Illustrated Parts Manual
Model 740AJ S/Ns 62899 64684 3121146 December 30, 2013
REVISION LOG October 2001 - Original Issue Of Manual (Edited to B/M 0010551 Revision 20) April 15, 2002 - Revised Manual to include info for S/N’s 62899 and 64684. (Note: These two machines were built without the ADE system.) August 15, 2002 - Added Deutz Engine June 1, 2006 - Revised September 25, 2006 - Revised April 18, 2007 - Revised July 31, 2007 - Revised December 10, 2007 - Revised April 27, 2011 - Revised July 29, 2011 - Revised October 21, 2011 - Revised January 10, 2012 - Revised July 31, 2012 - Revised December 14, 2012 - Revised March 26, 2013 - Revised June 20, 2013 - Revised September 16, 2013 - Revised December 30, 2013 - Revised
3121146
A
REVISION LOG
B
3121146
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
AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
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
CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ACCESSORY VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 FORD DUAL FUEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 2-28 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 ROTARY COUPLING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 ELECTRICAL OPTIONS INSTALLATIONS (TURNTABLE MOUNTED) . . . . . . . . . . . . . . . . . . . 2-48 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4
BOOM AND CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) . . . . . . . . . . . . . . . . . . . . . 3-12
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5
PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 CONTROLLER ASSEMBLY (SWING AND LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4 5-5 5-6
3121146
LEVEL CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 LIFT CYLINDER ASSEMBLY - JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 MASTER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 SLAVE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
i
TABLE OF CONTENTS FIGURE NO. 5-7 5-8
TITLE
PAGE NO.
STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 TELESCOPE CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4
DRIVE HYDRAULIC DIAGRAM (4WD/4WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP). . . . . . . . . 6-10 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-2
ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 HARNESS COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1
DECALS INSTALLATION - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
ii
3121146
SECTION 1 FRAME TABLE OF CONTENTS FIGURE
1-1 1-2 1-3 1-4 1-5 1-6
DESCRIPTION
AXLE AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
1-2 1-6 1-8 1-12 1-14 1-16
S E C T I O N 1 F R A M E
3121146
1-1
SECTION 1 FRAME S E C T I O N
FIGURE 1-1. AXLE AND STEERING INSTALLATION
1 F R A M E
1-2
3121146
SECTION 1 FRAME .
FIGURE 1-1. AXLE AND STEERING INSTALLATION FIG & ITEM #
PART NUMBER 0258286 0271654
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
0100011 0681608 Not Used 0641820 0642212 0962102 3422703 3538047 3539877 3539878 3841287 4070878 4070879 4070944 4070945 4711600 4740472 Not Used 4845658 4846413
0258909 0271352 101 102 103 104 105 106
107 to108 109 110 111
112
3121146
0100011 0362726 Not Used 0641608 0962152 0962224 0962448 Not Used 1683740
DESCRIPTION FIXED AXLE INSTALLATION OPTIONS Without Tow Package With Tow Package
QTY.
REV.
Ref Ref Ref
C B
Loctite #242 (Not Shown) Bolt 3/8”-16NC x 1” (Grade 8)
AR 4
Bolt 1/2”-13NC x 2 1/2” Bolt 3/4”-10NC x 1 1/2” Bushing, Garmax Pin, Axle Pivot Shim, Wear Plate, Stop Plate, Stop Keeper, Pin Shim 1/16” Shim 1/8” Shim 1/16” Shim 1/4” Flatwasher 3/8” Narrow Washer, Special
2 1 2 1 2 2 2 1 AR AR AR AR 4 1
Axle Weldment Options: Without Tow Package With Tow Package
1
STEERING INSTALLATIONS 4WS (Without Tow Package - Rear Steering Typical / Double Qty Listed) 2WS (With Tow Package)
1 F R A M E
Ref Ref
A
Ref
B
Loctite #242 (Not Shown) Tie-Rod
AR 1
Bolt 3/8”-16NC x 1” Bearing, Garmax Bearing, Garmax Options: Without Tow Package With Tow Package
7 2 4
Steer Cylinder Assembly (See CYLINDER SECTION for Breakdown)
2
Not Used 3422701 3422701 3422567 3422702
Pin, Steer, Spindle Attach Options: Without Tow Package With Tow Package (Left Side) With Tow Package (Right Side) Pin, Tie-Rod
S E C T I O N
AR 2 1 1 2
1-3
SECTION 1 FRAME S E C T I O N
FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
113
114 115 to 117 118 119
1
3422701 3422753 3422754 Not Used 3841143 4130358 4130390
120
F R A M E
1-4
121 122 123 124 125 126
4130357 4130388 4740111 Not Used 4740256 4740463 4740473 Not Used
301
2360570
DESCRIPTION Kingpin Options: Without Tow Package With Tow Package Pin, Attach
QTY. 4
2
Shaft, Keeper 3/8”x 3” Spindle Weldment (Left Side) Options: Without Tow Package With Tow Package Spindle Weldment Options: (Right Side) Without Tow Package With Tow Package Washer, Special
6 1
Washer, Thrust Washer, Thrust Washer, Special
2 4 2
FRAME WELDMENT
REV.
1
4
Ref
3121146
SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 1 F R A M E
3121146
1-5
SECTION 1 FRAME S E C T I O N
FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS
1 F R A M E
1-6
3121146
SECTION 1 FRAME .
FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS FIG & ITEM #
PART NUMBER 0270211
1 to 2 3 4 5
Not Used 0682016 0920117 7018612 2780228
6
3160204
7 8 9 10 to12 13 14
3300007 3311801 4300097 Not Used 4891800 4892000
0258399 0258333 0258334
101 102 103
4520205 4640113 4860188 0256196
201 202 203
3121146
1670776 0641550 0100011
DESCRIPTION WHEEL DRIVE INSTALLATION
QTY.
REV.
Ref
B
Bolt 5/8”-11NC x 2” (Grade 8) Drive Brake Assembly Kit, Repair Drive Hub Assembly (See DRIVE HUB ASSEMBLY for Breakdown) Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for Breakdown) Nut, Wheel Nut 1/2” - 13NC Stud
40 8 8
Flatwasher, 1/2” Flatwasher, 5/8”
8 32
TIRE AND WHEEL INSTALLATION IN445/55D19.5 (18 x 19.5) Foam-Filled IN445/55D19.5 (18 x 19.5) Foam-Filled Left Side IN445/55D19.5 (18 x 19.5) Foam-Filled Right Side 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 - IN445/55D19.5 (18 x 19.5): Valve, Air Rim, Wheel - 14 x 19.5 WHEEL COVER INSTALLATION (OPTIONAL) Cover, Wheel Bolt 5/16” - 18NC x 6 1/4” Loctite (Not Shown)
32 4 4
1
4
Ref Ref 2 2 Ref
F R A M E B B B
1 1 1 Ref
S E C T I O N
2/A
4 20 AR
1-7
SECTION 1 FRAME S E C T I O N
FIGURE 1-3. DRIVE HUB ASSEMBLY
1 F R A M E
1-8
3121146
SECTION 1 FRAME .
FIGURE 1-3. DRIVE HUB ASSEMBLY FIG & ITEM #
PART NUMBER 2780228
1 1A 1B 1C 1D 1E 1F 1G 1H 1I 1J 1K 1L 1M 1N 2 3 3A 3B 3C 3D 3E 3F 3G 4 5 6 6A 6B 6C 6D 6E 6F 6G 6H 7 8 9 10 11 12 13 14 15 16 17
3121146
Not Available 7017031 7000236 7000273 7000272 7000275 7000274 7017033 7000239 7000240 7011928 Not Used Not Used Not Used 7000265 7017034 Not Available 7017036 7011901 7011902 7001903 7017040 7017037 7011906 7017035 7000224 Not Available 7017032 7017042 7000220 7000231 7000235 7000213 7000238 7017048 7000282 7000283 7000284 7017027 7017044 7017045 7017043 7017046 7000287 7000288 7000289
DESCRIPTION DRIVE HUB ASSEMBLY Spindle/Housing Assembly Spindle Seal Cone, Bearing Cup, Bearing Cone, Bearing Cup, Bearing Housing Washer, Thrust Ring, Retaining Plug, Pipe
Stud, Wheel Gear, Ring Carrier Assembly Carrier Thrustwasher, Tanged Bearing, Needle Spacer, Thrust Shaft, Planet Gear, Cluster Rollpin Gear, Internal O-Ring Cover Assembly Cover Cap Bolt 1/4”-20NC x 3/4” Cap, Disengage Rod, Disengage O-Ring O-Ring Plug, Pipe Thrustwasher O-Ring Ring, Retaining Ring, Retaining Shaft, Input Spacer, Input Gear, Sun Spacer, Input Thrustwasher Thrustwasher Bolt 3/8”-16NC x 2 1/2” (Grade 8)
QTY.
REV.
Ref
A
1 1 1 1 1 1 1 1 1 1 1
S E C T I O N 1 F R A M E
10 1 1 1 6 96 3 3 3 3 1 1 1 1 1 4 1 1 1 1 1 2 1 1 1 1 1 1 AR 4 2 12
1-9
SECTION 1 FRAME S E C T I O N
FIGURE 1-3. DRIVE HUB ASSEMBLY FIG & ITEM #
PART NUMBER
18 19 20
Not Used 7000290 7017047 7017068
DESCRIPTION Coupling Pin, Dowel —————————— Seal Kit
QTY.
REV.
1 2 1
1 F R A M E
1-10
3121146
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 1 F R A M E
3121146
1-11
SECTION 1 FRAME S E C T I O N
FIGURE 1-4. DRIVE MOTOR ASSEMBLY
1 F R A M E
1-12
3121146
SECTION 1 FRAME .
FIGURE 1-4. DRIVE MOTOR ASSEMBLY FIG & ITEM #
PART NUMBER 3160204
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
3121146
DESCRIPTION DRIVE MOTOR ASSEMBLY Shaft - 13 Teeth Seal, Shaft Bearing, Cradle Housing Rod, Piston Piston, Stroking O-Ring Nut, Adapter 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
A
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
1-13
SECTION 1 FRAME S E C T I O N
FIGURE 1-5. DRIVE VALVES INSTALLATIONS
1 F R A M E
1-14
3121146
SECTION 1 FRAME .
FIGURE 1-5. DRIVE VALVES INSTALLATIONS FIG & ITEM #
PART NUMBER 0270211
1 2 3 to 9 10 10A 10B 10C 11
12 13 to14
0100011 0641628 Not Used 4641041 7022396 7021625 7022398 7023900 7022397 7022399 4641042 7021656 7021625 4751600 Not Used 0258343
101 102 103 104 105
3121146
0100011 0641608 3570686 3570690 4751600
DESCRIPTION WHEEL DRIVE INSTALLATION Loctite #242 (Not Shown) Bolt 5/8”-11NC x 3 1/2” Flow Divider Valve Assembly Cartridge, Flow Divider Seal Kit - 7022396 Cartridge Cartridge, Load Shuttle Seal Kit - 7022398 Cartridge Cartridge, Check Valves Seal Kit - 7022397 Cartridge Flow Divider Valve Assembly Cartridge, Flow Divider Seal Kit - 7021656 Cartridge Flatwasher, 3/8”
FRAME COVERS INSTALLATION Loctite #242 (Not Shown) Bolt, 3/8” - 16NC x 1” Plate, Cover Front Plate, Cover Rear Flatwasher, 3/8”
QTY.
REV.
Ref
B
AR 4 1 1 1 1 1 2 2 1 2 2 4
Ref
S E C T I O N 1 F R A M E
C
AR 10 1 1 10
1-15
SECTION 1 FRAME S E C T I O N
FIGURE 1-6. TOW PACKAGE INSTALLATION
1 F R A M E
1-16
3121146
SECTION 1 FRAME .
FIGURE 1-6. TOW PACKAGE INSTALLATION FIG & ITEM #
PART NUMBER 0271352
1 2 3 4 5 to 6 7 8 9 to 14 15 16 17 18 19 to 20 21 22 23 to 25 26
0100011 Not Used 0641508 0641608 Not Used 0962292 0962348 Not Used 3422813 3422848 3573001 3841143 Not Used 4740111 4740155 Not Used 4846414 0271655
101 102 103 104 105 106
201 202 203 204 205 206 207 208 209 210 211 212 213
3121146
0232121 0641504 3539662 4640261 4711500 0100011
DESCRIPTION TOW PACKAGE COMPONENTS
QTY.
REV.
Ref
B
Loctite, #242 (Not Shown)
AR
Bolt 5/16”-18NC x 1” Bolt 3/8”-16NC x 1”
1 AR
Bearing, Garmax Bearing, Composite
2 1
Pin Pin Link, Connecting Pin, Keeper 3/8”
1 1 1 AR
Washer, Thrust Washer, Thrust
AR AR
Bar, Pivot TOW BAR INSTALLATION Tow Bar Assembly (See Items 201 to 213 for Breakdown) Bolt 5/16”-18NC x 1/2” Plate, Valve Mounting Valve, Float Position Flatwasher 5/16” (Narrow) Loctite #242 (Not Shown)
1 F R A M E
1 Ref
A
1 2 1 1 2 AR
0232121
TOW BAR ASSEMBLY
Ref
0360406 4843777 0642038 3312001 4762000 4070450 4070561 4740036 3420447 3420372 1260135 3670170 4070560
Bar, Draw Weldment, Tow Bar Bolt Nut Lockwasher Shim, Spacer Shim, Spacer Flatwasher Pin, Towing Pin, Cotter Chain Ring Shim
1 1 5 5 5 AR AR 1 1 1 1 2 2
S E C T I O N
7
1-17
SECTION 1 FRAME S E C T I O N
FIGURE 1-6. TOW PACKAGE INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER 0271686
301 302 303 304 305 306
1
1260017 3311401 3420292 4751400 4846507 4846508
DESCRIPTION TOW BAR STORAGE INSTALLATION Chain Nut 1/4”-20NC Pin Flatwasher 1/4” (Wide) Bracket (Front) Bracket (Rear)
QTY.
REV.
Ref
A
2 2 2 2 1 1
F R A M E
1-18
3121146
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
3121146
DESCRIPTION
CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORD DUAL FUEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTARY COUPLING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL OPTIONS INSTALLATIONS (TURNTABLE MOUNTED) . . . . . . . . . . . . . . . . . . . HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TRAY JACK INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
2-2 2-6 2-10 2-12 2-14 2-16 2-18 2-24 2-28 2-30 2-36 2-40 2-42 2-44 2-48 2-50 2-54
S E C T I O N 2 T U R N T A B L E
2-1
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS
S E C T I O N 2 T U R N T A B L E
2-2
3121146
SECTION 2 TURNTABLE .
FIGURE 2-1. CONTROL VALVES INSTALLATIONS FIG & ITEM #
PART NUMBER 0258457
1
Use 4641453
2
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2120167 2120168 7020021 4640866 Not Available 2900708 7012959 2120163 2120150 7020020 4641061 7012943 7017479 7012518 4640906 7012944 7023981 7012905 7017481 7012972 3570979 Not Used 3841340 2220893 0641614 0641606 4711600 0641508 4891500 4711500 0641418 Not Used 0641414 0651406 4711400 3311405 0100011 4640921
25
4921927
26
4640922
27
4921928
3 3A 3B 4
5
6 6A
6B
3121146
DESCRIPTION VALVES INSTALLATION
QTY.
REV.
Ref
C
Main Control Valve Assembly (See MAIN CONTROL VALVE ASSEMBLY for Breakdown) (was p/n 4641099) Return Filter Assembly Element, Filter Indicator, Clogged Valve Assembly (Level) Cartridge Seal Kit - Cartridge Knob Pressure Filter Assembly Element, Filter Indicator Solenoid Valve Assembly (Brake) Coil Cartridge without Coil Seal Kit - 7017479 Cartridge Solenoid Valve Assembly (2 Speed) Coil Cartridge without Coil Seal Kit - 7017480 Cartridge Cartridge, Check Seal Kit - 7017481 Cartridge Plate, Spacer
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
Loop, Hose Fitting, Adapter Bolt 3/8”-16NC x 1 3/4” Bolt 3/8”-16NC x 3/4” Flatwasher 3/8” Narrow Bolt 5/16”-18NC x 1” Flatwasher 5/16” Flatwasher 5/16” Narrow Bolt 1/4”-20NC x 2 1/4”
4 1 3 8 6 2 2 2 2
Bolt 1/4”-20NC x 1 3/4” Bolt 1/4”-28NF x 3/4” Flatwasher 1/4” Narrow Locknut 1/4”-20NC Loctite #242 (Not Shown) Valve Assembly (Jib Control) (See ACCESSORY VALVE ASSEMBLY for Breakdown) Harness Assembly (Jib Control) (Not Shown - See ELECTRICAL SECTION for Breakdown): Valve Assembly (4WS Control) (See ACCESSORY VALVE ASSEMBLY for Breakdown) Harness Assembly (4WS Control) (Not Shown - See ELECTRICAL SECTION for Breakdown):
1
S E C T I O N 2 T U R N T A B L E
2 4 16 6 AR 1 1 1 1
2-3
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
28
4420060 0258410
101 102 103 104 105
2
4360417 0140001 0641406 4711400 3311405 0258670
T U R N T A B L E
201 Use 1001143191 7016779 7016781 7016780 7016785 7016782 7016783 7016784 Use 1001137460
70001059 See Note 70001069 70001068 70001067 1001137460
70003992 See Note
202 203 204
2-4
70003983 70003993 70003989 70003990 0902415 0641610 4751600
DESCRIPTION Tape, Double Sided TILT INDICATOR INSTALLATION Indicator, Tilt Horn Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Narrow Locknut 1/4”-20NC AUXILIARY PUMP INSTALLATION Note: Original Equipment pump may have been replaced with various Service Replacement pump. Identify component before ordering parts. Auxiliary Pump Assembly Options: Auxiliary Pump Service Kit (Original Equipment) (was p/n 3600287 & 1001091424) Service Parts for Fenner Brand (p/n 3600287 pump) Replacement Motor Assembly (p/n 3600287 pump) Brush Kit - 7016779 Motor Replacement Pump Assembly (p/n 3600287 pump) Seal Kit - 7016780 Pump Coupling, Pump/Motor (p/n 3600287 pump) Pump Mounting Kit (p/n 3600287 pump) Relief Valve Assembly (p/n 3600287 pump) Auxiliary Pump Assembly (Service Replacement) (was p/n 3600458) Service Parts for Haldex Brand (p/n 3600458 pump) (Service Replacement) Replacement Motor Assembly (p/n 3600458 pump) Pump (p/n 1001137460 pump) (Note: Not Available for Purchase) Seal Kit, Pump (p/n 3600458 pump) Motor/Coupling Kit (p/n 3600458 pump) Valve, Logic (p/n 3600458 pump) Auxiliary Pump Assembly (Service Replacement) Service Parts for Bucher Brand (p/n 1001137460 pump) (Service Replacement) Replacement Motor Assembly (p/n 1001137460 pump) Pump (p/n 1001137460 pump) (Note: Not Available for Purchase) Base Assembly (p/n 1001137460 pump) Seal Shaft - 70003983 Base Assembly Valve, Logic (p/n 1001137460 pump) Relief Valve (p/n 1001137460 pump) Bracket, Pump Mounting Bolt 3/8in-16NC x 1-1/4in Flatwasher 3/8in
QTY.
REV.
2in/5cm Ref
B
1 1 3 5 3 Ref Ref
B
1
1 1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1 1 3 3
3121146
SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) FIG & ITEM #
PART NUMBER
205 206 207
0641506 4711500 0100011
DESCRIPTION Bolt 5/16in-18NC x 3/4in Flatwasher 5/16in Narrow Compound, Locking
QTY.
REV.
4 4 AR
S E C T I O N 2 T U R N T A B L E
3121146
2-5
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-6
3121146
SECTION 2 TURNTABLE .
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY FIG & ITEM #
PART NUMBER 4641099 4641453
1 2
Not Used See Note
3
7010542 7010543 7010542 7010543 7010542 7010543 7010542 7010543 7010542 7010543 7017420 7012998 7017423 7012998 7018941 7018941 4641192 2900708 7021602 7017428 7012998 7017427 7012998 7017428 7012998 7017428 7012998 7012914 7012918 7012914 7012918 7018992 7012773 7018991 7018912 7012775 7012773
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20A 21
3121146
DESCRIPTION MAIN CONTROL VALVE ASSEMBLY Original Equipment Service Replacement Note: Original Equipment valve may have been replaced with Service Replacement valve. Visually identify the p/n stamped on valve before ordering parts.
Block (Note: Not Available - Purchase Complete Assy.) Cartridge, Load Sensing (Main Lift) Seal Kit - 7010542 Cartridge Cartridge, Load Sensing Seal Kit - 7010542 Cartridge Cartridge, Load Sensing (Swing) Seal Kit - 7010542 Cartridge Cartridge, Load Sensing Seal Kit - 7010542 Cartridge Cartridge, Load Sensing (Main) Seal Kit - 7010542 Cartridge Cartridge, Relief Valve (Main Lift) Seal Kit - 7017420 Cartridge Cartridge, Relief Valve (Swing) Seal Kit - 7017420 Cartridge Orifice Orifice Cartridge, Check Valve (Tower Lift) (was p/n 7017474) Seal Kit - 4641192 Cartridge Piston, Pilot Cartridge, Relief Valve (Platform Level Down) Seal Kit - 7017428 Cartridge Cartridge, Relief Valve (Platform Level Up) Seal Kit - 7017427 Cartridge Cartridge, Relief Valve (Front Steer) Seal Kit - 7017428 Cartridge Cartridge, Relief Valve (Front Steer) Seal Kit - 7017428 Cartridge Cartridge, Pilot Check (Platform Level) Seal Kit - 7012914 Cartridge Cartridge, Pilot Check (Platform Level) Seal Kit - 7012914 Cartridge Control Valve Assembly (Main Lift) Seal Kit - 7018992 Valve Coil Nut Control Valve Assembly (Swing) Seal Kit - 7012775 Valve
QTY.
REV.
Ref Ref Ref Ref
B B
S E C T I O N
1
2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1
T U R N T A B L E
2-7
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
21A
7012772 7018912 70002946
22 23 23A 23B 24
2 25
T U R N T A B L E
7018994 7012773 7012772 7018912 7018993 7017475 7010545 7000645 7021601 7017477
26 Use 70000579 70000579
7012769 70000583 26A 7012772 70000582
27 27A 28
28A 29
29A 30 30A 31
2-8
7018912 70000580 Use 70001976 7012773 7012772 7018912 Use 70001976 7012773 7012772 7018912 Use 70001976 7012773 7012772 7018912 Use 70001976 7012773 7012772 7018912 7012989 7012953
DESCRIPTION Coil Nut Flow Control Manifold Assembly (Main) (Includes Items 24 & 25) Control Valve Assembly (Main) Seal Kit - 7018994 Valve Coil Nut Plug Cartridge without Coil Seal Kit - 7017475 Cartridge Coil Cartridge, Flow Regulator (Main) Seal Kit - 7021601 Cartridge Control Valve Assembly Options (Main Tele): Original Equipment (was p/n 7012766) Service Replacement Note: Refer to Vendor P/N on Valve Nameplate before ordering Parts. P/N 7012766 is RR00567495 or R900567495. P/N 70000579 is R900930080. Seal Kit Options: 7012766 Valve 70000579 Valve Coil Options: 7012766 Valve (was p/n 7012768) 70000579 Valve Nut, Coil Options: 7012766 Valve 70000579 Valve Control Valve Assembly (Tower Tele) (was p/n 7012770) Seal Kit - 7012770 Valve Coil Nut Control Valve Assembly (Platform Level) (was p/n 7012770) Seal Kit - 7012770 Valve Coil Nut Control Valve Assembly (Platform Rotate) (was p/n 7012770) Seal Kit - 7012770 Valve Coil Nut Control Valve Assembly (Tower Lift) Seal Kit - 7012770 Valve (was p/n 7012770) Coil Nut Cartridge, Flow Regulator (Platform Rotate) Seal Kit - 7012989 Cartridge
QTY.
REV.
2 2 1 1 1 1 1 1 1 1 1 1 1 1
Ref
1
1
1
1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2 1 1
3121146
SECTION 2 TURNTABLE FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
32
7012774 7012773 7012772 7018912 7021310 7018945 7017478 7017477 7012941 7010543 7012944 7017428 7012998 7018942 7018951 7021311 3931048
32A 33 34 35
36 37 38 39 40
3121146
DESCRIPTION Control Valve Assembly (Front Steer) Seal Kit - 7012774 Valve Coil Nut Valve, Sandwich (Platform Rotate) O-Rings, Replacement - 7021310 Valve Cartridge, Check Valve (Main Pressure) Seal Kit - 7017478 Cartridge Cartridge without Coil (Main Dump) Seal Kit - 7017452 Cartridge Coil Cartridge, Relief Valve (Tower Tele) Seal Kit - 7017428 Cartridge Capscrew #10-24NC x 2in Capscrew 1/4in-20NC x 1-1/2in Capscrew #10-24NC x 4-1/2in Capscrew #10-24NC x 3in
QTY.
REV.
1 1 2 2 AR 2 1 1 1 1 1 1 1 28 4 4 4
S E C T I O N 2 T U R N T A B L E
2-9
SECTION 2 TURNTABLE FIGURE 2-3. ACCESSORY VALVE ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-10
3121146
SECTION 2 TURNTABLE .
FIGURE 2-3. ACCESSORY VALVE ASSEMBLY FIG & ITEM #
PART NUMBER
4640921 1
5 6
7012965 7012953 Use 70001976 7012773 7018945 7012772 7017421 7012998 7017422 7012998 4460499 7018946
7 8
7018942 Not Required
2 2A 2B 3 4
4640922 101
104 105 106
7017420 7012998 7012774 7012773 7018945 7012772 7017420 7012998 Not Required 4460499 7018946
107 108
7018942 7018948
102 102A 102B 103
3121146
DESCRIPTION
QTY.
ACCESSORY VALVE ASSEMBLIES
Ref
ARTICULATING JIB VALVE ASSEMBLY Cartridge, Flow Control Seal Kit - 7012965 Cartridge Directional Control Valve Assembly (was p/n 7012770) Seal Kit Nut Coil Cartridge, Relief Seal Kit - 7017421 Cartridge Cartridge, Relief Seal Kit - 7017422 Cartridge Connector, DIN with Diode (Part of Valve Harness) Capscrew, Socket Head #10-24NC x 5” (Not Shown - Used to Mount Valve Assembly) Capscrew, Socket Head #10-24NC x 2”
4WS VALVE ASSEMBLY (NOT SHOWN)
Ref
REV.
D
1 1 1 1 2 2 1 1 1 1 2 4
2
4
Ref
Cartridge, Relief Seal Kit - 7017420 Cartridge Directional Control Valve Assembly Seal Kit Nut Coil Cartridge Relief Seal Kit - 7017420 Cartridge
1 1 1 1 2 2 1 1
Connector, DIN with Diode (Part of Valve Harness) Capscrew, Socket Head #10-24NC x 5” (Not Shown - Used to Mount Valve Assembly) Capscrew, Socket Head #10-24NC x 2” O-Ring (Not Shown - Used to Mount Standard Steering Valve Assembly)
2 4
S E C T I O N
B
4 4
2-11
T U R N T A B L E
SECTION 2 TURNTABLE FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS
S E C T I O N 2 T U R N T A B L E
2-12
3121146
SECTION 2 TURNTABLE .
FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS FIG & ITEM #
PART NUMBER 4620119 0270331
SWING DRIVE INSTALLATION
Ref
3570488 2780205
3 4
0920119 7018612 3160279
5 6 7 8 9 10 11 12 13
0642018 4740004 3932224 0681836 4891800 0100011 0100019 3311802 3971820 0259055
201 202 203 204 205
3121146
Plate, Swing Drive Hub, Swing Assembly (See SWING HUB ASSEMBLY for Breakdown) Brake, Swing Assembly Kit, Repair Motor, Swing Assembly (See SWING MOTOR ASSEMBLY for Breakdown) Bolt 5/8” - 11NC x 2 1/4” Washer 5/8” (Hardened) Bolt 1/2” - 13NC x 1 1/2” Bolt 1/2” - 13NC x 4 1/2” (Grade 8) Flatwasher 1/2” Loctite, #242 (Not Shown) Loctite, #271 (Not Shown) Nut Jam 1/2” - 13NC Setscrew 1/2” - 13NC x 2 1/2 SWING BEARING INSTALLATION
Ref
0239585
TURNTABLE LOCK INSTALLATION
Ref
2751095 2180344 2160003 2220063 2751032
REMOTE BEARING LUBE INSTALLATION Hose, Grease Fitting, Bulkhead Fitting, Grease Elbow Fitting, Elbow Hose, Grease
A
B
1 1 2 9in/23cm
Ref
S E C T I O N 2
12 12 4 2 2 AR AR 2 2
1 36 36 AR
Pin Pin, Snap Ring, Quick Release Chain
B
1 1 1
Bearing, Turntable Bolt 5/8” - 11NC x 2 7/8” (Grade 8) Flatwasher, Hardened Loctite #271 (Not Shown)
Not Used 3421627 3421565 3760170 1260017
REV.
1 1
0440233 0682023 4892000 0100019
0255316 301 302 303 304 305
QTY. Ref Ref
1 2
101 102 103 104
DESCRIPTION TURNTABLE WELDMENT Standard Machines
2
1 2 2 2 1
2-13
T U R N T A B L E
SECTION 2 TURNTABLE FIGURE 2-5. SWING HUB ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-14
3121146
SECTION 2 TURNTABLE .
FIGURE 2-5. SWING HUB 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
3121146
PART NUMBER
QTY.
REV.
2780205
SWING HUB ASSEMBLY
DESCRIPTION
Ref
—
7010492 7000228 7000255 7000256 7000257 7000258 7017089 7007633 7000229 7010494 7001928 7000246
HOUSING ASSEMBLY Shaft, Output Seal, Lip Cup, Bearing Cone, Bearing Cup, Bearing Cone, Bearing Housing Thrustwasher Ring, Retaining Pipe, Plug Pipe, Plug Gear, In O-Ring
Ref 1 1 1 1 1 1 1 1 1 2 2 2
7001931 7001985 7001909 7000263 7001911 7001987 7010474 7001988 7000230 7000209 7010488 7000269 7000270 7000253 7000217 7000214 2200222
CARRIER ASSEMBLY Carrier Thrustwasher, Tanged Bearing, Needle Spacer, Thrust Shaft, Planet Gear, Cluster Rollpin Ring Gear O-Ring Cover, Input Gear, Sun Spacer, Input Thrustwasher Thrustwasher Bolt Bolt, Shoulder Pipe, Plug
Ref 1 6 96 3 3 3 3 1 2 1 1 1 1 2 8 4 1
S E C T I O N 2 T U R N T A B L E
2-15
SECTION 2 TURNTABLE FIGURE 2-6. SWING MOTOR ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-16
3121146
SECTION 2 TURNTABLE .
FIGURE 2-6. SWING MOTOR ASSEMBLY FIG & ITEM #
PART NUMBER 3160279
1 2 3 4 5 6 7 8 9 10 11 to 12 13 14 15 16 17 18 19 20 to 32 33 34 35 to 36 37
7020357 7009996 Kit Kit Kit Kit 7002117 7002111 7009998 7020358 Not Used 7020336 Kit 7020338 7020339 7020346 Not Used 7020340 Not Used 7020353 Kit Not Used 7020359 Not Available 7020360
3121146
DESCRIPTION SWING MOTOR ASSEMBLY
QTY.
REV.
Ref
A
Bolt Flange, Mounting Seal, Exclusion Washer, Back-up Seal, Pressure Seal Race, Bearing Washer, Thrust Shaft Housing Options:
4 1 1 1 1 1 1 1 1 1
Drive Seal, Body Plate, Spacer Rotor Set Assembly Cap, End
1 3 1 1 1
Bolt
7
Bolt O-Ring
4 2
Valve, Counterbalance Cartridge, Valve —————————— Seal Kit - (Includes Items - 3 thru 6, 14 & 34)
1 2
S E C T I O N 2 T U R N T A B L E
1
2-17
SECTION 2 TURNTABLE FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL)
S E C T I O N
15 15 20 407
17 21 23
308
401
126
FUEL 169 RETURN 130
130
138
150
163 167
9
404 309
VENT LINE
18 21 23
402
401
307 325
194
405
19
406
SEE DUAL FUEL INSTL.
153
2
10
2
155 154
16
403
155 311 155
T U R N T A B L E
20
TO ENGINE
314
155
16 3
185
305
129 161
150
319
155
322 164
12 315 318 130
304 131
310 312
329
143
178 129
118 330
328
AUX. PWR. RELAY
165E
157 188
AUX. PWR. PUMP
104
158
137 136
140 141 113
103
130
169 130
BAT.
302 TO ENG. BLOCK
130 169
125 135
105
130 169
INLET FROM TANK SUPPLY TUBE
124 180
166 110 139 109 144 141 139 145 141 170 142 142 171
13 142
135 136 168 165B
165 165A
165D
159
189 141
160C
STARTER
139 141 142
142 317
133
1 156
102
301
116
137 6 8 7
321 317
RETURN TO TANK
327
313 135 136 179
127
164
306
111
320
321 318
11
323
155
112
22
12
108
119
321
324
141 5
129
183 184
145 147 148 172
4 187 106
136 173
137 136
145 147 151
174 134 136
135 136 144
132 160
14
121 175
140 142 186
137
135 136
128 136
131 135 136
142
135 134
181 107
136 116 152
114
141 142 190 191
136 137
122 136 137
123 133
177 176
2-18
136 137
3121146
SECTION 2 TURNTABLE .
FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) FIG & ITEM #
PART NUMBER 0259478
1 2
2000166 3600295
3
3600278 7018995 3539972 4566605 4640989 2750532 1320022 3571498 3790152 0902539 1320019 0701022 0701014 0700810 0641812 0721014 0721006 4891800 4751500 4751000 4761500 3311005 0100011 0100020
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
0259479 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115
3121146
Not Used 3539872 0400075 0181727 0630498 3620040 Use 8180311 1600298 4846011 3740067 3740080 0080214 2060025 1580011 3570133 Not Used
DESCRIPTION ENGINE ASSEMBLY (DUAL FUEL) Engine - Ford LRG-425 Piston Pump Assembly (See PISTON PUMP ASSEMBLY for Breakdown) Piston Pump Assembly Seal Kit - 3600278 Motor Plate, Engine Mounting - Front Tube, Spacer Valve, Oil Drain Hose Clamp Plate, Module Mounting O-Ring Bracket Clamp Bolt, Metric 10mm-1.5 x 70mm Bolt, Metric 10mm-1.5 x 30mm Bolt, Metric 8mm-1.25 x 20mm Bolt 1/2”-13NC x 1 1/2” Screw #10-24NC x 1 3/4” Screw #10-24NC x 3/4” Washer, Hardened 1/2” Flatwasher 5/16” Flatwasher #10 Lockwasher 5/16” Locknut #10-24NC Loctite #242 (Not Shown) Sealant, Pipe (Not Shown) ENGINE INSTALLATION (DUAL FUEL)
Mount, Radiator Battery Tie-Down Bolt, Tie-Down Radiator Cap, Radiator (was p/n 7019656) Controller, ECM Weldment, Air Intake Tube Relay, Auxiliary Power Relay Relay, Bosch Relay Adapter, Fan Spacer Fan, Suction Container, Coolant Overflow Container Plate, Engine Mount-Ford (Rear)
QTY.
REV.
Ref
1/A
1 1 1 1 1 1 1
2
6in/21cm
1 1 1 1 1 2 2 3 4 2 3 2 2 8 2 5 AR AR Ref
S E C T I O N
T U R N T A B L E
5/E
1 1 1 2 1 1 1 1 1 2 1 1 1 1
2-19
SECTION 2 TURNTABLE FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156
3200362 Not Used 2720435 4360392 3841340 1703162 3570103 4845404 3422446 3841143 2750532 2720472 1320060 1320012 1320022 0641828 4751800 3311805 0641610 0641608 4751600 3311605 2220805 0641408 0641406 4751400 3311405 4740274 3960389 3539957 0100011 3311505 3900272 0100020 2180467 0641508 0940070 4567879 0701012 4832000 1340060 7012664 0340041 0080201 1320016 3311801 2720436 1641808 2220273
2 T U R N T A B L E
157 158 159 160 161 162 163
2-20
DESCRIPTION
QTY.
Mount, Rubber
4
Hose, Lower Radiator (Lower) Switch, Restriction Indicator Switch Hose Loop (Not Shown Located inside turntable) Decal - Fan Blade Plate, Engine Mount (Front) Tray, Engine Pin, Pivot Pin, Keeper Hose Hose Clamp, Hose - 0.625 Clamp, Hose, Radiator Clamp, Hose Bolt 1/2”-13NC x 3 1/2” Flatwasher 1/2” Hex Nut 1/2” - 13UNC Bolt 3/8”-16NC x 1 1/4” Bolt 3/8”-16NC x 1” Flatwasher 3/8” Locknut 3/8”-16UNC Fitting Bolt 1/4”-20NC x 1” Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4” x 20UNC Washer, Snubbing Seal Plate, Hold Down Loctite #242 (Not Shown) Hex Nut 5/16”-18NC Bolt 5/16”-18NC x 1 3/4” Sealant, Pipe (Not Shown) Fitting, Elbow Barbed Bolt 5/16”-18NC x 1” Bumper, Rubber Tube, Exhaust Bolt 10m x 1.5 x 25 mm Lockwasher Air Cleaner Assembly Filter, Air Cleaner Band, Muffler/Air Cleaner Fitting, Elbow Reducing Clamp, Worm Gear Hex Nut 1/2”-13 UNC Hose, Radiator (Upper) Bolt 1/2”-13NC x 1” Fitting, Reducer
1 1 2 2 1 1 1 1
REV.
5ft/1.5m
1 1 4 9 4 1 4 8 22 55 31 1 4 5 16 13 4 5ft/1.52m
2 AR 6 3 AR 2 3 1 1 4 4 1 1 2 1 2 1 1 2 1
3121146
SECTION 2 TURNTABLE FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) (CONTINUED) FIG & ITEM #
PART NUMBER
164 165 165A 165B 165C 165D 165E 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 to 193 194 195 to 200
2180798 2901608 7016800 7016807 7016808 7016824 7016825 4460611 2220250 3572414 2720058 0721004 4360294 3380429 1320223 3422532 0641606 0642010 4752000 0700819 4831900 0961986 1060637 1701542 4060804 4060806 1320032 4711400 3960468 3960469 0641410 4568158 0641424 Not Used 0902572 Not Used 2000166
301 302 303 304 305 306 307 308 309
3121146
7022133 7022134 7022135 7019986 7019977 7022136 7019996 7022137 7022139 7019994
DESCRIPTION Fitting, Restriction Indicator Battery Cable Kit Cable, Battery (Red) Cable, Battery (Black) Cable (Red) Cable (Red) Cable (Black) Terminal, Battery Jumper Post Fitting, Reducer Plate, Pump Mounting Hose 5/16” Bolt #10-24NC x 1/2” Breaker, Circuit-30 AMP Panel, Rubber Clamp, “J” Clip 1/2” Pin, Hitch Bolt 3/8”-16NC x 3/4” Bolt 5/8”-11NC x 1 1/4” Flatwasher 5/8” Bolt M8 x 1.25 x 55mm Lockwasher M8 Bearing, Flange Cable, Lanyard Decal - Gasoline (Not Shown - Located Near Tank) Flex-Trim Flex-Trim Clamp, Hose Flatwasher, 1/4” Seal, Foam Seal, Foam Bolt 1/4”-20NC x 1 1/4” Standoff 1/4” x 2” Bolt 1/4”-20NC x 3”
QTY. 4 1 1 1 1 1 1 1 1 1 2 1 1 4 1 3 1 1 4 4 2 1 1
T U R N T A B L E
19in/49cm 16in/41cm
2 1 1 1 3 4 4 1
ENGINE COMPONENTS
Ref
S E C T I O N 2
12ft/3.7m
Bracket, LP Mounting
Fuel Pump & Isolator Assembly Harness, Fuel Pump Wiring Filter, Fuel Starter (Not Shown) Alternator Actuator, Throttle Sensor, Air Temperature Harness, Engine Control Processor Sensor, MAP Sensor, EGR
REV.
1 1 1 1 1 1 1 1 1 1
2-21
SECTION 2 TURNTABLE FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330
2420187 2720341 7022142 7014501 7016662 7019993 7022143 7022158 7022159 7022160 7022161 7022162 7022178 7022142 7023637 7023613 7023644 7020120 7022150 70002567 7027402
2 T U R N T A B L E
3124114
401 402 403 404 405 406 407
2-22
DESCRIPTION Dipstick Horn, Rubber Air Options: Switch, Oil Pressure Filter, Oil (Case of 12) Coupling, Pump Pressure Regulator & Filter Assembly Gasket, Exhaust Manifold (Not Shown) Connector Connector Connector Tube, Supply Clamp Sensor, Crank Switch, Pressure (Black) Switch, Shutdown (White) Relay Hose, Water Pump (By-Pass) (Not Shown) Housing, Bell Belt, Timing Tensioner, Belt Belt, Drive (was p/n 7019979) ——————————— Service Manual, Ford EFI System Diagnostic
0258390
MUFFLER INSTALLATIONS Standard Spark Arresting
3220113 0340046 0902309 0641507 4711500 3311505 4567073
Muffler Band Bracket, Muffler Bolt 5/16”-18NC x 7/8” Flatwasher 5/16” Narrow Locknut 5/16”-18NC Tube, Exhaust
QTY.
REV.
1 1 1 1 Case 1 1 1 3 2 1 2 2 1 1 1 3 1 1 1 1 1 1 Ref Ref
1
1 2 1 4 8 4 1
3121146
SECTION 2 TURNTABLE FIGURE 2-7. FORD ENGINE WITH EFI INSTALLATION (DUAL FUEL) (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
3121146
2-23
SECTION 2 TURNTABLE FIGURE 2-8. FORD DUAL FUEL INSTALLATION
S E C T I O N 2 T U R N T A B L E
2-24
3121146
SECTION 2 TURNTABLE .
FIGURE 2-8. FORD DUAL FUEL INSTALLATION FIG & ITEM #
PART NUMBER 2000166
1 2 3 4 5 6 7 8 9
Not Available See Your Ford Dealer 7022165 7022171 Not Used 7022167 7022170 7022168 7022169 7023602 4360188 7023603 7022166 4400275 4400420 0259479
101 to 189 190 191 192 193
Not Used 4360336 3790012 1701543 1700818
194 195 196 197 198
Not Used 2720392 2180418 2220064 2221019 0255524
201 202 203 204 205 206 207 208 209 210 211 212
3121146
1320220 1320127 2720144 0100020 2221019 2180125 2220261 2180388 2180389 2180418 2180387 0641606 4751600
DESCRIPTION DUAL FUEL ASSEMBLY Dual Fuel Conversion Kit (Note: Includes hose, fittings, clamps and items indented below. For replacement hose, fittings and clamps supply locally.) Mixer Repair Kit - 7022165 Mixer Convertor Repair Kit - 7022167 Convertor Valve, Solenoid Bolt 1/4”-20NC x 2” Connector (Not Shown) Switch, Vacuum Adaptor Adaptor Tank, LP Options: Aluminum Steel DUAL FUEL ENGINE COMPONENTS
QTY.
REV.
Ref
C
1
1 1 1 1 1 2 1 1 1 1 1
Ref
Toggle, SPDT (Not Shown - Located on Console Box) O-Ring (Not Shown - Located on Console Box) Decal-LPG (Not Shown - See Decal Installation) Decal- Liquid Withdrawal System (Not Shown - See Decal Installation)
1 1 2 2
Hose Fitting, Straight Fitting, Elbow Fitting, Reducer
1 1 1 1
LP TANK AND BRACKETS INSTALLATION Clamp Kit - LP Clamp, Toggle (1 Per Clamp) Hose Sealant, Pipe (Not Shown) Fitting, Red Fitting - Elbow Fitting, Nipple Filter, Bulkhead Valve, Relief Fitting, Tee Fitting, LP Tank Bolt 3/8”-16NC x 3/4” Flatwasher 3/8”
Ref
S E C T I O N 2
2/B
7/E
2 2 2 AR 1 1 1 1 1 1 2 8 8
2-25
T U R N T A B L E
SECTION 2 TURNTABLE FIGURE 2-8. FORD DUAL FUEL INSTALLATION (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
213 214 215 216 217 218 219 220 221
2180418 2221018 1320218 3910808 4750800 3310805 0181949 2221024 0362519
DESCRIPTION Fitting, Straight Fitting, Nipple Clamp, Spring Screw, Machine #8-32NC x 1/2” Flatwasher #8 Locknut #8-32NC Support, Angle Fitting, Ball Check Bar, Clamp
QTY.
REV.
2 1 2 2 4 2 2 2 4
2 T U R N T A B L E
2-26
3121146
SECTION 2 TURNTABLE FIGURE 2-8. FORD DUAL FUEL 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
3121146
2-27
SECTION 2 TURNTABLE FIGURE 2-9. GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL)
S E C T I O N 2 T U R N T A B L E
2-28
3121146
SECTION 2 TURNTABLE .
FIGURE 2-9. GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) FIG & ITEM #
PART NUMBER 0257851
1 2
3580250
2A
2460011 7012558
2B
7012513 7020108 7012513 7003657
2C 2D 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
7010699 3580134 0902210 0200547 0480050 0701015 4812000 0100011 0681612 4751600 2860012 3311605 4564417 Not Used 4460023 0641508 4751500 Not Used 3520028 0721006 3311005 4751000 4360294 3740080 4360336 4740397 4060802 Not Used 2820031 3251102
3121146
DESCRIPTION GENERATOR INSTALLATION OPTIONS: 110V Generator Pulley Generator and Control Box Assembly Options: 110Volt Assembly Generator - 110V Note: Replacement Generator p/n 7012558 come standard with p/n 3580134 pulley. This pulley may not be correct for all applications. Refer to pulley options below. Cap, Brush Holder Brush Holder, Brush Box, Control Note: Replacement 110V Control Box comes with 2 standard Receptacles p/n 4460190. Optional Industrial Twist Lock Receptacles p/n 4460027 must be ordered separately. Voltmeter Pulley Bracket, Generator Mounting Arm, Adjusting V-Belt Bolt, Metric 10mm-1.5 x 35mm Flatwasher 10mm Loctite #242 (Not Shown) Bolt 3/8”-16NC x 1 1/2” (Grade 8) Flatwasher 3/8” Key, Woodruff Locknut 3/8”-16NC Spacer, Tube
QTY.
REV.
Ref Ref
2
1 1 I 1 Ref
T U R N T A B L E
1 1 1 1 1 2 2 AR 3 6 1 1 1 1 1 2
Plug, Hole Bolt #10-24NC x 3/4” Locknut #10-24NC Flatwasher #10 Breaker, Circuit - 30 Amp Relay, Bosch Switch, Toggle (Not Shown - Located at Platform) Bushing (Not Shown - Located at Platform) Guard, Switch (Not Shown - Located at Platform)
1 4 4 9 1 1 1 1 1
Heatshrink (Not Shown - Located at Platform) Decal (Not Shown - Located at Platform)
2
4 4 4 1 Ref
Connector, Strain Relief Bolt 5/16”-18NC x 1” Flatwasher 5/16”
S E C T I O N
4in/10cm
1
2-29
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION
S E C T I O N 2 T U R N T A B L E
2-30
3121146
SECTION 2 TURNTABLE .
FIGURE 2-10. DEUTZ ENGINE INSTALLATION FIG & ITEM #
PART NUMBER 0258415 0271371
1
2 3 4 5 6
7 7A 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31A 31B
3121146
2000146 2000173 2000189 4845404 3539872 3620033 2060025
Use 3600295 3600295 1340060 7012664 0340041 4640751 3600278 7018995 3200406 3537420 3539971 3537416 3537417 4846479 4846566 0400075 0181727 0630498 3740067 4567112 4360392 2180798 3422446 3841143 3960389 0940070 3841340 2720398 1703162 1320016 2901392 7008833 7008835
DESCRIPTION DEUTZ ENGINE INSTALLATIONS Standard Machines (Prior to SN 62045) ADE System Machines (SN 62045 to Present) Engine - Deutz F4M1011F Diesel Options: Prior to SN 62045 SN 62045 to SN 65695 SN 65695 to Present Tray Engine Plate, Radiator Mounting Cooler, Oil Fan Piston Pump Assembly Options (See PISTON PUMP ASSEMBLY for Breakdown): Prior to SN 42829 (Was p/n 3600277) SN 42829 to Present Air Cleaner Assembly Element, Air Cleaner (Not Shown) Band, Mounting Valve, Oil Drain Piston Pump Assembly Seal Kit - 3600278 Pump Mount, Rubber Engine (Rear) Bracket, Engine Mounting - Rear Bracket, Engine Mounting - Front Support, Engine - Right Support, Engine - Left Options: Prior to SN 41506 SN 41506 to SN 68269 SN 68269 to Present Battery Hold-Down, Battery Rod, Hold-Down Relay Tee, Air Intake Tube (Prior to SN 42682 Only) Switch, Restrictor Indicator Fitting Pin, Pivot Keeper, Pin Seal Bumper, Rubber Loop, Hose Hose, Oil Cooler Nameplate - Fan Caution Clamp, Hose Throttle Mounting Kit (Prior to SN 62045) Bracket, Throttle Coupling, Ball Joint
QTY.
REV.
Ref Ref Ref
6/F 9/F
1
1 1 1 1 1
S E C T I O N 2 T U R N T A B L E
1 1 2 1 1 1 2 1 1 1 1
1 1 2 2 1 1 1 1 1 5ft/1.5m
1 AR 2 2 4 1
2-31
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
31C 31D 32 33 34
7008836 7023340 2220451 Not Used
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
2 T U R N T A B L E
0902243 0902511 0641818 3311805 0641610 3311605 4751600 0701414 4891800 0641407 4751400 3311405 0721005 3321005 4751000 1320022 2220273 2180536 2220313 2750532 2220250 2220459 2720271 0641812 0100020 0100011 Not Used
61 62
2720351 2720449 0700808 Use 2910000
63 64 65 66 67 68 69 70 70A 70B 70C
0641508 3900272 2720434 4845395 0641510 3311505 0961986 2901609 7016800 7016809 7016802
2-32
DESCRIPTION Spring Screw, Shoulder 3/8” x 3/8” (Not Shown) Fitting, Straight Bracket, Control Module Mounting Options: Prior to SN 40385 SN 40385 to SN 62045 Bolt 1/2”-13NC x 2 1/4” Locknut 1/2”-13NC Bolt 3/8-16NC x 1 1/4” Locknut 3/8”-16NC x 1 1/4” Flatwasher 3/8” Bolt 1/4”-20NC x 3/4” Washer, Hardened 1/2” Bolt 1/4”-20NC x 7/8” Flatwasher 1/4” Locknut 1/4”-20NC Bolt #10-24NC x 5/8” (Prior to SN 62045) Locknut #10-24NC (Prior to SN 62045) Flatwasher #10 (Prior to SN 62045) Clamp, Hose Fitting, Reducer Fitting, Straight Fitting, Elbow Hose 3/8” Fitting, Reducer Fitting, Elbow Hose 3/16” Bolt 1/2”-13NC x 1 1/2” Sealant, Thread Loctite #242 Coupling, Rubber Intake Options: Prior to SN 67970 SN 67970 to Present Bolt, Metric M8 x 16mm Actuator Assembly (Was p/n 0060033) (See ELECTRICAL SECTION for Breakdown) (Prior to SN 62045) Bolt 5/16”-18NC x 1 1/4” Capscrew, Button Head 5/16”-18NC x 1 3/4” Elbow, Rubber Air Intake Adapter Weldment Bolt 5/16”-18NC x 1 1/4” Locknut 5/16”-18NC Bushing, Flanged Battery Cable Kit Cable, Battery (Red) Cable, Battery (Black) Cable (Red)
QTY.
REV.
AR 2 1
AR 4 AR 22 44 6 2 AR AR AR 2 2 2 6 2 1 1 6ft./1.83m
1 1 15ft./4.6m
4 AR AR
6in./15cm
1 4 1 3 3 1 1 3 AR 2 1 1 1 1
3121146
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
70D 70E 70F 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 103A 103B 104 105 106 107
7016803 7016824 7016825 4460611 4360294 1320222 1320223 0641606 3422532 3790044 3960407 4791400 0701012 0701015 0642010 4752000 1701505 2720058 2220794 4711600 1320031 3200362 4711400 3960468 3960469 0641608 4060805 4060804 1060637 0641808 3311801 4751800 3380429 3539957 1320131 4845394 4847815 2720423 0641826 4740274 1320258
108
0641810
109 110
4711900 4922737
3121146
DESCRIPTION Cable (Red) Cable (Red) Cable (Black) Terminal, Battery Jumper Post Breaker, Circuit - 30 Amp (Prior to SN 62045) J-Clip 3/8” J-Clip 1/2” Bolt 3/8”-16NC x 3/4” Pin, Hitch O-Ring Gasket Starwasher 1/4” Bolt, Metric M10 x 25mm Bolt, Metric M10 x 35mm Bolt 5/8”-11NC x 1 1/4” Flatwasher 5/8” Decal - Diesel (Not Shown - Located on Hood) Hose Fitting, Barbed Flatwasher 3/8” Narrow Clamp (Prior to SN 42682 Only) Mount, Rubber Engine (Front) Flatwasher 1/4” Narrow Seal, Foam Gasket Seal, Foam Gasket Bolt 3/8”-16NC x 1” Flex-Trim 1/4” Flex-Trim 3/16” Lanyard Bolt 1/2”-13NC x 1” Nut 1/2”-13NC Flatwasher 1/2” Panel, Rubber Plate, Hold Down Clamp (Prior to SN 42682 Only) Tuning Tube Weldment Options: Prior to SN 42682 SN 42682 to Present Hose (Prior to SN 42682 Only) Bolt 1/2”-13NC x 3 1/4” Washer, Snubbing Clamp (Not Shown - Located in Center of Turntable) (SN 42829 to SN 52924) Bolt 1/2”-13NC x 1 1/4” (Not Shown - Used with Item 107) (Prior to SN 52924) Flatwasher 9/16” Harness, Engine Grounding (SN 68561 to Present)
QTY.
REV.
1 1 1 1 1 1 3 3 1 1 1 4 4 4 1 1 1
S E C T I O N 2 T U R N T A B L E
16ft/4.9m
1 3 2 2 1 1 1 14 7in/18cm 16in/40cm
1 2 1 1 1 2 2 1
1 2 4 1 1 6 1
2-33
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
QTY.
REV.
Ref Ref Ref 1
— —
3220103 3220104
MUFFLER INSTALLATIONS Standard Equipment (Spark Arresting) Optional Equipment (Catalytic) Muffler Options: Spark Arresting Catalytic
2000146
ENGINE COMPONENTS (PRIOR TO SN 62045)
Ref
D
7016639 7016329 7016330 7016641 70002813 7016332 7019664 7020025 7020414 7020465
Filter, Fuel Alternator Switch, Oil Pressure (Not Shown) Filter, Oil Seal (Between Filter Head & Block) Starter Dipstick Kit - Engine Oil (Not Shown) Switch, Engine Oil Temperature (Not Shown) V-Belt Filler Cap, Oil (Not Shown)
1 1 1 1 1 1 1 1 1 1
0256689 0256690 201
301 302 303 304
2 T U R N T A B L E
305 306 307 308 309
2000173 2000189 351 352
353 354 355
7016328 7000663 7020464 70002234 70003556 7020461 7016331 7016332 7020479
356 7020418 7026631 7020487
357 358 359 360
Not Available 70001002 7020168 7020480 7020408 7020458 Use 7024318 Not Available 7026522
2-34
DESCRIPTION
ENGINE COMPONENTS SN 62045 to SN 65695 SN 65695 to Present Filter, Fuel Alternator (was p/n 7020410) Regulator Bracket, Adjustable Pulley Switch, Oil Pressure (Not Shown) Filter, Oil Starter Options: Engine p/n 2000173 Engine p/n 2000189 Dipstick, Oil Level Options (Not Shown): Dipstick for 2000173 Engine Dipstick for 2000189 Engine Seal, Dipstick (Not Shown) Tube, Dipstick Options (Not Shown): Tube for 2000173 Engine Tube for 2000189 Engine Switch, Engine Temperature (Not Shown) Seal, Temperature Switch (Not Shown) V-Belt Actuator Pump, Fuel Injection (was p/n 7020462) Injector, Fuel (Includes Nozzle Element) (Not Shown): Injector for 2000173 Engine Injector for 2000189 Engine
Ref Ref Ref
B A
1 1 1 1 1 1 1 1
1
1 1
1 1 1 1 4 4
3121146
SECTION 2 TURNTABLE FIGURE 2-10. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
361
362 363
7020463 7024413 7020411 70001423
364
7020027 Not Available 7024579 7024565
365
7020431
366 367 368 369 370
70001681 70002411 70002530 7020459 7020460 7020465 7020474 7020468 7020449 7020471 0256847
401 402 403 404 405 406 407
3121146
1660234 0080163 0700810 4831900 Not Used 4832000 3020021
DESCRIPTION Pump, Fuel Supply Options: Pump for 2000173 Engine Pump for 2000189 Engine Seal, Pump (Not Shown) Fuel Filter Head Flywheel Options (Not Shown): Flywheel for 2000173 Engine (Includes Ring Gear) Flywheel for 2000189 Engine Ring Gear for 2000189 Engine Sensor, Tach (Not Shown - Located on Flywheel Housing) (was p/n 7020481) Gasket, Valve Cover (Not Shown) Gasket, Cylinder Head Options: (Not Shown) 1 Notch 2 Notches 3 Notches Thermostat (Includes Spring) (Not Shown) Spring, Thermostat (Not Shown) Cap, Oil Fill (Not Shown) Pump Oil Lubrication (Not Shown) Ring, Pump Sealing (Not Shown) Gasket , Intake Manifold to Head (Not Shown) Gasket , Exhaust Manifold to Head (Not Shown) PUMP COUPLING INSTALLATION
QTY.
REV.
1
1 1 1
S E C T I O N
1
2
1 1
1 1 1 1 1 4 4 Ref
Coupling, Hayes Plate, Pump Adapter Bolt Metric 8mm x 20mm Lockwasher 8mm
1 1 63 6
Lockwasher 10mm Grease, Coupling (Not Shown)
8 AR
—
2-35
T U R N T A B L E
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-36
3121146
SECTION 2 TURNTABLE .
FIGURE 2-11. PISTON PUMP ASSEMBLY FIG & ITEM #
PART NUMBER 3600295
1 to 100 101 102 103 104 105 106 107 108 109 110 111 112 to 113 114 115 116 to117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 to 149 150 151 to 154 155 156 to 157
3121146
Not Used 7007413 7007414 Kit 7021200 7007417 Kit 7007419 7021201 Not Used 7007470 7007470 Not Used Kit 7007423 Not Used 7007425 Kit Kit Kit Not Used Kit Kit Kit Kit Kit Kit 7007435 7021202 7007437 7007438 7007439 7021203 7007441 7007442 Kit 7021205 Not Used 7007446 Kit Kit Not Used Not Serviced Not Used 7007452 Not Used
DESCRIPTION PISTON PUMP ASSEMBLIES
QTY.
REV.
Ref
A
Shim Kit Plug O-Ring Spring, Relief Valve Valve, Relief O-Ring (Part of Items 1103 & 1104) Plug Bracket, Lifting
1 1 1 1 1 2 2 1
Plug Plug
2 2
Gasket, Servo Cover Nut, Special
2 1
Bearing, Needle Ring, Retaining Washer Spring
1 1 1 1
Washer Retainer Pin, Slipper Holddown Piston Assembly Retainer, Slipper Guide, Retainer Pin, Spring Screw, 12 Point Head Bearing, Ball Ring, Retainer Ring Pin, Spring Handle, Pin (Part of Item 201) Sleeve, Bearing Gasket, Front Cover Pin (Part of Item 201)
1 1 3 7 1 1 1 1 1 2 2 2 1 1 1 1
Pin O-RIng Ring, Load Temper
1 1 1
Housing, Pump
1
Cover, Gerotor
1
S E C T I O N 2 T U R N T A B L E
2-37
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY (CONTINUED)
S E C T I O N 2 T U R N T A B L E
FIG & ITEM #
PART NUMBER
158 159 160 to 162 163 164 165 166 167 168 169 to 200 201 202 203 to 300 301 302 to 303 304 305 to 400 401 402 to 500 501 502 to 602 603 604 605 606 to 801 802 803 to 804 805 806 807 to 900 901 902 903 to 904 905 906 907 908 909 910 911 912 to 915 916 917 918 919 920 921 to 1000 1001 1002
7007208 7007454 Not Used 7021207 Not Used 7021208 7021209 7007494 Kit Not Used 7007457 7021212 Not Used Kit Not Used Kit Not Used 7021213 Not Used 7021214 Not Used 7007463 7007464 7007465 Not Used 7007466 Not Used Kit 7021218 Not Used 7021219 7021220 Not Used 7007483 7007484 7007485 7021221 7007487 7007488 7021222 Not Used Kit Not Used Kit 7021206 7021223 Not Used 7007472 Kit
2-38
DESCRIPTION
QTY.
Plug Cover, Front
1 1
Screw
6
Spring (Part of Items 1103 & 1104) Plug, SCR (Part of Items 1103 & 1104) Piston, Servo Bearing
2 2 1 2
Swashplate Assembly (Includes Items 135 & 138) Journal, Bearing
1 2
Seal, Lip
1
O-Ring
1
Shaft, Main Pump
1
Plate, Valve
1
Gerotor Assembly Pin Key, Woodruff
1 1 1
Adaptor, Remote Filtration
1
Seal, Filter Adapter Screw
1 3
Cover, Servo Cover, Servo
1 1
Guide, Spring Stop, Servo Spring Screw Guide, Spring Ring, Retaining Nut
1 1 1 1 1 1 1
Ring, Piston
2
O-Ring Nut Screw
2 1 10
Valve, Bypass Ring, Back-up
1 1
REV.
3121146
SECTION 2 TURNTABLE FIGURE 2-11. PISTON PUMP ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
1003 1004to1102 1103 1104 1105to1200 1201
Kit Not Used 7010122 7010122 Not Used 7007474 7007496 7007497 7007498 Not Used 7007478 7001498 Not Used Kit Not Used 7007475 Not Used 7021226 7021226 Not Used 7007453 7021227 Not Used 7021228 7021229 7021230 7021231
1202 1203 1204 1205to1219 1220 1221to1400 1401 1402 1403 1404 1402to1501 1502 1503 1504to1507 1508 1509 1510 1511
2900752 7007412 7010116
3121146
O-Ring
1
SCR Kit (Includes items 166, 106 & 165) SCR Kit (Includes items 166, 106 & 165)
1 1
Control, Dual Oil-Filled Coil Assembly (Pilot) Plug (Pump) Plug (Valve Harness)
1 1 1 1
S E C T I O N
Screw Screw
2 2
2
O-Ring
2
Plug, Orifice/Screen (.156)
1
Plug, Orifice Plug, Orifice
1 1
Screw Adapter, Flange
3 1
O-Ring Plate, Cover Screw O-Ring —————————— Seal Kit - Complete (Includes Items 103, 106, 114, 137, 141, 142, 168, 301, 304, 805, 916, 918, 1002, 1003 &1220) Seal Kit - Servo Piston (Includes Items 916 and 918) Cylinder Block Kit (Includes Items 119-128)
1 1 2 1
DESCRIPTION
QTY.
REV.
T U R N T A B L E
1 1 1
2-39
SECTION 2 TURNTABLE FIGURE 2-12. TANK INSTALLATIONS
S E C T I O N 2 T U R N T A B L E
2-40
3121146
SECTION 2 TURNTABLE .
FIGURE 2-12. TANK INSTALLATIONS FIG & ITEM #
PART NUMBER 0258382 0270396
1 2 3 3A 4 5 6 7 8 9 10 11 12 13 14
4845928 4400410 4400400 7019658 4240112 4240113 4360436 2200222 4280295 4420038 0641614 3311601 4751600 0100011 0100079
15 16 17 18 19 20 21 22 23 24
4641022 4568118 0100020 0100062 4568119 1320223 3572423 0641508 4711500 3311505 4400410
101 102 103 104 105 106
7014818 7014802 7014810 7014816 7014817 7014813 7014801
DESCRIPTION TANKS INSTALLATION OPTIONS: Diesel Gas Tray Weldment Hydraulic Tank Assy (See Items 101-106 for Breakdown) Tank, Fuel (Includes Non-Locking Cap) Fitting and Pick-up Tube Strap, Tank Strap, Tank Switch, Fuel Level Fitting Strip, Protective Tape, Rubber Bolt 3/8”-16NC x 1 3/4” Nut 3/8”-16NC Flatwasher 3/8” Loctite #242 (Not Shown) Permatex (Not Shown) Note: Items 15 - 24 Used on Gas Machines Only Valve, Needle Tube, Fuel Sealant (Not Shown) Retaining Compound #680 (Not Shown) Tube, Fuel Clamp Plate, Valve, Needle Bolt 5/16”-18NC x 1” Flatwasher 5/16” Locknut 5/16”-18NC HYDRAULIC TANK ASSEMBLY Strainer 1 1/2”NPT Gauge, Sight Neck, Fill Screen Breather/Fill Cap Plug, Magnetic Strainer 1 1/4”NPT FUEL TANK CAP INSTALLATION
201 7016314 1120484 1120487
3121146
Cap Options: Standard Non-Locking (Part of Item 3) Optional Lockable (Gas Machines) Optional Lockable (Diesel Machines)
QTY.
REV.
Ref Ref Ref
C B
1 1 1 1 4 1 1 1
2 T U R N T A B L E
25in/44cm 70in/1.78m
6 AR AR AR AR Ref 1 1 AR AR 1 1 1 2 4 2 Ref
S E C T I O N
G
1 1 1 1 1 1 1 Ref 1
2-41
SECTION 2 TURNTABLE FIGURE 2-13. ROTARY COUPLING INSTALLATION
S E C T I O N
4 6 5
7
2
3 2
T U R N T A B L E
4 6 5 3 2
7
1
8
1
2-42
3121146
SECTION 2 TURNTABLE .
FIGURE 2-13. ROTARY COUPLING INSTALLATION FIG & ITEM #
PART NUMBER 0255294
1 2 3 4 5 6 7 8
3121146
0641820 4751800 3311805 0641611 4751600 0100011 0902520 1660223 1660223EX
DESCRIPTION ROTARY COUPLING INSTALLATIONS (4WS) Bolt 1/2”-13NC x 2 1/2” Flatwasher 1/2” Locknut 1/2”-13NC Bolt 3/8”-16NC x 1 3/8” Flatwasher 3/8” Loctite #242 Bracket Coupling, Rotary Rebuilt Coupling Note: Due to complexity of repair, seal kit no longer available. Use rebuilt unit as replacement.
QTY.
REV.
Ref
2
2 4 2 4 4 AR 2 1 1
S E C T I O N 2 T U R N T A B L E
2-43
SECTION 2 TURNTABLE FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY
S E C T I O N 2 T U R N T A B L E
2-44
3121146
SECTION 2 TURNTABLE .
FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY FIG & ITEM #
PART NUMBER 0861197 0861155
1
1A 2 2A 2B 2C 3 3A 4 5
0861302 0861313 7020246 4360475 7020175 Not Required 7020176 4360469 2860030 1703468
6
4922077 4922272 4922046
7 8 9 10 11 12 13 14 15 16
Not Used 1840012 1840013 1840014 1840015 3910608 3640970 4460602 4460601 4460603
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
4460631 4460600 4460628 4460607 4750600 3740112 4360314 4360476 2760105 4420038 1704833 4460526 4460428 4460426 4740444 4060906 2420172
3121146
DESCRIPTION GROUND CONTROL BOX ASSEMBLIES Deutz Engine Ford Engine Box, Fiberglass Options: Deutz Engines Ford Engines Latch Switch, Emergency Stop Cap, Mushroom Head Boot Block, Contact Switch, Key Key Decal - Faceplate Engine Harness Assembly (See ELECTRICAL SECTION for Breakdown) Deutz Engine Machines Ford Engine Machines Valve Harness Assembly (See ELECTRICAL SECTION for Breakdown) Duct, Wiring - 2in/5cm Duct, Cover - 2in/5cm Duct, Wiring - 3in/7.6cm Duct, Cover - 3in/7.6cm Screw #6-32NC x 1/2” Rail Barrier, Terminal Block, Terminal Bussbar - 10 Position (Requires being cut into (2) 5 position bussbars) Marker, Terminal (Negative) Block, Terminal Marker, Terminal (1-50) Stop, Terminal Flatwasher #6 Relay, Bosch Switch, Toggle Switch, Contact Block Housing, Display Light Insulation, Adhesive Foam Decal - Ground Control Display Connector, Strain Relief Connector, Strain Relief Connector, Strain Relief Washer, Special Shield, Toggle Switch Gauge, Hourmeter
QTY.
REV.
Ref Ref Ref
5 3
1
2 1 1 0 1 1 1 1 1
S E C T I O N 2 T U R N T A B L E
1
1 1 1 1 8 1 1 10 1 1 46 2 1 14 1 AR 1 1 4in/10cm
1 1 3 1 AR AR 1
2-45
SECTION 2 TURNTABLE FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
0721005 3311001 4751000 3900268 3300205 0641506 0100011 3539219 3740049 4460630 4760600 3310601 4360314 4740444 4060906
2 T U R N T A B L E
4120012 4120012 50 3740057 3740057 51
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
2-46
3740066 3740066 4070987 3640986 0630518 3300408 1670829 4460711 1703622 4460234 0100009 4761000 3910804 3520174 4360387 3740113 3911024
DESCRIPTION Screw #10-24NC x 5/8” Nut #10-24NC Flatwasher #10 Screw #10-24NC x 1/2” Nut, Retainer Bolt 5/16”-18NC x 3/4” Loctite #242 (Not Shown) Plate, Reinforcement Relay - SPDT Marker, Terminal (Ignition) Lockwasher #6 Nut #6-32NC Switch, Toggle Washer, Nylon Shield, Toggle Switch Socket, Relay Options: Deutz Engine Machines Ford Engine Machines Relay Options: Deutz Engine Machines Ford Engine Machines Spring, Relay Options: Deutz Engine Machines Ford Engine Machines Shim, Switch Rail, Relay Mount Capscrew, Button Head Locknut, Plastic Insert Bezel Connector, Strain Relief Decal - Service Manual Reference Base, Tie-Strap (Not Shown) Silicone (Not Shown) Lockwasher #10 Screw #8-32NC x 1/4” Plug, Hole Switch, Pushbutton (Ford Engines Only) Relay, Timer (Ford Engines Only) Screw #10-24NC x 1 1/2” (Ford Engines Only)
QTY.
REV.
2 AR AR 9 4 4 AR 1 AR 1 8 8 1 1 1 AR 2 1 AR 2 1 AR 2 1 AR 1 2 AR 1 1 1 6 AR 4 6 AR 1 1 1
3121146
SECTION 2 TURNTABLE FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER 1001091538
101 102 103 104 to 108 109 308 110 111 112 113 114 115
Not Used 0641406 0641410 Not Used 3311405 3310605 Not Used 3740049 Not Used 4711400 Not Used 1001091778
116
1001091941
117 118 to 119 120 121 to 122 123
1001092527 Not Used 1001094484 Not Used 1001094791
124 to 126 127 128
Not Used 0100048 Not Used
3121146
DESCRIPTION TILT SENSOR INSTALLATION (PRE ADE SYSTEM)
Bolt 1/4”-20NC x 3/4” Bolt 1/4”-20NC x 1 1/4”
QTY.
REV.
Ref
E
Locknut 1/4”-20NC Locknut #6-32 NC
3 2 2 5 6
Relay
1
Flatwasher 1/4” (Narrow)
5
Harness, Tilt Switch Boom (Not Shown) (See ELECTRICAL SECTION for Breakdown) Harness, Console Tilt (Not Shown) (See ELECTRICAL SECTION for Breakdown) Plate, Module Mounting
1 1
Controller, UMS Module
1
Harness, Tilt Sensor Turntable (Not Shown) (See ELECTRICAL SECTION for Breakdown)
1
Grease, Dialectric (Not Shown)
S E C T I O N 2 T U R N T A B L E
1
AR
2-47
SECTION 2 TURNTABLE FIGURE 2-15. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)
10
16A
11 14
16
12
13 14
S E C T I O N 2
2
3
5 1
15
17
18
T U R N T A B L E
2-48
3121146
SECTION 2 TURNTABLE .
FIGURE 2-15. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) FIG & ITEM #
PART NUMBER
DESCRIPTION ELECTRICAL OPTIONS INSTALLATIONS (TURNTABLE MOUNTED)
0258674 1 2 3 4 5 6 to 9
0257887 0641508 4711500 Not Used 0100048 Not Used 0257885
10 11
4220162
12 13
0630491 0080241 3539281 0741606
14 15 16
0100011 4240032 Use 0272507
7016380 70001941 16A
17 18
3121146
4060907 2920215 4460234 0100048
ALARMS INSTALLATIONS Alarm/Harness Assembly Bolt 5/16”-18NC x 1” Flatwasher 5/16” Narrow Sealant, Silicone
STROBE LIGHT INSTALLATIONS (AMBER) (OPTIONAL) Note: If machine is equipped with BLUE Strobe Light, see Section 10 SkyGuard Kit. Spacer, Stop (Used with ECCO Model 6640 Only) Adapter Options: Adapter - Used with ECCO Model 6640 Adapter - Used with ECCO Model 6650 Plate, Mounting (Used with ECCO Model 6640 Only) Screw, Flathead Countersunk 3/8”-16NC x 3/4” (Used with ECCO Model 6640 Only) Compound, Locking Wire-Tile Strobe Light/Guard/Harness Assembly (was p/n 0255917) Bulb, Replacement Options: Bulb for ECCO Model 6640 Bulb for with ECCO Model 6650 Guard Options: Guard - Used with ECCO Model 6640 Guard - Used with ECCO Model 6650 Clamp Sealant, Silicone
QTY.
REV.
Ref
Ref
1
1 2 2 AR
Ref Ref
S E C T I O N 2
2
1 1
1 1 AR 1 1 1
1
1 AR
2-49
T U R N T A B L E
SECTION 2 TURNTABLE FIGURE 2-16. HOODS INSTALLATION
S E C T I O N 2 T U R N T A B L E
2-50
3121146
SECTION 2 TURNTABLE .
FIGURE 2-16. HOODS INSTALLATION FIG & ITEM #
PART NUMBER 0258609
1
2
3 3A 3B 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
3121146
2680451
2680448
2680450 2680435 3960453 7023366 3380444 1670842 3380442 3380443 3539979 0902412 0902351 0902161 0902426 0902219 0362770 2600244 4845411 3539934 0902491 0902223 0902143 0940071 4160139 4160143 3960389 3960470 3520033 0630507 4740171 3311805 3900232 0641609 0641608 4740076 4751600 3311605 3311601 0641508 3900210
DESCRIPTION HOODS INSTALLATION Hood Assembly - Engine Side (See Items 101-110 for Breakdown) Note: Replacement decals must be ordered separately - See DECAL SECTION. Hood Assembly - Tank Side (See Items 201-211 for Breakdown) Note: Replacement decals must be ordered separately - See DECAL SECTION. Hood Assembly- Engine Spacer Hood Seal Bracket Panel, Adapter Cover, Turntable End Cover, Top (Tank Side) Cover/Bracket Weldment (Tank Side) Plate, Baffle Bracket, Hood Mounting (Tank Side) Bracket, Hood Mounting (Engine Side) Bracket, Hood Spacer Mounting (Engine Side) Bracket, Bumper - Counterweight Mounted Bracket, Bumper Bar, Panel Mounting Adapter, Panel Hinge Exhaust Tube Weldment Plate, Seal Bracket, Latch (Engine Side) Bracket, Latch (Tank Side) Bracket, Latch Tank Side) Bumper Spring, Gas (Tank Side) Spring, Gas (Engine Side) Seal Seal, Latch Plug, Hole Bolt, Carriage 1/2”-13NC x 1 1/4” Washer, Hardened Locknut 1/2”-13NC Screw, Button Head 3/8”-16NC x 1 1/4” Bolt 3/8”-16NC x 1 1/8” Bolt 3/8”-16NC x 1” Washer, Fender Flatwasher 3/8” Locknut 3/8”-16NC Nut 3/8”-16NC Bolt 5/16”-18NC x 1” Screw, Button Head 5/16”-18NC x 3/4”
Ref
S E C T I O N
1 1
2
QTY.
REV.
Ref
3/C
1 Ref 1
68in/1.73m
T U R N T A B L E
1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 6 1 1 3.5ft/1m
1 2 6 6 6 5 5 26 5 56 10 12 17 3
2-51
SECTION 2 TURNTABLE FIGURE 2-16. HOODS INSTALLATION (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
39 40 41 42 43 44 45 46 47 48 49 50 51
4751500 3311505 0641406 4751400 3311405 0721006 4751000 4761000 3311001 4070410 4070411 4070412 0100011
2 T U R N T A B L E
101 102 103 104 105 106 107 108 109 110
301 302 303 304 305 306
2-52
Flatwasher 5/16” Locknut 5/16”-18NC Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4”-20NC Screw #10-24NC x 3/4” Flatwasher #10 Lockwasher #10 Nut #10-24NC Shim 1/16” Shim 1/8” Shim 3/16” Loctite #242 (Not Shown)
QTY.
HOOD ASSEMBLY (ENGINE SIDE)
Ref
2680436 2600209 3311605 4751600 2940088 0721008 4751000 3311005 3960464 3960462
Hood Hinge Locknut 3/8”-16NC Flatwasher 3/8” Latch Screw, Machine #10-24NC x 1” Flatwasher #10 Locknut #10-24NC Seal Seal
1 1 4 4 1 2 2 2
2680437 2600233 3311605 4711600 2940088 0721008 4751000 3311005 3960462 3960464 3960438
HOOD ASSEMBLY (TANK SIDE) Hood Hinge Locknut 3/8”-16NC Flatwasher 3/8” Narrow Latch Screw, Machine #10-24NC x 1” Flatwasher #10 Locknut #10-24NC Seal Seal Seal
REV.
26 10 4 4 4 6 6 6 6 AR AR AR AR
2680451
2680448 201 202 203 204 205 206 207 208 209 210 211
DESCRIPTION
A
65in/1.67m 61in/1.55m
Ref
A
1 1 5 5 2 4 4 4 53in/1.35m 83in/2.11m 55in/1.4m
0256823
NOISE REDUCTION INSTALLATION
Ref
2820078 2820079 2820080 2820081 3539955 0641506
Foam, Acoustical (Turntable Side) Foam, Acoustical (Hood Side) Foam, Acoustical (Hood Top) Foam, Acoustical (Located on #8) Plate, Baffle Bolt 5/16”-18NC x 3/4”
1 1 1 1 1 2
—
3121146
SECTION 2 TURNTABLE FIGURE 2-16. HOODS INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
307 308
4751500 0100011
DESCRIPTION Flatwasher 5/16” Loctite #242 (Not Shown)
QTY.
REV.
2 AR
S E C T I O N 2 T U R N T A B L E
3121146
2-53
SECTION 2 TURNTABLE FIGURE 2-17. ENGINE TRAY JACK INSTALLATION (OPTIONAL)
S E C T I O N
3A
16
15
2
9
T U R N T A B L E
4 5 19 18 17
12
2
7 3 14 7
4
7
1 3B
11 10
6
2
7 13
2-54
7 7 8
3121146
SECTION 2 TURNTABLE .
FIGURE 2-17. ENGINE TRAY JACK INSTALLATION (OPTIONAL) FIG & ITEM #
1 2 3 3A 3B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
3121146
PART NUMBER
QTY.
REV.
0258728
ENGINE TRAY JACK INSTALLATION
DESCRIPTION
Ref
1/A
3537445 3537446 2840016 7016321 7016322 0962051 3430816 4891800 4711800 3450404 0641609 3311605 4891600 0641818 3311805 3422530 1380147 3910608 3310601 4770600 4740119
Bracket Bracket Jack and Handle Assembly Handle Wiper Bearing, Flange Pin, Clevis Washer, Hardened Flatwasher 1/2” Narrow Pin, Cotter 1/8” x 1” Bolt 3/8”-16NC x 1 1/8” Locknut 3/8”-16NC Washer, Hardened Bolt 1/2”-13NC x 2 1/4” Locknut 1/2”-13NC Pin, Hitch Clip, Spring Screw, Round Head #6-32NC x 1” Nut #6-32NC Starwasher #6 Washer, Aluminum
1 2 1 1 1 2 1 1 6 1 4 4 4 4 4 1 1 2 2 2 2
S E C T I O N 2 T U R N T A B L E
2-55
SECTION 2 TURNTABLE FIGURE 2-17. ENGINE TRAY JACK INSTALLATION (OPTIONAL) (CONTINUED)
S E C T I O N
FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
2 T U R N T A B L E
2-56
3121146
SECTION 3 BOOM TABLE OF CONTENTS FIGURE
3-1 3-2 3-3 3-4
DESCRIPTION
BOOM AND CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) . . . . . . . . . . . . . . . . . . . .
PAGE
3-2 3-6 3-10 3-12
S E C T I O N 3 B O O M
3121146
3-1
3-2
204 205 206 208
5 22
5
14
8
58
50
39
48 13
13
20
48
35
36
38
203
25
3
24
40
13
23
8
(TOWER BOOM)
LIFT CYLINDER
207
48
37
8
6
41
47
43
42 51
28
16
8
47
13
48
17 201
35
202
15
7
47 7
47 7
32
204 205 206 208
32 30
47
44
19
27
B O O M 34
45
52 11 18
6 49
12
31
56
26
3
48
55 19
10
33
30
47
19
11
54
53 2
52
45
21
4 29
18 101
2
46
105 109
9
111
103 108 106 107 110
30 4 29
104
47
S E C T I O N
13
38
5
22
SECTION 3 BOOM
FIGURE 3-1. BOOM AND CYLINDER INSTALLATION
3121146
SECTION 3 BOOM .
FIGURE 3-1. BOOM AND CYLINDER INSTALLATION FIG & ITEM #
PART NUMBER 0271505
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0100011 0561237 0641404 0641416 0641604 0641606 0641607 0641608 0641611 0641614 0641618 0641820 0642214 0642620 0741607 0801136
17 18 19 20 21 22 23 24
0801314 0961947 0962335 1120510 1670769 1670844 1670850 Use 1684497
25
1683547
26
1683609
27
Use 1684228
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
1683682 2080044 3311605 3340835 3422561 3422563 3422583 3422681 3422683 3422684 3422685 3422686 3422687 3422688 3422689
3121146
DESCRIPTION BOOMS AND CYLINDERS INSTALLATIONS Loctite #242 (Not Shown) Block, Clamp Bolt 1/4”-20NC x 1/2” Bolt 1/4”-20NC x 2” Bolt 3/8”-16NC x 1/2” Bolt 3/8”-16NC x 3/4” Bolt 3/8”-16NC x 7/8” Bolt 3/8”-16NC x 1” Bolt 3/8”-16NC x 1 3/8” Bolt 3/8”-16NC x 1 3/4” Bolt 3/8”-16NC x 2 1/4” Bolt 1/2”-13NC x 2 1/2” Bolt 3/4”x 10NC x 1 3/4” Bolt 1”-8NC x 2 1/2” Screw 3/8”-16NC x 7/8” Boom Assembly (Upper - See MAIN BOOM ASSEMBLY for Breakdown) Boom Assembly (Tower - See Items 201-208 for Breakdown) Bearing, Garmax Bushing, Composite Cover, Upright Cover, Cable Cover, Upright Cover, Tower Fly Cylinder, Upright Level (See CYLINDER SECTION for Breakdown) (was p/n 1683546) Cylinder, Upper Lift (See CYLINDER SECTION for Breakdown) Cylinder, Extended Reach (See CYLINDER SECTION for Breakdown) Cylinder, Slave (See CYLINDER SECTION for Breakdown) (was p/n 1683677) Cylinder, Master (See CYLINDER SECTION for Breakdown) Fastener Locknut, 3/8”-16NC Pad, Boom Rest Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin
QTY.
REV.
Ref
B
S E C T I O N
AR 2 4 4 24 4 2 6 1 1 4 3 5 1 1 1
3 B O O M
1 6 4 2 1 4 1 1 1 1 1 1 4 5 1 2 1 1 2 1 1 2 1 1 1 1
3-3
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
3422729 3422860 3422861 3422867 3841143 3841287 3841340 3841356 3900239 4740439 4844816 4844817 4845593 4845716 Not Used 1683537
S E C T I O N 3 B O O M
0258766 101
0060031
102 103 104 105 106 107 108 109 110 111
0100011 0641606 0641810 0681610 0681820 3311805 3841340 4711600 4711800 4844790 0801314/0271519
201 202 203 204 205 206 207 208
3-4
0801311 0962102 0962122 1320250 1320251 3311605 3841340 3900262
DESCRIPTION
QTY.
Pin Pin Pin Pin Keeper, 3/8” Shaft, Keeper Rod, Hose Loop Shaft, Keeper Screw, Nylon Washer, Thrust Weldment, Top Tube Weldment, Bottom Tube Weldment, Upright Weldment, Pivot
1 1 2 1 7 5 1 1 1 2 1 2 1 1
Cylinder, Tower Lift (See CYLINDER SECTION for Breakdown)
1
ROTATOR AND SUPPORT INSTALLATION Rotator Actuator Assembly (See ROTATOR ASSEMBLY for Breakdown) Loctite #242 (Not Shown) Bolt 3/8”-16NC x 3/4” Bolt 1/2”-13NC x 1 1/4” Bolt 3/8”-16NC x 1 1/4” (Grade 8) Bolt 1/2”-13NC x 2 1/2” (Grade 8) Locknut 1/2”-13NC Rod, Hose Loop Flatwasher 3/8” Narrow Flatwasher 1/2” Narrow Support Weldment TOWER BOOM ASSEMBLY & COMPONENTS Weldment, Tower Boom Bushing, Composite (2 3/4”) Bushing, Composite (4”) Clamp, Bar Clamp, Block Locknut 3/8”-16NC Rod, Hose Loop Bolt 3/8”-16NC x 4 3/4”
Ref
REV.
D
1 AR 2 6 4 4 4 1 4 8 1 Ref
A/A
1 2 2 3 3 6 2 6
3121146
SECTION 3 BOOM FIGURE 3-1. BOOM AND CYLINDER INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 3 B O O M
3121146
3-5
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM ASSEMBLY
S E C T I O N 3 B O O M
3-6
3121146
SECTION 3 BOOM .
FIGURE 3-2. MAIN BOOM ASSEMBLY FIG & ITEM #
PART NUMBER 0801136
1 2 3
0801191 0801140 1683672
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
3422457 3422690 3841143 0561295 0962102 3340871 4070863 4070864 3340881 4070897 4070898 3760133 4711600 0100011 0641606 0641607 0641608 0641609 3900259 0641612 1670836 0961951 0258077
101 Use 1001099837 7016522 7016523 7016529 7006137 7016524 7016525 1001099837 70002013
102 103 104
3121146
70002014 4845729 4845730 3340840
DESCRIPTION MAIN BOOM ASSEMBLY Base Weldment Fly Weldment Telescope Cylinder Assembly (See CYLINDER SECTION for Breakdown) Pin Pin Keeper, Pin Block, Boom Rest Bushing, Garmax Pad, Wear Shim 1/8” Shim .05 Pad, Wear Shim .05 Shim 1/8” Ring, Retaining Flatwasher 3/8” Narrow Loctite #242 (Not Shown) Bolt 3/8”-16NC x 3/4” Bolt 3/8”-16NC x 7/8” Bolt 3/8”-16NC x 1” Bolt 3/8”-16NC x 1 1/8” Bolt, Shoulder Bolt 3/8”-16NC x 1 1/2” Cover, Boom Bushing, Garmax POWER TRACK INSTALLATION Carrier Options: Gemco Brand Power Track (Original Equipment) (was p/n 1180349) Carrier Repair Section (1ft length - Includes 1 Pin for each end) Rod Kit (Includes 1 Rod, 2 Screws & 2 Lockwashers) Roller, Plastic Rod Link Pin Assembly (Includes 1 Pin, 1 Roller & 2 Retaining Rings) Foot, Mounting (1 Pair) Clamping Carrier Section Gortrac Brand Power Track (Service Replacement) Carrier Repair Section (2ft length - Includes 1 Pin Assembly for each end) Mounting Foot Kit (Includes Both Pair of Feet) Push Tube Weldment Support Pad
QTY.
REV.
Ref
E
S E C T I O N
1 1 1 1 1 1 1 2 4 4 4 12 10 12 2 2 AR 16 10 5 6 4 2 6 2 Ref
3 B O O M
D
1
AR AR AR AR 2 2 AR 1 1 1 1
3-7
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121
3538758 3340764 4070969 0641640 0641606 4711600 0100011 4060805 0641622 1320248 1320249 0641607 3841406 1320263 3340860 3340861 3900232
S E C T I O N 3 B O O M
3-8
DESCRIPTION Plate, Backing Pad Shim Bolt 3/8”-16NC x 5” Bolt 3/8”-16NC x 3/4” Flatwasher 3/8” Narrow Loctite #242 (Not Shown) Flex-Trim Bolt 3/8”-16NC x 2 3/4” Clamp, Hose Clamp, Hose Bolt 3/8”-16NC x 7/8” Loop, Hose Clamp, Loop Pad, Rubber Pad, Rubber Screw, Button Head 3/8”-16NC x 1 14/”
QTY.
REV.
1 2 3 2 18 22 AR 8in/20cm
2 1 1 4 1 1 2 2 2
3121146
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 3 B O O M
3121146
3-9
SECTION 3 BOOM FIGURE 3-3. ROTATOR ASSEMBLY
S E C T I O N 3 B O O M
3-10
3121146
SECTION 3 BOOM FIGURE 3-3. ROTATOR ASSEMBLY FIG & ITEM #
PART NUMBER 0060031
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17A 17B 18
Not Serviced Not Serviced 7017100 Not Serviced Not Serviced Not Serviced 7017119 3272605 Kit Kit Kit Kit Kit Kit Kit Kit 7017101 7011331 2900770 7011332 7011311 Not Serviced 7017103 7017104
3121146
DESCRIPTION ROTATOR ASSEMBLIES Housing/Ring Gear Assembly Shaft Weldment Piston/Sleeve Cap, End Plug, Port Setscrew Bolt Nut Seal, Cap Ring, Back-up (Cap) Seal, Rod Seal, Piston Packing, Bearing Bearing, Cap Bearing, Shaft Thrustwasher Valve Assembly Cartridge, Valve Seal Kit - 7011331 Valve Cartridge, Valve Seal Kit - 7011332 Valve Bolt 1/4”-20NC (Grade 8) —————————— Seal Kit (Includes Items 9-13) Bearing Kit (Includes Items 14-16)
QTY.
REV.
Ref
F
1 1 1 1 6 2 1 1 1 1 1 1 2 1 1 2 1 2 2 2 2 3
S E C T I O N 3 B O O M
1 1
3-11
SECTION 3 BOOM FIGURE 3-4. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED)
S E C T I O N 3 B O O M
3-12
3121146
SECTION 3 BOOM .
FIGURE 3-4. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) FIG & ITEM #
PART NUMBER 0271989
1 2 3 4 5
0100035 3310805 3520035 3930824 Use 4360578
6 4460428 4460968 0258457 101
102 103 104
4640929 7012970 7012953 0641416 4711400 3311405 1001091538
201 202 to 203 204 205 to 207 208 209 210 211 212 213 214 215 to 217 218 219 220 to 221 222 223 to 225 226 227 to 228
3121146
0100011 Not Used 0641610 Not Used 3310605 Not Used 3311601 Not Used 3930606 Not Used 4761600 Not Used 1001094400 1001094401 Not Used 1001094639 Not Used 4751600 Not Used
DESCRIPTION BOOM VALVES AND LIMIT SWITCHES INSTALLATION Loctite #222 (Not Shown) Locknut #8-32NC Plug, Cap Capscrew, Socket Head #8-32NC x 1 1/2” Switch, Limit (was p/n 4360322 & p/n 4360549) (Note: P/N 4360549 & P/N 4360578 does not include #6 Connector Purchase Separately) Connector, Strain Relief Options: Use with p/n 4360322 Switch Use with p/n 4360549 & 4360578 Switches VALVES INSTALLATION Valve Assembly (Relief) Cartridge Seal Kit - 7012970 Cartridge Bolt 1/4”-20NC x 2” Flatwasher 1/4” Narrow Locknut 1/4”-20NC TILT SENSOR INSTALLATION (PRE ADE SYSTEM) Loctite #242 (Not Shown)
QTY.
REV.
Ref
A
S E C T I O N
AR 4 2 4 2
2
Ref
C
1 1 1 2 4 2 Ref
B O O M E
AR
Bolt 3/8”-16NC x 1 1/4”
2
Locknut #6-32 NC
6
Locknut 3/8”-16NC
2
Screw #6-32 NC
6
Lockwasher 3/8”
2
Sensor, Dual Axis Bracket, Tilt Sensor
2 1
Bracket, Tilt Sensor
1
Flatwasher 3/8”
2
3
3-13
SECTION 3 BOOM FIGURE 3-4. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED) (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 3 B O O M
3-14
3121146
SECTION 4
PLATFORM
TABLE OF CONTENTS FIGURE
4-1 4-2 4-3 4-4 4-5
DESCRIPTION
PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLLER ASSEMBLY (SWING AND LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
4-2 4-6 4-10 4-12 4-14
S E C T I O N 4 P L A T F O R M
3121146
4-1
SECTION 4
PLATFORM
FIGURE 4-1.PLATFORM COMPONENTS INSTALLATION
S E C T I O N 4 P L A T F O R M
4-2
3121146
SECTION 4
PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER 3510784
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
0641524 0681810 1060919 2080040 3271805 3300393 3311505 3520072 3900054 3900207 4751500 4751800 4844954 4845287 4845328 4846442 4846443 4846450 Not Used 0681814 4711800 0258048
101 102 103 104 105 106 107 108 109
3536089 0641414 3311405 4711400 2920140 7016399 4240099 2820035 Not Used 4460598
110 111
4920018 Not Used
3121146
DESCRIPTION PLATFORM INSTALLATION (FALL ARREST) Note: Replacement decals must be ordered separately - See DECAL SECTION.
QTY.
REV.
Ref Ref
C
Bolt 5/16”-18NC x 3” Bolt 1/2”-13NC x 1 1/4” (Grade 8) Cable, Fall Arrest Fastener, Huck Locknut 1/2-13NC” Collar Locknut 5/16”-18NC Cap, Plug Bolt, Shoulder 1/2”x 1 3/4” Fastener Flatwasher 5/16” (Wide) Flatwasher 1/2” (Wide) Weldment, Floor Weldment, Door Rail Weldment, Control Box Rail Weldment, Rail (Right Side) Weldment, Rail (Left Side) Weldment, Gate
4 4 1 8 6 16 4 5 1 16 4 8 1 1 1 1 1 1
Bolt 1/2”-13NC x 1 3/4” (Grade 8) Flatwasher 1/2” Narrow
2 2
WORKLIGHTS INSTALLATION (OPTIONAL)
Ref
Plate, Mounting Bolt 1/4”-20NC x 1 3/4” Locknut 1/4”-20NC Flatwasher 1/4” Narrow Worklight Bulb, Replacement (1 Per Worklight) Tie-Strap (Not Shown) Loom, Vinyl (Not Shown)
2 4 4 8 2 2 10 9
Connector, Strain Relief (Not Shown - Located at Console Box) Wire Options: (Not Shown)
1
S E C T I O N 4 P L A T F O R M
2/E
AR
4-3
SECTION 4
PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER 0861237
S E C T I O N
201 to 228 229 230 231 232 233 to 247 248
4 P L A T F O R M
Not Used 0641408 3311405 4740362 4460071 Not Used Use 0272970
4360031 1001117320
249 to 257 258 259 to 272 273 274 275
7000625 70003483 Not Used 4751400 Not Used 3380434 0641414 3311405
DESCRIPTION FOOTSWITCH AND COVERS INSTALLATION
Bolt 1/4”-20NC x 1” Locknut 1/4”-20NC Washer, Fender Terminal, Strain Relief Footswitch Assembly (was p/n 4360031) Note: Assembly p/n 0272970 may use either p/n 4360031 or p/n 1001117320. If Original Equipment was replaced as an “assembly,” p/n 1001117320 may have been used as part of the Service Replacement. Identify component before ordering parts. Footswitch Less Cable Options: Original Equipment Service Replacement Block, Contact Options (see Note Above): Contact Block for 4360031 Footswitch Contact Block for 1001117320 Footswitch
4-4
1580012 1580013
REV.
Ref
5/D
3 3 3 1 1 Ref
1
AR 2 1
Flatwasher 1/4”
4
Panel, Poly Bolt 1/4”-20NC x 1 3/4” Locknut 1/4”-20NC
1 2 2
TRAY INSTALLATIONS (OPTIONAL) 301 302
QTY.
Tray, Storage (Center) Tray, Storage (Rail Mounted - Not Shown)
Ref 1 1
3121146
SECTION 4
PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 4 P L A T F O R M
3121146
4-5
SECTION 4
PLATFORM
FIGURE 4-2.PLATFORM CONSOLE ASSEMBLY 59 52 301 49 77 12
51
23 203
8
23 19 202 17 22 17A
9 5
6 101
444
S E C T I O N
28 27
17B 18
468 13 23 201 20 22
19 22
33 59 4
7
4
10
P L A T F O R M
2 58 40 59
14 15
11
33 59
19 19 22 22
23 204
19 22
63 62 60
79 476
44 24 24
60 61 63
56
42
108 104
24
39
37 38
111
490 35
26
439 32
489
485 484 487 488 487
45 21
48
47 29 31 46
107
4-6
491
25
480
483
1 102
482
67 482 68 69
481 486
62 60
34 59 58 57
41 103
80 477
70 69
55
43
24
78 475
82 479 81 478
16 60 3
19 22
105
31 30
3121146
SECTION 4
PLATFORM
FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY FIG & ITEM #
PART NUMBER 0861237
1 2 3 4
0860984 4340678 3538819 1600284
5
1600283
6 7 8 9 10 11 12 13 14 15 16 17 17A 17B 18 19 20 21 22 23
4340684 1702676 1702564 1702565 1702566 1702567 2760105 4360387 2560136 4360407 3910610 4360475 7020175 7020176 4360476 4360314 4360331 0140026 3790012 3520028
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
1600218 0641610 4751600 4460467 4460510 0641408 3311405 4740362 4460071 0641404 3311401 1320060 1320095 3740058 3740063 4360232 0641406 1703090
3121146
DESCRIPTION CONSOLE BOX INSTALLATIONS Box, Console Support, Hand Plate, Mounting Controller Assembly (Swing & Lift) (See CONTROLLER ASSEMBLY (SWING & LIFT) for Breakdown) Controller Assembly (Drive & Steer) (See CONTROLLER ASSEMBLY (DRIVE & STEER) for Breakdown) Support, Hand Decal (Horn/Drive Speed/Level) Decal (Stop) Decal (Drive and Steer) Decal (Lift and Swing) Decal (Speed/Lower Lift/Tele/Rotate/Jib) Housing, Display Light Switch, Pushbutton Knob, Speed Control Controller, Speed Screw #6-32NC x 5/8” Switch, Emergency Stop Cap, Mushroom Head Block, Contact Switch, Contact Block Switch, Toggle Switch, Toggle Alarm O-Ring Plug, Hole (For switch call-outs at these locations, refer to options installation below) Card, Control Bolt 3/8”-16NC x 3/4” Flatwasher 3/8” Tool, Pin Extraction (Blue 16-18 Gauge) (Not Shown) Tool, Pin Extraction (Yellow 12-14 Gauge) (Not Shown) Bolt 1/4”-20NC x 1” Locknut 1/4”-20NC Washer 1/4” (Fender) Connector, Strain Relief Bolt 1/4”-20NC x 1/2” Nut 1/4”-20NC Clamp Clamp Relay - 4PDT Spring, Relay Breaker, Circuit - 15 Amp Bolt 1/4”-20NC x 3/4” Decal - Control Card (Lift)
QTY.
REV.
Ref
5/D
1 1 1 1
S E C T I O N
1 1 1 1 1 1 1 1 1 1 1 16 1 1 1 1 6 1 1 7 4
4 P L A T F O R M
4 4 4 1 1 3 3 3 1 8 1 1 1 3 3 2 3 1
4-7
SECTION 4
PLATFORM
FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
42 43 44 45 46 47 48
1703091 1703092 1703093 4460470 4460471 4460428 See Note
Decal - Control Card (Swing) Decal - Control Card (Flow Control) Decal - Control Card (Drive) Nut, Conduit Washer Connector, Strain Relief Footswitch (Note: See PLATFORM COMPONENTS INSTALLATION for Service Parts)
1 1 1 2 2 2 1
49 50
Not Used 4922155
1
51 52 53 to 54 55 56 57 58 59 60 61 62 63 64 to 66 67 68 69 70 71 72 73 to 75 76 77 78 79 80 81 82 83
1670829 0630464 Not Used 3740113 3740115 0641406 Not Used 0100011 0100035 0721010 0721003 4751000 Not Used 0721004 4711000 4761000 3311001 4460488 0100009 Not Used 3311605 1704260 3539275 3740049 0721003 4751000 3311005 2920129
Harness Assembly (Not Shown - See ELECTRICAL SECTION for Breakdown and Items 401-491 Below) Bezel Screw, Button Head #10-24NC x 1/2”
1 2
Relay, Time Delay Relay, Time Delay Bolt 1/4”-20NC x 3/4”
1 1 1
S E C T I O N 4 P L A T F O R M
0860984 101 102 103 104 105 106
4-8
1220022 1220023 2600211 3900224 3931672 Not Used
Loctite #242 Loctite #222 Screw, Machine #10-24NC x 1 1/4” Screw, Machine #10-24NC x 3/8” Flatwasher #10
AR AR 2 4 2
Screw, Machine #10-32NC x 1/2” Flatwasher #10 Narrow Lockwasher #10 Nut #10-24NC Base, Wire Tie (Not Shown) Silicone (Not Shown)
2 2 6 4 10 AR
Locknut 3/8”-16NC Decal - EMS Plate, Relay Mounting Relay, Bosch Screw #10-24NC x 3/8” Flatwasher #10 Locknut #10-24NC Bulb, Light
4 1 1 5 5 5 5 12
CONSOLE BOX ASSEMBLY Lid, Cast Bottom, Box Hinge Capscrew, Socket Head Countersunk 6mmx 16mm Capscrew, Socket Head 3/8”-16NC x 4 1/2”
Ref
REV.
6/E
1 1 2 8 1
3121146
SECTION 4
PLATFORM
FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
107 108 109 to 110 111
3311601 0100011 Not Used 3520173
DESCRIPTION Nut 3/8”-16NC Loctite #242 Plug (Located on back of console box) CONSOLE BOX OPTIONS
201
0258945 4360331 3790012
202 4360336 3790012 203
204
4360336 3790012 0258608 4360314 3790012 0275804
301
1707111
4922155 401 to 438 439 440 to 443 444 445 to 467 468 469 to 474 475 476 477 478 479 480 481 482 483 484 485 486 487
3121146
Not Used 1060012 Not Used 2920129 Not Used 4120035 Not Used 3539275 3740049 0721003 4751000 3311005 3641182 4460601 4460607 4460602 4460629 4460603 4460600 4460631
4WS Switch Option Components Switch, Toggle O-Ring Dual Switch Option Components Switch, Toggle O-Ring Lights Switch Option Components Switch, Toggle O-Ring Jib Switch Option Components Switch, Toggle O-Ring LIGHT PANEL DECAL INSTALLATION Decal - Light Panel Display Note: Machines should of been updated to this light panel installation. RELAY AND TERMINAL BLOCK INSTALLATIONS
Cable, Electrical - 12/4
QTY.
REV.
1 AR 4
S E C T I O N
Ref AR 1 1 AR 1 1 AR 1 1 AR 1 1
A
Ref
A
4
A
P L A T F O R M
1 Ref
Ref
5
7ft/2.1m
Bulb, Light
9
Base, Light
8
Plate, Relay Mounting Relay, Bosch Screw #10-24NC x 3/8” Flatwasher #10 Locknut #10-24NC Track Block, Terminal Stop, End Barrier, Terminal Marker, Terminal (6-15) Bar, Buss - 10 Position (Cut into [2] 5 Position Bars) Block, Terminal Marker, Terminal (Negative)
1 5 5 5 5 1 10 2 1 2 1 10 1
4-9
SECTION 4
PLATFORM
FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
488 489 490 491
4460632 4120013 4460613 4460503
DESCRIPTION Marker, Terminal (1-5) Socket, Relay Connector - 21 Position Connector - 31 Position
QTY.
REV.
1 3 1 1
S E C T I O N 4 P L A T F O R M
4-10
3121146
SECTION 4
PLATFORM
FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 4 P L A T F O R M
3121146
4-11
SECTION 4
PLATFORM
FIGURE 4-3.CONTROLLER ASSEMBLY (SWING AND LIFT)
1A
S E C T I O N
22
22
21
21
20
18
19
4
7
2
P L A T F O R M
11
9 3 6 1
9 6
3 26
5 8
25
4 17 13 10
14 15
20 16 12
24
4-12
3121146
SECTION 4
PLATFORM
FIGURE 4-3. CONTROLLER ASSEMBLY (SWING AND LIFT) FIG & ITEM #
PART NUMBER 1600284
1
1A 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
3121146
7019141 7003928 7022808 7019197 7019142 7019111 7019143 7019144 7019145 7019174 7003977 7019147 7003974 7019142 7003992 7003993 7003976 7019149 7003952 7019150 Use 7022813 Use 7022813 7003956 7003953 7019137 Not Serviced 4460266 4460268 4460265 4460267 7019122 7019123
DESCRIPTION CONTROLLER ASSEMBLY Mechanical Assembly (Includes Base, Handle Cap & Rod & Item 18 Boot) Spring Cap, Lift Handle Cap & Rod Plate Bearing, Gear Screw Spacer, Cam E-Clip Spacer Gear, Drive Shaft Potentiometer Plate Washer Nut Gear, Slave Setscrew Screw Gate Boot (was p/n 7003955) Plate, Plastic (was p/n 7003954) O-Ring Washer Screw Center, Detent Connector - 9 Pin Socket, Female Plug - 9 Pin (Part of Platform Wiring) (Not Shown) Pin, Male (Part of Platform Wiring) (Not Shown) Gimble, Outer Gimble, Inner
QTY.
REV.
Ref
A
1
S E C T I O N
1 1 1 2 4 2 2 4 2 2 4 2 2 2 2 2 2 4 1 1 1 1 4 4 1 1 8 1 8 1 1
4 P L A T F O R M
4-13
SECTION 4
PLATFORM
FIGURE 4-4.CONTROLLER ASSEMBLY (DRIVE AND STEER)
S E C T I O N 4 P L A T F O R M
4-14
3121146
SECTION 4
PLATFORM
FIGURE 4-4. CONTROLLER ASSEMBLY (DRIVE AND STEER) FIG & ITEM #
PART NUMBER 1600283
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
7022810 7019161 7019160 7019159 7019158 7019157 7019156 7003972 7019115 7019155 7019151 7019154 7019153 7019117 7019163 7019162 7019111 7019110 7019112 7003946 7019103 Not Serviced 7019168 7003992 7003993 7003935 7003969 7003941 7022810
101 102 103 104 105 106 107 108 109 110
3121146
7019164 7019194 7019165 7003983 7003972 7003973 7019166 7019167 7003980 7003989
DESCRIPTION CONTROLLER ASSEMBLY Handle Assembly (See items 101-110 for Breakdown) Boot and Sleeve Plate, Base Bracket, Mounting Plate, Mounting (Left Side) Plate, Pot Mounting Electric Assembly Boot, Rocker Stand-Off Shaft 8mm Tie-Strap Clamp, Wire Strip, Terminal - 5 Position Screw Potentiometer Coupling Assembly Spring Bearing Spacer, Head Gear Washer Spring, Return Pin Rivet Plate, Mounting (Right Side) Washer Nut Gear, Slave Screw Washer HANDLE ASSEMBLY Axle Coupling Rocker Setscrew Boot, Switch Half, Handle Switch, Micro Nut Screw Gasket
QTY.
REV.
Ref
B
1 1 1 1 1 1 1 1 2 1 AR 2 1 8 1 1 2 2 1 1 4 1 1 1 1 1 2 2
S E C T I O N 4 P L A T F O R M
Ref 1 1 1 2 1 2 2 4 4 2
4-15
SECTION 4
PLATFORM
FIGURE 4-5.SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)
S E C T I O N 4 P L A T F O R M
4-16
3121146
SECTION 4
PLATFORM
FIGURE 4-5. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) FIG & ITEM #
PART NUMBER 0271622
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
4845308 1670804 1670785 1670786 1671041 1671042 0940038 3539719 0630462 4761500 4751800 3311501 4751500 4460049 3530072 4360057 0731005 4751000 0200550 0641612 4751600 3311605 3010088 1260136 4360387 1702938 Not Used 1320043 0641406 4711400 3311405 1060330 4460425
0258763
4845872
3121146
DESCRIPTION SOFT TOUCH SYSTEM INSTALLTION (FALL ARREST) Weldment, Soft Touch Rail Cover, Rail Cover, Post (Right/Front) Cover, Post (Left/Front) Cover, Mid Rail (Right Side/End) Cover, Mid Rail (Left Side/End) Padding, Bumper Plate, Switch Strike Bolt, Carriage Lockwasher 5/16” Flatwasher 1/2” Nut 5/16”-18NC Flatwasher 5/16” Connector, Strain Relief Plug, Cap Switch, Limit Bolt #10-32NC x 5/8” Lockwasher #10 Arm, Switch Bolt 3/8”-16NC x 1 1/2” Flatwasher 3/8” Locknut 3/8”-16NC Link, Quick Chain Switch, Push Button Decal - Soft Touch Override Clamp Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4”-20NC Cable, Electrical - 16/3 Connector, Strain Relief (Not Shown - Located in Console Box) SOFT TOUCH COUNTERWEIGHT INSTALLATION (NOT SHOWN) Counterweight (Located in Frame)
QTY.
REV.
Ref
B
2 2 2 2 1 1 AR 2 8 8 8 8 8 2 4 2 4 4 2 8 40 8 16
S E C T I O N 4 P L A T F O R M
10ft/3m
1 1 4 4 8 4 16ft/4.9m
1
Ref
A
1
4-17
SECTION 4
PLATFORM
FIGURE 4-5. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 4 P L A T F O R M
4-18
3121146
SECTION 5
CYLINDER
TABLE OF CONTENTS FIGURE
5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8
DESCRIPTION
UPRIGHT LEVEL CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLAVE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPE CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
5-2 5-4 5-6 5-8 5-10 5-12 5-14 5-16
S E C T I O N 5 C Y L I N D E R
3121146
5-1
SECTION 5
CYLINDER
FIGURE 5-1.UPRIGHT LEVEL CYLINDER ASSEMBLY
S E C T I O N 5 C Y L I N D E R
5-2
3121146
SECTION 5
CYLINDER
FIGURE 5-1. UPRIGHT LEVEL CYLINDER ASSEMBLY FIG & ITEM #
PART NUMBER
1683546 1684497 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
1683544 Use 0370034 1683071 3760374 3932240 3480237 0961901 4640509 2900792 4640605 2900792 2220883 2220888 0962102 Not Used Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 Use 2901526 0100011 0100038 0100063 0641818
27 to 29
0630537 Not Used 2901526
3121146
DESCRIPTION
QTY.
Note: Original Equipment Cylinder may have been replaced with Service Replacement Cylinder. Identify p/n stamped on cylinder before ordering parts.
Ref
UPRIGHT LEVEL CYLINDER ASSEMBLY Original Equipment Service Replacement Rod Weldment Barrel Weldment (was p/n 1683545 & p/n 1683819) Head Ring, Washer Bolt, Socket Head 3/4in x 2-1/2in Piston Bushing, Tapered Cartridge, Valve Seal Kit - 4640509 Valve Cartridge, Valve Seal Kit - 4640605 Valve Plug, O-Ring Plug, O-Ring Bushing Ring, Lock Seal Ring, Washer Ring, Back-up Wiper Seal, Rod Ring, Wear O-Ring Ring, Back-up Compound, Locking Primer, Locking Loctite #RC609 Hardware Options: Bolt 1/2in-13NC x 2-1/2in (Prior to SN 0300045154) Bolt (SN 0300045154 to SN 0300069000) —————————— Seal Kit (Includes Items 14-22)
Ref Ref Ref
REV.
G C
S E C T I O N
1 1 1 1 8 1 1 1 1 1 1 2 1 4
5 C Y L I N D E R
2 2 1 2 1 1 1 1 1 AR AR AR 3
1
5-3
SECTION 5
CYLINDER
FIGURE 5-2.LIFT CYLINDER ASSEMBLY - JIB
S E C T I O N 5 C Y L I N D E R
5-4
3121146
SECTION 5
CYLINDER
FIGURE 5-2. LIFT CYLINDER ASSEMBLY - JIB FIG & ITEM #
PART NUMBER 1683609
1 1A 2 3 4 5 5A 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1684089 0962336 1683053 3760368 3931516 1684090 0962336 4640509 2900792 4641062 2220883 2220885 3480210 0961893 4566471 3900141 Kit Kit Kit Kit Kit Kit Kit Kit Kit 0100011 0100038 0100063 0630534 2901303
3121146
DESCRIPTION JIB LIFT CYLINDER ASSEMBLY Barrel Weldment Bushing Head Washer, Ring Bolt, Socket Head 5/16”-18NC x 2” Rod Weldment Bushing Cartridge, Valve (Counterbalance Non-Vented) Seal Kit - 4640509 Valve Plug, P.O. Check Plug, O-Ring Plug, O-Ring Piston Bushing, Tapered Spacer, Tube Setscrew 1/4”-20NC x 1/4” Ring, Lock Seal, Piston O-Ring Ring, Back-up O-Ring Ring, Back-up Seal Wiper Ring, Wear Loctite #242 (Not Shown) Primer, Locking (Not Shown) Loctite #RC609 (Not Shown) Capscrew, Socket Head #10-24NC x 1” —————————— Seal Kit (Includes Items 14-22)
QTY.
REV.
Ref
D
1 2 1 1 8 1 2 2 2 1 4 1 1 1 1 1 2 2 1 2 1 1 1 1 1 AR AR AR 3
S E C T I O N 5 C Y L I N D E R
1
5-5
SECTION 5
CYLINDER
FIGURE 5-3.LIFT CYLINDER ASSEMBLY - MAIN BOOM
S E C T I O N 5 C Y L I N D E R
5-6
3121146
SECTION 5
CYLINDER
FIGURE 5-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM FIG & ITEM #
PART NUMBER 1683547
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
1683821 1683549 3480238 0961901 2220888 1683071 3760374 3932240 Not Used Kit Kit Kit Kit Kit Kit Kit Kit Kit 0962102 4641062 4640509 2900792 2180615 0100011 4641027 0100038 2220883 2220775 2220516 0100063 Kit 0630537 2901514
3121146
DESCRIPTION MAIN BOOM LIFT CYLINDER ASSEMBLY Barrel Weldment Rod Weldment Piston Bushing, Tapered Plug, O-Ring Head Washer, Ring Bolt, Socket Head 3/4” x 2 1/2” O-Ring Ring, Back-up Wiper Seal, Rod O-Ring Ring, Back-up Ring, Wear T-Seal Seal Bushing, Garmax Plug Cartridge, Valve Seal Kit - 4640509 Valve Orifice Loctite #242 (Not Shown) Cartridge, Valve Primer, Locking (Not Shown) Plug Fitting Fitting Loctite RC609 (Not Shown) Ring, Wear Bolt —————————— Seal Kit (Includes Items 10-18 & 30)
QTY.
REV.
Ref
I
1 1 1 1 1 1 1 8
S E C T I O N
1 2 1 1 1 1 2 1 1 4 1 1 1 1 AR 1 AR 1 1 1 AR 1 3
5 C Y L I N D E R
1
5-7
SECTION 5
CYLINDER
FIGURE 5-4.LIFT CYLINDER ASSEMBLY - TOWER BOOM
S E C T I O N 5 C Y L I N D E R
5-8
3121146
SECTION 5
CYLINDER
FIGURE 5-4. LIFT CYLINDER ASSEMBLY - TOWER BOOM FIG & ITEM #
PART NUMBER 1683537
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
1683823 1683818 3760374 1683539 3480236 2220883 2220888 4640509 2900792 4640605 2900792 0962102 Not Used Kit Kit Kit Kit Kit Kit Kit Kit Kit 0961903 3932240 0100011 0100038 0100063 0630536 2901537
3121146
DESCRIPTION TOWER LIFT CYLINDER ASSEMBLY Barrel Weldment Head Ring, Washer (Prior to SN 45154 Only) Rod Weldment Piston Plug, O-Ring Plug, O-Ring Cartridge, Valve Seal Kit - 4640999 Valve Cartridge, Valve Seal Kit - 4640605 Valve Bushing, Garmax O-Ring Ring, Lock Seal Ring, Lock O-Ring Ring, Back-up Ring, Wear Seal Wiper Bushing, Tapered Capscrew, Socket Head 3/4” x 2 1/2” Loctite #242 (Not Shown) Primer, Locking (Not Shown) Loctite #RC609 (Not Shown) Bolt —————————— Seal Kit (Includes Items 12-20)
QTY.
REV.
Ref
G
1 1 1 1 1 2 1 1 1 1 1 4
S E C T I O N
1 1 2 2 1 2 1 1 1 1 8 AR AR AR 3
5 C Y L I N D E R
1
5-9
SECTION 5
CYLINDER
FIGURE 5-5.MASTER CYLINDER ASSEMBLY
S E C T I O N 5 C Y L I N D E R
5-10
3121146
SECTION 5
CYLINDER
FIGURE 5-5. MASTER CYLINDER ASSEMBLY FIG & ITEM #
PART NUMBER 1683682
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
0100011 0100038 0630535 0961894 0961951 0962155 1683055 1684125 1684126 3480188 Kit Kit Kit Kit 3760369 Kit Kit 3931620 Kit Kit Kit 4566468 0100063 2901301
3121146
DESCRIPTION MASTER CYLINDER ASSEMBLY Loctite #242 (Not Shown) Primer, Locking (Not Shown) Capscrew, Socket Head 1/4”-20NC x 1” Bushing, Tapered Bushing, Garmax Bushing, Garmax Head Barrel Rod Piston Ring, Wear Ring, Lock Ring, Back-up Ring, Back-up Ring, Washer O-Ring O-Ring Capscrew 3/8”-16NC x 1 1/4” Seal, Rod Wiper Seal Spacer, Tube Loctite #RC 609 (Not Shown) —————————— Seal Kit - (Includes Items 11-14, 16, 17 & 19-21)
QTY.
REV.
Ref
C
AR AR 3 1 2 1 1 1 1 1 2 2 1 2 1 1 1 8 1 1 2 1 AR
S E C T I O N 5 C Y L I N D E R
1
5-11
SECTION 5
CYLINDER
FIGURE 5-6.SLAVE CYLINDER ASSEMBLY
S E C T I O N 5 C Y L I N D E R
5-12
3121146
SECTION 5
CYLINDER
.
FIGURE 5-6. SLAVE CYLINDER ASSEMBLY FIG & ITEM #
PART NUMBER
DESCRIPTION Note: Original Equipment Cylinder may have been replaced with Service Replacement Cylinder. Identify p/n stamped on cylinder before ordering parts.
1683677 1684228 1 2 3 4 5 6 7
0100011 0100038 0630535 0961894 0961951 1683055 1683678 1684230
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1683680 1684232 2220883 2220885 3480188 Kit Kit Kit 3760369 Kit Kit Kit 3931620 Kit Kit Kit 4566468 4640605 2900792 4640932 7011112 0100063 2901301
3121146
SLAVE CYLINDER ASSEMBLIES: Original Equipment Service Replacement Loctite #242 (Not Shown) Primer, Locking (Not Shown) Capscrew, Socket Head 1/4”-20NC x 1” Bushing, Tapered Bushing, Garmax Head Barrel Options: Used with p/n 1683677 Used with p/n 1684228 Rod Used with p/n 1683677 Used with p/n 1684228 Plug Plug Piston Ring, Lock Ring, Back-up Ring, Wear Ring, Washer Ring, Back-up O-Ring O-Ring Capscrew 3/8”-16NC x 1 1/4” Seal Wiper Seal Spacer, Tube Valve, Cartridge Seal Kit - 4640605 Valve Valve, Cartridge Seal Kit - 4640932 Valve Loctite #RC 609 (Not Shown) —————————— Seal Kit - (Includes Items 12-14, 16-18 & 20-22)
QTY.
REV.
Ref
Ref Ref Ref
B C
S E C T I O N
AR AR 3 1 4 1 1
1
5
6 1 1 2 1 2 1 2 1 1 8 2 1 1 1 1 1 1 1 AR
C Y L I N D E R
1
5-13
SECTION 5
CYLINDER
FIGURE 5-7.STEER CYLINDER ASSEMBLY
S E C T I O N 5 C Y L I N D E R
5-14
3121146
SECTION 5
CYLINDER
FIGURE 5-7. STEER CYLINDER ASSEMBLY FIG & ITEM #
PART NUMBER 1683740
1 2 3 4 5 6 7 8 9 10 11 12 13 14
7017210 7017211 Kit Kit 7023023 7017236 7017213 Kit Kit Kit Kit 7017214 Kit 0961977 7017215
DESCRIPTION STEER CYLINDER ASSEMBLY Locknut Piston Seal O-Ring Barrel Weldment Rod Weldment Head O-Ring Ring, Back-up Ring, Retainer Seal Nut, Spanner Wiper Bushings —————————— Seal Kit (Includes Items 3, 4, 8-11 & 13)
QTY.
REV.
Ref
B
1 1 1 1 1 1 1 1 1 1 1 1 1 4
S E C T I O N
1
5 C Y L I N D E R
3121146
5-15
SECTION 5
CYLINDER
FIGURE 5-8.TELESCOPE CYLINDER ASSEMBLY - MAIN
S E C T I O N 5 C Y L I N D E R
5-16
3121146
SECTION 5
CYLINDER
FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY - MAIN FIG & ITEM #
PART NUMBER 1683672
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
0100011 0100038 0641806 0961897 0962219 1683673 1683675 1683663 2220885 3340838 3480234 3570775 Kit Kit Kit Kit Kit 3931448 3931664 0630535 Kit Kit Kit Kit Kit 4641033
27
0100063 2901712
3121146
DESCRIPTION TELESCOPE CYLINDER ASSEMBLY Loctite #242 (Not Shown) Primer, Locking (Not Shown) Bolt 1/2”-13NC x 3/4” Bushing, Tapered Spacer, Tube Barrel Rod Head Plug, O-Ring Pad, Wear Piston Plate Ring, Wear Ring, Back-up Ring, Wear O-Ring O-Ring Capscrew 1/4”-20NC x 3” Capscrew 3/8”-16NC x 4” Bolt 1/4”-20NC x 1 1/8” Ring, Back-up Seal, Rod Ring, Wear Wiper T-Seal Valve Assembly (No serviceable parts - sold as assembly only) Loctite #RC 609 (Not Shown) —————————— Seal Kit - (Includes Items 13-17 & 21-25)
QTY.
REV.
Ref
F
AR AR 4 1 1 1 1 1 1 2 1 1 2 1 2 3 1 4 8 3 2 1 2 1 1 1
S E C T I O N 5 C Y L I N D E R
AR 1
5-17
SECTION 5 FIG & ITEM #
PART NUMBER
CYLINDER DESCRIPTION
QTY.
REV.
S E C T I O N 5 C Y L I N D E R
5-18
3121146
SECTION 6
HYDRAULIC
TABLE OF CONTENTS FIGURE
6-1 6-2 6-3
DESCRIPTION
PAGE
DRIVE HYDRAULIC DIAGRAM (4WD/4WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
S E C T I O N 6 H Y D R A U L I C
3121146
6-1
SECTION 6
HYDRAULIC
FIGURE 6-1.DRIVE HYDRAULIC DIAGRAM
S E C T I O N 6 H Y D R A U L I C
6-2
3121146
SECTION 6
HYDRAULIC
S E C T I O N 6 H Y D R A U L I C
3121146
6-3
SECTION 6
HYDRAULIC
FIGURE 6-1. DRIVE HYDRAULIC DIAGRAM FIG & ITEM #
PART NUMBER 2792364
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
S E C T I O N 6 H Y D R A U L I C
6-4
2220811 2220500 2220415 2220365 2220711 2220800 2220374 2220373 2220502 2220499 2220466 2220504 2220362 2220582 2220646 2220999 2220618 2220479 2220602 2220380 2220609 2220596 2220628 4640778 2220235 2221029 2220605 2220375 2220451 2220600 2220517 2220377 2220366 2220810 2220237 2220242 2752495 2752580 2751014 2751021 2752459 2221030 2753160 2753090 2753156
DESCRIPTION DRIVE HYDRAULIC DIAGRAM Fitting, Reducer Fitting, Elbow Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Elbow Fitting, Elbow Fitting, Elbow Fitting, Tee Fitting, Tee Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Reducer Fitting, Straight Fitting, Tee Fitting, Straight Fitting, Reducer Fitting, Elbow Fitting, Elbow Valve, Restrictor Fitting, Plug Fitting, Office Fitting, Tee Fitting, Straight Fitting, Straight Fitting Fitting, Cap Fitting, Straight Fitting, Elbow Fitting, Reducer Fitting, Plug Fitting, Plug Hose Hose Hose Hose Hose Fitting, O-Ring Nipple Hose Hose Hose
QTY.
REV.
Ref
8/E
9 13 6 4 1 6 5 1 4 1 4 4 2 5 2 1 1 1 3 1 1 1 1 1 2 1 1 2 2 2 1 2 1 1 2 1 2 2 2 1 1 1 1 2 1
3121146
SECTION 6
HYDRAULIC
FIGURE 6-1. DRIVE HYDRAULIC DIAGRAM (CONTINUED) FIG & ITEM #
PART NUMBER
46 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
4100059 2751017 2752363 2752498 2752592 2753035 2752516 2752514 2752591 2752949 2751906 2753157 2753158 2753159 2753187 2752364 2752354 2751391 2752513 2751397 2752942 2752466 2752494 2752433 2752514 2752573 2752754 2752670 2220501 2220490 2220473 2220371 2220833 2752462 Not Used 2753087 Not Used 2752648 4100058 2752489 2753117 2752480 2220507
3121146
DESCRIPTION
QTY.
Sleeve, Nylon Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Elbow Fitting, Tee Fitting, Elbow Fitting, Straight Fitting, Reducer Hose
4 1 2 1 2 2 2 1 1 1 1 1 2 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 8 4 6 6 4 1
Hose
4
Hose Sleeve, Nylon Hose Hose Hose Fitting, Elbow
4 4 1 2 2 1
REV.
S E C T I O N 6 H Y D R A U L I C
6-5
SECTION 6
HYDRAULIC
FIGURE 6-2.STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP)
S E C T I O N 6 H Y D R A U L I C
6-6
3121146
SECTION 6
HYDRAULIC
FIGURE 6-2. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) FIG & ITEM #
PART NUMBER 2792528
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
3121146
2220238 2220415 Not Used 2220373 2220500 2220947 2220376 2220593 2220371 2220873 2220428 2220429 2220502 2220737 2220478 2220451 2752453 Not Used 2220466 2220582 2220473 2220602 2220999 2220619 2220605 Not Used 2220765 2220379 2220574 2220596 2220385 2220618 Not Used 2220852 2753197 2753196 2220490 4567139 0100020 2753216 2753641 2753231 2753010 2753639 2752721
DESCRIPTION STANDARD HYDRAULIC DIAGRAM
QTY.
REV.
Ref
3/B
Fitting, O-Ring Plug Fitting, Straight
2 10
Fitting, Straight Fitting, Elbow Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Pressure Check Cap, Dust Fitting, Elbow Kit, Split Flange Kit, Split Flange Fitting, Straight Hose
5 3 1 1 2 6 4 5 5 1 1 1 1 1
Fitting, Elbow Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Tee Fitting, Reducer (Female) Fitting, Tee
5 2 4 1 2 1 2
Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Reducer (Female)
1 1 1 1 1 1
Fitting, Straight Hose Hose Fitting, Tee Tube Sealant, Pipe (Not Shown) Hose Hose Hose Hose Hose Hose
3 1 1 2 1 AR 1 1 1 2 1 1
S E C T I O N 6 H Y D R A U L I C
6-7
SECTION 6
HYDRAULIC
FIGURE 6-2. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) (CONTINUED) FIG & ITEM #
PART NUMBER
46 47 to 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
2752438 Not Used 2753644 2752674 4640780 2753118 2220775 2220635 2220609 2752463 2220577 2753122 2752768 2752930 Not Used 2752462 2220497 2752573 2753637 2752767 2753642 2753190 2753640 2753643 2753638 2753006 2753636 2753124 2753125 2753126 2220501 4567757 2220591 2753645 2753128 4100062 2220873
S E C T I O N 6 H Y D R A U L I C
6-8
DESCRIPTION
QTY.
Hose
1
Hose Hose Fitting, Check Valve Hose Fitting, Elbow Fitting, Tee Fitting, Reducer Hose Fitting, Straight Hose Hose Hose
1 1 1 1 1 1 2 1 1 1 1 1
Hose Fitting, Straight Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Elbow Tube Fitting, Reducer Hose Hose Sleeve, Nylon Fitting, Nipple
2 2 1 2 1 1 1 1 1 2 3 3 1 1 2 3 1 2 2 2 2 1
REV.
3121146
SECTION 6
HYDRAULIC
FIGURE 6-2. STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND AUXILIARY PUMP) (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 6 H Y D R A U L I C
3121146
6-9
6-10
17
V1
30
X
X
V2
2
P2
29
28
Port Block on Lower Lift Cylinder
2
P1
X V1
3
37
31
X
P1
V2
21
56
LIFT DOWN
LIFT UP
27
V1
32
51
21
20
1
2
72
63
62
59
57
V2
T
V1
ROTATOR ACTUATOR
TELESCOPE IN
TELESCOPE OUT
30
52
4
17
RELIEF VALVE LOCATED IN UPRIGHT
22 69
V2
53
43
Port Block on Upright Lift Cylinder
X
3
V1
39
61
V2
SWING MOTOR
R
E
17
58
12
2 23
Master Cylinder
19
68
X
47
64
60
65
71
19
4
7
4
12
16
5
9
2
17
P
14
18
M4
11
T
9 10 11 35
10
15
M
X
33
66
V1
67
8
V2
SLAVE CYL
PLUG TOWER TELE
1
3
70 68
1
5
2
49
X
TOWER LIFT DOWN
1
64
62
"LS" PORT
3
39
9 10 11 2 35 23
OPPOSITE SIDE OF MAIN VALVE
2
X
9 10 11 35
3
40
X
X
76
M2
LS
MP
USE WITH HOSES COMING OUT OF THE TOWER BOOM POWERTRACT. DO NOT RUN WIRES THROUGH .
73
NOTE: Port V1 of the Slave Cyl. is RETRACT and SHOULD hose to the ROD end of the Master Cyl.V2 is EXTEND and SHOULD hose to the PISTON end of the Master Cyl. This NOTE Applies to the JIB SLAVE Cyl. and the NON-JIB SLAVE Cyl.
8 34
6
M7
13
8
35 11 10 74
6
4
UPPER LIFT CYLINDER
B
X X BRAKE
A
EXTEND-A-REACH CYLINDER
8
13
14
38
MT
2
T
M3
X
36
18
2
42
1
68
19
44
77
30
TOWER LIFT UP
AUX PUMP
9 10 11 35
7
6
45
X
15
25
IN
78 7 80
75 48
50
PORT "P1" ON BACK SIDE OF VALVE BLOCK
S E C T I O N
X
18 55
H Y D R A U L I C
54
X
41
24
HYD. OIL TANK
AUX PUMP CASE SUCTION PORT
OUT
26
CYLINDER PUMP SUCTION
DRIVE PUMP SUCTION
“IMPORTANT" PORT LOCATED ON THE INSIDE OF THE FILTER NEXT TO THE OUTLET PORT.
RETURN FILTER
79
SECTION 6 HYDRAULIC
FIGURE 6-3.STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP)
3121146
SECTION 6
HYDRAULIC
FIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) FIG & ITEM #
PART NUMBER 1001143189
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
3121146
2220238 2220415 2220373 2220500 2220947 2220376 2220593 2220371 2220873 2220428 2220429 2220502 2220737 2220478 2220451 Not Used 2220466 2220582 2220473 2220602 2220999 2220619 2220605 2220765 2220379 2220574 2220596 2220385 2220618 2220852 2753197 2753196 2220490 4567139 0100020 2753216 2753641 2753231 2753010 2753639 2752721 2752438 2753644 2752674 4640780
DESCRIPTION STANDARD HYDRAULIC DIAGRAM Fitting, O-Ring Plug Fitting, Straight Fitting, Straight Fitting, Elbow Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Pressure Check Cap, Dust Fitting, Elbow Kit, Split Flange Kit, Split Flange Fitting, Straight Fitting, Elbow Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Tee Fitting, Reducer (Female) Fitting, Tee Fitting, Straight Fitting, Straight Fitting, Straight Fitting, Elbow Fitting, Tee Fitting, Reducer (Female) Fitting, Straight Hose Hose Fitting, Tee Tube Sealant, Pipe Hose Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Check Valve
QTY.
REV.
Ref
A/A
2 9 5 3 1 1 2 5 4 5 5 1 1 1 1
S E C T I O N
5 2 4 1 2 1 2 1 1 1 1 1 1 3 1 1 2 1 AR 1 1 1 2 1 1 1 1 1 1
6 H Y D R A U L I C
6-11
SECTION 6
HYDRAULIC
FIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) (CONTINUED) FIG & ITEM #
PART NUMBER
46 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
Not Used 2220609 2752463 2220577 2753118 2752768 2752930 2752462 2220497 2752573 2753637 2752767 2753642 2753190 2753640 2753643 2753638 2753006 2753636 2753124 2753125 2753126 2220501 4567757 2220591 2753645 2753128 4100062 2220873 2220603 1001109690 2220606 2220923 1001143192 2220655
S E C T I O N 6 H Y D R A U L I C
6-12
DESCRIPTION Fitting, Reducer Hose Fitting, Straight Hose Hose Hose Hose Fitting, Straight Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Fitting, Elbow Tube Fitting, Reducer Hose Hose Sleeve, Nylon Fitting, Nipple Fitting, Straight Hose Fitting, Tee Fitting, Straight Hose Fitting, Elbow
QTY.
REV.
2 1 1 1 1 1 2 2 1 2 1 1 1 1 1 2 3 3 1 1 2 4 1 2 2 2 2 1 1 1 1 1 1 1
3121146
SECTION 6
HYDRAULIC
FIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) (CONTINUED) FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 6 H Y D R A U L I C
3121146
6-13
SECTION 6
HYDRAULIC
FIGURE 6-4.HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in the preceding pages. Information on diagrams not shown is available from JLG Service/Parts Departments.
Ref
2792502
Tow Package Hydraulic Diagram
Ref
2792364*
Drive Hydraulic Diagram
Ref
Standard Hydraulic Diagram Fenner & Haldex Brand Auxiliary Pump Bucher Brand Auxiliary Pump
Ref Ref Ref
Standard Hydraulic Schematic
Ref
Tilt Sensor Installation Adapter, Pressure Tap
Ref 1
2792528* 1001143189*
S E C T I O N
2792535 1001091538 1001094557
6 H Y D R A U L I C
6-14
3121146
SECTION 7
ELECTRICAL
TABLE OF CONTENTS FIGURE
7-1 7-2
DESCRIPTION
PAGE
ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
S E C T I O N 7 E L E C T R I C A L
3121146
7-1
SECTION 7
ELECTRICAL
FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM #
PART NUMBER
QTY.
REV.
ALARM ELECTRICAL DIAGRAMS Motion Alarm Travel Alarm
Ref Ref Ref
1/A 1/A
4933150
GENERATOR ELECTRICAL DIAGRAMS 110Volt
Ref Ref
2/B
4933175
GLOW PLUG DIAGRAM (DEUTZ ENGINES)
Ref
A
LIGHTS ELECTRICAL DIAGRAMS Strobe Light
Ref Ref
1/A
4922155
PLATFORM ELECTRICAL DIAGRAM
Ref
5/D
4932980
Ref
2/C
3740057 4120012 3740066 3740049 4460600
PLATFORM SOFT TOUCH SYSTEM ELECTRICAL DIAGRAM Relay (Located in Platform Console Box) Socket, Relay (Located in Platform Console Box) Spring, Relay (Located in Platform Console Box) Relay (Located in Platform Console Box) Block, Terminal (Located in Platform Console Box)
0258048
PLATFORM WORKLIGHTS ELECTRICAL DIAGRAM
Ref
2/F
4932982 4932981
STANDARD ELECTRICAL DIAGRAM Deutz Machines Ford Machines
Ref Ref Ref
5/F 4/C
1870063 1870148
STANDARD ELECTRICAL SCHEMATIC Deutz Machines Ford Machines
Ref Ref
I D
4933025/1282937 4633026/1282937
4933027/1282937
S E C T I O N 7 E L E C T R I C A L
7-2
DESCRIPTION
1 1 1 1 1
3121146
SECTION 7
ELECTRICAL
FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
S E C T I O N 7 E L E C T R I C A L
3121146
7-3
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION
S E C T I O N 7 E L E C T R I C A L
7-4
3121146
SECTION 7
ELECTRICAL
S E C T I O N 7 E L E C T R I C A L
3121146
7-5
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
DESCRIPTION HARNESS COMPONENTS INSTALLATION
4922155
1 to 38 39 40 to 43 44 45 to 47 48 49 50 51 to 54 55 56 57 to 59 60 61 62 63 64 65 66 67 68 69 to 89 90 91
S E C T I O N 7 E L E C T R I C A L
Not Used 1060012 Not Used 2920129 Not Used 4460265 4460418 4460419 Not Used 4460720 4460721 Not Used 4460464 4460508 3990001 Not Used 4460225 4460267 3990010 Not Used 4120035 Not Used 4460613 4460503
PLATFORM BOX HARNESS ASSEMBLY (Note: Also includes terminal block/rail assembly and Bosch relays - See PLATFORM SECTION)
Cable, Electrical - 12/4
4460470 4460471 4460428 0272028
201 to 202 203 204 205 206 206A 206B
7-6
Not Used 1320256 Not Used 4922172 1060016 4922180 1060676 4460465 4460865
Ref Ref
Plug, Male - 9 Position Connector - 6 Position Terminal, Female
2 9 45
Connector - 15 Position Socket, Female
4 38
Pin, Male (16 Gauge) Pin, Male (12 Gauge) Diode - 3 Amp (Not Shown)
10 4 14
Connector, Plug - 3 Position Pin, Male Diode - 6 Amp (Not Shown)
1 22 9
Base, Light
9
Connector - 21 Position Connector - 31 Position
1 1
BOOM CABLES INSTALLATION
Clamp, Block (Not Shown-Located on back of T/T) Harness Assembly - Upper Elevation (16/3) Cable, Electrical - 16/30 Harness Assembly - Upper Boom (10/4-18/16) Cable, Electrical - 16/30 Socket, Female Connector - 19 Position
2/B
7ft/2.13m 9
Nut, Conduit Washer Connector, Strain Relief
REV.
Ref
Bulb, Light
PLATFORM BOX ASSEMBLY COMPONENTS 101 102 103
QTY.
Ref 2 2 2 Ref
A
1 1 47ft/14.3m
1 64ft/19.5m
11 1
3121146
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
206C 206D 206E 206F 206G 207
4460509 4460473 4460466 4460464 4460866 4922181 1060516 4460502 4460465 4460466 4460473 4460464 4460503 4922216 1060708 4922680 1060016 4922681 1060708 4922682 1060516 4460502 4460465 4460466 4460473 4922683 1060676 4460465 4460466 4460473 4460614 4460509
207A 207B 207C 207D 207E 207F 208 209 210 211 211A 211B 211C 211D 212 212A 212B 212C 212D 212E
4932982 4932981 301
301A 302
302A
3121146
4922146 4922318 3990010 3730099 4460418 4460419 4922311 3730023 3990001 4460266 4460268
DESCRIPTION Socket, Female Clamp, Cable Seal, Plug Pin, Male (16 Gauge) Connector - 19 Position Harness Assembly - Upper Boom (16/30) Cable, Electrical - 16/30 Connector - 31 Position Socket, Female Seal, Plug Clamp. Cable Pin, Male (16 Gauge) Terminal - 31 Socket Harness Assembly - Upper Boom (10/3) Cable, Electrical - 10/3 Harness Assembly - Tower Elevation (16/3) Cable, Electrical - 16/3 Harness Assembly - Tower Boom (10/3) Cable, Electrical - 10/3 Harness Assembly - Tower Boom (16/30) Cable, Electrical - 16/30 Connector - 31 Position Socket, Female Seal, Plug Clamp. Cable Harness Assembly - Tower Boom (10/4-18/16) Cable, Electrical - 10/4-18/16 Socket, Female Seal, Plug Clamp. Cable Terminal - 21 Socket Socket, Female GROUND CONTROL BOX DIAGRAMS DEUTZ ENGINE MACHINES FORD EFI ENGINE MACHINES Harness Assembly - Ground Control Box Options: Deutz Ford EFI (SN 48538 to Present) Diode - 6 Amp (Not Shown) Resistor Adjustable (Not Shown) Connector - 6 Position Terminal, Female Harness Assembly - Light Panel Resistor 510 Ohn 1/2 Watt (Not Shown) Diode 3 Amp (Not Shown) Connector, Female - 9 Position Socket, Female
QTY.
REV.
4 1 8 11 1 64ft/19.5m
1 30 2 1 30 1 1
S E C T I O N
64ft/19.5m
1 41ft/12.5m
1 38ft/11.6m
1 37ft/11.3m
1 30 1 1 1
7
37ft/11.3m
16 1 1 1 4 Ref Ref Ref
E L E C T R I C A L
5/E 4/C
1 3/B 2/B 13 2 9 AR 1 1 4 1 9
3/C
7-7
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
302B
4120035 4460634 4460635 4460267 4460265
302C 303
304 to 311 312 313 to 316 317 318
S E C T I O N
Base, Light Terminal (Single Wire) Terminal (Double Wire) Pin, Male Plug, Male - 9 Position Sub-Harness - Start Options (Not Shown): Deutz Engine Machines Ford EFI Engine Machines Diode 6 Amp (Not Shown) Resistor 750 Ohm (Not Shown) Bulb, Light GROUND CONTROL BOX ASSY COMPONENTS
401 401A 401B 401C 401D 401E 401F 401G 401H 402
7 E L E C T R I C A L
4922473 4922472 Not Used 3990010 Not Used 3730099 2920129
DESCRIPTION
4922046 4460499 4460320 4460267 4460424 4460268 4460225 4460445 4460449
4922077 4922272
4922077 4922272 501 to 527 528 529 530 to 534 535 536 537 to 538 539 540 to 544 545 546 547 548
Not Used 4460268 4460267 Not Used 4460424 4460268 Not Used 4460499 Not Used 4460445 Not Used 4460265 4460266
549
Not Used
7-8
Valve Harness Assembly DIN Connector with Diode Plug, Male - 2 Position Pin, Male Receptacle, Female - 2 Position Socket, Female Housing, Terminal - 6 Position Receptacle, Female - 3 Position DIN Connector without Diode Engine Harness Assembly Options (See Items 501584 for Breakdown) Deutz Engine Machines Ford Engine Machines
QTY. AR 6 4 7 1 1
9 2 AR Ref 1 19 1 11 1 5 1 1 1 1
ENGINE HARNESS ASSEMBLY DEUTZ ENGINE MACHINES FORD ENGINE WITH EFI MACHINES
Ref Ref Ref
Socket, Female (Deutz Engine Only) Pin, Male (Deutz Engine Only)
11 12
Receptacle, Female - 2 Position Socket, Female
1 2
DIN Connector with Diode
REV.
2/D
5/F 6/G
AR
Housing, Terminal - 3 Position (Deutz Engine Only)
1
Plug, Male - 9 Position (Deutz Engine Only) Connector, Female - 9 Position (Deutz Engine Only)
1 1
3121146
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
550 551 552 to 559 560 561 562 563 564 565 566 567
4460374 4460375 Not Used 4460582 4460580 4460579 4460460 4460457 4460458 Not Used 4460713
568 569 570 571 572 to 573 574 575 576 577 578
4460725 4460726 4460800 4460799 Not Used 4460449 4460777 4460591 4460589
579 580 581 582 to 583 584
4460608 4460728 Not Used 2400061 2400060 Not Used 4460742
DESCRIPTION Plug, Sealed (Ford Engine Only) Terminal (Ford Engine Only) Terminal (Ford Engine Only) Lock, Terminal (Ford Engine Only) Housing - 3 Position (Ford Engine Only) Connector, Male - 4 Position Terminal, Female Seal, Terminal
Not Available 4460268 4460224 Not Available Use 2910000
602A
7008833 7008836 Not Available
602B 602C 602D 602E 602F
7016336 Not Serviced Not Serviced 2910001 Not Serviced Not Serviced
3121146
3 1 1 1 AR AR
1 2 29 9
DIN Connector without Diode Plug, Male - 4 Position (Deutz Engines Only) Lock, Terminal (Deutz Engines Only) Socket, Female (Deutz Engines Only) Options: Seal, Terminal (Deutz Engines Only) Pin, Male (Ford EFI Engine Only)
1 1 1 AR AR AR 4
1
Fuse (Ford EFI Engine Only) Fuseholder/Cover (Ford EFI Engine Only)
2 2
Plug - 2 Position (Ford EFI Engine Only)
2
Tilt Indicator Harness Socket, Female Connector, Female - 6 Position Throttle Actuator/Controller Harness (Deutz) Throttle Actuator & Controller Assembly (was p/n 0060033) Mounting Clamp Kit (Not Shown) Spring, Retract (Not Shown) Throttle Actuator & Harness (Purchase p/n 2910000) Boot Kit Pin, Male Connector, Male Controller & Harnesses (Purchase p/n 2910000) Socket, Female Connector, Female
REV.
1 5
Housing, Connector - 42 Position (Ford EFI Engine Only) Lock, Wedge - Center (Ford EFI Engine Only) Lock, Wedge - Side (Ford EFI Engine Only) Plug, Hole (Ford EFI Engine Only) Pin, Male (Ford EFI Engine Only)
STANDARD HARNESS COMPONENTS 601 601A 601B 602
QTY.
S E C T I O N 7 E L E C T R I C A L
Ref 1 6 1 1 1 1 1 1 1 9 1 1 9 1
7-9
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION
S E C T I O N 7
FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
602G
603 603A 603B 604 604A 604B 605
Not Available 4460693 4460591 4460608 Not Available Not Available Not Available Not Available 4460266 4460268 Not Available
1 4 1 4 1 1 1 1 1 9 1
605A 605B 606 607
4460266 4460268 Not Used Not Available
Plug, Male - 4 Position Pin, Male Clip Seal, Terminal Pump Harness Plug (Pump End) Plug (Engine Harness End) Controller Harness Assembly (Lift and Swing) Connector, Female - 9 Position Socket, Female Controller Harness/Circuit Board Assembly (Drive and Steer) Connector, Female - 9 Position Socket, Female
1
608 608A
Not Available 4460224 4460268 Not Used 1001091941 2920129 3990001 4460897 4460464 4460891 4460761 4460227 4460894 4460465 4460892 4460909 4460915 4460928 4460466 4460908 4460915 4460928 4460466 4460526 1001094791 1001097957 4460465 4460928 4461076 4460917 4461077 4460918
Ford Engine Harness ((For replacement parts refer to Ford engine dealer (Ford EFI Engine Machines) Speed Controller Harness Assembly Connector, Female - 6 Position Socket, Female
608 to 609 610 610A 610B 610C 610D 610E
E L E C T R I C A L
610F 610G 610H
610J
610K 611 611A 611B 611C 611D 611E
7-10
Tilt Harness (MTB Control Box) Bulb Diode, 3 AMP (Not Shown) Plug, Terminal - 2 Position Pin, Male (16 Gauge) Connector, Terminal - 2 Position Connector, Female - 4 Position Pin, Male Plug, Terminal - 6 Position Socket, Female Terminal, Buss Connector - 6 Position Connector - 12 Position (Black) Wedge Lock - 12 Position Socket, Female Terminal, Sealing Plug Connector - 12 Position (Gray) Wedge Lock - 12 Position Socket, Female Terminal, Sealing Plug Connector, Strain Relief Tilt Sensor Harness (Turntable) Cable, Electrical 16/4 Socket, Female Socket, Female Connector - 4 Position (With Wedge Lock & Seal) Pin, Male (Gold) Terminal, Plug - 4 Position Socket, Female (Gold)
REV.
1 9
1 1 6 1 1 2 1 2 1 1 4 2 8 2 1 1 9 3 1 1 2 10 1 1 8ft/2.4m 2 1 1 4 1 4
D
C
3121146
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
DESCRIPTION
QTY.
REV.
612 612A 612B 612C 612D
1001091778 1001097957 4460465 4460928 4461076 4460917 4461077 4460918
Tilt Sensor Harness (Boom) Cable, Electrical 16/4 Socket, Female Socket, Female Connector - 4 Position (With Wedge Lock & Seal) Pin, Male (Gold) Terminal, Plug - 4 Position Socket, Female (Gold)
1 8ft/2.4m 2 1 1 4 1 4
E
612E
OPTIONAL HARNESS COMPONENTS 701 701A 701B 701C 702 702A 702B 702C 703 703A 703B 704 704A 704B 705
705A 705B
4921928 4460268 4460445 4460499 4921927 4460326 4460267 4460499 Not Available 4460424 4460268 Not Available 4460320 4460267 0255382 0257176 0860038 4460346 4460125
705C 4060700 4060092 705D 4460205 4460233 705E 4460134 4460701 705F
705G
3121146
4921801 Not Available 1060494 4460205 4460233
4WS Valve Harness Socket, Female Connector, Female - 3 Position Connector, DIN with Diode Jib Valve Harness (800AJ Only) Plug, Male - 3 Position Pin, Male Connector, DIN with Diode Alarm Harness Plug, Male - 2 Position Socket, Female Strobe Light Harness Connector, Female - 2 Position Pin, Male AC to Platform Receptacle Components Options: 110V GFI Receptacle 220V GFI Receptacle Box, Switch Receptacle Options: 110V GFI 220V GFI Shield, Cover Options: 110V GFI 220V GFI Plug, Male Options: 110V GFI 220V GFI Connector, Female Options: 110V GFI 220V GFI Harness-Receptacle Box to Boom Options: 110V 220V Cable, Electrical - 12/3 Plug, Male (110V) Plug, Male (220V)
Ref 1 3 1 2 1 1 3 2 1 1 2 1 1 2
3/D
Ref Ref 1 1
4 4
S E C T I O N 7 E L E C T R I C A L
1
2
1
1
18in/47cm
1 1
7-11
SECTION 7
ELECTRICAL
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION FIG & ITEM #
PART NUMBER
706
706A 706B 706C 707
S E C T I O N
707A 707B 708 709
709A
7
710 710A 710B 711 711A
E L E C T R I C A L
4933150 4933149 3990010 4921938 4460027 4460125 4460190 4460125 4921829 4921955
1060494 4460205 4460233 4460134 4460701 Not Used 2920140 2820035 4460598 4460442 Not Available 1060341 4460425 Not Available 4460743 Not Available 4460458
DESCRIPTION Generator Electrical Components 110V 220V Diode - 6 Amp (Not Shown) Harness - On/Off Switch (Powermite Control Box to Ground Control Box) Receptacle, Electrical (Industrial) (110V) Receptacle, Electrical (220V) Receptacle, Electrical (Standard) (110V) Receptacle, Electrical (220V) Generator to Rear of Boom Harness (110V) Generator to Rear of Boom Harness (220V) Note: Harness used to connect AC at platform harness to generator receptacle to power platform receptacle. Cable, Electrical - 12/3 Plug, Male (110V) Plug, Male (220V) Receptacle, Female (110V) Receptacle, Female (220V)
REV.
Ref Ref 1 1
2/B 2/B
1 1 1 1 1 1 Ref
26ft/8m
1 1 1 1
Platform Worklights Harness (Includes Light and 2 Wire Only) 9ft/2.8m Loom, Vinyl Connector, Strain Relief 1 Terminal (Not Shown-Located in Platform Console) 2 Soft-Touch System Harness 1 Cable, Electrical - 16/3 16ft/4.9m Connector, Strain Relief 1 LP Lock Off Valve Harness 1 Connector - 2 Position 2 Pin, Male 2 Seal, Terminal 2 TOOLS
Ref
801 802
7002821 7002823
Crimper (For Wire to Pin/Socket Connections) Extractor (For Removal of Pin/Socket from Connectors)
1 1
803
4460467
Extractor, Pin (Blue 16-18 Gauge) (For Removal of Pin/Socket from Connectors) Extractor, Pin (Yellow 12-14 Gauge) (For Removal of Pin/Socket from Connectors) Stripper, Wire
1
4460510 804
7-12
QTY.
7002828
1 1
3121146
SECTION 8
DECALS
TABLE OF CONTENTS FIGURE
8-1
DESCRIPTION
PAGE
DECALS INSTALLATION - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
S E C T I O N 8 D E C A L S
3121146
8-1
13
30
8-2
4
7
203
26 22 20 24 21 38 37 23
740AJ
10
201
3
12
9 202
11
8
9
15
1
D E C A L S 8 5 305
3 4 27 24
27
4
3
25
32
34
37 38
24
6 2 328 14 23
S E C T I O N 203
201
24 25
4
101
23
40 325 17 16 18
26
7
740AJ
31
30
36
SECTION 8 DECALS
FIGURE 8-1.DECALS INSTALLATION - STANDARD
3121146
SECTION 8
DECALS
FIGURE 8-1. DECALS INSTALLATION - STANDARD FIG & ITEM #
PART NUMBER 0271038 0271588
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 to 29 30 31 32 33 34 35 36
1703797 1703798 1703805 1703804 Use 1707110 Use 1707111 1705007 1702860 1702774 1702773 1702868 1704277 1701645 1702688 3251813 1701502 1701503 1701504 1702153 Not Available 1700584 Not Available 1701509 1702300 1701500 1701501 3251243 Not Used 1703959 1703953 1702862 3820001 3252347 Not Used
37 38
1701542 1701505 1701543 1700818
39 40 41 to 47
Not Used Use 1001096141 Not Used
3121146
DESCRIPTION STANDARD DECAL INSTALLATIONS JLG Logo 740AJ
QTY.
REV.
Ref. Ref. Ref.
1 1
Decal - Danger/Warning Decal - Danger/Warning Decal - Danger/Electrocution Decal - Warning/Crushing Decal - Legend (Was p/n 1702784) Decal - Legend (Was p/n 1703808) Decal - 740AJ Decal - JLG Lift (5in) Decal - JLG Lift (3 1/2in) Decal - JLG (5in) Decal - No Hands Decal - Attach Lanyard Here Decal - 500LBS Max Capacity Decal - 500LBS Max Capacity Decal - USA Decal - High Oil Level Decal - Low Oil Level Decal - Hydraulic Oil Decal - Inspection Decal - Bar Code Decal - Patent Nameplate - Serial Number Decal - Manual Decal - Tie Down /Lift Decal - Tie Down /Lift Decal - Arrow Nameplate - Generator
1 1 2 4 1 1 2 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 2 4 4 4 1
Decal - Quik Stik Decal - Warning/Crushing Decal - JLG Lift Rivet Decal - Footswitch (Part of 4360031 Footswitch)
2 3 1 4 1
Decal - Fuel Options: Ford Engine Machines Diesel Engine Machines Decal - LPG Gas (Ford Engine Machines) Decal - LP Gas Liquid Withdrawal System (Ford Engine Machines)
1
Decal - Upright Level Override (was p/n 1702265)
S E C T I O N 8 D E C A L S
1 1
1
8-3
SECTION 8
DECALS
FIGURE 8-1. DECALS INSTALLATION - STANDARD (CONTINUED) FIG & ITEM #
PART NUMBER 0258671
101
201 202
S E C T I O N 8
203
0860520 1060279 0641408 0641406 4751400 3311405 0100011 0010551 0271585 1705012 0271674 1705014 0271584 1705006 1001091538
301 to 304 305 306
Not Used 1707110 1707111
307 to 324 325 326 to 327 328
Not Used 1001096141 Not Used 1001095809
DESCRIPTION MANUAL STORAGE BOX INSTALLATION Box, Manual Storage Cable, Lanyard Bolt 1/4”-20NC x 1” Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4”-20NC Loctite #242 (Not Shown)
QTY.
REV.
Ref.
A
1 1 1 1 6 5 A/R
DECAL INSTALLATIONS (OPTIONS) Decal Installation Decal - Fall Arrest Decal Installation Decal - Safety Decal Installation Decal - Jet Blast
Ref. Ref. 2 Ref. 2 Ref. 2
A
TILT SENSOR INSTALLATION
Ref.
E
Decal - Legend (Platform) Decal - Platform Display (Not Shown - Located on Platform Control Box)
1 1
Decal - Upright Level Over Ride
1
Decal - Legend (MTB Control)
1
A
A
D E C A L S
8-4
3121146
SECTION 9
RECOMMENDED SERVICE PARTS STOCK
MODEL 740AJ 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 infomation, contact your JLG dealer or the JLG Industries Parts Department.
JLG PART NUMBER
STANDARD PARTS 2120168 2120150 7012944 7018991 7012772 7000645 7012664 3740067 4360294 7014817 4360475 4360469 2860030 4360314 4360476 3740049 3740057 3740113 7016522 7006137 1600284 1600283 7003974 4360387 4360407 4360331 4360232 3740115 3990010 2400061
Element, Filter (Figure 2-1) Element Filter (Figure 2-1) Coil (Figure 2-1 & 2-2) Coil (Figure 2-2) Coil (Figure 2-2 & 2-3) Coil (Figure 2-2) Element, Air Cleaner (Figures 2-7 & 2-10) Relay (Figure 2-7) Breaker, Circuit (Figures 2-7 & 2-9) Breather, Hydraulic Tank (Figure 2-12) Switch, Mushroom (Figures 2-14 & 4-2) Switch, Key (Figure 2-14) Key, Replacement (Figure 2-14) Switch, Toggle (Figure 2-14 & 4-2) Contact, Switch Block (Figures 2-14 & 4-2) Relay (Figure 2-14 & 4-2) Relay (Figure 2-14) Relay (Figure 2-14 & 4-2) Powertrack Repair Section (Figure 3-2) Powertrack Pin Kit (Figure 3-2) Controller (Lift and Swing) (Figure 4-2) Controller (Drive and Steer) (Figure 4-2) Potentiometer (Lift/Swing & Drive/Steer) (Figure 4-3 & 4-4) Switch, Push Button (Figure 2-13, 4-2) Controller, Speed (Figure 4-2) Switch, Toggle (Figure 4-2) Breaker, Circuit (Figure 4-2) Relay (Figure 4-2) Diode (Figure 7-2) Fuse (Figure 7-2) VARIABLE PARTS
7014501 7016331 7022135 7016328 3740080 7023613
3121146
QTY PER FLEET
DESCRIPTION
Filter, Oil (Ford Engine Machines) (Figure 2-7) Filter, Oil (Deutz Engine Machines) (Figure 2-10) Filter, Fuel (Ford Engine Machines) (Figure 2-7) Filter, Fuel (Deutz Engine Machines) (Figure 2-10) Relay (Machines with Generator Option) (Figures 2-7 & 2-9) Relay (Ford Engine Machines) (Figure 2-7)
1-10
10-20
20 OR MORE
Ref.
Ref.
Ref.
4 4 1 1 1 1 1 Dozen 1 1 1 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1
8 8 1 1 1 1 1 Dozen 1 1 2 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1
12 12 1 1 1 1 1 Dozen 1 1 3 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1
2 2
2 2
2 2
Ref.
Ref.
Ref.
1 Dozen 1 Dozen 1 Dozen 1 Dozen 1
1 Dozen 1 Dozen 1 Dozen 1 Dozen 1
1 Dozen 1 Dozen 1 Dozen 1 Dozen 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 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
SECTION 9
RECOMMENDED SERVICE PARTS
MODEL 740AJ 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 infomation, contact your JLG dealer or the JLG Industries Parts Department.
JLG PART NUMBER 4360336 4360336 4360387
9-2
QTY PER FLEET
DESCRIPTION Switch, Toggle (Machines with Dual Fuel Option) (Figures 2-8 & 4-2) Switch, Toggle (Machines with Generator Option) (Figures 2-9 & 4-2) Switch, Push Button (Figure 4-5)
1-10
10-20
20 OR MORE
1
1
1
1
1
1
1
1
1
3121146
SECTION 10
SPECIAL OPTIONS
Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM #
PART NUMBER
10-1
MISCELLANEOUS SPECIAL OPTIONS:
QTY.
Air Compressor Installation
Ref.
0271511
Airline to Platform Installation
Ref.
ClearSky Telematics Kits ANSI Spec ANSI Export/CE/Japanese Specs Australian Spec CSA Spec Note: Refer to ClearSky (Telematics) Manual p/n 3128499 for Service Parts.
Ref. Ref. Ref. Ref. Ref. Ref.
Decal Installations Options: Decal - Biodegradable Hydraulic Fluid Decal - Lanyard Attach (GM K-1 Spec) Decal - Prop 65 Warning (Gasoline Machines) (California Spec) Government Warranty Decal Installation Sunbelt Decals Installation United Decals Installation Warning Stripes Installation
Ref. 1 1 1 Ref. Ref. Ref. Ref.
1001148902 1001148903 1001148904 1001148905 1001148906
Electrical Connector Kits Amp/Tyco Electrical Connector Kit Deutsch DT Electrical Connector Kit Deutsch HD Electrical Connector Kit Packard Electrical Connector Kit Various Electrical Connectors Kit
Ref. Ref. Ref. Ref. Ref. Ref.
1001110996 1001109693 1001110133
Filter Kits: Combined Filter Kit (Hydraulic/Air & Fuel/Engine Oil) Hydraulic/Air Filter Deutz Engine - Fuel/Engine Oil Filter
Ref. 1 1 1
1702788 1703175 1702961 0257195 0271112 0270959 4420051/1282946
1001149560 1001143256
REV.
Ref.
0272732
1001102841 1001102842 1001139132 1001104985
3121146
DESCRIPTION
S E C T I O N 1 0 S P E C I A L O P T I O N S
SkyGuard Component Options: SkyGuard Complete Add-On Kit (Non-UGM Machines) SkyGuard Blue Beacon Kit
10-1
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.
S E C T I O N
FIG & ITEM #
PART NUMBER 7002840 8896941 7002821 7002823 4460467 4460510
1 0
7002822 7016654 7004275 7004276 7002826 7016655 7016652 4921850 4922012
S P E C I A L
1001142504 1001142505
DESCRIPTION
QTY.
Tools for Service Antirotation Pin Removal Tool Wire Stripper Wire Crimper (To install wire ends to wires) Pin/Socket Extractor - Universal (To Remove Pins/ Sockets from Connectors) Extractor - 16-18 Gauge (For Removal of Pin/ Sockets from Deutsch Connectors) Extractor - 12-14 Gauge (For Removal of Pin/ Sockets from Deutsch Connectors) Screwdriver, Potentiometer (To Adjust Drive Controllers) Screwdriver, Magnetic Seal Installation Tool - 1” Seal Installation Tool - 1 1/2” Seal Installation Tool - 2” Wire Rope Sheave Gauge Huck Bolt Fastener (For Small Huck Bolts Only) Throttle Service Harness Horsepower Card Service Harness
Ref. 1 1 1 1
Platform Entry Kits Drop Bar (Replacing Swing Gate with Drop Bar) Swing Gate (Replacing Drop Bar with Swing Gate)
Ref. Ref. Ref.
REV.
1 1 1 1 1 1 1 1 1 1 1
O P T I O N S
10-2
3121146
3121146
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 813058
+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
