1/2" Collar Bolt 5/16"-18NC x 1 3/4" Lockwasher 5/16" Loctite #242 (Not Shown) Loctite #271 (Not Shown) ROTARY OIL COUPLING INSTALLATION (VARIABLE PARTS) Prior To April 1991 April 1991 To September 1994 September 1994 To Present Rotary Oil Coupling Assembly (6 Port) (See Items 101-105 for Breakdown) Prior to September 1994 September 1994 to Present Plug, Pipe Option:

1 2 2 2 1 4 4 A/R A/R

Ref. Ref. Ref.

2

— A 3

1

A/R

Prior to September 1994 September 1994 to Present With Collector Ring

1 0 0

ROTARY OIL COUPLING ASSEMBLIES

Ref.

Swivel Body Options: Body for 1660160 Coupling Body for 1660213 Coupling Swivel Housing Options: Housing for 1660160 Coupling Housing for 1660213 Coupling T-Seal Ring, Retaining (1660160 Coupling Only) O-Ring —————————— Seal Kit Options: 1660154, 1660160 & 1660185 Couplings (Includes Items 103 & 105) 1660213 Couplings (was p/n 7013175) Note: Due to complexity of repair, seal kit no longer available. Use rebuilt unit as replacement.

REV.

S E C T I O N

1

1

7 1 1 1

2-51

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-16. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION OPTIONAL COLLECTOR RING INSTALLATION (STANDARD PARTS)

201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218

2 T U R N T A B L E

Not Used 0960224 0641418 Not Used Not Used Not Used 3311801 3420290 0231047 Not Used 0721005 4761400 1320040 3911012 4751000 4761000 3311001 4751400

0232123 0252284 251 0230470 4843822 252 3460065 2180763 253 0230435 0961531 254 3760036 3760108 255 1670594 0234721

2-52

QTY.

REV.

Ref.

Bushing Bolt 1/4"-20NC x 2 1/4"

2 2 1

Nut 1/2"-13NC Pin, Drive Guide, Drive

2 2 2

Screw, Machine #10-24NC x 5/8" Lockwasher 1/4" Clamp, Cable Screw, Machine Flatwasher #10 Lockwasher #10 Nut #10-24NC Flatwasher 1/4"

4 2 2 1 6 5 5 2

COLLECTOR RING INSTALLATION - MACHINES WITH SINGLE OR NO AXLE JACK (VARIABLE PARTS) Machines With Single Or No Axle Jack Machines With Dual Axle Jacks

Ref. Ref.

Bracket Weldment Options: Machines With Single Or No Axle Jack Machines With Dual Axle Jacks Pipe Options: Machines With Single Or No Axle Jack Machines With Dual Axle Jacks Bushing Options: Machines With Single Or No Axle Jack Machines With Dual Axle Jacks Collector Ring Assembly Options: Machines With Single Or No Axle Jack Machines With Dual Axle Jacks Cover Options: Machines With Single Or No Axle Jack Machines With Dual Axle Jacks

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

7 3

3120801

SECTION 2 TURNTABLE FIGURE 2-16. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-53

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992)

2 T U R N T A B L E

2-54

3120801

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) FIG & ITEM #

PART NUMBER 0239865 0251167

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Not Used 3600139 3200229 3200228 3200133 3200183 3200227 Not Used Not Used Not Used 4060610 1060044 Not Used Not Used

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

0642032 3312005 4740242 0701427 4740191 0701215 4832100 Not Used Not Used Not Used 0641406 4761400 3311401 Not Used Not Used 4420001 0700617 0237627

34 35 36 37 38 39 40 41 42

3120801

0901402 1320070 1670414 3910812 4770800 3310801 1700821 4843384

DESCRIPTION DEUTZ ENGINE ASSEMBLY Standard Engine Clean Burn Engine

QTY.

REV.

Ref. Ref. Ref.

I G

Pump Assembly (See Figure 2-22 for Breakdown) Support, Motor (Front) Support, Motor (Rear Side) Mount, Engine (Front) Mount, Engine (Rear) Bracket, Mounting (Front)

1 1 2 1 2 1

Deflector (Prior to December 1990) Cable, Battery (Start Solenoid to Ground)

1 1

Throttle Shut-Off Components (See Figure 2-19 for Breakdown) Bolt 5/8"-20NC x 4" Locknut 5/8"-20NC Flatwasher, Special Bolt, Metric 14mm x 100mm Lockwasher, Metric 14mm Bolt, Metric 12mm x 35mm Lockwasher, Metric 12mm

Bolt 1/4"-20NC x 3/4" Lockwasher 1/4" Nut 1/4"-20NC

Tape, Sealant (Not Shown) Bolt, Metric 6mm x 45mm Electrical Panel Assembly (See Items 201-211 for Breakdown) Throttle Cable Components (See Figure 2-19 for Breakdown) Bracket, Terminal Strip Mounting Clamp Cover, Terminal Strip Screw, Machine #8-32NC x 3/4" Starwasher #8 Nut #8-32NC Decal - Wire Identification Tube, Air Intake

S E C T I O N 2 T U R N T A B L E

A/R 3 3 3 4 4 8 8

4 3 4

A/R 1 1

1 1 1 2 2 2 1 1

2-55

S E C T I O N 2

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) (CONTINUED) FIG & ITEM #

PART NUMBER

43 44 45 46 47 48 49 50 to 60 61

3820012 4750600 4921140 2420073 Not Used 4751400 0641416 Not Used

T U R N T A B L E

2000083 2000115 62 3200306 3200306

0239866 0251168 80 80A 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108

2-56

1340020 7004214 0340002 1120161 0080039 4562928 2720224 1320058 4300031 4761400 3311401 0400020 0236768 0361027 3980006 0400003 0400002 3980003 Not Used 3300029 1060046 1060109 1060149 1060132 4300034 4921139 0642022 4752000 4762000 3312001

DESCRIPTION

QTY.

Rivet Flatwasher #6 Harness, Wiring Sender, Oil Pressure

2 2 1 1

Flatwasher 1/4" Bolt 1/4"-20NC x 2"

3 3

Engine Assembly Options - F4L912: Standard Clean Burn Bracket, Mounting (Rear) Options: Standard Clean Burn

1

DEUTZ F4L912 ENGINE INSTALLATION Standard Engine Clean Burn Engine

REV.

1 1 Ref. Ref. Ref.

Air Cleaner Assembly Filter - 1340020 Air Cleaner Band, Mounting Bonnet Elbow Tube, Air Intake Hose Clamp Stud (Welded on Part - Not Shown) Lockwasher 1/4" Nut 1/4"-20NC Battery Rod, Tie-Down Strap Seat, Battery Battery Tie-Down Seat, Battery

1 1 2 1 1 1 1 4 11 11 11 1 4 1 1 1 1 1

Wingnut 3/8"-16NC Cable, Battery (- Battery to Ground) Cable, Battery (+ Battery to Starter) Cable, Battery (Aux. Relay to Starter) Cable, Battery (Aux. Relay to Aux Pump) Stud (Welded on Part) Battery Cable Assembly Bolt 5/8" - 11NC x 2 3/4" Flatwasher 5/8" Lockwasher 5/8" Nut 5/8"-11NC

4 1 1 1 1 A/R 1 2 2 2 2

E C

3120801

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) (CONTINUED) FIG & ITEM #

PART NUMBER

109 110 111 112 113

114 115 116 117 118 119 120 121 122 123 124

0641622 4751600 4761600 3311601 3600071 7004248 7004436 7012576 7004249 7004247 Not Available 0641610 2720271 2750532 2220063 2220720 4751700 1320022 3380375 4280002 1320059 2180536

125 126

3533407 1060031 0237627

201 202 203 204 205

206 207 208 209 210 211

3740059 3321001 3310801 3530425 3740030 3740080 3740067 3300220 0641405 4761400 3311401 4711400 0239915

301

302 303

3120801

3220058 3220077 4564359 1120169

DESCRIPTION Bolt 3/8" - 16NC x 2 3/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Auxiliary Pump Assembly Replacement Motor Only Replacement Motor with Bracket Replacement Mounting Bracket Only Replacement Coupling Replacement Pump Pump Seal Kit Bolt 3/8"-16NC x 1 1/4" Hose, Fuel Return Line Hose, Fuel Supply Line Fitting, 90° Fitting, Barbed Flatwasher 7/16" Clamp Baffle Strip, Neoprene Clamp Fitting, Coupling (Not Shown - Located in Fuel Return Line) Plate, Mounting - Air Cleaner Cable, Battery (Battery to Ground) ELECTRICAL PANEL ASSEMBLY Relay Nut #10-32NF Nut #8-32NC Plate, Mounting Relay Options: Relay, Adlo (Used Prior to April 1991) Relay, Sealed (Used April 1991 to October 1992) Relay Nut, Special Bolt 1/4"-20NC x 5/8" Lockwasher 1/4" Nut 1/4"-20NC Flatwasher 1/4" Narrow EXHAUST INSTALLATION Muffler Options: Prior to July 1990 July 1990 to October 1992 Pipe, Exhaust Rain Cap

QTY.

REV.

2 3 11 12 1 1 1 1 1 1 1 2 8 ft.

10 ft.

2 2 2 4 1

2 T U R N T A B L E

30 in./76cm

1 1 1 1 Ref.

F

1 3 1 1 1

2 6 7 7 7 6 Ref.

S E C T I O N

D

1

1 1

2-57

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) (CONTINUED) FIG & ITEM #

PART NUMBER

304 305 306 307 308 309 310 311 312 313 314 315 316 317

0960960 1320019 0901719 0641507 4751500 4761500 3311501 0641607 4751600 4761600 3311601 2551030 0181504

2 T U R N T A B L E

318

0901636 0901720 0080117

4931671 0251683 0239119 401

2180360 4360065 4360037 4360037 4360179 2180730

DESCRIPTION Tube Clamp Bracket, Support Bolt 5/16"-18NC x 7/8" Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC Bolt 3/8"-16NC x 7/8" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Gusset, Lower (Not Shown) Angle, Support - Lower (Not Shown) Support Bracket - Upper Options (Not Shown): Prior to July 1990 July 1990 to October 1992 Adaptor SWITCH INSTALLATIONS Engine Distress Installation Engine Run Light Installation Generator Installation Fitting, Tee Switch, Oil Pressure Options: Engine Distress Installation Engine Run Light Installation Generator Installation Switch, Temperature (Engine Distress Installation Only) (Not Shown- Located in Head Under Shroud) Fitting, Adapter (Generator Installation Only) ENGINE COMPONENTS (NOT SHOWN)

70002254 70002252 70002258 70002259 70002253 7020433 7014686

2-58

Head Repair Components: Piston/Cylinder Kit Ring, Head Fire Bolt, Cylinder Head Washer, Cylinder Head Engine & Maintenance Kits Components: Gasket Kit - Complete Engine Gasket Gasket and Filter Kit - Deutz F4L912 (Includes 3 Different Fuel Line Washers - 12 of each. 1 Oil Plug Washer, 1 Fuel Filter, 1 Oil Filter and 1 Gasket Set)

QTY.

REV.

1 4 2 2 2 2 2 1 1 1 1 1 1 1

1 Ref. Ref. Ref. Ref.

B B J

1 1

1 1 Ref. A/R 4 4 4 4 A/R 1 1 1

3120801

SECTION 2 TURNTABLE FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) (CONTINUED) FIG & ITEM #

PART NUMBER 7000649 Use 7029274 Use 7029276 7000697 7000698 7000663 7000872 Use 7020413 7020420 7019607 7016330 Use 7019607 7026173 7016364 7020432 7020407 70001361 7020422 7020421 7020423 7016309 7020400 7020401 7020402 7020403 70001927 70001928 7000699 7026125 7020208 7020405 7020409 7020498 7027250

3120801

DESCRIPTION Filter/Belt Components: Filter, Fuel (was p/n 7000649) Filter, Engine Oil (Case of 12) Filter, Engine Oil (1 Individual Filter) (was p/n 70006489) Belt, Blower Belt, Alternator Major Components: Alternator (Bosch) (was p/n 7020410 & 7020436) Alternator (Delco-Remy) Starter (was p/n 7000661) Starter, Remanufactured Electrical System Components: Solenoid, Fuel Shutdown 2nd Switch, Oil Pressure Switch, Solenoid (was p/n 7016341) Switch, Broken Belt Fuel System Components: Pump, Fuel Lift Repair Kit - Lift Pump Gasket, Lift Pump Pump, Fuel Injection Injector Nozzle, Injector Gasket, Injector Tip Washer, Copper Sealing Washer, Fuel Line Washer, Fuel Line Washer, Fuel Line Washer, Fuel Line Intake/Exhaust Components: Manifold, Exhaust Gasket, Exhaust Manifold Gasket, Doughnut Flange, Exhaust Coupling Components: Ring Gear Miscellaneous Components: Washer, Oil Plug Dipstick Fan Spring, Actuator Tension

QTY.

REV.

A/R 1 1 1 1 1 A/R 1 1 1 1 A/R 1 1 1 1 A/R 1 1 1 4 4 4 4 4 1 1 1 1 A/R 1 4 1 1 A/R 1 A/R 1 1 1 1

S E C T I O N 2 T U R N T A B L E

2-59

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT)

2 T U R N T A B L E

2-60

3120801

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) FIG & ITEM #

PART NUMBER 0253357 0253359 0255612

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Not Used 3600139 3200229 3200228 3200133 3200183 3200227 3200306 4565269 1320011 3220082 1060044 0340041 0901849 Not Used 0642032 3312005 4740242 0701427 4740191 0701215 4832100 3290607 3311405 0641408 4811700 4751400 Not Used 4831700 3311401 Not Used Not Used 4420001 0700617 0237627

34 35 36 37 38

3120801

0901402 1320070 1670414 3910812

DESCRIPTION DEUTZ ENGINE ASSEMBLY Standard Engine Clean Burn Engine EXHAUST INSTALLATION (STANDARD PARTS) (SEE SECTION 10 FOR NON-STANDARD EXHAUST SYSTEMS)

QTY.

REV.

Ref. Ref. Ref. Ref.

5 4 —

S E C T I O N 2

Pump Assembly (See Figure 2-22 for Breakdown) Support, Motor (Front) Support, Motor (Rear) Mount, Motor (Front) Mount, Motor (Rear) Plate, Mounting (Front) Plate, Mounting (Rear) Adapter, Exhaust Clamp, Exhaust Muffler Cable, Battery (Engine to Ground) Band, Muffler Bracket, Muffler

1 1 2 1 2 1 1 1 1 1 1 1 1

Bolt 5/8"-11NC x 4" Locknut 5/8"-11NC Flatwasher, Special Bolt, Metric 14mm x 100mm Lockwasher, Metric 14mm Bolt, Metric 12mm x 35mm Lockwasher 12mm Nut, Metric 6mm Nut 1/4"-20NC Bolt 1/4"-20NC x 1" Flatwasher 6mm Flatwasher 1/4"

3 3 3 4 4 4 8 4 2 2 9 4

Lockwasher 6mm Nut 1/4"-20NC

5 3

Tape, Sealing Bolt, Metric 6mm x 45mm Electrical Panel Assembly (See Items 201-211 for Breakdown) Throttle Cable Components (See Figure 2-19 for Breakdown) Bracket, Terminal Strip Clamp Cover, Terminal Strip Screw, Machine #8-32NC x 3/4"

T U R N T A B L E

A/R 5 1

1 1 1 2

2-61

S E C T I O N 2 T U R N T A B L E

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

39 40 41 42 43 44 45 46 47 48 49 50 51 52 to 59 60

4770800 3310801 1700821 4843384 4640742 2720042 4921140 2420073 Not Used 0641812 4761800 0701217 1320222 Not Used 2000083 2000115

0253358 0253360 0255612 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101

2-62

0641408 4844238 1670627 1340020 7004214 0340002 0080046 0080039 4565655 2720224 1320058 4300031 4761400 3311401 0400020 0236768 0361027 3980006 0400003 0400002 3980003 4751400 3300029 1060031 1060109 1060149

DESCRIPTION Starwasher #8 Nut #8-32NC Decal - Wire Identification Air Intake Weldment Valve, Drain Hose, Heater Engine Harness (Not Shown) Sender, Oil Pressure

QTY. 2 2 1 1 1 6 in./15cm

1 1

Bolt 1/2"-13NC x 1 1/2" Lockwasher 1/2" Bolt, Metric 12mm x 45mm (S/N 36614 to Present) Clamp (S/N 38344 to Present)

2 2 4

Engine, Deutz F4L912 Options: Standard Engine Clean Burn Engine

1

DEUTZ ENGINE INSTALLATION Standard Engine Installation Clean Burn Engine Installation EXHAUST INSTALLATION Bolt 1/4"-20NC x 1" Tube Cover, Base Plate Air Cleaner Assembly Filter Band, Mounting Elbow Elbow Tube Hose Clamp Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Battery Rod, Tie-Down Strap, Tie-Down Seat, Masonite Battery Tie-Down, Battery Seat, Masonite Flatwasher 1/4" Wingnut 3/8"-16NC Cable, Battery (- Batt to Ground) Cable, Battery (+ Batt to Start Solenoid) Cable, Battery (Start Solenoid to Aux Relay)

REV.

Ref. Ref. Ref. Ref.

5 4 2

4 1 1 1 1 2 1 A/R 1 1 A/R 8 12 12 1 4 1 1 1 1 1 A/R 4 1 1 1

3120801

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

102 103 104 105 106 107 108 109 110 111 112 113

1060132 4300034 4921139 0642020 4752000 4762000 3312001 0641622 4751600 4761600 3311601 3600071 7004248 7004436 7012576 7004249 7004247 Not Available 0641620 2720271 2750532 2220063 2220720 0641414 1320022 0253194 4280002 1320059 2180536 3311405 1060031 4751500 4740362 4761500 3535949 0362101 3536008 1320021 1120423 4844235 4565751 1320011 4751700 1320016

114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139

3120801

DESCRIPTION Cable, Battery (Aux Pump to Aux Relay) Stud (Welded on Part) Battery Cable Assembly (Includes Diode p/n 3990048) Bolt 5/8"-20NC x 2 1/2" Flatwasher 5/8" Lockwasher 5/8" Nut 5/8"-20NC Bolt 3/8"-16NC x 2 3/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Auxiliary Pump Assembly - Barnes Motor Assembly Motor Assembly With Mounting Bracket Bracket Only Coupling Pump Assembly Seal Kit - 7004247 Pump Bolt 3/8"-16NC x 2 1/2" Hose, Fuel (Return) Hose, Fuel (Supply) Fitting, Swivel Adapter Fitting, Barbed Bolt 1/4"-20NC x 1 3/4" Clamp, Hose Inlet Box Assembly Neoprene Clamp Fitting, Barbed Locknut 1/4"-20NC Cable, Battery (Aux Relay to Start Relay) Flatwasher 5/16" Washer, Fender Lockwasher 5/16" Plate, Hose Cover Bar, Spacer (Prior to S/N 42536) Plate, Cover Clamp, Muffler Raincap Snorkel Pipe, Exhaust Clamp, Exhaust Flatwasher 7/16" Clamp (S/N 36614 to Present)

QTY.

REV.

1 3 1 2 2 2 2 2 A/R 11 5 1 1 1 1 1 1 1 2 8 ft./2.4m 10 ft./3m 2 A/R 13 4 1

S E C T I O N 2 T U R N T A B L E

30 in./76cm

1 1 13 1 2 6 2 1 2 1 1 1 1 1 1 1 6

2-63

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER 0237627

201 202 203 204 205 206 207 208 209 210 211

2 T U R N T A B L E

3740059 3321001 3310801 3530425 3740080 3740067 3300220 0641405 4791400 3311401 4711400

0255152/0255568

0251683 0239119 0255274 301

2180360 4360065 4360037 4360037 4360065 4360179 2180730 2180749

0257216

401 402 403 404 405 406 407 408 409 410 411 412 413 414

2-64

2400054 2400044 0741008 4751000 3311005 4920970 4360155 0902374 1060044 1703476 4300038 4751500 4761500 3311501

DESCRIPTION

QTY.

REV.

ELECTRICAL PANEL ASSEMBLY

Ref.

9

Relay Nut #10-32NF Nut #8-32NC Plate, Mounting Relay, Sealed Relay Nut, Special Bolt 1/4"-20NC x 5/8" Starwasher 1/4" Nut 1/4"-20NC Flatwasher 1/4" Narrow SWITCH INSTALLATIONS Engine Distress Installation Engine Run Light Installation Generator Installation Low Oil Pressure Shutdown Installation Fitting, Tee Switch, Oil Pressure Options: Engine Distress Installation Engine Run Light Installation Generator Installation Low Oil Pressure Shutdown Installation Switch, Temperature (Engine Distress Installation Only) (Not Shown - Located in Head Under Shroud) Fitting, Adapter (Generator Installation Only) Fitting, 45° (Low Oil Pressure Shutdown Installation Only) BATTERY DISCONNECT INSTALLATION (S/N 28224 TO PRESENT) Fuse - 35 Amp Fuseholder Screw, Flathead #10-24NC x 1" Flatwasher #10 Locknut #10-24NC Harness Switch, Disconnect Bracket Cable, Battery Decal - Battery Connect and Disconnect Stud (Welded on Part) Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC

1 3 1 1 1 2 6 7 7 7 6

Ref. Ref. Ref. Ref.

3/— B 11 4

1 1

1 1 1

Ref.

2/A

1 1 2 2 2 1 1 1 1 1 2 2 2 2

3120801

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION ENGINE COMPONENTS (NOT SHOWN)

70002254 70002252 70002258 70002259 70002253 7020433 7014686

7000649 Use 7029274 Use 7029276 7000697 7000698 7000663 7000872 Use 7020413 7020420 7019607 7016330 Use 7019607 7026173 7016364 7020432 7020407 70001361 7020422 7020421 7020423 7016309 7020400 7020401 7020402 7020403 70001927 70001928 7000699 7026125

3120801

Head Repair Components: Piston/Cylinder Kit Ring, Head Fire Bolt, Cylinder Head Washer, Cylinder Head Engine & Maintenance Kits Components: Gasket Kit - Complete Engine Gasket Gasket and Filter Kit - Deutz F4L912 (Includes 3 Different Fuel Line Washers - 12 of each. 1 Oil Plug Washer, 1 Fuel Filter, 1 Oil Filter and 1 Gasket Set) Filter/Belt Components: Filter, Fuel (was p/n 7000649) Filter, Engine Oil (Case of 12) Filter, Engine Oil (1 Individual Filter) (was p/n 70006489) Belt, Blower Belt, Alternator Major Components: Alternator (Bosch) (was p/n 7020410 & 7020436) Alternator (Delco-Remy) Starter (was p/n 7000661) Starter, Remanufactured Electrical System Components: Solenoid, Fuel Shutdown 2nd Switch, Oil Pressure Switch, Solenoid (was p/n 7016341) Switch, Broken Belt Fuel System Components: Pump, Fuel Lift Repair Kit - Lift Pump Gasket, Lift Pump Pump, Fuel Injection Injector Nozzle, Injector Gasket, Injector Tip Washer, Copper Sealing Washer, Fuel Line Washer, Fuel Line Washer, Fuel Line Washer, Fuel Line Intake/Exhaust Components: Manifold, Exhaust Gasket, Exhaust Manifold Gasket, Doughnut Flange, Exhaust

QTY.

REV.

Ref. A/R 4 4 4 4 A/R 1 1 1

S E C T I O N 2 T U R N T A B L E

A/R 1 1 1 1 1 A/R 1 1 1 1 A/R 1 1 1 1 A/R 1 1 1 4 4 4 4 4 1 1 1 1 A/R 1 4 1 1

2-65

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER 7020208 7020405 7020409 7020498 7027250

2

DESCRIPTION Coupling Components: Ring Gear Miscellaneous Components: Washer, Oil Plug Dipstick Fan Spring, Actuator Tension

QTY.

REV.

A/R 1 A/R 1 1 1 1

T U R N T A B L E

2-66

3120801

SECTION 2 TURNTABLE FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-67

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-19. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES

2 T U R N T A B L E

2-68

3120801

SECTION 2 TURNTABLE FIGURE 2-19. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES FIG & ITEM #

PART NUMBER 0237635

1

2 3 4 5 6 7 8 9 10 11 12 13 14 15

101

0060023 7008804 7008829 7008821 7008828 0641409 4751400 1320041 0901389 0630400 4831900 3290801 4460302 4711400 3450203 Not Used 4761400 4751600 0641406 3311401

0250069 0237631

201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218

3120801

3740055 0641406 4751400 3311401 3321401 4160086 1360112 3321401 3430406 4751400 3450203 4842269 3311605 4751600 4160024 3840816 4842476 0630136

DESCRIPTION THROTTLE ACTUATOR INSTALLATION (TURNTABLE MOUNTED ACTUATOR)

QTY.

REV.

Ref.

4

Actuator Bellows, Rubber Board, Circuit Motor, Drive Cable, Throttle Bolt 1/4"-20NC x 1 1/8" Flatwasher 1/4" Clamp, Cable Bracket, Cable Bolt, Metric M8-1.25 x 90MM Lockwasher Metric 8mm Nut, Metric M8-1.25 Stop, Cable Flatwasher 1/4" Narrow Pin, Cotter 1/16" x 3/4"

1 1 1 1 1 2 2 2 1 2 2 2 1 1 1

Lockwasher 1/4" Flatwasher 3/8” Bolt 1/4”-20NC x 3/4” Nut 1/4”-20NC

3 2 1 1

STOP-RUN SOLENOID INSTALLATION (GOVERNOR MOUNTED) Fuel Shutdown Kit (Includes Mounting Hardware)

Ref.

STOP-RUN SOLENOID INSTALLATION (MOUNTED ON FLYWHEEL HOUSING)

Ref.

Solenoid Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Nut 1/4"-20NC Nut 1/4"-28NF Spring, Swivel Clevis Nut 1/4"-28NF Pin, Clevis Flatwasher 1/4" Pin, Cotter 1/16" x 3/4" Arm Locknut 3/8"-16NC Flatwasher 3/8" Spring Rod Bracket, Mounting Bolt, Metric 8MM x 24MM

S E C T I O N 2 T U R N T A B L E

—

1 —

1 4 4 4 1 1 3 1 3 3 3 1 1 1 1 1 1 4

2-69

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-20. GENERATOR INSTALLATIONS - DEUTZ ENGINE MACHINES

2 T U R N T A B L E

2-70

3120801

SECTION 2 TURNTABLE FIGURE 2-20. GENERATOR INSTALLATIONS - DEUTZ ENGINE MACHINES FIG & ITEM # 1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 to 21 22 23 to 24 25 26 27 28 29

3120801

PART NUMBER 0239119 4843133 Not Used 2460011 7012558 7027887 7020193 7026199 7020108 7020109 7012513 7012514 7020110 7020111 7020190 7003657

4360542 2420203 4460190 2920162 7020191 0480050 4340511 3580109 3580134 2860012 0700821 4761500 0681610 4751500 0641507 3251476 4460023 4300031 4761400 Not Used 4920039 Not Used 2180360 Not Used 4360037 3311401 2180730 4761600 4751600

DESCRIPTION GENERATOR INSTALLATION- DEUTZ Bracket, Generator Mounting Generator and Control Box Assembly Generator Only (Includes Item 7) Key, Woodruff Cord, Power Armature Brushes Holder, Brush Cap, Brush Holder Fan Bell, Front End Bell, Rear End Bearing Box, Control Note: Replacement 110V Control Box comes with 2 std. Receptacles p/n 4460190. Optional Industrial Twist Lock Receptacle p/n 4460027 must be ordered separately.

Circuit Breaker Voltmeter Receptacle Lamp Switch, Toggle V-Belt Support, Adjustment Pulley Pulley (Part of Item 3) Key, Woodruff Bolt, Metric 8m x 65mm Lockwasher 5/16" Bolt 3/8"-16NC x 1 1/4" (Grade 8) Flatwasher 5/16" Bolt 5/16"-18NC x 7/8" Nameplate - On/Off Connector Stud (Welded on Part) Lockwasher 1/4" Wire - Red

QTY.

REV.

Ref. 1

11

1 1 1 1 1 4 4 4 1 1 1 2 1

2 T U R N T A B L E

1 1 2 1 1 1 1 1 1 1 4 6 2 A/R 2 1 1 2 2 12ft/3.7m

Fitting, Tee (Not Shown - Located on Engine)

1

Switch, Oil Pressure (Not Shown - Located on Engine) Nut 1/4"-20NC Fitting, Adapter (Not Shown - Located on Engine) Lockwasher 3/8" Flatwasher 3/8"

1 2 1 2 4

S E C T I O N

2-71

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-21. PUMP COUPLING INSTALLATION

2 T U R N T A B L E

2-72

3120801

SECTION 2 TURNTABLE FIGURE 2-21. PUMP COUPLING INSTALLATION FIG & ITEM #

PART NUMBER 0239954

101

102 103 104 105 106

1660170 1660174 1660175 0701014 4832000 0080164 0701014 4832000 0250600

201 202 203 204 205 206 207 208

3120801

1660183 0701010 4832000 0080164 0701014 4832000 0701015 4751600

QTY.

REV.

LOVEJOY COUPLING INSTALLATION (DEUTZ ENGINES WITH DESIGN A) Coupling - Lovejoy Disc, Coupling Hub, Coupling Bolt, Metric 10mm x 30mm Lockwasher 10mm Adapter, Pump Bolt, Metric 10mm x 30mm Lockwasher 10mm

DESCRIPTION

Ref.

—

HAYES COUPLING INSTALLATION (DEUTZ ENGINES WITH DESIGN B)

Ref.

Coupling Bole, Metric 10mm x 20mm Lockwasher 10mm Adapter, Pump Bolt, Metric 10mm x 30mm Lockwasher 10mm Bolt, Metric 10mm x 35mm (S/N 36560 to Present) Flatwasher 3/8” (S/N 36560 to Present)

1 1 1 6 6 1 12 12

S E C T I O N 2

2

1 6 6 1 10 18 2 2

2-73

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-22. MAIN PUMP ASSEMBLY

2 T U R N T A B L E

2-74

3120801

SECTION 2 TURNTABLE FIGURE 2-22. MAIN PUMP ASSEMBLY FIG & ITEM #

PART NUMBER 3600139

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

3120801

DESCRIPTION MAIN PUMP ASSEMBLY

Kit 7009513 Not Used 7003103 7009500 7009503 Kit 7009509 Kit 7009510 7009508 7005599 7005598 7009504 7009505 7009511 7005597 7005562 7005595

Seal, Lip Cover, End with Bushings Plug Dowel Plate, Thrust Seal, Channel Shaft and Gear Seal, Gasket Housing, Gear Carrier, Bearing with Bushings Shaft, Connecting Gear Set Housing, Gear Carrier, Bearing with Bushings Cover, Rear with Bushings Washer Stud Nut

2900673

Seal Kit (Includes Items 1,7 and 9)

QTY.

REV.

Ref.

B

1 1 1 12 6 6 1 Set 6 1 1 2 2 1 1 1 4 4 4

S E C T I O N 2 T U R N T A B L E

1

2-75

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-23. TANKS INSTALLATION

2 T U R N T A B L E

2-76

3120801

SECTION 2 TURNTABLE FIGURE 2-23. TANKS INSTALLATION FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

Ref.

3

NOTE: For Machines with Oversize Tanks see Section 10.

0239857 1

2

4400279 4400386 4400278

3 4 5 6 7 8 9 10 11 12

0641614 4751600 4761600 3311601 0641616 1340046 4300034 4070410 4070411 4070412

4400279 4400386 101

102 103 104 105 106 107 108 109 110 111 112 113

3120801

Not Used 4400280 4400387 Not Used 4060574 4562516 Not Used 1320022 3311401 4761400 Not Used 2200052 0100020 2180467 33000205

FUEL AND HYDRAULIC INSTALLATION Fuel Tank Assembly Options (See Items 101-151 for Breakdown): Tank - Prior to June 1995 Tank - June 1995 to Present Hydraulic Tank Assembly (See Items 201 - 257 for Breakdown) Bolt 3/8"-16NC x 1 3/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Bolt 3/8"-16NC x 2" Breather Stud (Welded on Part - Not Shown) Shim 1/16" Shim 1/8" Shim 3/16"

1

2 1

T U R N T A B L E

4 8 8 8 3 1 1 A/R A/R A/R

FUEL TANK ASSEMBLY OPTIONS: MACHINES BUILT PRIOR TO JUNE 1995 MACHINES BUILT JUNE 1995 TO PRESENT

Ref. Ref. Ref.

Tank, Fuel Options: Machines Built Prior to June 1995 Machines Built June 1995 to Present

1

Protector, Gauge Tube, Sight

15 in./38cm

Clamp, Hose Nut 1/4"-20NC Lockwasher 1/4"

2 3 3

Plug, Pipe Sealant, Pipe (Not Shown) Fitting, Barbed 90º Nut, Retainer

S E C T I O N

B 2

1

1 A/R 2 3

2-77

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-23. TANKS INSTALLATION (CONTINUED) FIG & ITEM #

4400278 201 202 202A 202B 202C 202D 203 204

2 T U R N T A B L E

PART NUMBER

205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 to 249 250

Not Used 2120103 2120107 7004244 7012559 7016333 4740338 2420080 7016664 1340045 1670468 Not Used 2180605 3520022 0641612 4761600 3311601 2180606 2120104 3311401 4761400 0100020 2200268 2200203 3300205 2180614 2220728 3960371 4751400 4740322 Not Used 4400277

0236285 0257365 0257366 0258626

301 1120314 1120367 1120512

2-78

DESCRIPTION HYDRAULIC TANK ASSEMBLY

Filter Assembly Element, Filter Indicator, Pressure Gasket - Between Tank and Filter O-Ring - Under Cap Washer, Sealing Gauge, Level Washer, Sealing - Viton Strainer Lid Pipe Plug, Magnetic Bolt 3/8"-16NC x 1 1/2" Lockwasher 3/8" Nut 3/8"-16NC Nipple, Pipe Filter Nut 1/4"-20NC Lockwasher 1/4" Sealant, Pipe (Not Shown) Fitting, Coupling Plug, Pipe 1/2" Nut, Retainer 5/16"-18NC Fitting, Straight Fitting, Tee Gasket Flatwasher 1/4" Washer, Sealing Tank Weldment FUEL CAP ASSEMBLY Standard Fuel Cap Standard Fuel Cap Protectoseal (Red) Fuel Cap Protectoseal (Blue) Fuel Cap (S/N 38057 To Present) Cap, Fill Options: Standard Fuel Cap Protectoseal (Red) Fuel Cap Protectoseal (Blue) Fuel Cap (S/N 38057 To Present)

QTY.

REV.

Ref.

B

1 1 1 1 1 6 1 1 1 1 1 1 4 4 4 1 1 12 12 A/R 1 1 3 1 1 1 14 4 1 Ref. Ref. Ref. Ref. Ref.

5/E 1 2 1

1

3120801

SECTION 2 TURNTABLE FIGURE 2-23. TANKS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-79

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION

2 T U R N T A B L E

2-80

3120801

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION FIG & ITEM #

PART NUMBER 0251169 0257231 0258188 0251170 0257232 0251169 0257231

1 2 3 4 5 6 7 8 9 10

2600148 1780227 4751400 3311405 4300031 2940042 0100011 4300032 4751500 0860678 0861095 0861194 0860678 0861095 0860679

0861096

101 102 103 104 105 106

3120801

Not Used 0860562 Not Used 4420008 0610084 0610080

DESCRIPTION GROUND CONTROLS INSTALLATION (100HX BUILT PRIOR TO S/N 28224) GROUND CONTROLS INSTALLATION (100HX BUILT S/N 28224 TO S/N37394) GROUND CONTROLS INSTALLATION (100HX BUILT S/N 37394 TO PRESENT) GROUND CONTROLS INSTALLATION (110HXER & 100HX+10) GROUND CONTROLS INSTALLATION (110HXER & 100HX+10 BUILT S/N 28224 TO PRESENT) GROUND CONTROLS INSTALLATION (110HX BUILT PRIOR TO S/N 28224) GROUND CONTROLS INSTALLATION (110HX BUILT S/N 28224 TO PRESENT) Ground Control Box Assembly (See Items 101-220 for Breakdown) Hinge Door, Ground Control Flatwasher 1/4" Locknut 1/4"-20NC Stud (Welded on Part) Latch Loctite #242 (Not Shown) Stud (Welded on Part) Flatwasher 5/16" CONTROL BOX ASSEMBLY (100HX BUILT PRIOR TO S/N 28224) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (100HX BUILT S/N 28224 TO S/N 37394) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (100HX BUILT S/N 37394 TO PRESENT) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (110HX BUILT PRIOR TO S/N 28224) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (110HX BUILT S/N 28224 TO PRESENT) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (110HXER AND 100HX+10 BUILT PRIOR TO S/N 28224) (VARIABLE PARTS) CONTROL BOX ASSEMBLY (110HXER AND 100HX+10 BUILT S/N 28224 TO PRESENT) (VARIABLE PARTS)

Box Gasket Card, Circuit (Engine Relay) Card, Circuit (Select)

QTY.

REV.

Ref.

B

Ref.

1

Ref.

1

Ref.

B

Ref.

1

Ref.

B

Ref.

1

1 1 1 14 14 5 1 A/R 4 8 Ref.

11

Ref.

6

Ref.

3

Ref.

11

Ref.

6

Ref.

12

Ref.

5

1 15 ft./4.5m

1 1

2-81

S E C T I O N 2 T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

107

108 109 110 111 112 113 114 115 116 117 118 119 120

2 T U R N T A B L E

121 122 123 124 125

126

2-82

0610083 0610106 0610130 0610100 3740070 3740016 Not Used 3740049 Not Used 4460301 3640686 4460299 4460298 4460300 4460307 4460311 4460308 4460306 4460305 4360216 4360232 4360275 4360284 4360468 4360003

127 128 129 130

2860002 2920027 2920029 4360212 2920026 2920026

131 132 133 134 135 136 137 138 139 140 141 142 143

4360274 4360199 2920090 4360202 4760600 4751400 3311401 4751000 3311001 4460051 3300048 0960238 4460071

DESCRIPTION Card, Circuit (Load Radius) Options: Prior to April 1993 April 1993 to S/N 44618 S/N 44618 to Present Card, Circuit (Overload) Relay - SPDT Relay - 3PDT Relay - 5PDT (With Skirt) Marker, Terminal (1-50) Rail Stop, Terminal Block, Terminal Barrier, Terminal Sleeve, Terminal Bar, Buss Option: 5 Position 2 Position Washer, Terminal Screw, Terminal Breaker, Circuit - 30 Amp Breaker, Circuit - 15 Amp Switch, Toggle (Select) Options: Prior to January 1992 January 1992 to S/N 47729 S/N 47729 to Present Switch, Key (Master Switch) (Prior to January 1992 Only) Key, Replacement (Prior to January 1992 Only) Light, Indicator - Green (Axles Set) Bulb, Light Breaker, Circuit - 3 Amp Light, Indicator - Red (Radius Limit) Light, Indicator - Red (Broken Fan Belt Light - Prior to January 1992 Only) Switch, Push Button (Start) Switch, Toggle (Ignition) (Prior to January 1992 Only) Light, Indicator - Blue (Capacity Limit) Switch, Toggle Lockwasher #6 Flatwasher 1/4" Nut 1/4"-20NC Flatwasher #10 Nut #10-24NC Connector, Strain Relief Nut, Conduit Bushing, Reducer Connector, Strain Relief

QTY.

REV.

2 16 A/R 9 1 1 2 47 1 A/R 1

A/R A/R 1 2 1

1 1 1 3 1 1 1 1 1 1 4 A/R A/R A/R A/R A/R 4 6 6 1

3120801

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 to 176 172 177

4460244 3300177 0750806 0720803 4760800 3310801 0720603 Not Used 3790012 4460234 3520028 Not Used Not Used Not Used 3910616 4564088 3310601 Not Used 2420009 2420091 2420074 3520070 Not Used 4360200 4360198 4060229 0610091 Not Used Not Used 3252023 2920015 4360267 4360281

178 179 180

4360282 4360476 181 4360289 4360475 7012611

182 183 184 185 186 to 200

3120801

7012612 7020175 7020176 1704260 4070987 4070991 3910804 Not Used

DESCRIPTION Connector, Strain Relief Nut, Tinnerman Screw, Self-Tapping #8 x 3/4" Screw, Hex #8-32NC x 3/8" Lockwasher #8 Nut #8-32NC Screw, Hex #6-32NC x 3/8"

QTY.

REV.

1 3 3 6 6 6 2

O-Ring Clamp, Cable (Not Shown) Plug, Hole (Prior to January 1992 Only)

A/R 10 2

Screw, Hex #6-32NC x 1" Stand-Off #6-32NC x 1/4" Nut #6-32NC

A/R A/R A/R

Hourmeter Voltmeter Gauge, Oil Pressure Plug, Hole

1 1 1 1

Switch, Toggle (Auxiliary Power) Switch, Toggle (Proximity Manual Test) Guard, Switch Card, Circuit (Drive Accessories)

1 1 1 1

Nameplate (Prior to January 1992) Lamp (January 1992 to Present) Block, Contact - SPST (Prior to S/N 49405) Block, Contact (Prior to S/N 49405) Block, Contact Options: Prior to S/N 47729 S/N 47729 to Present Switch, Emergency Stop Options: Prior to S/N 47729 S/N 47729 to Present Cap Options: Cap, Mushroom Head (Used on Switch p/n 4360289) Boot (Used on Switch p/n 4360289) Cap, Red (Used on Switch p/n 4360475) Contact Block (Used on Switch p/n 4360475) Decal - EMS (S/N 47729 to Present) Shim .015 (S/N 47729 to Present) Shim .125 (S/N 47729 to Present) Screw #8-32NC x 1/4” (S/N 47729 to Present)

1 1 1 3 1

S E C T I O N 2 T U R N T A B L E

1

1

1

1 1 1 6

2-83

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

201 3251856 3252146 3252359 3252545 3252659

2

3251856 3252146 3252359 3252545 3252655

T U R N T A B L E

3251857 3252148 3252360 3252546 3252656 202 0140019 0140011 203 Not Required 3740016 204 Not Required 3740049 205 Not Required 4360202 206 Not Required 4120002 207 Not Required 4160025 208 3252017 Not Required 209 4120013 4120037 210 3740058 3740123 211 3740063 3740124

2-84

DESCRIPTION Lid/Nameplate Options: 100HX: Prior to October 1991 October 1991 to May 1994 May 1994 to S/N 33726 S/N 33726 to S/N 37394 S/N 37394 to Present 110HX: Prior to October 1991 October 1991 to May 1994 May 1994 to S/N 33726 S/N 33726 to S/N 47729 S/N 47729 to Present 100HX+10 & 110HXER Prior to October 1991 October 1991 to May 1994 May 1994 to S/N 33726 S/N 33726 to S/N 47729 S/N 47729 to Present Alarm Options: Prior to S/N 28224 S/N 28224 to Present Relay - 3PDT Options: 100HX & 110HX 100HX+10 & 110HXER Relay - 5PDT (With Skirt) Options: 100HX & 110HX 100HX+10 & 110HXER Switch, Toggle (Extend-A-Reach) 100HX & 110HX 100HX+10 & 110HXER Base, Relay Options: 100HX & 110HX 100HX+10 & 110HXER Spring, Relay Options: 100HX & 110HX 100HX+10 & 110HXER Nameplate Options: Prior to January 1992 January 1992 to Present Socket, Relay Options: Prior to S/N 28224 S/N 28224 to Present Relay Options: Prior to S/N 28224 S/N 28224 to Present Spring, Relay Options: Prior to S/N 28224 S/N 28224 to Present

QTY.

REV.

1

1

A/R 0 1 A/R 0 1 A/R 0 1 A/R 0 1 A/R 0 1 1

2

2

2

3120801

SECTION 2 TURNTABLE FIGURE 2-24. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

212 Not Required 4360069 213 Not Required Not Required 4460309 0253378

301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318

3120801

3790012 4360202 4060229 3640930 4460299 3740019 4120028 4160112 3740086 4120029 3640555 3740090 4120030 4160112 Not Used 0720603 4760600 3310601

DESCRIPTION Breaker, Circuit - 10 Amp Options: Prior to S/N 28224 S/N 28224 to Present Bar, Buss - 3 Position Options: 100HX & 110HX 100HX+10 & 110HXER Prior to S/N 28224 100HX+10 & 110HXER S/N 28224 to Present TUV MONITORING SYSTEM INSTALLATION (110HXER AND 100HX+10)

QTY.

REV.

A/R 0 3 A/R 0 0 1 Ref.

O-Ring Switch, Toggle Switch, Guard Rail Mounting Stop, Terminal Relay, Latch Socket, Relay Spring, Relay Relay Socket, Relay Rail Mounting Time Delay, Relay Socket, Relay Spring, Relay

1 1 1 1 5 2 2 2 3 1 1 2 2 2

Screw #6-32 x 3/8" Lockwasher #6 Nut #6-32

4 4 4

C/2

S E C T I O N 2 T U R N T A B L E

2-85

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-25. LOAD MANAGEMENT INSTALLATION

2 T U R N T A B L E

2-86

3120801

SECTION 2 TURNTABLE FIGURE 2-25. LOAD MANAGEMENT INSTALLATION FIG & ITEM #

PART NUMBER 0239868

1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

4843310 4844080 4844272 4160099 0630422 3313002 3273001 4360263 4360259 3841004 3321501 3533414 4843128 0630510 3321405 3900104 4920140 4460342 3421677 0642252 3312205 2160002 4220120 4220121 4070729 4070728 Not Used Not Used Not Used Not Used 4220157 4220158 0100019

3120801

DESCRIPTION LOAD MANAGEMENT INSTALLATION Base Weldment Options: Prior to May 1992 May 1992 to September 1992 September 1992 to Present Spring Bolt 1 1/4"-&NC x 14" Nut, Jam 1 1/4"-7NC Nut 1 1/4"-7NC (Grade 8) Switch, Limit Switch, Proximity Rod, Actuator Nut 5/16"-18 Plate, Actuator Mounting Actuator, Switch (Prior to S/N 27316) Bolt, Leveler (S/N 27316 to Present) Locknut 1/4"-28NF Screw, Drilled Head #10-24NC x 2 1/4" Lockwire Connector, Strain Relief Pin, Load Moment Pivot Bolt 3/4"-10NC x 6 1/2" Locknut 3/4"-10NC Fitting, Grease Stop, Turntable Stop, Turntable Shim 11 GA x 1 1/2" x 4" Shim 16 GA x 1 1/2" x 4"

Stop, Turntable 1/2" x 1 1/2"" x 4" Stop, Turntable 1/4" x 1 1/2" x 4" —————————— Loctite

QTY.

REV.

Ref.

7

1

5 5 5 5 1 1 1 1 1 1 1 1 4 2 2 1 1 1 2 2 A/R A/R A/R

S E C T I O N 2 T U R N T A B L E

A/R A/R A/R

2-87

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-26. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE)

2 T U R N T A B L E

2-88

3120801

SECTION 2 TURNTABLE FIGURE 2-26. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE) FIG & ITEM #

PART NUMBER

DESCRIPTION HOOD INSTALLATION (STANDARD PARTS)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

29

30

31 32 33 34 35 36 37 38 39

3120801

Not Used 4843337 0641408 4751400 3311405 3941405 4761400 Not Used 0641406 4751400 3311405 2940051 Not Used 1780172 0641406 4751400 3311405 Not Used 4842227 0641406 4751400 3311405 2940042 0901595 3311505 4751500 4300038 0940036 0901198 0901197 3311505 4751500 4300038 0641508 4761500 4751500 4160081 3311505 4751500 3200222 0630383 4751500 3311505 0901500 Not Used

QTY.

REV.

Ref.

Panel - Top Hood (Right Side) Bolt, 1/4"-20NC x 1" Flatwasher 1/4" Locknut 1/4"-20NC Screw, Self Tap 1/4"-20NC x 5/8" Lockwasher 1/4"

1 10 10 10 4 4

Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Locknut 1/4"-20NC Latch

16 16 16 2

Panel - Side (Right Side) Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Locknut 1/4"-20NC

1 5 5 5

Door (Right Side) Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Locknut 1/4"-20NC Latch Bracket, Door Latch Locknut 5/16"-18NC Flatwasher 5/16" Stud (Welded on Part) (Not Shown) Bumper, Rubber Bracket, Door Stop (Located on Left Side & at Bottom of Hydraulic Tank on Right Side) Bracket, Door Stop (Located at Bottom of Fuel Tank) Locknut 5/16"-18NC Flatwasher 5/16" Stud (Welded on Part) (Not Shown) Bolt 5/16"-18NC x 1" Lockwasher 5/16" Flatwasher 5/16" Spring, Gas Locknut 5/16"-18NC Flatwasher 5/16" Bracket, Gas Spring Bolt, Carriage 5/16"-18NC x 3/4" Flatwasher 5/16" Locknut 5/16"-18NC Bracket, Mounting - Hood (Right Side)

1 12 12 12 2 2 4 4 4 4 1

S E C T I O N 2 T U R N T A B L E

1 2 2 2 2 2 2 2 4 4 2 2 2 2 1

2-89

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-26. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE) (CONTINUED) FIG & ITEM #

PART NUMBER

40 41

3311605 4751600 4300034 4843963 3380378 0641406 4751400 3311405 3941405 4761400 2940045 0901502 3311605 4751600 4300034 1780381 3311505 4751500 4300034 1670516 3311405 4751400 4300031 3380379 Not Required 3311605 4751600 4300034

42 43 44 45 46 47 48 49 50 51 52

2 T U R N T A B L E

53 54 55 56 57 58 59 60 61 62

0239867 101 102 103 104 105 106

3380377 4843070 3380382 4842227 4843324 Not Required 0250178

201 202 203 204 205 206

2-90

Not Used 0140024 4300031 4751400 4761400 3311401

DESCRIPTION

QTY.

Locknut 3/8"-16NC Flatwasher 3/8" Stud (Welded on Part - Not Shown) Hood, Top and Side - Rear (Right Side) Hood, Top & Side - Rear (Left Side) Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Locknut 1/4"-20NC Screw, Self Tap 1/4"-20NC x 5/8" Lockwasher 1/4" Latch Bracket, Mounting Locknut 3/8"-16NC Flatwasher 3/8" Stud (Welded on Part - Not Shown) Panel, End Locknut 5/16"-18NC Flatwasher 5/16" Stud (Welded on Part - Not Shown) Cover, Front Locknut 1/4"-20NC Flatwasher 1/4" Stud (Welded on Part - Not Shown) Panel, Hood

2 2 2 1 1 6 6 6 4 4 A/R A/R A/R A/R A/R 1 4 4 4 1 4 4 4 1

Locknut 3/8"-16NC Flatwasher 3/8" Stud (Welded on Part - Not Shown)

A/R A/R A/R

HOOD INSTALLATION - DEUTZ ENGINE MACHINES Panel - Top Hood (Left Side) Ventilator Panel - Side (Left Side) (Without Door) Door (Left Side) Bracket, Mounting - Hood (Left Side)

ALARM INSTALLATION

Alarm Stud (Welded on Part - Not Shown) Flatwasher 1/4" Lockwasher 1/4" Nut 1/4"-20NC

Ref.

REV.

A

1 2 1 1 1

Ref.

B

1 2 2 2 2

3120801

SECTION 2 TURNTABLE FIGURE 2-26. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 2 T U R N T A B L E

3120801

2-91

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-27. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620078 TURNTABLE)

2 T U R N T A B L E

2-92

3120801

SECTION 2 TURNTABLE FIGURE 2-27. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620078 TURNTABLE) FIG & ITEM #

PART NUMBER 0253362

1 2

3536417 4844114 4844390

3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

3120801

3380378 3380419 3380400 4844087 1780172 4844236 3535948 2940051 4844113 3380379 4844074 Not Used 4843334 3941405 4761400 4300034 4751600 3311605 4160081 0630383 4751500 3311505 0641406 3311405 4751400 0901500 4843324 0901502 Not Used 1670516 4844083 4740362 0641408 3537819 0641512 0940036 0901197 Not Used 0641508 4761500 3200222

DESCRIPTION HOODS INSTALLATION

QTY.

REV.

Ref.

5

Panel - Hood Top (Engine Side) Panel - Top Hood (Right Side) Options: October 1992 to February 1993 February 1993 to Present Panel - Hood (Valve Side) Options: Prior to July 1995 July 1995 to Present Panel - Hood (Engine Side) Panel - Door (Engine Side) Door (Valve Side) Duct, Discharge (Engine Side) Plate, Baffle (Engine Side) Latch Door (Valve Side) Panel - Hood Top (Valve Side) Door (Engine Side)

1 1

1 1 1 1 1 1 1 1 1

Mounting, Gas Spring Screw, Self-Tap 1/4" x 5/8" Lockwasher 1/4" Stud (Welded on Part) Flatwasher 3/8" Locknut 3/8"-16NC Spring, Gas Bolt, Carriage 5/16"-18NC x 3/4" Flatwasher 5/16" Locknut 5/16"-18NC Bolt 1/4"-20NC x 3/4" Locknut 1/4"-20NC Flatwasher 1/4" Bracket, Mounting - Hood Bracket, Mounting - Hood Bracket, Mounting - Hood

1 8 8 16 16 16 2 4 10 6 40 70 48 1 1 3

Cover, Front Hood (Front) Washer, Fender Bolt 1/4"-20NC x 1" Plate, Extension - Base Bolt 5/16"-18NC x 1 1/2" Bumper, Door Bracket, Door Stop

1 1 41 22 1 5 2 2

Bolt 5/16"-18NC x 1" Lockwasher 5/16" Mounting, Gas Spring

4 4 2

S E C T I O N 2

1

T U R N T A B L E

2-93

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-27. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620078 TURNTABLE) (CONTINUED) FIG & ITEM #

PART NUMBER

43 44 45 46 47 48 49 50 51 52 53 54 55

2940042 Not Used Not Used 4300032 3536414 3536415 3535951 3820018 2820059 2820058 2820053 2820057 4060803

2 T U R N T A B L E

0100011 0252652 101 102 103 104

3960418 3960389 3960429 3960433 0251543

201 202 203 204

2-94

0140032 0641406 4751400 3311405

DESCRIPTION Mounting, Latch

Stud (Welded on Part) Plate, Seal Plate, Seal Plate, Hinge Shield Rivet Acoustical Foam - 33 x 20 Acoustical Foam - 20 x 17 Acoustical Foam - 6 3/4" x 14 3/4" Acoustical Foam - 24" x 16 3/4" Flex-Trim (July 1995 to Present) —————————— Loctite #242 HOOD SEALS INSTALLATION Seal Seal, Door Tape, Sealant Seal ALARM INSTALLATION (OPTIONAL) Alarm Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Locknut 1/4"-20NC

QTY.

REV.

5

5 1 1 1 10 1 1 1 1 2ft/61cm A/R Ref.

A

13 ft./4m 8 ft./2.4m 7 ft./2.1m 6 ft./1.8m Ref.

2

1 2 4 2

3120801

SECTION 3 BOOM TABLE OF CONTENTS FIGURE

3-1 3-2 3-3 3-4 3-5 3-6 3-7

DESCRIPTION

BOOM ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTEND-A-REACH INSTALLATIONS (Prior to May 1992) (100HX+10 & 110HXER Only) . . . .

EXTEND-A-REACH INSTALLATIONS (May 1992 to Present) (100HX+10 & 110HXER Only) .

BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION. . . . . . . . . . . . . . . . . . .

BROKEN CHAIN LIMIT SWITCH INSTALLATION (German/Austrian Specs.) . . . . . . . . . . . . . .

BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

3-2 3-14 3-18 3-22 3-24 3-28 3-30

S E C T I O N 3 B O O M

3120801

3-1

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 1 OF 2)

3 B O O M

3-2

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 2 OF 2)

S E C T I O N 3 B O O M

3120801

3-3

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION FIG & ITEM #

PART NUMBER

DESCRIPTION BOOM ASSEMBLIES (STANDARD PARTS)

1 to 9 10 11

13 to 14 15 16 17 18 19 20 21 22 23

Not Used 3580139 0238927 0961293 0237151 0961353 Not Used 3421286 1360171 3421279 3450408 3313002 3300244 3312602 3300243 0238901

24 25 26 27 28 29

Not Used Not Used 3421570 4751600 3450303 0238919

30 31 32 33 34 35

3421280 4751000 3450202 Not Used 3420659 0238945

36 37 38 39 40 41 42 43 44 45 46 47

Not Used 3300240 3312002 4761600 Not Used 4843105 3421539 3450814 4070616 0560689 2160002 3421538 3421778 4740307 3421290 Not Used

12

3 B O O M

48 49 50

3-4

QTY.

Sheave - Outer Mid Extend Chain Sheave Assembly - Fly Extend Chain Bushing, Bronze (1 Per Sheave) Sheave Assembly - Outer Mid Retract Chain Bushing, Bronze (1 Per Sheave)

1 3 3 2 2

Pin, Attach Clevis Pin, Attach Pin, Cotter 1/8" x 2" Nut, Jam 1 1/4"-7NC Locknut, Nylon 1 1/4"-7NC Grade 8 Nut, Jam 1"-8NC Locknut, Nylon 1"-8NC Grade 8 Adjustable Clevis Assembly - Outer Mid Extend Chain (See Figure 3-2 for Breakdown)

4 1 1 2 1 1 2 2 1

Pin, Attach Flatwasher 3/8" Pin, Cotter 3/22" x 3/4" Adjustable Clevis Assembly - Fly Extend Chain (See Figure 3-2 for Breakdown) Pin, Attach Flatwasher #10 Pin, Cotter 1/16" x 1/2"

2 35 10 1

Pin, Attach (Mid 1990 to Present) Adjustable Clevis Assembly - Outer Mid Retract Chain (See Figure 3-2 for Breakdown)

REV.

Ref.

A B

4 A/R A/R 2 1

Locknut, Nylon 5/8"-11NC (Grade 8) Nut, Jam 5/8"-11NC Lockwasher 3/8"

4 4 A/R

Mount, End - Chain Pin, Sheave Pin, Cotter 1/4" x 3 1/2" Shim 1/32"/.8mm Block, Mounting - Wear Pad Fitting, Grease Pin, Sheave (Prior to Mid 1990) Pin, Sheave (Mid 1990 to Present) Washer, Thrust Pin, Sheave

1 1 2 A/R 2 7 2 1 A/R 2

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

51 52 53 54 55 56

4740311 3951606 0100011 3421497 3421293 3340475

57 58 59

4070535 4070536 3340263

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83

4070544 4070545 3340563 4070615 1120019 0721003 4761000 0641605 0641607 0641609 4761800 0641808 4751800 0641614 0641630 3340496 4070602 4070603 0641608 0641636 0239607 0961370 Not Used 3340506 3340500

84 85 86

4070708 4070709 3340502

87 88 89 to 90 91 92 93 94 95 96

4070710 4070711 Not Used 3311601 0641610 Not Used 4280242 1320121 0641404

3120801

DESCRIPTION

QTY.

Washer, Thrust Setscrew 3/8"-16NC x 3/4" Loctite #242 (Not Shown) Pin, Trunion Pin, Cylinder Pad, Wear (Fly Rear Top, Inner Mid Rear Top and Outer Mid Rear Top) Shim 1/8"/3.2mm Shim 1/16"/1.6mm Pad, Wear (Carrier Support - Left Side, Fly Rear Sides and Outer Mid Rear Sides) Shim 1/16"/1.6mm Shim 1/8"/3.2mm Pad, Skid Shim 1/16"/1.6mm Cap Bolt #10-24NC x 3/8" Lockwasher #10 Bolt 3/8"-16NC x 5/8" Bolt 3/8"-16NC x 7/8" Bolt 3/8"-16NC x 1 1/8" Lockwasher 1/2" Bolt 1/2"-13NC x 1" Flatwasher 1/2" Bolt 3/8"-16NC x 1 3/4" Bolt 3/8"-16NC x 3 3/4" Pad, Wear (Base Front Bottom) Shim 1/8"/3.2mm Shim 1/16"/1.6mm Bolt 3/8"-16NC x 1" Bolt 3/8"-16NC x 4 1/2" Sheave Assembly Bushing, Bronze (1 Per Sheave)

12 5 A/R 2 1 6

Pad, Wear (Outer Mid Front Bottom) Pad, Wear (Outer Mid Front Sides and Top, Inner Mid Front Top and Base Front Top) Shim 1/16"/1.6mm Shim 1/8"/3.2mm Pad, Wear (Inner Mid Front Sides and Base Front Sides) Shim 1/16"/1.6mm Shim 1/8"/3.2mm

2 10

A/R A/R

Nut 3/8"-16NC Bolt 3/8"-16NC x 1 1/4"

20 6

Strip, Reinforcing Clamp (Prior to S/N 51528) Bolt 1/4"-20NC x 1/2"

2 4 2

REV.

S E C T I O N 3

A/R A/R 9

B O O M

A/R A/R 4 A/R 4 12 12 2 18 52 1 1 2 7 6 2 A/R A/R 8 4 1 1

A/R A/R 8

3-5

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

97 98 to 99 100 101 102

3450806 Not Used 3840956 2660042

3

103 104 105

B O O M

106 107

108 109 110 111 to 113 114 115 to 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 to 143 144

3-6

3840957 0902470 Not Used 4843080 Use 1060515 1060515 4921168 Use 1060516 1060516 3840844 4340519 0880090 Not Used 3532793 Not Used 4340413 4300098 3311401 4751400 4761400 4300032 3840858 4562516 4340453 0181175 4761500 0641510 3311501 4751500 4340520 4740349 3421632 Not Used 3421571 1380124 4920385 Not Used 3430408 3450203 3421628 Not Used 4160098

DESCRIPTION

QTY.

Pin, Cotter 1/4" x 1 1/2"

2

Hanger (Left Side) Holder Rod, Hose Retainer (Left Side) Options: Prior to S/N 40625 S/N 40625 to Present

1 1 1

Bracket, Support - Carrier Wear Pad (Left Side) Cable, Electrical - 12/4 Prior toS/N 52883 (Was P/N1060012) S/N 52883 to Present Harness - 110V (Prior to May 1992) Cable, Electrical - 16/30 Prior toS/N 52883 (Was P/N1060229) S/N 52883 to Present Hanger (Right Side) Support Brace

1 131ft./40m

1 131ft./40m

1 4 4

Plate, Hose Cover

1

Support, Hydraulic Line Stud (Welded on Part) Nut 1/4"-20NC Flatwasher 1/4" Lockwasher 1/4" Stud (Welded on Part) Rod, Tube Retainer Tube Support, Bracket Angle Lockwasher 5/16" Bolt 5/16"-18NC x 1 1/4" Nut 5/16"-18NC Flatwasher 5/16" Support Washer, Special Pin

8 8 18 21 18 10 1 1 1 2 3 3 3 6 2 1 1

Pin, Attach Clip, Retainer (Prior to October 1995) Wire, Safety (Prior to October 1995)

2 34

Pin, Clevis 1/4" x 1" Pin, Cotter 1/16" x 3/4" Pin Washer, Belleville

REV.

17.6’/5.4m

1 1 2 A/R

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

145 146 147 148 149 150 to 152 153 154 155 156 to 157 158 159 160 161 162

4712000 0361727 1260261 1360223 1060016 Not Used 3340494 4070600 4070601 Not Used 0741608 3520029 4740304 0641407 1670836

163

0641611

0800799 0800801 0800648 0800692 0800797 0800897 0800597

0800687

0800784 0800782

201 0800802 0800649 0800603 202 0800785 0800650 0800694 0800766

3120801

DESCRIPTION

QTY.

REV.

Flatwasher Bar Chain (Mid 1990 to Present) Clevis (Mid 1990 to Present) Cable, Electrical - 16/3 (Not Shown)

80ft/24.4m

Pad, Wear (Inner Mid Front Bottom) Shim 1/8"/3.2mm Shim 1/16"/1.6mm

2 A/R A/R

3

1 4 2 2 8

B O O M

Screw, Countersunk 3/8"-16NC x 1" Plug, Hole Washer, Spacer Bolt 1/4"-20NC x 7/8" Cover, Boom (Located on bottom of boom sections) (Not Shown) (S/N 34323 to Present) Bolt 3/8”-16NC x 1 3/8” (S/N 40625 to Present)

2 1 1 1

S E C T I O N

2

BOOM ASSEMBLY (VARIABLE PARTS) 100HX Standard Machine with 4620078 Turntable 100HX With Chip Covers & 4620078 Turntable 110HX Standard Machine with 4620044 Turntable Machines Built Prior To Early 1990 110HX Standard Machine with 4620044 Turntable Machines Built Early 1990 To May 1992 110HX Standard Machine with 4620078 Turntable Machines 110HX With Chip Covers & 4620078 Turntable Machines 100HX+10 &110HXER Standard Machine with 4620044 Turntable Machines Built Prior To Early 1990 100HX+10 &110HXER Standard Machine with 4620044 Turntable Machines Built Early 1990 To May 1992 100HX+10 & 110HXER Standard Machine with 4620078 Turntable 100HX+10 & 110HXER With Chip Covers & 4620078 Turntable

Ref. Ref. Ref. Ref.

12 12 A

Ref.

E

Ref.

10

Ref.

8

Ref.

D

Ref.

G

Ref.

11

Ref.

11

Base Weldment Options: 100HX 110HX 100HX+10 &110HXER Inner Mid Weldment Options: 100HX 110HX with 4620044 Turntable Machines Built Prior To Early 1990 110HX with 4620044 Turntable Machines Built Early 1990 To May 1992 110HX with 4620078 Turntable Machines

1

1

3-7

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0800604 0800689

202A 203

0800785 3532549

3

0800786 0800651

B O O M

0800695 0800767 0800605 0800690 0800786 203A 3532569 3532549 204 0800804 0800556 0800696 0800796 0800565 0800691 0800787 205 1682032 1682821 1682030 1682820 1682032 1682821 206 1260239 1260235 1260239 207 1260238 1260234 1260238

3-8

DESCRIPTION 100HX+10 &110HXER with 4620044 Turntable Machines Built Prior To Early 1990 100HX+10 &110HXER with 4620044 Turntable Machines Built Early 1990 To May 1992 100HX+10 & 110HXER With 4620078 Turntable Plate, Skid Outer Mid Weldment Options: 100HX 110HX with 4620044 Turntable Machines Built Prior To Early 1990 110HX with 4620044 Turntable Machines Built Early 1990 To May 1992 110HX with 4620078 Turntable Machines 100HX+10 &110HXER with 4620044 Turntable Machines Built Prior To Early 1990 100HX+10 &110HXER with 4620044 Turntable Machines Built Early 1990 To May 1992 100HX+10 & 110HXER with 4620078 Turntable Plate, Skid 4620044 Turntable Machines 4620078 Turntable Machines Fly Weldment Options: 100HX 110HX with 4620044 Turntable Machines Built Prior To Early 1990 110HX with 4620044 Turntable Machines Built Early 1990 To May 1992 110HX with 4620078 Turntable Machines 100HX+10 &110HXER with 4620044 Turntable Machines Built Prior To Early 1990 100HX+10 &110HXER with 4620044 Turntable Machines Built Early 1990 To May 1992 100HX+10 & 110HXER with 4620078 Turntable Telescope Cylinder Assembly Options (See Section 5 for Breakdown) 100HX Prior to October 1992 100HX October 1992 to Present 110HX Prior to October 1992 110HX October 1992 to Present 100HX+10 & 110HXER Prior to October 1992 100HX+10 & 110HXER October 1992 to Present Chain, Extend - Outer Mid Options (BL866): 100HX 110HX 100HX+10 & 110HXER Chain, Extend - Fly Options (BL823): 100HX 110HX 100HX+10 & 110HXER

QTY.

REV.

1 1

1

1

1

1 set

1 set

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

208 1260282 1260232 1260275 1260236 1260282 209 1260237 1260233 1260237 210 0232901 0440074 3960206 0239606 0961369 211 0239267 0239268 0239267 212 3421216 3421629 213 3420659 3421280 214 0238946 0238945 215 3421289 3422040 216 0901503 0901700 217 4843103 4844126 218 218A 1180187 1180188

3120801

DESCRIPTION Chain, Retract - Fly Options: 100HX 110HX 4620044 Turntable (BL423) 110HX with 4620078 Turntable (BL446) 100HX+10 & 110HXER with 4620044 Turntable (BL423) 100HX+10 & 110HXER with 4620078 Turntable (BL446) Chain, Retract - Outer Mid Options (BL446): 100HX 110HX 100HX+10 & 110HXER Sheave Assembly - Fly Retract Chain Options: 4620038 & 4620044 Turntable Machines: Sheave Assembly - Fly Retract Chain Bearing, Roller (1 Per Sheave) Seal (2 Per Sheave) 4620078 Turntable Machines: Sheave Assembly - Fly Retract Chain Bushing, Bronze (1 Per Sheave) Adjustable Clevis Assembly - Outer Mid Extend Chain Options (See Figure 3-2 for Breakdown): 100HX 110HX 100HX+10 & 110HXER Pin, Attach Options: 4620044 Turntable Machines 4620078 Turntable Machines Pin, Attach Options: 4620044 Turntable Machines 4620078 Turntable Machines Adjustable Clevis Assembly - Fly Retract Chain Options (See Figure 3-2 for Breakdown): 4620044 Turntable Machines (BL423 Chain) 4620078 Turntable Machines (BL446 Chain) Pin, Sheave Options: 4620044 Turntable Machines 4620078 Turntable Machines Bracket, Wear Pad Options: 4620044 Turntable Machines 4620078 Turntable Machines Tube, Hose and Cable (Left Side) Options: 4620044 Turntable Machines 4620078 Turntable Machines Carrier (Left Side) Options: Power Track for 4620044 Turntable Machines: 110HX with 4620044 Turntable 100HX+10 & 110HXER with 4620044 Turntable

QTY.

REV.

1

S E C T I O N 3

1

B O O M

2 2 4 2 2 1

2

2

1

2

1

1

1

3-9

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

218B 7006178 Use 7006143

Use 7006138

3 218C 1180286

B O O M

1180295 1180288 1180296 1180292 218D 7006193 7006514 7006178 7006145 7006196 7006143 7006138

7016520 7016531

7006165 218E 70003143 70003144

3-10

DESCRIPTION Power Track Replacement Parts (4620044 Turntable Machines): Repair Section - 1 Foot Bracket, Mounting (Includes 1 left, 1 right mounting brackets & 2 spacers) (was p/n 7006179) Pin Assembly (Includes 1 link pin, 1 retaining ring & 4 washers of various thicknesses) (was p/n 7006180) Power Track 4620078 Turntable Machines : 100HX without Chip Covers & 4620078 Turntable (was p/n 1180286 - Gemco is Original Equipment/Gortrac is Service Replacement) 100HX, 100HX+10 & 110HXER with Chip Covers & 4620078 Turntable 110HX without Chip Covers & 4620078 Turntable 110HX with Chip Covers & 4620078 Turntable 100HX+10 & 110HXER with 4620078 Turntable Gemco Power Track Replacement Parts (4620078 Turntable Machines): Repair Section - 1 Foot without Chip Covers (100HX, 100HX+10 & 110HXER) Repair Section - 1 Foot without Chip Covers (110HX) Repair Section - 1 Footwith Chip Covers (100HX) Repair Section - 1 Footwith Chip Covers (100HX+10 & 110HXER) Repair Section - 1 Footwith Chip Covers (110HX) Bracket, Mounting (Includes 1 left, 1 right mounting brackets & 2 spacers) Pin Assembly (Includes 1 link pin, 1 retaining ring & 4 washers of various thicknesses) Rod W/Roll Pin (1180286 Power Track Only) Clamping Carrier Assembly (Includes 2 link pins, 1 clamping carrier, 1 clamping stiffener, 1 bolt, 1 nut & 1 lockwasher) (1180286 Power Track Only) Kit, Rod Carrier (Includes 1 rod, 1 sleeve & 2 screws) (1180286 Power Track Only) Gortrac Power Track Replacement Parts (4620078 Turntable Machines): Repair Section (Includes 1 set of attaching hardware) (1001119696 Power Track Only) Mounting Bracket Kit (Includes 4 mtg feet & hardware to attach to track) (1001119696 Power Track Only)

QTY.

REV.

A/R 4

A/R

A/R A/R A/R A/R A/R 4 A/R

1 1

1

A/R A/R

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

219 1180297 1180185 1180297 1180186 1180293 220 3840831 3841013 221 3860046 3860050 222 1320072 1320155 223 1180189 1180254 224 224A Use 1001119693

224B 7006178 Use 7006143

Use 7006138

224C 70003149 70003150

224D 1180236 1180258 224E 7006153 7006145 Use 7006143

3120801

DESCRIPTION Carrier Tube Weldment (Left Side) Options: 100HX 110HX with 4620044 Turntable 110HX with 4620078 Turntable 100HX+10 & 110HXER with 4620044 Turntable 100HX+10 & 110HXER with 4620078 Turntable Rod, Roller Options: 4620044 Turntable Machines 4620078 Turntable Machines Roller Options: 4620044 Turntable Machines 4620078 Turntable Machines Clamp, U-Bolt Options: 4620044 Turntable Machines 4620078 Turntable Machines Carrier Tube Weldment (Right Side) Options: 4620044 Turntable Machines 4620078 Turntable Machines Carrier (Right Side) Options: Power Track 4620044 Turntable Machines: Machines with 4620044 Turntable (was p/n 1180106 - Gemco is Original Equipment/Gortrac is Service Replacement) Gemco Power Track Replacement Parts (4620044 Turntable Machines): Repair Section - 1 Foot Bracket, Mounting (Includes 1 left, 1 right mounting brackets & 2 spacers) (was p/n 7006179) Pin Assembly (Includes 1 link pin, 1 retaining ring & 4 washers of various thicknesses) (was p/n 7006180) Gortrac Power Track Replacement Parts (4620044 Turntable Machines): Repair Section (Includes 1 set of attaching hardware) (1001119693 Power Track Only) Mounting Bracket Kit (Includes 4 mtg feet & hardware to attach to track) (1001119693 Power Track Only) Power Track 4620078 Turntable Machines : Machines without Chip Covers & 4620078 Turntable Machines with Chip Covers & 4620078 Turntable Gemco Power Track Replacement Parts (4620078 Turntable Machines): Repair Section - 1 Foot without Chip Covers Repair Section - 1 Foot with Chip Covers Bracket, Mounting (Includes 1 left, 1 right mounting brackets & 2 spacers) (was p/n 7006179)

QTY.

REV.

1

S E C T I O N

2

3 2

B O O M

2

1

1 1

A/R 4

A/R

A/R A/R

1

A/R A/R 4

3-11

S E C T I O N

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

224E cont’d

Use 7006138

7016520 7016531

3

7006165

B O O M

225 4843087 4843107 226 4060568 4060685 4060685 227 4060673 4060684 4060684 228 3532841 3536001 229 Not Required 3840975 Not Required 230 Not Required 1670321 231 4070498 Not Required 232 1260254 1260242 1260254 1260242 1260254 233 1360218 1360234

3-12

DESCRIPTION Pin Assembly (Includes 1 link pin, 1 retaining ring & 4 washers of various thicknesses) (was p/n 7006180) Rod W/Roll Pin (1180236 Power Track Only) Clamping Carrier Assembly (Includes 2 link pins, 1 clamping carrier, 1 clamping stiffener, 1 bolt, 1 nut & 1 lockwasher) (1180236 Power Track Only) Kit, Rod Carrier (Includes 1 rod, 1 sleeve & 2 screws) (1180236 Power Track Only) Cover, Boom End Options: 4620044 Turntable Machines 4620078 Turntable Machines Shield, Hose and Cable (Right Side) Options: 100HX & 110HX with 4620038 & 4620044 Turntable 100HX+10 & 110HXER with 4620038 & 4620044 Turntable 4620078 Turntable Machines Shield, Hose and Cable (Right Side) Options: 100HX & 110HX with 4620038 & 4620044 Turntable 100HX+10 & 110HXER with 4620038 & 4620044 Turntable 4620078 Turntable Machines Plate, Ramp (Left Side) Options: 4620038 & 4620044 Turntable Machines 4620078 Turntable Machines Rod, Hose Retainer (Right Side) Options: 100HX, 100HX+10 & 110HXER 110HX with 4620038 & 4620044 Turntable 110HX with 4620078 Turntable Cover Options: 4620038 & 4620044 Turntable Machines 4620078 Turntable Machines Shim Options: 4620038 & 4620044 Turntable Machines 4620078 Turntable Machines Chain Options: 100HX 110HX Built Prior To Early 1990 110HX Built Early 1990 To Present 100HX+10 &110HXER Built Prior To Early 1990 100HX+10 &110HXER Built Early 1990 To Present Clevis Options: 110HX Built Prior To Early 1990 110HX Built Early 1990 To Present

QTY.

REV.

A/R

1 1

1 1

2

1

1

A/R 0 1 0 A/R 0 1 A/R A/R 0 1

1

3120801

SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0258596 0251098 0252764 0251100 0251100

301 302 303

3120801

4420016 4420018 4420017 4420015

DESCRIPTION RADIUS LIMIT TAPE INSTALLATIONS 100HX 110HX (4620044 and 4620078 T/T Machines Built Prior to February 1993) 110HX (4620078 T/T Machines Built February 1993 to Present) 100HX+10/110HXER (4620044 and 4620078 T/T Machines Built Prior to February 1993) 100HX+10/110HXER (4620078 T/T Machines Built February 1993 to Present) Tape - Yellow Tape - Blue Tape - Red Tape - White

QTY.

REV.

Ref. Ref. Ref.

1 A/G

Ref.

3/C

Ref.

4/F

Ref.

4/C

S E C T I O N 3 B O O M

A/R A/R A/R A/R

3-13

S E C T I O N

SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES

3 B O O M

3-14

3120801

SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES FIG & ITEM #

PART NUMBER 0238946

1 2 3 4 5 6 7 8

4843025 3532458 0560324 3420552 0630197 4740156 4740270 3450504 0238945 0238945

51 52 53 54 55 56 57 58

4843026 3532466 1360175 3420552 0630197 4740156 4740270 3450504 0238919

101 102 103 104 105 106 107

0630410 1360209 3532425 3421535 3421534 3450506 4740111 0238901

201 202 203 204 205 206 207

3120801

0630409 1360206 3532410 3421535 3421534 3450506 4740111

DESCRIPTION CHAIN ADJUSTER ASSEMBLY (FLY RETRACT PRIOR MAY 1992) Chain Plate Weldment Plate, Top Clevis Pin, Clevis Eyebolt Washer, Thrust Washer, Special Pin, Cotter 5/32" x 1" CHAIN ADJUSTER ASSEMBLY (FLY RETRACT MAY1992 TO PRESENT) CHAIN ADJUSTER ASSEMBLY (OUTER MID RETRACT) Chain Plate Weldment Plate, Top Clevis Pin, Clevis Eyebolt Washer, Thrust Washer, Special Pin, Cotter 5/32" x 1" CHAIN ADJUSTER ASSEMBLY (FLY EXTEND) EXTEND) Eyebolt Clevis Plate Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Washer, Thrust CHAIN ADJUSTER ASSEMBLY (OUTER MID EXTEND) Eyebolt Clevis Plate Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Washer, Thrust

QTY.

REV.

Ref.

—

1 1 2 2 1 2 2 2

3

Ref.

—

Ref.

—

1 1 2 2 1 2 2 2 Ref.

—

1 2 2 1 2 3 2 Ref.

S E C T I O N

—

1 2 2 1 2 3 2

3-15

B O O M

S E C T I O N

SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM #

3 B O O M

PART NUMBER

QTY.

REV. B

0239267

CHAIN ADJUSTER AND ROD ASSEMBLY - 100HX, 100HX+10 AND 110HXER (OUTER MID EXTEND)

Ref.

301 302 303

3840955 1360208 0238900

1 1 1

304

0100003

Rod Clevis, Rod Chain Adjuster Assembly (See Items 401-407 for Breakdown) Loctite #277 (Not Shown)

A/R

0239268

CHAIN ADJUSTER AND ROD ASSEMBLY - 110HX (OUTER MID EXTEND)

Ref.

351 352 353

3840945 1360208 0238900

1 1 1

354

0100003

Rod Clevis, Rod Chain Adjuster Assembly (See Items 401-407 for Breakdown) Loctite #277 (Not Shown)

0238900

401 402 403 404 405 406 407

3-16

DESCRIPTION

1360207 1360206 3532410 3421535 3421534 3450506 3534436

CHAIN ADJUSTER ASSEMBLY (OUTER MID RETRACT) Clevis, Rod Clevis, Chain Plate, Chain Adjuster (Top) Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Plate, Chain Adjuster Plate (Bottom)

B

A/R Ref.

B

1 2 1 1 2 3 1

3120801

SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 3 B O O M

3120801

3-17

S E C T I O N

SECTION 3 BOOM FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY)

3 B O O M

3-18

3120801

SECTION 3 BOOM FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) FIG & ITEM #

PART NUMBER 0239040 0251633

1 1A 2

4843058 0961185 1681955

3 4 4A 4B 5 5A 5B 6 6A 6B 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 to 50 51

Not Used 4843059 0961313 0961098 4843061 0961200 0961201 4843060 0961200 0961201 0641624 3311605 0100011 4740332 3760233 Not Used 3421567 0641606 4751600 4761600 4740333 3760237 3421513 2160002 Not Used Not Used 3421376 1320145 0361524 3311605 4300076 3311602 1670477 2160006 Not Used

1681791 1682459

3120801

DESCRIPTION EXTEND-A-REACH INSTALLATIONS Prior To February 1991 February 1991 To May 1992 Boom, Jib Bushing, Oilite Extend-A-Reach Lift Cylinder Assembly (See Section 5 for Breakdown) Link Bushing, Oilite Bushing, Oilite Pivot, Link (Right Side) Bushing, Oilite Bushing, Oilite Pivot, Link (Left Side) Bushing, Oilite Bushing, Oilite Bolt 3/8"-16NC x 3" Locknut 3/8"-16NC Loctite #242 (Not Shown) Washer, Hardened Ring, Retaining

QTY.

REV.

Ref. Ref.

C B

1 2 1

3 B O O M

1 2 2 1 1 1 1 1 1 1 1 A/R 4 4

Pin Bolt 3/8"-16NC x 3/4" Flatwasher 3/8" Lockwasher 3/8" Washer, Hardened Ring, Retaining Pin Fitting, Grease

1 2 6 2 4 4 1 4

Pin Clamp Bar Locknut 3/8"-16NC Stud (Welded on Part) Nut, Jam 3/8"-16NC Cover, Hose Fitting, Grease

1 2 2 4 4 4 1 2

Extend-A-Reach Platform Level Cylinder Assembly Options (See Section 5 for Breakdown): Prior To February 1991 February 1991 To May 1992

1

S E C T I O N

3-19

S E C T I O N

SECTION 3 BOOM FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) (CONTINUED) FIG & ITEM #

PART NUMBER

52 3421568 3841822 53 3421429 Not Required

3

54

B O O M

55

3760133 Not Required Not Required 3421827 3421950 56

57

3-20

Not Required 4740385 4740390 3900158 0741606

DESCRIPTION Pin Options: Prior To February 1991 February 1991 To May 1992 Pin Options: Prior To February 1991 February 1991 To May 1992 Ring, Retaining Options: Prior To February 1991 February 1991 To May 1992 Pin Options: Prior To February 1991 February 1991 To July 1991 July 1991 to May 1992 Washer, Hardened Options: Prior To February 1991 February 1991 To July 1991 July 1991 to May 1992 Screw, Countersunk 1/2"-13NC x 3/4" Screw, Countersunk 3/8"-16NC x 3/4"

QTY.

REV.

1

A/R 1 0 A/R 1 0 A/R 0 1 1 A/R 0 1 1 1 1

3120801

SECTION 3 BOOM FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 3 B O O M

3120801

3-21

S E C T I O N

SECTION 3 BOOM FIGURE 3-4. EXTEND-A-REACH INSTALLATIONS (MAY 1992 TO PRESENT) (100HX+10 & 110HXER ONLY)

3 B O O M

3-22

3120801

SECTION 3 BOOM FIGURE 3-4. EXTEND-A-REACH INSTALLATIONS (MAY 1992 TO PRESENT) (100HX+10 & 110HXER ONLY) FIG & ITEM #

PART NUMBER 0252858

1 1A 2 2A 2B 3 3A 4

4844166 0960565 4844167 0961654 0960565 4844094 0961654 4844095 1320051

5

6

1682635 1683725 1682753 1683493

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

3120801

3422062 3422077 3422079 3422081 3422083 3422037 Not Used 2160002 0641608 4761600 0641610 3311605 3422085 1320184 3535978 1670642 4300076 3311602 4751600 0100011 0641606 4060803

DESCRIPTION EXTEND-A-REACH INSTALLATION Snoot Weldment (Standard) Bushing, Bronze Level Link Weldment Bushing, Bronze (Platform End) Bushing, Bronze (Boom End) Level Plate Weldment Bushing, Bronze Pivot Attach Weldment Clamp, Hose Extend-A-Reach Lift Cylinder Assembly Options: (See Section 5 for Breakdown) Prior to S/N 49403 S/N 49403 to Present Extend-A-Reach Platform Level Cylinder Assembly (May 1992 to S/N 29913) Extend-A-Reach Platform Level Cylinder Assembly (S/ N 29913 to Present) (See Section 5 for Breakdown) Pin, Attach (Lift Cylinder - Barrel End) Pin, Attach (Snoot and Level Link to Jib) Pin, Attach (Lift Cylinder - Rod End) Pin, Attach (Snoot to Pivot) Pin, Attach (Level Link to Level Plate) Pin, Attach (Level Cylinder - Barrel End)

QTY.

REV.

Ref.

5

1 4 1 2 2 1 2 1 1 1

S E C T I O N 3 B O O M

1 1 1 1 1 2 1 1 1 2

Fitting, Grease 9 Bolt 3/8"-16NC x 1" 2 Lockwasher 3/8" 3 Bolt 3/8"-16NC x 1 1/4" 6 Locknut 3/8"-16NC 10 Pin, Attach (Level Cylinder - Rod End) 1 Clamp, Hose and Cable 2 Plate 2 Cover, Hose and Cable 1 Stud (Welded on Part) 4 Nut, Jam 3/8"-16NC 4 Flatwasher 3/8" 4 Loctite #242 (Not Shown) A/R Bolt 3/8"-16NC x 3/4" 1 Trim, Flexible (Not Shown - Located on Front on Boom) 10in/25m

3-23

S E C T I O N

SECTION 3 BOOM FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION

3 B O O M

3-24

3120801

SECTION 3 BOOM FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION FIG & ITEM #

PART NUMBER 0250119

1

0239485

2 3 4

4300032 4761400 3311401 0239485

101

0860575

102 103 104 105 106 107

4360153 3910408 4770400 Not Used 4460428 3730024 0860575

201 202 203 204 205 206

7000637 7000638 7000639 7012526 7000647 7016515

0251020 0251020 0255815 301 302

3534395 4360277

303

4360236

304

4360278

3120801

DESCRIPTION BOOM LENGTH/INDICATOR INSTALLATION Boom Length Indicator Assembly (See Item 101-104 for Breakdown) Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC BOOM LENGTH INDICATOR SUBASSEMBLY

QTY.

REV.

Ref.

2

1 4 4 4 Ref.

Indicator Box Assembly (See Items 201-207 for Breakdown) Pendulum Screw #4NC x 1/2" Starwasher #4

1 4 4

Connector, Strain Relief Resistor - 100 Ohms (Not Shown)

1 1

INDICATOR BOX ASSEMBLY Potentiometer Switch Spring, Reel (Not Shown) Spring, Extension (Not Shown) Cable Pulley, Nylon (Not Shown) BOOM LIMIT SWITCHES INSTALLATION Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Plate, Mounting Switch, Limit Options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Head, Switch Options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Arm, Actuator Options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present

3 D

B O O M

1

Ref.

E

1 1 1 1 1 1 Ref. Ref. Ref. Ref.

S E C T I O N

7/H 7/H 3

1 A/R 2 2 1 A/R 2 2 1 A/R 2 2 1

3-25

S E C T I O N

SECTION 3 BOOM FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

305

4460052

306 307 308

3900168 4920140

3 B O O M

309 310 311 312 313 314

315 316

317 318

3-26

3533183 3533183 Not Required 4300031 4761400 3311401 1670579 Not Used 4564880 3533183 3533183 Not Required 1320040 1060016 1060016 Not Required 1060079 1670836

DESCRIPTION Connector, Strain Relief Options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Screw, Fillister Wire, Safety Cover Options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Cover Tube options: Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Clamp, Cable Cable, Electrical - 16/3 Euro Spec Australian Spec Prior To July 1995 Australian Spec July 1995 To Present Cable, Electrical - 16/4 Cover, Boom (Not Shown) (S/N 34323 to Present)

QTY.

REV.

A/R 2 2 1 A/R A/R A/R 1 1 0 A/R A/R A/R 1 A/R 3 3 2 2 A/R 50ft/15.25m 50ft/15.25m

0 52ft/15.85m

2

3120801

SECTION 3 BOOM FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 3 B O O M

3120801

3-27

S E C T I O N

SECTION 3 BOOM FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN SPECS BUILT PRIOR TO S/N 28224)

3 B O O M

3-28

3120801

SECTION 3 BOOM FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN SPECS BUILT PRIOR TO S/N 28224) FIG & ITEM #

QTY.

REV.

0253062

BROKEN CHAIN LIMIT SWITCH INSTALLATION

Ref.

3

1 2 3 4 5 6 7 8 9 10 11 12

4360277 4360236 4360237 4460052 4920140 3900168 3303240 3450202 1360250 3536145 4160098 3680051

1 1 1 1 1 2 1 1 1 1 48 1

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

4565798 4565799 0641630 0641632 3311605 3536146 1320049 3536147 0641609 0960407 4460049 4844201 3536148 Not Used 0721003 4761000

Switch, Limit Head, Switch Arm, Actuator Connector, Strain Relief Wire, Safety Screw, Special Locknut Pin, Cotter 1/16" x 1/2" Clevis, Chain Plate, Switch Washer, Bellville Cable Reel Assembly (See Items 100-114 For Breakdown) Tube, Cable Tube, Cable Bolt 3/8"-16NC x 3 3/4" Bolt 3/8"-16NC x 4" Locknut 3/8"-16NC Plate, Mounting Clamp, Hose Plate, Mounting Bolt 3/8"-16NC x 1 1/8" Bushing, Reducer Connector, Strain Relief Plate, Switch Mounting Cover

6 24 12 12 31 1 1 1 7 1 1 1 1

Bolt #10-24NC x 3/8" Lockwasher #10

4 4

100 101 102 103 104 105 106 107 108 109 110 111 112 113 114

3680051 7010836 7010837 7010848 7010847 7010836 Not Available 7010846 7010839 7010845 7010840 7010844 7010841 7010843 Not Available 7010842

3120801

PART NUMBER

DESCRIPTION

CABLE REEL ASSEMBLY Nut Cover, Slip Ring Slip Ring Assembly Gasket, Cover Nut Pin, Drive Drum/Entrance Assembly Cable Kit Flange, Front Gasket, Drum Cartridge, Spring Base Guide Arm Assembly Fitting, 90° Seal, Watertight

Ref. 6 1 1 1 4 1 1 1 1 1 1 1 1 1 1

S E C T I O N 3 B O O M

—

3-29

S E C T I O N

SECTION 3 BOOM FIGURE 3-7. BOOM WIPERS INSTALLATION

3 B O O M

3-30

3120801

SECTION 3 BOOM FIGURE 3-7. BOOM WIPERS INSTALLATION FIG & ITEM #

PART NUMBER 0239257 0253245

1 to 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 to 50 51

Not Used 0540074 Not Used 0540078 0540075 0540077 0540079 2660067 Not Used 2660071 2660068 2660070 2660072 3820001 1670491 0641404 4761400 4711600 Not Used 3200286 3200344

52 3200288 3200346 53 3200290 3200348 54 3200287 3200345 55 3200289 3200347 56 3200291 3200349 57 0540076 0540089 58 2660069 2660085

3120801

QTY.

REV.

BOOM WIPERS INSTALLATION Prior To May 1992 May 1992 To Present

DESCRIPTION

Ref. Ref. Ref.

A A

Brush, Wiper (Base Top)

1

Brush, Wiper (Outer Mid Top) Brush, Wiper (Base Side) Brush, Wiper (Inner Mid Side) Brush, Wiper (Outer Mid Side) Holder (Base Top)

1 2 2 2 1

Holder (Outer Mid Top) Holder (Base Side) Holder (Inner Mid Side) Holder (Outer Mid Side) Rivet Cover Bolt 1/4"-20NC x 1/2" Lockwasher 1/4" Flatwasher 3/8"

1 2 2 2 30 1 4 4 4

Mount, Wiper (Base Top) Options: Prior to May 1992 May 1992 to Present Mount, Wiper (Inner Mid Top) Options: Prior to May 1992 May 1992 to Present Mount, Wiper (Outer Mid Top) Options: Prior to May 1992 May 1992 to Present Mount, Wiper (Base Side) Options: Prior to May 1992 May 1992 to Present Mount, Wiper (Inner Mid Side) Options: Prior to May 1992 May 1992 to Present Mount, Wiper (Outer Mid Side) Options: Prior to May 1992 May 1992 to Present Brush, Wiper (Inner Mid Top) Options: Prior to May 1992 May 1992 to Present Holder (Inner Mid Top) Options: Prior to May 1992 May 1992 to Present

1

S E C T I O N 3 B O O M

A/R 1 2 1

2

2

2

A/R 1 2 A/R 1 2

3-31

S E C T I O N

SECTION 3 BOOM FIGURE 3-7. BOOM WIPERS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

3 B O O M

3-32

3120801

SECTION 4 PLATFORMS TABLE OF CONTENTS FIGURE

4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8

3120801

DESCRIPTION

PLATFORM COMPONENTS INSTALLATION - 100HX/110HX . . . . . . . . . . . . . . . . . . . . . . . . .

PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (Prior to May 1992) . . . .

PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (May 1992 to Present). .

ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONSOLE BOX ASSEMBLY - OEM CONTROLLERS (Prior to September 1991) . . . . . . . . . .

CONSOLE BOX ASSEMBLY - OEM CONTROLLERS (September 1991 to Present) . . . . . . . .

CONTROLLER ASSEMBLIES - OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

PAGE

4-2 4-6 4-10 4-14 4-16 4-20 4-26 4-28

S E C T I O N 4 P L A T F O R M S

4-1

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX

4 P L A T F O R M S

4-2

3120801

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX FIG & ITEM #

PART NUMBER 0239183

1 1A 2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

4843099 0961259 0239182 0960565 1120299 4842915 0235238 0361675 4070705 4070706 4751500 4761500 3311501 3340454 4160026 2880404 0652014 4752000 0681610 4751600 3300143 0641840 4751800 3311805 2160002 0641520 3421583 4740158 1670451 4300038

29

30 31 32 33 34 35 36 37 38 39

3120801

1681973 1682590 1683536 3421582 3421577 3532054 0641506 0641524 4070707 3520035 0641816 4761800 4060804

DESCRIPTION SUPPORT INSTALLATION Support Weldment Bushing Pivot Weldment Bushing, Bronze Cap Shaft, Rotator Rotator Assembly (See Items 101-126 for Breakdown) Bar, Stop Shim 1/8" Shim 1/16" Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC Pad, Brake Washer, Belleville Key Bolt 5/8"-18NF x 1 3/4" Flatwasher 5/8" Bolt 3/8"-16NC x 1 1/4" (Grade 8) Flatwasher 3/8" Locknut 3/8"-16NC Bolt 1/2"-13NC x 5" Flatwasher 1/2" Locknut 1/2"-13NC Fitting, Grease Bolt 5/16"-18NC x 2 1/2" Pin Washer, Thrust Cover Stud (Welded on part - Not Shown) Platform Level Cylinder Assembly Options (See Section 5 for Breakdown): Prior to May 1992 May 1992 to S/N 33111 S/N 33111 to Present Pin Pin Plate, Retainer Bolt 5/16"-18NC x 3/4" Bolt 5/16"-18NC x 3" Shim 1/32" Plug, Hole (Prior to February 1994) Bolt 1/2"-13NC x 2" Lockwasher 1/2" Flexguard

QTY.

REV.

Ref.

6

1 2 1 2 1 1 1 1 A/R A/R 2 4 4 2 8 1 1 1 10 20 10 1 1 1 3 1 1 1 1 2

S E C T I O N 4 P L A T F O R M S

1

1 1 1 2 1 A/R 1 2 2 10.5in/27cm

4-3

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX (CONTINUED) FIG & ITEM #

PART NUMBER 0235238

4 P L A T F O R M S

101

3160083

102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

0080099 2760064 0440134 4740199 0440120 2440043 3440816 0080098 2440044 4740256 0440135 1760068 Not Used 3931010 3441228 3931620 4761600 3931612 4070585 4070586 4070587 0100019 0100021 2160001 3020025

DESCRIPTION ROTATOR ASSEMBLY Note: For Machines Built Prior to September 1991 refer to Service Information Bulletin #91-5 for required upgrade.

Rotator Motor Assembly (See Figure 4-4 for Breakdown) Adapter, Motor Housing, Gear Bearing, Sleeve Washer, Thrust Bearing, Thrust Gear, Worm Rollpin 1/4" x 1" Adapter, Motor to Worm Gear Gear, Worm Washer, Thrust Bearing, Sleeve Disc, Brake Bolt, Socket Head #10-24NC x 5/8" Rollpin 3/8" x 1 3/4" Bolt, Socket Head 3/8"-16NC x 1 1/4" Lockwasher 3/8" Bolt, Socket Head 3/8"-16NC x 3/4" Shim.010 Shim.005 Shim.002 Loctite #271 (Not Shown) Primer (Not Shown) Fitting, Grease - 90° (Not Shown) Grease (Not Shown) PLATFORM WELDMENTS

201 3510301 3510294 3510302 3510295 3510303

4-4

Platform Options (Includes Items 301-307): 3’ x 5’ (91.5cm x 152.5cm) Platform with Kickplates & Self-Closing Gate 3’ x 6’ (91.5cm x 183cm) Platform without Kickplates Platform with Kickplates & Self-Closing Gate 3’ x 8’ (91.5cm x 244cm) Platform without Kickplates Platform with Kickplates & Self-Closing Gate

QTY.

REV.

Ref.

E

1 1 1 2 4 2 1 4 1 1 2 1 1 5 2 2 6 4 A/R A/R A/R A/R A/R 1 A/R Ref. 1

3120801

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX (CONTINUED) FIG & ITEM #

301 302 303 304 305 306 307 308 309 310

PART NUMBER

Not Required 2600095 3311805 2160006 1780253 2940006 2560010 4160028 3534508 3534121 3534122 3534120 0237963

401

3120801

0641408 3311405 4740362 4360031 7000625 4460071

DESCRIPTION

QTY.

PLATFORM ASSEMBLY COMPONENTS

Ref.

Pin, Hinge Locknut 1/2"-13NC Fitting, Grease Door Weldment Latch, Door Handle Spring, Tension Kickplate (Door) Kickplate (Ends) Options: 3’ x 5’ (91.5cm x 152.5cm) Platforms 3’ x 6’ (91.5cm x 183cm) Platforms 3’ x 8’ (91.5cm x 244cm) Platforms

2 2 2 1 1 1 1 1 2

FOOTSWITCH INSTALLATION Bolt 1/4"-20NC x 1" Locknut 1/4"-20NC Washer, Fender Footswitch Block, Contact Connector, Strain Relief

Ref.

REV.

S E C T I O N 4 P L A T F O R M S

7

3 3 3 1 2 1

4-5

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992)

4 P L A T F O R M S

4-6

3120801

SECTION 4 PLATFORMS FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992) FIG & ITEM #

PART NUMBER 0237672

1 1A 2

2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

29 30 31

4842609 0960569 0237975 0251512 0961185 1120299 4842046 0235238 1670421 3340454 4160026 2880404 0652014 4752000 0681610 4751600 3300143 0641836 1670422 2160002 3760237 4740158 0641404 4761400 4751400 0641408 4562083 0641811 4761800 4751800 3421426 3421825 3422019 3311805 0641406 Not Required 4740385 0362079

32

3900159

33 34

0100011 0901411

3120801

DESCRIPTION ROTATOR AND SUPPORT INSTALLATION Support Weldment Bushing, Bronze Pivot Weldment Options: Pivot (Prior to January 1991) Pivot (January 1991 to May 1992) Bushing, Bronze Cap Rotator Shaft Rotator Assembly (See Items 201-226 for Breakdown) Cover Pad, Brake Washer, Belleville Key Bolt 5/8"-18NF x 1 3/4" Flatwasher 5/8" Bolt 3/8"-16NC x 1 1/4" (Grade 8) Flatwasher 3/8" Locknut 3/8"-16NC Bolt 1/2"-13NC x 4 1/2" Cover, Motor Fitting, Grease Ring, Retaining (Prior to January 1991) Washer, Thrust Bolt 1/4"-20NC x 1/2" Lockwasher 1/4" Flatwasher 1/4" Bolt 1/4"-20NC x 1" Spacer Bolt 1/2"-13NC x 1 3/8" Lockwasher 1/2" (Prior to Flatwasher 1/2" Pin Options: Pin (Prior to January 1991) Pin (January 1991 to November 1991) Pin (November 1991 to May 1992) Locknut 1/2"-13NC Bolt 1/4"-20NC x 3/4" Retainer Options: (Prior to January 1991) Washer (January 1991 to November 1991) Bar (November 1991 to May 1992) Screw, Countersunk 1/2"-13NC x 3/4" (Used January 1991 to May 1992) Loctite #242 (Not Shown) Mount, Rotator (Not Shown)

QTY.

REV.

Ref.

D

1 2 1

S E C T I O N 4 P L A T F O R M S

2 1 1 1 1 2 8 1 1 1 10 21 10 1 1 4 1 1 1 A/R A/R 1 1 2 2 3 1

1 2 1

1 A/R 1

4-7

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

35

0641405

Bolt 1/4"-20NC x 5/8" (Used November 1991 to May 1992)

1

0235238

4 P L A T F O R M S

101

3160083

102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

0080099 2760064 0440134 4740199 0440120 2440043 3440816 0080098 2440044 4740256 0440135 1760068 Not Used 3931010 3441228 3931620 4761600 3931612 4070585 4070586 4070587 0100019 0100021 2160001 3020025

201 3510299 3510284 3510300

4-8

ROTATOR ASSEMBLY Note: For Machines Built Prior to September 1991 refer to Service Information Bulletin #91-5 for required upgrade.

Rotator Motor Assembly (See Figure 4-4 for Breakdown) Adapter, Motor Housing, Gear Bearing, Sleeve Washer, Thrust Bearing, Thrust Gear, Worm Rollpin 1/4" x 1" Adapter, Motor to Worm Gear Gear, Worm Washer, Thrust Bearing, Sleeve Disc, Brake Bolt, Socket Head #10-24NC x 5/8" Rollpin 3/8" x 1 3/4" Bolt, Socket Head 3/8"-16NC x 1 1/4" Lockwasher 3/8" Bolt, Socket Head 3/8"-16NC x 3/4" Shim .010 Shim .005 Shim .002 Loctite #271 Primer Fitting, Grease - 90° Grease PLATFORM WELDMENTS Platform Options (Includes Items 301-307): 3’ x 5’ (91.5cm x 152.5cm) Platform with Kickplates & Self-Closing Gate 3’ x 6’ (91.5cm x 183cm) Platform without Kickplates & Self-Closing Gate Platform with Kickplates & Self-Closing Gate

Ref.

REV.

E

1 1 1 2 4 2 1 4 1 1 2 1 1 5 2 2 6 4 A/R A/R A/R A/R A/R 1 A/R Ref. 1

3120801

SECTION 4 PLATFORMS FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992) (CONTINUED) FIG & ITEM #

301 302 303 304 305 306 307 308 309 310

PART NUMBER

Not Required 2600095 3311805 2160006 1780253 2940006 2560010 4160028 3534508 3534121 3534122 3534120 0237963

401

3120801

0641408 3311405 4740362 4360031 7000625 4460071

DESCRIPTION

QTY.

PLATFORM ASSEMBLY COMPONENTS

Ref.

Pin, Hinge Locknut 1/2"-13NC Fitting, Grease Door Weldment Latch, Door Handle Spring, Tension Kickplate (Door) Kickplate (Ends) Options: 3’ x 5’ (91.5cm x 152.5cm) Platforms 3’ x 6’ (91.5cm x 183cm) Platforms 3’ x 8’ (91.5cm x 244cm) Platforms

2 2 2 1 1 1 1 1 2

FOOTSWITCH INSTALLATION Bolt 1/4"-20NC x 1" Locknut 1/4"-20NC Washer, Fender Footswitch Block, Contact Connector, Strain Relief

Ref.

REV.

S E C T I O N 4 P L A T F O R M S

7

3 3 3 1 2 1

4-9

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT)

4 P L A T F O R M S

4-10

3120801

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) FIG & ITEM #

PART NUMBER

1 3510304 3510364 3510365 3510405 3510306

101 102 103 104 105 106 107 108

201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222

3120801

DESCRIPTION PLATFORM ASSEMBLY OPTIONS: 3’ x 5’ (91.5cm x 152.5cm) Platform with Kickplates & Self-Closing Gate 3’ x 6’ (91.5cm x 183cm) Platform without Kickplates & Self-Closing Gate Platform with Kickplates & Self-Closing Gate Platform with Kickplates & Slide Bar 3’ x 8’ (91.5cm x 244cm) Platform with Kickplates & Self-Closing Gate

QTY.

PLATFORM ASSEMBLY COMPONENTS

Ref. 1 1 1 2 2 1 1 2

3534121 3534146 3534120

Door Weldment Latch, Door Handle, Latch Fitting, Grease Bushing, Bronze Spring, Tension Kickplate (Door) (Was P/N 3534508) Kickplate (Ends) Options: 3’ x 5’ (91.5cm x 152.5cm) Platforms 3’ x 6’ (91.5cm x 183cm) Platforms 3’ x 8’ (91.5cm x 244cm) Platforms

0252682

ROTATOR AND SUPPORT INSTALLATION

Ref.

1780253 2940006 2560010 2160006 0960564 4160028 3536066

4842046 1120299 0235238 3340454 2880404 4160026 4752000 0652014 0641836 4751800 3311805 0901834 0641811 1380137 0641412 4761400 4751400 0641408 4562083 4740158 1670632 4920986

Shaft Weldment Cap Rotator Assembly (See Items 301-325 for Breakdown) Pad, Brake Key Washer, Belleville Flatwasher 5/8" Bolt 5/8"-18NF x 1 3/4" Bolt 1/2"-13NC x 4 1/2" Flatwasher 1/2" Locknut 1/2"-13NC Bracket Bolt 1/2"-13NC x 1 3/8" Clip, Retainer Bolt 1/4"-20NC x 1 1/2" Lockwasher 1/4" Flatwasher 1/4" Bolt 1/4"-20NC x 1" Tube, Spacer Washer, Thrust Cover Wire, Safety

REV.

1

S E C T I O N 4 P L A T F O R M S

2

1 1 1 2 1 8 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 ft./30cm

4-11

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

223 224

2160002 4565665 0235238

4 P L A T F O R M S

301

3160083

302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325

0080099 2760064 0440134 4740199 0440120 2440043 3440816 0080098 2440044 4740256 0440135 1760068 Not Used 3931010 3441228 3931620 4761600 3931612 4070585 4070586 4070587 Not Used Not Used 2160001

401

4-12

DESCRIPTION Fitting, Grease Tube, Spacer ROTATOR ASSEMBLY Rotor Motor Assembly (See Figure 4-4 for Breakdown) Adaptor, Motor Housing, Gear Bearing, Sleeve Washer, Thrust Bearing, Thrust Gear, Worm Rollpin 1/4" x 1" Adaptor - Motor to Worm Gear Gear, Worm Washer, Thrust Bearing, Sleeve Disc, Brake Bolt, Socket Head #10-24NC x 5/8" Rollpin 3/8" x 1 3/4" Bolt, Socket Head 3/8" - 16NC x 1 1/4" Lockwasher 3/8" Bolt, Socket Head 3/8" - 16NC x 3/4" Shim, Rotator -.010"/.25mm Shim, Rotator -.005"/.13mm Shim, Rotator -.002"/.05mm

QTY. 2 1 Ref.

E

1 1 1 2 4 2 1 4 1 1 2 1 1 5 2 2 6 4 A/R A/R A/R

0100019 0100021 3020025

Fitting, Grease - 90° —————————— Loctite #271 Primer, Locking - “N” Grease

A/R A/R A/R

0237963

FOOTSWITCH INSTALLATION

Ref.

0641408 3311401 4740362 Not Used 4360031 7000625 4460071

REV.

1

Bolt 1/4"-20NC x 1" Nut 1/4"-20NC Flatwasher 1/4"

3 3 3

Footswitch Assembly Block, Contact Connector

1 2 1

7

3120801

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 4 P L A T F O R M S

3120801

4-13

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-4. ROTATOR MOTOR ASSEMBLY

4 P L A T F O R M S

4-14

3120801

SECTION 4 PLATFORMS FIGURE 4-4. ROTATOR MOTOR ASSEMBLY FIG & ITEM #

PART NUMBER 3160083

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7002105 7002123 Kit 7002104 7002111 7002117 Kit Kit 7002116 7002103 Kit Kit 7002115 7002112 7002107 7002100 7000166 7002125 7002110

2900455 2900733

DESCRIPTION ROTATOR MOTOR ASSEMBLY Flange, Mounting Screw, Cap Seal, Dust Key, Woodruff Bearing, Thrust Needle Thrust, Bearing Race Seal, O-Ring Seal, Pressure Shaft, Output Housing Seal Plug, Housing Seal, O-Ring Drive Cap, End Screw, Cap Lockwasher Gerotor Sub-Assembly Plate, Spacer —————————— Seal Kit (Includes Items 3,7,8,11 and 12) (P/N 1011009-007) Seal Kit (Includes Items 3,7,8,11 and 12) (P/N’s 1011009-008 and 101-1009-009)

QTY.

REV.

Ref.

A

1 4 1 1 1 1 1 1 1 1 1 1 3 1 1 7 7 1 1

P L A T F O R M S

1 1

Note: Identify by P/N stamped on nameplate located on Item 10.

3120801

S E C T I O N 4

4-15

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-5. CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991)

4 P L A T F O R M S

4-16

3120801

SECTION 4 PLATFORMS FIGURE 4-5. CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991) FIG & ITEM #

PART NUMBER 0860672 0860673

1

6 6A 6B 6C 7 8 9 10 11 12

3251853 3251854 0751006 4740120 3300177 4420038 0100001 0860538 2940052 2600132 2600105 3311505 4751500 0641508 Not Used Not Used Not Used

13

1600092

14

4360274 3790015 4360132 4360131 4360199 3790012 4360199 3790012 4360199 3790012 4360274 3790015 2920026 2920029 3252025

2 3 4 5

15 16 17 18 19 20

21

22 23

24

3120801

4360202 3790012 2920027 2920024 4360202 3790012 4060229 4360202 3790012

DESCRIPTION CONSOLE BOX ASSEMBLY (110HX) CONSOLE BOX ASSEMBLY (100HX+10 AND 110HXER) Nameplate Options: 100HX AND 110HX 100HX+10 AND 110HXER Screw, Pan Head #10-24NC x 3/4" Washer, Nylon Nut, Tinnerman Tape, Insulation Adhesive Box, Console Latch Hinge (Top to Bottom) Hinge (Rear Access Panel) Locknut 5/16"-18NC Flatwasher 5/16" Bolt 5/16"-18NC x 1"

OEM Controller Assembly (See Figure 4-7 for Breakdown) Switch, Push Button (Horn) O-Ring Switch, Push-Pull (Emergency Stop) Lens Switch, Toggle (High Engine) O-Ring Switch, Toggle (Pump Volume) O-Ring Switch, Toggle (Wheel Motor Speed) O-Ring Switch, Push Button (Start) O-Ring Light, Indicator - Red Bulb Nameplate - Broken Extend Chain Switch, Toggle (Extend-A-Reach Lift) (100HX+10 and 110HXER Only) O-Ring Light, Indicator - Green (Axles Set) Bulb Switch, Toggle (Rotate) O-Ring Shield Switch, Toggle (Level) O-Ring

QTY.

REV.

Ref.

C

Ref.

B

1

21 21 21 1m A/R 1 2 1 1 4 8 4

S E C T I O N 4 P L A T F O R M S

4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4-17

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-5. CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991) (CONTINUED) FIG & ITEM # 25

26 27

4

28

P L A T F O R M S

29

30

31

32

33 34 35 36 37

38 39

40 41

PART NUMBER 4060229 4360199 3790012 4060229 2920015 4360204 3790012 4060229 4360202 3790012 4060229 4460244 0960238 3300048 4460071 0960238 3300048 3740049 4761000 3311001 3640500 3910608 4750600 4760600 3310601 4460299 4460300 4460298 4460301 4460311 4460305 4460306 4460307 0140019 4360209 3911012 4761000 3311001 2920026 2920029 2920090 2920029

42 3252015 3252018

4-18

DESCRIPTION Shield Switch, Toggle (Creep) O-Ring Shield Lamp, Indicator (Out of Level) Switch, Toggle (Auxiliary Power) O-RIng Shield Switch, Toggle (Steer) O-RIng Shield Connector, Strain Relief Bushing Nut, Conduit Connector, Strain Relief Bushing Nut, Conduit Relay Lockwasher #10 Nut #10-24NC Rail, Mounting Screw, Round Head #6-32NC x 1/2" Flatwasher #6 Lockwasher #6 Nut #6-32NC Stop, Terminal Strip Barrier, Terminal End Block, Terminal Strip, Marking Bar, Buss - 5 Position Screw, Terminal Block Washer, Terminal Block Sleeve, Terminal Block Alarm Breaker, Circuit - 20 Amp Screw, Round Head #10-24NC x 3/4" Lockwasher #10 Nut #10-24NC Light, Indicator - Red Bulb Light, Indicator - Blue Bulb Grid Nameplate Options: 100HX and 110HX 100HX+10 and 110HXER

QTY.

REV.

1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 6 6 6 1 2 2 2 2 2 1 A/R 1 1 5 5 5 1 1 1 1 1 1 1 1 1 1

3120801

SECTION 4 PLATFORMS FIGURE 4-5. CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 4 P L A T F O R M S

3120801

4-19

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT)

4 P L A T F O R M S

4-20

3120801

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

0258187

CONSOLE BOX ASSEMBLY - 100HX CONSOLE BOX ASSEMBLY - 110HX BUILT PRIOR TO S/N 28224 CONSOLE BOX ASSEMBLY - 110HX BUILT S/N 28224 TO PRESENT CONSOLE BOX ASSEMBLY - 100HX+10/110HXER BUILT PRIOR TO S/N 28224 CONSOLE BOX ASSEMBLY - 100HX+10/110HXER BUILT S/N 28224 TO PRESENT

Ref.

3

Ref.

G

Ref.

4/C

Ref.

I

Ref.

4/C

0860672 0861094 0860673 0861093

1 1A 1B 1C 2 3 4

0860538 2600132 2600105 2940052 Not Used 4420038 0100001

5

6 7 8 9 10

1600092 1600247 Not Used 4360199 3790012 4060229 4360289 4360475 7012611

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

3120801

7012612 7020175 7020176 4360204 4360202 4360274 3790015 2920015 2920027 2920029 2920026 2920090 0751006 4740120 3300177 0140019 3311505 4751500 0641508

Box Weldment Hinge (Top to Bottom) Hinge (Rear Access Door) Latch Tape, Insulation Adhesive (Not Shown) Controller Assembly Options (See Figure 4-7 for Breakdown): Prior to S/N 27148 S/N 27148 to Present Switch, Toggle O-Ring Shield, Switch Switch, Emergency Stop Options: Prior to S/N 47729 S/N 47729 to Present Cap Options: Cap, Mushroom Head (Used on Switch p/n 4360289) Boot (Used on Switch p/n 4360289) Cap, Red (Used on Switch p/n 4360475) Contact Block (Used on Switch p/n 4360475) Switch, Toggle Switch, Toggle Switch, Push Button O-Ring Lamp Lamp - Green Bulb Lamp - Red Lamp - Blue Screw #10-24NC x 3/4" Washer, Nylon Nut, Tinnerman Alarm Locknut 5/16"-18NC Flatwasher 5/16" Bolt 5/16"-18NC x 1"

S E C T I O N 4 P L A T F O R M S

1 1 1 2 39 in/1m A/R 4

4 A/R A/R 1

1

1

1 3 2 2 1 1 3 1 1 21 21 21 1 4 8 4

4-21

S E C T I O N 4 P L A T F O R M S

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

27 28 29 30 31 32 33 34 35 to 60 61

4460244 3300048 0960238 4460051 3740049 4761000 3311001 3911012 Not Used 3640500 3640970 3310601 3910608 4750600 4760600 4460298 4460300 4460299 4460301 4460311 4460305 4460306 4460307

62 63 64 65 66 67 68 69 70 71 72 73 74

75 76 77 78 79 80 81 82 83 84 85 86 to 99 101

4360282 4360476 Not Used 4070749 3900127 Not Used 4460051 0140026 4460386 3300147 0960905 4460071 1704260 Not Used 3252145 3252375 3252145 3252373

102 Not Required 4360202 103 4932118 Not Required

4-22

DESCRIPTION

QTY.

Connector, Strain Relief (Prior to S/N 30520 Only) Locknut, Conduit Bushing Connector, Strain Relief Relay Lockwasher #10 Nut #10-24NC Screw #10-24NC x 3/4"

1 A/R A/R 1 6 7 7 1

Rail, Mounting (Prior to S/N 30931) Rail, Mounting (S/N 30931 to Present) Nut #6-32NC Screw, Round Head #6-32NC x 1/2" Flatwasher #6 Lockwasher #6 Block, Terminal Barrier, Terminal Stop, Terminal Marker, Terminal Bar, Buss - 5 Position Screw, Terminal Washer, Terminal Sleeve, Terminal Block, Contact Options: Prior to S/N 47729 S/N 47729 to Present

1 1 2 2 2 2 47 1 2 1 1 A/R A/R A/R 1

Shim, OEM Controller Screw, Round Head

1 1

Connector, Strain Relief (Prior to S/N 30520 Only) Alarm, Intermittent Connector, Strain Relief (S/N 30520 to Present Only) Nut, Conduit (S/N 30520 to Present Only) Bushing (S/N 30520 to Present Only) Connector, Strain Relief (S/N 30520 to Present Only) Decal - EMS (S/N 47729 to Present)

1 1 1 1 1 1 1

Lid Options: 110 HX September 1991 to May 1994 110 HX May 1994 to Present 100HX+10/110HXER September 1991 to May 1994 100HX+10/110HXER May 1994 to Present Switch, Toggle Options: 110 HX 100HX+10/110HXER Harness - Footswitch Options: Prior to S/N 28224 S/N 28224 to Present

1

REV.

A/R 0 1 A/R 1 0

3120801

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

104 4360209 Not Required 105 Not Required 4360112 106 Not Required 4360069 107 Not Required 4360161 108 Not Required 4460308 109 Not Required 3300396

DESCRIPTION Breaker, Circuit - 20 Amp Options: Prior to S/N 28224 S/N 28224 to Present Breaker, Circuit - 5 Amp Prior to S/N 28224 S/N 28224 to Present Breaker, Circuit - 10 Amp Prior to S/N 28224 S/N 28224 to Present Breaker, Circuit - 20 Amp Prior to S/N 28224 S/N 28224 to Present Bar, Buss - 2 Position Prior to S/N 28224 S/N 28224 to Present Cap, Circuit Breaker Prior to S/N 28224 S/N 28224 to Present OPTIONAL INSTALLATIONS

201

202 203

204

205

4360199 4060087 3790012 1540002 Not Used 4360199 4060087 3790012 0251683 2920027 2920029 1702528 0255274 0255568 2920026 2920029 3252074 0254433

301 302 303 304 305 306

3120801

Supply Locally Supply Locally 1060461 1700598 1700599 Supply Locally

Glow Plug/Choke Components Switch, Toggle Shield, Switch O-Ring Capacitor Lights Components Switch, Toggle Shield, Switch O-Ring Engine Run Light Components Lamp, Indicator - Green Bulb, Light Decal - Engine Run Low Oil Pressure Light Components Engine Distress Light Components Lamp, Indicator - Red Bulb, Light Decal - Engine Distress POWER CORD TO PLATFORM INSTALLATION Cover, Weathershield Receptacle, Electrical Cable, Electrical - 12/3 Decal - Ground (Not Shown) Decal - Neutral (Not Shown) Plug, Terminal

QTY.

REV.

A/R 1 0 A/R 0 2 A/R 0 1 A/R 0 1 A/R 0 1 A/R 0 4

P L A T F O R M S

Ref.

1 1 1 1

1 1 1 B 1 1 1 4 — 1 1 1 Ref.

S E C T I O N 4

2

1 1 128ft/39m 2 2 1

4-23

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

307

Supply Locally

DESCRIPTION Clamp, Cable (Not Shown)

QTY.

REV.

1

4 P L A T F O R M S

4-24

3120801

SECTION 4 PLATFORMS FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 4 P L A T F O R M S

3120801

4-25

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-7. CONTROLLER ASSEMBLIES - OEM

4 P L A T F O R M S

4-26

3120801

SECTION 4 PLATFORMS FIGURE 4-7. CONTROLLER ASSEMBLIES - OEM FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

1600092 1600247

CONTROLLER ASSEMBLY (PRIOR TO S/N 27148) CONTROLLER ASSEMBLY (S/N 27148 TO PRESENT)

Ref. Ref.

B —

1 2 3 4 5 6 7 8 to 11 12 13 14 15 to 22 23 24 to 28 29 30 31 32 to 33 34 35 36 to 45

7003927 7003928 7003930 7003931 7003932 7003937 7003938 Not Used 7003933 7003941 7003940 Not Used 7003961 Not Used 7003935 Not Used 7003939 Not Used 7003936 7003950 Not Used

46

7003947 7019120

3120801

Knob (Upper) Spring, Knob Knob (Lower) Boot Tube, Interlock Ring, Retaining Clamp, Boot

1 1 1 1 1 1 1

Gasket Washer, Nylon Screw

1 2 2

Microswitch

3

Gear, Slave

1

Shaft

1

Spring, Return Plate, Zinc Retainer

1 1

PC Board Assembly (Includes Potentiometer) (1600092) PC Board Assembly (1600247) Note: Recommend replacing complete controller due to cost comparison.

S E C T I O N 4 P L A T F O R M S

1

4-27

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS

4 P L A T F O R M S

4-28

3120801

SECTION 4 PLATFORMS FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS FIG & ITEM #

PART NUMBER 0239259 0252054/0231203

1

2 3 4

1670482 1670607 1670526 Not Used Not Used Not Used

DESCRIPTION CONSOLE BOX COVER INSTALLATIONS (PRIOR TO SEPTEMBER 1990) CONSOLE BOX COVER INSTALLATIONS (SEPTEMBER 1990 TO PRESENT) Note: See Section 10 for Metal Console Covers.

Cover Options: Cover (Prior to September 1990) Cover (Black/September 1990 to Present) Cover (Yellow/September 1990 to Present)

BEACON LIGHT OPTIONS:

51

0252211/0252210

52 53 54 55

2920009 2920018 Not Used Not Used Not Used 2540016 2900068 0253686 0253987 0254748

101

2920013 2920111

0250143 151

152 153

3120801

4160028 0900232 0901056 4220007 Not Used Not Used

Beacon Mounted Under Console (September 1991 to Present) Beacon (Red) Beacon (Amber)

Grommet (Not Shown) WORKLIGHT OPTIONS (PRIOR TO NOVEMBER 1992) WORKLIGHT OPTIONS (NOVEMBER 1992 TO MAY 1995) WORKLIGHT OPTIONS (MAY 1995 TO PRESENT) WORKLIGHT OPTIONS WITH PADDED PLATFORM Floodlight (Prior to November 1992) Halogen Light (November 1992 to Present) (Uses P/N 3536089 Mounting Plate) SELF-CLOSING GATE INSTALLATION Spring Bracket (Door Mounted) Bracket (Platform Mounted) Stop, Door

QTY.

REV.

Ref.

—

Ref.

2/2

1

Ref.

A/R

3/3

1 Ref.

F

Ref.

—

Ref. Ref.

4 2

2 2

Ref.

A

1 1 1 1

4-29

S E C T I O N 4 P L A T F O R M S

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

1281083

PLATFORM BUMPERS INSTALLATION (WELDED-ON TYPE)

Ref.

I

Ref. Ref. Ref.

C C D

0250689 0250071 0239743 0251349

4

0251350

P L A T F O R M S

0250919 0253426 0252902

201 202 203

4360215 4460521 0940038 4360274 3251596 3740049

1282197

0254463 0254464 0254465 251

252 253

0630440 3010088 1260136 4360057 0200048 0940038 1670663 1670664 1670715 1670720 1670665 1670666 1670667 1670716 1670721 1670671 1670717

4-30

3’ x 5’ STANDARD PLATFORM (100HX/110HX) 3’ x 6’ STANDARD PLATFORM (100HX/110HX) 3’ x 8’ STANDARD PLATFORM (100HX/110HX) 3’ x 5’ EXTEND-A-REACH PLATFORM (110HXER/ 100HX+10) (PRIOR TO MAY 1992) 3’ x 6’ EXTEND-A-REACH PLATFORM (110HXER/ 100HX+10) (PRIOR TO MAY 1992) 3’ x 5’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) (MAY 1992 TO PRESENT) 3’ X 6’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) (MAY 1992 TO PRESENT) 3’ X 8’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) (MAY 1992 TO PRESENT) Switch, Proximity Connector, Strain Relief Padding, Bumper Switch, Push Button (Override) Nameplate - Override Relay (Not Shown) PLATFORM BUMPERS INSTALLATION - SOFT TOUCH SYSTEM (CHAIN MOUNTED TYPE) 3’ x 5’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) 3’ x 6’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) 3’ x 8’ LOW MOUNT PLATFORM (110HXER/ 100HX+10) Eyebolt Link, Quick Chain Switch, Limit Arm, Actuator Padding (Bottom Rail) Padding (Rail Behind Console Box) (Prior to S/N 44770) Padding (LH Top Rail - 36" x 60" Platform) Padding (LH Top Rail - 36" x 72" Platform) Padding (LH Top Rail - 36" x 96" Platform) Padding (Vertical Rails) Padding (Gate) Padding (RH Top Rail - 36" x 60" Platform) Padding (RH Top Rail - 36" x 72" Platform) Padding (RH Top Rail - 36" x 96" Platform) Padding (LH Mid Rail - 36" x 60" Platform) Padding (LH Mid Rail - 36" x 72" Platform)

Ref. Ref. Ref. Ref.

A

Ref.

A

4 4 A/R 1 1 1

Ref.

D

Ref.

6

Ref.

7

Ref.

7

8 8 A/R 1 1 A/R 1 1 1 1 4 1 1 1 1 1 1

3120801

SECTION 4 PLATFORMS FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM #

254

255

PART NUMBER

DESCRIPTION

QTY.

1670722 1670672 1670718 1670723 1670673 1670719 1670724 4360274 3252238

Padding (LH Mid Rail - 36" x 96" Platform) Padding (RH Mid Rail - 36" x 60" Platform) Padding (RH Mid Rail - 36" x 72" Platform) Padding (RH Mid Rail - 36" x 96" Platform) Padding (Bumper Rail - 36" x 60" Platform) Padding (Bumper Rail - 36" x 72" Platform) Padding (Bumper Rail - 36" x 96" Platform) Switch, Push Button Decal - Soft Touch System Cable, Electrical 16-2 Options (Not Shown) (S/N 36200 to Present): 3’ x 5’ Platform 3’ x 6’ Platform 3’ x 8’ Platform

1 1 1 1 1 1 1 1 1

1060341

0258917

301 302 303 304 305 306 307 308

0940038 Not Used 1670720 1670665 1670666 1670721 1670722 1670723 0251059

401 402

3120801

4844395 Not Used

PLATFORM - 3’ X 8’ BUMPER PADDING INSTALLATION (S/N 39684 TO PRESENT) Padding, Bumper Cover, (LH Top Rail) Cover, (Vertial Rails) Cover, (Gate Top Rail) Cover, (RH Top Rail) Cover, (LH Mid Rail) Cover, (RH Mid Rail) ACCESS STEP INSTALLATION Step Weldment

REV.

A/R 14ft/4.3m 12ft/3.7m 12ft/3.7m

Ref.

2

38ft/11.6m

1 4 1 1 1 1 Ref.

2/A

1

4-31

S E C T I O N 4 P L A T F O R M S

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

4 P L A T F O R M S

4-32

3120801

SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE

5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14

3120801

DESCRIPTION

AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLE LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEVEL CYLINDER ASSEMBLY (Model 100HX & 110HX Built Prior To May 1992) . . . . . . . . . .

LEVEL CYLINDER ASSEMBLY (Model 100HX & 110HX Built May 1992 to Present) . . . . . . . .

LEVEL CYLINDER ASSEMBLY (Model 100HX+10 & 110HXER Built Prior To May 1992) . . . .

LEVEL CYLINDER ASSEMBLY (Model 100HX+10 & 110HXER Built May 1992 to Present) . .

LIFT CYLINDER ASSEMBLIES - BOOM (Prior To May 1992) . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER ASSEMBLIES - BOOM (May 1992 to Present) . . . . . . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER ASSEMBLIES - BOOM (May 1992 to Present) . . . . . . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER ASSEMBLIES - EXTEND-A-REACH (100HX+10 & 110HXER Only) . . . . . . .

MASTER CYLINSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TELESCOPE CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER BELLOWS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

5-2 5-4 5-6 5-8 5-10 5-12 5-14 5-16 5-18 5-20 5-22 5-24 5-26 5-30

S E C T I O N 5 C Y L I N D E R S

5-1

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-2

3120801

SECTION 5 CYLINDER FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1681964

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16

1681965 1681967 1680892 3480120 4564046 3300187 3300273 1120179 Kit Kit Kit Kit Kit Kit Kit Kit 3951403 3900170

17 18 19 20 21

2200201 0100011 Not Used 0100035 0100038 2900381

3120801

DESCRIPTION AXLE EXTENSION CYLINDER ASSEMBLY Barrel Weldment Rod Weldment Head Piston Spacer, Tube Nut Options: Prior to February 1991 February 1991 to Present (Hex Style) (Not Shown) Retainer Wiper, Rod Seal, Rod Ring, Wear O-Ring Ring, Back-Up Ring, Wear O-Ring Seal, Piston Setscrew Options: Setscrew 1/4"-20NC x 3/8" (Prior to February 1991) Setscrew 3/8"-16NC x 3/8" (February 1991 to Present) Plug, Pipe 1/8" NPT Loctite #242 (Not Shown) Loctite #222 (Not Shown) Primer, Locking (Not Shown) —————————— Seal Kit (Includes Items 8-15)

QTY.

REV.

Ref.

C

1 1 1 1 1 1

S E C T I O N 5

1 1 1 1 1 2 1 1 1 A/R 2

C Y L I N D E R S

1 2 A/R A/R A/R 1

5-3

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-2. AXLE LIFT CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-4

3120801

SECTION 5 CYLINDER FIGURE 5-2. AXLE LIFT CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1681991 1683596

1

2 2A 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17 18 19

1681992 1683597 1681963 0960946 1120336 0100035 1681843 3480102 3300281 0100011 0100038 4564128 4640509 Kit Kit Kit Kit Kit Kit Kit 3900170 Not Used Not Used 2200202 2200222 0100020

20

21 22

2200201 2200221 0100020 Not Used 2160002 2901102

3120801

DESCRIPTION AXLE LIFT CYLINDER ASSEMBLIES Prior To S/N 39439 S/N 39439 To Present Rod Assembly Options: Prior to S/N 39439 S/N 39439 to Present Barrel Assembly Bushing, Bronze Cap Loctite #222 Head Piston Nut, Special Loctite #242 Primer Spacer Valve Ring, Wiper Seal T-Seal Ring, Wear Seal Ring, Guidelock O-Ring Setscrew 3/8"-16NC x 3/8"

Plug 1/4" Options: Prior to S/N 39439 S/N 39439 to Present Loctite Plug 1/8" Options: Prior to S/N 39439 S/N 39439 to Present Loctite

QTY.

REV.

Ref. Ref. Ref.

B 2

1

1 2 1 A/R 1 1 1 A/R A/R 1 2 1 1 1 1 2 2 1 1

5 C Y L I N D E R S

2

A/R 4

A/R

Fitting, Grease

1

Seal Kit (Includes Items 9 - 15)

1

S E C T I O N

5-5

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-3. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992)

5 C Y L I N D E R S

5-6

3120801

SECTION 5 CYLINDER FIGURE 5-3. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992) FIG & ITEM #

PART NUMBER 1681973

1 2 3 4

1681976 4640509 2900792 2200202 0100020 2200201 0100020

5

6 7 8 9 10 11 12 13 14 15 16 17 18 19

3300257 3300301 3900170 0100011 0100038 3480120 Kit Kit Kit 4564057 1680892 Kit Kit Kit Kit Kit 1120179 0100035 1681974 0960097 2160002

2900381

3120801

DESCRIPTION PLATFORM LEVEL CYLINDER ASSEMBLY Barrel Assembly Valve, Cartridge Seal Kit - 4640509 Valve (1 Per Cartridge) Plug, Pipe Sealant, Pipe Plug, Pipe Sealant, Pipe Nut Options: Nut, Standard Production (Without Setscrew) Nut, Hex Style Replacement (Requires Setscrew) Setscrew 3/8"-16NC x 3/8" (Not Shown) Loctite #242 Primer, Locking Piston Ring, Wear Seal, Piston O-Ring Spacer Head Ring, Wear Ring, Back-up O-Ring Seal, Rod Seal, Wiper Retainer Loctite #222 Rod Assembly Bushing Fitting, Grease —————————— Seal Kit - 1681973 Cylinder (Includes Items 7-9 &1215)

QTY.

REV.

Ref.

E

1 2 2 2 A/R 6 A/R 1

S E C T I O N 5 C Y L I N D E R S

1 A/R A/R 1 1 2 1 1 1 1 2 1 1 1 1 A/R 1 1 2

1

5-7

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-4. LEVEL CYLINDER ASSEMBLY (100HX & 110HX)

5 C Y L I N D E R S

5-8

3120801

SECTION 5 CYLINDER FIGURE 5-4. LEVEL CYLINDER ASSEMBLY (100HX & 110HX) FIG & ITEM #

PART NUMBER

1682590 1683536 1

2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1682591 1683535 1681974 0960097 1680892 3480120 4564057 3300308 1120179 Kit Kit Kit Kit Kit Kit Kit Kit 2160002 4640634 2900770 3900170 2220885 0100011 0100038 0100035 2900381

3120801

DESCRIPTION PLATFORM SLAVE LEVEL CYLINDER ASSEMBLY OPTIONS: May 1992 To S/N 33111 S/N 33111 To Present Barrel Assembly Options: May 1992 to S/N 33111 S/N 33111 to Present Rod Assembly Bushing Head Piston Spacer Nut Retainer Seal, Wiper Seal, Rod Ring, Wear O-Ring Ring, Back-up Ring, Wear O-Ring Seal, Piston Fitting, Grease Valve, Cartridge - Holding Seal Kit - 4640634 Valve (1 Per Assembly) Setscrew 2/8"-16NC x 3/8" Plug, Socket Head #6 Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit - 1682590 Cylinder (Includes Items 8-14)

QTY.

REV.

Ref. Ref. Ref.

C 1/A

1

S E C T I O N 5

1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 1 2 A/R A/R A/R

C Y L I N D E R S

1

5-9

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992)

5 C Y L I N D E R S

5-10

3120801

SECTION 5 CYLINDER FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

1681791 1682459

PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: Prior To February 1991 February 1991 To May 1992

Ref. Ref. Ref.

F 2

1

2 3 4 5 6 7

8 9 10 11 12 13 14 15 16

1681796 1682460 1681797 0961182 1681792 1120305 4563657 3480124 3300234 3300276 4640509 2900792 Kit Kit Kit Kit Kit Kit Kit 3951403 3900170

17 2200213 2200233 18

19 20 21 22 23

2200201 2200221 0100020 2160002 0100011 0100038 0100035 2900394

3120801

Barrel Assembly Options: Prior To February 1991 February 1991 To May 1992 Rod Assembly Bushing, Bronze Head Retainer Spacer Piston Nut Options: Nut (Prior to January 1991) Nut, Hex (January 1991 to May 1992) Valve, Cartridge - Holding Seal Kit - 4640509 Valve (1 Per Cartridge) Seal, Wiper Seal, Rod Ring, Wear O-Ring Ring, Wear T-Seal O-Ring Setscrew Options: Setscrew 1/4"-20NC x 3/8" Setscrew 3/8"-16NC x 3/8" Plug, Pipe 1/4" Options: Prior to S/N 39439 S/N 39439 to Present Plug, Pipe 1/8" Options: Prior to S/N 39439 S/N 39439 to Present Sealant, Thread Fitting, Grease Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit - Cylinder (Includes Items 9-15)

1 1 1 1 2 1 1 1 1 1

S E C T I O N 5 C Y L I N D E R S

2 2 1 1 1 1 1 1 1 A/R 2 1 2

2

A/R 3 A/R A/R A/R 1

5-11

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER)

5 C Y L I N D E R S

5-12

3120801

SECTION 5 CYLINDER FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER) FIG & ITEM #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 to 22 23

PART NUMBER

DESCRIPTION

QTY.

REV.

1682753 1683493

PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: May 1992 To S/N 29913 S/N 29913 To Present

Ref. Ref. Ref.

F A

1682754 0961595 1682755 0961182 1120305 1681792 3480167 4565913 3300279 4640634 2900770 2220885 2220883 3900170 Kit Kit Kit Kit Kit Kit Kit Not Used 4640634 2900770 4640996 Not Available 0100038 0100011 0100035 2901206

3120801

Barrel Weldment Bushing, Bronze Rod Weldment Bushing, Oilite Retainer Head Piston Spacer Nut Cartridge, Holding Valve Seal Kit - 4640634 Valve Plug 3/8" Plug 1/4" Setscrew 3/8"-16NC x 3/8" Wiper, Rod Seal, Rod Ring, Wear O-Ring O-Ring Ring, Guide Ring, Lock Cartridge, Holding Valve Options: Cartridge, Holding Valve (May 1992 to S/N 29913) Seal Kit - 4640634 Valve Cartridge, Holding Valve (S/N 29913 to Present) Seal Kit - 4640996 Valve —————————— Primer, Loctite Loctite #242 Loctite #222 —————————— Seal Kit (Includes Items 12-18)

1 2 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2

S E C T I O N 5 C Y L I N D E R S

1 1 1 1 A/R A/R A/R 1

5-13

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-7. LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO MAY 1992)

5 C Y L I N D E R S

5-14

3120801

SECTION 5 CYLINDER FIGURE 5-7. LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO MAY 1992) FIG & ITEM #

PART NUMBER 1682034

1 2 3 4 5 6

1682035 0961082 4640181 3900138 3931440 2160002 3300192 3300297 0100011 0100038

7

8 9 10 11 12 13 14 15 16 17 18 19 20 21

3900136 3900171 Kit Kit 3480104 Kit 4564142 Kit Kit Kit 1681298 Kit 1120238 0100035 1681835 0961082 3900136 3951404 0100011 2900338

3120801

DESCRIPTION LIFT CYLINDER ASSEMBLY Barrel Assembly (Includes Item 2) Bushing, Bronze Valve, Block Orifice (Located in Valve Block) Capscrew, Socket Head 1/4"-20NC x 2 1/2" Fitting, Grease Nut Options: Nut, Special (Prior to January 1991) Nut, Hex (January 1991 to Present) Loctite #242 (Not Shown) Primer, Locking (Not Shown) Setscrew Options: Setscrew (Prior to January 1991) Setscrew (January 1991 to Present) Ring, Lock Seal, Piston Piston O-Ring Spacer Ring, Wear Seal, Rod O-Ring Head Wiper Cap, Retainer Loctite #222 (Not Shown) Rod Assembly (Includes Item 20) Bushing, Bronze Setscrew Options: Setscrew 1/2"-13NC x 1/2" (Prior to January 1991) Setscrew 1/4"-20NC x 1/2" (January 1991 to Present) Loctite #242 (Not Shown) —————————— Seal Kit (Includes Items 8,9,11,13,14,15 and 17)

QTY.

REV.

Ref.

B

1 2 1 1 4 2 1

S E C T I O N 5 C Y L I N D E R S

A/R A/R A/R 2 1 2 2 1 1 1 1 2 1 1 1 1 A/R 1 2 A/R 2 1 A/R 1

5-15

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-8. LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT)

5 C Y L I N D E R S

5-16

3120801

SECTION 5 CYLINDER FIGURE 5-8. LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT) FIG & ITEM #

PART NUMBER 1682630

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1682631 0960509 1682633 0961082 1120363 1682118 3480162 4565652 3300306 2220887 4640709 2900770 3900171 2160002 Kit Kit Kit Kit Kit Kit Kit Kit 2220883 0100011 0100038 0100035 2901118

3120801

DESCRIPTION LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT) Barrel Weldment Bushing, Bronze Rod Weldment Bushing, Bronze Retainer Head Piston Spacer Nut Plug Cartridge, Holding Valve Seal Kit - 4640709 Valve Setscrew 1/2"-13NC x 1/2" Fitting, Grease Wiper, Rod Seal, Rod O-Ring Ring, Back-Up Ring, Wear Ring, Guide O-Ring Ring, Lock Plug —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 12-19)

QTY.

REV.

Ref.

B

1 2 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1

S E C T I O N 5 C Y L I N D E R S

A/R A/R A/R 1

5-17

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-9. LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE)

5 C Y L I N D E R S

5-18

3120801

SECTION 5 CYLINDER FIGURE 5-9. LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE) FIG & ITEM #

PART NUMBER 1682587

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1682588 0961082 1681835 0961082 1120238 1681298 4565603 3480104 3300297 4640731 4640495 2900770 3900171 2160002 Kit Kit Kit Not Used Kit Kit Kit Kit 3900141 0100011 0100038 0100035 2900338

3120801

DESCRIPTION LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE)

QTY.

REV.

Ref.

Barrel Weldment Bushing, Bronze Rod Weldment Bushing, Bronze Retainer Head Spacer Piston Nut Valve, Needle Cartridge, Holding Valve Seal Kit - 4640495 Valve Setscrew 1/2"-13NC x 1/2" Fitting, Grease Wiper, Rod Seal, Rod O-Ring

1 2 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1

Ring, Wear Ring, Guide O-Ring Ring, Lock Setscrew 1/4"-20NC x 3/8" —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 12-19)

1 2 1 1 1

S E C T I O N 5 C Y L I N D E R S

A/R A/R A/R 1

5-19

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-10. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (100HX+10 & 110HXER ONLY)

5 C Y L I N D E R S

5-20

3120801

SECTION 5 CYLINDER FIGURE 5-10. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (100HX+10 & 110HXER ONLY) FIG & ITEM #

PART NUMBER

1681955 1682635 1683725 1

1A 2

1681956 1682636 1683724 0961185 1681957 1682638

2A

3 4 5 6 7

Not Required 0961595 1120305 1681423 4564009 3480113 3300226 3300285

8

9 10 11 12 13 14 15 16 17 18 19

3900141 3900170 4640495 2900770 2160002 2200201 Kit Kit Kit Kit Kit Kit Kit 2200222 0100020 0100011 0100038 0100035 2901142

3120801

DESCRIPTION LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH OPTIONS (STANDARD PARTS): Prior To May 1992 May 1992 To S/N 49403 S/N 49403 To Present Barrel Weldment Options: Prior to May 1992 May 1992 to S/N 49403 S/N 49403 to Present Bushing, Bronze Rod Weldment Options: Prior to May 1992 May 1992 to Present Bushing, Bronze Options: Prior to May 1992 May 1992 to Present Retainer Head Spacer Piston Nut Options: Nut (Prior to May 1991) Nut, Hex (May 1991 to Present) Setscrew Options: Setscrew 1/4"-20NC x 3/8" Setscrew 3/8"-16NC x 3/8" Cartridge, Holding Valve Seal Kit - 4640495 Valve Fitting, Grease Plug, Pipe 1/8" NPT Wiper, Rod Seal, Rod Ring, Wear Seal, Head Ring, Guide Ring, Lock O-Ring Plug, Pipe 1/4" NPT —————————— Sealant, Pipe Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 12-18)

QTY.

REV.

Ref. Ref. Ref. Ref.

C 1

S E C T I O N

1

5 C Y L I N D E R S

2 1

A/R 0 2 1 1 1 1 1 1 1 A/R 2 1 1 1 2 4 1 1 1 1 2 2 1 2 A/R A/R A/R A/R 1

5-21

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-11. MASTER CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-22

3120801

SECTION 5 CYLINDER FIGURE 5-11. MASTER CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER

1681978 1681978 1681580

1

Not Used 1681979 1681979 1681490

2

Not Used 1681974 1681974 1681488

2A 3 4 5 6

7 8 9 10 11 12 13 14 15 16

17 18

0960097 1120179 1680892 3480120 3300101 3300272 Kit Kit Kit Kit Kit Kit Kit Kit 3900170 Not Used 4564057 4564057 4563031 2160002 2200201 0100011 0100038 0100035 2900381

3120801

DESCRIPTION MASTER CYLINDER ASSEMBLY Note: Refer to P/N stamped on Barrel for identification. Also, all 1681978 Cylinders have the new piston configuration.

100HX & 110HX 100HX+10 & 110HXER With 4620038 Turntable 100HX+10 & 110HXER With 4620044 & 4620078 Turntables Barrel Weldment Options: 100HX & 110HX 100HX+10 & 110HXER with 4620038 Turntable 100HX+10 & 110HXER with 4620044 & 4620078 Turntables Rod Weldment Options: 100HX & 110HX 100HX+10 & 110HXER with 4620038 Turntable 100HX+10 & 110HXER with 4620044 & 4620078 Turntables Bushing, Bronze Retainer Head Piston Nut Options: Nut (Prior to August 1992) Nut, Hex (August 1992 to Present) Ring, Wear Z-Seal Wiper, Rod O-Ring Ring, Back-Up Seal, Piston Ring, Wear O-Ring Setscrew 3/8"-16NC x 3/8" Tube, Spacer Options: 100HX & 110HX 100HX+10 & 110HXER with 4620038 Turntable 100HX+10 & 110HXER with 4620044 & 4620078 Turntables Fitting, Grease Plug, Pipe 1/8" NPT —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 7-14)

QTY.

REV.

Ref. Ref. Ref.

C C F

S E C T I O N 5

1

C Y L I N D E R S

1 1

1 1 1 1 1

1 1 1 1 2 1 1 1 1 1

1 1 A/R A/R A/R 1

5-23

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-12. STEER CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-24

3120801

SECTION 5 CYLINDER FIGURE 5-12. STEER CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1681934

1 2

1681933 3300187 3300273

3

4 5 6 7 8 9 10 11 12 13 14 15 16 17

3900141 3900170 Kit Kit Kit 3480134 4563963 3900141 Kit Kit 1681344 Kit Kit 1120108 1681411 2160002 0100011 0100038 0100035 2901123

3120801

DESCRIPTION STEER CYLINDER ASSEMBLY Barrel Nut Options: Nut (Prior to August 1992) Nut, Hex (August 1992 to Present) Setscrew Options: Setscrew 1/4"-20NC x 3/8" (Prior to August 1992) Setscrew 3/8"-16NC x 3/8" (August 1992 to Present) O-Ring T-Seal Ring, Wear Piston Spacer Setscrew 1/4"-20NC x 3/8" Ring, Wear O-Ring Head Seal, Rod Wiper, Rod Retainer Rod Fitting, Grease ————————— Loctite #242 Loctite, Primer Loctite #222 ————————— Seal Kit (Includes Items 4, 5,6, 10, 11, 13 and 14)

QTY.

REV.

Ref.

E

1 1

A/R 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

S E C T I O N 5 C Y L I N D E R S

A/R A/R A/R 1

5-25

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES

5 C Y L I N D E R S

5-26

3120801

SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES FIG & ITEM #

PART NUMBER 1682032 1682821 1682030 1682820

1 1681949 1681926 2

3 4 5 6 7 8

9 10

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

3120801

1681950 1681922 1682031 4843016 3840944 0560773 1120345 1681925 1682298 3480133 3300249 3300299 0181404 3340560 Kit Kit Kit Kit Kit Kit Kit Kit 4640487 7011317 3312202 0641812 4761800 0641608 4761600 3311601 0641605 3951405

DESCRIPTION TELESCOPE CYLINDER ASSEMBLIES 100HX, 100HX+10 & 110HXER Prior To October 1992 100HX, 100HX+10 & 110HXER October 1992 To Present 110HX Prior To October 1992 110HX October 1992 To Present Barrel Weldment Options: Prior to October 1992 October 1992 to Present Rod Weldment Options: Prior to October 1992 October 1992 to Present Spacer Rod Support Weldment Rod, Guide Block, Nylatron Retainer Head Options: Prior to October 1992 October 1992 to Present Piston Nut Options: Nut (Prior to January 1991) Nut, Hex (January 1991 to Present) Angle Pad, Wear Seal, Rod Wiper, Rod O-Ring Ring, Back-Up Ring, Wear Ring, Guide Seal, Piston T-Seal Cartridge, Valve Kit, Seal Nut, Jam 3/4"-10NC Bolt 1/2"-13NC x 1 1/2" Lockwasher 1/2" Bolt 3/8"-16NC x 1" Lockwasher 3/8" Nut 3/8"-16NC Bolt 3/8"-16NC x 5/8" Setscrew 1/4"-20NC x 5/8"

QTY.

REV.

Ref. Ref.

E

Ref.

A

Ref. Ref.

D A

S E C T I O N

1

5

1

C Y L I N D E R S

1 1 2 1 1 1

1 1

1 1 3 1 1 1 1 2 2 1 1 1 2 2 2 2 7 2 5 1

5-27

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM #

PART NUMBER

30 3951403 3900171 31 32 33 34 35 36

5

2200221 2200224 2200222 Not Used Not Used 3340566 0100020 0100011 0100035 0100038

C Y L I N D E R S

2901109 2901234

5-28

DESCRIPTION Setscrew Options: Setscrew 1/4"-20NC x 3/8" (Prior to January 1991) Setscrew 1/2"-13NC x 1/2" (January 1991 to Present) Plug, Pipe 1/8" NPT Plug, Pipe 3/8" NPT Plug, Pipe 1/4" NPT

Pad, Wear —————————— Sealant, Pipe Loctite #242 Loctite #222 Primer, Locking —————————— Seal Kit (Includes Items 13-20) (Prior to October 1992) Seal Kit (Includes Items 13-20) (October 1992 to Present)

QTY.

REV.

A/R 2 1 1 2 1

1 A/R A/R A/R A/R

1 1

3120801

SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 5 C Y L I N D E R S

3120801

5-29

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-14. CYLINDER BELLOWS INSTALLATION

5 C Y L I N D E R S

5-30

3120801

SECTION 5 CYLINDER FIGURE 5-14. CYLINDER BELLOWS INSTALLATION FIG & ITEM #

PART NUMBER 0239258 0253636 0253637

1 2

0460075 0460080 0460071 0460088

3 Not Required Not Required 0460087 4

5 6 7 8

3120801

0460079 0460086 0460086 0460071 1320037 1320059 1320122

DESCRIPTION CYLINDER BELLOWS INSTALLATION (OPTIONAL) 100HX & 110HX Prior To May 1992 100HX & 110HX May 1992 To Present 100HX+10 & 110HXER May 1992 To Present Bellow (Steer) Bellow (Platform Level) Options: 100HX & 110HX Prior To May 1992 100HX & 110HX May 1992 To Present 100HX+10 & 110HXER May 1992 To Present Bellow (Extend-A-Reach Lift) 100HX & 110HX Prior To May 1992 100HX & 110HX May 1992 To Present 100HX+10 & 110HXER May 1992 To Present Bellow (Boom Lift) Options: 100HX & 110HX Prior To May 1992 100HX & 110HX May 1992 To Present 100HX+10 & 110HXER May 1992 To Present Bellow (Master) Options: Clamp Clamp Clamp

QTY.

REV.

Ref. Ref. Ref. Ref.

B 2 2

S E C T I O N

1 1

5 A/R 0 0 1 1

C Y L I N D E R S

1 1 1 2

5-31

S E C T I O N

SECTION 5 CYLINDER FIGURE 5-14. CYLINDER BELLOWS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

5 C Y L I N D E R S

5-32

3120801

SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE

6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12

3120801

DESCRIPTION

HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (WITHOUT TWO PACKAGE AND WITH DUAL FRAME JACKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER). . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - ROTATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - SEQUENCE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

6-2 6-4 6-6 6-8 6-12 6-14 6-16 6-18 6-22 6-24 6-26 6-28

S E C T I O N 6 H Y D R A U L I C S

6-1

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM LIST FIG & ITEM #

PART NUMBER

DESCRIPTION HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in the following pages.

Information on diagrams not shown are available from the JLG Service/ Parts Department.

2791454

Axle Jack Hydraulic Diagram (Single Axle Jack without Tow Package) (For other options see Axle Extension Hydraulic Diagrams)

6 H Y D R A U L I C S

2791431 2792283* 2791926

Axle Extension/Steering/Axle Jack/Tow Hydraulic Diagrams: Without Tow Package & Without Axle Jacks Without Tow Package & With Dual Axle Jacks With Tow Package & Without Axle Jacks

2791552*

Brake with Pressure Reducing Valve (Used with Ausco Drive Brakes)

2791423*

Drive Hydraulic Diagram

2791425*

Extend-A-Reach Hydraulic Diagram (100HX+10 & 110HXER Only)

2791605 2791993 2792025*

Level Hydraulic Diagrams: 100HX & 110HX: Prior to June 1993 June 1993 to present 100HX+10 & 110HXER: Prior to November 1992 November 1992 to June 1993 June 1993 to Present

2791599 2791599 2792235*

Lift Hydraulic Diagrams: 4620044 Turntable 4620078 Turntable Machines Built Prior to Sptember 1995 4620078 Turntable Machines Built September 1995 to Present

1692883 0253729

Manual Descent Hydraulic Diagram (Prior to October 1992) Manual Descent Hydraulic Diagram (October 1992 to Present)

0252917

Oil Cooler Hydraulic Diagram

2791438* 2791594*

Pump Hydraulic Diagrams: Deutz Engine Machines Ford & Cummins Engine Machines

2791604* 2791433 2791987*

Rotate Hydraulic Diagrams: 100HX & 110HX 100HX+10 & 110HXER (Prior to May 1992) 100HX+10 & 110HXER (May 1992 to Present)

2791428 2792026*

0251703/1281353*

6-2

Sequence Hydraulic Diagram

3120801

SECTION 6 HYDRAULICS

S E C T I O N

FIGURE 6-1. HYDRAULIC DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER

DESCRIPTION Steer Hydraulic Diagrams (See Axle Extension Hydraulic Diagrams)

2791426*

Swing Hydraulic Diagram

2791427*

Telescope Hydraulic Diagram Tow Hydraulic Diagram (See Axle Extension Hydraulic Diagrams)

6 H Y D R A U L I C S

3120801

6-3

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS)

6 H Y D R A U L I C S

6-4

3120801

SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS) FIG & ITEM #

PART NUMBER 2792283

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

3120801

2220473 2220371 2220606 2220873 2220428 2220429 2752461 2751003 2752462 2220385 2220619 2220899 2752470 2752471 2751114 2750896 2750891 2220414 2220416 2220582 2220605 2220237 2220399 2751395 2220635 2751132 2750779 2750991 2750908

DESCRIPTION HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS) Fitting, 90º Fitting, Straight Fitting, Tee Fitting, Straight Fitting, Quick Disconnect Fitting, Dust Cap Hose Hose Hose Fitting, Tee Fitting, Reducer Fitting, Tee Hose Hose Hose Hose Hose Fitting, Straight Fitting, 90º Fitting, Straight Fitting, Tee Fitting, Plug Fitting, Straight Hose Fitting, Tee Hose Hose Hose Hose

QTY.

REV.

Ref.

2/B

6 6 3 2 2 2 2 2 1 2 2 1 3 1 2 1 2 2 4 4 2 2 4 2 1 1 1 2 2

S E C T I O N 6 H Y D R A U L I C S

6-5

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES)

6 H Y D R A U L I C S

6-6

3120801

SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES) FIG & ITEM #

PART NUMBER 2791552

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

3120801

4640522 Not Used 3311401 4761400 4751400 2220250 2220752 2220428 2220429 2220584 2220417 2751397 Not Used Not Used 2220414 0641416 2750899 2220605 2751018 4640197

DESCRIPTION HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES)

QTY.

REV.

Ref.

D

Valve, Pressure Reducing

1

Nut 1/4"-20NC Lockwasher 1/4" Flatwasher 1/4" Fitting, Reducer Fitting, Tee Fitting, Quick Disconnect Cap, Dust Fitting, Pipe Fitting, Straight Hose

2 2 4 2 2 1 1 1 1 1

Fitting, Straight Bolt 1/4"-20NC x 2" Hose Fitting, Tee Hose Valve, Check

2 2 1 1 1 1

S E C T I O N 6 H Y D R A U L I C S

6-7

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE

6 H Y D R A U L I C S

6-8

3120801

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE FIG & ITEM #

PART NUMBER 2791423

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

3120801

2751466 2220415 2220800 Not Used 2220451 2220385 2220618 2750889 2220466 2220414 4640013 2220261 4640197 2220673 2220417 Not Used Not Used 2751010 2220602 0100020 2750979 2750759 2220362 2220374 2750894 2220504 Not Used 2220585 2220466 Not Used Not Used Not Used 2751013 2220465 2751339 2220435 Not Used Not Used 2750759 Not Used Not Used 2751409 2220375 2751489 2751337 2220568 2220500

DESCRIPTION HYDRAULIC DIAGRAM - DRIVE

QTY.

REV.

Ref.

6

Hose Fitting, Straight Fitting, Straight

1 2 5

Fitting, Straight Fitting, Tee Fitting, Reducer Hose Fitting, 90° Fitting, Straight Valve, Shuttle Fitting, Straight Valve, Check Fitting, 90° Fitting, Straight

2 2 2 2 2 2 1 1 1 1 1

Hose Fitting, Tee Sealant, Pipe Hose Hose Fitting, Tee Fitting, Straight Hose Fitting, Tee

1 1 A/R 1 2 1 2 4 2

Fitting, 90° Fitting, 90°

1 2

Hose Fitting, 90° Hose Fitting, Straight

1 2 2 2

Hose

1

Hose Fitting, Straight Hose Hose Fitting, 45° Fitting, 45°

1 2 3 2 2 1

S E C T I O N 6 H Y D R A U L I C S

6-9

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (CONTINUED) FIG & ITEM #

PART NUMBER

48 49 50 51

Not Used 2220822 2220909 2220811

DESCRIPTION Fitting Fitting Fitting, Reducer

QTY.

REV.

1 1 2

6 H Y D R A U L I C S

6-10

3120801

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 6 H Y D R A U L I C S

3120801

6-11

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER)

6 H Y D R A U L I C S

6-12

3120801

SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER) FIG & ITEM #

PART NUMBER 2791425

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3120801

2220399 2751170 4563167 4640216 2220343 2220280 2220113 0100020 2751168 2220600 2750929 2220386 2220385 2751494 2220373

DESCRIPTION HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER) Fitting, Straight Hose Tube Valve, Color Flow (Adjustable Restrictor) Fitting, Straight Fitting, Straight Fitting, 90° Sealant, Pipe (Not Shown) Hose Fitting, Straight Hose Fitting, 90° Fitting, Tee Hose Fitting, Straight

QTY.

REV.

Ref.

4

2 2 2 2 2 2 2 A/R 2 1 1 1 2 1 1

S E C T I O N 6 H Y D R A U L I C S

6-13

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-6. HYDRAULIC DIAGRAM - LEVEL

6 H Y D R A U L I C S

6-14

3120801

SECTION 6 HYDRAULICS FIGURE 6-6. HYDRAULIC DIAGRAM - LEVEL FIG & ITEM #

PART NUMBER 2792026 2792025

1 2 3 4 5 6 7

2750918 4563167 2220591 2220371 2750778 2220473 2750920 2751002

8

9

2220607 2220609 2220899 2220606

10

11 12 13 14 15 16 17 18 19 20 21 22

23

3120801

2220417 2220619 2750998 2220490 2220343 2220495 2751830 2751871 2752162 2180615 2180379 2750785 2750991 2220868 2220867 2220362 2220444 2220444 2220635

DESCRIPTION HYDRAULIC DIAGRAM - LEVEL (100HX & 110HX) HYDRAULIC DIAGRAM - LEVEL (100HX+10 & 110HXER) Hose Tube Fitting, Reducer Fitting, Straight Hose Fitting, 90° Hose (100HX & 110HX) Hose (100HX+10 & 110HXER) Fitting, Straight Options: Prior to S/N 36614 S/N 36614 to Present Fitting, Tee Fitting, Tee Fitting, Straight Options: Prior to S/N 36614 S/N 36614 to Present Hose Fitting, Tee Fitting, Straight Fitting, 90° Hose Hose (100HX & 110HX) Hose (100HX+10 & 110HXER) Orifice (.047) Fitting, Modified Tee Hose Hose Fitting, Straight Fitting, Tee Options: Prior to S/N 36614 S/N 36614 to Present Fitting, Tee Prior to S/N 36614 S/N 36614 to Present

QTY.

REV.

Ref.

2

Ref.

3

1 2 2 2 2 3 2 2 1

S E C T I O N 6 H Y D R A U L I C S

2 2 1

1 2 1 1 2 2 2 2 2 1 2 1 1

1

6-15

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-7. HYDRAULIC DIAGRAM - LIFT

6 H Y D R A U L I C S

6-16

3120801

SECTION 6 HYDRAULICS FIGURE 6-7. HYDRAULIC DIAGRAM - LIFT FIG & ITEM #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

3120801

PART NUMBER

QTY.

REV.

2792235

HYDRAULIC DIAGRAM - LIFT

DESCRIPTION

Ref.

2

2220577 2751110 2220343 2751111 2220606 2750785 0100020 2751002 4640216 2220396 2220758 4640128 2220773 2220727 2220752 2220221 2220473 2180480 2180682 2220591

Fitting, Straight Hose Fitting, Straight Hose Fitting, Tee Hose Sealant, Pipe (Not Shown) Hose Valve, Color Flow 3/8" Fitting, Straight Fitting, Union Valve, Color Flow 1/4" Fitting, 90° Fitting, Reducer Fitting, Tee Fitting, Reducer Fitting, 90° Fitting, Straight Orifice (.109) Fitting

1 1 1 1 1 1 A/R 1 1 1 1 1 2 1 1 1 1 1 1 2

S E C T I O N 6 H Y D R A U L I C S

6-17

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP

6 H Y D R A U L I C S

6-18

3120801

SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP FIG & ITEM #

PART NUMBER 2791438

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

3120801

Not Used 1320031 2220809 2220808 2220451 Not Used 2220347 Not Used 2220681 0100020 2220621 Not Used 2220371 2220466 2750902 2220618 2220375 Not Used Not Used Not Used Not Used 2220373 Not Used 4640575 2750786 2751320 Not Used Not Used 2220428 2220429 2220114 Not Used 2220407 2220820 Not Used 2220700 2220622 2220696 2751617 Not Used Not Used 2220738 2750968 2220596 2220237 2220582 2750777

DESCRIPTION HYDRAULIC DIAGRAM - PUMP

QTY.

REV.

Ref.

8

Clamp Fitting, 45° Fitting, 45° Fitting, Straight

8 1 1 3

Fitting, Straight

1

Fitting, Tee Sealant, Pipe (Not Shown) Fitting, Reducer

6 H Y D R A U L I C S

1 A/R 1

Fitting, Straight Fitting, 90° Hose Fitting, Reducer Fitting, Straight

1 1 1 1 1

Fitting, Straight

2

Valve, Check Hose Hose

2 1 1

Fitting, Quick Disconnect Cap, Dust Fitting, 90°

3 3 1

Fitting, 90° Fitting, 90°

1 1

Fitting, Tee Fitting, Reducer Fitting, Reducer Hose

2 4 2 1

Fitting, Tee Hose Fitting, 90° Fitting, Plug Fitting, Straight Hose

1 1 1 1 2 1

S E C T I O N

6-19

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP (CONTINUED) FIG & ITEM #

PART NUMBER

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

Not Used 2750977 2750757 Not Used Not Used 2751015 2220435 Not Used 2180491 2750872 Not Used Not Used 2750777 2220385 2751021 Not Used 2751353 2750129 2220072 2220414 2220605 2720280 2750889 2220472

6 H Y D R A U L I C S

6-20

DESCRIPTION

QTY.

Hose Hose

1 1

Hose Fitting, Straight

1 1

Fitting, Modified 90° Hose

2 1

Hose Fitting, Tee Hose

1 1 1

Hose Hose Hose Fitting, Straight Fitting, Tee Hose, Suction 1 1/2" x 70" Hose Fitting, 90°

1 1 1 1 1 2 1 2

REV.

3120801

SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 6 H Y D R A U L I C S

3120801

6-21

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-9. HYDRAULIC DIAGRAM - ROTATE

6 H Y D R A U L I C S

6-22

3120801

SECTION 6 HYDRAULICS FIGURE 6-9. HYDRAULIC DIAGRAM - ROTATE FIG & ITEM #

PART NUMBER 2791604 2791987

1 2 3 4 5 6 7 8 9 10 11

3120801

2220446 2220438 2220416 4563167 2220609 2220497 0100020 4640383 2751455 2751919 2752452 2220507

DESCRIPTION HYDRAULIC DIAGRAM - ROTATE (100HX & 110HX) HYDRAULIC DIAGRAM - ROTATE (100HX+10 & 110HXER) Fitting Fitting, Nipple Fitting, Straight Tube Fitting, Reducer Fitting, Straight Sealant, Pipe (Not Shown) Valve, Restrictor Hose Hose (100HX & 110HX) Hose (100HX+10 & 110HXER) Fitting, 90° (100HX+10 & 110HXER Only)

QTY.

REV.

Ref.

2

Ref.

2

2 2 2 2 2 2 A/R 2 2 2 2 2

S E C T I O N 6 H Y D R A U L I C S

6-23

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-10. HYDRAULIC DIAGRAM - SEQUENCE LINE

6 H Y D R A U L I C S

6-24

3120801

SECTION 6 HYDRAULICS FIGURE 6-10. HYDRAULIC DIAGRAM - SEQUENCE LINE FIG & ITEM #

PART NUMBER 2791703

1 2 3 4 5 6 7 8

3120801

2220582 2220605 Not Used 2220909 Not Used 2751015 2220684 2220250

DESCRIPTION HYDRAULIC DIAGRAM - SEQUENCE LINE

QTY.

REV.

Ref.

A

Fitting, Straight Fitting, Tee

1 1

Orifice (.015)

1

Hose Fitting, Tee Fitting, Tee

1 1 1

S E C T I O N 6 H Y D R A U L I C S

6-25

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-11. HYDRAULIC DIAGRAM - SWING

6 H Y D R A U L I C S

6-26

3120801

SECTION 6 HYDRAULICS FIGURE 6-11. HYDRAULIC DIAGRAM - SWING FIG & ITEM #

PART NUMBER 2791426

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

3120801

2220577 0100020 4640013 Not Used 2220635 2180377 2180270 0100011 2220609 2750900 2220416 2220414 2220466 2220415 2751014 2750999

DESCRIPTION HYDRAULIC DIAGRAM - SWING

QTY.

REV.

Ref.

3

Fitting, Straight Sealant, Pipe (Not Shown) Valve, Shuttle

2 A/R 1

Fitting, Tee Fitting, Modified Orifice (.12) Loctite (Not Shown) Fitting, Reducer Hose Fitting, 90° Fitting, Straight Fitting, 90° Fitting, 90° Hose Hose

2 2 2 A/R 2 3 2 1 1 1 1 2

S E C T I O N 6 H Y D R A U L I C S

6-27

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE

6 H Y D R A U L I C S

6-28

3120801

SECTION 6 HYDRAULICS FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE FIG & ITEM #

PART NUMBER 2791427

1 2 3 4 5 6 7 8 9 10

3120801

2220577 0100020 Not Used 2220492 2220221 2220758 4640216 2220343 2752163 2220396

DESCRIPTION HYDRAULIC DIAGRAM - TELESCOPE Fitting, Straight Sealant, Pipe (Not Shown) Fitting, Straight Fitting, Reducer Fitting, Straight Valve, Color Flow Fitting, Straight Hose Fitting, Straight

QTY.

REV.

Ref.

4

1 A/R 2 1 1 1 1 2 1

S E C T I O N 6 H Y D R A U L I C S

6-29

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

6 H Y D R A U L I C S

6-30

3120801

SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE

7-1 7-2 7-3

DESCRIPTION

PAGE

ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 WIRING SCHEMATIC - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 WIRING SCHEMATIC - STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

S E C T I O N 7 E L E C T R I C A L

3120801

7-1

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST FIG & ITEM #

PART NUMBER

7—1

7

4931947/1281985 4931947/1281985 4932595/1281985

E L E C T R I C A L

4931947/1281985

4932032 4931947/1281985

0610091 3740049 3990010 0140026 4932637/1282091 4932637/1282091 4932639/1282091 4932637/1282091

See Note 4932637/1282091 0610104 3740049 3990010 1060641 0140026 1540002 4932635

4932877 1060042 3990010 3740049 4921877

4932029 1281671 4932029 1282370

7-2

DESCRIPTION

QTY.

ELECTRICAL DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in the following pages. Diagrams not shown are available from the JLG Service Department.

Ref.

Alarm Wiring Diagrams Prior to April 1993 Back-up Alarm Wiring Diagram Descent Alarm Wiring Diagram Motion Alarm Wiring Diagram Swing Alarm Wiring Diagram Tilt Alarm Wiring Diagram Travel Alarm Wiring Diagram Card, Circuit (All except Motion and Tilt) Relay Diode - 6 Amp Alarm (Tilt Only - Located at Console) April 1993 to Present Back-up Alarm Wiring Diagram Descent Alarm Wiring Diagram Motion Alarm Wiring Diagram Swing Alarm Wiring Diagram Tilt Alarm Wiring Diagram (Note: See Standard Wiring Diagram) Travel Alarm Wiring Diagram Card, Circuit (All except Motion and Tilt) Relay (Motion Only) Diode - 6 Amp (Motion Only) Cable, Electrical - 16/2 (Motion Only) Alarm (Tilt Only - Located at Console) Capacitor (Tilt Only - Located at Console) Australian Spec Wiring Diagram Axle Jack Control Functions Wire Diagram (Dual Jacks Only) Cable, Electrical - 16/5 (Collector Ring to MTB) Diode 6 Amp Relay, Bosch Harness (Collector Ring to Frame Mounted Controls and Valve) Beacon/Strobe Light Wiring Diagrams Beacon Light - Platform Mounted (Prior to September 1991) Beacon Light - Platform Mounted (September 1991 to Present) Beacon/Strobe Light - Turntable Mounted (Prior to January 1995) Beacon/Strobe Light - Turntable Mounted (January 1995 to Present)

REV.

Ref. Ref. Ref. Ref. Ref. Ref. Ref. 1 1 1 1

G/G G/G A/G G/G A G/G

Ref. Ref. Ref. Ref.

2/A 2/A 2/A 2/A

Ref. Ref. 1 1 1 8ft/2.4m 1 1

2/A

Ref.

D

Ref.

—

10ft/3m 6 1 1 Ref. Ref.

—

Ref.

D

Ref.

—

Ref.

C

3120801

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER

1060515 1060516

Not Required 4931960 4931961 3730024 3730040

4932608

4932099 1060300 3740057 4120012 3740066

4931671 4360179 4360089 3740013 4360065 2920034 3251695

Boom Cables Cable, Electrical - 12/4 Cable, Electrical - 16/30 Boom Indicator Pendulum Wiring Diagrams: 1st Generation (Not Used on Euro Spec Machines) 2nd Generation (Nineth Machine to Mid 1989) 3rd/4th/5th Generations (Mid 1989 to Present) Resistor - 100 Ohms Resistor, Variable - 500 Ohms (2nd Generation Only) Broken Fly Chain Limit Switch (German/Austrian Spec Prior to S/N 28224) Eight Meter (8m) Drive Cutout Wiring Diagram (Dutch & German Spec) (Prior to S/N 28224) Cable, Electrical - 16/3 Relay (Located in Ground Control Box) Socket, Relay (Located in Ground Control Box) Spring, Relay (Located in Ground Control Box) Engine Distress Wiring Diagram - Deutz Engines (Prior to September 1994) Switch, Temperature Flasher Relay Switch, Pressure Lamp (Located at Platform Console) Nameplate - Engine Distress

QTY.

REV.

A/R 131ft/40m 131ft/40m Ref. Ref. Ref. Ref. 1

7

A B

E L E C T R I C A L

1

Ref.

B

Ref.

A

15ft/4.6m 1 1 1

Ref.

B

1 1 1 1 1 1

2920026 2920029 4360065 4360179 3740049

Engine Distress Wiring Diagram - Deutz Engines (September 1994 to Present) Lamp, Indicator Bulb, Light Switch, Oil Pressure Switch, Temperature Relay

0251683 2920027 2920029 4360037 1702528

Engine Run Light Wiring Diagram - Deutz Engines Lamp, Indicator Bulb, Light Switch, Pressure Decal - Engine Run

Ref. 1 1 1 1

B

4932892

Engine Shut-Down Wiring Diagram - Deutz Engines

Ref.

—

0255568

3120801

DESCRIPTION

Ref.

S E C T I O N

—

1 1 1 1 1

7-3

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

4932492 1693405 1693406 1692927

French Spec Wiring Diagram (Prior to S/N 28224) Relay, Timer Clip, Retainer Socket, Relay

Ref. 1 1 1

C

4931858 3990001

Generator Wiring Diagram - 110V (Deutz) Diode - 3.5 Amp

Ref. 1

A

0252928

Heaters Wiring Diagram

Ref.

F

Ref.

A

7 E L E C T R I C A L

4932312 3740057 4120012 3740066

1 1 1

4360232 3740049 4360199 4460052 3300047 3251019

Lights Wiring Diagram - Headlights and Taillights (Prior to January 1995) Breaker, Circuit - 15 Amp Relay - SPDT Switch, Toggle Connector, Strain Relief Nut, Conduit Nameplate - Lights On/Off

1282370

Lights Wiring Diagram (January 1995 to Present)

Ref.

C

4933007

Load Sensing System (French Spec)

Ref.

1/A

0255274 2920026 2920029 4360065 3740049 3990010 3740080 3252074

Low Oil Pressure Shutdown Wiring Diagram Lamp, Indicator Bulb, Light Switch, Oil Pressure Relay (In Platform Console Box) Diode - 6 Amp Relay (In Platform Console Box) Nameplate - Engine Distress

Ref. 1 1 1 1 1 1 1

3

Ref.

C

Ref.

2

4931941

3990001 3990010 3740049 3740274 1701746

Manual Descent Wiring Diagram (French & Italian Spec) (Prior to January 1993) Manual Descent Wiring Diagram (French & Italian Spec) (January 1993 to Present) Diode Diode (January 1993 to Present) Relay Switch, Push Button Decal - Manual Descent

0252917

Oil Cooler Wiring Diagram

1692883 4932607

7-4

Horizontal Drive Cutout (Italian Spec) (Prior to S/N 8224) Relay (Located in Ground Control Box) Socket, Relay (Located in Ground Control Box) Spring, Relay (Located in Ground Control Box)

Ref.

E

1 1 1 1 1 1

3 1 1 1 1 Ref.

3

3120801

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER

QTY.

4932125

4932952 4932953 3990010 1060012

Platform Wiring Diagrams (S/N 28224 to Present) 100HX &110HX 100HX+10 & 110HXER Diode 6 Amp Cable, Electrical - 12/4

Ref. Ref. Ref. 11 7.5ft/2.3m

Platform Bumper Wiring Diagram Wiring Diagram - Chain Mounted (Soft-Touch) Bumper Wiring Diagram - Welded on Bumper

Ref.

4932100 4932101 4932102 4932103 4932104 4932112 4932115 4932105 4932106 4932108 4932109 4932110 4932113 4932114 4932117 4932119 4932120 4932107 4932116 4932118 4932111 4932122 4932121 4932123 4932124

1282197 4932059

4932089 3740049 0960239 1060300

3120801

DESCRIPTION Platform Wiring Diagrams (Prior to S/N 28224) Wiring Diagram - Start Wiring Diagram - Tele Wiring Diagram - Swing Wiring Diagram - Lift Wiring Diagram - Auxiliary Power Wiring Diagram - Level Wiring Diagram - Overload Warning Alarm Wiring Diagram - High Engine Wiring Diagram - Steer Wiring Diagram - Drive Wiring Diagram - Rotate Wiring Diagram - 2 Speed Wiring Diagram - Horn Wiring Diagram - Hi-Drive Wiring Diagram - Axles Set Light Wiring Diagram - 0# Light Indicator Wiring Diagram - 500# Light Indicator Wiring Diagram - 3° Tilt Wiring Diagram - Emergency Stop Wiring Diagram - Footswitch Wiring Diagram - Bang-Bang Dump (100HX & 110HX) Wiring Diagram - Bang-Bang Dump (100HX+10 & 110HXER) Wiring Diagram - Power Distribution (100HX & 110HX) Wiring Diagram - Power Distribution (100HX+10 & 110HXER) Wiring Diagram - Extend-A-Reach (100HX+10 & 110HXER Only) Wiring Diagram - Broken Chain Light

Platform Gate Interlock Wiring Diagram (French Spec) (Prior to S/N 28224) Relay (Located in Ground Control Box) Bushing Cable, Electrical - 16/3

REV.

Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref.

S E C T I O N 7 E L E C T R I C A L

Ref. Ref. Ref. Ref. Ref. Ref.

3/C 2/C

Ref.

G

Ref.

A

Ref.

G

1 2 15ft/4.6m

7-5

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER 2900068 2920013 0253686 0253987 0254748 2920111

DESCRIPTION Platform Work Lights Wiring Diagram Wiring Diagram (Prior to November 1992) Worklight Wiring Diagram (November 1992 to May 1995) Wiring Diagram (May 1995 to Present) Wiring Diagram with Padded Platform Worklight

QTY. Ref. Ref. 2 Ref. Ref. Ref. 2

REV. F — C 2

7 E L E C T R I C A L

1060300 1060042 1060300

Standard Wiring Diagrams Deutz Engine Machines 100HX &110HX Built Prior to S/N 28224 100HX &110HX Built S/N 28224 to Present 100HX+10 &110HXER Prior to S/N 28224 100HX+10 &110HXER S/N 28224 to Present Socket Plug, 6 Position Plug, 3 Position Plug, 4 Position Harness, Engine Diode - 6 Amp Strip, Terminal - 14 Position Terminal, Buss Bar - 2 Position Harness, MTB to Engine Terminal Strip Harness, Valve Diode - 6 Amp Resistor - 7.5 Ohm Resistor Condensor, Capacitor Cable, Electrical -16/3 (To Axles Limit Switches) Cable, Electrical -16/3 (To Horizontal Limit Switch) Cable, Electrical -16/3 (To Overload Switches) Cable, Electrical -16/5 (To Boom Angle Indicator) Cable, Electrical -16/3 (To Load Management)

1870001*

Standard Wiring Schematic

Ref.

C

4932570

TUV Monitoring System Wiring Diagram (Optional on German TUV Machines)

Ref.

E

4932087 4932954 4932090 4932955 4460226 4460225 4460326 4460321 4921140 3990010 4460277 4460264 4921141 4921142 3990010 3730095 3730099 1540003 1060300 1060016

7-6

Ref. Ref. Ref. Ref. Ref. Ref. 12 1 1 1 1 1 1 1 1 1 2 1 1 1 15ft/4.6m

M 2/D M 2/C

C

F I

15ft/4.6m 16ft/4.9m 15ft/4.6m 15ft/4.6m

3120801

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (Continued) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

S E C T I O N 7 E L E C T R I C A L

3120801

7-7

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-2. WIRING SCHEMATIC - PLATFORM (SHEET 1 OF 2).

7 E L E C T R I C A L

7-8

3120801

SECTION 7 ELECTRICAL

S E C T I O N

FIGURE 7-2. WIRING SCHEMATIC - PLATFORM (SHEET 2 OF 2).

7 E L E C T R I C A L

3120801

7-9

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-3. WIRING SCHEMATIC - STANDARD (SHEET 1 OF 2).

7 E L E C T R I C A L

7-10

3120801

SECTION 7 ELECTRICAL

S E C T I O N

FIGURE 7-3. WIRING SCHEMATIC - STANDARD (SHEET 2 OF 2).

7 E L E C T R I C A L

3120801

7-11

SECTION 7 ELECTRICAL

S E C T I O N 7 E L E C T R I C A L

THIS PAGE INTENTIONALLY LEFT BLANK

7-12

3120801

SECTION 8 DECALS TABLE OF CONTENTS FIGURE

8-1 8-2

DESCRIPTION

PAGE

DECALS INSTALLATION - BROWN DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 DECALS INSTALLATION - BLACK DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

S E C T I O N 8 D E C A L S

3120801

8-1

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS

8 D E C A L S

8-2

3120801

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS FIG & ITEM #

PART NUMBER

DESCRIPTION DECALS INSTALLATION - BROWN (STANDARD PARTS)

1 2 3

Not Available 1700584^-

4

1700157 1701509^Not Used

5

1700643

6

3251813

7 8 to 10 11 12 13

1700477 Not Used 1700476 Not Used

14 15

16 17

1700585 1701518^1700977 1700978 1701501^Not Used 1700419 1701504^-

18

19 20

1700976 1700975 1701500 1702300 Not Used 1700431 1701703^-

21

22 23 24

1700640 1701518 3820001 0641408 1060279

25

1700580

26 27 28

Not Used 1700981 1700981 1701702^-

3120801

Nameplate - Serial Number (Location Will Vary) Decal - Patent Decal - Manual Options: Decal (Prior to August 1991) Decal (August 1991 to Present) Decal - Caution (Prior to August 1991) (110HXER & 100HX+10 Only) Decal - USA (Location Will Vary) (November 1989 to August 1995 Only) Decal - Attach Belt (Prior to August 1991)

QTY. Ref.

1 1 1

8 1 2 2

Decal - Crushing Options: Decal (Prior to August 1991) Decal (August 1991 to Present) Decal - FWD (Brown) (Prior to August 1991 Only) Decal - Arrow Options: Decal - Arrow (Brown) (Prior to August 1991) Decal - Arrow (Black/White) (August 1991 to Present)

4

Decal - Brown/Orange Stripe Options: Decal (Prior to September 1995) Decal (September 1995 to Present) Decal - Crushing Options: Decal (Prior to August 1991) Decal (August 1991 to Present) Rivet (Not Shown) Bolt 1/4"-20NC x 1" Cable, Lanyard Decal - Electrocution Hazard (Prior to August 1991 Only) Decal - JLG (Brown) (Prior to September 1995 Only) Decal - JLG Options: Decal - JLG (Brown) (Prior to September 1995) Decal - JLG (Brown) (September 1995 to Present)

D E C A L S

1

Decal - No Hands (Prior to August 1991)

Decal - Hydraulic Options: Decal - Hydraulic (Brown) (Prior to August 1991) Decal - Hydraulic (August 1991 to Present) Decal - Tie-Down/Lift Up Options: Decal - Tie-Down (Brown) (Prior to August 1991) Decal - Lift Here (Brown) (August 1991 to Present) Decal - Lift Here (August 1991 to Present) Decal - Tie-Down (August 1991 to Present)

REV.

S E C T I O N

4 4

1

A/R 4 2 4 4 A/R 32ft/9.75m 27ft/8.23m

A/R

A/R 1 1 3

3 1

8-3

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

29 30 31 32 33 34 35

Not Used 1700593 Not Used Not Used 0961127 0100010

8 D E C A L S

36 37 38 39

1700756 1701502^0860520 3311405 4751400 Not Used

40

1701296

41 42

Not Used

43 44

1700975 1700377 1701500^Not Available 1700431 1700431 1701704

45 1700981 1701699^46

1701503^-

47

1701499^-

48 to 50 51 52 to 55 56 57

Not Used 4420052 Not Used 1703484^1702928^-

DESCRIPTION Decal - Inspection (Prior to August 1991 Only)

Bushing, Snap Loctite, Adhesive Decal - Full/Add Decal - Full/Add (Brown) (Prior to August 1991) Decal - Full/Add ((August 1991 to Present) Box, Manual Storage Locknut 1/4"-20NC Flatwasher 1/4" Decal - Load Management (August 1989 to August 1991)

1701543 1701542 1701505

73

74

8-4

3251028 3252356 1700818

REV.

1

1 A/R 1

1 5 6

1

Decal Options: 2 Decal - Lift Here (Creme) (Prior to June 1991) Decal - Lift Here (Brown) (June 1991 to August 1991) Decal - Tie-Down/Lift Up (August 1991 to Present) Decal - Bar Code (September 1995 to Present) 1 Decal - Brown/Orange Stripe Options: A/R Decal (100HX & 110HX) (Prior to September 1995) 24ft/7.3m Decal (100HX+10 & 110HXER) (Prior to September 16ft/4.9m 1995) 27ft/8.23m Decal (September 1995 to Present) Decal Options: 1 Decal - JLG (Brown) (Prior to September 1995) Decal - JLG Lift (Brown) (September 1995 to Present) Decal - Hydraulic Oil Low (August 1991 to Present 1 Only) Decal - Don’t Lift/Tie Down (August 1991 to Present 1 Only) Decal - Safety Stripe Decal - Max Wheel Load Decal - CE DECALS INSTALLATION (OPTIONAL PARTS)

71 72

QTY.

Decal - Fuel LP Gas Decal - Fuel Options: Decal - Gas Decal - Diesel (Brown) Decal - Caution LP Gas Options: Decal (Prior to May 1994) Decal (May 1994 to Present) Decal - LP Gas Liquid Withdraw System

19ft/5.8m 4 1 Ref. 1 1

1

1

3120801

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

75 76 77

Not Used Not Used 0255580 3252449 3820001 1702788

78

0258612 0239383 0252122 0239181 0252656 81 82

Lifting Diagram Installation Decal - Lifting Diagram Rivet Decal - Biodegradable Hydraulic Fluid DECALS INSTALLATION (VARIABLE PARTS) 100HX 110HX Prior To August 1991 110HX August 1991 To Present 100HX+10 & 110HXER Prior To August 1991 100HX+10 & 110HXER August 1991 To Present

QTY.

REV.

Ref. 2 8 1

—

Ref. Ref. Ref. Ref. Ref. Ref.

8

1 L 5 N 4

D E C A L S

Not Used Not Available 1701059^ 1701058 1701380-

83 Not Required 1700880 1701375 1701431

0252142 0257252 0252879 0252124 0252123 0252687 0253314 0252142 0258629 201 3251637 1701533^1701534 1701564 1701698 1701797 3251637 1702301

3120801

DESCRIPTION

Decal - Model Options (Location Will Vary): 100HX Decal 110HX Decal (Brown) 110HXER Decal (Brown) (Prior to July 1990) 100HX+10 Decal (Brown) (July 1990 to Present) Decal - Extend-A-Reach Options: 100HX & 110HX 100HX & 110HXER Prior to September 1990 100HX & 110HXER September 1990 to September 1995 100HX & 110HXER Prior to September 1995 DECAL INSTALLATION (VARIABLE PARTS) Australian Spec Prior To S/N 28224 Australian Spec S/N28224 To Present Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec110HX & 100HX+10 UK Spec100HX Nameplate - Axle Extend/Retract Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec 110HX & 100HX+10 UK Spec 100HX

A/R

A/R 0 2 2 2 Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref.

S E C T I O N

B 2 3 3 2 2 2 3 2

1

8-5

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

202 3252347 1703518^1693292 1693294 1701600 1701791 3252347

8

203 3251870 1701531^1701506 1701562 1701696 1701795 3251870

D E C A L S

204 1700037 1701616^1701515 1693285 1701599 1701789 1700037 205 1701296 1703529 1701532 1703606^1701507 1703607 1701563 1703608 1701697 1703609 1701799 1703611 1701296 1703529 206 1690697 1701567^1701649 1690697 1690697 1690697 1690697

8-6

DESCRIPTION

QTY.

Nameplate - Footswitch Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Nameplate - Valve Select Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Ground Control Location Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Load Management Options: Australian Spec Prior to S/N 3372 Australian Spec S/N 33726 to Present Dutch Spec Prior to S/N 33726 Dutch Spec S/N 33726 to Present French Spec Prior to S/N 33726 French Spec S/N 33726 to Present German & Austrian Spec Prior to S/N 33726 German & Austrian Spec S/N 33726 to Present Italian Spec Prior to S/N 33726 Italian SpecS/N 33726 to Present Spanish Spec Prior to S/N 33726 Spanish Spec S/N 33726 to Present UK Spec Prior to S/N 3372 UK Spec S/N 33726 to Present Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec

1

REV.

1

1

1

1

3120801

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

207 1690696 Not Required 1693286 1693288 1701601 1701794 1690696 208

208

1691483 1701596^9983243 1693289 1693291 1701602 1701798 1691483

Not Available 2900984 2900985 Not Available Not Available Not Available Not Available Not Available

3120801

DESCRIPTION Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Caution Options: Australian Spec Dutch Spec French Spec Prior to August 1991 French Spec August 1991 to Present German & Austrian Specs Italian Spec Spanish Spec UK Spec ————————— Decal Kit Options: Australian Spec Dutch Spec 110HX (Items with ^ Included in kit) Dutch Spec 110HXER (Items with - Included in kit) French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec

QTY.

REV.

A/R 1 0 1 1 1 1 1 1

S E C T I O N 8 D E C A L S

1

8-7

S E C T I O N

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS

8 D E C A L S

8-8

3120801

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS FIG & ITEM #

PART NUMBER

DESCRIPTION DECALS INSTALLATION (STANDARD PARTS)

1 2 3

Not Available 1700584

4 5

1700157 1701509 Not Used 1700643

6

3251813

7 8 to 10 11 12 13

1700477 Not Used 1700476 Not Used

14 15

16 17

1700585 1701518 1700053 1700058 1701501 Not Used 1700195 1701504

18

19 20

1701326 1700232 1701500 1702300 Not Used 1701334 1701703

21

22 23 24

1700640 1701518 3820001 0641408 1060279

25

1700580

26 27 28

Not Used 1701321 1701321 1702729

3120801

QTY.

Nameplate - Serial Number (Location Will Vary) Decal - Patent Decal - Manual Options: Decal (Prior to August 1991) Decal (August 1991 to Present)

1 1 1

Decal - Caution (Prior to August 1991) (110HXER & 100HX+10 Only) Decal - USA (Location Will Vary) (November 1989 to August 1995 Only) Decal - Attach Belt (Prior to August 1991)

1 1

Decal - No Hands (Prior to August 1991)

2

Decal - Crushing Options: Decal (Prior to August 1991) Decal (August 1991 to Present) Decal - FWD (Black) (Prior to August 1991 Only) Decal - Arrow Options: Decal - Arrow (Black) (Prior to August 1991) Decal - Arrow (Black/White) (August 1991 to Present)

4

Decal - Hydraulic Options: Decal - Hydraulic (Black) (Prior to August 1991) Decal - Hydraulic (August 1991 to Present) Decal - Tie-Down/Lift Up Options: Decal - Tie-Down (Black) (Prior to August 1991) Decal - Lift Here (Black) (August 1991 to Present) Decal - Lift Here (August 1991 to Present) Decal - Tie-Down (August 1991 to Present) Decal - Black Stripe Options: Decal (Prior to September 1995) Decal (September 1995 to Present) Decal - Crushing Options: Decal (Prior to August 1991) Decal (August 1991 to Present) Rivet (Not Shown) Bolt 1/4"-20NC x 1" Cable, Lanyard Decal - Electrocution Hazard (Prior to August 1991 Only) Decal - JLG (Black) (Prior to September 1995 Only) Decal - JLG Options: Decal - JLG (Black) (Prior to September 1995) Decal - JLG (Black) (September 1995 to Present)

REV.

Ref.

S E C T I O N 8 D E C A L S

2

4 4

1

A/R 4 2 4 4 A/R 32ft/9.75m 27ft/8.23m

A/R

A/R 1 1 3

3 1

8-9

S E C T I O N

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

29 30 31 32 33 34 35

Not Used 1700593 Not Used Not Used 0961127 0100010

8 36 37 38 39 40 41 42

D E C A L S

43 44

1701336 1701502 0860520 3311405 4751400 Not Used Not Used Not Used 1700975 1700377 1701500 Not Available 1701334 1701334 1702731

45 1701321 1702730 46

1701503

47

1701499

48 to 50 51 52 to 55 56 57

Not Used 4420052 Not Used 1703484 1702928

DESCRIPTION Decal - Inspection (Prior to August 1991 Only)

Bushing, Snap Loctite, Adhesive Decal - Full/Add Decal - Full/Add (Black) (Prior to August 1991) Decal - Full/Add ((August 1991 to Present) Box, Manual Storage Locknut 1/4"-20NC Flatwasher 1/4"

1701543 1701542 1701505

73

74 75 76

8-10

3251028 3252356 1700818 Not Used Not Used

REV.

1

1 A/R 1

1 5 6

Decal Options: 2 Decal - Lift Here (Creme) (Prior to June 1991) Decal - Lift Here (Brown) (June 1991 to August 1991) Decal - Tie-Down/Lift Up (August 1991 to Present) Decal - Bar Code (September 1995 to Present) 1 Decal - Black Stripe Options: A/R Decal (100HX & 110HX) (Prior to September 1995) 24ft/7.3m Decal (100HX+10 & 110HXER) (Prior to September 16ft/4.9m 1995) 27ft/8.23m Decal (September 1995 to Present) Decal Options: 1 Decal - JLG (Black) (Prior to September 1995) Decal - JLG Lift (Black) (September 1995 to Present) Decal - Hydraulic Oil Low (August 1991 to Present 1 Only) Decal - Don’t Lift/Tie Down (August 1991 to Present 1 Only) Decal - Safety Stripe Decal - Max Wheel Load Decal - CE DECALS INSTALLATION (OPTIONAL PARTS)

71 72

QTY.

Decal - Fuel LP Gas Decal - Fuel Options: Decal - Gas Decal - Diesel (Brown) Decal - Caution LP Gas Options: Decal (Prior to May 1994) Decal (May 1994 to Present) Decal - LP Gas Liquid Withdraw System

19ft/5.8m 4 1 Ref. 1 1

1

1

3120801

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

77

0255580 3252449 3820001 1702788

0252125 0252657

78

81 82

QTY.

REV.

Lifting Diagram Installation Decal - Lifting Diagram Rivet Decal - Biodegradable Hydraulic Fluid

Ref. 2 8 1

—

DECALS INSTALLATION (VARIABLE PARTS) 110HX 100HX+10 & 110HXER

Ref. Ref. Ref.

Decal - Model Options (Location Will Vary): 110HX Decal (Black) 100HX+10 Decal (Black) Decal - Extend-A-Reach Options: 110HX 100HX+10 & 110HXER

A/R

40 C

Not Used 1701335 1701688

83 Not Required 1701431

0252142 0257252 0252879 0252124 0252123 0252687 0253314 0252142 0258629 201 3251637 1701533^1701534 1701564 1701698 1701797 3251637 1702301 202 3252347 1703518^1693292 1693294 1701600 1701791 3252347

3120801

DESCRIPTION

DECAL INSTALLATION (VARIABLE PARTS) Australian Spec Prior To S/N 28224 Australian Spec S/N28224 To Present Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec110HX & 100HX+10 UK Spec100HX Nameplate - Axle Extend/Retract Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec 110HX & 100HX+10 UK Spec 100HX Nameplate - Footswitch Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec

8 D E C A L S

A/R 0 2 Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref.

S E C T I O N

B 2 3 3 2 2 2 3 2

1

1

8-11

S E C T I O N

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

203 3251870 1701531^1701506 1701562 1701696 1701795 3251870

8

204 1700037 1701616^1701515 1693285 1701599 1701789 1700037

D E C A L S

205 1701296 1703529 1701532 1703606^1701507 1703607 1701563 1703608 1701697 1703609 1701799 1703611 1701296 1703529 206 1690697 1701567^1701649 1690697 1690697 1690697 1690697 207 1690696 Not Required 1693286 1693288 1701601 1701794 1690696

8-12

DESCRIPTION

QTY.

Nameplate - Valve Select Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Ground Control Location Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Load Management Options: Australian Spec Prior to S/N 3372 Australian Spec S/N 33726 to Present Dutch Spec Prior to S/N 33726 Dutch Spec S/N 33726 to Present French Spec Prior to S/N 33726 French Spec S/N 33726 to Present German & Austrian Spec Prior to S/N 33726 German & Austrian Spec S/N 33726 to Present Italian Spec Prior to S/N 33726 Italian SpecS/N 33726 to Present Spanish Spec Prior to S/N 33726 Spanish Spec S/N 33726 to Present UK Spec Prior to S/N 3372 UK Spec S/N 33726 to Present Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec

1

REV.

1

1

1

A/R 1 0 1 1 1 1 1

3120801

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

208 1691483 1701596^9983243 1693289 1693291 1701602 1701798 1691483

Not Available 2900984 2900985 Not Available Not Available Not Available Not Available Not Available

3120801

DESCRIPTION Decal - Caution Options: Australian Spec Dutch Spec French Spec Prior to August 1991 French Spec August 1991 to Present German & Austrian Specs Italian Spec Spanish Spec UK Spec ————————— Decal Kit Options: Australian Spec Dutch Spec 110HX (Items with ^ Included in kit) Dutch Spec 110HXER (Items with - Included in kit) French Spec German & Austrian Specs Italian Spec Spanish Spec UK Spec

QTY.

REV.

1

S E C T I O N 8 D E C A L S

1

8-13

S E C T I O N

SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

8 D E C A L S

8-14

3120801

SECTION 9 RECOMMENDED SERVICE PARTS STOCK

MODELS 100HX/110HX+10/110HX EURO SPEC The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.

JLG PART NUMBER

S E C T I O N

QTY PER FLEET

DESCRIPTION 1-10

10-20

20 OR MORE

1 1 1 1 1 Dozen 1 1 1 1 1 case 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 1 1 1 1 1 1

1 1 1 1 1 Dozen 1 1 1 1 1 case 1 1 1 1 1 2 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 1 1 1 1 1 1

1 1 1 1 1 Dozen 1 1 1 1 1 case 1 1 1 1 1 3 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 1 1 1 1 1 1

9

STANDARD PARTS 4360280 7012339 7002450 7000418 7004214 3740067 3740080 3740059 7000649 7014503 2400054 4360155 7008828 7008829 1660183 1340046 2120107 3740070 3740016 3740049 4360216 4360232 4360284 4360003 2860002 4360212 4360274 4360202 4360200 3740123 4360069 4360263 4360259 7006180 7000637 7000638 7000647 4360153 2940006 4360031

3120801

Switch, Tilt Indicator (Figure 2-4) Coil - Vickers Valve (Figure 2-6) Coil - Bang-Bang Valve (Dump) (Figure 2-8) Coil - Bang-Bang Valve (Working) (Figures 2-8 and 2-11) Element, Air Filter (Figures 2-21 and 2-27) Relay (Figures 2-21 and 2-27) Relay (Figures 2-21 and 2-27) Relay (Deutz) (Figure 2-18) Filter, Engine Fuel (Deutz) (Figure 2-18) Filter, Engine Oil (Deutz) (Figure 2-18) Fuse (Figure 2-18) Switch, Disconnect (Figure 2-18) Cable, Throttle (Deutz) (Figure 2-19) Board, PC (Deutz) (Figure 2-19) Coupling (Deutz) (Figure 2-21) Breather, Hydraulic Tank (Figure 2-23) Element, Hydraulic Oil Filter (Figure 2-23) Relay - SPDT (Figure 2-24) Relay - 3PDT (Figure 2-24) Relay - SPDT (Figures 2-24, 4-5 and 7-1) Breaker, Circuit - 30 Amp (Figure 2-24) Breaker, Circuit - 15 Amp (Figure 2-24) Switch, Toggle (Figure 2-24) Switch, Key (Figure 2-24) Key (Figure 2-24) Breaker, Circuit - 3 Amp (Deutz) (Figure 2-24) Switch, Push Button (Figures 2-24 & 4-6) Switch, Toggle (Figures 2-24 & 4-6) Switch, Toggle (Figures 2-24 & 4-6) Relay, Latch (Figure 2-24) Breaker, Circuit - 10 Amp (Deutz) (Figures 2-24 & 4-6) Switch, Toggle (Figure 2-25) Switch, Proximity (Figure 2-25) Power Track - Pin Kit (Figure 3-1) Poteniometer (Figure 3-5) Switch (Figure 3-5) Cable (Figure 3-5) Pendulum (Figure 3-5) Latch, Platform Door (Figures 4-1, 4-2 and 4-3) Footswitch (Figures 4-1, 4-2 and 4-3)

9-1

R E C O M M E N D E D S E R V I C E P A R T S S T O C K

S E C T I O N 9 R E C O M M E N D E D S E R V I C E

SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 100HX/110HX+10/110HX EURO SPEC The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.

JLG PART NUMBER 1600247 4360199 4360289 4360112 4360161 7003961 3990010

Controller, PQ (Figure 4-6) Switch, Toggle (Figure 4-6) Switch, Push Pull (Figure 4-6) Breaker, Circuit - 5 Amp (Figure 4-6) Breaker, Circuit - 20 Amp (Figure 4-6) Microswitch - 1600247 Controller (Figure 4-7) Diode - 6 Amp (Figure 7-1)

1-10

10-20

20 OR MORE

1 1 1 1 1 1 2

1 1 1 1 1 1 2

1 1 1 1 1 1 2

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 2

1 2

1 2

2

2

2

2

2

2

2

2

2

2

2

2

VARIABLE PARTS 4360277 4360171 7000645 7012539 7004368 7006075 4360314 7004368 7009745 7000645 7003640 7004368 7010555 4360263 7006193 7006514

P A R T S

QTY PER FLEET

DESCRIPTION

7006196 7006153 7006145

Switch, Limit (Figures 1-6, 2-2, 3-5 and 3-6) Switch, Limit (Figure 2-3) Coil - Dual Axle Jack (Figure 1-6) Coil - Dual Axle Jack (Figure 1-6) Coil - 2 Speed Valve (Hydraforce Version) (Figure 1-6) Coil - 2 Speed Valve (FPS Version) (Figure 1-6) Switch, Toggle (Dual Axle Jack) (Figures 1-6) Coil - Dump Valve (Hydraforce Version) (Figure 2-3) Coil - Dump Valve (Vickers/Modular Controls Version) (Figure 2-3) Coil - Dump Valve (Hydraforce Version) (Figure 2-3) Coil - Dump Valve (Vickers/Modular Controls Version) (Figure 2-3) Coil - Dump Valve (Hydraforce Version) (Figure 2-9) Coil - Dump Valve (Vickers/Modular Controls Version) (Figure 2-9) Switch, Limit (Figure 2-25) Power Track - 1 ft. Section (100HX & 100HX+10 Standard Left Side (Figure 3-1) Power Track - 1 ft. Section (110HX Standard - Left Side (Figure 3-1) Power Track - 1 ft. Section (100HX, 110HX & 100HX+10 with Chip - Left Side (Figure 3-1) Power Track - 1 ft. Section (100HX, 110HX & 100HX+10 Standard - Right Side (Figure 3-1) Power Track - 1 ft. Section (100HX, 110HX & 100HX+10 with Chip - Right Side (Figure 3-1)

S T O C K 9-2

3120801

SECTION 10 SPECIAL OPTIONS

Note: This list is to accommodate 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

DESCRIPTION MISCELLANEOUS SPECIAL OPTIONS

Ref.

0237063

Air Cleaner Service Indicator Installation

Ref.

0239261 0239262

Airline to Platform Installations 1/2" Airline Installation 3/4" Airline Installation

Ref. Ref. Ref.

0270723

Beacon Installation (Mounted on the platform)

Ref.

0239755

Bumper, CWT

Ref.

0256789

Camera Mounting Installation

Ref.

0253634

Cover Installation - Metal Console

Ref. Ref.

0250633 0254109

Exhaust Installations - Specials Deutz Engines: Exhaust Purifier Installation (Prior to April 1993) Exhaust Purifier Installation (April 1993 to Present)

0254472

Generator Installation - 230-240V/50Hz (Deutz Engines)

Ref.

0252928

Heaters Installation Deutz Engines

Ref. Ref.

0239998 0239257 0239258

Hostile Environment Package Installation Boom Wipers Installation Cylinder Bellows Installation

Ref. Ref. Ref.

4360295

Ignition Switch with Individual Coded Keys

Ref.

Lights Installation - Special Beacon Light Installation - Amber (On Hood) (Prior to January 1995) Beacon Light Installation - Amber (On Hood) (January 1995 to Present) Beacon Light Installation - Red (On Hood) (Prior to January 1995) Beacon Light Installation - Red (On Hood) (January 1995 to Present) Brake Lights Installation (Prior to January 1995) Brake Lights Installation (January 1995 to Present) Headlights and Taillights Installation (Prior to January 1995)

Ref.

0250176/1281175 0255277/1282370 0250177/1281175 0255278/1282370

0254409 0255273/1282370 0250179/1281175

3120801

QTY.

Ref. Ref.

Ref. Ref. Ref. Ref. Ref. Ref. Ref.

REV.

S E C T I O N 10 S P E C I A L O P T I O N S

S E C T I O N

SECTION 10 SPECIAL OPTIONS FIG & ITEM #

PART NUMBER 0255271/1282370 0255816/1282370 0254474/1281175 0255272/1282370

10 S P E C I A L

Ref. Ref. Ref. Ref.

0252917

Oil Cooler Installation

Ref.

Oxy-Acetelene Lines Installation

Ref.

0253558 3536566

Receptacle Mounting Plate Installation (Australian Spec) Plate

Ref. 1

0255937 4400389

Tank Installations - Fuel and Oil (Special) 52 Gallon Tank Fuel Installation Tank - 52 Gallon

Ref. Ref. 1

7016654 7002822 7004275 7004276 7002828 7014676 9900443

Tools for Service: Crimper, Wire Fastener Kit - U.S. Standards Pin Extractor - Universal (For Electrical Connectors with Pins and Sockets) Screwdriver, Magnetic Screwdriver, Pontiometer Seal Tool 1" (For Cylinders) Seal Tool 1 1/2" (For Cylinders) Stripper, Wire Tool Kit - U.S. Standards Tool Box and Tools

Ref. Ref. Ref. Ref. Ref. Ref. Ref.

0257728

Tube Rack Installation

Ref.

0253050

Turntable Pinion Shield Installation

Ref.

7002823

REV.

Ref.

Load Sensing System (French Spec)

7002821 2900838

10-2

Headlights and Taillights Installation (January 1995 to Present) Strobe Light Installation - Amber (On Hood) Turn Signals Installation (Prior to January 1995) Turn Signals Installation (January 1995 to S/N 39439)

QTY.

0258039

0239260/1281002

O P T I O N S

DESCRIPTION

Ref. Ref. Ref.

3120801

3120801

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 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia

JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil

+61 2 65 811111 +61 2 65 810122

+55 19 3295 1025

JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany +49 (0)421 69 350 20 +49 (0)421 69 350 45

+55 19 3295 0407

JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N. T. Hong Kong (852) 2639 5783

JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP - England +44 (0)161 654 1000 +44 (0)161 654 1001 JLG Industries (Italia) s.r.l.

Via Po. 22 20010 Pregnana Milanese - MI Italy +39 029 359 5210 +39 029 359 5845

JLG France SAS Z.I. de Baulieu 47400 Fauillet France +33 (0)5 53 88 31 70 +33 (0)5 53 88 31 79

Oshkosh-JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4, Jurong Industrial Estate Singapore, 639379 +65-6591 9030

(852) 2639 5797

+65-6591 9031 Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755 Castellbisbal, Barcelona Spain +34 93 772 4700

JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden +46 (0)850 659 500 +46 (0)850 659 534

+34 93 771 1762

www.jlg.com