JLG 120Hx Parts Manual (3120820) - PDF DOWNLOAD (Eng)

Illustrated Parts Manual

Model 120HX

P/N 3120820 August 31, 2011

REVISION LOG May 1992 - Original Issue Of Manual May 1995 - Revised June 1997 - Revised May 1998 - Revised December 1998 - Revised November 12, 1999 - Revised (Manual edited to 0010448 Revision 32) March 2, 2000 - Revised (Manual edited to 0010448 Revision 32) October 1, 2000 - Revised (Manual edited to 0010448 Revision 33) February 24, 2004 - Revised January 4, 2008 - Revised August 31, 2011 - Revised

3120820

A

REVISION LOG

B

3120820

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

FRAME, VALVES AND SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 STEERING AND AXLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 DRIVE MOTOR ASSEMBLY - REXROTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22 JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

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

TURNTABLE, BOOM AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .2-2 VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 VALVES ASSEMBLY - HYDRO AIR (PRIOR TO S/N 38697) . . . . . . . . . . . . . . . . . . . . . .2-8 VALVE ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . . . .2-10 ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . .2-14 SWING DRIVE AND BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 SWING BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992) . . . . . . . . . . . . .2-36 REMOTE DRIVE CONTROL BOX ASSEMBLY (JULY 1992 TO PRESENT) . . . . . . . . . .2-38 DEUTZ F4L-912 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 GENERATOR INSTALLATION- DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54 PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697) . . . . . . . . . . . . . . . . . .2-58 PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT). . . . . . . . . . . . . . . . . . . . .2-60 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62 HOOD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7

BOOM ASSEMBLY COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 JIB BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 EXTEND-A-REACH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION. . . . . . . . . . . . . .3-18 BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN EN280 SPECS & ALL CE SPECS) . . . . . . . . . . . . . . . . . . . .3-22 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

SECTION 4 - PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5

3120820

PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) . . . . . . . . . . . . . . . . . . . .4-2 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) . . . . . . . . . . . . . . . . . . . . .4-8 PLATFORM CONSOLE ASSEMBLY (S/N 25609 TO PRESENT) . . . . . . . . . . . . . . . . . .4-12 OPTIONAL PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

i

TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9

AXLE EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 EXTEND-A-REACH LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 JACK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 CYLINDER BELLOWS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

SECTION 6 - HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4 6-5 6-6

HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS) . . . . . 6-10 HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697). . . . . . . . . . . . . . . . . . . . 6-12 HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . 6-16 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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

ELECTRICAL SCHEMATIC (PRIOR TO S/N 38697) (SHEET 1 OF 4) . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC (S/N 38697 TO PRESENT) (SHEET 1 OF 4). . . . . . . . . . . . 7-6 ELECTRICAL COMPONENTS AND DIAGRAM CHART . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

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

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

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

ii

3120820

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

3120820

DESCRIPTION

FRAME, VALVES AND SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING AND AXLES INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE MOTOR ASSEMBLY - REXROTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 1-6 1-8 1-12 1-14 1-18 1-22 1-24

1 F R A M E

1-1

S E C T I O N

SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION

1 F R A M E

1-2

3120820

SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION FIG & ITEM #

PART NUMBER

DESCRIPTION FRAME, VALVES AND SHIELDS INSTALLATION

1

2360353 2360369

0252709 0258677 101 102

103 4640260 Not Available 7009739 7007321 7007323 4640923 7012992 7012980 7012993 4640629 2900745 105

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

3120820

VALVES INSTALLATION - FRAME MOUNTED Prior To S/N 38697 S/N 38697 To Present

REV.

Ref. 1 1 Ref. Ref. Ref.

4 2

1 F R A M E

Not Used 4640739 4641066

104

Frame Weldment (Prior to June 1993) Frame Weldment (June 1993 to Present)

QTY.

4640743 7000645 7012905 Not Used 4711600 4761600 0641609 4711500 4761500 0641520 0641524 4300036 4711400 4761400 3311401

Valve Assembly - Hydro Air Options: Prior to S/N 38697 (See Figure 1-2 for Breakdown) S/N 38697 to Present (See Figure 1-2 for Breakdown) Valve Assembly - Flow Divider Options: Prior to S/N 38697 Components: Valve Assembly - Flow Divider Cartridge (Vickers/Modular Controls Version) Seal Kit (Vickers/Modular Controls Version) Cartridge (Fluid Controls Version) Seal Kit (Fluid Controls Version) S/N 38697 to Present Components: Valve Assembly - Flow Divider Cartridge Seal Kit Plug, Orifice Valve Assembly - Flow Divider (Prior to S/N 38697 Only) Seal Kit - Cartridge (Includes O-Rings & Back-Up Rings) (2 Per Valve) Valve Assembly - Hydraforce 3-Way Solenoid Coil Seal Kit Flatwasher 3/8" Narrow Lockwasher 3/8" Bolt 3/8"-16NC x 1 1/8" Flatwasher 5/16" Narrow Lockwasher 5/16" Bolt 5/16"-18NC x 2 1/2" Bolt 5/16"-18NC x 3" (Prior to S/N 38697) Stud (Welded on Part) Flatwasher 1/4" Narrow Lockwasher 1/4" Nut 1/4"-20NC

S E C T I O N

1

2

1 2 1 1 1 4 7 4 A/R A/R 4 3 2 4 2 2

1-3

S E C T I O N

SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0252684

201 202 203 204

1

4060824 4300031 4751400 3300151 0100011

DESCRIPTION FRAME SHIELDS INSTALLATION Shield Stud (Welded on Part) Flatwasher 1/4" Nut, Acorn 1/4"-20NC —————————— Loctite #242

QTY.

REV.

Ref.

2

2 8 8 8 A/R

F R A M E

1-4

3120820

SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

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

3120820

1-5

S E C T I O N

SECTION 1 FRAME FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR

1 F R A M E

1-6

3120820

SECTION 1 FRAME FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR FIG & ITEM #

PART NUMBER 4640739 4641066

1 7012723 7012730 7012725 7012731 7017491 7021404 7021401 7021402 7021403 2 4640788 7012730 7012725 7017490 7021400 7021401 7021402 7021403 3 7012724 7012725 7012730

4 5

7017491 7021404 7021401 7021402 7021403 7012914 7012912 7012918 7012998

3120820

DESCRIPTION

QTY.

REV.

VALVE ASSEMBLY - HYDRO AIR Prior To S/N 38697 S/N 38697 To Present

Ref. Ref. Ref.

A A

Rexroth Valve Section - Complete (Jack) Options: Prior to S/N 38697 Components: Rexroth Valve Section - Complete (Jack) Coil, Solenoid (2 Per Section) Seal Kit - Rexroth Valve Section Orifice 1.5mm (Located in B Port) S/N 38697 to Present Components: Rexroth Valve Section - Complete (Jack) Spool (2 Per Section) Coil (2 Per Section) Seal Kit End Cap (2 Per Section) Rexroth Valve Section - Complete (Steer) Options: Prior to S/N 38697 Components: Rexroth Valve Section - Complete (Steer) Coil, Solenoid (2 Per Section) Seal Kit - Rexroth Valve Section S/N 38697 to Present Components: Rexroth Valve Section - Complete (Steer) Spool (2 Per Section) Coil (2 Per Section) Seal Kit End Cap (2 Per Section) Rexroth Valve Section - Complete (Extend) Options: Prior to S/N 38697 Components: Rexroth Valve Section - Complete (Extend) Seal Kit - Rexroth Valve Section Coil, Solenoid (2 Per Section) S/N 38697 to Present Components: Rexroth Valve Section - Complete (Jack) Spool (2 Per Section) Coil (2 Per Section) Seal Kit End Cap (2 Per Section) Cartridge, Valve - Hydraforce Cartridge, Valve - Hydraforce —————————— Seal Kit - 7012914 Cartridge Valve (1 Per Cartridge) Seal Kit - 7012912 Cartridge Valve (1 Per Cartridge)

A/R 2 4 1 2

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

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

1-7

S E C T I O N

SECTION 1 FRAME FIGURE 1-3. STEERING AND AXLES INSTALLATION

1 F R A M E

1-8

3120820

SECTION 1 FRAME FIGURE 1-3. STEERING AND AXLES INSTALLATION FIG & ITEM #

PART NUMBER 0252605

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

4130282 4130283 0252674 3841167 3841166 3421990 3420372 1260017 3323002 1660202 3300229 1660203 3421972 0641506 4761500 3532054 3421948 3324203 3451012 1682605 3422044 3531946 4740130 4740314 3422023 3422633 3420592 4713000 3760170 1260017 2160001 2160003 4220174 3450808

0252604 0253776 101 102

3120820

4844090 0960821 4844089 0960821

DESCRIPTION STEERING AND AXLES INSTALLATION Spindle Weldment Spindle Weldment Tie-Rod Assembly Rod, Inner - Tie-Rod (1 Per Assembly) Tube, Outer - Tie-Rod (1 Per Assembly) Pin, Extension Lock (1 Per Assembly) Hairpin (1 Per Assembly) Chain - #3 (1 Ft./2.5cm Per Assembly) Nut, Jam 1 1/4"-12NF (RH Threads) Rod, End (RH Threads) Nut, Jam 1 1/4"-12NF Rod, End (LH Threads) Pin (Tie-Rod) Bolt 5/16"-18NC x 3/4" Lockwasher 5/16" Plate, Retainer Kingpin Nut, Slotted 2"-9NF Pin, Cotter 5/16" x 3" Steer Cylinder Assembly (See Section 5 for Breakdown) Pin (Steer Cylinder) Plate, Retainer Washer, Thrust Washer, Thrust Pin (Steer Cylinder) (Prior to S/N 33213) Pin (Steer Cylinder) (S/N 33213 to Present) Hairpin Flatwasher 1 1/4" Narrow Ring Chain - #3 (7.25 in./18.5cm Per Location) Fitting, Grease - 90° Fitting, Grease - 45° Weldment, Stop (Prior to S/N 47227) Cotter Pin (S/N 47227 to Present) EXTENDABLE AXLES INSTALLATION Prior To June 1993 June 1993 To Present Axle Weldment Bushing (2 Per Axle) (Kingpin Pivot) Axle Weldment Bushing (2 Per Axle) (Kingpin Pivot)

QTY.

REV.

Ref.

4

2 2 2 2 2 2 2 2 Ft./5cm 2 2 2 2 4 12 12 4 4 4 4 2

A

1 F R A M E

2 2 2 4 2 2 2 2 4 14.5 in/37cm

2 1 4 4 Ref. Ref. Ref.

S E C T I O N

B 3

2 4 2 4

1-9

S E C T I O N

SECTION 1 FRAME FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

103

104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139

1 F R A M E

1682618 1683532 3421953 3760133 3340197 4070810 4070811 0641618 4761600 Not Used 0641809 4711800 0560675 0560674 0560673 3535884 4070803 4070804 3972218 3312202 3535883 0641609 3311605 4360277 4360236 3900168 4920140 4360237 4460052 2160002 4060807 3311505 4070845 0641807 4761800 3536794 0641605 4070849 0100011

1-10

DESCRIPTION Axle Extension Cylinder Assembly Options (See Section 5 for Breakdown): Prior to S/N 33105 S/N 33105 to Present Pin (Extension Cylinder) Ring, Retaining Pad, Wear (Rear Top) Shim Shim Bolt 3/8"-16NC x 2 1/4" Lockwasher 3/8" Bolt 1/2"-13NC x 1 1/8" Lockwasher 1/2" Block, Axle Shim (Bottom) Block, Axle Shim (Bottom) Block, Axle Shim (Top) Plate, Axle Stop Shim 1/16"/1.6mm Shim 1/32"/.8mm Setscrew 3/4"-10NC x 2 1/4" Nut, Jam 3/4"-10NC Plate, Cylinder Retaining Bolt 3/8"-16NC x 1 1/8" Locknut 3/8"-16NC Switch, Limit Head, Actuator Bolt, Socket Head #10-24NC Lockwire Switch, Arm Connector, Strain Relief Fitting, Grease Flex-Trim Nut 5/16"-18NC Shim (June 1993 to Present Only) Bolt 1/2"-13NC x 7/8" (June 1993 to Present Only) Lockwasher 1/2" (June 1993 to Present Only) Plate (June 1993 to Present Only) Bolt 3/8"-16NC x 5/8" (June 1993 to Present Only) Shim (June 1993 to Present Only) —————————— Loctite #242

QTY.

REV.

2

4 8 4 A/R A/R 8 8 12 12 4 4 8 4 A/R A/R 24 24 2 4 4 4 4 8 4 4 4 4 92 in/2.34cm

16 A/R 12 12 2 4 A/R A/R

3120820

SECTION 1 FRAME FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

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

3120820

1-11

S E C T I O N

SECTION 1 FRAME FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

1 F R A M E

1-12

3120820

SECTION 1 FRAME FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS FIG & ITEM #

PART NUMBER

DESCRIPTION TIRE AND WHEEL DRIVE INSTALLATIONS

0252606 1

2780189

2 0920084 0920110 3 See Note 3160213 4 5 6 7 8 9 10 11

4300092 4761800 4751800 3311801 Not Used 0642216 4762200 3300007 0100011

0251590 0259545 12 0251589 0259444 0259445

4520136 4520218

3120820

WHEEL DRIVE INSTALLATION Drive Hub Assembly (See Figure 1-5 for Breakdown) Drive Brake Assembly Options (See Figure 1-6 for Breakdown): Prior to S/N 33476 S/N 33476 to Present Drive Motor Assembly Options (See Figure 1-7 for Breakdown): Prior to July 1995 (was p/n 3160176) Note: Use p/n 3160213 Motor Plus p/n 2900869 Conversion Kit as Replacement.

July 1995 to Present (See Figure 1-7 for Breakdown) Stud 1/2"-13NC x 5 1/2" (2 Per Wheel) Lockwasher 1/2" (2 Per Wheel) Flatwasher (2 Per Wheel) Nut 1/2"-13NC (2 Per Wheel) Bolt 3/4"-10NC x 2" (12 Per Wheel) Lockwasher 3/4" (12 Per Wheel) Lugnut 3/4"-16NC (12 Per Wheel) —————————— Loctite #242 TIRE AND WHEEL INSTALLATION (FOAM-FILLED) Prior To S/N 43718 S/N 43718 To Present Tie and Wheel Assembly (Foam-Filled) Options: Prior To S/N 43718 S/N 43718 To Present : Right Side (Foam-Filled) Left Side (Foam-Filled) 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.

Tire Options: Tire 445/65R x 22.5 (Prior to S/N 43718) Tire 445/65 x 22.5 (S/N 43718 To Present)

QTY.

REV.

Ref. Ref.

3

4 4

1 F R A M E

4

8 8 8 8 48 48 48 A/R Ref. Ref. Ref.

S E C T I O N

2 A

A/R 4 2 2

4

1-13

S E C T I O N

SECTION 1 FRAME FIGURE 1-5. DRIVE HUB ASSEMBLY

1 F R A M E

1-14

3120820

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

PART NUMBER 2780189

1

7007698

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

7007657 7001910 7001963 Kit 7001965 7000282 7000283 7000284 7000285 7010472 7001995 7010471 7001993 7001972 7001973 7001974 7001975 7000290 Not Used Not Used Not Used 7001976 Not Used 7001977 7007698

101 102 103 104 105 106 107 108 109 110

7007699 Kit 7001947 7001948 7001949 7001950 7001951 7001928 7000265 7001952 7001910

201 202 203 204

3120820

7001955 7001956 7001957 7001958

DESCRIPTION DRIVE HUB ASSEMBLY

QTY.

REV.

Ref.

—

Hub and Spindle Assembly (See Items 101-110 for Breakdown) Gear, Internal Carrier Assembly (See Items 201-208 for Breakdown) Gear, Ring O-Ring Cover Assembly (See Items 301-309 for Breakdown) Washer, Thrust Spring Ring, Retaining - Internal Ring, Retaining - External Shaft, Input Spacer, Input Gear, Sun Spacer, Input Washer, Thrust Bearing, Thrust Bolt 1/2"-13NC x 3 3/4" Bolt, Socket Head 3/8"-16NC x 3 1/2" Coupling

1 1 1 2 1 2 1 1 1 1 1 1 1 4 2 16 4 1

Lockwasher

20

Ring, Keeper

1

HUB AND SPINDLE ASSEMBLY Spindle Seal, Lip Cup, Bearing Cone, Bearing Washer, Thrust Ring, Retaining - External Housing Plug, Pipe Stud 3/4"-16NF Plug, Pipe CARRIER ASSEMBLY Carrier Rollpin Cup, Bearing Cone, Bearing

1

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

Ref. 1 1 2 2 1 1 1 2 12 2 Ref. 1 3 6 6

1-15

S E C T I O N

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

PART NUMBER

205 206 207 208

7001959 7017003 7001961 7001962

1

301 302 303 304 305 306 307 308 309

F R A M E

Shaft, Planet Gear, Cluster Spacer, Thrust Ring, Retainer - External

7001965

COVER ASSEMBLY

7001966 7001967 7000220 7000231 7001968 Kit Kit 7000243 7001928

Plate, Cover Cap, Cover Bolt 1/4"-20NC x 3/4" Cap, Disengage Rod, Disengage O-Ring O-Ring Plug, Pipe - 1/8" Plug, Pipe - 3/8" —————————— Seal Kit (Includes Items 5, 102, 306 and 307)

2900560

1-16

DESCRIPTION

QTY.

REV.

3 3 3 3 Ref. 1 1 4 1 1 1 1 1 1 1

3120820

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

PART NUMBER

DESCRIPTION

QTY.

REV.

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

3120820

1-17

S E C T I O N

SECTION 1 FRAME FIGURE 1-6. DRIVE BRAKE ASSEMBLY

1 F R A M E

1-18

3120820

SECTION 1 FRAME FIGURE 1-6. DRIVE BRAKE ASSEMBLY FIG & ITEM #

PART NUMBER

DESCRIPTION DRIVE BRAKE ASSEMBLY

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

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 Not Used Kit 7007933 2900766 2900768

0920084 0920110 51 52

7011712 7007979 7007980 Not Required

53 Not Required 7007970 7018602

3120820

Seal, Oil Bearing Ring, Retaining

QTY.

REV.

Ref. 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

2 2

Seal Kit (Includes Items 1,11,18,19, 20, 21, 28 and 29) Bearing Kit (Includes Items 1, 2,11, 28 and 29)

1 1

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

Ref. Ref.

F R A M E

A B

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

1-19

S E C T I O N

SECTION 1 FRAME FIGURE 1-6. DRIVE BRAKE ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER

54

7007914 7018609

Housing Options: Prior To S/N 33476 S/N 33476 To Present 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

7011713 7018605 55 7007985 7018607 56

1

7011717 7018606 57

F R A M E

7007923 7018603 58 7007923 Kit 7011715 7011714 7007983 7018603 Kit 59

1-20

DESCRIPTION

QTY.

REV.

1

4

1

1

1 1 2 4 2 1 1

1

3120820

SECTION 1 FRAME FIGURE 1-6. DRIVE BRAKE ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

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

3120820

1-21

S E C T I O N

SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY - REXROTH

1 F R A M E

1-22

3120820

SECTION 1 FRAME FIGURE 1-7. DRIVE MOTOR ASSEMBLY - REXROTH FIG & ITEM #

PART NUMBER 3160176 3160213

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

7012701 Kit 7012702 Not Available 7012703 7012704 Kit 7012705 7012706 7012707 7012708 7012709 7012710 Kit 7012711 7012712 Kit 7012713 Kit Not Available Kit 7012714 7012715 7012700

2900788 7012716

3120820

DESCRIPTION DRIVE MOTOR ASSEMBLY - REXROTH Prior to July 1995 July 1995 to Present Shaft - 13 Teeth Seal, Shaft Bearing, Cradle Housing Rod, Piston Piston, Stroking O-Ring Nut, Adaptor Bearing, Roller Bolt, Metric Socket Head M12 x 65 Block, Port Shim Pin, Dowel M6 x 18 O-Ring Nut, Cap M10 x 1 Screw, Adjusting O-Ring Nut, Jam M10 x 1 Rotary Group Assembly Plug Plate, Swash Bearing, Roller V-Ring Control Plate Assembly —————————— Seal Kit (Includes Items 2,7,14,17 and O-Rings under Item 24) Rotary Group Kit (Includes Items 19 and 21)

QTY.

REV.

Ref. Ref. Ref.

— —

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

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

1 1

1-23

S E C T I O N

SECTION 1 FRAME FIGURE 1-8. JACK CYLINDER INSTALLATION

1 F R A M E

1-24

3120820

SECTION 1 FRAME FIGURE 1-8. JACK CYLINDER INSTALLATION FIG & ITEM #

PART NUMBER 0252607

1 2 3 4 5 6 7 8

1682511 0641812 4761800 3535906 0641816 4711800 3311805 3252185

9

4360314

10

4740397

11

0630448

12 13 14 15 16

4761400 Not Used 3340630 0641852 3311801 0100011

3120820

DESCRIPTION

QTY.

REV.

JACK CYLINDER INSTALLATION

Ref.

2

Jack Cylinder Assembly (See Section 5 for Breakdown) Bolt 1/2"-13NC X 1 1/2" (4 Per Cylinder) Lockwasher 1/2" (4 Per Cylinder) Plate, Mounting (1 Per Cylinder) Bolt 1/2"-13NC x 2" (4 Per Cylinder) Flatwasher 1/2" Narrow (4 Per Cylinder) Locknut 1/2"-13NC (4 Per Cylinder) Nameplate - Jack Operator (1 Per End of Machine) Switch, Toggle (Extend and Retract of Jack Cylinder and Axles) (2 Per Nameplate) Washer, Special (2 Per Nameplate) Screw, Button Head 1/4"-20NC x 3/4" (4 Per Nameplate) Lockwasher 1/4" (4 Per Nameplate)

2 8 8 2 8 8 8 2

Jack Pad Weldment Bolt 1/2" -13 NC x 6 1/2" Nut 1/2" - 13 NC —————————— Loctite

2 4 4

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

4 4 8 8

A/R

1-25

S E C T I O N

SECTION 1 FRAME FIGURE 1-8. JACK CYLINDER INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

1 F R A M E

1-26

3120820

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

3120820

DESCRIPTION

TURNTABLE, BOOM AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE ASSEMBLY - HYDRO-AIR (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE ASSEMBLY - HYDRO-AIR (S/N 38697 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SWING DRIVE AND BEARING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

REMOTE DRIVE CONTROL BOX ASSEMBLY (Prior to July 1992). . . . . . . . . . . . . . . . . . . . . .

REMOTE DRIVE CONTROL BOX ASSEMBLY (July 1992 to Present) . . . . . . . . . . . . . . . . . . .

DEUTZ F4L-912 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR INSTALLATION - DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP ASSEMBLY - BARNES (October 1992 to S/N 38697). . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

HOODS AND ALARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL COOLER INSTALLATION (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

2-2 2-6 2-8 2-10 2-14 2-18 2-20 2-22 2-26 2-28 2-30 2-36 2-38 2-40 2-48 2-52 2-54 2-58 2-60 2-62 2-66 2-70

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

2-1

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION

2 T U R N T A B L E

2-2

3120820

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION FIG & ITEM #

PART NUMBER 4620078

1 2

0252852 0960594 0961392

0252609 0258418 0252932 0258416 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

3120820

1682630 1682895 1681580 3952014 3312002 2160002 0681812 4740171 Not Used 1120368 Not Used 3421555 0236548 4740006 0651608 4761600 4300038 4300034 4751500 4751600 4761500 4761600 3311501 3311601 3420085 3450610 3421676 4712200 4762200 0682213 3421678 4740361 3900159

DESCRIPTION TURNTABLE ASSEMBLY Boom Pivot Assembly Bushing, Self-Aligning (1 Per Assembly) Bushing, Bronze (Base Pivot) BOOM AND CYLINDERS INSTALLATION Standard Boom Prior To S/N 37026 Standard Boom S/N 37026 To Present Boom With Chip Covers Prior To S/N 37026 Boom With Chip Covers S/N 37026 To Present

QTY.

REV.

Ref.

F/6

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

Boom Assembly (See Section 3 for Breakdown) Lift Cylinder Assembly Options (See Section 5 for Breakdown) : Prior to November 1992 November 1992 to Present Master 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

2 2 3 4 4

Cap, Boom Pivot

2

Pin, Boom Pivot Pin, Top Master Cylinder Washer, Special Bolt 3/8"-24NF x 1" Lockwasher 3/8" Stud (Welded on Part) (Prior to July 1995) Stud (Welded on Part) (July 1995 to Present) Flatwasher 5/16" (Prior to July 1995) Flatwasher 3/8" (July 1995 to Present) Lockwasher 5/16" (Prior to July 1995) Lockwasher 3/8" (July 1995 to Present) Nut 5/16"-18NC (Prior to July 1995) Nut 3/8"-16NC (July 1995 to Present) Pin, Bottom Master Cylinder Pin, Cotter 3/16" x 2 1/2" 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"

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

C F 1 D 1

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

1 1

1

2-3

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

130 131 132 133

0641840 3311805 2160001 4740040 0100019

2

0251007

T U R N T A B L E

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

0251006

301 302 303 304 305 306 307 308 309 310 311 212 213 214

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

2-4

DESCRIPTION Bolt 1/2"-13NC x 5" Locknut 1/2"-13NC Fitting, Grease - 90° Flatwasher, Special —————————— Loctite #271

QTY. 1 1 1 2 A/R

HORIZONTAL CUTOUT LIMIT SWITCH INSTALLATION (RIGHT SIDE)

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 8 METER CUTOUT LIMIT SWITCH INSTALLATION (DUTCH AND GERMAN SPECS) (LEFT SIDE) 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 Bolt 1/4”-20NC x 1" Lockwasher 1/4” —————————— Loctite #271

REV.

2

2 2 A/R

Ref.

B

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

3120820

SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0239844

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

3120820

2160002 2220001 2751032 2750528 2750807 2200261 2750527 2220063 4300031 4761400 3311401 1320040

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

QTY.

REV.

Ref.

3

3 3 1 1 1 2 2 3 1 1 1 1

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

2-5

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED

2 T U R N T A B L E

2-6

3120820

SECTION 2 TURNTABLE FIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED FIG & ITEM #

PART NUMBER

DESCRIPTION VALVES INSTALLATION - TURNTABLE MOUNTED

0252709 0258677 1 4640738 4641065

2 to 5 6

4641181 Not Used 4640758 7012906 7012907

7

8

9 10 11 12 to 15 16 17 18 19 20 21 22 23 24 25 26

4640626 4641079 4640543 7009745 7004368 4711600 4761600 0641609 Not Used 4300036 4711400 4761400 3311401 Not Used 0641616 3535942 0641420 3311605 0140001 0641406 0252926

101 4360171 4360362 102

3120820

2820022

Prior To S/N 38697 S/N 38697 To Present

QTY.

Ref. Ref.

Valve Assembly - Hydro-Air Options: Prior to S/N 38697 (See Figure 2-3 for Breakdown) S/N 38697 to Production (See Figure 2-4 for Breakdown) Post Production (See Figure 2-4 for Breakdown)

1

Valve Assembly - 3 - Way Solenoid Coil Seal Kit Valve, Counterbalance Options: Prior to S/N 38697 S/N 38697 to Present Valve Assembly - Solenoid Coil (Vickers/Modular Controls Version) Coil (Hydraforce Version) Flatwasher 3/8" Lockwasher 3/8" Bolt 3/8"-16NC x 1 1/8"

1 1 1 1

1 1 1 11 7 3

Stud (Welded on Part) Flatwasher 1/4" Lockwasher 1/4" Nut 1/4"-20NC

4 17 11 17

Bolt 3/8"-16NC x 2" Plate, Valve Mounting Bolt 1/4"-20NC x 2 1/2" Nut 3/8"-16NC Horn Bolt 1/4"-20NC x 3/4"

4 1 2 4 1 1

TILT INDICATOR INSTALLATION Switch, Level Sensor - 3° Options: Prior to May 1993 May 1993 to Present Tubing, Vinyl (6 in/14cm Per Switch) (Prior to May 1993)

REV.

Ref. 4 2

S E C T I O N 2

Ref.

T U R N T A B L E

3

1

6 in./14cm

2-7

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-3. VALVES ASSEMBLY - HYDRO AIR (PRIOR TO S/N 38697)

2 T U R N T A B L E

2-8

3120820

SECTION 2 TURNTABLE FIGURE 2-3. VALVES ASSEMBLY - HYDRO AIR (PRIOR TO S/N 38697) FIG & ITEM #

PART NUMBER 4640738

1

7012717 7012728

2

7012718

3

4

5 6

7 8 9

10 11 12 13 14

7012728 7012720 7012730 7012734 7012719 7012729 7012735 7012736 4640788 7012730 7012722 7012730 7012736 7012908 7012915 7012909 7012916 7012910 2900756 7000645 7010542 7010543 7012912 7010541 7012913 2900708 7012914 7012918 7018942 7012725

3120820

DESCRIPTION VALVE ASSEMBLY - HYDRO-AIR (PRIOR TO S/N 38697) Rexroth Valve Section - Complete (Swing and Lift) Coil, Solenoid (2 Per Section) Rexroth Valve Section - Complete (Flow) (was p/n 4640782) Coil, Solenoid (1 Per Section) Rexroth Valve Section - Complete (Telescope) Coil, Solenoid (2 Per Section) Orifice 2.7mm (Located in T Port) Rexroth Valve Section - Complete (Extend-A-Reach) Coil, Solenoid (2 Per Section) Diode Circuit Board (2 Per Section) Orifice 1.2mm (Located in Port A Only) Rexroth Valve Section - Complete (Rotate) Coil, Solenoid (2 Per Section) Rexroth Valve Section - Complete (Platform Level) Coil, Solenoid (2 Per Section) Orifice 1.2mm (Located in A and B Ports) Cartridge, Valve Seal Kit - 7012908 Cartridge Cartridge, Valve Seal Kit - 7012909 Cartridge Cartridge, Valve (Without Coil) Seal Kit - 7012910 Cartridge Coil - 12V Cartridge, Valve Seal Kit - 7010542 Cartridge (1 Per Cartridge) Cartridge, Valve Seal Kit - 7012912 Cartridge (1 Per Cartridge) Cartridge, Valve Seal Kit - 7012913 Cartridge (1 Per Cartridge) Cartridge, Valve Seal Kit - 7012914 Cartridge (1 Per Cartridge) Capscrew, Socket Head #10-24NC x 2” —————————— Seal Kit - Rexroth Valve Sections (1 Per Valve Section)

QTY.

REV.

Ref.

—

2 4

S E C T I O N

1

2

1 1 2 1 1 2 2 1 1 2 1 2 2 1 1 1 1 1 1 1 4 4 7 7 1 1 2 2 A/R

T U R N T A B L E

7

2-9

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-4. VALVE ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT)

23 22 21

2

20 4

T U R N T A B L E

7 26

19

3

6

16 25

2

4 14 15 13 13 12 11

9 27

18 24

10 29 7 26

1 8

17 25

5

28 5

29

4

2-10

3120820

SECTION 2 TURNTABLE FIGURE 2-4. VALVE ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) FIG & ITEM #

PART NUMBER 4641065 4641181

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

16

17 18

19

3120820

7017482 7012518 7012997 7010545 7017483 7012953 7010542 7010543 7012914 7012918 7017484 7012942 7017485 Not Available 7021637 7012972 7017487 7017496 7017421 7012998 7017418 7012998 7017488 7012998 7017422 7012998 7017489 7012998 7017422 7012998 7012910 2900708 7010635 2900708 7017452 7017402 7012944 7021622 7021405 7021401 7021402 7021406 7024826

DESCRIPTION VALVE ASSEMBLIES PRODUCTION POST PRODUCTION Cartridge, Valve Seal Kit - 7017482 Cartridge Cartridge, Flow Control (Lift Down Speed Control) Seal Kit - 7012997 Cartridge Cartridge, Flow Control Seal Kit - 7017483 Cartridge Cartridge, Load Shuttle Seal Kit - 7010542 Cartridge (1 Per Cartridge) Cartridge, Pilot Check Seal Kit - 7012914 Cartridge (1 Per Cartridge) Cartridge, Pilot Directional Seal Kit - 7017484 Cartridge (1 Per Cartridge) Cartridge, Proportional Valve (Without Coil) (Lift, Swing, Tele, EAR & Rotate) Seal Kit - 7017485 Cartridge Cartridge, Relief Valve (Main Pressure Adjustment) Seal Kit - 7021637 Cartridge Cartridge, Relief Valve (Lift Down Pressure) Seal Kit - 7017487 Cartridge Cartridge, Relief Valve (Swing Pressure) Seal Kit - 7017421 Cartridge Cartridge, Relief Valve (EAR Up Pressure) Seal Kit - 7017418 Cartridge Cartridge, Relief Valve (EAR Down Pressure) Seal Kit - 7017488 Cartridge Cartridge, Relief Valve (Rotate Right, Rotate Left) Seal Kit - 7017422 Cartridge Cartridge, Relief Valve (Level Down Pressure) Seal Kit - 7017489 Cartridge Cartridge, Relief Valve (Level Up Pressure) Seal Kit - 7017489 Cartridge Cartridge, Solenoid Valve (Without Coil) (Main Dump) Seal Kit - 7012910 Cartridge Cartridge, Solenoid Valve (Without Coil) (Lift Down) Seal Kit - 7010635 Cartridge Cartridge, Solenoid Valve (Without Coil) (Telescope) Seal Kit - 7017452 Cartridge Coil - 12V Bosch Valve Section - Complete (Lift) Spool (2 Per Section) Coil (2 Per Section) Seal Kit (2 Per Section) Cap, End (2 Per Section) Bolt

QTY.

REV.

Ref. Ref. Ref.

E B

1 1 1 1 2 2 4 4 2 2 2 2 3

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

3 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 4

2-11

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-4. VALVE ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

20

7017491 7021404 7021401 7021402 7021403 7024826 7017491 7021404 7021401 7021402 7021403 7024826 7017490 7021400 7021401 7021402 7021403 7024826 7017491 7021404 7021401 7021402 7021403 7024826 7012944 7012943 7017451 7017492 7017493 7017494

21

2 T U R N T A B L E

22

23

24 25 26 27 28 29

2-12

DESCRIPTION Bosch Valve Section - Complete (Swing) Spool (2 Per Section) Coil (2 Per Section) Seal Kit (2 Per Section) Cap, End (2 Per Section) Bolt Bosch Valve Section - Complete (EAR) Spool (2 Per Section) Coil (2 Per Section) Seal Kit (2 Per Section) Cap, End (2 Per Section) Bolt Bosch Valve Section - Complete (Rotate) Spool (2 Per Section) Coil (2 Per Section) Seal Kit (2 Per Section) Cap, End (2 Per Section) Bolt Bosch Valve Section - Complete (Level) Spool (2 Per Section) Coil (2 Per Section) Seal Kit (2 Per Section) Cap, End (2 Per Section) Bolt Coil Coil Coil Orifice Orifice Orifice

QTY.

REV.

1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 1 4 2 2 3 1 1 2

3120820

SECTION 2 TURNTABLE FIGURE 2-4. VALVE ASSEMBLY - HYDRO AIR (S/N 38697 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

3120820

2-13

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION

2 T U R N T A B L E

2-14

3120820

SECTION 2 TURNTABLE FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION FIG & ITEM #

PART NUMBER

DESCRIPTION

0250611 0254882

ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION OPTIONS: Prior To September 1994 September 1994 To Present

1 1660185

2 3 4 5 6 7 8

101 102 103 104 105

1660213 7013175 3530403 3951820 0641807 4761800 1440154 0641512 0641514 4761500 0100011 0100019 1660185

ROTARY OIL COUPLING ASSEMBLY

0620106 2760091 Kit 3760004 Kit

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

2901146 Use 1660213EX

0252284

201 202 203 204 205 206 207 208 209 210 211

3120820

Rotary Oil Coupling Assembly Options: Prior To September 1994 (See Items 101-105 For Breakdown) September 1994 to Present Seal Kit - 1660213 Coupling 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 1/2" (Prior to S/N 36536) Bolt 5/16"-18NC x 1 3/4" (S/N 36536 to Present) Lockwasher 5/16" Loctite #242 Loctite #271

4843822 0960224 0641418 2180763 0961531 3760108 3311801 3420290 0231047 0234721 0721004

COLLECTOR RING INSTALLATION (FOUR WHEEL STEER ONLY) Bracket Weldment Bushing Bolt 1/4"-20NC x 2 1/4" Pipe Bushing Collector Ring Assembly Nut 1/2"-13NC Pin, Drive Guide, Drive Cover Screw, Machine #10-24NC x 1/2"

QTY.

REV.

Ref. Ref. Ref.

B 3

1

—

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

A

Ref.

—

1 1 7 1 1 1

Ref.

3

1 2 2 1 1 1 2 2 2 1 4

2-15

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 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

212 213 214 215 216 217 218

4761400 1320040 3911012 4751000 4761000 3311001 4751400

2

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

QTY.

REV.

2 2 2 6 6 6 2

T U R N T A B L E

2-16

3120820

SECTION 2 TURNTABLE FIGURE 2-5. ROTARY COULPING 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

3120820

2-17

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION.

2 T U R N T A B L E

2-18

3120820

SECTION 2 TURNTABLE FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION. FIG & ITEM #

PART NUMBER 0252675

1 2

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

17 18 19

3160184

0920083 0920109 2780116 4844109 2440058 3533337 Not Used 3900164 0642216 0641810 4761800 3931864 4740189 Not Used 4740171 4640741 7011320 2900770 0641520 4761500 3790155 0100019 0100009 0250348

101 102 103 104 105 106

0440193 0682016 4740004 0100019 Not Used 0682016 0682026 0239842

201 202 203 204 205

3120820

4843318 3421565 1260017 3760170 3421563

DESCRIPTION SWING DRIVE INSTALLATION

QTY.

REV.

Ref.

5

Swing Motor Assembly (See Figure 2-7 for Breakdown) Swing Brake Assembly Options (See Figure 2-8 for Breakdown): Prior to S/N 33476 S/N 33476 to Present Swing Hub Assembly (See Figure 2-9 for Breakdown) Mounting Weldment - Swing Drive Gear, Pinion Plate, Retaining

1 1

Screw, Countersunk 1/2"-20NF x 1" Bolt 3/4"-10NC x 2" Bolt 1/2"-13NC x 1 1/4" Lockwasher 1/2" Bolt, Socket Head 1/2"-13NC x 4" (Grade 8) Washer, Special

2 8 2 2 2 2

Washer, Special Hardened Motor Control Valve Assembly Cartridge Seal Kit Bolt 5/16"-18NC x 2 1/2" Lockwasher 5/16" O-Ring (S/N 40756 to Present) —————————— Loctite #271 Sealant, Pipe

2 1 2 2 4 4 1

TURNTABLE BEARING INSTALLATION

1 40 80 A/R

Bolt Options: Prior to S/N 53244 Use Bolt 5/8”-11NC x 2” Prior to S/N 53244 Use Bolt 5/8”-11NC x 3 1/4”

40

Bushing Weldment Pin, Snap Chain - #3 Ring, Quick Release Pin, Turntable Lock

T U R N T A B L E

A/R A/R

Bearing Bolt 5/8"-11NC x 2" Washer, Special Hardened Loctite #271 (Not Shown)

TURNTABLE LOCK INSTALLATION

2

1 1 1 1

Ref.

Ref.

S E C T I O N

7/F

2

1 1 9 in/23cm 2 1

2-19

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR ASSEMBLY

2 T U R N T A B L E

2-20

3120820

SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR ASSEMBLY FIG & ITEM #

PART NUMBER 3160184

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

Kit Kit Kit 7004196 7004167 7004179 Kit Kit 7004171 7010780 Not Used 7010781 Not Used Not Used 7010782 Not Used 7004192 Not Used Not Used Not Used Kit 7010776 2900798

3120820

DESCRIPTION SWING MOTOR ASSEMBLY

QTY.

REV.

Ref.

B

Seal, Dust Ring, Back-Up Seal, Lip Valve, Rotary Ball, Check Valve IGR Assembly Ring, Snap Seal, Ring Plug, Vent (Includes O-Ring) Bolt

1 1 1 1 2 1 1 3 1 8

Shaft, Spline

1

Body/Bearing Assembly

1

Cover/Bearing Assembly

1

Ring, Retaining Plate, Commutator —————————— Seal Kit (Includes Items 1,2,3,7,8 and 21))

1 1

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

1

2-21

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY

2 T U R N T A B L E

2-22

3120820

SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY FIG & ITEM #

PART NUMBER

DESCRIPTION SWING BRAKE ASSEMBLY

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

Kit Kit 7007977 Not Used Kit Not Used 7011719 Not Used 7007987 Kit Kit Kit Kit Kit Kit 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 55 7007985 7018607

3120820

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 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 Bolt, Washer Head 0920083 Brake 0920109 Brake

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

4

2-23

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER

56

57

2

Not Required 7011717 7018606 7007923 7007923 7018603

58 Kit 7011715 7011714 7007983 7018604

T U R N T A B L E

59 7007914 7018609 60 Not Required 7011716

2900767 7018608

2-24

DESCRIPTION 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.

1

1

A/R 1 2 4 2 1 1

A/R

1

3120820

SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY (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

3120820

2-25

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-9. SWING HUB ASSEMBLY

2 T U R N T A B L E

2-26

3120820

SECTION 2 TURNTABLE FIGURE 2-9. SWING HUB ASSEMBLY FIG & ITEM #

PART NUMBER 2780116

1

7001916

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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

3120820

DESCRIPTION SWING HUB ASSEMBLY

QTY.

REV.

Ref.

—

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

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

2-27

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-10. LOAD MANAGEMENT INSTALLATION

2 T U R N T A B L E

2-28

3120820

SECTION 2 TURNTABLE FIGURE 2-10. 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

3120820

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

2-29

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION

2 T U R N T A B L E

2-30

3120820

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION FIG & ITEM #

PART NUMBER 0252712/0257206

0258614

1

2 3 4 5 6 7 8 9 10

0860776 0861090 0861221 2600148 1780227 4751400 3311405 3311401 4300031 2940042 Not Used 4300032 4751500 0100011

0860776 0861090 0861221 101

102 103 104 105 106 107

108 109 110 111 112 113 114

3120820

3252195 3252357 3252547 3252646 0860562 0140019 4420037 0610084 0610080 0610083 0610106 0610130 0610100 3740070 3740016 3740057 3740122 3740049 4360069 4460301

DESCRIPTION GROUND CONTROLS INSTALLATIONS PRIOR TO S/N 38697 S/N 38697 TO PRESENT Ground Control Box Assembly - Deutz (See Items 101-182 for Breakdown) Prior to S/N 25609 S/N 25609 to S/N 38697 S/N 38697 to Present Hinge Door, Ground Control Flatwasher 1/4" Locknut 1/4"-20NC (Prior to S/N 38697) Nut 1/4"-20NC (S/N 38697 to Present) Stud (Welded on Part) (Prior to S/N 38697) Latch Stud (Welded on Part) Flatwasher 5/16" —————————— Loctite #242 GROUND CONTROL BOX ASSEMBLY PRIOR TO S/N 25609 S/N 25609 TO S/N 38697 S/N 38697 TO PRESENT Lid/Nameplate Options: Prior to May 1994 May 1994 to S/N 34119 S/N 34119 to S/N 45584 S/N 45584 to Present Box Alarm Gasket Card, Circuit (Engine Relay) Card, Circuit (Select) Card, Circuit (Load Radius) Options: Prior to April 1993 April 1993 to S/N 44577 S/N 44577 to Present Card, Circuit (Overload) Relay - SPDT Relay - 3PDT Relay - 2PDT (Prior to S/N 25609) Relay - 2PDT (S/N 25609 to Present) Relay - 5PDT (With Skirt) Breaker, Circuit - 10 Amp (S/N 25609 to Present) Marker, Terminal (1-50)

QTY.

REV.

Ref. Ref. Ref.

A/1 1

1

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

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

H 4 4

1

1 1 15 ft./4.5m

1 1 1

2 16 6 2 2 A/R 3 1

2-31

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

115 116 117 118 119 120 121 122 123 124 125

3640686 4460442 4460387 4460388 4460307 4460441 4460306 4460305 4360216 4360232

2 T U R N T A B L E

4360319 4360470

126 127 128 129 130 131 132 133

7012560 2860030 4460299 2920027 2920029 4360212 2920026 4360274 4460390 2920090

134

4360314

135 136 137 138 139 140

4760600 4751400 3311401 4751000 3311001

141 142 143 144 145 146 147 148 149 150 151 152 153 154

2-32

4460071 4460051 3300048 0960238 4460071 4460386 3300177 0750806 0720804 4760800 3310801 3910606 4460451 3790012 4460234 4460452

DESCRIPTION Rail Stop, Terminal Block, Terminal Barrier, Terminal Sleeve, Terminal Bar, Buss - 5 Position Washer, Terminal Screw, Terminal Breaker, Circuit - 30 Amp Breaker, Circuit - 15 Amp Switch, Key (Master Select) Options: Prior to S/N 45584 S/N 45584 to Present Key, Replacement Options: Use with 4360319 Switches Use with 4360470 Switch Stop, Terminal Light, Indicator - Green (Axles Set) Bulb, Light Breaker, Circuit - 3 Amp Light, Indicator - Red (Radius Limit) Switch, Push Button (Start) Bar, Buss - 5 Position (S/N 25609 to Present) Light, Indicator - Blue (Capacity Limit) Switch, Toggle (Extend-A-Reach, Lift, Swing, Level, Telescope and Rotate) Lockwasher #6 Flatwasher 1/4" Nut 1/4"-20NC Flatwasher #10 Nut #10-24NC Connector, Strain Relief Options: Prior to S/N 25609 S/N 25609 to Present Nut, Conduit Bushing, Reducer Connector, Strain Relief (Prior to S/N 38697) Connector, Strain Relief Nut, Tinnerman Screw, Self-Tapping #8 x 3/4" Screw, Hex #8-32NC x 1/2" Lockwasher #8 Nut #8-32NC Screw, Hex #6-32NC x 3/8" Strip, Terminal Marking - #98 O-Ring Clamp, Cable Strip, Terminal marking - #99

QTY.

REV.

1 1 35 4 20 4 20 20 1 2 1

1

1 1 3 1 1 1 4 1 6 A/R A/R A/R 4 4 A/R 1 6 6 6 1 1 3 3 6 6 6 2 20 8 10 20

3120820

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

155

156 157

158 159 160 161 162 163 164 165 166 167 168 169 170 171

4120012 4120036 3300147 4460704 3740066 3740124 3910616 4564088 3310601 Not Used 2420009 2420091 2420074 3520070 0960905 4360330 4360328 4060229 0610091 4120013 4120037

172 4120013 4120037 173 3740058 3740123 174 4360282 4360476 175 4360289 4360475 7012611

176 177 178 179 180 181 182

3120820

7012612 7020175 7020176 Not Used 4740120 4750800 4070991 4070987 3910804 1704260

DESCRIPTION Base, Relay Options: Prior to S/N 25609 S/N 25609 to Present Nut, Conduit Strip, Terminal Marking - #97 Prior to S/N 25609 S/N 25609 to Present Screw, Hex #6-32NC x 1" Stand-Off #6-32NC x 1/4" Nut #6-32NC Hourmeter Voltmeter Gauge, Oil Pressure Plug, Hole Bushing Switch, Toggle (Auxiliary Power) Switch, Toggle (Proximity Manual Test) Guard, Switch Card, Circuit (Prior to S/N 38697) Socket, Relay Options: Prior to S/N 25609 S/N 25609 to S/N 38697 Relay Options: Prior to S/N 25609 S/N 25609 to S/N 38697 Spring, Relay Options: Prior to S/N 25609 S/N 25609 to Present Block, Contact Options: Prior to S/N 45584 S/N 45584 to Present Switch, Emergency Stop Options: Prior to S/N 45584 S/N 45584 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) Washer, Nylon Washer, Flat Shim .125 (S/N 45584 to Present) Shim .015 (S/N 45584 to Present) Screw #8-32NC x 1/4” (S/N 45584 to Present) Decal - EMS (S/N 45584 to Present)

QTY.

REV.

2

1 A/R 2 12 10 A/R A/R

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

1 1 1 1 1 1 1 1 1 1

1

A/R

1

1

1

1

3 6 1 1 6 1

2-33

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0253378

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

2-34

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

DESCRIPTION TUV MONITORING SYSTEM INSTALLATION

QTY.

REV.

Ref.

C/2

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

3120820

SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS 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

3120820

2-35

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-12. REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992)

2 T U R N T A B L E

2-36

3120820

SECTION 2 TURNTABLE FIGURE 2-12. REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992) FIG & ITEM #

PART NUMBER 0252717

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

3120820

3503928 4420037 3251831 3251830 3251829 4460052 3300047 0960239 1060304 3941004 4360074 4843020 4360071 4360141 4060802 Not Used Not Used Not Used Not Used 2560116 3300352 4360340 3730091 3990001

DESCRIPTION REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992) Lid, Control Box Tape, Insulation Nameplate - Emergency Stop Nameplate - Drive/Steer Functions Nameplate - Caution Connector, Strain Relief Locknut, Conduit Bushing Cable, Electrical - 16/10 Screw #10 x 1/2" Switch, Toggle Control Box Weldment Switch, Toggle Guard, Switch Shield

Knob, Speed Control Nut, Special Switch, Potentiometer Resistor Diode

QTY.

REV.

Ref.

A

1 21 in./53cm

1 1 1 1 1 1

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

23 ft./7.62m

4 2 1 1 1 4

1 1 1 1 6

2-37

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-13. REMOTE DRIVE CONTROL BOX ASSEMBLY (JULY 1992 TO PRESENT)

2 T U R N T A B L E

2-38

3120820

SECTION 2 TURNTABLE

1

S E C T I O N

1

2

FIGURE 2-13. REMOTE DRIVE CONTROL BOX ASSEMBLY (JULY 1992 TO PRESENT) FIG & ITEM #

PART NUMBER 0253148 0253604

1 0860798 0860831 2

3 4

5 6

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

3536234 3536613 4420037 1701774 1701872 1702291 1701775 4360289 4360475 4060802 4360074 4360340 3300352 4460052 3300047 0960239 Use 1060018 4740120 3300177 0750804 2560116 4711600 3730091 3990001

3120820

DESCRIPTION REMOTE DRIVE CONTROL BOX ASSEMBLY 2WS (July 1992 To October 1992) 4WS (October 1992 To Present) Box, Remote Options: 2WS 4WS Plate, Remote Box Lid Options: 2WS 4WS Tape, Insulation Decal, Remote Box Options: 2WS 4WS (October 1992 to March 1994) 4WS (March 1994 to Present) Decal, Potentiometer Switch, Emergency Stop Options: Prior to S/N 44577 S/N 44577 to Present Shield, Toggle Switch, Toggle Switch, Potentiometer Nut, Special Connector, Strain Locknut Bushing Cable, Control 16/10 (was p/n 1060304) Washer, Nylon Nut, Tinnerman #8 Screw #8 x 1/2 Lg. Knob, Speed Control (Black) Flatwasher 3/8" —————————— Resistor (Not Shown) Diode (Not Shown)

QTY.

REV.

Ref. Ref. Ref.

— 6

T U R N T A B L E

A/R 1 1 1 1 1

A/R A/R 1 1 1 1 1 25 ft.

4 4 4 1 1 1 A/R

2-39

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION

2 T U R N T A B L E

2-40

3120820

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION FIG & ITEM #

PART NUMBER 0252496 0253353 0258730 0252500 0253355 0258731

1

2000083 2000115

2

3 4 5 6 7 8 9

3600164 3600260 3200229 3200228 3200133 3200183 3200227 3200306

3600191 2900660 3600205 3600286 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

3120820

0901829 2120135 2120136 1060044 0641812 4761800 0250069 0642032 3312005 4740242 0701427 4740191 0701215 4832100 4751600 4891600 0641610 0641620 4761600 0100011 0701015 4831700

DESCRIPTION DEUTZ F4L-912 ENGINE ASSEMBLY Standard Engine Prior To October 1992 Standard Engine October 1992 To S/N 38697 Standard Engine S/N 38697 To Present Clean Burn Engine Prior To October 1992 Clean Burn Engine October 1992 To S/N 38697 Clean Burn Engine S/N 38697 To S/N 43911 Engine - Deutz Diesel F4L-912 Engine - Deutz Diesel F4L-912 - Clean Burn Pump Assembly - Sunstrand Options (See Figure 2-17 for Breakdown): 13 Tooth Spline (Prior to S/N 28163) 15 Tooth Spline (S/N 28163 to Present) Motor Support Weldment (Front) Motor Support Weldment (Rear) Mount, Rubber Motor (Front) Mount, Rubber Motor (Rear) Plate, Engine Mounting (Front) Plate, Engine Mounting (Rear) Pump Assembly Options: Pump Used Prior to October 1992 (Not Field Serviceable) Shaft Seal Kit - 3600191 Pump Pump Used October 1992 to S/N 38697 (See Figure 2-18 For Breakdown) Pump Used S/N 38697 to Present (See Figure 2-19 For Breakdown) Bracket, Filter Filter - Charge Pump Element Cable, Battery (Starter to Ground) Bolt 1/2"-13NC x 1 1/2" Lockwasher 1/2" Fuel Shutdown Kit (Includes Mounting Hardware) Bolt 5/8"-11NC x 4" Locknut 5/8"-11NC Flatwasher, Special Bolt, Metric 14mm x 100mm Lockwasher, Metric 14.2mm Bolt, Metric 12mm x 35mm Lockwasher 12mm Flatwasher 3/8" (Prior to S/N 38697) Flatwasher 3/8" (S/N 38697 to Present) Bolt 3/8"-16NC x 1 1/4" (Prior to S/N 38697) Bolt 3/8"-16NC x 1 1/4" (S/N 38697 to Present) Lockwasher 3/8" (Prior to S/N 38697) Loctite #242 (S/N 38697 to Present) Bolt, Metric 10mm x 35mm Lockwasher 6mm

QTY.

REV.

Ref. Ref. Ref. Ref. Ref. Ref. Ref.

B E 4 B E 4

1 1

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

1

1 2 1 2 1 1 1

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

2-41

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

28 29 30 31 32 33

3311401 0641405 4761400 Not Used 0700617 0237627

34

0237635

35 36 37 38 39 40 41 42 43 44 45 46 47

0901402 1320070 1670414 3910812 4770800 3310801 1700821 4843384 4565269 Not Used 4921414 2420073

48 49 to 50 51 52 53 54 to 56 57 58 59 60

4811700 Not Used 4640742 2720042 4832000 Not Used 3290607 Not Used 1320222 3790152

2 T U R N T A B L E

4420001

0252495 0252499 0253354 0258723 0253356 0258729 78

79 80

2-42

4844165 4844238 1670627 1340020 7004214

DESCRIPTION

QTY.

Nut 1/4"-20NC Bolt 1/4"-20NC x 5/8" Lockwasher #1/4"

3 4 4

Bolt, Metric 6mm x 45mm Electrical Panel Assembly (See Items 201-211 for (Breakdown) Throttle Cable Installation (See Items 301-315 for Breakdown) Bracket, Terminal Strip Clamp, Wire Cover, Terminal Strip Screw, Machine #8-32NC x 3/4" Starwasher #8 Nut #8-32NC Decal, Wire Identification Air Intake Weldment Adapter, Exhaust (S/N 38697 to Present)

5 1

Harness, Wiring Gauge, Sender Unit Coupling Installations (See Figure 2-16 for Breakdown) Flatwasher 6mm Valve, Oil Drain Hose, Heater Lockwasher, Metric 10mm Locknut, Metric 6mm (S/N 38697 to Present) Clamp (Not Shown) (S/N 38697 to Present) O-Ring —————————— Tape, Sealant DEUTZ ENGINE INSTALLATION Standard Engine Prior To October 1992 Clean Burn Engine Prior To October 1992 Standard Engine October 1992 To S/N 38697 Standard Engine S/N 38697 To Present Clean Burn Engine October 1992 To S/N 38697 Clean Burn Engine S/N 38697 To S/N 43911 Tube Weldment Prior to October 1992 October 1992 to Present Cover, Base Plate Air Cleaner Assembly Element

REV.

1 1 1 1 2 2 2 1 1 1 1 1 1 9 1 6 in./15cm

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

B B 3 1 2 2

1

1 1 1

3120820

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113

0340002 0080046 0080039 4565655 2720224 1320058 4300031 4761400 3311401 0400020 0236768 0361027 3980006 0400003 0400002 3980003 4751400 3300029 1060031 1060109 1060149 1060132 4300034 4921139 0642022 4752000 4762000 3312001 0641622 4751600 4761600 3311601

114 115 116 117 118 119 120 121

122 123 124 125

3120820

3600050 3600208 0641620 2720271 2750532 2220063 2220720 0641414 1320022 0252866 0253194 4280002 1320059 2180536 3311405

DESCRIPTION Band, Mounting Elbow Elbow Tube Hose 2 3/4" ID x 3" Lg. Clamp Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Battery (Large) Rod, Tie-Down Bar, Hold-Down Seat, Battery Battery (Small) Hold-Down Seat, Battery Flatwasher 1/4" Wingnut 1/4"-20NC Cable, Battery (Large Battery to Ground) Cable, Battery (Large Battery to Starter) Cable, Battery (Starter to Aux. Relay) Cable, Battery (Aux. Relay to Aux. Pump) Stud (Welded on Part) Cable, Battery (Positive to Positive - Batteries) Bolt 5/8"-11NC x 2 3/4" Flatwasher 5/8" Lockwasher 5/8" Nut 5/8"-11NC Bolt 3/8"-16NC x 2 3/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Auxiliary Pump Assembly Options (See Items 501506 for Breakdown): Prior to April 1993 April 1993 to Present Bolt 3/8"-16NC x 2 1/2" Fuel Line (Return) Fuel Line (Supply) Fitting, 90° Fitting, Barbed Bolt 1/4"-20NC x 1 3/4" Clamp Air Inlet Box Assembly Options: Prior to October 1992 October 1992 to Present Neoprene 1/8" x 2" Clamp Fitting, Coupling Locknut 1/4"-20NC

QTY.

REV.

2 1 2 1 1 8 8 6 12 1 4 1 1 1 1 1 A/R 4 1 1 1 1 A/R 1 2 2 2 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

1

2 8 ft./2.4m 10 ft./3m 2 2 13 4 1

30 in./76cm

1 1 13

2-43

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

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

126 127 128 129 130 131 132 133 133 to 137 138

1060031 4751500 4740362 4761500 3535949 0362101 3536008 1320021 Not Used 4751700 0237627

201 202 203 204 205 206 207 208 209 210 211

3740059 3321001 3310801 3530425 3740080 3740067 3300220 0641405 4761400 4791400 3311401 4711400 0237635

301

302 303 304 305 306 307 308 309 310 311 312 313 314 315

2-44

0060023 7008804 7008829 7008821 7008828 0901389 4460302 3450203 4711400 0641409 4751400 0630400 4761500 4831900 3290801 1320041 4761400 4751600 0641406 3311401

DESCRIPTION

QTY.

Cable, Battery (Small Battery to Ground) Flatwasher 5/16" Washer, Fender Lockwasher 5/16" Plate, Hose Cover Bar, Spacer Plate, Shield Clamp, Muffler

1 2 6 2 1 1 1 1

Flatwasher 7/16" (S/N 38697 to Present)

1

ELECTRICAL PANEL ASSEMBLY Relay Nut #10-32NF Nut #8-32NC Plate, Mounting Relay, Sealed Relay Nut, Special Bolt 1/4"-20NC x 5/8" Lockwasher 1/4" (Prior to S/N 37522) Starwasher 1/4" (S/N 37522 to Present) Nut 1/4"-20NC Flatwasher 1/4" THROTTLE CABLE INSTALLATION Actuator Bellows, Rubber Board, Circuit Motor, Drive Cable, Throttle Bracket, Throttle Cable Stop, Terminal Pin, Cotter 1/16" x 3/4" Flatwasher 1/4" Narrow Bolt 1/4"-20NC x 1 1/8" Flatwasher 1/4" Bolt, Metric 8mm - 1.25 x 90mm Lockwasher 5/16" (Prior to S/N 37522) Lockwasher 8mm (S/N 37522 to Present) Nut, Metric 8mm - 1.25 Clamp Lockwasher 1/4" Flatwasher 3/8" Bolt 1/4"-20NC x 3/4" Nut 1/4"-20NC

Ref.

REV.

7

1 3 1 1 1 2 6 7 7 7 7 6 Ref.

4

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 1 3 2 1 1

3120820

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 0252694

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

451 452 453 454 455 456 457 458 459 460 461 462 463 464

3220080 0340041 0641406 4751400 4761400 3311401 4565269 Not Used 4565663 4844169 4565267 4565664 1320011 4100025

EXHAUST INSTALLATION (PRIOR TO OCTOBER 1992)

QTY.

REV.

Ref.

—

Muffler Band, Mounting Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Lockwasher 1/4" Nut 1/4"-20NC Adaptor, Exhaust

1 2 8 4 8 8 1

Tube, Exhaust Snorkel Elbow, Exhaust Tube, Flex Exhaust Clamp, Muffler - 2 1/2" Sleeve, Fiberglass

1 1 1 1 4 42 in./1m

0255613

EXHAUST INSTALLATION (OCTOBER 1992 TO PRESENT)

1320011 3220082 3220088 0340041 0641408 4751400 3311405 0901849 4565751 3311405 4751400 4844235 1120423 Not Used 0641408

Clamp, Muffler Muffler (Standard) Muffler (Exhaust Purifier - Optional Not Shown) Band, Mounting Bolt 1/4"-20NC x 1" Flatwasher 1/4" Locknut 1/4"-20NC Bracket, Exhaust Mounting Tube, Exhaust Locknut 1/4"-20NC Flatwasher 1/4" Stack, Exhaust Cap, Rain

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

Bolt 1/4"-20NC x 1"

4

3600050

501 7004249 7004412 502 7004248 7000482 503 7010923 7004414

3120820

DESCRIPTION

AUXILIARY PUMP ASSEMBLY - BARNES OR STONE PUMP (PRIOR TO APRIL 1993) Coupling Options: Barnes Brand Pump Stone Brand Pump Motor Options: Barnes Brand Pump Stone Brand Pump Pump Options: Barnes Brand Pump Stone Brand Pump

Ref.

Ref.

S E C T I O N 2

2

D

1

1

1

2-45

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER 3600208

504 505 506

7013711 7013710 7013753 7013712

2 0255152 0255274

T U R N T A B L E

0270566 0239119 601

4360179

602 603

2180360 4360065 4360065 4360037

604 2180749 Not Required 2180730

0257216 701 702 703 704 705 706 707 708 709 710 711 712 713 714

2-46

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

DESCRIPTION AUXILIARY PUMP ASSEMBLY (APRIL 1993 TO PRESENT) Coupling Motor 12VDC Brush Kit Pump ENGINE DISTRESS INSTALLATION Engine Distress Installation Low Oil Pressure Shutdown Installation (Prior to S/N 54482) Low Oil Pressure Shutdown Installation (S/N 54482 to Present) Generator Installation - 110 Volt Switch, Temp Head (Located Under Top Engine Cover) (Engine Distress Installation Only) Fitting, Tee Switch, Oil Pressure Options: Engine Distress Installation Low Oil Pressure Shutdown Installation Generator Installation - 110 Volt Fitting Options: Fitting, 45° (Engine Distress Installation and Low Oil Pressure Shutdown S/N 54482 to Present) Low Oil Pressure Shutdown Installation Prior to S/N54482 Fitting, Adapter (Generator Installation - 110V) BATTERY DISCONNECT SWITCH INSTALLATION (S/N 25609 TO PRESENT) Fuse, 35 Amp Fuse Holder Screw #10-24NC x 1” Flatwasher #10 Locknut #10-24NC Harness Switch, Disconnect Bracket Cable, Battery Decal, Battery Connect and Disconnect Weld Stud 5/16”-18NC x 1” Flatwasher 5/16” Lockwasher 5/16” Nut 5/16”-18NC

QTY.

REV.

Ref.

A

1 1 1 1 Ref. Ref. Ref.

3 4

Ref.

1/B

Ref.

11

1 1 1

A/R 1 0 1

Ref.

A/2

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

3120820

SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION ENGINE COMPONENTS

7000663 7000872 Use 7020413 7020420 70001927 7000697 7000698 7026125 Use 7029274 Use 7029276 7014503 7016309 7016330 Use 7019607 7016364 7019607 7020208 7020400 7020401 7020402 7020403 7020405 7020407 7020409 7020421 7020422 7020423 7020432 7020433 7020498 7026173 7027250 70001361 70001928 70002252 70002253 70002254 70002258 70002259

3120820

Alternator (Bosch) Alternator (Delco-Remy) Starter Options: Starter (New) ( was p/n 7000661) Starter ( Remanufactured) Manifold, Exhaust Belt, Blower Belt, Alternator Flange, Exhaust Filter, Fuel (was p/n 7000649) Filter, Oil (was p/n 7000648) Filter, Oil (Case of 12) Washer, Copper Sealing Switch, Oil Pressure Switch, Solenoid (was p/n 7016341) Pump, Fuel Lift Solenoid, Fuel Shutdown Gear, Ring Washer, Fuel Line Washer Washer, Fuel Line Washer, Fuel Line Washer, Oil Plug Gasket, Lift Pump Dipstick Nozzle, Injector Injector Gasket, Injector Tip Kit, Lift Pump Repair Gasket Fan Switch, Broken Belt Spring, Tension (Actuator) Pump, Fuel Injection Gasket, Exhaust Manifold Ring, Head Fire Gasket Set, Complete Engine Kit, Piston/Cylinder Bolt, Cylinder Head Washer, Cylinder Head Bolt

QTY.

REV.

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

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

2-47

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ

2 T U R N T A B L E

2-48

3120820

SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ FIG & ITEM #

PART NUMBER 0239119

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

3120820

4843133 Not Used 2460011 7012558 7020193 7026199 7020108 7020109 7012513 7012514 7020110 7020111 7020190 7003657

Use 2420203 Use 4360542 4460190 2920162 7020191 3520028 0480050 4340511 3580109 Not Used 2860012 0700821 4761500 0681610 4751500 0641507 3251476 4460023 4300031 4761400 Not Used 4920039 Not Used Not Used 2180360 Not Used Not Used 4360037 3311401

DESCRIPTION GENERATOR INSTALLATION- DEUTZ

QTY.

REV.

Ref.

11

Bracket, Generator Mounting

1

Generator and Control Box Assembly Generator Cord, Power Armature Brush Holder, Brush Cap, Brush Holder Fan End, Bell Front End, Bell Rear Bearings Box, Control Note: Replacement Generator p/n 7012558 comes standard with Pulley p/n 3580134. This Pulley may not be correct for all applications.

Refer to Pulley options below.

Voltmeter (was p/n 7010699) Breaker, Circuit (was p/n 7020194) Receptacle Lamp Switch, Toggle Plug, Hole V-Belt Support, Adjustment Pulley

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

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

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

1 2

S E C T I O N

2-49

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (CONTINUED) FIG & ITEM #

PART NUMBER

27 28 29

2180730 4761600 4751600

DESCRIPTION Fitting, Adapter (Not Shown - Located on Engine) Lockwasher 3/8" Flatwasher 3/8"

QTY.

REV.

1 2 4

2 T U R N T A B L E

2-50

3120820

SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (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

3120820

2-51

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-16. PUMP COUPLING INSTALLATION

2 T U R N T A B L E

2-52

3120820

SECTION 2 TURNTABLE FIGURE 2-16. PUMP COUPLING INSTALLATION FIG & ITEM #

PART NUMBER

DESCRIPTION PUMP COUPLING INSTALLATIONS

0239954

1

2 3 4

1660170 1660174 1660175 0701014 4832000 0080164

0250600 0256849 101

102 103 104 105

1660183 1660233 0701014 4832000 0080164 0701010 3020021

3120820

PUMP COUPLING INSTALLATION - LOVEJOY (STANDARD PARTS WHEN EQUIPPED) Note: Used with 13 tooth pump.

Coupling, Pump - Lovejoy Disc, Coupling Hub, Coupling Bolt, Metric 10mm x 30mm Lockwasher, Metric 10mm Adaptor, Pump Mounting Plate PUMP COUPLING INSTALLATION - HAYES 13 Tooth Pump 15 Tooth Pump Coupling, Pump - Hayes Options: 13 Tooth Pump 15 Tooth Pump Bolt, Metric 10mm x 30mm Lockwasher 10mm Plate, Adaptor Bolt, Metric 10mm x 20mm ——————————— Grease

QTY.

REV.

Ref.

Ref.

—

1 1 1 18 18 1 Ref. Ref. Ref.

S E C T I O N 2

— —

1

12 18 1 6 A/R

2-53

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND

2 T U R N T A B L E

2-54

3120820

SECTION 2 TURNTABLE FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND FIG & ITEM #

PART NUMBER 3600164 3600260

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

3120820

7007413 7007414 Kit 7007416 7007417 Kit 7007419 Not Used Not Used 7007420 7007208 7007421 Not Used 7007422 7007423 7007424 Not Used 7007425 Kit Kit Kit Not Used Kit Kit Kit Kit Kit Kit 7007435 7007436 7007437 7007438 7007439 7007440 7007441 7007442 Kit 7007444 7007445 Kit Kit Kit 7007449 Kit

DESCRIPTION PISTON PUMP ASSEMBLY - SUNSTRAND 13 Tooth Pump Spline (Prior to S/N 28163) 15 Tooth Pump Spline (S/N 28163 to Present)

QTY.

REV.

Ref. Ref. Ref.

A —

Shim Kit - Relief Valve Plug O-Ring Spring, Relief Valve Valve, Relief O-Ring Plug

1 1 1 1 1 2 2

Plug Plug Screw

2 2 10

Gasket, Servo Cover Nut, Special Cover, Adjustment

2 1 1

Bearing, Needle Ring, Retaining Washer Spring

1 1 1 1

Washer Retainer Pin, Slipper Holddown Piston Assembly Guide, Slipper Guide, Retainer Pin, Spring Screw - 12 Point Head Bearing, Ball Ring Ring Pin, Spring Handle, Pin Sleeve, Bearing Gasket, Front Cover Pin Plug, Expansion Pin O-Ring Ring, Load Temper Housing, Pump Ring, Back-Up

1 1 3 7 1 1 1 1 1 2 2 2 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

2-55

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND (CONTINUED) FIG & ITEM #

PART NUMBER

45 46 47 48 49 50 51 52 53 54 55 56 57

Kit Kit 7007453 7007208 7007454 Kit 7007456 7001438 Kit 7007458 Kit Kit

2 T U R N T A B L E

58 59 60 61 62 63 64 65 66 67

68 69 70 71 72 73 74 75 76 77 78 79 80 81

82 83 84 85

2-56

7007461 7010121 Kit Kit Kit Kit 7007466 Kit 7007468 7007469 7007470 7007471 7007490 7007491 7007492 7007482 7007483 7007484 7007485 7007486 7007487 7007488 7007499 Kit 7007494 Kit 7007472 7007473 7007474 7007496 7007497 7007498 7007478 7001498 Kit Kit

DESCRIPTION O-Ring Cover, Gerotor Bolt, Hex Plug Cover, Front Block, Cylinder Screw - 12 Point Head Washer Swashplate Journal, Bearing Seal, Lip O-Ring Shaft, Main Pump 13 Tooth Spline (Prior to S/N 30660) 15 Tooth Spline (S/N 30660 to Present) Plate, Valve Gerotor Assembly Pin Key, Woodruff Adaptor, Remote Filtration (Without Bypass) O-Ring Screw Screw Plug Cover, Servo (With Adjuster) Stop, Servo (Not Shown) Nut, Special (Not Shown) Ring, External (Not Shown) Cover, Servo (Without Adjuster) Guide, Spring Stop, Servo Spring Screw Guide, Spring Ring, Retaining Locknut Ring, Piston Piston, Servo O-Ring Valve, By-Pass Valve, Pressure Release (Includes Item 6) Control, Dual Oil-Filled Coil Assembly (Pilot) Plug (Pump) Plug (Valve Harness) Screw Screw O-Ring O-Ring

QTY.

REV.

1 1 3 1 1 1 6 10 1 1 1 1 1

1 1 1 1 1 3 2 2 1 1 2 2 2 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 2 2 2 1

3120820

SECTION 2 TURNTABLE FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND (CONTINUED) FIG & ITEM #

PART NUMBER

86 87 88 89

7007475 7007477 7007476 7010120

2900752

7007412 2900826 2900827

3120820

DESCRIPTION Plug, Orifice/Screen -.156 Plug, Orifice -.37 Adapter, Auxiliary Pump Spacer/Gasket —————————— Seal Kit - Complete (Includes Items 3,6,14,15,37,41,42, 44,45,55,56,63,76,78,84 and 85) Seal Kit - Servo Piston (Includes Items 76 and 78) Charge Pump Kit (Includes Items 41,42,46,59,60,61) Cylinder Block Kit (Includes Items 19-28, 40,50,53,55,58)

QTY.

REV.

1 2 1 1

S E C T I O N

1

2

1 1

T U R N T A B L E

1

2-57

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-18. PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697)

2 T U R N T A B L E

2-58

3120820

SECTION 2 TURNTABLE FIGURE 2-18. PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697) FIG & ITEM #

PART NUMBER 3600205

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

7010955 Kit 7010956 Kit Kit 7010957 Kit 7010996 7010959 Not Used 7010997 7010998 7010960 7010961 7010953

3120820

DESCRIPTION PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697)

QTY.

REV.

Ref.

—

Ring, Retaining

1

Flange, Mounting

1

Bearing O-Ring Housing, Gear Pin, Dowel

2 2 1 4

Gear, Idler Gear, Drive Cover, End Bolt —————————— Seal Kit (Includes Items 2,4,5 and 7)

1 1 1 4

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

1

2-59

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-19. PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT)

2 T U R N T A B L E

2-60

3120820

SECTION 2 TURNTABLE FIGURE 2-19. PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT) FIG & ITEM #

PART NUMBER 3600286

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

7010105 Not Serviced Not Serviced 7010103 7010126 7010125 Kit Kit 7010124 7010104 7010127 Kit Kit

7007489

3120820

DESCRIPTION PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT)

QTY.

REV.

Ref.

—

Bearing/Bushing Housing Flange, Mounting Cover, End Gear, Drive Gear, Idler Ring, Anti-Extrusion Seal Bolt Ring, Retaining Pin, Dowel Seal, O-Ring Seal, Shaft

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

—————————— Seal Kit (Includes Items 7,8,12 and 13)

1

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

2-61

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-20. TANKS INSTALLATION

2 T U R N T A B L E

2-62

3120820

SECTION 2 TURNTABLE FIGURE 2-20. TANKS INSTALLATION FIG & ITEM #

PART NUMBER 0252524

1 4400279 4400386 2

4400340

3 4 5 6 7 8 9

0641614 4711600 3311605 0641616 1340046 2220893 2120134 2120129 4300034

4400279 4400386 101

102 103 104

105 106 107 108 109 110 111 112

4400280 4400387 Not Used 2180467 4562663 4562516 1320022 2200052 0100020 4060574 3311401 4761400 4751400 3300205 4400340

201 202 203 204 205 206

3120820

4400341 Not Used 4740338 2420080 7016664 1670625 Not Used

DESCRIPTION TANKS INSTALLATION Fuel Tank Assembly Options (See Items 101-112 for Breakdown): Prior to June 1995 June 1995 to Present Hydraulic Oil Tank Assembly (See Items 201-216 for Breakdown Bolt 3/8"-16NC x 1 3/4" Flatwasher 3/*’ Locknut 3/8"-16NC Bolt 3/8"-16NC x 2" Breather Fitting Filter, Hydraulic Element —————————— Stud, Weld FUEL TANK ASSEMBLY Prior To June 1995 June 1995 To Present Tank Weldment Options: Prior to June 1995 June 1995 to Present Fitting, 90° Tube, Sight Options: Prior to February 1993 February 1993 to Present Clamp Plug, Pipe - 1/4" Sealant, Thread (Not Shown) Protector, Gage Nut 1/4"-20NC Lockwasher 1/4" Flatwasher 1/4" Nut, Retainer 5/16"-18NC HYDRAULIC OIL TANK ASSEMBLY

QTY.

REV.

Ref.

5

1

2

1 4 15 8 3 1 1 1 1 4 Ref. Ref. Ref.

B 2

1

2 15 in./38cm

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

Tank Weldment

1

Washer, Sealing Gage, Level Washer, Sealing Lid

6 1 2 1

S E C T I O N

B

2-63

T U R N T A B L E

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-20. TANKS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

207 208 209 210 211 212 213 214 215 216

3520022 1340045 3960371 3300205 2180606 2120104 3311401 4761400 0100020 4751400

2 T U R N T A B L E

0255869

301 302

4845158 3960465

4400279 4400386 0257365 0257366 0258626 401 1120314 1120367 1120512

2-64

DESCRIPTION Plug, Magnetic Basket, Strainer Gasket Nut, Retainer 5/16"-18NC Nipple, Pipe Filter Nut 1/4"-20NC Lockwasher 1/4" Sealant, Thread (Not Shown) Flatwasher 1/4" FUEL FILL EXTENSION KIT Note: For use on fuel tanks built prior to June 1995. Tanks built June 1995 to present are already equipped with extension.

Fill Tube Extension Weldment Seal FUEL CAP ASSEMBLY - STANDARD Prior To June 1995 June 1995 To S/N 30382 S/N 30382 to Present with Standard Cap S/N 30382 to Present with Red Protectoseal Cap S/N 30382 to Present with Blue Protectoseal Cap Cap, Fill Options: Standard Cap Red Protectoseal Cap Blue Protectoseal Cap

QTY.

REV.

1 1 1 3 1 1 14 14 A/R 14 Ref.

—

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

B 2 1 2 1

1

3120820

SECTION 2 TURNTABLE FIGURE 2-20. 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

3120820

2-65

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-21. HOOD INSTALLATION

2 T U R N T A B L E

2-66

3120820

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

PART NUMBER 0252589 0253362

1 3380399 3536417 2 4844115 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

3120820

3380378 3380419 3380400 4844087 1780172 4844078 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

DESCRIPTION

S E C T I O N

QTY.

REV.

HOOD INSTALLATION Prior To October 1992 October 1992 To Present Note: Replacement Decals Must be Ordered Separately - See Section 8.

Ref. Ref. Ref.

B 5

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

1

2

1

T U R N T A B L E

Ref.

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

1 1 41 22 1

2-67

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-21. HOOD INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

0641512 0940036 0901197 Not Used 0641508 4761500 3200222 2940042 Not Used Not Used 4300032 3536414 3536415 3535951 3820018 2820059 2820058

53

2820053

54

2820057

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

2-68

0140032 0641406 4751400 3311405

DESCRIPTION

QTY.

Bolt 5/16"-18NC x 1 1/2" (October 1992 to Present) Bumper, Door Bracket, Door Stop

5 2 2

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

4 4 2 5

Stud (Welded on Part) Plate, Seal (October 1992 to Present) Plate, Seal (October 1992 to Present) Plate, Hinge Shield Rivet Acoustical Foam - 33 x 20 (October 1992 to Present) Acoustical Foam - 20 x 17 (October 1992 to Present) Acoustical Foam - 6 3/4" x 14 3/4" (October 1992 to Present) Acoustical Foam - 24" x 16 3/4" (October 1992 to Present) —————————— Loctite #242

5 1 1 1 10 1 1

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

REV.

1 1

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

3120820

SECTION 2 TURNTABLE FIGURE 2-21. HOOD 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

3120820

2-69

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-22. OIL COOLER INSTALLATION

2 T U R N T A B L E

2-70

3120820

SECTION 2 TURNTABLE FIGURE 2-22. OIL COOLER INSTALLATION FIG & ITEM #

PART NUMBER 0252906

1 2

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

3120820

4844177 3620015 3620003 2060012 0641508 4751500 4761500 3311501 4751600 1320060 0731006 4751000 4761000 3740080 4460374 4460375 4300048 4751800 4761800 3311801 2220369 2220282 4360181

DESCRIPTION OIL COOLER INSTALLATION (OPTIONAL) Bracket, Oil Cooler Oil Cooler Assembly Options: Prior to October 1992 October 1992 to Present Fan, Oil Cooler Bolt 5/16"-18NC x 1" Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC Flatwasher 3/8" Clamp Bolt #10-32NF x 3/4" Flatwasher #10 Lockwasher #10 Relay Plug Terminal Stud (Welded on Part) Flatwasher 1/2" Lockwasher 1/2" Nut 1/2"-13NC Fitting, Tee Fitting, Reducer Switch, Temperature

QTY.

REV.

Ref.

3

1 1

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

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

2-71

S E C T I O N

SECTION 2 TURNTABLE FIGURE 2-22. OIL COOLER INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

2 T U R N T A B L E

2-72

3120820

SECTION 3 BOOM TABLE OF CONTENTS FIGURE

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

3120820

DESCRIPTION

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

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

JIB BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTEND-A-REACH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN EN280 SPECS & CE SPECS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PAGE

3-2 3-10 3-14 3-16 3-18

S E C T I O N 3

3-22 3-24

B O O M

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

3120820

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

3120820

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 ASSEMBLY COMPONENTS INSTALLATION BOOM ASSEMBLIES (STANDARD PARTS)

1 2

3

3

B O O M

0800765 0800766 3532549 0800767 3535816

4 0800768 0801155 5 1682030 1682820 1683701 1682030 1682820 6 7 8 9 10 11 12 13

3-4

1260235 1260234 1260275 1260233 3580139 0238927 0961293 0237151 0961353 0239606 0961369

14

0239268

15 16 17 18 19 20 21 22

3421286 1360171 3421279 3450408 3313002 3300244 3312602 3300243

23

0238901

24 25 26 27 28

Not Used Not Used 3421570 4751600 3450303

29

0238919

Base Weldment Inner Mid Weldment Plate, Skid (Rear Bottom) Outer Mid Weldment Plate, Skid (Rear Bottom) Fly Weldment Options: Fly Weldment (Prior to S/N 37026) Fly Weldment (S/N 37026 to present) Telescope Cylinder Assembly Options (See Section 5 for Breakdown): Standard Boom Prior To November 1992 Standard Boom November 1992 To S/N 38697 Standard Boom S/N 38697 To Present Boom with Chip Covers Prior To November 1992 Boom with Chip Covers November 1992 To Present Chain, Extend - Outer Mid BL866 Chain, Extend - Fly BL823 Chain, Retract - Fly BL446 Chain, Retract - Outer Mid BL446 Sheave - Outer Mid Extend Chain Sheave Assembly - Fly Extend Chain Bushing, Bronze (1 Per Sheave) Sheave Assembly - Outer Mid Extend Chain Bushing, Bronze (1 Per Sheave) Sheave Assembly - Fly Retract Chain Bushing, Bronze (1 Per Sheave) Adjustable Clevis Assembly - Outer Mid Retract Chain (See Figure 3-2 for Breakdown) 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 Retract Chain (See Figure 3-2 for Breakdown)

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

QTY.

REV.

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

1 set 1 set 1 set 1 set 1 3 3 2 2 2 2

— 6

B B —

1 4 1 1 2 1 1 2 2 1

2 35 8 1

3120820

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

PART NUMBER

DESCRIPTION

QTY.

30 31 32 33 34

3421280 4751000 3450202 3421629 3420659

6 10 8 2 2

35

0238945

Pin, Attach Flatwasher #10 Pin, Cotter 1/16" x 1/2" Pin, Attach Pin, Attach Adjustable Clevis Assembly - Outer Mid and Fly Retract Chain (See Figure 3-2 for Breakdown)

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Not Used 3300240 3312002 4761600 Not Used 4843105 3421539 3450814 4070616 0560689 2160002 3421778 4740307 3421290 3422040 4740311 3951606 Not Used 3421497 3421293 3340475

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

2 2 100

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 Washer, Thrust Pin, Sheave Pin, Sheave Washer, Thrust Setscrew 3/8"-16NC x 3/4"

1 1 2 A/R 2 7 1 12 2 2 12 5

57 58 59

4070535 4070536 3340263

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

4070544 4070545 3340563 4070615 1120019 0721003 4761000 0641605 0641607 0641609 4761800 0641808 4751800 0641614 0641630 3340496 4070602

3120820

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

REV.

S E C T I O N

2

3 B O O M

2 1 6 A/R A/R 9 A/R A/R 4 A/R 4 12 12 2 18 52 1 1 1 7 6 2 A/R

3-5

S E C T I O N

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

PART NUMBER

77 78 79 80 81 82

4070603 0641608 0641636 0239607 0961370 0901700 3340506

83

3340500

84 85

4070708 4070709

86

3340502

87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102

4070710 4070711 4844126 Not Used 3311601 0641610 1180287 4280242 1320121 0641404 3450806 3841013 3860050 3840956 2660042

3 B O O M

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

3-6

3840957 0902470 1320155 4843080 1060394 Not Used 1060392 3840844 4340519 0880090 1180254 Not Used 4843107 4843087 3532793 4060685 4060684 4340632 4300098 3311401 4751400

DESCRIPTION Shim 1/16"/1.6mm Bolt 3/8"-16NC x 1" Bolt 3/8"-16NC x 4 1/2" Sheave Assembly - Safety Chain Bushing, Bronze Bracket, Wear Pad 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 Tube, Hose and Cable (Left Side) Nut 3/8"-16NC Bolt 3/8"-16NC x 1 1/4" Carrier Tube Weldment (Left Side) Strip, Reinforcing Clamp (Prior to S/N 51528) Bolt 1/4"-20NC x 1/2" Pin, Cotter 1/4" x 1 1/2" Rod, Roller Roller Hanger (Left Side) Holder Rod, Hose Retainer (Left Side) Options: Prior to S/N 37026 S/N 37026 to Present Clamp, U-Bolt Bracket, Support - Carrier Wear Pad (Left Side) Cable, Electrical - 10/4 Cable, Electrical - 16/36 Hanger (Right Side) (Prior to August 1992) Support (Prior to August 1992) Brace (Prior to August 1992) Carrier Tube Weldment (Right Side) Cover, Boom End (Prior to September 1992) Cover, Boom End (September 1992 to Present) Plate, Hose Cover Shield, Hose and Cable (Right Side) Shield, Hose and Cable (Right Side) Support, Hydraulic Line Stud (Welded on Part) Nut 1/4"-20NC Flatwasher 1/4"

QTY.

REV.

A/R 8 4 1 1 1 2 10 A/R A/R 8 A/R A/R 1 20 6 1 2 4 2 2 2 2 1 1 1 1 1 2 1 149 ft./45m

149 ft./45m

1 4 4 1 1 1 2 1 8 8 18 21

3120820

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

PART NUMBER

121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138

4761400 4300032 3840858 4562516 4340453 0181175 4761500 0641510 3311501 4751500 4340520 4740349 3421632 3536001 3421571 1380124 4920385 3840975

139 140 141 142 143 144

3430408 3450203 3421628 1260254 1360234 4160098

145 146 147 148 149

4712000 0361727 1260261 1360223 1060016

150 to 152 153 154 155 156 157 158 159 160 161

3120820

Not Used 3340494 4070600 4070601 1670321 Not Used 0741608 3520029 4740304 0641407

DESCRIPTION Lockwasher 1/4" Stud (Welded on Part) Rod, Tube Retainer Tube Support, Bracket Angle (Prior to August 1992) Lockwasher 5/16" Bolt 5/16"-18NC x 1 1/4" Nut 5/16"-18NC Flatwasher 5/16" Support (Prior to August 1992) Washer, Special Pin (Prior to March 1993) Plate, Ramp (Left Side) Pin, Attach Clip, Retainer (Prior to May 1995) Wire, Safety (Prior to May 1995) Rod, Hose Retainer (Right Side) (Prior to March 1993) Pin, Clevis 1/4" x 1" Pin, Cotter 1/16" x 3/4" Pin, Attach Chain, Safety (Upper) Clevis, Chain Washer, Belleville Note: Top of base section requires qty 75 on both standard machines & machines with broken chain limit switch (See Figure 3-6). Standard machines require qty 27 at the bottom of inner mid section. Machines with broken chain limit switch require the standard qty 27 plus an additional qty 48 per Figure 3-6 for a total qty of 75 at bottom of inner mid section.

Flatwasher 5/8” (Narrow) Bar Chain, Safety (Lower) Clevis, Chain Cable, Electrical - 16/3 Options: Prior to S/N 47227 S/N 47227 to Present

QTY.

REV.

18 8 1 1 1 1 3 3 3 6 2 1 1 1 2 34

3 B O O M

17.6’/5.4m

1 1 1 2 1 1 104

2 1 1 1 A/R 50 ft./15.3m 30 ft./9.1m

Pad, Wear (Inner Mid Front Bottom) Shim 1/8"/3.2mm Shim 1/16"/1.6mm Cover (Prior to S/N 40599)

2 A/R A/R 1

Screw, Countersunk 3/8"-16NC x 1" Plug, Hole (Prior to S/N 47227) Washer, Spacer Bolt 1/4" - 20 NC x 7/8"

1 4 2 2

S E C T I O N

3-7

S E C T I O N

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

PART NUMBER

162

1670836

163

0641611 0100011

3

0800764 0801158 0800805 0801160

B O O M

201 201A

Use 1001119696

201B 7006193 7006143 201B (cont’d)

7006138 7006165 7016520 7016531

201C 70003143 70003144

201D 201E

1180296 7006196 7006143 7006138

202 202A

Use 1001099842

202B 7006153 7006143 7006138

3-8

DESCRIPTION Cover (Not Shown) Located on Bottom of Boom Sections) Bolt 3/8"-16NC x 1 3/8" (S/N 40599 to Present) —————————— Loctite #242 BOOM ASSEMBLY (VARIABLE PARTS) Boom Without Chip Covers (Prior To S/N 37026) Boom Without Chip Covers (S/N 37026 To Present) Boom With Chip Covers (Prior To S/N 37026) Boom With Chip Covers (S/N 37026 To Present) Carrier (Left Side) Options: Carrier Without Chip Covers (was p/n 1180286 Gemco is Original Equipment/Gortrac is Service Replacement) Gemco Power Track Replacement Parts : Repair Section - 1 Foot 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) Kit, Rod Carrier (Includes 1 rod, 1 sleeve & 2 screws) Rod w/Roll Pin Clamping Carrier Assembly (Includes 2 link pins, 1 clamping carrier, 1 clamping stiffener, 1 bolt, 1 nut & 1 lockwasher) Gortrac Power Track Replacement Parts: 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) Carrier With Chip Covers Gemco Power Track Replacement Parts : Repair Section - 1 Foot 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) Carrier (Right Side) Options: Carrier Without Chip Covers (was p/n 1180236 Gemco is Original Equipment/Gortrac is Service Replacement) Gemco Power Track Replacement Parts : Repair Section - 1 Foot 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)

QTY.

REV.

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

11 5 10 5

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

A/R A/R A/R

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

3120820

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

PART NUMBER

202B (cont’d)

7006165 7016520 7016531

202C 70002008 70002009

202D 201E

1180258 7006145 7006143 7006138

0252764/1282060

301 302

3120820

4420017 4420015

DESCRIPTION Kit, Rod Carrier (Includes 1 rod, 1 sleeve & 2 screws) Rod w/Roll Pin Clamping Carrier Assembly (Includes 2 link pins, 1 clamping carrier, 1 clamping stiffener, 1 bolt, 1 nut & 1 lockwasher) Gortrac Power Track Replacement Parts: Repair Section (Includes 1 set of attaching hardware) (1001099842 Power Track Only) Mounting Bracket Kit (Includes 4 mtg feet & hardware to attach to track) (1001099842 Power Track Only) Carrier With Chip Covers Gemco Power Track Replacement Parts : Repair Section - 1 Foot 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) RADIUS LIMIT TAPE INSTALLATION Tape - Red Tape - White

QTY.

REV.

A/R A/R 1

S E C T I O N

A/R A/R

3

A/R

B O O M

1 A/R A/R 4 A/R

Ref.

3

6 in./15.3cm 6 in./15.3cm

3-9

S E C T I O N

SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES

3 B O O M

3-10

3120820

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

PART NUMBER

0238945

1 2 3 4 5 6 7 8

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

0630409 1360206 3532410 3421535 3421534 3450506 4740111

0239268

301 302

3840945 1360208

303

0238900

0100003

0238900

401 402

3120820

1360207 1360206

DESCRIPTION

QTY.

CHAIN ADJUSTER ASSEMBLIES

Ref.

CHAIN ADJUSTER ASSEMBLY (OUTER MID AND FLY 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) Eyebolt Clevis Plate Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Washer, Thrust CHAIN ADJUSTER ASSEMBLY (OUTER MID RETRACT) Eyebolt Clevis Plate Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Washer, Thrust CHAIN ADJUSTER AND ROD ASSEMBLY (OUTER MID RETRACT) Rod Clevis, Rod Chain Adjuster Assembly (See Items 401-407 for Breakdown) —————————— Loctite #277 CHAIN ADJUSTER ASSEMBLY (OUTER MID RETRACT) Clevis, Rod Clevis, Chain

Ref.

REV.

—

1 1 2 2 1 2 2 2 Ref.

3

—

1 2 2 1 2 3 2

Ref.

—

1 2 2 1 2 3 2

Ref.

B

1 1 1

A/R

Ref.

S E C T I O N

B

1 2

3-11

B O O M

S E C T I O N

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

PART NUMBER

403 404 405 406 407

3532410 3421535 3421534 3450506 3534436

DESCRIPTION Plate, Chain Adjuster (Top) Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Plate, Chain Adjuster Plate (Bottom)

QTY.

REV.

1 1 2 3 1

3 B O O M

3-12

3120820

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

3120820

3-13

S E C T I O N

SECTION 3 BOOM FIGURE 3-3. JIB BOOM INSTALLATION

3 B O O M

3-14

3120820

SECTION 3 BOOM

1

S E C T I O N

1

3

FIGURE 3-3. JIB BOOM INSTALLATION FIG & ITEM #

PART NUMBER 0252658 0258414

1 0800769 0801156 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

3422041 3422727 3323403 3422053 3422679 3420592 3451012 0901835 4360277 4360307 4460049 0721016 3311005 4751000 0641615 3311605 1320184 3535978 1670635 4300076 3311602 4751600 3532793 4300032 3311405 4751400 4060803 2880814 Not Required 0962181

3120820

DESCRIPTION JIB BOOM INSTALLATION OPTIONS: Prior To S/N 37026 S/N 37026 To Present Boom, Jib Options: Prior to S/N 37026 S/N 37026 to Present Pin (Left Side Attach) Options: Prior to S/N 37026 S/N 37026 to Present Nut, Slotted 1 1/2" x 12NF Pin (Right Side Attach) Options: Prior to S/N 37026 S/N 37026 to Present Hairpin Pin, Cotter 5/16" x 3" Bracket, Limit Switch Switch, Limit Head, Switch Connector, Strain Relief Screw, Machine #10-24NC x 2" Locknut #10-24NC Flatwasher #10 Bolt 3/8"-16NC x 1 7/8" Locknut Clamp, Hose and Cable Plate Cover, Hose and Cable Stud (Welded on Part) Nut, Jam 3/8"-16NC Flatwasher 3/8" Plate, Hose Cover Stud (Welded on Part) Locknut 1/4"-20NC Flatwasher 1/4" Trim, Flexible Keystock (Welded on Part) Bushing, Garmax Prior to S/N 37026 S/N 37026 to Present

QTY.

REV.

Ref. Ref. Ref.

4 1

B O O M

1 1

1 1 1 1 1 1 2 2 2 2 6 2 2 1 4 4 4 1 4 4 4 10 in.

2 A/R 0 2

3-15

S E C T I O N

SECTION 3 BOOM FIGURE 3-4. EXTEND-A-REACH INSTALLATION

3 B O O M

3-16

3120820

SECTION 3 BOOM FIGURE 3-4. EXTEND-A-REACH INSTALLATION FIG & ITEM #

PART NUMBER 0252610

1 2

3 4

4844092 0960565 4844093 0961654 0960565 4844094 0961654 4844095 1320051

5 1682635 1683725 6

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

1682642 1682753 1683493 3422087 3422077 3422079 3422081 3422083 3422037 Not Used 2160002 0641608 4761600 0641610 3311605 3422085 1320184 3535978 1670634 4300076 3311602 4751600 0100011

3120820

DESCRIPTION EXTEND-A-REACH INSTALLATION

QTY.

REV.

Ref.

5

Snoot Weldment Bushing, Bronze Level Link Weldment Bushing, Bronze (Platform End) Bushing, Bronze (Jib 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 Options: (See Section 5 for Breakdown) Prior to April 1992 Prior to S/N 29913 S/N 29913 to Present 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)

1 4 1 2 2 1 2 1 1

Fitting, Grease Bolt 3/8"-16NC x 1" Lockwasher 3/8" Bolt 3/8"-16NC x 1 1/4" Locknut 3/8"-16NC Pin, Attach (Level Cylinder - Rod End) Clamp, Hose and Cable Plate Cover, Hose and Cable Stud (Welded on Part) Nut, Jam 3/8"-16NC Flatwasher 3/8" —————————— Loctite #242

9 3 3 6 10 1 2 2 1 4 4 4

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

1

1

1 2 1 1 1 2

A/R

3-17

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

3-18

3120820

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

4360153 3910408 4770400 Not Used 4460428 0860575

201 202 203 204 205 206 207

7000637 7000638 7000639 7012526 7000647 3730024 7016535

0251020

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

3120820

3534395 4360277 4360236 4360278 4460052 3900168 4920140 3533183 4300031 4761400 3311401 1670579 Not Used 4564880 1320040 1060016 1060079

DESCRIPTION BOOM LENGTH/INDICATOR INSTALLATION Boom Length Indicator Assembly (See Item 101-106 for Breakdown) Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC BOOM LENGTH INDICATOR SUBASSEMBLY Indicator Box Assembly (See Items 201-207 for Breakdown) Pendulum Screw #4NC x 1/2" Starwasher #4 Strain Relief INDICATOR BOX ASSEMBLY Potentiometer Switch Spring, Reel Spring, Extension Cable Resistor - 100 Ohms Plate BOOM LIMIT SWITCHES INSTALLATION (AUSTRALIAN SPEC - PRIOR TO SEPTEMBER 1995 AND ALL EN280 AND CE SPEC BUILT TO PRESENT)

QTY.

REV.

Ref.

2

1 4 4 4 Ref.

3 D

B O O M

1 1 4 4 1 Ref.

E

1 1 1 1 1 1 1

Ref.

Plate, Mounting - Limit Switch Switch, Limit Head, Switch Arm and Roller Connector, Strain Relief Bolt, Socket With Hole #10-24NC x 1 1/2" Wire, Safety Cover (Top Limit Switch) Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Cover (Side Limit Switch)

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

Tube, Cable Clamp, Cable Cable, Electrical - 16/3 Cable, Electrical - 16/4

3 3

S E C T I O N

7

50 ft./15.3m 52 ft./15.9m

3-19

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

318

1670836

Cover, Boom (Not Shown Located on Opposite Side of Boom) (S/N 40599 to Present)

0255815

BOOM LIMIT SWITCHES INSTALLATION (AUSTRALIAN SPEC ONLY - SEPTEMBER 1995 TO PRESENT)

3 B O O M

3-20

401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417

3534395 4360277 4360235 4360278 4460052 3900168 4920140 Not Used 4300031 4761400 3311401 1670579 Not Used 4564880 1320040 Not Used 1060079

418

1670836

DESCRIPTION

QTY. 1

Ref.

Plate, Mounting - Limit Switch Switch, Limit Head, Switch Arm and Roller Connector, Strain Relief Bolt, Socket With Hole #10-24NC x 1 1/2" Wire, Safety

1 1 1 1 1 2 1

Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Cover (Side Limit Switch)

6 6 6 1

Tube, Cable Clamp, Cable

2 2

Cable, Electrical - 16/4 Cover, Boom (Not Shown Located on Opposite Side of Boom) (S/N 40599 to Present)

REV.

4

52 ft./15.9m

2

3120820

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

3120820

3-21

S E C T I O N

SECTION 3 BOOM FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN EN280 SPECS & ALL CE SPECS)

3 B O O M

3-22

3120820

SECTION 3 BOOM FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN EN280 SPECS & ALL CE SPECS) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

BROKEN CHAIN LIMIT SWITCH INSTALLATION Switch, Limit Head, Switch Arm, Actuator Connector, Strain Relief Wire, Safety Bolt, Socket With Hole #10-24NC x 1 1/2" Locknut Pin, Cotter 1/16” x 1/2” Clevis, Chain Plate, Switch Washer, Bellville Note: Machines with broken chain limit switch require the standard qty 27 per Figure 3-1 plus an additional qty 48 for a total qty of 75 at this location.

Cable Reel Assy (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

Ref. 1 1 1 1 1 2 1 1 1 1 48

3

1 2 3 4 5 6 7 8 9 10 11

0253062 4360277 4360236 4360237 4460052 4920140 3900168 3303240 3450202 1360250 3536145 4160098

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

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

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 100 101 102 103 104 105 106 107 108 109 110 111 112

3680051 4565798 4565799 0641630 0641632 3311605 3536146 1320049 3536147 0641609 0960407 4460049 4844201 3536148 Not Used 0721003 4761000 3680051 7010836 7010837 7010848 7010847 7010836 Not Available 7010846 7010839 7010845 7010840 7010844 7010841 7010843

113

Not Available

114

7010842

3120820

3 B O O M

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

Fitting, 90

1

Seal, Watertight

1

S E C T I O N

3-23

S E C T I O N

SECTION 3 BOOM FIGURE 3-7. BOOM WIPERS INSTALLATION

3 B O O M

3-24

3120820

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

PART NUMBER 0253303

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

3120820

3200344 3200346 3200348 3200345 3200347 3200349 0540074 0540089 0540078 0540075 0540077 0540079 2660067 2660085 2660071 2660068 2660070 2660072 3820001 1670491 0641404 4761400 4711600

DESCRIPTION BOOM WIPERS INSTALLATION Mount, Boom Wiper (Base/Top) Mount, Boom, Wiper (Inner Mid/Top) Mount, Boom, Wiper (Outer Mid/Top) Mount, Boom, Wiper (Base/Side) Mount, Boom Wiper (Inner Mid/Side) Mount, Boom Wiper (Outer Mid/Side) Blade, Boom Wiper (Base/Top) Blade, Boom Wiper (Inner Mid/Top) Blade, Boom Wiper (Outer Mid/Top) Blade, Boom Wiper (Base/Side) Blade, Boom Wiper (Inner Mid/Side) Blade, Boom Wiper (Outer Mid/Side) Holder, Brush (Base/Top) Holder, Brush (Inner Mid/Top) Holder, Brush (Outer Mid/Top) Holder, Brush (Base/Side) Holder, Brush (Inner Mid/Side) Holder, Brush (Outer Mid/Side) Rivet, Pop Cover Weldment Bolt 1/4" -20NC x 1/2" Lockwasher Flatwasher

QTY.

REV.

Ref.

2

1 2 1 2 2 2 1 2 1 2 2 2 1 2 1 2 2 2 30 1 4 4 4

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

3-25

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

3-26

3120820

SECTION 4 PLATFORMS TABLE OF CONTENTS FIGURE

4-1 4-2 4-3 4-4 4-5

DESCRIPTION

PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PLATFORM CONSOLE ASSEMBLY (Prior to S/N 25609) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLATFORM CONSOLE ASSEMBLY (S/N 25609 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PAGE

4-2 4-6 4-8 4-12 4-16

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

3120820

4-1

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (LOW MOUNT)

4 P L A T F O R M S

4-2

3120820

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) FIG & ITEM #

PART NUMBER 3510365

1

3510364

2 3 4 5 6 7

4160028 Not Used 3534146 0721003 4740371 3311005 3510364

101 102 103 104 105

1780252 2940006 2560010 2160006 0960564 0252682

201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224

3120820

4842046 1120299 0235238 3340454 2880404 4160026 4752000 0652014 0641836 4751800 3311805 0901834 0641811 1380137 0641412 4761400 4751400 0641408 4562083 4740158 1670632 4920986 2160002 4565665

DESCRIPTION PLATFORM ASSEMBLY LOW MOUNT Note: Replacement Decals Must be Ordered Separately - See Section 8.

QTY.

REV.

Ref.

3

Ref.

Platform Weldment (.9m x 1.83m) (See Items 101 to 105 for Serviced Parts) Spring, Tension

1

Plate, Kick (Ends) Screw, Machine #10-24NC x 3/4” Washer, Special Locknut #10-24NC

2 32 64 32

PLATFORM ASSEMBLY COMPONENTS Door Weldment Latch, Door Handle, Latch Fitting, Grease Bushing, Bronze ROTATOR AND SUPPORT INSTALLATION 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 Fitting, Grease Tube, Spacer

1

Ref.

4 P L A T F O R M S

3

1 1 1 2 2 Ref.

S E C T I O N

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 2 1

4-3

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) (CONTINUED) FIG & ITEM #

PART NUMBER 0235238

301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325

4 P L A T F O R M S

401

3160083 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

4-4

ROTATOR ASSEMBLY Rotor Motor Assembly (See Figure 4-2 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.

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

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

0252044

501 502 503 504 505

DESCRIPTION

4360277 0721016 3311001 4751000 4761000

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

PLATFORM GATE INTERLOCK SWITCH INSTALLATION (FRENCH MACHINES ONLY) Switch, Limit Screw, Machine #10-24NC x 2” Nut #10-24NC Flatwasher #10 Lockwasher #10

Ref.

7

3

1 2 2 2 2

3120820

SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) (CONTINUED) FIG & ITEM #

PART NUMBER

506 507 508 509 510 511 512

1100066 4460049 4761600 0641608 3440418 4360307 2540016

DESCRIPTION Cam, Interlock Connector, Strain Relief Lockwasher 3/8” Bolt 3/8”-16NC x 1” Roll Pin 1/8” x 1 1/8” Head, Switch Grommet (Not Shown)

QTY.

REV.

1 1 1 1 1 1 2

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

3120820

4-5

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-2. ROTATOR MOTOR ASSEMBLY

4 P L A T F O R M S

4-6

3120820

SECTION 4 PLATFORMS FIGURE 4-2. 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 101-1009-007) Seal Kit (Includes Items 3,7,8,11 and 12) (P/N’s 101-1009-008 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

4 P L A T F O R M S

1 1

Note: Identify by P/N stamped on nameplate located on Item 10.

3120820

S E C T I O N

4-7

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609)

4 P L A T F O R M S

4-8

3120820

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) FIG & ITEM #

1

PART NUMBER

DESCRIPTION

QTY.

REV.

0860773

PLATFORM CONSOLE ASSEMBLY (MACHINES BUILT PRIOR TO S/N 25609)

Ref.

10

0860538 2940052 2600105 2600132

2

7 8 9

3252181 3252370 4420037 Not Used 4360336 3790012 4740397 4360330 4060802 4360314

10 11 12 13

3790015 4360274 2920027 2920029

14

2920015

3 4 5 6

15 16

2920104 2920090 4360289 4360475 7012611

17 18

19

20 21 22 23 24 25

3120820

7012612 7020175 7020176 2920026 1600135 7003797 7003751 7003789 7003790 1600155 7011928 7003751 0140019 0751006 4740120 3300177 4761000 3311001

Box Weldment Latch Hinge (Rear Access Door) Hinge (Top to Bottom Sections) Lid Options: Prior to May 1994 May 1994 to Present Tape, Insulation Switch, Toggle (Engine Speed and Creep) O-Ring Washer, Spacer Switch, Toggle (Auxiliary Power) Shield, Switch Switch, Toggle (Front Steer, Extend-A-Reach, Level, Telescope and Rotate) O-Ring Switch, Push-Button Light, Indicator - Green (Axles Set) Bulb, Light Lamp, Indicator - Red (Chassis Out of Level) (Prior to July 1992) Lamp, Red (July 1992 to Present) Light, Indicator - Blue (Capacity) Switch, Emergency Stop Options: Production Post Production 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) Light, Indicator - Red (Radius) Controller (Drive/Rear Steer) Electrical Assembly Potentiometer Switch, Rocker Cap, Rubber Controller (Lift and Swing) Electrical Assembly Potentiometer Alarm Screw, Pan Head #10-24NC x 3/4" Washer, Nylon Nut, Tinnerman Lockwasher #10 Nut #10-24NC

1 2 1 1 1

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

129 in/3.27m

2 8 8 1 8 5 2 2 1 3 1 1 1 1

1

1 1 1 1 1 1 2 1 1 1 21 21 21 A/R A/R

4-9

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) (CONTINUED) FIG & ITEM #

PART NUMBER

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

3740049 4360209 4360232 4761000 3311001 4761000 0641508 4751500 3311505 3640752 3310601 3910608 4750600 4760600 4460298 4460299 4460300 4460301 4460311 4460305 4460306 4460307 4120013 3740058 3740063 Not Used

4 P L A T F O R M S

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

4-10

4360282 4360476 2560112 Not Used Not Used Not Used Not Used 2920108 Not Used 4460387 4460388 4220038 4460071 3300048 0960238 4460386 3300147 0960905 4460051 3300048 0960238 4460052

DESCRIPTION

QTY.

Relay - SPST Breaker, Circuit - 20 Amp Breaker, Circuit - 15 Amp Lockwasher #10 Nut #10-24NC Lockwasher #10 Bolt 5/16"-18NC x 1" Flatwasher 5/16" Locknut 5/16"-18NC Track Nut #6-32NC Screw, Machine #6-32NC x 1" Flatwasher #6 Lockwasher #6 Block, Terminal Stop, Terminal Barrier, Terminal Strip, Marking Bar, Terminal Buss Screw, Terminal Washer, Terminal Sleeve, Terminal Socket, Relay Relay - 4PDT Spring, Relay

A/R 1 1 2 2 4 4 8 4 1 6 6 10 6 29 3 3 1 2 12 12 12 3 3 3

Block, Contact - NC Options: Production Post Production Knob, Controller

1

Bulb

1

Block, Terminal Barrier, Terminal Tape, Insulation Connector, Strain Relief Nut, Conduit Bushing Connector, Strain Relief Nut, Conduit Bushing Connector, Strain Relief Nut, Conduit Bushing Connector, Strain Relief

18 1

REV.

2

1.5 in./4cm

1 1 1 1 1 1 1 1 1 1

3120820

SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) (CONTINUED) FIG & ITEM #

PART NUMBER

73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91

3300047 0960239 Not Used 4460414 4460412 4460411 4460451 4460452 0720803 4750800 4760800 4360327 4460308 1600153 3910616 4460415 4460413 3300352

92 93 94 95

96 97 98

2560115 2560136 2920104 4460442 2920108 0140019 0140026 4420008 3520033 3520034 0100001

3120820

DESCRIPTION

QTY.

Nut, Conduit Bushing

1 1

Strip, Marking - #4 Strip, Marking - #2 Strip, Marking - #1 Strip, Marking - #98 Strip, Marking - #99 Screw, Machine #8-32NC x 3/8" Flatwasher #8 Lockwasher #8 Potentiometer - 200 Ohm Bar, Terminal Buss Board, Circuit - Controller Drive Screw, Machine #6-32NC x 1" Strip, Marking - #5 Strip, Marking - #3 Nut, Special Knob, Potentiometer Options: Production Post Production Lamp-Red Stop, Terminal Bulb, Light Alarm Options: Prior to May 1994 May 1994 to Present Tape, Insulation Plug, Hole Plug, Hole 5/16" —————————— Adhesive

2 2 2 10 10 20 20 20 1 1 1 4 10 4 1 1

REV.

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

1 1 1 1

5.75ft/1.75m

1 2 A/R

4-11

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (S/N 25609 TO PRESENT)

4 P L A T F O R M S

4-12

3120820

SECTION 4 PLATFORMS FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (S/N 25609 TO PRESENT) FIG & ITEM #

PART NUMBER 0861089 0861217

1

2 3 4 5 6 7 8

0861105 2940052 2600105 2600132 3252370 4420037 Not Used 4360336 4740397 4360330 4060802

9

4360314

10 11 12 13 14 15 16

3790015 4360274 2920027 2920029 2920104 2920090 4360289 4360475 7012611

17 18

7012612 7020175 7020176 2920026 1600135 7003797 7003751 7003789 7003790

19

20 21 22 23 24

3120820

1600155 7011928 7003751 1600277 7020512 7003751 0140019 0751006 4740120 3300177 4761000

DESCRIPTION PLATFORM CONSOLE ASSEMBLY S/N 25609 To S/N 38697 S/N 38697 To PRESENT Box Weldment Latch Hinge (Rear Access Door) Hinge (Top to Bottom Sections) Lid Tape, Insulation Switch, Toggle (Engine Speed and Creep) Washer, Spacer Switch, Toggle (Auxiliary Power) Shield, Switch Switch, Toggle (Front Steer, Extend-A-Reach, Level, Telescope and Rotate) O-Ring Switch, Push-Button Light, Indicator - Green (Axles Set) Bulb, Light Lamp, Red Light, Indicator - Blue (Capacity) Switch, Emergency Stop Options: Prior to S/N 44645 S/N 44645 to Present 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) Light, Indicator - Red (Radius) Controller (Drive/Rear Steer) Electrical Assembly Potentiometer Switch, Rocker Cap, Rubber Controller (Lift and Swing) Options: Controller Used Prior to S/N 38697 Electrical Assembly Potentiometer Controller Used S/N 38697 to Present Electrical Assembly Potentiometer Alarm Screw, Pan Head #10-24NC x 3/4" Washer, Nylon Nut, Tinnerman Lockwasher #10

QTY.

REV.

Ref. Ref. Ref.

6 3

1 2 1 1 1

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

129 in/3.27m

2 8 1 8 5 2 2 1 3 1 1 1

1

1 1 1 1 1 1 A/R 2 1 1 2 1 1 1 21 21 21 A/R

4-13

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (S/N 25609 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

3311001 3740049 4360161 4360112 4360069 Not Used Not Used 0641508 4751500 3311505 3641172 3310601 3910608 4750600 4760600 4460298 4460299 4460300 4460301 4460311 4460305 4460306 4460307 4120037 3740123 3740124 Not Used

4 P L A T F O R M S

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

4-14

4360282 4360476 2560112 Not Used Not Used Not Used Not Used 2920108 Not Used 4460387 4460388 Not Used 4460071 3300048 0960238 4460386 3300147 0960905 Not Used Not Used Not Used

DESCRIPTION

QTY.

Nut #10-24NC Relay - SPST Breaker, Circuit - 20 Amp Breaker, Circuit - 5 Amp Breaker, Circuit - 10 Amp

A/R A/R 1 2 1

Bolt 5/16"-18NC x 1" Flatwasher 5/16" Locknut 5/16"-18NC Track Nut #6-32NC Screw, Machine #6-32NC x 1" Flatwasher #6 Lockwasher #6 Block, Terminal Stop, Terminal Barrier, Terminal Strip, Marking Bar, Terminal Buss Screw, Terminal Washer, Terminal Sleeve, Terminal Socket, Relay Relay - 4PDT Spring, Relay

4 8 4 1 6 6 10 6 29 3 3 1 2 12 12 12 3 3 3

Block, Contact - NC Options: Prior to S/N 44645 S/N 44645 to Present Knob, Controller

1

Bulb

1

Block, Terminal Barrier, Terminal

18 1

Connector, Strain Relief Nut, Conduit Bushing Connector, Strain Relief Nut, Conduit Bushing

2 2 2 1 1 1

REV.

2

3120820

SECTION 4 PLATFORMS FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (S/N 25609 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91

4460052 3300047 0960239 3300396 4460414 4460412 4460411 4460451 4460452 0720803 4750800 4760800 4360327 4460308 1600153 3910616 4460415 4460413 3300352

92 93 94 95 96 97 98 99 100

2560115 2560136 2920104 4460442 2920108 0140026 4420008 Not Used Not Used 4460704 1704260 0100001

3120820

DESCRIPTION Connector, Strain Relief Nut, Conduit Bushing Seal, Cap Strip, Marking - #4 Strip, Marking - #2 Strip, Marking - #1 Strip, Marking - #98 Strip, Marking - #99 Screw, Machine #8-32NC x 3/8" Flatwasher #8 Lockwasher #8 Potentiometer - 200 Ohm Bar, Terminal Buss Board, Circuit - Controller Drive Screw, Machine #6-32NC x 1" Strip, Marking - #5 Strip, Marking - #3 Nut, Special Knob, Potentiometer Options: Production Post Production Lamp - Red Stop, Terminal Bulb, Light Alarm Tape, Insulation

Strip, Marking - #97 Decal - EMS (S/N 44645 to Present) —————————— Adhesive

QTY.

REV.

1 1 1 4 2 2 2 10 10 20 20 20 1 1 1 4 10 4 1 1

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

1 1 1 1 5.75ft/1.75m

4 1 A/R

4-15

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-5. OPTIONAL PLATFORM MOUNTED COMPONENTS

4 P L A T F O R M S

4-16

3120820

SECTION 4 PLATFORMS FIGURE 4-5. OPTIONAL PLATFORM MOUNTED COMPONENTS FIG & ITEM #

PART NUMBER

0251203 0252054 1

1670526 1670607 3900022 3901406 4751400 0253077

2 3 to 7

0140026 Not Used 0253987 0254748

8

2920111 3536089 0250143

9

10 to 14

4160028 0900232 0901056 4220007 Not Used

1282197 0255695 0259365

15

16 17

0630440 3010088 1260136 4360057 0200048 0940038 1670663 1670715 1670665 1670666 1670716 1670717

3120820

DESCRIPTION

QTY.

OPTIONAL PLATFORM MOUNTED COMPONENTS

Ref.

CONSOLE COVER INSTALLATION (YELLOW) CONSOLE COVER INSTALLATION (BLACK)

Ref. Ref.

Cover (Yellow Vinyl) Cover (Black Vinyl) Screw, Self-Tapping 1/4" (Prior to S/N 26766) Screw, Self-Tapping 1/4"-20 (S/N 26766 to Present) Flatwasher 1/4" TILT ALARM INSTALLATION Alarm

WORKLIGHTS INSTALLATION WORKLIGHTS INSTALLATION (WITH BUMPERS) Light, Halogen Plate, Mounting SELF-CLOSING GATE INSTALLATION Spring Bracket (Door Mounted) Bracket (Platform Mounted) Stop, Door

PLATFORM BUMPERS INSTALLATION - SOFT TOUCH SYSTEM (CHAIN MOUNTED TYPE) 3’ x 6’ LOW MOUNTED PLATFORM (Prior to S/N 43389) 3’ x 6’ LOW MOUNTED PLATFORM (S/N 43389 to Present) Eyebolt Link, Quick Chain Switch, Limit Arm, Actuator Padding, Bumper Cover (Rail Behind Console Box) (Prior to S/N 44770) Cover (LH Top Rail) Cover (Vertical Rails) Cover (Gate) Cover (RH Top Rail) Cover (LH Mid Rail)

REV.

2 2

1 1 4 4 4 Ref.

4 5

1

Ref. Ref.

4 2

2 2 Ref.

S E C T I O N

A

1 1 1 1

Ref.

H

Ref.

5

Ref.

2

8 8 A/R 1 1 62Ft/18.9m

1

4 1 1 1

4-17

P L A T F O R M S

S E C T I O N

SECTION 4 PLATFORMS FIGURE 4-5. OPTIONAL PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM #

PART NUMBER

17 (cont’d)

1670718 1670719 4360274 3252238

18

DESCRIPTION Cover (RH Mid Rail) Cover (Bumper Rail) Switch, Push Button Decal - Soft Touch System

QTY.

REV.

1 1 1 1

4 P L A T F O R M S

4-18

3120820

SECTION 5 CYLINDERS TABLE OF CONTENTS FIGURE

5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9

3120820

DESCRIPTION

AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTEND-A-REACH LIFT CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JACK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MASTER CYLINSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER BELLOWS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

5-2 5-4 5-6 5-8 5-10 5-12 5-14 5-16 5-20

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 CYLINDERS FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-2

3120820

SECTION 5 CYLINDERS FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1682618 1683532

1

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

1682620 1683531 1682622 1120108 1681283 3480092 4565647 3300287 3841164 3323402 4640495 2900770 3900170 Kit Kit Kit Kit Kit Kit Kit 0100038 0100011 0100035 2900396

3120820

DESCRIPTION AXLE EXTENSION CYLINDER ASSEMBLY Prior To S/N 33105 S/N 33105 To Present Barrel Weldment Options: Prior to S/N 33105 S/N 33105 to Present Rod Weldment Retainer Head Piston Spacer Nut Rod-End Nut, Jam 1 1/2"-12NF Cartridge, Holding Valve Seal Kit - 4640495 Cartridge Valve (1 Per Valve) Setscrew 3/8"-16NC x 3/8" Wiper, Rod Seal, Rod Ring, Wear O-Ring Ring, Lock O-Ring Seal, Hydrolock —————————— Primer, Locking Loctite #242 Loctite #222 —————————— Seal Kit (Includes Items 12-18)

QTY.

REV.

Ref. Ref. Ref.

— 1

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

S E C T I O N 5 C Y L I N D E R S

A/R A/R A/R 1

5-3

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-2. BOOM LIFT CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-4

3120820

SECTION 5 CYLINDERS FIGURE 5-2. BOOM LIFT CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1682630 1682895

1 2 3 4 5 6 7 8 9

1682631 0960509 1682633 0961082 1120363 1682118 3480162 4565652 3300306 2220887 4640709 4640771

10 11 12 13 14 15 16 17 18 19 20

2900770 3900171 2160002 Kit Kit Kit Kit Kit Kit Kit Kit 2220883 0100011 0100038 0100035 2901118

3120820

DESCRIPTION BOOM LIFT CYLINDER ASSEMBLY OPTIONS: Prior To November 1992 November 1992 To Present Barrel Weldment Bushing, Bronze Rod Weldment Bushing, Bronze Retainer Head Piston Spacer Nut Plug Cartridge, Holding Valve Options: Cartridge, Holding Valve (Prior to November 1992) Cartridge, Holding Valve (November 1992 to Present) 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. Ref. Ref.

B —

1 2 1 2 1 1 1 1 1 1 1

S E C T I O N 5 C Y L I N D E R S

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

5-5

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-3. EXTEND-A-REACH PLATFORM LEVEL CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-6

3120820

SECTION 5 CYLINDERS FIGURE 5-3. EXTEND-A-REACH PLATFORM LEVEL CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER

1682753 1683493 1

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

1682754 1682754 0961595 1682755 0961182 1120305 1681792 3480167 4565913 3300279 4640634 2900770 2220885 2220883 3900170 Kit Kit Kit Kit Kit Kit Kit 4640634 4640996 2900770 0100038 0100011 0100035 2901206

DESCRIPTION EXTEND-A-REACH PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: Prior To S/N 29913 S/N 29913 To Present Barrel Weldment Options: Prior to S/N 29913 S/N 29913 to Present 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 Valve Options: Cartridge, Holding Valve (Prior to S/N 29913) Valve, Counterbalance (S/N 29913 to Present) Seal Kit - 4640634 Valve —————————— Primer, Loctite Loctite #242 Loctite #222 —————————— Seal Kit (Includes Items 12-18)

QTY.

REV.

Ref. Ref. Ref.

B —/—

1

5 2 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 1

C Y L I N D E R S

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

3120820

S E C T I O N

5-7

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-4. EXTEND-A-REACH LIFT CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-8

3120820

SECTION 5 CYLINDERS FIGURE 5-4. EXTEND-A-REACH LIFT CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER

1682635 1683725 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19

1682636 0961185 1682638 0961595 1120305 1681423 4564009 3480113 3300285 3900170 4640634 4640495 2900770 2160002 2200201 Kit Kit Kit Kit Kit Kit Kit 2200222 0100020 0100011 0100038 0100035 2901142

3120820

DESCRIPTION EXTEND-A-REACH LIFT CYLINDER ASSEMBLY OPTIONS: Prior To S/N 49403 S/N 49403 To Present Barrel Weldment Bushing, Bronze Rod Weldment Bushing, Bronze Retainer Head Spacer Piston Nut Setscrew 3/8"-16NC x 3/8" Cartridge, Holding Valve Options: Prior to S/N 49403 S/N 49403 to Present 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.

— 1

1 2 1 2 1 1 1 1 1 1

S E C T I O N 5 C Y L I N D E R S

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

5-9

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-5. JACK CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-10

3120820

SECTION 5 CYLINDERS FIGURE 5-5. JACK CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1682511

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

1682512 1682514 3340630 1120358 3480137 1682098 3300281 4565225 0641852 3311801 Kit Kit Kit Kit Kit Kit Kit 0100011 0100035 0100038 2901115

3120820

DESCRIPTION JACK CYLINDER ASSEMBLY Barrel Weldment Rod Weldment Jack Pad Weldment Retainer Piston Head Nut Tube, Spacer Bolt 1/2"-13NC x 6 1/2" Nut 1/2"-13NC T-Seal Ring, Wear O-Ring Ring, Wear O-Ring Seal, Rod Wiper, Rod —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 11-17)

QTY.

REV.

Ref.

A

1 1 1 1 1 1 1 1 2 2 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

5-11

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-6. MASTER CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-12

3120820

SECTION 5 CYLINDERS FIGURE 5-6. MASTER CYLINDER ASSEMBLY FIG & ITEM #

PART NUMBER 1681580

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

1681490 1681488 0960097 1120179 1680892 3480120 3300272 Kit Kit Kit Kit Kit Kit Kit Kit Not Used 4563031 2160002 2200201 Not Used Not Used 3900170 0100011 0100038 0100035 2900381

3120820

DESCRIPTION

QTY.

REV.

MASTER CYLINDER ASSEMBLY

Ref.

F

Barrel Weldment Rod Weldment Bushing, Bronze Retainer Head Piston Nut Ring, Wear Z-Seal Wiper, Rod O-Ring Ring, Back-Up Seal, Piston Ring, Wear O-Ring

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

Tube, Spacer Fitting, Grease Plug, Pipe 1/8" NPT

1 1 1

Setscrew 3/8"-16NC x 3/8" —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 7-14)

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

5-13

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-7. STEER CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-14

3120820

SECTION 5 CYLINDERS FIGURE 5-7. STEER CYLINDER ASSEMBLY FIG & ITEM #

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

PART NUMBER

STEER CYLINDER ASSEMBLY

1682606 1682608 1120108 1681344 3480134 3300273 4563963 3900170 3900141 2160002 Kit Kit Kit Kit Kit Kit Kit

Barrel Weldment Rod Weldment Retainer Head Piston Nut Tube, Spacer Setscrew 3/8"-16NC x 3/8" Setscrew 1/4"-20NC x 3/8" Fitting, Grease T-Seal O-Ring Ring, Wear Ring, Wear O-Ring Seal, Rod Wiper, Rod —————————— Loctite #242 Primer, Locking Loctite #222 —————————— Seal Kit (Includes Items 11-17)

0100011 0100038 0100035 2901123

3120820

DESCRIPTION

1682605

QTY.

REV.

Ref.

—

1 1 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

5-15

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY

5 C Y L I N D E R S

5-16

3120820

SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY FIG & ITEM #

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 to 35 36

3120820

PART NUMBER

DESCRIPTION

QTY.

REV.

1682030 1682820 1683701 1682030 1682820

TELESCOPE CYLINDER ASSEMBLIES TELESCOPE CYLINDER ASSEMBLIES Standard Boom Prior To November 1992 Standard Boom November 1992 To S/N 38697 Standard Boom S/N 38697To Present Boom with Chip Covers Prior To November 1992 Boom with Chip Covers November 1992 To Present

Ref. Ref. Ref. Ref. Ref. Ref. Ref.

D A 2 D A

1681926 1681922 1682031 4843016 3840944 0560773 1120345 1681925 1682298 3480133 3300299 0181404 3340560 Kit Kit Kit Kit Kit Kit Kit Kit 4640487 4641083 7011317 3312202 0641812 4761800 0641608 4761600 3311601 0641605 3951405 3900171 2200221 2200224 2200222 Not Used 3340566

Barrel Weldment Rod Weldment Spacer Rod Support Weldment Rod, Guide Block, Nylatron Retainer Head Prior to November 1992 November 1992 to Present Piston Nut Angle Pad, Wear Seal, Rod Wiper, Rod O-Ring Ring, Back-Up Ring, Wear Ring, Guide Seal, Piston T-Seal Cartridge, Valve Options: 1682030 & 1682820 Cylinders 1683701 Cylinder Seal Kit 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" Setscrew 1/2"-13NC x 1/2" Plug, Pipe 1/8" NPT Plug, Pipe 3/8" NPT Plug, Pipe 1/4" NPT Pad, Wear ——————————

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

1 1 1 1 3 1 1 1 1 2 2 1 1

1 2 2 2 2 7 2 5 1 1 1 2 1 1

5-17

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY (CONTINUED) FIG & ITEM #

PART NUMBER 0100020 0100011 0100035 0100038

2901109 2901234

5

DESCRIPTION Sealant, Pipe Loctite #242 Loctite #222 Primer, Locking ————————— Seal Kit Options (Includes Items 13-20) : Prior to November 1992 November 1992 to Present

QTY.

REV.

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

C Y L I N D E R S

5-18

3120820

SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY (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

3120820

5-19

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-9. CYLINDER BELLOWS INSTALLATION (OPTIONAL)

5 C Y L I N D E R S

5-20

3120820

SECTION 5 CYLINDERS FIGURE 5-9. CYLINDER BELLOWS INSTALLATION (OPTIONAL) FIG & ITEM #

PART NUMBER 0252829

1 2 3 4 5 6 7

0460089 0460088 0460087 0460086 0460071 1320037 1320059

DESCRIPTION CYLINDER BELLOWS INSTALLATION (OPTIONAL) Bellow (Steer) Bellow (Extend-A-Reach Level) Bellow (Extend-A-Reach Lift) Bellow (Boom Lift) Bellow (Master) Clamp Clamp

QTY.

REV.

Ref.

2

2 1 1 1 1 5 1

S E C T I O N 5 C Y L I N D E R S

3120820

5-21

S E C T I O N

SECTION 5 CYLINDERS FIGURE 5-9. CYLINDER BELLOWS INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM #

PART NUMBER

DESCRIPTION

QTY.

REV.

5 C Y L I N D E R S

5-22

3120820

SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE

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

DESCRIPTION

HYDRAULIC DIAGRAM - DRIVE (4WD - Deutz Engine) (Prior to S/N 38697) . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - DRIVE (4WD - Deutz Engine) (S/N 38697 to Present) . . . . . . . . . . .

HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS) . . . . . . . . . .

HYDRAULIC DIAGRAM - STANDARD (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM - STANDARD (S/N 38697 to Present) . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE

6-2 6-6 6-10 6-12 6-16 6-20

S E C T I O N 6 H Y D R A U L I C S

3120820

6-1

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697)

6 H Y D R A U L I C S

6-2

3120820

SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697) FIG & ITEM #

PART NUMBER 2791925

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

3120820

2220377 2210014 2720281 2220375 2220385 2220618 2220606 2751026 2751017 2220582 2751484 2751906 2220408 2751623 2750834 2220578 2220738 2220621 2220609 2220451 2750835 2220500 2220501 2220377 2752322 2220365 2220498 2752249 2220435 2752383 2220596 2220866 2901194 2752322 2220363 2220710 2752247 2220481 2220622 2220466 2220504 2751021 2220899 2220415 2750900 4640013

DESCRIPTION HYDRAULIC DIAGRAM - DRIVE Fitting, Straight Fitting, 90° Barbed Hose, Suction Fitting, Straight Fitting, Tee Fitting, Reducer Fitting, Tee Hose Hose Fitting, Straight Hose Hose Fitting, Straight Hose Hose Fitting, 90° Fitting, Tee Fitting, Reducer Fitting, Reducer Fitting, Straight Hose Fitting, 45° Fitting, 45° Fitting, Straight Hose Fitting, 45° Fitting, 45° Hose Fitting, Straight Hose Fitting, 90° Flange Bolt Kit - Flange Hose Fitting, Tee Fitting, Reducer Hose Fitting, Tee Fitting, Reducer Fitting, 90° Fitting, Tee Hose Fitting, Tee Fitting, Straight Hose Valve, Shuttle

QTY.

REV.

Ref.

6

1 1

S E C T I O N

64 in./16.3m

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

6 H Y D R A U L I C S

6-3

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697) (CONTINUED) FIG & ITEM #

PART NUMBER

47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

2220416 2220261 4640197 2220727 2220820 Not Used Not Used 2751018 Not Used 2751015 2751406 2751899 2220602 2750979 2220362 2751489 2752932 2220374 2220671 2750762 2752337 2220365 Not Used 1320033 Not Used 2751013 2220472 Not Used 4100026 2750904 2220909 2220811 2220646 Not Used 4160174 4160175 3311401 4761400 1320110 3570980 4280307 0641508 4711500 3311505

6 H Y D R A U L I C S

63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

6-4

DESCRIPTION

QTY.

Fitting, 90° Fitting, Nipple Valve, Check Fitting Fitting, 90°

2 1 1 1 1

Hose

1

Hose Hose Hose Fitting, Tee Hose Fitting, Tee Hose (Prior to July 1995) Hose (July 1995 to Present) Fitting, Straight (Prior to July 1995) Fitting, Straight (July 1995 to Present) Hose Hose Fitting, 45°

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

Clamp

4

Hose Fitting, 90°

1 1

Cover, Nylon Hose Fitting Fitting, Reducer Fitting

12 2 1 2 1

Spring, Anchor Spring, Extension Nut 1/4"-20NC Lockwasher Clamp Plate, Spring Rubber Bolt 5/16"-18NC x 1" Flatwasher Locknut 5/16"

4 4 8 4 4 4 8 4 8 4

REV.

3120820

SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697) (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

3120820

6-5

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT)

6 H Y D R A U L I C S

6-6

3120820

SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT) FIG & ITEM #

PART NUMBER 2792376

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

3120820

2220377 2210014 2720281 2220375 2220385 2220618 2220606 2751026 2751017 2220582 2751484 2751906 2220408 2751623 2750834 2220578 2220738 2220621 2220609 2220451 2750835 2220500 2220501 2220377 2752322 2220365 Not Used 2752249 2220435 2752383 2220596 2220866 2901194 2752322 2220363 2220710 2752247 2220481 2220622 2220466 2220504 2751021 2220899 2220415 2750900 4640013

DESCRIPTION HYDRAULIC DIAGRAM - DRIVE

QTY.

REV.

Ref.

1

Fitting, Straight Fitting, 90° Barbed Hose, Suction Fitting, Straight Fitting, Tee Fitting, Reducer Fitting, Tee Hose Hose Fitting, Straight Hose Hose Fitting, Straight Hose Hose Fitting, 90° Fitting, Tee Fitting, Reducer Fitting, Reducer Fitting, Straight Hose Fitting, 45° Fitting, 45° Fitting, Straight Hose Fitting, 45°

1 1 1 5 3 3 2 1 1 2 1 5 2 1 1 1 1 1 8 2 1 1 1 2 1 2

Hose Fitting, Straight Hose Fitting, 90° Flange Bolt Kit - Flange Hose Fitting, Tee Fitting, Reducer Hose Fitting, Tee Fitting, Reducer Fitting, 90° Fitting, Tee Hose Fitting, Tee Fitting, Straight Hose Valve, Shuttle

2 2 6 8 8 8 1 2 4 2 2 4 8 4 2 1 1 2 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 6-2. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 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 87 88

2220416 2220261 4640197 2220727 2220820 2752405 Not Used 2751018 Not Used 2751015 2751406 2751899 2220602 2750979 2220362 2752932 2220671 2750762 2752337 2220365 Not Used 1320033 Not Used 2751013 2220472 Not Used 4100026 2750904 2220909 2220811 Not Used 0100020 4160174 4160175 3311401 4761400 1320110 3570980 4280307 0641508 4711500 3311505

6 H Y D R A U L I C S

6-8

DESCRIPTION

QTY.

Fitting, 90° Fitting, Nipple Valve, Check Fitting Fitting, 90° Hose

2 1 1 1 1 2

Hose

1

Hose Hose Hose Fitting, Tee Hose Fitting, Tee Hose Fitting, Straight Hose Hose Fitting, 45°

1 2 1 1 1 2 4 4 1 2 2

Clamp

4

Hose Fitting, 90°

1 1

Cover, Nylon Hose Fitting Fitting, Reducer

12 2 1 2

Sealant, Pipe (Not Shown) Spring, Anchor Spring, Extension Nut 1/4"-20NC Lockwasher Clamp Plate, Spring Rubber Bolt 5/16"-18NC x 1" Flatwasher Locknut 5/16"-18NC

A/R 4 4 8 4 4 4 8 4 8 4

REV.

3120820

SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT) (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

3120820

6-9

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS)

6 H Y D R A U L I C S

6-10

3120820

SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS) FIG & ITEM #

PART NUMBER 0253649

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

3120820

4640543 2220468 2750900 2220605 Not Used 2751396 4640731 2220415 4300051 3311405 4751400 Not Used 1701746

DESCRIPTION HYDRAULIC DIAGRAM - MANUAL DESCENT

QTY.

REV.

Ref.

B

Valve Assembly Fitting, Straight Hose Fitting, Tee

1 2 1 1

Hose Valve Fitting, Straight Stud (Weld on Part) Locknut 1/4”-20NC Flatwasher 1/4”

1 1 1 2 2 8

Decal - Manual Descent (Not Shown)

1

S E C T I O N 6 H Y D R A U L I C S

6-11

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697)

6 H Y D R A U L I C S

6-12

3120820

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697) FIG & ITEM #

PART NUMBER 2791921

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

3120820

2751013 2220472 2220606 2220609 2750910 2230043 2220473 2220727 2220261 2220428 2220429 2751852 2751111 2750897 2750896 2751432 2751433 2750908 2750990 2220371 2220399 Not Used 2220582 2220415 2220343 2750762 2220600 2220726 2750766 2220373 2220238 2220600 2750758 2751504 2220593 2751483 2220385 4640744 2220619 2751004 2751467 2220375 2720281 1320033 2220376 2210014 2751617

DESCRIPTION HYDRAULIC DIAGRAM - STANDARD

QTY.

REV.

Ref.

E

Hose Fitting, 90° Fitting, Tee Fitting, Reducer Hose Fitting, 90° Fitting, 90° Fitting, Adapter Fitting, Straight Fitting, Quick Disconnect Cap, Dust Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Straight Fitting

4 4 6 6 4 4 5 1 1 5 5 2 2 1 1 1 1 2 2 12 2

Fitting, Straight Fitting, Straight Fitting, Straight Hose Fitting, Straight Fitting, 90° Hose Fitting, Straight Fitting, Plug Fitting, Straight Hose Hose Fitting, Straight Hose Fitting, Tee Valve, Check Fitting, Reducer Hose Hose Fitting, Straight Hose, Suction Clamp Fitting, Straight Fitting, 90° Hose

8 3 5 1 6 2 1 7 1 2 1 1 1 1 2 1 1 1 1 1

S E C T I O N 6 H Y D R A U L I C S

64 in./16.3m

4 1 1 1

6-13

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697) (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 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

2220464 2220710 2220466 2751015 2220346 2220497 2750757 2220651 Not Used 2752173 4640757 2220602 Not Used 2751494 2220596 2750771 2750763 2751466 2220726 2751168 2750785 Not Used 2220490 2220495 2750999 2751151 2751455 4563167 2752172 2220895 4640752 2750889 2750907 2751002 2220414 1320041 2220810 2220635 2220741 2220438 2750785

6 H Y D R A U L I C S

6-14

DESCRIPTION

QTY.

Fitting, 90° Fitting, Reducer Fitting, 90° Hose Fitting, Straight Fitting, Straight Hose Fitting, Swivel

1 1 3 1 2 4 1 1

Hose Valve, Flow Control Fitting, Tee

2 1 2

Hose Fitting, 90° Hose Hose Hose Fitting, 90° Hose Hose

1 1 2 2 2 2 2 3

Fitting, Tee Fitting, 90° Hose Hose Hose Tube Hose Fitting, Nipple Valve, Restrictor Hose Hose Hose Fitting, Straight Clamp Fitting, Reducer Fitting, Tee Fitting, Adapter Fitting, Nipple Hose

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

REV.

3120820

SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697) (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

3120820

6-15

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT)

6 H Y D R A U L I C S

6-16

3120820

SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) FIG & ITEM #

PART NUMBER 2792375

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

3120820

2751013 2220472 2220606 2220609 2750910 2230043 2220473 2220727 2220261 2220428 2220429 2751852 2751111 2750897 2750896 2751432 2751433 2750908 2750990 2220371 2220399 2750785 2220582 2220415 2220343 2750762 2220600 2220726 2750766 2220373 2220238 2220600 2750758 2751498 2220593 2751483 2220385 4640744 2220619 2751004 2751467 2220375 2720281 1320033 2220376 2210014 2751617

DESCRIPTION HYDRAULIC DIAGRAM - STANDARD Hose Fitting, 90° Fitting, Tee Fitting, Reducer Hose Fitting, 90° Fitting, 90° Fitting, Adapter Fitting, Straight Fitting, Quick Disconnect Cap, Dust Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Straight Fitting Hose Fitting, Straight Fitting, Straight Fitting, Straight Hose Fitting, Straight Fitting, 90° Hose Fitting, Straight Fitting, Plug Fitting, Straight Hose Hose Fitting, Straight Hose Fitting, Tee Valve, Check Fitting, Reducer Hose Hose Fitting, Straight Hose, Suction Clamp Fitting, Straight Fitting, 90° Hose

QTY.

REV.

Ref.

1

4 4 6 6 4 4 5 1 1 5 5 2 2 1 1 1 1 2 2 12 2 2 8 3 5 1 6 5 1 6 1 2 1 1 1 1 2 1 1 1 1 1 1 4 1 1 1

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 6-5. HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM #

PART NUMBER

48 49 50 51 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73

2220464 2220710 2220466 2220438 2751015 2220346 2220497 2220741 2220635 2220810 2752173 2751002 2750907 2750889 2220873 2752172 2750771 2750763 2751466 4563167 2751168 2750785 2751455 2220490 2220495 2750999 2751151

6 H Y D R A U L I C S

6-18

DESCRIPTION Fitting, 90° Fitting, Reducer Fitting, 90° Fitting, Nipple Hose Fitting, Straight Fitting, Straight Fitting, Adapter Fitting, Tee Fitting, Reducer Hose Hose Hose Hose Fitting, Nipple Hose Hose Hose Hose Tube Hose Hose Hose Fitting, Tee Fitting, 90° Hose Hose

QTY.

REV.

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

3120820

SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) (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

3120820

6-19

S E C T I O N

SECTION 6 HYDRAULICS FIGURE 6-6. HYDRAULIC DIAGRAM LIST FIG & ITEM #

PART NUMBER

DESCRIPTION HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in preceding pages. Information on Diagrams not shown are available from JLG Service/Parts Departments.

2791925*

6

2792376*

H Y D R A U L I C S

Ref. Ref.

Hydraulic Diagram - Manual Descent (Prior to October 1992)

Ref.

0253649*

Hydraulic Diagram - Manual Descent (October 1992 to Present)

Ref.

1281814

Hydraulic Diagram - Oil Cooler

Ref.

2791921*

Hydraulic Diagram - Standard (Prior to S/N 38697) Hydraulic Diagram - Standard (S/N 38697 to Present)

Ref.

2791922 2792377

Hydraulic Schematic (4WD) (Prior to S/N 38697) Hydraulic Schematic (4WD) (S/N 38697 to Present)

REV.

Ref.

1692883

2792375*

6-20

Hydraulic Diagram - Drive (4WD/ Deutz Engine) (Prior to S/N 38697) Hydraulic Diagram - Drive (4WD/ Deutz Engine) (S/N 38697 to Present)

QTY.

Ref.

Ref. Ref.

3120820

SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE

7-1 7-2 7-3

DESCRIPTION

PAGE

ELECTRICAL SCHEMATIC (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC (S/N 38697 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 ELECTRICAL COMPONENTS AND DIAGRAM CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

S E C T I O N 7 E L E C T R I C A L

3120820

7-1

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL SCHEMATIC (PRIOR TO S/N 38697) (SHEET 1 OF 4)

7 E L E C T R I C A L

1870022 - C

7-2

3120820

SECTION 7 ELECTRICAL

S E C T I O N

FIGURE 7-1. ELECTRICAL SCHEMATIC (PRIOR TO S/N 38697) (SHEET 2 OF 4)

7 E L E C T R I C A L

1870022 - C

3120820

7-3

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL SCHEMATIC (PRIOR TO S/N 38697) (SHEET 3 OF 4)

7 E L E C T R I C A L

1870022 - C

7-4

3120820

SECTION 7 ELECTRICAL

S E C T I O N

FIGURE 7-1. ELECTRICAL SCHEMATIC (PRIOR TO S/N 38697) (SHEET 4 OF 4)

7 E L E C T R I C A L

1870022 - C

3120820

7-5

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL SCHEMATIC (S/N 38697 TO PRESENT) (SHEET 1 OF 4)

7 E L E C T R I C A L

1870088 - A

7-6

3120820

SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL SCHEMATIC (S/N 38697 TO PRESENT) (SHEET 2 OF 4)

S E C T I O N 7 E L E C T R I C A L

1870088 - A

3120820

7-7

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL SCHEMATIC (S/N 38697 TO PRESENT) (SHEET 3 OF 4)

7 E L E C T R I C A L

1870088 - A

7-8

3120820

SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL SCHEMATIC (S/N 38697 TO PRESENT) (SHEET 4 OF 4)

S E C T I O N 7 E L E C T R I C A L

1870088 - A

3120820

7-9

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART FIG & ITEM #

7

PART NUMBER

Ref.

REV.

3740049 3990010 1060341 0253077 0140026 1540002 4932635

Australian Spec Wiring Diagram

Ref.

D

1281819 1060394

Boom Electric Components Cable, Electrical - 10/4 Options: Prior to S/N 37026 S/N 37026 to Present Cable, Electrical - 16/36 Options: Prior to S/N 37026 S/N 37026 to Present

Ref.

H

0610091 3740049 4932639/1282091 4932638/1282091

1060392

—

2/C 2/C

5

140 ft./43m 149ft/45.4m

140 ft./43m 149ft/45.4m

4931961 3730024

Boom Length Indicator Electrical Diagram Resistor - 100 ohms/1/2 watt

Ref. 1

1

4932608

Broken Chain Indicator Electrical Diagram

Ref.

B

Ref.

A

4932099 1060300 4120012 3740057 3740066

4932312 4120012 3740057 3740066

7-10

QTY.

Alarm Wiring Diagrams Ref. Alarms Electrical Diagram (Travel, Backup, Swing Ref. and Descent) (Prior to April 1993) Card, Circuit 1 Relay 1 Alarms Electrical Diagram (Backup, Swing and Ref. Descent) (April 1993 to Present) Alarms Electrical Diagram (Travel) (April 1993 to Ref. Present) Relay 1 Diode 6 Amp 2 Cable, Electrical - 16/2 11Ft/3.4m Alarm Electrical Diagram (Tilt) Ref. Alarm 1 Capacitor (Prior to S/N 38697) 1

4932507

E L E C T R I C A L

DESCRIPTION ELECTRICAL COMPONENTS AND DIAGRAM CHART Note: Diagrams with Asterisk (*) are shown in preceding pages. Diagrams not shown are available from the JLG Service Department.

Drive Cut-Out Electrical Diagram - 8m (Dutch and German Spec Only (Not Shown) Cable, Electrical - 16/3 Socket, Relay Relay - 2PDT Spring, Relay Drive Cut-Out Electrical Diagram - Horizontal (Italian Spec Only) (Not Shown) Socket, Relay Relay - 2PDT Spring, Relay

15 ft./4.6m

1 1 1

Ref.

A

1 1 1

3120820

SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM #

PART NUMBER 0255152 4360179 4360065

4932892 4921886 3740080

Engine Distress Electrical Diagram Switch, Temperature Switch, Oil Pressure Engine Shutdown Electrical Diagram (Broken Fan Belt) Harness Relay, Bosch

QTY.

REV.

Ref. 1 1

3

Ref.

—

1 1

3300047 0960239 4932484 4921417

Frame Electrical Diagram Harness Assembly

Ref. 1

A

4932492 1693405 1692927

French Spec Modification Electrical Diagram Relay, Time Delay Base, Relay

Ref. 1 1

C

4931858 3990010 4460027

Generator Electrical Diagram Diode 6 Amp Receptacle, Twist Lock

Ref. 1 1

A

1282370

Lights Electrical Diagrams: Beacon Light Installation - Amber (Australian Spec - Prior to September 1995 and EN280 and CE Specs Built to Present) Light, Rotary Beacon - Amber Beacon Light Installation - Amber (Australian Spec - Prior to September 1995 to Present) Light, Rotary Beacon - Amber Beacon Light Components - Red Light, Rotary Beacon - Red Headlights/Taillights Components Headlight Bracket Taillight Cable, Electrical - 16/4 Options: Prior to S/N 37026 S/N 37026 to Present Switch, Toggle Breaker, Circuit - 15 Amp Relay Nameplate, Head Light (S/N 31730 to Present)

Ref.

C

Ref.

2

1060042 4460049

0255277 2920018 0255816 2920105 0255278 2920009 0255271 2920110 0901927 2920113 1060079

4360199 4360287 3740080 3250585

Ref.

7

Four Wheel Steer Electrical Diagram Cable, Electrical - 16/5 Connector, Strain Relief (Locate at Ground Control Box) Nut, Conduit Bushing

4932434/1281684

3120820

DESCRIPTION

—/A

15 ft./4.6m

1 1 1

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

S E C T I O N

2

2 5

140 ft./43m 149ft/45.4m

1 1 1 1

7-11

E L E C T R I C A L

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM #

PART NUMBER 0255273 3740049 3990010 0255272 2920113 0901928 4360089

7 E L E C T R I C A L

Stop Lights Components Relay Diode 6 Amp Turn Signal Components Taillight Bracket Switch, Flasher

QTY.

REV.

Ref. 4 5 Ref. 2 2 1

2

2

0255274 0270566 2920026 2920029 4360065 3740049 3990010 3740080 3252074

Low Oil Pressure Shutdown Electrical Diagrams Prior to S/N 54482 S/N 54482 to Present Lamp, Red (At Console Box) Bulb, Light Switch, Oil Pressure Relay Diode 6 Amp Relay Nameplate, Engine Distress (S/N 27440 to Present)

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

4932597 3990010 3990001 4360274 3740049

Manual Descent Electrical Diagram Diode 6 Amp Diode 1 Amp Switch, Push Button Relay

Ref. 1 1 1 1

A

Oil Cooler Electrical Diagram

Ref.

3/A

Platform Electrical Diagram (EN280 SPEC) Platform Electrical Diagram (CE SPEC) (Prior to S/N 38697) Diode - 6 Amp Cable, Electrical - 12/4 (To Footswitch) Cable, Shielded Electrical - 20/3 (1600153 Control Card to Function Speed Switch) Resistor - 180 ohm 1/2 watt Resistor - 510 ohm 1/2 watt Capacitor

Ref.

I

Ref.

1

0252906/1281814

4932481 4932941 3990010 1060012 1060128 3730102 3730023 1540003

4933045 3990010 1060012 1060128 3730102 3730023 1540003

7-12

DESCRIPTION

Platform Electrical Diagram (CE SPEC) (S/N 38697 to Present) Diode - 6 Amp Cable, Electrical - 12/4 (To Footswitch) Cable, Shielded Electrical - 20/3 (1600153 Control Card to Function Speed Switch) Resistor - 180 ohm 1/2 watt Resistor - 510 ohm 1/2 watt Capacitor

4 1/A

15 8 ft./2.5m 4 ft./1.3m

1 1 1

Ref.

3

20 8 ft./2.5m 4 ft./1.3m

1 1 1

3120820

SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM #

PART NUMBER

QTY.

4360057 4360274 3252238 3740049 1060341

Platform Bumpers Electrical Diagrams Prior to S/N 43389 S/N 43389 to Present Switch, Limit Switch, Push Button Decal - Softtouch Relay Cable, Electrical - 16/2

12 ft./3.7m

4932621 1060300

Platform Gate Interlock Electrical Diagram Cable, Electrical

15 ft./4.6m

0253987

Platform Worklights Electrical Diagram Platform Worklights Electrical Diagram (With Bumpers) Light, Halogen

0255695/1282197 0259365/1282197

0254748 2920111 0254435/1282163

Supply Locally Supply Locally 1060545

4932482 3990010 1060341 1060016 1060302 4921415 4921416 4921418 1540003 3730095

4932942 4933048 3990010 1060341 1060016

3120820

DESCRIPTION

Receptacle at Platform Electrical Components Cover, Receptacle Receptacle Cable, Electrical - 10/3 Options: Prior to S/N 37026 S/N 37026 to Present Standard Electrical Diagram - Deutz (Prior to S/N 25609) Diode - 6 Amp Cable, Electrical - 16/2 (GCB to Horizontal Limit Switch -15 ft./4.6m and Override Test Switch to Load Management Limit Switch - 14 ft./4.3m) Cable, Electrical - 16/3 (Override Test Switch to Proximity Switch) Cable, Electrical - 16/5 (GCB to Boom Length Measuring Device) Harness (Engine Terminal Strip to GCB) Harness (Valves to GCB) Harness (GCB to Collector Ring) Capacitor Resistor - 7.5 Ohm Standard Electrical Diagram - Deutz (S/N 25609 to S/N 38697) Standard Electrical Diagram - Deutz (S/N 38697 to Present) Diode - 6 Amp Cable, Electrical - 16/2 (GCB to Horizontal Limit Switch - 15 ft./4.6m and Override Test Switch to Load Management Limit Switch - 14 ft./4.3m) Cable, Electrical - 16/3 (Override Test Switch to Proximity Switch)

Ref. Ref. Ref. 1 1 1 2

Ref.

REV. 5/G 2/H

7 A

Ref.

4

Ref.

2

2 Ref. 1 1 A/R

3/B

160ft./48.8m 149ft/45.4m

Ref.

S E C T I O N

J

20 30 ft./9.1m

15 ft./4.6m

15 ft./4.6m

1 1 1 1 2

Ref.

1

Ref.

1

22 30 ft./9.1m

15 ft./4.6m

7-13

E L E C T R I C A L

S E C T I O N

SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM #

PART NUMBER 1060302 4921415 4921416 4921418 1540003 3730095 3730115

7 E L E C T R I C A L

7-14

DESCRIPTION Cable, Electrical - 16/5 (GCB to Boom Length Measuring Device) Harness (Engine Terminal Strip to GCB) Harness (Valves to GCB) Harness (GCB to Collector Ring) Capacitor Resistor - 7.5 Ohm Resistor Adjustable - 7.5 Ohm

QTY.

REV.

15 ft./4.6m

1 1 1 2 2 1

1870022* 1870088*

Standard Electrical Schematic (Prior to S/N 38697) Standard Electrical Schematic (S/N 38697 to Present)

Ref. Ref.

C A

4932570

TUV Monitoring System Wiring Diagram (Optional on German TUV Machines)

Ref.

E

3120820

SECTION 8 DECALS TABLE OF CONTENTS FIGURE

8-1

DESCRIPTION

PAGE

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

S E C T I O N 8 D E C A L S

3120820

8-1

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION

8 D E C A L S

8-2

3120820

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION FIG & ITEM #

PART NUMBER 0252839 0257221

1 2 3 4 5 6 to 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 to 27 28 29 30 31 32 33 34 35 36 37 38 to 41 42 43 44 45 46 47 48 49 to 51 52

Not Available 1700584* 1701509* Not Used 3251813 Not Used 1701518* 1701501* Not Used 1701504* 1701500* 1701704* 1701703 Not Used 3820001 0641408 1060279 Not Used 1701700 1701699* 1701701* Not Used 0961127 Not Used 1701502* 1701503* 0860520 3311405 4751400 Not Used Not Used 1701499* Not Used 1701702* 4420052* Not Used 1702300* Not Used 4420051* Not Available Not Used 1704421 0100011

3120820

DESCRIPTION DECALS INSTALLATION (STANDARD PARTS) PRIOR TO S/N 25609 S/N 25609 TO PRESENT

QTY.

REV.

Ref. Ref. Ref.

E 1

Nameplate - Serial Number Decal - Patent Decal - Manual

1 1 1

Decal - USA

1

Decal - Crushing Decal - Arrow

7 4

Decal - Hydraulic Oil Decal - Tie Down/Lift Up Decal - Stripe Decal - Stripe

1 4

Rivet Bolt 1/4"-20NC x 1" Cable, Lanyard

A/R 1 1

Bushing, Snap

1

Decal - Hydraulic Oil Full Decal - Hydraulic Oil Low Box, Manual Storage Locknut 1/4"-20NC Flatwasher 1/4"

1 1 1 5 6

Decal - Do Not Tie Down/Do Not Lift Up

2

Decal - Tie-Down Decal - Corner Warning Strip Decal - Bar Code Decal - Extend/Retracted (S/N 47227 to Present) —————————— Loctite #242

D E C A L S

27 ft./8.2m

2 2 2

Decal - JLG Decal - Corner Warning Strip

8

34 ft./10.4m

Decal - 120HX Decal - JLG Lift Decal - 4 x 4 x 4

S E C T I O N

1 10ft./3m 4 11ft./3.4m 1 2 A/R

8-3

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM #

101 102 103

8

PART NUMBER

DESCRIPTION

QTY.

0010448

DECAL INSTALLATION - FUEL (VARIABLE PARTS)

Ref.

1701505 1701543 1701542

0252840 0257226 0252844 0252841 0252842 0252843 0253264 0252840

D E C A L S

201

202 203

3252347 1703518 1693292 1693294 1701600 1701791 3252347 3820001 1700037* 1701616 1701515 1693285 1701599 1701789 1700037

204 1701296 1703529* 1701532 1703606 1701507 1703607 1701563 1703608 1701697 1703609 1701799 1703611 1701296 1703529

8-4

Decal - Diesel Fuel Decal - L.P. Fuel Decal - Gasoline Fuel DECAL INSTALLATION (VARIABLE PARTS) Australian Spec Prior To S/N 25609 Australian Spec S/N 25609 To Present Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Nameplate - Footswitch Warning Options: Australian Spec Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Rivet Decal - Ground Control Location Options: Australian Spec Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Decal - Load Management Options: Australian Spec Prior to S/N 33726 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 Spec S/N 33726 to Present Spanish Spec Prior to S/N 33726 Spanish Spec S/N 33726 to Present UK Spec Prior to S/N 33726 UK SpecS/N 33726 to Present

REV.

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

A 3 4 4 2 2 2 2

1

4 1

1

3120820

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

205 1690697* 1701596 1701577 1701649 1690697 1690697 1690697 1690697 1690697 206 1690696* Not Required 1693286 1693288 1701601 1701794 1690696 207 1691483* Not Required 1693289 1693291 1701602 1701798 1691483 208 1701728* 1701732 1701729 1701730 1701731 1701800 1701728 209 Not Required 1701567 210 Not Required 1701596 211 Not Required Not Required 1703677* 212 Not Required Not Required 1703665*

3120820

DESCRIPTION Decal - Caution Options: Australian Spec Dutch Spec French Spec Prior to S/N 29214 French Spec S/N 29214 to S/N 38697 French Spec S/N 38697 to Present German & Austrian Spec Italian Spec Spanish Spec UK Spec Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Decal - Caution Options: Australian Spec Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Decal - Light Indicates Options: Australian Spec Dutch Spec French Spec German & Austrian Spec Italian Spec Spanish Spec UK Spec Decal - Capacity Options: All Specs Except Dutch Spec Dutch Spec Decal - Caution Options: All Specs Except Dutch Spec Dutch Spec Decal - Safe Working Load Options: All Specs Except Australian Spec Australian Spec Prior to S/N 34839 Australian Spec S/N 34839 to Present Decal - Danger Options: All Specs Except Australian Spec Australian Spec Prior to S/N 34839 Australian Spec S/N 34839 to Present

QTY.

REV.

1

S E C T I O N 8 D E C A L S

1

1

2

A/R 0 2 A/R 0 1 A/R 0 0 1 A/R 0 0 2

8-5

S E C T I O N

SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM #

PART NUMBER

213 Not Required Not Required 1703663* 214 Not Required Not Required 1703664*

8

215 Not Required Not Required 1702612*

D E C A L S

Not Available 2900998

0257223

301 302

8-6

1703481 1702928

DESCRIPTION

QTY.

Decal - Maintenance Options: All Specs Except Australian Spec Australian Spec Prior to S/N 34839 Australian Spec S/N 34839 to Present Decal - Caution Options: All Specs Except Australian Spec Australian Spec Prior to S/N 34839 Australian Spec S/N 34839 to Present Decal - Attach Belt Options: All Specs Except Australian Spec Australian Spec Prior to S/N 34839 Australian Spec S/N 34839 to Present —————————— Decal Kit Options: All Specs Except Australian Spec Australian Spec (Note: Items with * Included in kit):

A/R 0 0 1 A/R 0 0 1 A/R 0 0 2

CE DECAL INSTALLATION Note: Not Required on Australian Machines.

Decal - Max Tire Load Decal - CE

REV.

A/R 0 1

Ref.

2

4 1

3120820

SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS EURO 120HX 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

QTY PER FLEET

DESCRIPTION 1-10

10-20

20 OR MORE

STANDARD PARTS 7000645 7012730 7021401 4360314 4360277 7012906 4360363 7017451 7012943 7012944 4360263 4360259 3740070 3740016 3740122 3740049 4360216 4360232 4360112 4360470 2860030 4360212 4360069 4360274 4360330 4360328 3740123 4360282 4360476 4360475 4360074 4360340 3990001 2120136 7004214 3740059 3740080 3740067 7008829 7008828

3120820

Coil (Figure 1-1) Coil (Figure 1-2) Coil (Figures 1-2 and 2-4) Switch, Toggle (Figures 1-8, 2-11 and 4-4) Switch, Limit (Figures 1-3, 2-1, 3-3, 3-5, 3-6 and 4-1) Coil (Figure 2-2) Switch, Level Sensor (Figure 2-2) Coil (Figure 2-4) Coil (Figure 2-4) Coil (Figure 2-4) Switch, Limit (Figure 2-10) Switch, Proximity (Figure 2-10) Relay - SPDT (Figure 2-11) Relay - 3PDT (Figure 2-11) Relay (Figure 2-11) Relay - SPDT (Figures 2-11, 4-4 and 7-3) Breaker, Circuit - 30 Amp (Figure 2-11) Breaker, Circuit - 15 Amp (Figures 2-11) Breaker, Circuit - 5 Amp (Figure 2-11) Switch, Key (Figure 2-11) Key, Replacement (Figure 2-11) Breaker, Circuit - 3 Amp (Figure 2-11) Breaker, Circuit - 10 Amp (Figures 2-11 and 4-4) Switch, Push Button (Figures 2-11, 4-4 and 7-3) Switch, Toggle (Figures 2-11 and 4-4) Switch, Toggle (Figure 2-11) Relay (Figures 2-11 and 4-4) Block, Contact (Figures 2-11 and 4-4) Block, Contact (Figures 2-11 and 4-4) Switch, Push Button (Figures 2-11 and 4-4) Switch, Toggle (Figure 2-13) Switch, Potentiometer (Figure 2-13) Diode - 6 Amp (Figures 2-13 and 7-3) Element, Charge Pump Filter (Figure 2-14) Element, Air Filter (Figure 2-14) Relay (Figure 2-14) Relay (Figure 2-14) Relay (Figure 2-14) Board, Circuit (Figure 2-14) Cable, Throttle (Figure 2-14)

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 4 1 Dozen 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 8 1 Dozen 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 12 1 Dozen 1 1 1 1 1

9-1

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 P A R T S S T O C K

S E C T I O N

SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS EURO 120HX 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

9

7029274 7014503 1660183 1660233 2120129 1340046 7006138 7000638 7000647 2940006 4360031 4360336 1600277 7020512 7003797 7003789 4360161 4360057 3990010

R E C O M M E N D E D S E R V I C E

QTY PER FLEET

DESCRIPTION Filter, Engine Fuel (Deutz) (Figure 2-14) Filter, Engine Oil (Deutz) (Figure 2-14) Coupling (Deutz) (Figure 2-16) Coupling (Deutz) (Figure 2-16) Element, Hydraulic Oil Filter (Figure 2-20) Breather, Hydraulic (Figure 2-20) Pin Kit - Powertrack (Figure 3-1) Switch (Figure 3-5) Cable (Figure 3-5) Latch, Door (Figure 4-1) Footswitch (Figure 4-1) Switch, Toggle (Figure 4-4) Controller, PQ (Figure 4-4) Board, Circuit - 1600155 Controller (Figure 4-4) Board, Circuit - 1600135 Controller (Figure 4-4) Switch, Steer - 1600135 Controller (Figure 4-4) Breaker, Circuit - 20 Amp (Figure 4-4) Switch, Limit (Figures 4-5 & 7-3) Diode - 6 Amp (Figure 7-3)

1-10

10-20

20 OR MORE

1 1 case 1 1 4 1 24 1 1 1 1 1 1 1 1 1 1 1 1

1 1 case 1 1 8 1 24 1 1 1 1 1 1 1 1 1 1 1 1

1 1 case 1 1 12 1 24 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

VARIABLE PARTS 7006193 7006196 7006153

P A R T S

7006145 1693405 3740057

Powertrack Repair Section Without Chip Covers - Left Side (Figure 3-1) Powertrack Repair Section With Chip Covers - Left Side (Figure 3-1) Powertrack Repair Section Without Chip Covers - Right Side (Figure 3-1) Powertrack Repair Section With Chip Covers - Right Side (Figure 3-1) Relay (French Spec Only) (Figure 7-3) Relay (Italian Spec Only) (Figure 7-3)

S T O C K

9-2

3120820

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.

FIGURE 10-1. MISCELLANEOUS SPECIAL OPTIONS FIG & ITEM #

PART NUMBER

DESCRIPTION MISCELLANEOUS SPECIAL OPTIONS Airline Installation - 1/2"

Ref.

2910105

Axle Hose Retract Springs Kit

Ref.

1702788 1703479 1704174

Biodegradable Hydraulic Fluid Decal Biodegradable Hydraulic Fluid Decal (German Spec) SYN Biodegradable Hydraulic Fluid Decal SYN Biodegradable Hydraulic Fluid Decal (German Spec)

Ref. Ref. Ref.

9983982

Cable, Control 10/3

Ref.

0256789

Camera Mounting Installation

Ref.

0258888

Decals Installation - Lifting

Ref.

0257221

Decals Installation - Common Global (S/N 25609 to Present)

Ref.

0254109 3220088 4566219

Exhaust Purifier Installation Muffler, Exhaust Purifier Tube, Exhaust

Ref. 1 1

1282370

Ref.

0255278 0255271 0255273 0255272

Lights Installations Options: Beacon Light Installation - Amber (Mounted on Hood) (Australian Spec Built Prior to September 1995 and All EN280 & CE Specs Built to Present) Beacon Light Installation - Amber (Mounted on Hood) (Australian Spec Built September 1995 to Present) Beacon Light Installation - Amber (Mounted on Platform) Beacon Light Installation - Red Headlights/Taillights Installation Stop Light Installation Turn Signals Installation

0253050

Pinion Installation

Ref.

0256436

Pipe Rack Installation

Ref.

0238442

Platform Step Installation

Ref.

0254435

Receptacle Installation at Platform

Ref.

0255277 0255816 0270723

REV.

Ref.

0255060

1704175

3120820

QTY.

S E C T I O N 10 S P E C I A L

Ref.

O P T I O N S

Ref. Ref. Ref. Ref. Ref. Ref. Ref.

10-1

S E C T I O N

SECTION 10 SPECIAL OPTIONS FIGURE 10-1. MISCELLANEOUS SPECIAL OPTIONS (CONTINUED) FIG & ITEM #

PART NUMBER

7016654 7002822 7004275 7004276 7002828 7014676 9900443 0257728

Tube Rack Installation

Ref.

0253050

Turntable Pinion Shield Installation

Ref.

0258918

Utility Rack Installation

Ref.

0255061

Weld Leads Installation

Ref.

7002823

S P E C I A L

QTY.

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

7002821 2900838

10

DESCRIPTION

REV.

Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref.

O P T I O N S

10-2

3120820

3120820

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