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Parts 3120806 10-05

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September 2018
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Illustrated Parts Manual Model 60HA P/N 3120806 October 5, 2012 REVISION LOG May 1991 - Original Issue Of Manual September 1994 - Revised Manual (Format Change) April 1995 - Revised Manual November 5, 2003 - Revised Manual (Edited to 0010400 Revision 21) November 15, 2006 - Revised Manual (Edited to 0010400 Revision 21) September 8, 2010 - Revised Manual October 5, 2012 - Revised Manual 3120806 a REVISION LOG b 3120806 TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS) . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20 DRIVE MOTOR ASSEMBLY - REXROTH (2WD/4WS AND 4WD/4WS). . . . . . . . . . . . . .1-24 DRIVE BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26 DRIVE BRAKE ASSEMBLY - MICO (PRIOR TO JULY 1991) . . . . . . . . . . . . . . . . . . . . . .1-28 DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) . . . . . . . . . . . . . . . . . . .1-30 DRIVE HUB ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34 DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42 VALVES INSTALLATION (FRAME MOUNTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46 CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG . . . . . . . . . . . . . . . . . . . . . .1-50 TOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52 SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 3120806 CONTROL VALVES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) . . . . . . . . . . .2-8 CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT) . . . . . . .2-12 CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG . . . . . . . . . . . . . . . . . . . . . .2-16 CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (JUNE 1995 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG . . . . . . . . . . . . . . . .2-26 TURNTABLE, SWING DRIVE AND BEARING INSTALLATIONS . . . . . . . . . . . . . . . . . . .2-30 SWING MOTOR ASSEMBLY (PRIOR TO AUGUST 1991) . . . . . . . . . . . . . . . . . . . . . . .2-32 SWING MOTOR ASSEMBLY (AUGUST 1991 TO PRESENT) . . . . . . . . . . . . . . . . . . . .2-34 BRAKE ASSEMBLY (PRIOR TO AUGUST 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36 BRAKE ASSEMBLY - AUSCO 37845 (AUGUST 1991 TO PRESENT) . . . . . . . . . . . . . .2-38 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42 110 VOLT GENERATOR INSTALLATION - DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58 PRECISION GOVERNOR INSTALLATION - FORD LSG423 ENGINEMACHINES BUILT PRIOR TO FEBRUARY 1995. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES MACHINES BUILT PRIOR TO FEBRUARY 1995. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) . . . . . . . . .2-70 GENERATOR INSTALLATION - FORD LRG423 (MACHINES BUILT FEBRUARY 1995 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 DUAL FUEL INSTALLATION (OPTIONAL ON FORD MACHINES) . . . . . . . . . . . . . . . . .2-80 MAIN PUMP ASSEMBLY - GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86 i TABLE OF CONTENTS FIGURE NO. 2-25 2-26 2-27 2-28 2-29 TITLE PAGE NO. ROTARY COUPLING AND COLLECTOR ASSEMBLY AND INSTALLATION . . . . . . . . . 2-90 GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 LIGHTS AND ALARMS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 HOODS INSTALLATIONS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 HOODS INSTALLATIONS - NOISE REDUCTION PACKAGE . . . . . . . . . . . . . . . . . . . . . 2-102 SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-3 3-4 BOOMS AND LIMIT SWITCHES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 SECTION 4 - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-2 4-3 4-4 4-5 4-6 STANDARD PLATFORM AND FOOTSWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . 4-2 LOW MOUNT PLATFORMS AND FOOTSWITCH INSTALLATIONS . . . . . . . . . . . . . . . 4-6 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993). . . . . . . . . . . . . . . . . . . . . . . 4-12 CONSOLE BOX ASSEMBLY (JANUARY 1993 TO PRESENT) . . . . . . . . . . . . . . . . . . . . 4-16 OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . 4-20 SECTION 5 - CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 ii AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . 5-8 AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 AXLE LOCKOUT CYLINDER ASSEMBLIES - 4WD/4WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) . . . . . . . . . . . . . . . . . . . . 5-12 LEVEL (UPRIGHT) CYLINDER ASSEMBLY (PRIOR TO APRIL 1992 . . . . . . . . . . . . . . . 5-14 LEVEL (UPRIGHT) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) . . . . . . . . . . . . 5-16 MAIN LIFT CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) . . . . . . . . . . . . . . . . . . . . 5-18 MAIN LIFT CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) . . . . . . . . . . . . . . . . . . 5-20 TOWER LIFT CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) . . . . . . . . . . . . . . . . . 5-22 TOWER LIFT CYLINDER ASSEMBLIES (APRIL 1992 TO PRESENT) . . . . . . . . . . . . . . 5-24 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) . . . . . 5-28 SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) . . . . 5-30 STEER CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 CYLINDER BELLOWS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 3120806 TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 HYDRAULIC DIAGRAM - LIFT (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 HYDRAULIC DIAGRAM - LIFT (TOWER BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 HYDRAULIC DIAGRAM - PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 HYDRAULIC DIAGRAM - ROTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 HYDRAULIC DIAGRAM - SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 HYDRAULIC DIAGRAM - SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 HYDRAULIC DIAGRAM - TELESCOPE (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . .6-30 HYDRAULIC DIAGRAM - TELESCOPE (TOWER BOOM) . . . . . . . . . . . . . . . . . . . . . . .6-32 SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1 8-2 DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) . . . . . . . . . . . . . . . . . . . . . .8-2 DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) . . . . . . . . . . . . . . . . . . . .8-6 SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 3120806 iii TABLE OF CONTENTS FIGURE NO. iv TITLE PAGE NO. 3120806 SECTION 1 FRAME TABLE OF CONTENTS FIGURE 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 3120806 DESCRIPTION PAGE FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 DRIVE MOTOR ASSEMBLY - REXROTH (2WD/4WS AND 4WD/4WS . . . . . . . . . . . . . . . . . . . 1-24 DRIVE BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 DRIVE MOTOR ASSEMBLY - MICO (PRIOR TO JULY 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . 1-30 DRIVE HUB ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS 1-38 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 VALVES INSTALLATION (FRAME MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 CONTROL VALVE ASSEMBLY - 2 SECTION RACINE BANG-BANG . . . . . . . . . . . . . . . . . . . . 1-50 TOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 S E C T I O N 1 F R A M E 1-1 SECTION 1 FRAME S E C T I O N FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) 1 F R A M E 1-2 3120806 SECTION 1 FRAME FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) FIG & ITEM # PART NUMBER DESCRIPTION FRAME, STEERING AND AXLE INSTALLATIONS 2WD AND 4WD (WITH 2 WHEEL STEER) 1 2360304 2360311 2360312 2360303 Frame (2WD Fixed Axle) Frame (2WD Oscillating Axle) Frame (4WD Fixed Axle) Frame (4WD Oscillating Axle) 0251314 OSCILLATING AXLE INSTALLATION - 2WD (OPTIONAL) (PRIOR TO SEPTEMBER 1992) OSCILLATING AXLE INSTALLATION - 2WD (OPTIONAL) (SEPTEMBER 1992 TO PRESENT) OSCILLATING AXLE INSTALLATION - STANDARD 4WD (OPTIONAL) (PRIOR TO SEPTEMBER 1992) OSCILLATING AXLE INSTALLATION - STANDARD 4WD (OPTIONAL) (SEPTEMBER 1992 TO PRESENT) 0253120 0251517 0253121 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1682376 1682724 1682452 1682727 3421224 3450808 0641406 4761400 4751400 4843269 0641508 4761500 4751500 4842691 4842153 4843271 3450814 4740158 0641608 4740185 0961029 0961773 18 0961003 0961771 19 20 21 4220098 3311801 4761800 3120806 Lockout Cylinder Assembly Options (See Section 5 for Breakdown): 2WD (Prior to September 1992) 2WD (TUV) (September 1992 to Present) 4WD (Prior to September 1992) 4WD (TUV) (September 1992 to Present) Pin (Bottom) Pin, Cotter 1/4” x 2” Bolt 1/4”-20NC x 3/4” Lockwasher 1/4” Flatwasher 1/4” Pin (Top) Bolt 5/16”-18NC x 1” Lockwasher 5/16” Flatwasher 5/16” Axle Weldment (2WD) Axle Weldment (4WD) Pin Pin, Cotter 1/4” x 3 1/2” Washer, Thrust Bolt 3/8”-16NC x 1” Flatwasher, Hardened Bushing (Spindle Pivot Point) (4WD) (Prior to February 1994) Bushing (Spindle Pivot Point) (4WD) February 1994 to Present) Bushing (Axle Pivot Point) (Prior to February 1994) Bushing (Axle Pivot Point) (February 1994 to Present) Stop, Axle Nut 1/2”-13NC Lockwasher 1/2” QTY. REV. Ref. 1 1 1 1 Ref. B Ref. A Ref. D Ref. A S E C T I O N 1 F R A M E 2 2 4 2 2 2 2 2 2 2 1 1 1 1 2 1 1 4 4 2 2 2 4 4 1-3 SECTION 1 FRAME S E C T I O N FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER 22 4751800 4300048 4070528 4070800 3311601 4761800 4751800 4300034 1320125 3311601 4761600 4300030 2160002 2160003 3780184 23 24 25 26 1 27 28 29 F R A M E 30 31 32 Flatwasher 1/2” Stud (Welded on Part) Shim, Stop Shim, Stop (.125) Nut 3/8”-16NC Lockwasher 12” Flatwasher Stud (Welded on Part) Clamp Nut 3/8”-16NC Lockwasher 3/8” Stud (Welded on Part) Fitting, Grease Fitting, Grease - 45° O-Ring 0236449 STEERING AND SPINDLES INSTALLATION 33 1681562 34 35 36 37 38 39 40 41 3431622 4712600 3450606 0440091 3300175 2160003 3840863 0560714 0560605 3300229 3323002 0630425 0440091 3312601 0100011 Not Used 4130160 4130161 0960523 0961778 0440183 3300208 3313403 3451012 Steer Cylinder Assembly (See Section 5 for Breakdown) Pin, Clevis Flatwasher Pin, Cotter Washer, Thrust Locknut, Special Fitting, Grease - 45° Rod, Tie Block, Tie Rod (Left Side) Block, Tie Rod (Right Side) Nut, Jam (Left Side) Nut, Jam (Right Side) Bolt, Special Washer, Thrust Nut 1”-8NC Loctite 42 43 44 45 46 47 48 49 50 51 52 53 3421243 3422261 3780183 1-4 DESCRIPTION Spindle (R.H.) Spindle (L.H.) Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Bearing, Thrust Nut, Slotted Nut, Slotted 1 1/2”-6NC Pin, Cotter 5/16” x 3” Kingpin Options: (Prior to February 1994) (February 1994 to Present) O-Ring (February 1994 to Present Only) QTY. REV. 4 4 A/R A/R 4 4 4 4 1 1 1 1 3 1 2 Ref. O 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 A/R 1 1 4 4 2 2 2 2 4 3120806 SECTION 1 FRAME FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER 54 2160002 4640812 3960098 0440019 0440018 2780091 0630137 4740016 3323403 3313403 3450810 3451012 1120032 0721003 4761000 3300012 55 56 57 58 59 60 61 62 63 64 65 66 0250255 67 1681555 68 69 70 71 72 73 3431622 4712600 3450606 0630369 0440091 3312602 0100011 2160003 4640812 3841029 0560714 0560605 3300229 3300023 0642628 0440091 3312601 0100011 4130223 4130224 3422221 3421190 3421833 74 75 76 77 78 79 80 81 82 83 84 85 3120806 0440161 0630083 DESCRIPTION Fitting, Grease Valve, Relief Seal, Hub Cone, Bearing Cup, Bearing Hub Stud, Wheel Washer, Hardened Nut, Slotted 1 1/2”-12NF Nut, Slotted 1 1/2” - 6NC Pin, Cotter 1/4” x 2 1/2” Pin, Cotter 5/16” x 3” Cap, Hub Bolt #10-24NC x 3/8” Lockwasher #10 Nut, Wheel STEERING AND SPINDLES INSTALLATION (STANDARD 4WD BUILT PRIOR TO FEBRUARY 1994) Steer Cylinder Assembly (See Section 5 for Breakdown) Pin, Clevis Flatwasher Pin, Cotter Bolt, Special Washer, Thrust Nut, Jam 1”-8NC Loctite #242 Fitting, Grease Valve, Relief Rod, Tie Block, Tie Rod (Left Side) Block, Tie Rod (Right Side - Not Shown) Nut, Jam (Left Side) Nut, Jam (Right Side - Not Shown) Bolt 1”-8NC x 3 1/2” Washer, Thrust Nut 1”-8NC Loctite Spindle (R.H.) Spindle (L.H.) Kingpin (Machines built February 1994 to Present) Kingpin (Machines Built Prior to February 1994) Kingpin (CSA Machines Built Prior to February 1994) O-Ring (February 1994 to Present Only) Bearing, Thrust Bolt, Special QTY. REV. 2 2 2 4 4 2 20 2 2 2 2 2 2 6 6 20 Ref. S E C T I O N 1 F R A M E E 1 1 1 1 1 1 1 A/R 6 4 1 1 1 1 1 2 2 2 A/R 1 1 4 4 4 8 4 8 1-5 SECTION 1 FRAME S E C T I O N FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 86 4761600 4920096 3530244 3536410 0641404 2080026 4761400 Lockwasher 3/8” Wire, Safety Plate, Cover (Prior to September 1992) Plate, Cover (September 1992 to February 1994) Bolt 1/4”-20NC x 1/2” (Prior to September 1992) Tack (September 1992 to February 1994) Lockwasher 1/4” (Prior to September 1992) 8 A/R 4 4 8 8 2 87 88 89 REV. 1 F R A M E 1-6 3120806 SECTION 1 FRAME FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 2 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-7 SECTION 1 FRAME S E C T I O N FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) 1 F R A M E 1-8 3120806 SECTION 1 FRAME FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) FIG & ITEM # PART NUMBER DESCRIPTION FRAME, STEERING AND AXLE INSTALLATIONS 2WD AND 4WD (WITH 4 WHEEL STEER) 1 2360332 2360333 Frame (2WD) Frame (4WD) 0251773 0251314 FIXED FRONT AXLE INSTALLATION -2WD OSCILLATING FRONT AXLE INSTALLATION - 2WD (PRIOR TO SEPTEMBER 1992) OSCILLATING FRONT AXLE INSTALLATION - 2WD (SEPTEMBER 1992 TO PRESENT) 0253120 2 3 4 5 6 7 8 9 10 11 12 1682376 1682724 3421224 3450808 0641406 4761400 4751400 4843269 0641508 4761500 4751500 4642691 0961003 0961771 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 3120806 4843271 3450814 4740158 0641608 4751600 3780184 4220098 3311801 4761800 4751800 4300045 4070528 4070800 3311601 4761800 4751800 1320125 Lockout Cylinder Assembly Options (2WD with Oscillating Front Axle) (See Section 5 for Breakdown) Cylinder (Prior to September 1992) Cylinder (TUV) (September 1992 to Present) Pin (Bottom) Pin, Cotter 1/4” x 2” Bolt 1/4”-20NC x 3/4” Lockwasher 1/4” Flatwasher 1/4” Pin (Top) Bolt 5/16”-18NC x 1” Lockwasher 5/16” Flatwasher 5/16” Axle Weldment (2WD) Bushing, Bronze (Axle Pivot Point) (Prior to February 1994) Bushing, Bronze (Axle Pivot Point) (February 1994 to Present) Pin Pin, Cotter 1/4” x 3 1/2” Washer, Thrust Bolt 3/8”-16NC x 1” Flatwasher Hardened O-Ring Stop, Axle (2WD) Nut 1/2”-13NC Lockwasher 1/2” Flatwasher 1/2” Stud (Welded on Part) Shim, Stop (2WD) Shim, Stop (2WD) (.125) Nut 3/8”-16NC Lockwasher 1/2” Flatwasher 1/2” Clamp (2WD) QTY. REV. Ref. 1 1 Ref. Ref. B B Ref. A S E C T I O N 1 F R A M E 2 2 4 2 2 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 4 4 4 4 A/R A/R 4 4 4 1 1-9 SECTION 1 FRAME S E C T I O N FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER 28 3311601 4761600 4300030 2160002 2160003 0560951 0641616 4751600 4070224 4070225 0100019 29 30 31 32 1 33 F R A M E 0254294 0251703 0253123 34 35 36 37 38 39 40 41 42 43 44 45 46 1682406 1682757 3421861 4843286 0641407 4761400 4751400 4843826 3422064 3422360 3780187 0641610 4761600 4740185 0961529 0961686 0961776 0961509 0961687 0961777 47 1-10 2160003 2160002 3780184 4640812 DESCRIPTION Nut 3/8”-16NC Lockwasher 3/8” Stud (Welded on Parts) Fitting, Grease Fitting, Grease - 45° Block, Axle (2WD with Fixed Front Axle) Bolt 3/8”-16NC x 2” Flatwasher 3/8” Shim - .12 Shim - .06 Loctite #271 FIXED FRONT AXLE INSTALLATION - 4WD OSCILLATING FRONT AXLE INSTALLATION - 4WD (PRIOR TO SEPTEMBER 1992) OSCILLATING FRONT AXLE INSTALLATION - 4WD (SEPTEMBER 1992 TO PRESENT) Lockout Cylinder Assembly Options (4WD with Oscillating Axle) (See Section 5 for Breakdown): Cylinder (Prior to September 1992) Cylinder (TUV) (September 1992 to Present) Pin (Bottom) Pin (Top) Bolt 1/4”-20NC x 7/8” Lockwasher 1/4” Flatwasher 1/4” Axle Weldment (4WD) Pin (Prior to February 1994) Pin (February 1994 to Present) O-Ring (September 1992 to Present Only) (Not Shown) Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Flatwasher, Hardened Bushing, Bronze (Top) (Prior to May 1992) Bushing, Bronze (Top) (May 1992 to February 1994) Bushing, Bronze (Top) (February 1994 to Present) Bushing, Bronze (Bottom) (Prior to May 1992) Bushing, Bronze (Bottom) (May 1992 to February 1994) Bushing, Bronze (Bottom) (February 1994 to Present) Fitting, Grease - 45° Fitting, Grease - Straight O-Ring (Not Shown) Valve, Relief Fitting (Not Shown) QTY. REV. 1 1 1 3 1 2 4 4 A/R A/R A/R Ref. Ref. A C Ref. D 2 2 2 4 4 4 1 1 1 2 1 1 1 2 2 2 2 2 2 3 4 8 5 3120806 SECTION 1 FRAME FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION 0236449 FRONT STEERING AND SPINDLES INSTALLATION (STANDARD) (2WD) 48 1681562 49 50 51 52 53 54 55 56 3431622 4712600 3450606 0440091 3300175 2160003 3840863 0560714 0560605 3300229 3323002 0630425 0440091 3312601 0100011 4130160 4130161 0960523 0961778 0440183 3300208 3313403 3451012 Steer Cylinder Assembly (2WD Front) (See Section 5 for Breakdown) Pin, Clevis Flatwasher Pin, Cotter Washer, Thrust Locknut, Special Fitting, Grease - 45° Rod, Tie (2WD Front) Block, Tie Rod (Left Side) Block, Tie Rod (Right Side) Nut, Jam (Left Side) Nut, Jam (Right Side) Bolt, Special Washer, Thrust Nut 1”-8NC Loctite Spindle (Right Side) (2WD Front) Spindle (Left Side) (2WD Front) Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Bearing, Thrust Nut, Slotted Nut, Slotted 1 1/2”-6NC Pin, Cotter 5/16” x 3” Kingpin Options: (Prior to February 1994) (February 1994 to Present) O-Ring (February 1994 to Present Only) Fitting, Grease Valve, Relief Seal, Hub Cone, Bearing Cup, Bearing Hub Stud, Wheel Washer, Hardened Nut, Slotted 1 1/2”-12NF Nut, Slotted 1 1/2”-6NC Pin, Cotter 1/4” x 2 1/2” Pin, Cotter 5/16” x 3” Cap, Hub Bolt #10-24NC x 3/8” Lockwasher #10 Nut, Wheel 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 3120806 3421243 3422261 3780183 2160002 4640812 3960098 0440019 0440018 2780091 0630137 4740016 3323403 3313403 3450810 3451012 1120032 0721003 4761000 3300012 QTY. REV. Ref. O 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 A/R 1 1 4 4 2 2 2 2 2 S E C T I O N 1 F R A M E 4 2 2 2 4 4 2 20 2 2 2 2 2 2 6 6 20 1-11 SECTION 1 FRAME S E C T I O N FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER 0251594 0251913 1 F R A M E 81 1681555 82 83 84 85 86 87 3431622 4712600 3450606 0630439 0440091 3312602 0100011 2160002 2160003 4640182 3840868 0560714 0560605 3300229 3323402 3312601 0440091 0100011 4130255 4130256 3421856 3421927 3780184 3421858 3421929 3780184 0440082 0630083 4761600 4920096 88 89 90 91 92 93 94 95 96 97 98 99 100 0251541 0251593 0251914 101 1682203 1681555 1-12 DESCRIPTION FRONT STEERING AND SPINDLES INSTALLATION - 4WD (PRIOR TO FEBRUARY 1994) FRONT STEERING AND SPINDLES INSTALLATION - 4WD (DOMESTIC BUILT FEBRUARY 1994 TO PRESENT) Steer Cylinder Assembly (4WD Front) (See Section 5 for Breakdown) Pin, Clevis Flatwasher Pin, Cotter Bolt, Special Washer, Thrust Nut, Jam 1”-8NC Loctite #242 Fitting, Grease Fitting, Grease - 45° Valve, Relief Rod, Tie (4WD Front) Block, Tie Rod (Left Side) Block, Tie Rod (Right Side - Not Shown) Nut, Jam (Left Side) Nut, Jam (Right Side - Not Shown) Nut 1”-8NC Washer, Thrust Loctite Spindle (Right Side) (4WD Front) Spindle (Left Side) (4WD Front) Kingpin (Top) (Prior to February 1994) Kingpin (Top) (February 1994 to Present) O-Ring Kingpin (Bottom) (Prior to February 1994) Kingpin (Bottom) (February 1994 to Present) O-Ring Bearing, Thrust (When Equipped) Bolt, Special Lockwasher 3/8” Wire, Safety REAR STEERING AND SPINDLES INSTALLATION 2WD REAR STEERING AND SPINDLES INSTALLATION 4WD (PRIOR TO FEBRUARY 1994) REAR STEERING AND SPINDLES INSTALLATION 4WD (FEBRUARY 1994 TO PRESENT) Steer Cylinder Assembly (2WD Rear) (See Section 5 for Breakdown) Steer Cylinder Assembly (4WD Rear) (See Section 5 for Breakdown) QTY. REV. Ref. E Ref. D 1 1 1 1 1 1 1 A/R 1 4 4 1 1 1 1 1 2 2 A/R 1 1 4 4 4 4 4 4 2 8 8 A/R Ref. C Ref. E Ref. C 1 1 3120806 SECTION 1 FRAME FIGURE 1-2. FRAME, STEERING AND AXLE INSTALLATIONS - 2WD AND 4WD (WITH 4 WHEEL STEER) (CONTINUED) FIG & ITEM # PART NUMBER 102 103 104 105 106 107 3431622 4712600 3450606 0630439 0440091 3312602 0100011 2160003 4640812 3780184 3840868 0560714 0560605 3300229 3323002 3300175 0440091 4130254 4130256 4130253 4130255 3421856 3421927 3421858 3421929 4740082 0630083 4761600 4920096 0961529 0961686 0961776 0961509 0961687 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 0961777 3120806 DESCRIPTION Pin, Clevis Flatwasher 1” Narrow Pin, Cotter 3/16” x 1 1/2” Bolt, Special Bearing, Thrust Nut, Jam 1”-8NC Loctite #242 Fitting, Grease - 45° Valve, Relief O-Ring Tie-Rod (Rear) Block, Tie-Rod (Left Side) Block, Tie-Rod (Right Side) Nut, Jam (Left Side) Nut, Jam (Right Side) Locknut, Special Bearing, Thrust Spindle (Left Side) (2WD Rear) Spindle (Left Side) (4WD Rear) Spindle (Right Side) (2WD Rear) Spindle (Right Side) (4WD Rear) Kingpin (Top) (Prior to February 1994) Kingpin (Top) (Built February 1994 to Present) Kingpin (Bottom) (Prior to February 1994) Kingpin (Bottom) (February 1994 to Present) Washer, Thrust (When Equipped) Bolt, Special Lockwasher 3/8” Wire, Safety Bushing, Bronze (Top) (Prior to May 1992) Bushing, Bronze (Top) (May 1992 to February 1994) Bushing, Bronze (Top) (February 1994 to Present) Bushing, Bronze (Bottom) (Prior to May 1992) Bushing, Bronze (Bottom) (May 1992 to February 1994) Bushing, Bronze (Bottom) (February 1994 to Present) QTY. REV. 1 1 1 1 1 1 A/R 6 4 8 1 1 1 1 1 2 2 1 1 1 1 2 2 2 2 2 4 4 A/R 2 2 2 2 2 S E C T I O N 1 F R A M E 2 1-13 SECTION 1 FRAME S E C T I O N FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS 1 F R A M E 1-14 3120806 SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS FIG & ITEM # PART NUMBER DESCRIPTION TIRE AND WHEEL DRIVE INSTALLATIONS 0250313 0251540 0250272 0251592 1 3160140 2 3160080 3 3160176 4 0920072 0920081 0920084 5 6 7 8 9 3311801 4761800 4740252 4320008 4300092 0100011 2780114 2780170 2780170 10 13 0642014 3932028 4762000 0100011 3300012 3300012 3160080 14 15 16 17 0641810 4761800 4751800 2780151 11 12 2780192 3120806 WHEEL DRIVE INSTALLATION (2WD/2WS) WHEEL DRIVE INSTALLATION (2WD/4WS) WHEEL DRIVE INSTALLATION (4WD/2WS) WHEEL DRIVE INSTALLATION (4WD/4WS) Drive Motor Assembly - Vickers (2WD/2WS) (See Figure 1-4 for Breakdown) Drive Motor Assembly - Cessna (4WD/2WS Rear) (See Figure 1-5 for Breakdown) Drive Motor Assembly - Rexroth (All 4WS) (See Figure 1-6 for Breakdown) Note: All 4WS - Use p/n 3160204 Motor Plus p/n 2900869 Conversion Kit as Replacement. Drive Brake Assembly - Ausco (See Figure 1-7 for Breakdown) Drive Brake Assembly - Mico (Prior to July 1991) (See Figure 1-8 for Breakdown) Drive Brake Assembly - Mico (July 1991 to Present) (See Figure 1-9 for Breakdown) Nut 1/2”-13NC Lockwasher 1/2” Washer, Hardened (When Equipped) Stud (Use with Ausco Brake) Stud (Use with Mico Brake) Loctite #242 Drive Hub Assembly (0250313/0251540 Installations - 2WD) (See Figure 1-10 for Breakdown) Drive Hub Assembly (0250272 Installations - 4WD Rear) (See Figure 1-11 for Breakdown) Drive Hub Assembly (0251592 Installations 4WD/4WS Front and Rear) (See Figure 1-11 for Breakdown) Bolt 5/8”-11NC x 1 3/4” Bolt, Socket Head 5/8”-11NC x 1 3/4” Lockwasher 5/8” Loctite #242 Lug Nut (2WD - 10 Per Wheel) Lug Nut (4WD - 9 Per Wheel) Drive Motor Assembly - Cessna (4WD/2WS) (See Figure 1-5 for Breakdown) Bolt 1/2”-13NC x 1 1/4” Lockwasher 1/2” Flatwasher 1/2” Drive Hub/Brake Assembly (4WD/2WS - Front Only Built Prior to February 1992) (See Figure 1-13 for Breakdown) Drive Hub/Brake Assembly (4WD/2WS - Front Only Built February 1992 to Present) (See Figure1-13 for Breakdown) QTY. REV. Ref. Ref. Ref. Ref. Ref. 5 5 5 7 2 S E C T I O N 1 2 F R A M E 2/4 Ref. 2 2 2 4 4 4 4 4 A/R 2 2 4 16 16 16 A/R 20 36 2 4 4 4 2 2 1-15 SECTION 1 FRAME S E C T I O N FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 18 19 0642014 4762000 0250548 0250172 0251865 1 0254769 0253832 F R A M E 0251700 101 0250170 0250171 0236626 0236625 0253833 0253834 0254770 0254771 0250171 0250170 0251866 0255803 0253833 0253834 0251701 0251702 1-16 DESCRIPTION Bolt 5/8”-11NC x 1 3/4” Lockwasher 5/8” QTY. REV. 6 6 TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 14 X 17.5) (2WD/2WS) TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 14 X 17.5) (4WD/2WS) TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 14 X 17.5) (4WD/4WS) TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 15 X 19.5) (2WD/2WS) TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 15 X 19.5) (4WD/2WS) TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED 15 X 19.5) (4WD/4WS) Ref. A Ref. A Ref. A Ref. _ Ref. A Ref. _ 2WD Options: Tire and Wheel Assembly - 2WD Left Side Front (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 2WD Right Side Front (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 2WD/2WS Left Side Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 2WD/2WS Right Side Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 2WD/4WS Right Side Front (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 2WD/2WS Left Side Front (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 2WD/2WS Right Side Rear (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 2WD/2WS Left Side Rear (Foam-Filled 15 x 19.5) Ref. 1 A 1 A 1 A 1 _ 1 2 1 2 1 3 1 3 4WD Options: Tire and Wheel Assembly - 4WD/2WS Left Side Front and Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 4WD/2WS Right Side Front and Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 4WD/4WS Left Side Front and Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 4WD/4WS Right Side Front and Rear (Foam-Filled 14 x 17.5) Tire and Wheel Assembly - 4WD/2WS Right Side (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 4WD/2WS Left Side (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 4WD/4WS Right Side (Foam-Filled 15 x 19.5) Tire and Wheel Assembly - 4WD/4WS Left Side (Foam-Filled 15 x 19.5) Ref. 2 A 2 A 2 A 2 _ 2 2 2 2 2 2 2 2 3120806 SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire and wheel assembly, otherwise purchase complete assembly. 4520024 4520025 4520009 4520007 4520125 4520171 4520142 4520200 4860115 4860119 0236539 4860129 4860130 4860108 4860148 4860123 3120806 QTY. REV. Ref. Tire Options (Prior to May 1995): Tire - 14 x 17.5 Goodyear Hi-Miller Tire - 14 x 17.5 Goodyear X-Tra Grip Tire - 15 x 19.5 General Jumbo Cargo Tire - 15 x 19.5 General Jumbo All Grip Tire - 15 x 19.5 Goodyear Sure Grip Loader Tire Options (May 1995 to Present): Tire - 14 x 17.5 Galaxy Tire - 15 x 19.5 Denman E M Loader Tire - 15 x 19.5 Galaxy Super Sidewall Rim Options: Rim, Wheel (14 x 17.5 Tires) (2WD Front With 2WS/4WD Front and Rear With 2WS) Rim, Wheel (14 x 17.5 Tires) (2WD Rear for 0250102 and 0250217 Installations Only) Rim, Wheel (14 x 17.5 Tires (2WD Rear With 2WS for all except 0250102 and 0250217 Installations) Rim, Wheel (14 x 17.5 Tires) (4WD Front and Rear With 4WS) Rim, Wheel (15 x 19.5 Tires) (2WD Front With 4WS and 4WD Front and Rear With 4WS) Rim, Wheel (15 x 19.5 Tires) (2WD Rear With 4WS) (Production) Rim, Wheel (15 x 19.5 Tires) (2WD Rear With 4WS) (Post Production Alternative) Rim, Wheel (15 x 19.5) (4WD Front and Rear With 2WS) S E C T I O N 1 F R A M E 1-17 SECTION 1 FRAME S E C T I O N FIGURE 1-4. DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS) 1 F R A M E 1-18 3120806 SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 3120806 PART NUMBER 3160140 7006766 7006767 7006768 7006772 7006774 7006776 Kit 7006786 7006787 7006788 7006789 7006721 7006796 7006791 7006792 Kit 7006794 7006795 7996719 7006797 7006798 7006703 Kit 7009300 7009301 Kit Kit Kit 7009305 7009306 7006706 7009307 7009308 7006717 7006716 7006715 7006714 7006713 7006712 7006711 7006710 7006709 7009309 7006707 7009310 7006704 2900659 DESCRIPTION DRIVE MOTOR ASSEMBLY - VICKERS (2WD/2WS) Yoke Roll Pin Spherical Seat Spring Seat Yoke Spring Yoke Stop Gasket Housing Washer Screw Screw Shim (Included in Kit 7006794 Retaining Ring Shaft Steel Bearing Pintle Bearing O-Ring Shim Kit Cover Bearing Piston Piston Rod Plug O-Ring Screw Control Block Gasket O-Ring Back-Up Ring Retaining Ring Valve Block Pin Pin Shaft Piston and Shoes Shoe Plate Spherical Washer Pin, Retainer Pin Cylinder, Block Spring Washer Spring Spring Washer Retaining Ring Bearing Spacer Kit Wafer Plate Bearing S/A Seal Kit (Includes 7, 14, 17, 24, 27, 28 and 29) QTY. REV. Ref. 1 1 1 1 1 1 1 1 6 6 4 1 1 1 2 2 2 1 2 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 9 1 1 1 3 1 1 1 1 1 1 1 1 1 A S E C T I O N 1 F R A M E 1-19 SECTION 1 FRAME S E C T I O N FIGURE 1-5. DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) 1 F R A M E 1-20 3120806 SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) FIG & ITEM # PART NUMBER 3160080 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 3120806 7004939 7004938 Kit 7004941 7004933 7004942 7004943 Kit 7004944 7004945 Kit 7004946 Kit 7004918 7004917 7004947 7004937 7004929 7004948 Kit Kit 4100028 4100027 4100029 Kit 7004916 7004936 7004950 7004951 7004952 7004953 7004954 7004955 7004956 7004957 7004958 7004928 Kit Kit 7004906 Kit 7004907 7004908 7004912 DESCRIPTION DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) Control Piston Housing Assembly Screw, Cap, Socket Head Housing, Control Piston (Not Sold Separately - Part of Item 26) O-Ring Backplate Assembly Screw, Cap, Hex Head Plug Assembly Plug O-Ring Plug Assembly (Shuttle Spool) Plug O-Ring Spool, Shuttle O-Ring Washer, Backup Bearing, Needle Backplate Ring, Retaining Pin, Connector Control Piston Assembly Ring, Slippery O-Ring Piston, Control (Not Sold Separately) Spacer, Piston - .105 Spacer, Piston - .092 Spacer, Piston - .110 Gasket, Housing Rotating Kit Assembly Ring, Retaining Washer, Machined Spring, Compression Pin, Loading Keeper, Pin Piston, Assembly Spider Pivot Washer, Wave Block, Piston Connector, Camplate Ring, Retaining Seal, Shaft Washer Ring, Retaining Race, Thrust Bearing, Thrust Shaft, Drive QTY. REV. Ref. A 1 4 1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 4 2 1 1 1 1 A/R A/R A/R 1 1 1 2 1 3 1 9 1 1 1 1 1 1 1 1 2 2 1 1 S E C T I O N 1 F R A M E 1-21 SECTION 1 FRAME S E C T I O N FIGURE 1-5. DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) (CONTINUED) FIG & ITEM # PART NUMBER 45 46 47 48 49 50 Kit 7004913 Kit 7004911 7004914 7004927 7004959 7004960 7004961 7004910 51 52 53 1 F R A M E 2900449 1-22 DESCRIPTION Ring, Retaining Cover, Trunnion O-Ring Race, Inner Bearing‘ Camplate Housing Assembly Pin, Roll (1/4” Dia. X. 1/2” Long) Housing Bearing —————————— Seal Repair Kit (Includes Items 3, 7, 10, 12, 19, 20, 25, 38, 39, 41, 45 and 47) QTY. REV. 2 2 2 1 2 1 1 2 1 1 1 3120806 SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - CESSNA (4WD/2WS) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-23 SECTION 1 FRAME S E C T I O N FIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTH (2WD/4WS AND 4WD/4WS) 1 F R A M E 1-24 3120806 SECTION 1 FRAME . FIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTH (2WD/4WS AND 4WD/4WS) FIG & ITEM # PART NUMBER 3160176 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 2012702 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 3120806 DESCRIPTION DRIVE MOTOR ASSEMBLY - REXROTH (2WD/4WS AND 4WD/4WS) Shaft - 13 Teeth Seal, Shaft Bearing, Cradle Housing Rod, Piston Piston, Stroking O-Ring Nut, Adaptor Bearing, Roller Bolt, Metric Socket Head M12 x 65 Block, Port Shim Pin, Dowel M6 x 18 O-Ring Nut, Cap M10 x 1 Screw, Adjusting O-Ring Nut, Jam M10 x 1 Rotary Group Assembly Plug Plate, Swash Bearing, Roller V-Ring Control Plate Assembly —————————— Seal Kit (Includes Items 2, 7, 14, 17 and O-rings under Item 24) Rotary Group Kit (Includes Items 19 and 21) QTY. REV. Ref. _ 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 1-25 SECTION 1 FRAME S E C T I O N FIGURE 1-7. DRIVE BRAKE ASSEMBLY - AUSCO 1 F R A M E 1-26 3120806 SECTION 1 FRAME FIGURE 1-7. DRIVE BRAKE ASSEMBLY - AUSCO FIG & ITEM # PART NUMBER 0920072 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7003047 Kit 7003049 Kit 7003051 7003052 7003070 7000717 7003054 7003006 7003055 7003056 7003057 Kit Kit Kit Kit 7000760 7000796 7003071 7003007 7003059 7000728 Kit 2900662 3120806 DESCRIPTION DRIVE BRAKE ASSEMBLY - AUSCO Housing Gasket Bearing Seal, Oil Retainer, Spring Spring, Compression Shaft, Splined Pin, Torque Disc, Primary Spring, Separator Disc, Rotating Disc, Stationary Piston Ring, Backup O-Ring Ring, Backup O-Ring Bearing Screw, Bleeder Plate, Power Screw Valve, Pressure Plug Gasket —————————— Seal Kit (Includes Items 2, 4, 14, 15, 16, 17 and 24) QTY. REV. Ref. D 1 1 1 1 1 8 1 2 1 6 3 3 1 1 1 1 1 1 1 1 4 1 1 2 S E C T I O N 1 F R A M E 1 1-27 SECTION 1 FRAME S E C T I O N FIGURE 1-8. DRIVE BRAKE ASSEMBLY - MICO (PRIOR TO JULY 1991) 1 F R A M E 1-28 3120806 SECTION 1 FRAME . FIGURE 1-8. DRIVE BRAKE ASSEMBLY - MICO (PRIOR TO JULY 1991) FIG & ITEM # PART NUMBER 0920081 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 Kit Kit 7007977 7007978 7007979 7007980 7007981 Kit 7007983 Kit 7007985 7007986 7007914 7007987 Kit Kit Kit Kit Kit Kit 7007989 7007924 Not Used Not Used Kit Kit 2900767 2900766 2900768 3120806 DESCRIPTION DRIVE BRAKE ASSEMBLY - MICO (PRIOR TO JULY 1991) QTY. REV. Ref. - Seal, Oil Bearing Ring, Retaining Shaft Spring (Small) Spring (Large) Housing Plate, Return Separator Seal, Case Bolt, Washer Head Cover Screw, Bleeder Pin, Dowel Ring, Back-up (Inner) O-Ring (Inner) Ring, Back-up (Outer) O-Ring (Outer) Rotor Stator Piston Plug, Pipe 1 1 1 1 6 6 1 1 2 1 4 1 1 2 1 1 1 1 2 2 1 1 O-Ring Gasket —————————— Lining Kit (Includes Items 8, 10, 19, 20, 25 and 26) Seal Kit (Includes Items 1, 10, 15, 16, 17, 18, 25 and 26) Bearing Kit (Includes Items 1, 2, 10, 25 and 26) 2 2 S E C T I O N 1 F R A M E 1 1 1 1-29 SECTION 1 FRAME S E C T I O N FIGURE 1-9. DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) 1 F R A M E 1-30 3120806 SECTION 1 FRAME . FIGURE 1-9. DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) FIG & ITEM # PART NUMBER 0920084 0920110 1 2 7011712 7011717 7018606 3 7007979 7007980 7007970 7018602 4 7011713 7018605 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3120806 Kit 7011715 7011714 7007983 Kit Kit Kit Kit 7007985 7018607 7007986 7000796 7018609 7007987 Kit 7011716 Kit 7007977 Kit Kit Kit Kit 7007923 7018603 7007933 Kit 7007924 DESCRIPTION DRIVE BRAKE ASSEMBLY OPTIONS: Production Post Production Alternative Shaft Guide, Spring Options: 0920084 Brake 0920110 Brake Spring Options: 0920084 Brake (Inner) 0920084 Brake (Outer) 0920110 Brake (Red) 0920110 Brake (Blue) Housing Options: 0920084 Brake 0920110 Brake Return Plate & Separator Assembly Options: Return, Plate - 0920084 Brake Separator Assy - 0920084 Brake Pin Separator Return Plate & Separator - 0920110 Brake Rotor Stator Seal, Case Bolt, Washer Head Options: 0920084 Brake 0920110 Brake Cover Hardware Options: Screw, Bleeder Plug, Pipe Pin, Dowel Seal, Oil Ring, Retaining Bearing Ring, Retaining Ring, Back-Up Ring, Back-Up O-Ring O-Ring Piston Options: 0920084 Brake 0920110 Brake Gasket O-Ring Plug, Pipe ——————————— QTY. REV. Ref. Ref. Ref. A C 1 1 S E C T I O N 1 A/R 6 6 6 3 1 F R A M E A/R 1 2 4 2 1 2 2 1 4 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1-31 SECTION 1 FRAME S E C T I O N FIGURE 1-9. DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 2900766 2900768 2900767 7018608 DESCRIPTION Seal Kit (Includes Items 8,13,17,18,19,20,22 & 23) Seal Kit (Includes Items 8,13,15,22 & 23) Lining Kit Options: (Includes Items 5,6,7,8,22 & 23) 0920084 Brake 0920110 Brake QTY. REV. 1 1 1 1 F R A M E 1-32 3120806 SECTION 1 FRAME FIGURE 1-9. DRIVE BRAKE ASSEMBLY - MICO (JULY 1991 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-33 SECTION 1 FRAME S E C T I O N FIGURE 1-10. DRIVE HUB ASSEMBLY (2WD) 1 F R A M E 1-34 3120806 SECTION 1 FRAME . FIGURE 1-10. DRIVE HUB ASSEMBLY (2WD) FIG & ITEM # PART NUMBER 2780114 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 3120806 7001937 Kit 7000272 7000273 7000274 7000275 7000276 Kit Kit 7001928 7000265 7001917 7001918 7001900 7007645 7001902 7001903 7001904 7001927 7001906 Not Used 7000279 Kit 7000280 7000218 7000219 7000220 Kit Kit Kit Kit 7000243 7000282 7000283 7000284 7000285 7000222 7000286 7000221 Not Used 7000287 7000288 7000289 7000225 7000290 QTY. REV. DRIVE HUB ASSEMBLY (2WD) DESCRIPTION Ref. A Hub and Spindle Assembly Spindle, Cast Seal Cup, Bearing Cone, Bearing Cup, Bearing Cone, Bearing Hub Spacer Ring, Retaining Plug Bolt, Wheel Gear, Internal —————————— Carrier Assembly Carrier Washer, Thrust Roller, Needle Spacer Shaft, Pinion Gear, Cluster Pin, Roll 1 1 1 1 1 1 1 1 1 1 2 10 1 Gear, Ring O-Ring Cover Assembly Cover Cap, Cover Bolt Cap, Disconnect Rod, Disconnect O-Ring O-Ring Plug, Pipe Washer Spring Ring, Retaining Ring, Retaining Shaft, Input Spacer, Thrust Gear, Input 1 2 1 1 1 4 1 1 1 1 1 2 1 1 1 1 1 1 Washer, Thrust Bearing, Thrust Bolt Bolt, Shoulder Coupling 4 2 8 4 1 S E C T I O N 1 F R A M E 1 1 6 84 3 3 3 3 1-35 SECTION 1 FRAME S E C T I O N FIGURE 1-10. DRIVE HUB ASSEMBLY (2WD) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 2900202 2900138 —————————— Seal Kit (Includes Items 2, 8, 9 and 22) Cover Repair Kit (Includes Items 2, 8, 9, 22, 26, 27, 28, 29 and New Style Cover) 1 1 REV. 1 F R A M E 1-36 3120806 SECTION 1 FRAME FIGURE 1-10. DRIVE HUB ASSEMBLY (2WD) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-37 SECTION 1 FRAME S E C T I O N FIGURE 1-11. DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS 1 F R A M E 1-38 3120806 SECTION 1 FRAME . FIGURE 1-11. DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 2780170 DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS) Ref. - 19 20 21 22 23 Use 70001111 Use 70001111 7000220 Use 70001111 Use 70001111 7000220 7000215 7000213 7000243 Use 70001111 7000217 7000214 4751500 7000230 7001988 7000253 7001984 7001931 7001985 7001909 7000263 7001911 7001987 7001913 7001990 7000252 7000250 7000260 7000261 7000263 7000262 7000246 24 25 26 27 28 29 30 31 32 33 34 35 7000229 7000232 7000257 7000258 7007601 7000242 7007697 Kit Kit 7001998 7001997 7000206 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 3120806 Cover Assembly (was p/n 7001989) Cap, Disconnect (was p/n 7000211) Bolt, Hex Head Rod, Disconnect (was p/n 7000212) Cap, Cover (was p/n 7000227) Bolt, Hex Head O-Ring O-Ring Plug, Pipe Cover (was p/n 7000226) Bolt, Hex Head Bolt, Hex Head - Shoulder Flatwasher O-Ring Gear, Ring Washer, Thrust Planet Carrier Assembly Carrier Washer, Thrust Bearing, Needle Roller Spacer Shaft, Planet Gear, Cluster Rollpin Gear, Input Spacer, Sun Gear Input Shaft Assembly Shaft, Input Ring, Retaining Spacer Spring Gear, Stationary Internal Hub Assembly Ring, Retaining Spacer Bearing, Tapered Roller Cone, Bearing Hub Plug, Pipe Stud, Wheel Cone, Bearing Bearing, Tapered Roller Seal Spindle Coupling, Input 1 1 2 1 1 2 1 1 1 1 12 4 16 2 1 2 1 1 6 96 3 3 3 3 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 9 1 1 1 1 1 S E C T I O N 1 F R A M E 1-39 SECTION 1 FRAME S E C T I O N FIGURE 1-11. DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS (CONTINUED) FIG & ITEM # PART NUMBER 7010429 DESCRIPTION Bearing Kit (Includes Items 31 and 32) QTY. REV. 1 1 F R A M E 1-40 3120806 SECTION 1 FRAME FIGURE 1-11. DRIVE HUB ASSEMBLY (4WD REAR WITH 2WS AND 4WD FRONT AND REAR WITH 4WS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-41 SECTION 1 FRAME S E C T I O N FIGURE 1-12. DRIVE HUB/BRAKE ASSEMBLY 1 F R A M E 1-42 3120806 SECTION 1 FRAME . FIGURE 1-12. DRIVE HUB/BRAKE ASSEMBLY FIG & ITEM # PART NUMBER 2780151 2780192 1 Not Available 2 3 4 5 6 7 8 9 10 11 12 13 14 Kit 7007683 7007684 7007685 7007686 7007687 7007688 7007689 7007690 7000241 7000242 7007617 7007691 7001984 7001931 7001985 7001909 7000263 7001911 7001987 7001913 7010474 7001988 Kit Use 70001111 Use 70001111 Use 70001111 7000220 Use 70001111 Use 70001111 Kit Kit 7000243 7000250 7000260 7000261 7000262 7000263 7001990 7000252 7007653 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 3120806 QTY. REV. DRIVE HUB/BRAKE ASSEMBLY (4WD/2WS FRONT ONLY BUILT PRIOR TO FEBRUARY 1992) DRIVE HUB/BRAKE ASSEMBLY (4WD/2WS FRONT ONLY BUILT FEBRUARY 1992 TO PRESENT) DESCRIPTION Ref. A Ref. - Hub/Spindle Assembly Spindle (No Longer Available Due to Changes in Spindle Machining to Accommodate New Brake Must Purchase Spindle/Brake Assembly) Seal Cup, Bearing Cone, Bearing Cup, Bearing Cone, Bearing Hub Washer, Tongued Lockwasher Locknut Stud Plug, Pipe Plug, Magnetic Gear, Internal Carrier Assembly Carrier Washer, Thrust Roller, Needle Spacer Shaft, Planet Gear, Cluster Pin, Roll (2780151 Hub) Pin, Roll (2780192 Hub) Gear, Ring O-Ring Cover Assembly (was p/n 7001989) Cover (was p/n 7000226) Cap, Cover (was p/n 7000227) Bolt Cap, Disconnect (was p/n 7000211) Rod, Disconnect (was p/n 7000212) O-Ring O-Ring Plug, Pipe Input Shaft Assembly Shaft, Input Ring, Retaining Spring Spacer Gear, Input Spacer, Thrust (2780151 Hub) Spacer, Thrust (2780192 Hub) 1 1 S E C T I O N 1 1 1 1 1 1 1 1 1 1 9 2 2 1 1 1 6 96 3 3 3 3 3 1 2 1 1 1 4 1 1 1 1 1 1 1 1 1 2 1 1 1 F R A M E 1-43 SECTION 1 FRAME S E C T I O N FIGURE 1-12. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 38 39 40 41 42 43 44 Not Used 7000253 7000217 7000214 7007603 7007692 7010453 7010452 7010473 7001922 7010459 Not Used 7010455 7010470 1 45 46 47 48 F R A M E 2900754 7010453 7010452 101 102 103 104 7003087 7003089 7003088 Not Serviced 2900755 7010473 101 102 103 104 Kit Kit Kit Kit 7010475 7010476 7010477 7010478 1-44 DESCRIPTION QTY. Washer, Thrust Bolt Bolt, Shoulder Flatwasher Gasket Brake Assembly (2780151 Hub Model W1BJ4Y349) Brake Assembly (2780151 Hub Model W1BJ4U349) Brake Assembly (2780192 Hub) Washer, Thrust Ring, Retaining 2 12 4 16 1 1 1 1 1 1 Coupling (2780151 Hub) Coupling (2780192 Hub) —————————— Seal Kit - Hub (Includes Items 2, 23, 29, 30, 43) 1 1 BRAKE ASSEMBLY (2780151 HUB MODEL W1BJ4Y349) BRAKE ASSEMBLY (2780151 HUB MODEL W1BJ4U349) Disc, Stationary Disc, Rotating Piston Spring —————————— Seal Kit - Brake (Includes Piston Rings and Gaskets) BRAKE ASSEMBLY (2780192 HUB) Disc, Stationary Disc, Rotating Piston Spring —————————— Brake Lining Repair Kit (Includes Items 101, 102 and 5 O-Rings) Brake O-Ring Kit (Includes all 5 O-Rings) Brake Spring Kit (Includes Item 104 and Cover O-Ring) Piston Repair Kit (Includes Item 103 and All 5 O-Rings) REV. 1 Ref. Ref. 2 3 1 10 1 Ref. 7 6 1 8 1 1 1 1 3120806 SECTION 1 FRAME FIGURE 1-12. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-45 SECTION 1 FRAME S E C T I O N FIGURE 1-13. VALVES INSTALLATION (FRAME MOUNTED) 1 F R A M E 1-46 3120806 SECTION 1 FRAME . FIGURE 1-13. VALVES INSTALLATION (FRAME MOUNTED) FIG & ITEM # PART NUMBER 0239523 0251000 1 2 3 4 5 6 7 8 4640260 7009739 7007321 7007323 4640451 7010630 7011317 4640682 7011316 7011317 0641626 4761600 3311601 2220061 2220844 2220377 4640671 7010510 7009739 Use 70003445 See Note 9 10 11 12 0641522 4751500 4761500 3311501 0251546 0251547 101 4640684 102 103 104 3311501 4761500 4751500 4300038 3120806 DESCRIPTION QTY. REV. VALVES INSTALLATION (FRAME MOUNTED Ref. COUNTERBALANCE AND FLOW DIVIDER INSTALLATION - 2WD COUNTERBALANCE AND FLOW DIVIDER INSTALLATION - 4WD Ref. - Ref. C Valve, Flow Divider Cartridge (Vickers/Modular Controls Version) Seal Kit (Vickers/Modular Controls Version) Cartridge (Fluid Controls Version) Seal Kit (Fluid Controls Version) Valve, Counterbalance (2WD) Cartridge Seal Kit Valve, Counterbalance (4WD) Cartridge Seal Kit Bolt 3/8”-16NC x 3 1/4” Lockwasher 3/8” Nut 3/8”-16NC Fitting, Adapter (2WD) Fitting, Adapter (4WD) Fitting Valve, Flow Divider (4WD Only) Cartridge (Vickers/Modular Controls Version) Seal Kit (Vickers/Modular Controls Version) Cartridge (Fluid Controls Version) (was p/n 7007322) Seal Kit (Fluid Controls Version) (was p/n 7007373) (Note: No Longer Available) Bolt 5/16”-18NC x 2 3/4” Flatwasher 5/16” Lockwasher 5/16” Nut 5/16”-18NC CONTROL VALVE INSTALLATION (4WS WITHOUT ROTATE) CONTROL VALVE INSTALLATION (4WS WITH ROTATE) Control Valve Assembly - Bang-Bang 2 Section (See Figure 1-16 for Breakdown) Nut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Stud (Welded on Part) 1 1 1 1 1 1 2 2 1 2 2 2 2 2 1 1 1 2 1 1 1 S E C T I O N 1 F R A M E 1 2 2 2 2 Ref. D Ref. D 1 4 4 4 4 1-47 SECTION 1 FRAME S E C T I O N FIGURE 1-13. VALVES INSTALLATION (FRAME MOUNTED) (CONTINUED) FIG & ITEM # 201 202 203 204 205 206 207 208 209 210 211 1 F R A M E 1-48 PART NUMBER DESCRIPTION QTY. REV. 0251310 OSCILLATION LOCKOUT VALVE INSTALLATION (MACHINES WITH OSCILLATING AXLE BUILT OCTOBER 1992 TO PRESENT) Ref. D 4640668 7012516 3931016 4751000 4761000 3311001 4843742 0641620 4751600 4761600 3311601 3534778 Valve, Lockout Repair Kit Bolt, Socket Head #10-24NC x 1” Flatwasher #10 Lockwasher #10-24NC Nut #10-24NC Plate, Mounting Bolt 3/8”-16NC x 2 1/2” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Spacer 1 1 4 4 4 4 1 2 2 2 2 1 3120806 SECTION 1 FRAME FIGURE 1-13. VALVES INSTALLATION (FRAME MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 1 F R A M E 3120806 1-49 SECTION 1 FRAME S E C T I O N FIGURE 1-14. CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG 1 F R A M E 1-50 3120806 SECTION 1 FRAME . FIGURE 1-14. CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG FIG & ITEM # PART NUMBER 4640684 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 7002315 7004859 7002274 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002327 7002339 7000468 7000414 3120806 DESCRIPTION CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG Steer Section - Complete (Front and Rear) Solenoid Assembly Washer Spring Guide Tube Assembly Cone, Female O-Ring O-Ring Pin, Push Plunger Tube, Guide Pin, Actuator Ring, Quad Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Nameplate Screw Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) —————————— Seal Kit - Working Section QTY. REV. Ref. - 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 S E C T I O N 1 F R A M E 2 1-51 SECTION 1 FRAME S E C T I O N FIGURE 1-15. TOW INSTALLATION 1 F R A M E 1-52 3120806 SECTION 1 FRAME . FIGURE 1-15. TOW INSTALLATION FIG & ITEM # PART NUMBER 0239990 0250673 0254389 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 3120806 4843481 4843566 2551279 0361852 2620032 3421151 3323002 2880410 2160001 3840643 3841048 3323002 1660114 0642628 4762600 3040293 3040382 0253413 3420477 4740036 3420372 3533498 3507049 3420292 1260017 4640261 0641507 4761500 4751500 0900479 3250872 3820001 3250840 1702305 3820001 DESCRIPTION QTY. REV. TOW INSTALLATION (2WD/2WS) TOW INSTALLATION (4WD/2WS) TOW INSTALLATION (2WD/4WS) Ref. Ref. Ref. D D A Mount Weldment - Hitch (Welded on Part) (2WD) Mount Weldment - Hitch (Welded on Part) (4WD) Gusset (4WD Only) Bar, Support (4WD Only) Hitch, Tow Pin Nut, Jam 1 1/4”-12NF Keystock 1/4” Sq. X. 1 1/4” (Welded on Part) Fitting, Grease Tie-Rod (2WD) Tie-Rod (4WD) Nut, Jam 1 1/4”-12NF End, Toe-Rod Bolt 1”-8NC x 3 1/2” Lockwasher 1” Lug, Spindle (Welded on Part) (2WD) Lug, Spindle (Welded on Part) (4WD) Tow Bar Assembly Pin, Towing Flatwasher, Special Hairpin Bracket, Storage Bar Pin, Quick Release Chain Valve, Select Bolt 5/16”-18NC x 3/4” Lockwasher 5/16” Flatwasher 5/16” Bracket, Mounting - Valve Nameplate - Tow Select Rivet Nameplate - Tow Instructions (Prior to May 1994) Nameplate - Tow Instructions (May 1994 to Present) Rivet 1 1 2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 1 1 4 1 1 4 S E C T I O N 1 F R A M E 1-53 SECTION 1 FRAME S E C T I O N FIGURE 1-15. TOW INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 1 F R A M E 1-54 3120806 SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27 2-28 2-29 3120806 DESCRIPTION CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY - VICKERS (Prior To October 1994) . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY - VICKERS (October 1994 to Present) . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORY VALVE ASSEMBLY (Hydraforce) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG) . . . . . . . . . . . . . . . . . . . . TURNTABLE, SWING DRIVE AND BEARING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . SWING MOTOR ASSEMBLY (Prior to August 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING MOTOR ASSEMBLY (August 1991 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING BRAKE ASSEMBLY (Prior to August 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE ASSEMBLY - AUSCO 37845 (August 1991 to Present) . . . . . . . . . . . . . . . . . . . . . . . . SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 VOLT GENERATOR INSTALLATION DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (Prior to February 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (February 1993 to February1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECISION GOVERNOR INSTALLATION - FORD LSG423 ENGINE MACHINES . . . . . . . . . 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES (Built Prior to February 1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORD LRG423 ENGINE INSTALLATION (February 1995 to Present). . . . . . . . . . . . . . . . . . . . 110 VOLT GENERATOR INSTALLATION - FORD LRG423 (Built February 1995 to Present) . . DUAL FUEL INSTALLATIONS (Optional on Ford Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN PUMP ASSEMBLY - GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTARY COUPLING AND COLLECTOR ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTS AND ALARMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOODS INSTALLATIONS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOODS INSTALLATIONS - NOISE REDUCTION PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 2-2 2-8 2-12 2-16 2-20 2-24 2-26 2-30 2-32 2-34 2-36 2-38 2-40 2-42 2-48 S E C T I O N 2 2-52 2-58 2-64 2-66 2-70 2-76 2-80 2-84 2-86 2-90 2-92 2-98 2-100 2-102 2-1 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATION S E C T I O N 2 T U R N T A B L E 2-2 3120806 SECTION 2 TURNTABLE . FIGURE 2-1. CONTROL VALVES INSTALLATION FIG & ITEM # PART NUMBER 0251410 0251546 0251411 0251547 1 4640554 4640914 2 3 4 5 6 7 8 0641708 4761700 0901616 3311601 4761600 4751600 4300034 Not Used Not Used 4640578 4640942 4640249 4640945 9 10 11 12 13 14 15 16 17 18 19 3120806 3311501 4761500 4751500 4300038 4640123 7006075 7012518 7000558 7004368 3311401 4761400 4751400 4640580 4640716 3311501 4761500 4751500 0641528 DESCRIPTION CONTROL VALVES INSTALLATION (WITHOUT ROTATE AND WITHOUT 4WS) CONTROL VALVES INSTALLATION (WITHOUT ROTATE AND WITH 4WS) CONTROL VALVES INSTALLATION (WITH ROTATE AND WITHOUT 4WS) CONTROL VALVES INSTALLATION (WITH ROTATE AND WITH 4WS) QTY. REV. Ref. D Ref. D Ref. D Ref. D Valve, Assembly - 4 Section (Vickers) (Prior to October 1994) (See Figure 2-2 for Breakdown) Valve, Assembly - 4 Section (Vickers) (October 1994 to Present) (See Figure 2-3 for Breakdown) Bolt 7/16”-14NC x 1” Lockwasher 7/16” Bracket Nut 3/8”-16NC Lockwasher 3/8” Flatwasher 3/8” Stud (Welded on Part) 1 3 Section Valve Assembly - Bang-Bang (2WS) (Prior to June 1995) (See Figure 2-4 for Breakdown) 3 Section Valve Assembly - Bang-Bang (2WS) (June 1995 to Present) (See Figure 2-5 for Breakdown) 2 Section Valve Assembly - Bang-Bang (4WS) (Prior to September 1995) (See Figure 2-4 for Breakdown) 2 Section Valve Assembly - Bang-Bang (4WS) (September 1995 to Present) (See Figure 2-5 for Breakdown) Nut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Stud (Welded on Part) Valve, Solenoid - Selector Seal Kit (FPS Version) Seal Kit (Hydraforce Version) Coil (FPS Version) Coil (Hydraforce Version) Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Accessory Valve Options: (See Figure 2-6 for Breakdown) Valve (Prior to September 1991) Valve (September 1991 to Present) Nut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Bolt 5/16”-18NC x 3 1/2” 1 S E C T I O N 2 1 3 3 1 2 2 2 2 T U R N T A B L E 1 1 1 4 4 4 4 1 1 1 1 1 2 2 2 1 4 2 2 2 2-3 SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 20 4640543 7009745 7004368 3311401 4761400 4751400 4300042 4640150 0641514 4761500 4640681 Valve, Solenoid (Upright Level Blocking Valve) Coil, Solenoid (Vickers/Modular Controls Version) Coil, Solenoid (Hydrafore Version) Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Stud (Welded on Part) Valve, Check Bolt 5/16”-18NC x 1 3/4” Lockwasher 5/16” 3 Section Valve Assembly - Bang-Bang (Without Rotator) (See Figure 2-7 for Breakdown) 4 Section Valve Assembly - Bang-Bang (With Rotator) (See Figure 2-7 for Breakdown) Bolt 3/8”-16NC x 1 1/4” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Valve, Solenoid Dump (Pump Volume) Coil (Vickers/Modular Controls Version) Coil (Hydraforce Version) Cartridge with Coil (Vickers/Modular Controls Version) Cartridge without Coil (Vickers/Modular Controls Version) Cartridge without Coil (Hydraforce Version) Cartridge, Check Valve (Modular Controls Version) Seal Kit (Hydraforce Version) Nut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Stud (Welded on Part) Valve, Pilot Operated Relief Seal Kit Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Stud (Welded on Part) Valve, Counterbalance Cartridge Valve (Requires Pressure Adjusted to 5000 PSI, 4000 PSI is Standard) Seal Kit Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Stud (Welded on Part) 1 1 1 4 2 4 2 1 2 2 1 S E C T I O N 21 22 23 24 25 26 27 2 4640680 T U R N T A B L E 28 29 30 31 32 0641610 4751600 4761600 3311601 4640360 7003647 7004368 7003634 7004289 33 34 35 36 37 38 39 40 41 42 43 2-4 7010635 7003635 7010637 3311501 4761500 4751500 4300033 4640603 2900770 3311401 4761400 4751400 4300042 4640626 4640634 2900770 3311401 4761400 4751400 4300042 REV. 1 4 4 4 4 1 1 1 1 1 1 1 1 4 2 4 2 1 1 2 2 2 2 1 1 1 2 2 2 2 3120806 SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0251233 44 45 4360171 2820022 4300106 4360280 0239585 46 47 48 3421565 3421565 1260017 3421627 0251240 0253167 49 50 51 52 53 4640005 2900062 0901732 3311601 4761600 4751600 4300034 1701428 1701494 1701426 1701463 1701462 1701778 0251415 54 55 56 57 58 59 60 61 62 63 3120806 3600179 7016673 2900779 0641609 4751600 4761600 3311601 7010652 1380136 3941003 4640603 2900770 0641414 DESCRIPTION 3° TILT INDICATOR INSTALLATION Sensor, Level - 5° Tubing, Vinyl Stud, Grooved Sensor, Level - 3° TURNTABLE LOCK INSTALLATION Pin, Snapper Pin, Quick Release Chain Pin, Lock QTY. REV. Ref. A 1 6 in. 2 1 Ref. B 1 2 9 in. 1 2 MANUAL DESCENT INSTALLATION - OPTIONAL (PRIOR TO SEPTEMBER 1992) MANUAL DESCENT INSTALLATION - OPTIONAL (SEPTEMBER 1992 TO PRESENT) Ref. B Ref. B Valve, Needle Valve, Kit Bracket Nut 3/8”-16NC Lockwasher 3/8” Flatwasher 3/8” Stud (Welded on Part) —————————— Nametag - 1 Nametag - 2 Nametag - 3 Nametag - 4 Nametag - 5 Nametag - 6 A/R 4 1 2 2 2 2 HAND PUMP INSTALLATION (USE WITH OPTIONAL MANUAL DESCENT) Ref. Pump, Manual with Handle (Includes Item 59) Pump, Manual - w/o Handle Seal Kit Bolt 3/8”-16NC x 1 1/8” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Handle, Pump Clip, Gripper Screw, Self-Tapping #10 Valve, Relief Seal Kit Bolt 1/4”-20NC X 1 3/4” S E C T I O N T U R N T A B L E 1 1 1 1 1 1 C 1 1 2 2 2 2 1 2 2 1 1 2-5 SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 64 65 66 4751400 4761400 3311401 S E C T I O N 0255504 67 4360386 2820022 4300106 DESCRIPTION Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC TILT INDICATOR INSTALLATION - 4WD BUILT AFTER JANUARY 1995 ONLY Sensor, Level - 8.5° Tubing, Vinyl Stud, Grooved QTY. REV. 1 1 1 Ref. A 1 6 in./15cm 2 2 T U R N T A B L E 2-6 3120806 SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES 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 3120806 2-7 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-2. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) 2 T U R N T A B L E 2-8 3120806 SECTION 2 TURNTABLE . FIGURE 2-2. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 4640554 CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) Ref. A 1 2 3 4 5 6 7 7006724 7006725 7006733 Kit Kit Kit 7006760 1 1 1 1 5 1 1 8 7009327 9 7009327 10 7006763 11 Use 7012325 & 7020361 Kit 7009316 7009315 7009319 Kit 7006744 7006726 7006727 7006728 7006729 7006730 7006731 7006745 Inlet Body Setscrew Plug O-Ring O-Ring O-Ring Working Section - Complete (Drive) (Includes Items 11-47) Working Section - Complete (Main Lift) (Includes Items 11-47) Working Section - Complete (Tower Lift) (Includes Items 11-47) Working Section - Complete (Swing) (Includes Items 11-47) Nut, Retaining (2 Per Section) (was p/n 7009317) O-Ring (2 Per Section) Core Tube (Includes O-Ring) (2 Per Section) Coil and Frame (2 Per Section) Pin (2 Per Section) O-Ring (2 Per Section) Spool (2 Per Section) Plug, Torque (2 Per Section) O-Ring (2 Per Section) Shim Kit (2 Per Section) Spring (2 Per Section) Poppet (2 Per Section) Ball (2 Per Section) Screw (8 Per Section) Cap, End (Not Sold Separately) (2 Per Section) Ball (2 Per Section) O-Ring (2 Per Section) Plug (2 Per Section) Gasket (2 Per Section) Spring (2 Per Section) Retainer (2 Per Section) Spool (Not Sold Separately) (1 Per Section) Seal (2 Per Section) Ring, Back-Up (2 Per Section) O-Ring (2 Per Section) Servo Stem Assembly (2 Per Section) Poppet (2 Per Section) Retainer (13/16”-2.11cm Length) (Design A) (1 Per Section) Retainer (1 3/16”-3cm Length) (Design B) (1 Per Section) Retainer (Design C) 8 8 8 8 8 8 8 8 8 8 8 8 32 8 8 8 8 8 8 8 4 8 8 8 8 8 4 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 7006746 Kit 7009323 7006748 7009324 7009325 7006757 Kit Kit 7009320 7006737 7009321 7009363 Not Required 3120806 S E C T I O N 2 1 1 T U R N T A B L E 1 8 4 0 2-9 SECTION 2 TURNTABLE FIGURE 2-2. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) (CONTINUED) FIG & ITEM # S E C T I O N 39 40 41 42 43 44 45 46 2 T U R N T A B L E 47 48 49 50 51 52 PART NUMBER DESCRIPTION QTY. Kit 7006752 Kit Kit 7006773 7006756 7009328 7006771 Kit 7006761 O-Ring (1 Per Section) Retainer (2 Per Section) Ring, Back-Up (2 Per Section) O-Ring (2 Per Section) Spring (2 Per Section) Poppet (Drive and Swing Sections) (2 Per Section) Poppet (Lift Sections) (2 Per Section) Plug, Torque (2 Per Section) O-Ring (2 Per Section) Ball (Design A - All Sections Except Swing) (2 Per Section) Ball (Design A - Swing Section) (4 Per Section) Ball (Design B - All Sections) (8 Per Section) Poppet (Design C - All Sections) (8 Per Section) Spring (Design C - All Sections) (4 Per Section) Pin, Solid (Design A - Swing Section Only) Pin, Solid (Design B and Design C) Cover, End Plug, Torque O-Ring Rod, Tie Nut —————————— Seal Kit (Includes Items 4, 5, 6, 12, 16, 27, 34, 35, 38, 40, 41, 45, 50 and Servo Stem O-Rings) Seal Kit - Valve Face (Includes Items 4, 5 and 6) 4 8 8 8 8 6 2 8 8 6 7006761 7006761 7009369 7009368 7006777 Not Required 7006780 7006778 Kit 7009329 7006782 7009330 7009395 2-10 REV. 4 8 8 4 1 0 1 1 1 3 6 4 5 3120806 SECTION 2 TURNTABLE FIGURE 2-2. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-11 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-3. CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT) 2 T U R N T A B L E 2-12 3120806 SECTION 2 TURNTABLE . FIGURE 2-3. CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM # PART NUMBER 4640914 1 2 3 4 5 6 7006724 7006733 Kit Kit Kit 7006725 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 Kit 7012319 Kit Kit Kit 7012322 Kit Kit 7006730 7012325 7012339 7009319 7012326 7012327 7006745 7006731 7006748 7006746 7009323 7012330 7012329 7012328 7009324 7009320 7006737 7006757 Not Used 7006773 Kit Kit 7009398 Kit Kit 7012333 Kit Kit Kit Kit 3120806 DESCRIPTION VICKERS VALVE ASSEMBLY - 4 SECTION INLET SECTION Inlet Body Plug O-Ring O-Ring O-Ring Setscrew WORKING SECTIONS (STANDARD PARTS) Cap (2 Per Section) Screw (2 Per Section) Nut (2 Per Section) Plug (2 Per Section) Packing (2 Per Section) Packing (2 Per Section) Piston (2 Per Section) Spring (2 Per Section) Poppet (2 Per Section) Nut, Retaining (2 Per Section) Coil (2 Per Section) Pin (2 Per Section) Core Tube Sub Assembly (2 Per Section) Spool Screw (8 Per Section) Ball Gasket Ball Plug (2 Per Section) Shim (A/R Per Section) Retainer (2 Per Section) Shim (A/R Per Section) Spring (2 Per Section) Stem Servo Sub Assembly (2 Per Section) Poppet (2 Per Section) Seat (2 Per Section) Spring (2 Per Section) O-Ring (2 Per Section) Back-up (2 Per Section) Retainer (2 Per Section) Back-up Ring (2 Per Section) O-Ring (2 Per Section) Load Sense (2 Per Section) O-Ring (2 Per Section) O-Ring (2 Per Section) O-Ring (5 Per Section) O-Ring (2 Per Section) QTY. REV. Ref. Ref. 1 1 1 1 1 1 Ref. A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R S E C T I O N 2 T U R N T A B L E A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R 2-13 SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 138 Not Serviced Cap, End (2 Per Section) —————————— Seal Kit (1 Per Section) Piston/Spring Kit (Includes Items 1 ea. of Items 100, 102, 103, 106 and 107) (2 Per Section) A/R S E C T I O N 7009330 7012383 150 Ref. #2 WORKING SECTION OPTIONS: Lift (All Models) Spool Poppet Ref. 151 152 153 #3 WORKING SECTION OPTIONS: Swing (“H” and “HX” Models Without Prop. Tele.) Spool Poppet Piston Telescope (“H” and “HX” Models With Prop. Tele.) Lift (“HA” Models) Spool Poppet Piston Ref. 7012335 7012340 7009399 7012300 7012334 7012334 7012331 7009397 7012300 201 202 203 204 205 206 207 208 7006782 7009361 7012337 Kit 7006778 7012338 Kit 7012336 OUTLET SECTION Nut Rod, Tie Cover End O-Ring Plug Setscrew Orifice Sub-Assembly O-Ring Plug Ref. 6 3 1 2 2 1 1 1 151 152 153 2 150 T U R N T A B L E 151 152 153 150 151 152 153 150 2-14 A/R A/R #1 WORKING SECTION OPTIONS: Drive (All Models) Spool Poppet 7012332 7012331 7009399 Not Required 7012334 7012331 7009397 Not Required REV. 1 2 1 2 1 2 2 Ref. Ref. 1 2 2 3120806 SECTION 2 TURNTABLE FIGURE 2-3. CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-15 SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG S E C T I O N 2 T U R N T A B L E 2-16 3120806 SECTION 2 TURNTABLE . FIGURE 2-4. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG FIG & ITEM # PART NUMBER 4640578 4640249 1 7002304 2 7004823 Kit 7002229 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7004822 Kit 7002346 7004839 7004838 7004841 Kit 7002340 Kit 7004834 7002334 7004835 7000417 7004836 7002338 7004837 7002322 Kit 24 25 26 27 7002321 7002328 7002294 7002320 Kit 7002329 7002323 Kit 7002326 7002324 7004894 7004859 28 7002315 29 30 31 32 7004859 7003825 7002348 7002305 22 23 3120806 DESCRIPTION CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (PRIOR TO JUNE 1995) CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG (4WS) (PRIOR TO SEPTEMBER 1995) (NOT SHOWN) Dump Section - Complete Solenoid Assembly Seat O-Ring Ball Guide Tube Assembly Cone, Female O-Ring Pin, Push Plunger Tube, Guide Pin, Push O-Ring Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Screw Seat O-Ring Main Relief (Poppet) Valve Case, Poppet Spring Poppet Seat, Adjustable O-Ring Spring Plug O-Ring Orifice Plug Working Section - Complete (Tower Tele) Solenoid Assembly (Refer to Items 30-45 for Serviced Parts) Working Section - Complete (Steer) (3 Section Valve Only) Solenoid Assembly Washer, Hat (2 Per Section) Spring (2 Per Section) Guide Tube Assembly (2 Per Section) QTY. REV. Ref. Ref. B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 S E C T I O N 2 T U R N T A B L E 1 2 4 4 4 2-17 SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 33 39 40 41 42 43 44 45 46 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002339 7000468 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 47 48 2220237 2220238 Cone, Female (2 Per Section) O-Ring O-Ring Pin, Push (2 Per Section) Plunger (2 Per Section) Tube, Guide (2 Per Section) Pin, Actuator (2 Per Section) Ring, Quad (2 Per Section) Guide, External Push Pin (2 Per Section) O-Ring (2 Per Section) Sleeve, Inner Flux (2 Per Section) Spring (2 Per Section) Sleeve, Outer Flux (2 Per Section) Coil (2 Per Section) Case, Solenoid (2 Per Section) Plate, End (2 Per Section) Screw (4 Per Section) Relief Valve Block Assembly (No Longer Field Serviceable) Plug Plug —————————— Seal Kit - Working Section Seal Kit - Dump Section S E C T I O N 34 35 36 37 38 2 T U R N T A B L E 7000414 7000413 2-18 REV. 1 1 2 1 3120806 SECTION 2 TURNTABLE FIGURE 2-4. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (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 3120806 2-19 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (JUNE 1995 TO PRESENT) 2 T U R N T A B L E 2-20 3120806 SECTION 2 TURNTABLE . FIGURE 2-5. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (JUNE 1995 TO PRESENT) FIG & ITEM # PART NUMBER 4640942 4640945 DESCRIPTION CONTROL VALVE ASSEMBLY - 3 SECTION BANGBANG (2WS) (JUNE 1995 TO PRESENT) CONTROL VALVE ASSEMBLY - 2 SECTION BANG-BANG (4WS) (SEPTEMBER 1995 TO PRESENT) (NOT SHOWN) DUMP SECTION ASSEMBLY 1 2 3 4 7002447 7002448 7002449 7002450 7002451 7011118 7000448 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 7004859 7003825 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002327 7002339 7000414 7004600 3120806 Dump Section - Complete Cartridge Seal Kit - 7002448 Cartridge Coil Cartridge Without Coil Seal Kit - 7002451 Cartridge —————————— O-Ring (Between Sections) WORKING SECTIONS (STANDARD PARTS) Solenoid Assembly Washer Spring Guide Tube Assembly Cone, Female O-Ring O-Ring Pin, Push Plunger Tube, Guide Pin, Actuator Ring, Quad Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring Sleeve, Outer Flux Coil Case, Solenoid Plate, End Nameplate Screw —————————— Seal Kit - Working Section (1 Per Section) Stacking Kit QTY. REV. Ref. - Ref. - Ref. 1 1 1 1 1 1 S E C T I O N 2 T U R N T A B L E 2 Ref. 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 2-21 SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (JUNE 1995 TO PRESENT) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER DESCRIPTION WORKING SECTIONS - COMPLETE (INCLUDES ITEMS 101-117) 151 152 7002315 7000468 153 7004894 Steer Section Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) Tower Tele Section QTY. REV. Ref. 1 1 1 2 T U R N T A B L E 2-22 3120806 SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG (2WS) (JUNE 1995 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-23 SECTION 2 TURNTABLE FIGURE 2-6. ACCESSORY VALVE ASSEMBLY S E C T I O N 2 T U R N T A B L E 2-24 3120806 SECTION 2 TURNTABLE . FIGURE 2-6. ACCESSORY VALVE ASSEMBLY FIG & ITEM # 1 2 3 4 5 PART NUMBER DESCRIPTION QTY. REV. 4640580 ACCESSORY VALVE ASSEMBLY (MACHINES BUILT PRIOR TO SEPTEMBER 1991) Note: Not sold as a complete assembly. Ref. - 7004365 7004366 7004367 7004369 7004368 Seal Kit (Sequence and Pressure Reducing) Seal Kit (Main Relief) Seal Kit (Dump) 4640716 ACCESSORY VALVE ASSEMBLY (MACHINES BUILT SEPTEMBER 1991 TO PRESENT) Note: Refer to P/N stamped on cartridge hex nut for Identification. Ref. Cartridge - Sequence (Hydraforce PS10-34A) Cartridge - Sequence (Vickers/Modular Controls PSV7-10V) Cartridge - Pressure Reducing (Hydraforce PR10-32A) Cartridge - Pressure Reducing (Vickers/Modular Controls PRV1-10V) Cartridge - Main Relief (Hydraforce RV50-26A) Cartridge - Main Relief (Vickers/Modular Controls RV5-10V) Cartridge - Dump (Hydraforce SV16-21) Cartridge - Dump (Vickers/Modular Controls SV3-16V) Coil (Hydraforce 6352012) Coil (Vickers/Modular Controls 565966) —————————— Seal Kit (Sequence) (Hydraforce Version) Seal Kit (Sequence) (Vickers/Modular Controls Version) Seal Kit (Pressure Reducing) (Hydraforce Version) Seal Kit (Pressure Reducing) (Vickers/Modular Controls Version) Seal Kit (Main Relief) (Hydraforce Version) Seal Kit (Main Relief) (Vickers/Modular Controls Version) Seal Kit (Dump) (Hydraforce Version) Seal Kit (Dump) (Vickers/Modular Controls Version) 1 1 7012506 7010552 102 7012505 7010553 103 7012507 7010554 104 7004369 7010556 7004368 7009745 7012509 7010557 7012510 7010558 7012511 7010559 2900709 7010560 3120806 1 1 1 1 1 2900707 2900708 2900709 101 105 Cartridge - Sequence Cartridge - Pressure Reducing Cartridge - Main Relief Cartridge Less Coil - Dump Coil Ref. 2 1 1 S E C T I O N 2 T U R N T A B L E - Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2-25 SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG S E C T I O N 2 T U R N T A B L E 2-26 3120806 SECTION 2 TURNTABLE . FIGURE 2-7. CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG FIG & ITEM # PART NUMBER 4640680 4640681 1 2 3 4 7002317 7002347 7000448 7004859 5 Not Used 7002316 7002347 7000448 7004859 6 7002262 7002325 7 8 7002316 7002347 7000448 7004859 9 7002262 7002325 10 11 12 13 14 15 16 17 18 19 20 21 22 3120806 7002315 7002347 7000448 7004859 7003825 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 DESCRIPTION CONTROL VALVE ASSEMBLY - 4 SECTION BANG-BANG CONTROL VALVE ASSEMBLY - 3 SECTION BANG-BANG QTY. REV. Ref. B Ref. A Working Section - Complete (Rotate) (4 Section Only) Ring, Quad (Located Between Sections 1 ea.) Ring, Quad (Located Between Sections 1 ea.) Solenoid Assembly (Refer to Items 12-27 for Serviced Parts) 1 A/R A/R 2 Working Section - Complete (Platform Level) Ring, Quad (Located Between Sections 1 ea.) Ring, Quad (Located Between Sections 1 ea.) Solenoid Assembly (Refer to Items 12-27 Serviced Parts) Dual Pilot Check Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) O-Ring (Located Between Dual Pilot Check Valve Assembly & Working Section 2 ea.) Working Section - Complete (Upright Level) Ring, Quad (Located Between Sections 1 ea.) Ring, Quad (Located Between Sections 1 ea.) Solenoid Assembly (Refer to Items 12-27 for Serviced Parts) Dual Pilot Check Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) O-Ring (Located Between Dual Pilot Check Valve Assembly & Working Section 2 ea.) Working Section - Complete (Main Tele) Ring, Quad (Located Between Sections 1 ea.) Ring, Quad (Located Between Sections 1 ea.) Solenoid Assembly (Refer to Items 12-27 for Serviced Parts) Washer Spring Guide Tube Assembly Cone, Female O-Ring O-Ring Pin, Push Plunger Tube, Guide Pin, Actuator Ring, Quad Guide, External Push Pin O-Ring Sleeve, Inner Flux Spring 1 A/R A/R 1 S E C T I O N 2 T U R N T A B L E 1 1 A/R A/R 2 1 1 A/R A/R 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2-27 SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 23 24 25 26 27 28 7002336 7000418 7002335 7002338 7002339 7000468 Sleeve, Outer Flux Coil Case, Solenoid Plate, End Screw Crossover Relief Valve Assembly (Due to various suppliers, internal components are no longer field serviceable) O-Ring (Located Between Crossover Relief Valve Assembly & Working Section 2 ea.) —————————— Seal Kit - Working Section 1 1 1 1 4 1 S E C T I O N 7002325 7000414 2 REV. 4 T U R N T A B L E 2-28 3120806 SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - 3 AND 4 SECTION BANG-BANG (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 3120806 2-29 SECTION 2 TURNTABLE FIGURE 2-8. TURNTABLE, SWING DRIVE AND BEARING INSTALLATIONS S E C T I O N 2 T U R N T A B L E 2-30 3120806 SECTION 2 TURNTABLE . FIGURE 2-8. TURNTABLE, SWING DRIVE AND BEARING INSTALLATIONS FIG & ITEM # PART NUMBER 0250315 1 3160156 3160181 2 3 4 0681836 4740171 0100009 0920068 0920086 5 2780055 6 0641912 0100019 2440022 2440059 0741606 3501916 4740367 0100019 7 8 9 0239725 10 Use 2915092 11 12 13 0681820 4740003 0682032 0682028 4740004 4740048 3300183 0100019 0100004 2160001 14 15 16 DESCRIPTION QTY. REV. SWING DRIVE INSTALLATION Ref. D Swing Motor Assembly (Prior to August 1991) (See Figure 2-9 for Breakdown) Swing Motor Assembly (August 1991 to Present) (See Figure 2-10 for Breakdown) Note: When replacing complete motor recommend using p/n 3160181 motor. Bolt 1/2”-13NC x 4 1/2” (Grade 8) Washer, Hardened Sealant Swing Brake Assembly (Prior to August 1991) (See Figure 2-11 for Breakdown) Swing Brake Assembly (August 1991 to Present) (See Figure 2-12 for Breakdown) Swing Hub Assembly (See Figure 2-13 for Breakdown) Bolt 9/16”-12NC x 1 1/2” Loctite #271 Gear, Pinion (0239488 Installation) Gear, Pinion (0250315 Installation) Screw, Flat Head 3/8”-16NC x 3/4” Plate, Retaining (0239488 Installation) Plate, Retaining (0250315 Installation) Loctite TURNTABLE BEARING INSTALLAITON Bearing Kit (was p/n 0440055) (Kit Includes Bearing & Mounting Hardware) Bolt 1/2”-13NC x 2 1/2” (Grade 8) Washer, Hardened Bolt 5/8”-11NC x 4” (Grade 8) Bolt 5/8”-11NC x 3 1/2” (Grade 8) Washer, Hardened Washer, Special Nut 5/8”-11NC (Grade 8) Loctite #271 Devcon Fitting, Grease TURNTABLE WELDMENTS 4620047 4620091 3120806 Turntable (Prior to February 1993) Turntable (February 1993 to Present with Noise Reduction Package) 1 1 Ref. 2 2 A/R 1 2 1 1 9 A/R 1 1 2 1 1 A/R Ref. S E C T I O N E 1 24 24 20 3 16 7 23 A/R A/R 1 Ref. 1 1 2-31 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-9. SWING MOTOR ASSEMBLY (PRIOR TO AUGUST 1991) S E C T I O N 2 T U R N T A B L E 2-32 3120806 SECTION 2 TURNTABLE . FIGURE 2-9. SWING MOTOR ASSEMBLY (PRIOR TO AUGUST 1991) FIG & ITEM # PART NUMBER 3160156 1 2 3 4 5 6 7 8 9 10 11 12 13 Kit Kit Kit 7004166 7004167 7004193 7004191 Kit 7004171 7004173 7004194 7004195 7004192 7004177 3120806 DESCRIPTION SWING MOTOR ASSEMBLY (PRIOR TO AUGUST 1991) Seal, Dust Ring, Back-Up Seal, Quad Ring Valve, Rotary Ball, Check Valve IGR Assembly Ring, Snap (Standard) Seal, Ring Plug, Vent (Includes O-Ring) Bolt Shaft, Spline Body/Bearing Assembly Cover/Bearing Assembly ————————— Seal Kit (Includes Items 1,2,3,8 and Vent Plug O-Ring) QTY. REV. Ref. — 1 1 1 1 2 1 1 2 1 8 1 1 1 S E C T I O N 2 T U R N T A B L E 1 2-33 SECTION 2 TURNTABLE FIGURE 2-10. SWING MOTOR ASSEMBLY (AUGUST 1991 TO PRESENT) S E C T I O N 2 T U R N T A B L E 2-34 3120806 SECTION 2 TURNTABLE FIGURE 2-10. SWING MOTOR ASSEMBLY (AUGUST 1991 TO PRESENT) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART NUMBER DESCRIPTION QTY. REV. 3160181 SWING MOTOR ASSEMBLY (AUGUST 1991 TO PRESENT) Ref. A Kit 7010775 Kit 7004196 7004167 7004193 Kit Kit 7004171 7010777 7010779 7010778 7004192 Kit 7010776 2900798 3120806 Seal, Dust Ring, Back-Up Seal, Quad Ring Valve, Rotary Ball, Check Valve IGR Assembly Ring, Snap Seal, Ring Plug, Vent (Includes O-Ring) Bolt Shaft, Spline Body/Bearing Assembly Cover/Bearing Assembly Ring, Snap Plate, Commutator —————————— Seal Kit (Includes Items 1,2,3,7 and 8) 1 1 1 1 2 1 1 3 1 8 1 1 1 1 1 S E C T I O N 2 T U R N T A B L E 1 2-35 SECTION 2 TURNTABLE FIGURE 2-11. BRAKE ASSEMBLY (PRIOR TO AUGUST 1991) S E C T I O N 2 T U R N T A B L E 2-36 3120806 SECTION 2 TURNTABLE . FIGURE 2-11. BRAKE ASSEMBLY (PRIOR TO AUGUST 1991) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NUMBER QTY. REV. 0920068 BRAKE ASSEMBLY (PRIOR TO AUGUST 1991) Ref. - 7003067 7000782 7000798 7003060 7003061 7003062 7000718 7000732 7003006 7003063 7003064 Kit Kit Kit Kit 7000796 7003065 7000728 7000729 7003066 Kit Housing Spring, Compression Spring, Compression Ring, Retaining Shaft, Splined Pin, Torque Disc, Primary Disc, Rotating Spring, Compression Disc, Stationary Piston Ring, Back-Up O-Ring Ring, Back-Up O-Ring Bleeder Plate, Power Plug Lockwasher Bolt Gasket —————————— Seal Kit (Includes Items 12, 13, 14, 15 and 21) 1 7 7 2 1 2 1 2 4 1 1 1 1 1 1 1 1 1 4 4 2 2900649 3120806 DESCRIPTION S E C T I O N 2 T U R N T A B L E 1 2-37 SECTION 2 TURNTABLE FIGURE 2-12. BRAKE ASSEMBLY - AUSCO 37845 (AUGUST 1991 TO PRESENT) S E C T I O N 2 T U R N T A B L E 2-38 3120806 SECTION 2 TURNTABLE . FIGURE 2-12. BRAKE ASSEMBLY - AUSCO 37845 (AUGUST 1991 TO PRESENT) FIG & ITEM # PART NUMBER 0920086 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7003092 Kit 7003049 7003050 7003051 7003052 7003093 7003094 7003054 7003006 7003055 7003056 7003095 Kit Kit Kit Kit 7000760 7000796 7003096 7003007 7003059 N.S. Kit 2900662 7003069 3120806 DESCRIPTION BRAKE ASSEMBLY - AUSCO 37845 (AUGUST 1991 TO PRESENT) Housing Gasket Ball Bearing Oil Seal Spring Retainer Compression Spring Shaft Torque Pin Primary Disc Compression Spring Rotating Disc Stationary Disc Piston Backup Ring O-Ring Backup Ring O-Ring Ball Bearing Bleeder Screw Power Plate Hex Screw Pressure Relief Valve Plug, Shipping Gasket —————————— O-Ring Kit (Includes Items 2, 14-17 and 24) Gasket Kit (Includes Item 24) QTY. REV. Ref. A 1 1 1 1 1 12 1 2 1 2 1 1 1 1 1 1 1 1 1 1 4 1 1 2 S E C T I O N 2 T U R N T A B L E 1 1 2-39 SECTION 2 TURNTABLE FIGURE 2-13. SWING HUB ASSEMBLY S E C T I O N 2 T U R N T A B L E 2-40 3120806 SECTION 2 TURNTABLE . FIGURE 2-13. SWING HUB ASSEMBLY FIG & ITEM # PART NUMBER 2780055 1 2 3 4 5 6 7 8 9 7000209 7000217 7000214 4751500 7000242 Kit 7000208 7000253 7000207 10 11 12 13 7000270 7000268 7000269 7000246 7000271 Kit Kit 7000258 7000257 7000210 7000242 7000255 7000256 Kit 7000233 14 15 16 17 18 19 20 21 22 23 2900034 3120806 DESCRIPTION SWING HUB ASSEMBLY Cover Bolt, Hex Head Bolt, Hex Head, Shoulder Flatwasher Plug, Pipe O-Ring Gear, Ring Washer, Thrust Planet Carrier Assembly (No Service Breakdown Parts Purchase Entire Assembly) Washer, Thrust Gear, Sun-Input Spacer, Sun Gear Gear, Internal Hub Assembly Ring, Retaining Spacer Bearing, Tapered Roller Cup, Bearing Hub Plug, Pipe Cup, Bearing Bearing, Tapered Roller Seal Shaft, Output —————————— Kit, Repair (Includes Items 6, 14,15 and 22) QTY. REV. Ref. — 1 8 4 12 1 2 1 2 1 S E C T I O N 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 T U R N T A B L E 1 2-41 SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ ENGINE INSTALLATION S E C T I O N 2 T U R N T A B L E 2-42 3120806 SECTION 2 TURNTABLE . FIGURE 2-14. DEUTZ ENGINE INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0250037 DEUTZ ENGINE INSTALLATION - F3L-1011 (WITHOUT NOISE REDUCTION PACKAGE/PRIOR TO OCTOBER 1991) DEUTZ ENGINE INSTALLATION - F3L-1011 (WITH NOISE REDUCTION/OCTOBER 1991 TO PRESENT) Ref. F Ref. E Engine Deutz - F3L-1011 Diesel Options: Prior to August 1995 August 1995 to Present Bolt 1/2”-13NC x 45 1/2” Lockwasher 1/2” Adapter —————————— Coupling Installation - Lovejoy (Design A) Coupling Installation - Hayes (Design B) Coupling, Lovejoy (Design A) Hub, Coupling (Lovejoy) Disc, Coupling (Lovejoy) Bolt, Metric 8MM x 25MM Lockwasher, Metric 8MM Coupling, Hayes (Design B) Bolt, Metric 8MM x 20MM Lockwasher, Metric 8MM Plate, Adapter Bolt, Metric 10MM x 30MM Lockwasher, Metric 10MM —————————— Pump Assembly (See Figure 2-25 for Breakdown) Bolt 1/2”-13NC x 1 1/4” Lockwasher 1/2” Adapter, Throttle (Prior to September 1995) Adapter, Throttle (September 1995 to Present) Setscrew #10-24NC x 3/8” (Prior to September 1995) Bracket, Throttle (September 1995 to Present) Pin, Cotter 1/16” x 1/2” Flatwasher 1/4” (September 1995 to Present) Bolt 6mm x 10mm (September 1995 to Present) Scoop, Intake (Prior to March 1995) Scoop, Intake (March 1995 to Present) Clamp (Prior to March 1995 Only) Seal Adapter, Air Intake Bolt 5/16”-18NC x 1 1/4” Lockwasher 5/16” Nut 5/16”-18NC Gasket, Adapter Hose, Air Intake (0252297 Installation Only) Clamp, Hose 1 0252297 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3120806 2000107 2000138 0641844 4761800 0080174 0250125 0250597 1660169 1660172 1660173 0700812 4831900 1660184 0700810 4831900 0080163 0701014 4832000 3600139 0641810 4761800 0080172 4460302 3951003 0902244 3450202 4711400 0700605 1840004 1840010 1320059 3960389 0080177 0641510 4761500 3311501 3960407 2720334 1320031 4 4 4 1 1 1 1 1 6 6 1 6 6 1 8 8 S E C T I O N 2 - T U R N T A B L E 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 3 3 3 1 1 4 2-43 SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 24 2720178 2720351 4564493 0080039 1340020 7004214 0340002 0641406 4751400 3311405 1120161 2720058 2720271 1320022 2200805 2220273 2180536 2220273 4420001 2420110 Hose, Rubber (0250037 Installation) Hose, Rubber (0252297 Installation) Tube, Air Intake (0250037 Installation Only) Elbow (0250037 Installation Only) Air Cleaner Assembly Element Band, Mounting Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4”-20NC Cap, Inlet (0250037 Installation Only) Hose, Fuel Line (Supply) Hose, Fuel Line (Return) Clamp, Hose Fitting, 90° Barbed (Fuel Supply) Fitting, Reducer (Fuel Supply) Fitting, Barbed (Fuel Return) Fitting, Reducer (Fuel Return) Tape, Sealant Sender, Oil Pressure (See end of this parts list for options) Fitting, Straight Connector Fitting, Straight Fitting, Nipple Tailpipe (Standard - 0250037 Installation) Tailpipe (Standard - 0252297 Installation) Tube, Exhaust (Standard - 0252297 Installation) Sleeve, Fiberglass (Standard - 0252297 Installation) Tube, Exhaust (With Spark Arrestor) Tailpipe (With Spark Arrestor) Muffler (Standard - Not Shown) Arrestor, Spark (Optional - Not Shown) Clamp, Muffler Snorkel, Exhaust Bolt 1/4”-20NC x 3/4” Lockwasher 1/4” Locknut 1/4”-20NC Bracket, Muffler (Standard) Bracket, Muffler (With Spark Arrestor Only) Clamp, Muffler Cable, Battery (Starter to Start Relay) Cable, Battery (Start Relay to Aux. Relay) Cable, Battery (Aux. Relay to Aux. Pump) Cable, Battery (Positive - Battery to Aux. Relay) Cable, Battery (Negative - Battery to Ground) Cable, Battery (Engine to Ground) Nut 3/8”-16NC Lockwasher 3/8” Stud (Welded on Part) Battery 1 1 1 1 1 1 2 4 4 4 1 10 ft. 10 ft. 4 1 1 1 1 A/R 1 S E C T I O N 25 26 27 28 29 30 31 32 33 34 2 T U R N T A B L E 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 2-44 2180730 2200261 2180104 4564413 4565278 4565988 4100025 4565162 4565163 7000694 3220036 1320019 4843372 0641406 4761400 3311405 0901705 0901759 1320176 1060099 1060092 1060129 1060074 1060172 1060045 3311601 4761600 4300034 0400075 REV. 1 1 1 1 1 1 2 ft/.6m 1 1 1 1 2 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 3120806 SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 52 53 54 3980007 0361810 0236768 3841026 4711600 3300029 3600141 55 56 57 7004290 7004291 7004249 3600071 58 59 60 61 62 63 64 65 66 67 68 69 70 71 7004248 7004436 7004247 7004249 7012576 0641608 4761600 4711600 0901307 3311601 4761600 4711601 4300034 4844312 3311405 4751400 2820060 0901800 1120405 4640751 2750532 1320022 0250233/ 1281186 2901111 0700808 4761500 3311401 4761400 4300031 2580001 3120806 DESCRIPTION Seat, Masonite Holddown, Battery Rod, Tie-Down (10”) Rod, Tie-Down (11”) Flatwasher 3/8” Narrow Wingnut Auxiliary Pump Assembly - John S. Barnes (Prior to October 1990) Motor Pump Coupling Auxiliary Pump Assembly - John S. Barnes, Motor (Alt. Haldex Barnes, Inc.) (October 1990 to Present) Motor Motor with Mounting Bracket Pump Coupling Bracket Bolt 3/8”-16NC x 1” Lockwasher 3/8” Flatwasher 3/8” Narrow Bracket, Auxiliary Pump Nut 3/8”-16NC Lockwasher 3/8” Flatwasher 3/8” Narrow Stud (Welded on Parts) Box, Intake (0252297 Installation Only) Lockout 1/4”-20NC (0252297 Installation Only) Flatwasher 1/4” (0252297 Installation Only) Foam, Acoustical (0252297 Installation Only) Bracket, Air Cleaner (0252297 Installation Only) Rain Cap (0252297 Installation Only) Valve, Oil Drain (0252297 Installation Only) Hose, Drain (0252297 Installation Only) Clamp (0252297 Installation Only) COLD WEATHER PACKAGE INSTALLATION (OPTIONAL - NOT SHOWN) Kit, Cold Weather Start Bolt, Metric M8 x 16 Grade 8.8 Lockwasher 5/16” Nut 1/4”-20NC Lockwasher 1/4” Stud (Welded on Part) —————————— Heater, Battery QTY. REV. S E C T I O N 1 1 2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 2 2 2 1 2 2 2 2 1 10 A/R 1 1 1 1 6 in/15cm 1 Ref. T U R N T A B L E B/F 1 1 1 4 4 4 1 2-45 SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # S E C T I O N PART NUMBER DESCRIPTION QTY. REV. 0251682 ENGINE SHUTDOWN INSTALLATION (NOT SHOWN) Note: The following Items located at Item 36. Switch, Pressure Fitting, 90° Fitting, Nipple Fitting, Tee Relay (Located in Ground Control Box - Not Shown) Ref. Ref. 1 1 1 1 1 - ENGINE PRESSURE SWITCH INSTALLATION (USE WITH 110V GENERATOR OPTION - NOT SHOWN) Note: The following items located at Item 36 Switch, Pressure Fitting, Connector (Prior to S/N 23615) Fitting, Tee (Prior to S/N 23615) Fitting Options: Fitting, Brass Nipple (Prior to S/N 23615) Fitting, Adapter (S/N 23615 to Present) Fitting, 45° Ref. L 4360065 2220318 2180643 2180360 3740049 0250229 2 4360037 2200261 2180360 T U R N T A B L E 2180537 2180730 2180749 2000107 7020457 Use 7020023 7014502 7020471 7020424 70003622 7020455 7012698 7020477 7016308 7027250 7012626 7027210 Use 7019607 Use 7019607 7014684 7016309 2000138 7020417 70000851 7020024 7020435 7000699 2-46 ENGINE COMPONENTS Deutz F3L1011 Engine Alternator Filter, Fuel (was p/n 7012598) Filter, OIl (Case of 12) Gasket Options: Exhaust Manifold Injector Tip Injector Muffler Pump, Fuel Ring, Gear (Flywheel) Ring, Plastic Air Intake Spring, Tension (Actuator) Starter Switch, Oil Temp Sender Switch, Solenoid (was p/n 7016341) Shutdown Device (was p/n 7016359) Tune-up Kit (Includes fuel line and oil plug washers, oil and fuel filters, valve cover and injector tip gaskets) Washer, Copper Sealing Deutz F3L1011F Engine Alternator Bracket, Alternator Mounting Breather Cap (Crankcase) Dipstick Exhaust Seal (Doughnut) Ref. 1 1 1 1 1 Ref. Ref. 1 1 1 3 3 3 1 1 1 1 1 1 1 1 2 1 1 Ref. 1 1 1 1 1 3120806 SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 7016331 7020412 8320270 7020023 7020471 7020411 7020424 7020430 7020220 7020419 7020426 7020455 7020425 7019607 7012599 7020463 7024579 7020208 7020477 7020406 7016359 7027250 7016332 7020479 7020168 7020414 0251537 2180360 2180749 4360065 3120806 DESCRIPTION Filter, OIl Fitting, Tee Fuel, Filter (Thumbscrew Mounted) Fuel, Filter (Spin-On) Gasket Options: Exhaust Manifold Lift Pump Injector Tip Valve Cover Harness Hose, Fuel Return Injector Muffler Nozzle, Injector Throttle Shutdown Pump, Fuel Injector Pump, Fuel Supply Ring, Gear (Flywheel) (110 Teeth) Ring, Gear (Flywheel) (129 Teeth) Ring, Gear (Flywheel) (133 Teeth) Ring, Sealing Shutdown Device Spring, Tension (Actuator) Starter (11 Teeth) Starter (9 Teeth) Switch, Oil Pressure Sender V-Belt ENGINE DISTRESS INSTALLATION (OPTIONAL NOT SHOWN) Note: The following Items located at Item 36. Fitting, Tee Fitting, 45° Switch, Pressure QTY. REV. S E C T I O N 1 1 1 1 3 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 Ref. 2 T U R N T A B L E D Ref. 1 1 1 2-47 SECTION 2 TURNTABLE FIGURE 2-15. 110 VOLT GENERATOR INSTALLATION - DEUTZ S E C T I O N 2 T U R N T A B L E 2-48 3120806 SECTION 2 TURNTABLE . FIGURE 2-15. 110 VOLT GENERATOR INSTALLATION - DEUTZ FIG & ITEM # PART NUMBER 0250229 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3120806 2460011 7012558 7020109 7020108 7012513 7012514 7020190 7020110 7020111 7020193 7003657 2420203 4360542 4460190 4460027 2920162 7020191 3520028 0681610 4761600 4751600 0361815 0681510 4761500 4751500 4843410 0701012 4812000 0100011 0701414 0480059 3580134 2860012 3580158 See Item 1 0641406 4751400 4761400 3311401 0901633 3311401 4761400 DESCRIPTION 110 VOLT GENERATOR INSTALLATION (DEUTZ) Generator Assembly with Control Box Generator Assembly Holder, Brush Brush Cap, Brush Holder Fan Bearing End Bell, Front End Bell, Rear Cord, Power Control Box Assembly Note: Replacement 110V Control Box comes with 2 std receptacles p/n 4460190. Optional Twist Lock receptacles p/n 4460027 must be ordered separately. Meter (was p/n 7010699) Breaker, Circuit (was p/n 7020194) Receptacle, Double (110V Box) Receptacle, Double Twist Lock (110V Box) Lamp Switch, Toggle Plug, Hole Bolt 3/8"-16NC x 1 1/4" (Grade 8) Lockwasher 3/8" Flatwasher 3/8" Arm, Adjustable Bolt 5/16"-18NC x 1 1/4" (Grade 8) Lockwasher 5/16" Flatwasher 5/16" Bracket, Mounting - Generator Bolt, Metric 10MM x 25M Flatwasher, Metric 10MM Loctite Bolt, Metric 14MM x 30MM V-Belt Pulley (Included with Item #2) Key Pulley Box, Control Bolt 1/4"-20NC x 3/4" Flatwasher 1/4" Lockwasher 1/4" Nut 1/4"-20NC Bracket, Mounting - Box Nut 1/4"-20NC Lockwasher 1/4" QTY. REV. Ref. L 1 1 4 4 4 1 2 1 1 1 1 Ref. S E C T I O N 2 T U R N T A B L E 1 1 1 1 1 1 1 2 2 2 1 2 2 2 1 2 2 A/R 1 1 1 1 1 1 2 2 2 2 1 2 2 2-49 SECTION 2 TURNTABLE FIGURE 2-15. 110 VOLT GENERATOR INSTALLATION - DEUTZ (CONTINUED) FIG & ITEM # PART NUMBER 25 4751400 4300068 3251476 4460023 1060012 S E C T I O N 26 27 28 DESCRIPTION Flatwasher 1/4" Stud (Welded on Part)) Decal - Generator Terminal Cable - 12/4 QTY. REV. 2 2 1 1 A/R 2 T U R N T A B L E 2-50 3120806 SECTION 2 TURNTABLE FIGURE 2-15. 110 VOLT GENERATOR INSTALLATION - DEUTZ (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-51 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) 2 T U R N T A B L E 2-52 3120806 SECTION 2 TURNTABLE . FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0250278 FORD ENGINE INSTALLATION - LSG-423 (STANDARD) FORD ENGINE INSTALLATION - LSG-423 (DUAL FUEL) Ref. F Ref. H Engine (Ford LSG-423) Engine Mount, Front Bolt, Metric M10 x 30 (Grade 8) Bolt, Metric M10 x 60 (Grade 8) Lockwasher 3/8” Spacer Support, Engine (Front) Bolt 3/8”-16NC x 2 3/4” Lockwasher 3/8” Flatwasher 3/8” Nut 3/8”-16NC Mount, Engine Bolt 5/8”-11NC x 4 1/4” Washer, Special Spacer, Tube Locknut 5/8”-11NC Support, Engine (Rear) Bolt 5/8”-11NC x 2 3/4” Flatwasher 5/8” Lockwasher 5/8” Nut 5/8”-11NC —————————— Coupling Installation - Love Joy (Design A) Coupling Installation - Hayes (Design B) Coupling Assembly - Love Joy (Design A) Disc Coupling Hub, Coupling Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Coupling Assembly - Hayes (Design B) Bolt 3/8”-16NC x 7/8” Lockwasher 3/8” Adapter, Pump Bolt 3/8”-16NC x 1 1/4 Lockwasher 3/8” —————————— Pump Assembly - Gear (See Figure 2-23 for Breakdown) Bolt 1/2”-13NC x 1 1/2” Lockwasher 1/2” Bracket, Terminal Strip Cover, Strip Decal - Terminal Strip Label 1 1 3 1 4 1 1 2 2 2 2 3 3 5 3 3 1 2 2 2 2 0250311 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2000088 3200198 0711014 0711020 4761600 4562637 3200227 0641622 4761600 4751600 3311601 3200260 0642032 4740242 4563674 3312005 3200226 0642022 4752000 4762000 3312001 25 26 27 0239962 0250599 1660170 1660175 1660174 0641610 4761600 1660183 0641607 4761600 0080163 0641610 4761600 28 3600139 29 30 31 0641812 4761800 0901401 1670414 1700901 21 22 23 24 32 3120806 1 1 1 1 1 6 6 1 6 6 1 8 8 S E C T I O N 2 T U R N T A B L E - 1 4 4 1 1 1 2-53 SECTION 2 TURNTABLE FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 33 1320070 3910812 4770800 3310801 3980003 0400025 0400003 0400002 2910479 0361810 0236768 3841026 4751600 3300029 34 35 36 37 38 2 39 40 T U R N T A B L E 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 2-54 1060093 1060129 1060119 1060093 1060172 1060045 1060129 1060092 1060099 0181488 0641408 4751400 4761400 3311401 3620026 0630360 4761500 3311501 0630375 4751700 4761700 3311701 4340509 3311601 4761600 4300034 2680356 2680386 3940804 4760800 2060014 3250914 2720254 1320012 DESCRIPTION Clamp, Wiring Screw, Round Head #8-32NC x 3/4” Starwasher #8 Nut #8-32NC Masonite Battery - 13” Length Battery - 10” Length Holddown (Design A) Clips Holddown (Design A) Holddown (Design B) Rod, Tie Down - 11” Rod Rod, Tie Down - 10” Rod Flatwasher 3/8” Wingnut 3/8”-16NC —————————— Cable, Battery (Positive to Aux. Relay) (19” Length) Cable, Battery (Positive to Aux. Relay) (40” Length) Cable, Battery (Positive to Aux. Relay) (48” Length) Cable, Battery (Negative to Ground) (13” Length) Cable, Battery (Negative to Ground) (18” Length) Cable, Battery (Engine to Ground) Cable, Battery (Aux. Relay to Aux. Power) Cable, Battery (Aux. Relay to Start Relay) Cable, Battery (Starter to Start Relay) Angle, Radiator Support (Front) Bolt 1/4”-20NC x 1” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Radiator (Specify when ordering: Modine or Long) Bolt, Carriage 5/16”-18NC x 1 1/4” Lockwasher 5/16” Nut 5/16”-18NC Bolt, Carriage 7/16”-14NC x 1” Flatwasher 7/16” Lockwasher 7/16” Nut 7/16”-18NC Support, Radiator Nut 3/8”-16NC Lockwasher 3/8” Stud (Welded on Part) Shroud, Fan (Use with Long Radiator) Shroud, Fan (Use with Modine Radiator) Screw, Self-Tapping #8-32NC x 1/2” Lockwasher #8 Fan Decal - Caution Fan Hose, Radiator (Top) Clamp QTY. REV. 2 1 1 1 1 1 1 1 2 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 3 2 2 2 2 1 2 2 2 1 1 6 6 1 1 1 2 3120806 SECTION 2 TURNTABLE FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) (CONTINUED) FIG & ITEM # PART NUMBER 70 71 72 2720232 1320012 0238044 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 102 2720160 0080092 4300056 3311405 2200053 4843260 1320058 0080039 4561815 1120161 1340020 0340002 3311401 4761400 0641408 7004214 2420047 0100020 0901569 4564167 0701010 4740116 1320019 1320019 3220043 2220273 2180360 4360037 4360182 2420033 2420131 2420024 2420140 4564281 2420109 3600071 103 104 105 7004248 7004436 7004247 7004249 7012576 0641612 4761600 0901307 89 90 91 92 93 94 95 96 97 98 99 100 101 3120806 DESCRIPTION Hose, Radiator (Bottom) Clamp Choke and Throttle Installation - Precision Governor (See Figure 2-18 for Breakdown) Hose Adapter, Choke Stud, Carburetor Locknut 1/4”-20NC Plug (Standard Machines) Tube, Intake Clamp Elbow, Rubber Tube, Connector Cap, Air Cleaner Air Cleaner Assembly (Includes Item 88 Element) Band Nut 1/4”-20NC Lockwasher 1/4” Bolt 1/4”-20NC x 1” Element, Air Cleaner (Part of Item 88) Service Indicator (Optional - Not Shown) Sealant Plate, Support Tube, Weldment Bolt, Metric M10 x 20MM Lockwasher 10MM Clamp Clamp Muffler Fitting, Reducer Fitting, Tee Switch, Oil Pressure (Standard) Switch, Oil Pressure (With Engine Distress Light) Sender, Oil Pressure (Prior to June 1992) Sender, Oil Pressure (June 1992 to Present) Sender, Temperature (Prior to June 1992) Sender, Temperature (June 1992 to Present) Tube, Dipstick Dipstick Auxiliary Pump Assembly - John S. Barnes, Motor (Alt. Haldex Barnes, Inc.) Motor Motor with Mounting Bracket Pump Coupling Bracket Bolt 3/8”-16NC x 1 1/2” Lockwasher 3/8” Bracket, Mounting - Auxiliary Power QTY. REV. 1 2 1 A/R 1 1 1 1 1 4 2 1 1 1 2 4 4 4 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 S E C T I O N 2 T U R N T A B L E 1 1 1 1 1 2 2 1 2-55 SECTION 2 TURNTABLE FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 106 107 108 3311601 4761600 4711600 4300034 2720015 1320022 2220317 4420001 0901708 109 110 111 112 2 4920959 0250232 T U R N T A B L E QTY. Nut 3/8”-16NC Lockwasher 3/8” Flatwasher 3/8” Stud (Welded on Parts) Hose, Fuel LIne Clamp Fitting, Barbed Tape, Sealant Bracket, Radiator Support (Rear) —————————— Harness (Not Shown) 2 2 2 2 10 ft. 2 1 A/R 1 COLD WEATHER PACKAGE INSTALLATION (NOT SHOWN) Ref. Heater, Engine Block Heater, Battery 1 1 2000088 ENGINE COMPONENTS Ref. 7010633 Use 7012679 7000874 7014678 7000871 7000869 7000870 7022180 7014679 Use 7019932 Use 7021869 7000646 7024321 7022153 7019931 Fitting, Tee (Water By-Pass) Harness, Engine Major Components Kit (Include 1 each of standard carburetor, water pump, fuel pump, starter and alternator) (See figure 2-18 for carburetor replacement parts) Pump, Fuel Starter (was p/n 7000868) Alternator Gasket and Ignition Kit (Includes upper and lower gasket sets, thermostat, ring gear, belt, coil, ignition module, voltage regulator, starter solenoid and hoses) Coil Module, Ignition Regulation, Voltage Ring Gear (132 Teeth) Tune-up Kit (Includes 4 spark plugs, and 1 each of oil filter, fuel filter, cap, rotor and wire set) Plugs, Spark (was p/n 7012595) Filter, Oil (was p/n 7014501) Gasket, Carburetor Gasket, Carburetor (Top) Water Pump Assembly Wire Set - Spark Plug REV. 1 2580022 2580001 7023667 7000867 7014677 2-56 DESCRIPTION B 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 2 3120806 SECTION 2 TURNTABLE FIGURE 2-16. FORD LSG423 ENGINE INSTALLATIONS - WITHOUT NOISE REDUCTION (PRIOR TO FEBRUARY 1993) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0252626 2180360 4360182 4360157 ENGINE DISTRESS INSTALLATION Fitting, Tee Switch, Oil Pressure (Located at Item 98) Switch, Water Temperature (Located on far side of engine block) Ref. 1 1 1 B S E C T I O N 2 T U R N T A B L E 3120806 2-57 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) 2 T U R N T A B L E 2-58 3120806 SECTION 2 TURNTABLE . FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) FIG & ITEM # PART NUMBER 0253710 0253712 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2000088 3600139 0901912 2720232 0641812 4761800 1320012 4832000 2720254 3200198 0701014 Not Used 0701020 4562637 4740242 3200183 0642032 3312005 3200226 3200227 0238044 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 2060014 0901401 1700901 1670414 1320060 3910812 4770800 3310801 0100020 2180360 4360037 2220273 2420131 2420149 Not Used Not Used 0080092 2720160 1060045 4751800 Not Used Not Used Not Used 3120806 DESCRIPTION ENGINE ASSEMBLY - STANDARD GAS‘ ENGINE ASSEMBLY -DUAL FUEL QTY. REV. Ref. Ref. B B Engine Pump Assembly (See Figure 2-23 for Breakdown) Bracket, Exhaust Hose, Radiator (Bottom) Bolt 1/2”-13NC x 1 1/2” Lockwasher 1/2” Clamp, Hose Lockwasher, Metric 10mm Hose, Radiator (Top) Support, Engine (Front) Bolt, Metric 10mm x 30mm 1 1 1 1 2 2 4 4 1 1 2 Bolt, Metric 10mm x 60mm Spacer Flatwasher Mount, Motor Bolt 5/8”-20NC x 4” Locknut 5/8”-20NC Plate, Engine Mounting (Rear) Plate, Engine Mounting (Front) Throttle and Choke Installation (See Figure 2-18 for Breakdown) Fan Bracket, Terminal Strip Decal - Terminal Label Cover, Terminal Strip Clamp, Wire Screw #8-32NC x 3/4” Starwasher #8 Nut #8-32NC Sealant, Thread (Not Shown) Fitting, Tee Switch, Oil Pressure Fitting, Reducer Sender, Oil Pressure Sender, Water Temperature 1 1 5 3 3 3 1 1 1 Adapter, Choke Hose Cable, Battery (Engine to Ground) Flatwasher 1/2” S E C T I O N 2 T U R N T A B L E 1 1 1 1 2 2 2 2 A/R 1 1 1 1 1 1 1 ft./.3m 1 2 2-59 SECTION 2 TURNTABLE FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) (CONTINUED) S E C T I O N 2 T U R N T A B L E FIG & ITEM # PART NUMBER 45 46 47 48 49 50 51 52 53 54 55 to 66 67 68 69 Not Used 0701010 4740116 4564281 2420109 4844337 4921160 0901896 2720015 1320022 Not Used 1120432 Not Used 4300056 0253711 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 2-60 DESCRIPTION Bolt, Metric 10mm x 20mm Lockwasher, Metric 10mm Tube, Oil Dipstick Dipstick Adapter, Exhaust Harness Bracket Hose Clamp, Hose QTY. REV. 7 7 1 1 1 1 1 1”/2.5cm 1 Cap, Vacuum 1 Stud, Carburetor 1 Ref. A 0253713 0254218 ENGINE INSTALLATION - STANDARD GAS INSTALLATION ENGINE INSTALLATION - DUAL FUEL EXHAUST INSTALLATION Ref. Ref. B - 0641622 4751600 4761600 3311601 0642022 0080201 4762000 3312001 0181691 3271501 4761400 3311401 3620026 3940804 4750800 0630375 4751700 4761700 3311701 2680386 4566007 4300031 4920959 0641408 2220317 4420001 2720015 1320022 2200051 Bolt 3/8”-16NC x 2 3/4” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Bolt 5/8”-11NC x 2 3/4” Elbow Lockwasher 5/8” Nut 5/8”-11NC Angle Nut 5/16”-18NC (Grade 8) Lockwasher 1/4” Nut 5/16”-18NC Radiator Screw, Self-Tapping #8-32NC x 1/2” Flatwasher #8 Bolt, Carriage 7/16”-14NC x 1” Flatwasher 7/16” Lockwasher 7/16” Nut 7/16”-14NC Shroud, Fan Tube, Exhaust Stud (Welded on Part) Harness (Starter to Start Relay) Bolt 1/4”-20NC x 1” Fitting, Barbed Tape, Sealant Fuel LIne Clamp Plug, Pipe (Not Shown - Located on Tank) 2 10 8 6 2 1 2 2 1 3 5 5 1 6 6 2 2 2 2 1 1 4 1 3 1 A/R 10 ft/3m 2 1 3120806 SECTION 2 TURNTABLE FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) (CONTINUED) FIG & ITEM # PART NUMBER 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 1340020 7004214 0340002 1120161 0080039 4844291 1320058 Not Used 4761500 4751400 0400003 0236768 0400002 3980003 0630360 Use 3220043 1060119 3300029 1060172 1060129 1060092 1060099 1320019 0641614 3600071 130 131 to 135 136 137 138 139 140 7004248 7004436 7004247 7004249 7012576 4300034 Not Used 2220314 4340509 0901307 0901708 4300038 0239962 201 202 203 204 205 3120806 1660170 1660175 1660174 0080163 0641610 4761600 0641610 DESCRIPTION QTY. Air Cleaner Assembly Element, Air Cleaner Band, Mounting Bonnet Elbow Tube Clamp 1 1 2 1 1 1 4 Lockwasher 5/16” Flatwasher 1/4” Battery Rod, Tie-Down Hold-Down, Battery Masonite Bolt, Carriage 5/16”-18NC x 1 1/4” Muffler (was p/n 3220052) Cable, Battery (+ Battery to Starter) Wingnut 3/8”-16NC Cable, Battery (- Battery to Ground) Cable, Battery (Aux. Pump to Aux. Relay) Cable, Battery (Aux. Relay to Start Relay) Cable, Battery (Start Relay to Starter) Clamp Bolt 3/8”-16NC x 1 3/4” Auxiliary Pump Assembly - John S. Barnes, Motor (Alt. Haldex Barnes, Inc.) Motor Motor with Mounting Bracket Pump Coupling Bracket Stud (Welded on Part) 3 5 1 2 1 1 2 1 1 2 1 1 1 1 3 4 1 Fitting, Barbed - 90° Support, Radiator Bracket, Auxiliary Pump Bracket Stud (Welded on Part) 1 1 1 1 1 PUMP COUPLING INSTALLATION - LOVEJOY OPTION Coupling Disc, Coupling Hub, Coupling Adapter, Pump Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Bolt 3/8”-16NC x 1 1/4” REV. 2 T U R N T A B L E 1 1 1 1 1 2 Ref. S E C T I O N - 1 1 1 1 6 6 8 2-61 SECTION 2 TURNTABLE FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 206 4761600 0250599 2 T U R N T A B L E 211 1660183 212 213 214 215 216 0080163 0641607 4761600 0641610 4761600 3020021 0250232 Lockwasher 3/8” PUMP COUPLING INSTALLATION - HAYES OPTION Coupling Note: Coupling internal Spines must be lubed with Lithium based grease prior to Installation. Adapter, Pump Bolt 3/8”-16NC x 7/8 Lockwasher 3/8” Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Grease, Coupling COLD WEATHER PACKAGE INSTALLATION (NOT SHOWN) QTY. Ref. 1 6 6 8 8 A/R Ref. 1 1 2000088 ENGINE COMPONENTS Ref. 7010633 Use 7012679 7000874 7014678 7000871 7000869 7000870 7022180 7014679 Use 7019932 Use 7021869 7000646 7024321 7022153 7019931 - 1 Ref. Heater, Engine Block Heater, Battery Fitting, Tee (Water By-Pass) Harness, Engine Major Components Kit (Include 1 each of standard carburetor, water pump, fuel pump, starter and alternator) (See figure 2-18 for carburetor replacement parts) Pump, Fuel Starter (was p/n 7000868) Alternator Gasket and Ignition Kit (Includes upper and lower gasket sets, thermostat, ring gear, belt, coil, ignition module, voltage regulator, starter solenoid and hoses) Coil Module, Ignition Regulation, Voltage Ring Gear (132 Teeth) Tune-up Kit (Includes 4 spark plugs, and 1 each of oil filter, fuel filter, cap, rotor and wire set) Plugs, Spark (was p/n 7012595) Filter, Oil (was p/n 7014501) Gasket, Carburetor Gasket, Carburetor (Top) Water Pump Assembly Wire Set - Spark Plug REV. 8 2580022 2580001 7023667 7000867 7014677 2-62 DESCRIPTION B 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 2 3120806 SECTION 2 TURNTABLE FIGURE 2-17. FORD LSG423 ENGINE INSTALLATION - WITH NOISE REDUCTION (FEBRUARY 1993 TO FEBRUARY 1995) (CONTINUED) FIG & ITEM # PART NUMBER 0252626 2180360 4360182 4360157 DESCRIPTION ENGINE DISTRESS INSTALLATION Fitting, Tee Switch, Oil Pressure (Located at Item 32) Switch, Water Temperature (Located on far side of engine block) QTY. REV. Ref. B 1 1 1 S E C T I O N 2 T U R N T A B L E 3120806 2-63 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-18. PRECISION GOVERNOR INSTALLATION - FORD LSG423 ENGINEMACHINES BUILT PRIOR TO FEBRUARY 1995. 2 T U R N T A B L E 2-64 3120806 SECTION 2 TURNTABLE . FIGURE 2-18. PRECISION GOVERNOR INSTALLATION - FORD LSG423 ENGINEMACHINES BUILT PRIOR TO FEBRUARY 1995. FIG & ITEM # 1 2 3 4 5 6 7 8 9 PART NUMBER DESCRIPTION QTY. REV. 0238044 PRECISION GOVERNOR INSTALLATION (STANDARD PARTS) Ref. A 0901373 2500004 0641408 3311401 4751400 4761400 3840898 3321401 1660157 0238044 51 0237568 52 53 54 55 3910812 4760800 2720016 2180666 Bracket, Governor Governor Bolt 1/4”-20NC x 1” Nut 1/4”-20NC Flatwasher 1/4” Lockwasher 1/4” Rod Nut 1/4”-28NF Coupling, Ball - Joint PRECISION GOVERNOR INSTALLATION (VARIABLE PARTS REQUIRED ON 1987-1989 MODELS WITHOUT BUILT-IN CHOKE. 1990 MODELS HAVE CARBURETOR WITH BUILT-IN CHOKE Choke and Vacuum Pull-Off Assembly (Includes Sensor) Screw, Round Head #8-32NC x 3/4” Lockwasher #8 Hose Fitting CARBURETOR REPLACEMENT PARTS 7000643 7000878 1140009 7000877 7000884 7012578 7012577 7000894 3120806 Carburetor with built-in choke Rebuilt Kit - Carburetor (Standard Gas) Carburetor (LPG) Fuel Shut-Off with Wire Fuel Shut-Off with Terminal Post Vacuum Line Assembly Fitting, Vacuum Line Automatic Choke 1 1 7 7 7 7 1 2 2 Ref. S E C T I O N 2 A 1 2 2 1 ft. 1 Ref. 1 1 1 1 1 1 1 1 2-65 T U R N T A B L E SECTION 2 TURNTABLE S E C T I O N FIGURE 2-19. 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES MACHINES BUILT PRIOR TO FEBRUARY 1995 2 T U R N T A B L E 2-66 3120806 SECTION 2 TURNTABLE . FIGURE 2-19. 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES MACHINES BUILT PRIOR TO FEBRUARY 1995 FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 3120806 PART NUMBER DESCRIPTION QTY. REV. 0251004 110 VOLT GENERATOR INSTALLATION (APRIL 1990 TO FEBRUARY 1995) Ref. C 2460011 7012558 7020109 7020108 7012513 7012514 7020190 7020110 7020111 7020193 7003657 Generator Assembly with Control Box Generator Assembly Holder, Brush Brush Cap, Brush Holder Fan Bearing End Bell, Front End Bell, Rear Cord, Power Control Box Assembly Note: Replacement 110V Control Box comes with 2 std receptacles p/n 4460190. Optional Twist Lock receptacles p/n 4460027 must be ordered separately. Meter (was p/n 7010699) Breaker, Circuit (was p/n 7020194) Receptacle, Double (110V Box) Receptacle, Double Twist Lock (110V Box) Lamp Switch, Toggle Plug, Hole Bolt 3/8”-16NC x 1 1/4” (Grade 8) Flatwasher 3/8” Lockwasher 3/8” Adjusting Bracket Bolt 5/16”-18NC x 1” Lockwasher 5/16” Flatwasher 5/16” Bar, Mounting Bolt, Metric 10mm - 1.5mm x 65mm Lockwasher, Metric - 10mm Spacer, Tube (Front) Spacer, Tube (Rear) Bracket, Mounting Bolt, Metric 10mm - 1.50mm x 70mm Lockwasher, Metric - 10mm Spacer, Tube Shield, Heat Pulley (Included with Item #2) Nut (Supplied with Generator) Lockwasher (Supplied with Generator) Key Woodruff Belt Box, Control Bolt 1/4”-20NC x 3/4” 1 1 4 4 4 1 2 1 1 1 1 Ref. 2420203 4360542 4460190 4460027 2920162 7020191 3520028 0681610 4751600 4761600 4340565 0641508 4761500 4751500 0361704 0701021 4740116 4564329 4564328 4843156 0701022 4740116 4564123 4060696 3580134 2860012 0480048 See Item 1 0641406 S E C T I O N 2 T U R N T A B L E 1 1 1 1 1 1 1 2 2 2 1 2 2 1 1 2 2 1 1 1 2 2 2 1 1 1 1 1 1 1 2 2-67 SECTION 2 TURNTABLE FIGURE 2-19. 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES MACHINES BUILT PRIOR TO FEBRUARY 1995 (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 23 24 25 26 27 28 4751400 4761400 3311401 3251476 4460023 4460071 0960238 3300048 1060012 4460052 0960239 3300047 29 30 2 DESCRIPTION Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Nameplate - Generator Connector (Not Shown) Connector Bushing Locknut, Conduit Cable, Electrical Connector Bushing Locknut, Conduit QTY. REV. 2 2 2 1 1 1 1 1 1 1 1 1 T U R N T A B L E 2-68 3120806 SECTION 2 TURNTABLE FIGURE 2-19. 110 VOLT GENERATOR INSTALLATION - FORD LSG423 ENGINES MACHINES BUILT PRIOR TO FEBRUARY 1995 (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-69 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) 2 T U R N T A B L E 2-70 3120806 SECTION 2 TURNTABLE . FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) FIG & ITEM # QTY. REV. 0255675 0255676 FORD ENGINE ASSEMBLY - STANDARD GAS FORD ENGINE ASSEMBLY - DUAL FUEL Ref. Ref. C C 1 2 3 2000126 4360405 3600139 1 1 1 4 5 6 7 8 9 10 11 12 13 14 15 16 3200377 4566605 2500005 0902088 3841255 1660157 0902089 0902087 2420024 2420131 4360037 2220273 Engine Switch, Oil Pressure (July 1995 to Present) Pump Assembly - Main (See Figure 2-25 for Breakdown) Mount, Engine (Front) Tube, Spacer Precision Governor Actuator Bracket, Governor Mounting Rod, Throttle Coupling, Ball Joint Bracket, Terminal Strip Mounting Bracket, Fuel Pump Mounting Sender, Water Temperature Sender, Oil Pressure Switch, Oil Pressure Fitting, Reducer Fitting Options: Prior to July 1995 July 1995 to Present Stud, Carburetor Valve, Oil Drain Options: Prior to S/N 34331 S/N 34331 to Present Lockwasher 1/4” (July 1995 to Present) Clamp, Hose Decal, Terminal Strip Cover, Terminal Fitting Options: Fitting, 90° (Prior to July 1995) Fitting, Straight Pipe (July 1995 to Present) Fuel Line Fitting, Straight Pipe Hose, Vacuum Bolt 10mm x 70mm Bolt 10mm x 30mm Lockwasher 10mm Bolt 8mm x 20mm Lockwasher 8mm Bolt 1/2”-13NC x 1 1/2” Lockwasher 1/2” Bolt 1/4”-20NC x 1” Hardware Options: Lockwasher 1/4” (Prior to July 1995) Bolt 1/4”-20NC x 1/2 (July 1995 to Present) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 PART NUMBER 2180360 2180994 4300057 4640750 4640989 4791400 1320022 1700901 1670414 2220805 2220315 2720058 2180536 2720271 0701022 0701014 4832000 0700810 4831900 0641812 4761800 0641408 4761400 0641404 3120806 DESCRIPTION 1 1 1 1 1 2 1 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 2 1 1 A/R 2 1 18in/48cm 1 30 in/78cm 2 2 4 3 3 2 2 4 A/R 4 2 2-71 SECTION 2 TURNTABLE FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) FIG & ITEM # S E C T I O N PART NUMBER 36 3311401 3311405 37 38 39 40 41 42 43 44 2 T U R N T A B L E 1320019 2220437 0721014 3311001 4761000 3321401 0100020 0701015 4791600 0255138 0255146 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 2-72 Not Used 0641622 4751600 4761600 3311601 0642022 0080201 4762000 3312001 0181691 3311501 4761400 3311401 3620026 3940804 4750800 0630375 Not Used 4761700 3311701 2680386 4300031 0641408 2220315 4420001 2720015 2720058 1320022 2200051 1340020 7004214 DESCRIPTION Nut Options: Nut 1/4”-20NC (Prior to July 1995) Locknut 1/4”-20NC (July 1995 to Present) Hardware Options: Clamp (Prior to July 1995) Fitting (July 1995 to Present) Bolt #10-24NC x 1 3/4” Nut #10-24NC Lockwasher #10 Nut 1/4”-28NF Sealant, Pipe (Not Shown) Bolt, Metric 10mm x 35mm Starwasher 3/8” FORD ENGINE INSTALLATION - STANDARD GAS FORD ENGINE INSTALLATION - DUAL FUEL QTY. REV. A/R 4 6 A/R 1 1 2 2 2 1 A/R 1 2 Ref. Ref. Bolt 3/8”-16NC x 2 3/4” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Bolt 5/8”-11NC x 2 3/4” Fitting, 90° Lockwasher 5/8” Nut 5/8”-11NC Angle, Support Nut 5/16”-18NC Lockwasher 1/4” Nut 1/4”-20NC Radiator Screw, Self-Tapping #8-32NC x 1/2” Flatwasher #8 Bolt, Carriage 7/16”-14NC x 1” 2 10 9 7 2 1 2 2 1 3 5 5 1 6 6 2 Lockwasher 7/16” Nut 7/16”-14NC Shroud, Fan Stud (Welded on Part)< Bolt 1/4”-20NC x 1” Fitting, Barbed Tape, Sealant Line, Fuel Options: Prior to August 1995 August 1995 to Present Clamp, Hose Plug, Pipe Air Cleaner Assembly Element, Air Cleaner 2 2 1 4 3 1 A/R A/R C E 10 ft/3m 7 ft/2.1m 2 1 1 1 3120806 SECTION 2 TURNTABLE FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) FIG & ITEM # PART NUMBER 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 0340002 1120161 0080039 4844903 1320058 4761500 4751400 0400003 0236768 0400002 3980003 0630360 1060119 3300029 1060172 1060129 1060099 148 149 4921717 4921764 0641614 3600071 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 7004248 7004436 7004247 7004249 7012576 4300034 2220314 4340509 0901307 0901708 4300038 Not Used 1320012 Not Used 4740242 3200183 0642032 3312005 3200226 3200227 2060014 0080211 0080092 2720160 1060045 0701010 0701012 3120806 DESCRIPTION QTY. Band, Mounting Cap, Air Elbow Tube, Air Intake Clamp Lockwasher 5/16” Flatwasher 1/4” Battery Rod, Tie-Down Hold-Down, Battery Seat, Battery Bolt, Carriage 5/16”-18NC x 1 1/4” Cable, Battery (Battery to Starter) Wingnut 3/8”-16NC Cable, Battery (Battery to Ground) Cable, Battery (Aux. Relay to Aux. Pump) Cable, Battery (Aux. Relay to Starter) Harness, Wiring Options: Prior to June 1995 June 1995 to Present Bolt 3/8”-16NC x 1 3/4” Auxiliary Pump Assembly - John S. Barnes, Motor (Alt. Haldex Barnes, Inc.) Motor Motor with Mounting Bracket Pump Coupling Bracket Stud (Welded on Part) Fitting, 90° Barbed Bracket, Support Bracket, Auxiliary Pump Bracket Stud (Welded on Part) 2 1 1 1 4 3 5 1 2 1 1 2 1 2 1 1 1 1 Clamp, Hose 4 Flatwasher, Special Mount, Engine Bolt 5/8”-11NC x 4” Locknut 5/8”-11NC Plate, Mounting (Rear) Plate, Mounting (Front) Fan Spacer, Fan Adapter, Choke Hose 1/2” (Not Shown) (Prior to August 1995) Cable, Battery (Engine to Ground) Bolt, Metric 10mm x 20mm Bolt, Metric 10mm x 25mm REV. S E C T I O N 2 T U R N T A B L E 2 1 1 1 1 1 1 2 1 1 1 1 1 5 3 3 3 1 1 1 1 1 A/R 1 2 2 2-73 SECTION 2 TURNTABLE FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) FIG & ITEM # PART NUMBER S E C T I O N 172 173 174 175 176 177 178 179 180 4832000 0902096 4564281 2420171 2720015 1320022 4791600 0641610 2 181 3911012 3910812 3311001 3310801 T U R N T A B L E 182 183 184 185 186 4761000 4760800 3740080 0630400 1320032 4831900 0255147 201 202 203 204 4844337 4566625 Use 3220043 1320019 2000126 301 302 303 304 305 306 307 308 309 2-74 7012680 7016600 7016601 7012682 7012681 7012679 7025145 Use 7021869 7012690 7019933 7012683 7023471 7024321 1660218 Use 1660249 7020120 7019976 7022180 DESCRIPTION Lockwasher, Metric 10mm Bracket, Exhaust Tube, Dipstick Dipstick Hose 1/4” (Not Shown) (Prior to August 1995) Clamp Starwasher 3/8” Bolt 3/8”-16NC x 1 1/4” Screw, Machine Options: #10-24NC x 3/4” (Prior to August 1995) #8-32NC x 3/4” (August 1995 to Present) Nut Options: #10-24NC (Prior to August 1995) #8-32NC (August 1995 to Present) Lockwasher Options: #10 (Prior to August 1995) #8 (August 1995 to Present) Relay, Bosch Bolt, Metric 8mm x 90mm Clamp Lockwasher, Metric 8mm EXHAUST INSTALLATION Tube, Exhaust Tube, Exhaust Muffler (was p/n 3220052) Clamp, Exhaust ENGINE COMPONENTS: Alternator Fuel Pump - Electric Filter, Fuel (Used with Facet Pump) Harness, Engine Module, Ignition Starter (Far Side - Not Shown) Solenoid, Start Filter, Oil (was p/n 7014501) Carburetor Carburetor Repair Kit Spring Float Assembly Gasket, Carburetor (Top) Flywheel Housing and Coupling Assembly Coupling (was p/n 7012656) Housing, Flywheel Flywheel (Not Shown) Ring Gear (132 Teeth) (Not Shown) QTY. REV. 4 1 1 1 A/R A/R 2 1 2 2 2 2 4 1 4 Ref. A 1 1 1 3 Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3120806 SECTION 2 TURNTABLE FIGURE 2-20. FORD LRG423 ENGINE INSTALLATION (FEBRUARY 1995 TO PRESENT) FIG & ITEM # PART NUMBER 310 7019921 7019929 Use 7019926 Use 7019927 7000884 7016605 7022143 70002307 4360157 7000646 Use 7022153 7019924 7025126 7019925 7019930 7019931 7019932 7022178 311 312 313 314 315 316 317 318 319 320 321 322 323 324 0256338/ 1281186 2580048 3311401 4761400 4300031 2580001 3120806 DESCRIPTION Belt Pulley, Idler (Tensioner Assembly) Hose, Radiator (Top) (was p/n 7016375) Hose, Radiator (Bottom) (was p/n 7016376) Solenoid, Fuel Choke, Automatic Gasket (Not Shown - Exhaust Manifold to Head) Gasket (Exhaust Manifold to Exhaust Pipe) Switch, Water Temperature (Not Shown) Gasket, Carburetor (Not Shown) Water Pump (was p/n 7016638) Manifold, Exhaust (Not Shown) Manifold, Intake (was p/n 7019923) PCV Valve (Not Shown) Coil, Ignition (Not Shown) Wire Set - Spark Plug (Not Shown) Plug, Spark (Not Shown) Sensor, Crank (Not Shown) COLD WEATHER PACKAGE INSTALLATION (OPTIONAL - NOT SHOWN) Kit, Cold Weather Start Nut 1/4”-20NC Lockwasher 1/4” Stud (Welded on Part) —————————— Heater, Battery QTY. REV. S E C T I O N 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 Ref. 2 -/F 1 4 4 4 1 2-75 T U R N T A B L E SECTION 2 TURNTABLE S E C T I O N FIGURE 2-21. GENERATOR INSTALLATION - FORD LRG423 (MACHINES BUILT FEBRUARY 1995 TO PRESENT) 2 T U R N T A B L E 2-76 3120806 SECTION 2 TURNTABLE . FIGURE 2-21. GENERATOR INSTALLATION - FORD LRG423 (MACHINES BUILT FEBRUARY 1995 TO PRESENT) FIG & ITEM # PART NUMBER 0255226 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 3120806 3580250 2460011 7012558 7020109 7020108 7012513 7012514 7020190 7020110 7020111 7020193 7003657 2420203 4360542 4460190 4460027 2920162 7020191 3520028 3580134 2860012 0902104 0200530 4564417 0641508 4751500 4761500 0641612 4751600 4761600 3311601 4566650 0701015 4812000 4832000 3580239 4740275 0480090 0100011 0641406 3311401 4751400 4761400 DESCRIPTION GENERATOR INSTALLATION Pulley, Crankshaft Generator Assembly with Control Box Generator Assembly Holder, Brush Brush Cap, Brush Holder Fan Bearing End Bell, Front End Bell, Rear Cord, Power Control Box Assembly Note: Replacement 110V Control Box comes with 2 std receptacles p/n 4460190. Optional Twist Lock receptacles p/n 4460027 must be ordered separately. Meter (was p/n 7010699) Breaker, Circuit (was p/n 7020194) Receptacle, Double (110V Box) Receptacle, Double Twist Lock (110V Box) Lamp Switch, Toggle Plug, Hole Pulley (Included with Item #2) Key, Woodruff Bracket, Generator Mounting Arm, Adjusting Tube, Spacer Bolt 5/16”-18NC x 1” Flatwasher 5/16” Lockwasher 5/16” Bolt 3/8”-16NC x 1 1/2” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Tube, Spacer Bolt 10mm - 1.5 x 35mm Flatwasher 10mm Lockwasher Pulley, Idler Washer Belt, Generator Loctite (Not Shown) Bolt 1/4”-20NC x 3/4” Nut 1/4”-20NC Flatwasher 1/4” Lockwasher 1/4” QTY. REV. Ref. D 1 1 1 4 4 4 1 2 1 1 1 1 Ref. S E C T I O N 2 T U R N T A B L E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 2 2 2 1 1 1 A/R 2 2 6 2 2-77 SECTION 2 TURNTABLE FIGURE 2-21. GENERATOR INSTALLATION - FORD LRG423 (MACHINES BUILT FEBRUARY 1995 TO PRESENT) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 27 28 29 30 31 32 33 3251476 4460052 0960239 3300047 Not Used 2180360 4360037 DESCRIPTION QTY. Nameplate, Generator Connector, Strain Relief Bushing Nut, Conduit 1 1 1 1 Fitting, Tee (June 1995 to Present) Switch, Oil Pressure (June 1995 to Present) 1 1 REV. 2 T U R N T A B L E 2-78 3120806 SECTION 2 TURNTABLE FIGURE 2-21. GENERATOR INSTALLATION - FORD LRG423 (MACHINES BUILT FEBRUARY 1995 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-79 SECTION 2 TURNTABLE FIGURE 2-22. DUAL FUEL INSTALLATION (OPTIONAL ON FORD MACHINES) S E C T I O N 2 T U R N T A B L E 2-80 3120806 SECTION 2 TURNTABLE . FIGURE 2-22. DUAL FUEL INSTALLATION (OPTIONAL ON FORD MACHINES) FIG & ITEM # PART NUMBER DESCRIPTION DUAL FUEL INSTALLATION 1 3530210 0902089 2 3 0641711 4700005 7017515 0641416 4751400 4761400 3311401 2220082 2120077 Not Used 2720249 2180389 2180388 2180418 2720144 2180387 2220313 2220675 1320022 2750532 2220251 2180535 1320030 2720112 0080124 2720058 2220315 2220648 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2220437 27 28 29 30 31 32 33 34 35 3120806 1320022 4640391 1320060 2220430 2220273 2200652 2180360 3460132 2180104 4360188 Not Used 2200204 1700818 QTY. Plate, Regulator Mounting (Prior to February 1995) Plate, Regulator Mounting (February 1995 to Present Not Shown) Bolt 7/16 -14NC x 1 3/8” Regulator Repair Kit Bolt 1/4”-20NC x 2” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Fitting, 90° L.P. Filter Lock 1 1 Hose Valve, Relief Filter Fitting, Straight Hose Fitting, L.P. Tank Fitting, 90° (Prior to February 1995) Fitting, 90° (February 1995 to Present) Clamp, Hose Hose Fitting, Reducer Fitting, Straight Clamp, Hose Hose Adapter, Carburetor Hose Fitting, Barbed Fitting, 90° (Located at Fuel Pump - Feb. 1995 to Present) Fitting, Reducer (Located at Fuel Pump - Feb. 1995 to Present) Clamp, Hose Valve, Fuel Lock Clamp, Mounting (Not Shown) Fitting, Reducer (Prior to February 1995) Fitting, Reducer (February 1995 to Present) Fitting, 90° (Prior to February 1995) Fitting, Tee (February 1995 to Present) Fitting, Nipple (Prior to February 1995) Fitting, Nipple (February 1995 to Present) Switch, Vacuum 1 1 1 1 1 1 2 2 2 24” 1 1 2 A/R 1 9” 2 1 Plug, 3/4” Decal - LPG Liquid Withdraw System REV. Ref. 2 1 1 2 2 2 2 1 1 S E C T I O N 2 T U R N T A B L E 1 2 1 1 1 1 1 1 1 1 1 1 1 2-81 SECTION 2 TURNTABLE FIGURE 2-22. DUAL FUEL INSTALLATION (OPTIONAL ON FORD MACHINES) (CONTINUED) FIG & ITEM # PART NUMBER 36 2220633 2220314 1320032 2720160 S E C T I O N 37 38 DESCRIPTION Fitting, Straight Barbed (Prior to February 1995) Fitting, 90° Barbed (February 1995 to Present) Clamp Hose QTY. REV. 1 1 1 1 2 T U R N T A B L E 2-82 3120806 SECTION 2 TURNTABLE FIGURE 2-22. DUAL FUEL INSTALLATION (OPTIONAL ON FORD MACHINES) (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 3120806 2-83 SECTION 2 TURNTABLE FIGURE 2-23. MAIN PUMP ASSEMBLY - GEAR S E C T I O N 2 T U R N T A B L E 2-84 3120806 SECTION 2 TURNTABLE . FIGURE 2-23. MAIN PUMP ASSEMBLY - GEAR FIG & ITEM # PART NUMBER 3600139 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Kit 7009513 Not Used 7003103 7009500 7009503 Kit 7009509 Kit 7009510 7009508 7005599 7005598 7009504 7009505 7009511 7005597 7005562 7005595 2900673 3120806 DESCRIPTION QTY. REV. MAIN PUMP ASSEMBLY - GEAR Ref. B Seal, Lip Cover, End with Bushings Plug Dowel Plate, Thrust Seal, Channel Shaft and Gear Seal, Gasket Housing, Gear Carrier, Bearing with Bushings Shaft, Connecting Gear Set Housing, Gear Carrier, Bearing with Bushings Cover, Rear with Bushings Washer Stud Nut —————————— Kit, Seal (Includes Items 1,7 and 9) 1 1 1 12 6 6 1 Set 6 1 1 2 2 1 1 1 4 4 4 S E C T I O N 2 T U R N T A B L E 1 2-85 SECTION 2 TURNTABLE FIGURE 2-24. TANKS INSTALLATION S E C T I O N 2 T U R N T A B L E 2-86 3120806 SECTION 2 TURNTABLE FIGURE 2-24. TANKS INSTALLATION FIG & ITEM # PART NUMBER 0250243 0253109 0250319 0253110 0251374 0255604 1 2 3 4 3311505 4761500 4751500 4300073 0641514 4070410 4070411 4070412 4400294 4400344 5 4400381 4400295 4400345 6 7 8 9 10 11 12 13 14 4400382 1120314 2180467 0100020 1320022 4562516 2200052 2200223 3311505 4761500 4751500 4300073 0641514 4070410 4070411 4070412 4400266 4400291 3120806 DESCRIPTION FUEL AND HYDRAULIC TANKS INSTALLATION (STANDARD - PRIOR TO OCTOBER 1992) FUEL AND HYDRAULIC TANKS INSTALLATION (STANDARD - OCTOBER 1992 TO PRESENT) FUEL AND HYDRAULIC TANKS INSTALLATION (WITH HEATERS - PRIOR TO OCTOBER 1992) FUEL AND HYDRAULIC TANKS INSTALLATION (WITH HEATERS - OCTOBER 1992 TO PRESENT) HYDRAULIC TANK INSTALLATION (LPG ONLY MACHINES) FUEL AND HYDRAULIC TANKS INSTALLATION (WITH LOW FUEL INDICATOR) Locknut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Stud (Welded on Part) Bolt 5/16”-18NC x 1 3/4” Shim (1/16”) Shim (1/8”) Shim (3/16”) —————————— Fuel Tank Assembly (0250243 and 0250319 Installations) Fuel Tank Assembly (0253109 and 0253110 Installations) Fuel Tank Assembly (0255604 Installation) Fuel Tank Weldment (0250243 and 0250319 Installations) Fuel Tank Weldment (0253109 and 0253110 Installations Fuel Tank Weldment (0255604 Installation) Cap Fitting, 90° Sealant Clamp Tube, Sight Plug, Pipe - 1/4” Plug, Pipe - 1/2” (0255604 Installation Only - Not Shown) Locknut 5/16”-18NC Lockwasher 5/16” Flatwasher 5/16” Stud (Welded on Part) Bolt 5/16”-18NC x 1 3/4” Shim (1/16”) Shim (1/8”) Shim (3/16”) —————————— Hydraulic Tank Assembly (Standard) Hydraulic Tank Assembly (With Heater) QTY. REV. Ref. - Ref. - Ref. - Ref. - Ref. 2 Ref. A S E C T I O N 2 4 4 4 4 A/R A/R A/R A/R 1 - 1 - 1 1 - T U R N T A B L E 1 1 1 2 A/R 2 26 in. 1 A/R 4 4 4 4 A/R A/R A/R A/R 1 1 C B 2-87 SECTION 2 TURNTABLE FIGURE 2-24. TANKS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 15 4400265 4400290 1670468 3311401 4761400 4751400 3960371 2120103 7004244 7012559 7016333 0641612 4761600 4740322 3311601 2120107 1340045 4740338 2180467 0100020 1320022 4562516 2120104 0100020 3520022 0100020 2180527 0100020 2200268 0100020 2180711 1600043 2580018 1340046 4060695 4060767 0721005 4751000 4761000 3311001 3311405 4761400 4751400 S E C T I O N 16 17 18 19 20 21 2 22 23 24 25 26 27 T U R N T A B L E 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 2-88 DESCRIPTION Hydraulic Tank Weldment (Standard) Hydraulic Tank Weldment (With Heater) Lid Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Gasket Filter, Return (Includes Item 26) Indicator, Pressure Gasket (Between the Filter & Tank) O-Ring (Under Cap) Bolt 3/8”-16NC x 1 1/2” Lockwasher 3/8” Washer, Sealing Nut 3/8”-16NC Element (Part of Item 21) Filler, Strainer Washer, Sealing Fitting, 90° Sealant Clamp Tube, Sight Filter, Suction Sealant Plug - 3/4” Sealant Plug - 1/16” Sealant Fitting, Coupling Sealant Pipe, Return Controller, Thermostat (With Heater Only) Heater, Immersion (With Heater Only) Breather Filler/Shield (Standard) Filler/Shield (LPG Only) Screw, Machine #10-24NC x 5/8” Flatwasher #10 Lockwasher #10 Nut #10-24NC Locknut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” QTY. REV. 1 1 1 14 14 14 1 1 1 1 1 4 4 4 4 1 1 6 2 A/R 2 26 in. 1 A/R 1 A/R 1 A/R 1 A/R 1 1 1 1 1 1 6 12 6 6 6 6 6 3120806 SECTION 2 TURNTABLE FIGURE 2-24. TANKS INSTALLATION (CONTINUED) FIG & ITEM # 47 48 49 50 PART NUMBER DESCRIPTION QTY. REV. 0250232 0250233 COLD WEATHER PACKAGE INSTALLATION - FORD COLD WEATHER PACKAGE INSTALLATION - DEUTZ Ref. Ref.‘ B B 1 1 3 4 4 1 1 C Ref. B 0231756 1670199 4460049 3311401 4761400 3251837 3251243 0239594 51 52 53 54 55 3120806 4400275 1320023 3311605 4761600 4751600 4300034 4070774 Junction Box Assembly Cover Connector, Strain Relief Nut 1/4”-20NC Lockwasher 1/4” Decal - Battery and Oil Tank Heaters Decal - 120V/60HZ LP TANK AND BRACKETS INSTALLATION STANDARD Tank, LP Bracket Locknut 3/8”-16NC Lockwasher 3/8” (When Equipped) Flatwasher 3/8” Stud (Welded on Part) Shim (Not Shown) S E C T I O N 2 T U R N T A B L E 2 2 sets 8 8 8 8 A/R 2-89 SECTION 2 TURNTABLE S E C T I O N FIGURE 2-25. ROTARY COUPLING AND COLLECTOR ASSEMBLY AND INSTALLATION 2 T U R N T A B L E 2-90 3120806 SECTION 2 TURNTABLE . FIGURE 2-25. ROTARY COUPLING AND COLLECTOR ASSEMBLY AND INSTALLATION FIG & ITEM # PART NUMBER 0238032 0250611 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1660160 1660185 1440154 0641512 4761500 3951820 0100011 0620058 0620106 2760091 Kit Kit 2901146 3760004 3530403 0641807 4761800 0100019 2200222 0251561 15 16 17 18 19 20 21 22 23 24 25 26 27 28 3120806 4843822 0641418 4761400 4751400 0960224 1320040 3911012 4751000 4761000 3311001 2180763 0961531 3760053 3311801 3420290 0231047 1670594 0721004 3311001 DESCRIPTION ROTARY OIL COUPLING INSTALLATION (2WS) ROTARY OIL COUPLING INSTALLATION (4WS) Oil Coupling Assembly (2WS) (Includes Items 6-10) Oil Coupling Assembly (4WS) (Includes Items 6-10) Collar Bolt 5/16”-18NC x 1 1/2” Lockwasher 5/16” Setscrew, Socket 1/2”-13NC x 2 1/2” Loctite #242 —————————— Body, Swivel (2WS) Body, Swivel (4WS) Housing, Swivel O-Ring Seal Seal Kit (Includes Items 8 and 9) Ring, Retaining —————————— Fork, Retaining Bolt 1/2”-13NC x 7/8” Lockwasher 1/2” Loctite #271 Plug, Pipe - 1/4” (2WS Only) COLLECTOR RING ASSEMBLY (4WS ONLY) Bracket Weldment Bolt 1/4”-20NC x 2 1/4” Lockwasher 1/4” Flatwasher 1/4” Bushing Clamp Screw, Machine #10-24NC x 3/4” Flatwasher #10 Lockwasher #10 Nut #10-24NC Pipe Bushing, Collector Ring Collector Ring Assembly Nut 1/2”-13NC Pin, Drive Guide, Drive Cover Screw, Round Head #10-24NC x 1/2” Nut #10-24NC QTY. REV. Ref. Ref. B C 1 1 1 4 4 2 A/R B B 2 1 1 1 1 7 1 1 1 2 2 A/R 1 Ref. S E C T I O N B 1 2 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 4 4 2-91 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY S E C T I O N 2 T U R N T A B L E 2-92 3120806 SECTION 2 TURNTABLE . FIGURE 2-26. GROUND CONTROL BOX 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 3120806 PART NUMBER 3252044 3252383 4420037 0750806 4740120 3300177 3911412 4751400 4761400 3311401 4420037 0860576 0641405 4751400 4761400 3311401 2420009 2420129 Not Used Not Used 4360274 3790015 3520028 4360284 7010698 4360267 4360281 4360199 4360141 3790012 4360202 3790012 3520026 4360202 3790012 4360202 3790012 4360202 3790012 4360202 3790012 4360202 3790012 4360200 3790012 DESCRIPTION QTY. GROUND CONTROL BOX ASSEMBLY Ref. Lid (Prior to May 1994) Lid (May 1994 to Present) Strip, Rubber (Not Shown) Screw, Self-Tapping #8 x 3/4” Washer, Fiber Nut, Tinnerman Screw, Round Head 1/4”-20NC x 3/4” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Strip, Rubber (Not Shown) Box Bolt 1/4”-20NC x 5/8” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Hourmeter Voltmeter 1 1 14cm 2 2 2 3 3 3 3 38 in. 1 4 4 4 4 1 1 Switch, Push Button (Start) O-Ring Plug, Hole Switch, Key (Select) Key, Replacement Block, Contact - SPST - N.O. Block, Contact - N.O. Switch, Toggle (Ignition) Guard, Switch O-Ring Switch, Toggle (Platform Rotate) O-Ring Plug, Hole Switch, Toggle (Tower Lift) O-Ring Switch, Toggle (Main Lift) O-Ring Switch, Toggle (Swing) O-Ring Switch, Toggle (Tower Tele) O-Ring Switch, Toggle (Main Tele) O-Ring Switch, Toggle (Auxiliary Power) O-Ring 1 1 1 1 1 set 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REV. S E C T I O N 2 T U R N T A B L E 2-93 SECTION 2 TURNTABLE FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 30 3740049 3311001 4761000 4751000 4360216 4360232 3640711 3910606 4750600 4760600 3310601 4460299 3740058 4120013 3740063 4460300 4460298 4460301 4460308 4460305 4460306 4460307 4460311 4460305 4460306 4460307 4460071 0960238 3300048 4460244 0960238 3300048 Not Used 3740067 3740059 3311001 4761000 4751000 4360202 4060229 3790012 3251903 Not Used 2420024 S E C T I O N 31 32 33 2 34 35 T U R N T A B L E 36 37 38 39 40 41 42 43 44 45 46 47 48 0860687 80 2-94 2420111 DESCRIPTION Relay Nut #10-24NC Lockwasher #10 Flatwasher #10 Switch, Circuit Breaker - 30 Amp Switch, Circuit Breaker - 15 Amp Rail Screw #6-32NC x 3/8” Flatwasher #6 Lockwasher #6 Nut #6-32NC Stop, Terminal Relay Base, Relay Spring Barrier, Terminal Block, Terminal Marker, Terminal Bar, Buss (2 Position) Screw Washer Sleeve Bar, Buss (5 Position) Screw Washer Sleeve Connector, Strain Relief Bushing Nut, Conduit Connector, Strain Relief Bushing Nut, Conduit QTY. 15 1 1 1 1 1 42.4cm 2 2 2 2 2 3 3 3 2 45 1 1 2 2 2 1 5 5 5 1 1 1 4 4 4 Relay (Continuous Duty) Relay (Start) Nut #10-24NC Lockwasher #10 Flatwasher #10 Switch, Toggle (Platform Level Override) Shield O-Ring Decal - Platform Level Override 1 1 3 3 3 1 1 1 1 Light, Panel (Optional) 1 GROUND CONTROL BOX ASSEMBLY - DEUTZ VARIABLE PARTS) REV. Ref. H Gage, Oil Pressure 3120806 SECTION 2 TURNTABLE FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 81 2420125 3990001 3740077 3311001 4761000 4751000 3740058 4120013 3740063 3910614 4770600 3310601 0060023 7008804 7008829 7008821 7008828 4360212 Not Used 82 83 84 85 86 to 89 0860749 80 81 82 to 85 86 87 88 89 2420128 2420127 Not Used 3311001 4761000 4751000 1600098 3311001 4761000 4751000 3740061 3311001 4761000 4751000 4360228 4564088 3910606 4760600 3310601 0860952 80 81 82 3120806 2420128 2420127 Not Used DESCRIPTION Gage, Oil Temperature Diode - 3.5 Amp Relay, Bosch Nut #10-24NC Lockwasher #10 Flatwasher #10 Relay Base, Relay Spring, Relay Screw, Round Head #6-32NC x 7/8” Starwasher #6 Nut #6-32NC Actuator, Adeco Throttle Bellows, Rubber Board, Circuit Motor, Drive Cable, Throttle Breaker, Circuit GROUND CONTROL BOX ASSEMBLY - FORD (BUILT PRIOR TO FEBRUARY 1995) (VARIABLE PARTS) QTY. Ref. 1 1 Regulator, Voltage (Supplied with Engine) Nut #10-24NC Lockwasher #10 Flatwasher #10 Controller, Precision Governor Nut #10-24NC Lockwasher #10 Flatwasher #10 Relay, Start Lockout Nut, #10-24NC Lockwasher #10 Flatwasher #10 Card, Mid Engine Circuit Stand-Off Screw #6-32NC x 3/4” Lockwasher #6 Nut #6-32NC 1 2 2 2 1 4 4 4 1 2 2 2 1 2 2 2 2 Gage, Oil Pressure Gage, Oil Temperature S E C T I O N 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 1 1 1 Gage, Oil Pressure Gage, Oil Temperature GROUND CONTROL BOX ASSEMBLY - FORD BUILT FEBRUARY 1995 TO PRESENT REV. Ref. 2 E A 1 1 2-95 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 83 3740058 4120013 3740063 3910614 4770600 3310601 Not Used Not Used Not Used 1600211 3311001 4761000 4751000 Not Used Not Used S E C T I O N 84 85 86 87 2 88 89 T U R N T A B L E 2-96 DESCRIPTION QTY. Relay Base, Relay Spring, Relay Screw, Machine #6-32NC x 7/8” Starwasher #6 Nut #6-32NC 2 2 2 3 2 2 Controller, Precision Governor Nut #10-24NC Lockwasher #10 Flatwasher #10 1 4 4 4 REV. 3120806 SECTION 2 TURNTABLE FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 2 T U R N T A B L E 3120806 2-97 SECTION 2 TURNTABLE FIGURE 2-27. LIGHTS AND ALARMS INSTALLATION S E C T I O N 2 T U R N T A B L E 2-98 3120806 SECTION 2 TURNTABLE . FIGURE 2-27. LIGHTS AND ALARMS INSTALLATION FIG & ITEM # PART NUMBER 0250013 0250014 1 2920018 2920105 2920009 2920109 2 3 4 3941404 2540016 3536597 3941404 4060829 0641405 3311405 REV. Ref. B Ref. B 1 1 1 1 4 1 2 2 Ref. 0140024 0140032 2540016 3941404 4751400 Alarm (Optional - Prior to January 1993) Alarm (Optional - January 1993 to Present) Grommet Screw, Self-Tap 1/4” x 1/2” Flatwasher 1/4” 1 1 1 4 4 0250016 0253910 HEADLIGHT AND TAILLIGHT INSTALLATION HEADLIGHT AND TAILLIGHT INSTALLATION (HALOGEN) Ref. Ref. 2920001 2920152 2920079 3941406 4751400 2920019 0181386 7 2920001 2920152 0641608 4761600 3311601 Headlight Options: Production Post Production Alternative Bulb (Halogen) Screw, Self-Tap 1/4” x 3/4” Flatwasher 1/4” Taillight Angle, Mounting BACK-UP LIGHTS INSTALLATION Light, Back-Up Options: Production Post Production Alternative Bolt 3/8”-16NC x 1” Lockwasher 3/8” Nut 3/8”-16NC C 2 2 2 2 4 4 2 2 Ref. S E C T I O N 2 2 2 1 TRAVEL ALARM INSTALLATION (OPTIONAL) 0250476 3120806 Light, Beacon - Amber (Optional - Prior to January 1993) Light, Beacon - Amber (Optional - January 1993 to Present) Light, Beacon - Red (Optional - Prior to January 1993) Light, Beacon - Red (Optional - January 1993 to Present) Screw, Self-Tapping 1/4” x 1/2” Grommet Plate, Mounting (Optional Only - January 1993 to Present) Screw, Self-Tapping 1/4” x 1/2” Guard, Light (Optional Only - January 1993 to Present) Bolt 1/4”-20NC x 5/8” Locknut 1/4”-20NC QTY. 0250015 5 6 DESCRIPTION STROBE LIGHT INSTALLATION - AMBER (OPTIONAL) STROBE LIGHT INSTALLATION - RED (OPTIONAL) 2 2 4 4 4 2-99 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-28. HOODS INSTALLATIONS - STANDARD S E C T I O N 2 T U R N T A B L E 2-100 3120806 SECTION 2 TURNTABLE . FIGURE 2-28. HOODS INSTALLATIONS - STANDARD FIG & ITEM # PART NUMBER 0250240 0250188 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4843371 1260017 0641408 4751400 4761400 3311401 2940051 4843424 4843448 3941406 4761400 3300151 4300031 2940048 3820019 2940050 3820012 4843423 3532202 3941406 4751400 4843256 4843426 18 19 20 21 22 4843425 4843643 0641408 4761400 4751400 3311401 2940048 3820019 0252317 0250669 23 24 25 26 27 28 29 3120806 1780245 0641405 4751400 4761400 3311401 2940057 2600157 DESCRIPTION HOODS INSTALLATION - FORD HOODS INSTALLATION - DEUTZ Note: Replacement decals must be ordered separately - See Section 8. QTY. REV. Ref. Ref. Ref. D C Ventilator Chain Bolt 1/4”-20NC x 1” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Latch Top, Hood (Ford) Top, Hood (Deutz) Screw, Self-Tapping 1/4” x 3/4” Lockwasher 1/4” Nut, Acorn 1/4”-20NC Stud (Welded on Part) Latch Rivet Latch Rivet Cover, Ground Control Plate, Cover Screw, Self-Tapping 1/4” x 3/4” Flatwasher 1/4” Cover - Counterweight (Turntable Side Length 38 15/ 16”) Cover - Counterweight (Turntable Side Length - 31 13/ 16”) Cover - Front (Ford) Cover - Front (Deutz) Bolt 1/4”-20NC x 1” Lockwasher 1/4” Flatwasher 1/4” Nut 1/4”-20NC Latch (Front Cover Only) Rivet 1 15 in. 10 10 10 10 1 1 1 12 16 5 5 2 2 1 2 1 1 6 6 1 GROUND CONTROL DOOR INSTALLATION - FORD GROUND CONTROL DOOR INSTALLAITON DEUTZ Ref. Ref. Door - Ground Control Bolt 1/4”-20NC x 5/8” Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Latch, Sliding Hinge S E C T I O N 2 T U R N T A B L E 1 1 1 6 6 6 3 1 2 B C 1 4 4 4 4 1 1 2-101 SECTION 2 TURNTABLE FIGURE 2-29. HOODS INSTALLATIONS - NOISE REDUCTION PACKAGE S E C T I O N 2 T U R N T A B L E 2-102 3120806 SECTION 2 TURNTABLE . FIGURE 2-29. HOODS INSTALLATIONS - NOISE REDUCTION PACKAGE FIG & ITEM # PART NUMBER 0252294 0253692 0253707 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 3120806 4844295 4844345 3960417 4844357 4300031 3941406 0641408 4751400 4761400 3300151 4070798 4844294 4844293 1670662 0641408 4751400 3311405 4844296 4844015 2600180 3941406 4751400 2940042 2940042 2940113 2940070 3960418 4060832 3311405 4751400 0641406 4160106 3311505 0901920 3311605 4751600 0641610 4843423 1670612 3310801 DESCRIPTION HOODS INSTALLATION - DEUTZ (PRIOR TO FEBRUARY 1993) HOODS INSTALLATION - DEUTZ (FEBRUARY 1993 TO PRESENT) HOODS INSTALLATION - FORD Note: Replacement decals must be ordered separately - See Section 8. Shield Weldment (Ford) Door Weldment (Deutz) (Not Shown) Seal (Deutz) Panel, Filler (Deutz - October 1993 to Present) (Not Shown) Weld Stud - 1/4”-20NC x 5/8” (Ford) (Prior to June 1994) Self Tapping - 1/4”-20NC (Ford) (June 1994 to Present) Bolt 1/4”-20NC x 1” (Deutz) Flatwasher 1/4” Lockwasher 1/4” Acorn Nut 1/4”-20NC (Prior to June 1994) Shim (Deutz) Hood Support Weldment Cover (Ford) Cover (Deutz - October 1993 to Present) (Not Shown) Hex Head Capscrew 1/4”-20NC x 1” Flatwasher 1/4” Locknut 1/4”-20NC Door Weldment (Ford) Door Weldment (Deutz) Hinge (Welded to Door) Screw, Self-Tapping 1/4” x 3/4” Lockwasher 1/4” Latch (Ford) Latch (Deutz) (Production) Latch (Deutz) (Post Production Alternative) Pawl, Latch (Deutz - Front Door Item 1 only) Seal Door Shield Locknut 1/4”-20 Flatwasher 1/4” Bolt 1/4”-20NC x 3/4” Gas Spring Locknut 5/16”-18 Bracket, Gas Spring Locknut 3/8”-16NC Flatwasher 3/8” Bolt 3/8”-16NC x 1 1/4” Ground Control Cover (Welded on) Cover, 110V Access Hex Nut #8-32 QTY. REV. Ref. Ref. 2 Ref. Ref. A 1 1 5 Ft. 1 S E C T I O N 2 8 T U R N T A B L E 8 4 A/R A/R A/R A/R 1 1 1 4 4 4 1 1 1 5 5 2 3 3 1 15 Ft. 2 2 2 2 1 2 1 3 3 3 1 1 4 2-103 SECTION 2 TURNTABLE FIGURE 2-29. HOODS INSTALLATIONS - NOISE REDUCTION PACKAGE (CONTINUED) FIG & ITEM # PART NUMBER 30 31 32 33 34 35 36 37 38 39 40 4760800 4750800 3910812 4844226 3532202 4751400 3941406 3520064 1670616 1670321 4300031 4751400 4761400 3311401 1670613 2820044 2820045 3820012 1670615 S E C T I O N 2 T U R N T A B L E 41 42 0252312 0255131 0250669 43 44 45 46 47 2-104 1780245 2940057 2600157 3311401 4761400 4751400 0641405 DESCRIPTION Lockwasher #8 Flatwasher #8 Machine Screw #8-32NC x 34” Counterweight Cover (Welded on) Cover Plate Flatwasher 1/4” Self-Tapping Screw 1/4”-20NC x 3/4” Plug, Hole Cover (Deutz) Cover (Deutz) Stud (Welded on Part) Flatwasher 1/4” Lockwasher 1/4” Nut 1/4”-20NC Cover, Inlet Box (Deutz) Foam, Acoustical - Bottom (Deutz) Foam, Acoustical- Side (Deutz) Rivet Cover - Base (Deutz) GROUND CONTROL DOOR INSTALLATION - FORD MACHINES BUILT PRIOR TO FEBRUARY 1995 GROUND CONTROL DOOR INSTALLATION - FORD MACHINES BUILT FEBRUARY 1995 TO PRESENT GROUND CONTROL DOOR INSTALLATION - DEUTZ Door Latch, Sliding Hinge Nut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Bolt 1/4”-20NC x 5/8” QTY. REV. 4 4 4 1 1 6 6 1 1 2 17 17 17 17 1 1 1 10 1 Ref. B Ref. - Ref. C 1 1 1 4 4 4 4 3120806 SECTION 3 BOOM TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 3-4 DESCRIPTION BOOM AND LIMIT SWITCHES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3-2 3-6 3-10 3-14 S E C T I O N 3 B O O M 3120806 3-1 SECTION 3 BOOM FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS S E C T I O N 3 B O O M 3-2 3120806 SECTION 3 BOOM . FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0251412 BOOM INSTALLATION (STANDARD - PRIOR TO APRIL 1992) BOOM INSTALLATION (STANDARD - APRIL 1992 TO PRESENT) Ref. D Ref. A 0253119 1 2 Not Used 0800743 3 4 5 6 7 3421603 0641832 4751800 3311805 0800585 8 9 10 11 12 13 14 15 16 17 3421614 0641832 4751800 3311805 4843132 3421617 0641840 4751800 3311805 1682013 18 19 3421616 0681810 4761800 4740307 3421598 0641528 4751500 3311505 1682053 20 21 22 23 24 25 1682739 26 27 28 29 30 31 32 33 34 3421615 0641814 4761800 4751800 3421599 3422075 0641528 4751500 3311505 1682019 1682745 3120806 Main Boom Assembly (See Figure 3-2 for Breakdown) Pin Bolt 1/2”-13NC x 4” Flatwasher 1/2” (When Equipped) Locknut 1/2”-13NC Tower Boom Assembly (See Figure 3-3 for Breakdown) Pin Bolt 1/2”-13NC x 4” Flatwasher 1/2” (When Equipped) Locknut 1/2”-13NC Upright Weldment Pin Bolt 1/2”-13NC x 5” Flatwasher 1/2” (When Equipped) Locknut 1/2”-13NC Master Level Cylinder Assembly (See Section 5 for Breakdown) Pin (Turntable Attach) Bolt 1/2”-13NC x 1 1/4” (Grade 8) Lockwasher 1/2” Washer, Thrust Pin (Tower Boom Attach Bolt 5/16”-18NC x 3 1/2” Flatwasher 5/16” (When Equipped) Locknut 5/16”-18NC Tower Lift Cylinder Assembly (Standard) (See Section 5 for Breakdown) (Prior to April 1992) Tower Lift Cylinder Assembly - TUV (Standard) (See Section 5 for Breakdown) (April 1992 to Present) Pin (Turntable Attach) Bolt 1/2”-13NC x 1 3/4” Lockwasher 1/2” Flatwasher 1/2” (When Equipped) Pin (Tower Boom Attach) (Prior to February 1991) Pin (Tower Boom Attach) (February 1991 to Present) Bolt 5/16”-18NC x 3 1/2” Flatwasher 5/16” (When Equipped) Locknut 5/16”-18NC Upright Level Cylinder Assembly (See Section 5 for Breakdown) (Prior to April 1992) Upright Level Cylinder Assembly - TUV (See Section 5 for Breakdown) (April 1992 to Present) S E C T I O N 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 B O O M 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3-3 SECTION 3 BOOM FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 35 3421605 2160002 4640812 0681810 4761800 3421618 0641840 4751800 3311805 1682072 S E C T I O N 36 37 38 39 40 41 42 1682764 43 44 45 46 47 48 49 50 3 B O O M 3421619 0641832 4751800 3311805 3421602 0641528 4751500 3311505 0239603 51 52 53 54 1600110 0641406 4761400 3311401 0250413 55 56 57 58 59 60 61 62 63 64 65 66 67 68 3-4 4640310 7012649 0630415 0630427 3311605 3311802 0100011 4360266 3930812 0100019 0901644 0641407 4761400 3311401 4070738 0901643 0641610 4761600 3311601 DESCRIPTION Pin (Tower Boom Attach) Fitting, Grease Valve, Relief Bolt 1/2”-13NC x 1 1/4” Lockwasher 1/2” Pin (Upright Attach) Bolt 1/2”-13NC x 5” Flatwasher 1/2” (When Equipped) Locknut 1/2”-13NC Main Lift Cylinder Assembly (See Section 5 for Breakdown) (Prior to April 1992) Main Lift Cylinder Assembly - TUV (See Section 5 for Breakdown) (April 1992 to Present) Pin (Upright Attach) Bolt 1/2”-13NC x 4” Flatwasher 1/2” (When Equipped) Locknut 1/2”-13NC Pin (Main Boom Attach) Bolt 5/16”-18NC x 3 1/2” Flatwasher 5/16” (When Equipped) Locknut 5/16”-18NC LEVEL SENSOR INSTALLATION Sensor, Level Bolt 1/4”-20NC x 3/4” Lockwasher 1/4” Nut 1/4”-20NC BOOM VALVES AND SWITCHES INSTALLATIONS Valve, Plunger Seal Kit - 4640310 Valve (1 Per Valve) Screw, Plow (3/8” Threads) Screw, Plow (1/2” Threads) Locknut 3/8” - 16NC Nut, Jam 1/2”-13NC Loctite #242 Switch, Limit Bolt, Socket Head #8-32NC x 3/4” Adhesive Bracket, Switch Mounting Bolt 1/4”-20NC x 7/8” Lockwasher 1/4” Nut 1/4”-20NC Shim Cover, Switch Bracket Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Nut 3/8”-16NC QTY. REV. 2 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ref. - 1 2 2 2 Ref. G 2 2 2 2 2 2 A/R 1 2 A/R 1 2 2 2 A/R 1 2 2 2 3120806 SECTION 3 BOOM FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 69 70 71 80 1100043 4360266 3930812 0100019 0901645 0641409 4761400 3311401 4070439 1100044 4360277 4360236 4360278 4460052 81 82 3900168 4920140 72 73 74 75 76 77 78 79 DESCRIPTION Cam (Prior to September 1995) Switch, Limit (Prior to September 1992) Bolt #8-32NC x 3/4” (Prior to September 1992) Adhesive Bracket, Switch Mounting (Prior to September 1992) Bolt 1/4”-20NC x 1 1/8” (Prior to September 1992) Lockwasher 1/4” (Prior to September 1992) Nut 1/4”-20NC (Prior to September 1992) Shim (Prior to September 1992) Cam (Prior to September 1992) Switch, Limit (September 1992 to Present) Head, Actuator (September 1992 to Present) Arm and Roller (September 1992 to Present) Connector, Strain Relief (September 1992 to Present) Screw, Special (September 1992 to Present) Wire, Safety (September 1992 to Present) QTY. REV. 1 1 2 A/R 1 2 2 2 A/R 1 1 1 1 1 S E C T I O N 3 2 A/R B O O M 3120806 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 3120806 SECTION 3 BOOM . FIGURE 3-2. MAIN BOOM ASSEMBLY FIG & ITEM # PART NUMBER 0800743 1 2 3 4 5 6 7 8 9 10 11 12 13 0800717 3340473 0641608 4761600 0100019 4070678 4070677 4070676 3340552 0641607 4761600 0100019 4070670 4070671 4070672 1682415 14 3421601 3760133 3421604 3422043 3760133 0681520 15 16 17 3271501 0800581 0961593 0961768 18 19 20 21 22 23 24 25 3120806 2160002 4640812 3780184 3340552 0641607 0641608 4761600 0100019 4070670 4070671 4070672 3340473 0641609 4761600 0100019 4070678 4070677 4070676 DESCRIPTION MAIN BOOM ASSEMBLY Boom Fly Weldment Pad, Wear (Fly Rear Top) Bolt 3/8”-16NC x 1” Lockwasher 3/8” Loctite Shim 1/32” Shim 1/16” Shim 1/8” Pad, Wear (Fly Rear Side and Bottom) Bolt 3/8”-16NC x 7/8” Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” Shim 1/8” Telescope Cylinder Assembly (See Section 5 for Breakdown) Pin (Fly Attach) Ring, Retaining Pin (Base Attach) (Prior to March 1992) Pin (Base Attach) (March 1992 to Present) Ring, Retaining (March 1992 to Present Only) Bolt 5/16”-18NC x 2 1/2” (Grade 8) (Prior to March 1992 Only) Nut 5/16”-18NC (Prior to March 1992 Only) Boom Base Weldment Bushing, Bronze (Boom Pivot) (Prior to February 1994) Bushing, Bronze (Boom Pivot) (February 1994 to Present) Fitting, Grease Valve, Relief (February 1994 to Present) O-Ring (February 1994 to Present) Pad, Wear (Base Front Top and Sides) Bolt 3/8”-16NC x 7/8” (Sides) Bolt 3/8”-16NC x 1” (Top) Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” Shim 1/8” Pad, Wear (Base Front Bottom) Bolt 3/8”-16NC x 1 1/8” Lockwasher 3/8” Loctite Shim 1/32” Shim 1/16” Shim 1/8” QTY. REV. Ref. E 1 2 3 3 A/R A/R A/R A/R 6 3 3 A/R A/R A/R A/R 1 S E C T I O N 3 B O O M 1 2 1 1 2 1 1 1 2 K 2 2 2 4 6 2 2 2 A/R A/R A/R A/R 2 3 3 A/R A/R A/R A/R 3-7 SECTION 3 BOOM FIGURE 3-2. MAIN BOOM ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 26 27 28 29 4843468 3311405 4761400 4751400 4300031 1670450 3311405 4761400 4751400 4300031 4843147 1180190 7006139 7006151 7006152 Cover, Boom Locknut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Stud (Welded on Part - Not Shown) Cover, Hose Locknut 1/4”-20NC Lockwasher 1/4” Flatwasher 1/4” Stud (Welded on Part - Not Shown) Cover, Hose Carrier, Hose and Cable Powertrack - 1 Ft. Section Mounting Feet Pin Kit (Includes 1 pin, 1 Retaining Ring & 4 Washers) Spacer Shim, Nylon) Rod Screw Bolt 1/4”-20NC x 5/8” Bolt 1/4”-20NC x 5/8” Lockwasher 1/4” Flatwasher 1/4” Cover Bolt 3/8”-16NC x 1” Flatwasher 3/8” Lockwasher 3/8” Locknut 3/8”-16NC Cable, Control - 16/30 Cable, Control - 12/4 Cable, Control - 12/3 (Prior to September 1993) Decal - Ground (Prior to September 1993) Decal - Neutral (Prior to September 1993) Block, Cover Support Bolt 3/8”-16NC x 1” Lockwasher 3/8” Shim 1 4 4 4 4 1 4 4 4 4 1 1 A/R 2 Pair A/R S E C T I O N 30 31 32 33 34 35 3 B O O M 36 37 38 39 40 41 42 43 44 45 46 47 48 7006162 7006163 7006156 7006158 0641405 0641405 4761400 4751400 4843146 0641608 4751600 4761600 3311605 1060229 1060012 1060461 1700598 1700599 0560923 0641608 4761600 4070559 0251396 3534745 3-8 BOOM NOSE PROTECTOR INSTALLATION OPTIONAL (NOT SHOWN) Plate, Skid (Welded to end of Item 1) REV. A/R A/R A/R A/R 4 4 8 8 1 4 8 4 4 82 ft./25m 82 ft./25m 82 ft./25m 2 2 1 2 2 A/R Ref. - 1 3120806 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 3120806 3-9 SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY S E C T I O N 3 B O O M 3-10 3120806 SECTION 3 BOOM . FIGURE 3-3. TOWER BOOM ASSEMBLY FIG & ITEM # PART NUMBER 0800585 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3120806 0800588 0960929 0961770 3340580 0641609 4761600 0100019 4070555 4070838 4070556 4070837 3340550 0641610 4761600 0100019 4070670 4070671 4070854 4070672 4070855 3340580 3900166 0100019 4070555 4070838 4070556 4070837 0800587 3340580 0641609 4761600 0100019 4070555 4070838 4070556 4070837 3340550 0641609 4761600 0100019 4070670 4070671 4070854 4070672 4070855 3340500 DESCRIPTION TOWER BOOM ASSEMBLY (SEE SECTION 10 FOR BOEING MACHINES) Boom Fly Weldment Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Pad, Wear (Fly Rear Top) Bolt 3/8”-16NC x 1 1/8” Lockwasher 3/8” Loctite Shim 1/8” (Prior to December 1992) Shim 1/8” (December 1992 to Present) Shim 1/16” (Prior to December 1992) Shim 1/16” (December 1992 to Present) Pad, Wear (Fly Rear Side) Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” (Prior to February 1994) Shim 5/64” (February 1994 to Present) Shim 1/8” (Prior to February 1994) Shim 1/8” (February 1994 to Present) Pad, Wear (Fly Rear Bottom) Screw, Countersink Socket 3/8”-16NC x 1” Loctite Shim 1/8” (Prior to December 1992) Shim 1/8” (December 1992 to Present) Shim 1/16” (Prior to December 1992) Shim 1/16” (December 1992 to Present) Boom Mid Weldment Pad, Wear (Mid Front Top and Bottom) Bolt 3/8”-16NC x 1 1/8” Lockwasher 3/8” Loctite Shim 1/8” (Prior to December 1992) Shim 1/8” (December 1992 to Present) Shim 1/16” (Prior to December 1992) Shim 1/16” (December 1992 to Present) Pad, Wear (Mid Front Side) Bolt 3/8”-16NC x 1” Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” (Prior to February 1994) Shim 5/64” (February 1994 to Present) Shim 1/8” (Prior to February 1994) Shim 1/8” (February 1994 to Present) Pad, Wear (Mid Rear Top) QTY. REV. Ref. H S E C T I O N 1 2 2 2 3 3 A/R A/R A/R A/R A/R 4 2 2 A/R A/R A/R A/R A/R A/R 2 3 A/R A/R A/R A/R A/R 1 4 12 12 A/R A/R A/R A/R A/R 4 8 8 A/R A/R A/R A/R A/R A/R 2 3 B O O M 3-11 SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 24 25 45 0641608 4761600 0100019 4070786 4070787 3340550 0641609 4761600 0100019 4070670 4070671 4070854 4070672 4070855 3340580 0641608 4761600 0100019 4070555 4070838 4070556 4070837 0800586 0960929 0961770 3340580 0641610 4761600 0100019 4070555 4070838 4070556 4070837 3340550 0641607 4761600 0100019 4070670 4070671 4070854 4070672 4070855 1681997 46 47 48 49 50 51 3421597 3760257 3421596 3311801 3951810 0961355 S E C T I O N 26 3 31 32 33 27 28 29 30 B O O M 34 35 36 37 38 39 40 41 42 43 44 3-12 DESCRIPTION Bolt 3/8”-16NC x 1” Lockwasher 3/8” Loctite Shim 1/16” Shim 1/8” Pad, Wear (Mid Rear Sides) Bolt 3/8”-16NC x 1 1/8” Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” (Prior to February 1994) Shim 5/64” (February 1994 to Present) Shim 1/8” (Prior to February 1994) Shim 1/8” (February 1994 to Present) Pad, Wear (Mid Rear Bottom) Bolt 3/8”-16NC x 1” Lockwasher 3/8” Loctite Shim 1/8” (Prior to December 1992) Shim 1/8” (December 1992 to Present) Shim 1/16” (Prior to December 1992) Shim 1/16” (December 1992 to Present) Boom Base Weldment Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Pad, Wear (Base Front Top and Bottom) Bolt 3/8”-16NC x 1 1/4” Lockwasher 3/8” Loctite Shim 1/8” (Prior to December 1992) Shim 1/8” (December 1992 to Present) Shim 1/16” (Prior to December 1992) Shim 1/16” (December 1992 to Present) Pad, Wear (Base Front Side) Bolt 3/8”-16NC x 7/8” Lockwasher 3/8” Loctite Shim 1/32” Shim 5/64” (Prior to February 1992) Shim 5/64” (February 1994 to Present) Shim 1/8” (Prior to February 1994) Shim 1/8” (February 1994 to Present) Telescope Cylinder Assembly (See Section 5 for Breakdown) Pin (Fly Attach) Ring, Retaining Pin (Base Attach) Nut 1/2”-13NC Setscrew 1/2”-13NC x 1 1/4” Spacer QTY. REV. 2 2 A/R A/R A/R 4 2 2 A/R A/R A/R A/R A/R A/R 2 3 3 A/R A/R A/R A/R A/R 1 2 2 4 12 12 A/R A/R A/R A/R A/R 4 8 8 A/R A/R A/R A/R A/R A/R 1 1 2 1 2 2 2 3120806 SECTION 3 BOOM FIGURE 3-3. TOWER BOOM ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 52 53 54 55 56 3532976 0641811 4761800 4843160 1180192 7006139 7006151 7006152 0641406 0641408 4761400 4751400 1180191 3311801 4761800 4300045 1670487 3311401 4761400 2160002 4640812 3780185 1060267 4921567 1320103 4740368 3311601 1320131 57 58 59 60 61 62 63 64 65 66 67 68 69 70 0251421 101 3120806 1320050 DESCRIPTION Plate, Mounting - Telescope Cylinder Bolt 1/2”-13NC x 1 3/8” Lockwasher 1/2” Cover, Hose Carrier Powertrack - 1 Ft. Section Feet, Mounting Pin Kit (1990 to Present) Bolt 1/4”-20NC x 3/4” Bolt 1/4”-20NC x 1” Lockwasher 1/4” Flatwasher 1/4” Carrier Nut 1/2”-13NC Flatwasher 1/2” Stud (Welded on Part - Not Shown) Cover, Boom Nut 1/4”-20NC Lockwasher 1/4” Fitting, Grease Valve, Relief (February 1994 to Present) O-Ring (February 1994 to Present) Cable, Control - 16/16 (Prior to December 1992) Harness (December 1992 to Present) Clamp Lockwasher, Special Nut 3/8”-16NC Clamp (Mount with Existing Hardware) HOSE CLAMPS INSTALLATION Clamp QTY. REV. 1 4 4 1 1 A/R 2 Pair A/R 4 4 8 12 1 3 3 3 1 4 4 2 2 4 S E C T I O N 3 B O O M 42 ft/12.8m 1 1 2 2 1 Ref. - 4 3-13 SECTION 3 BOOM FIGURE 3-4. BOOM WIPERS INSTALLATION S E C T I O N 3 B O O M 3-14 3120806 SECTION 3 BOOM . FIGURE 3-4. BOOM WIPERS INSTALLATION FIG & ITEM # PART NUMBER 0250196 1 3 4 0540081 0540083 2660075 2660080 3820001 3200308 5 6 7 8 0540082 2660076 3820001 3200309 2 DESCRIPTION BOOM WIPERS INSTALLATION Brush, Wiper (Top) Brush, Wiper (Bottom) (Not Shown) Holder, Brush (Top) Holder, Brush (Bottom) (Not Shown) Rivet Mount (Top and Bottom) (Use Existing Hardware to Attach) Brush, Wiper (Side) Holder, Brush (Side) Rivet Mount (Side) (Use Existing Hardware to Attach) QTY. REV. Ref. B 1 1 1 1 3 2 S E C T I O N 2 2 6 2 3 B O O M 3120806 3-15 SECTION 3 BOOM FIGURE 3-4. BOOM WIPERS INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 3 B O O M 3-16 3120806 SECTION 4 PLATFORM TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 4-6 DESCRIPTION STANDARD PLATFORM AND FOOTSWITCH INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSOLE BOX ASSEMBLY - (Prior to January 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSOLE BOX ASSEMBLY - (January 1993 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . PAGE 4-2 4-6 4-10 4-12 4-16 4-20 S E C T I O N 4 P L A T F O R M 3120806 4-1 SECTION 4 PLATFORM FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION S E C T I O N 4 P L A T F O R M 4-2 3120806 SECTION 4 PLATFORM FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION FIG & ITEM # PART NUMBER 0239701 0253114 1 FIXED SUPPORT INSTALLATION (PRIOR TO APRIL 1992) FIXED SUPPORT INSTALLATION -TUV (APRIL 1992 TO PRESENT) 10 11 12 13 14 3421600 3421612 3532054 0641506 4060804 Support Weldment Bushing, Bronze Lockwasher 5/16” Bolt 3/8”-16NC x 1 1/4” (Grade 8) Flatwasher 3/8” Locknut 3/8”-16NC Fitting, Grease Bolt 5/16”-18NC x 2 1/2” Bolt 5/16”-18NC x 3” Pin, Nose Slave Cylinder Assembly (Machines Built Prior to April 1992) (See Section 5 for Breakdown) Slave Cylinder Assembly - TUV (Machines Built April 1992 to Present) (See Section 5 for Breakdown) Pin, Attach (Lower) Pin, Attach (Upper) Plate, Retainer Bolt 5/16”-18NC x 3/4” Shield, Hose (3/16” Flex-Guard) 15 3311501 Nut 5/16”-18NC 2 3 4 5 6 7 8 9 4843280 0960565 4761500 0681610 4751600 3300143 2160002 0641520 0641524 3421613 1682057 DESCRIPTION 1682742 0239514 0253112 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 3120806 4843636 0961259 0239512 0960565 1120299 4842915 0235238 0361675 4070705 4070706 4751500 4761500 3311501 3340454 4160026 2880404 0652014 QTY. REV. Ref. B Ref. A S E C T I O N 1 2 2 8 16 8 1 1 1 1 1 4 1 P L A T F O R M 1 1 1 2 10 in/ 28cm 2 ROTATING SUPPORT INSTALLATION (STANDARD PRIOR TO APRIL 1992) ROTATING SUPPORT INSTALLATION (STANDARD APRIL 1992 TO PRESENT) Ref. F Ref. A Support Weldment Bushing, Bronze Pivot Attach Weldment Bushing, Bronze Cap Shaft Weldment Rotator Assembly (See Items 201-225 for Breakdown) Block, Stop Shim 1/8” Shim 1/16” Flatwasher 5/16” Lockwasher 5/16” Nut 5/16”-18NC Pad, Brake Washer, Bellville Key, Square Bolt 5/8”-18NF x 1 3/4” 1 2 1 2 1 1 1 1 A/R A/R 2 4 2 2 8 1 1 4-3 SECTION 4 PLATFORM FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. 116 117 118 119 120 121 122 123 124 125 126 127 128 129 4752000 0681610 4751600 3300143 0641840 4751800 3311805 2160002 0641522 3421613 4740158 1670451 4300038 1682057 1 8 16 8 1 1 1 3 2 1 1 1 2 1 S E C T I O N 130 131 132 133 134 3421600 3421612 3532054 0641506 4060804 Flatwasher 5/8” Bolt 3/8”-16NC x 1 1/4” Flatwasher 3/8” Locknut 3/8”-16NC Bolt 1/2”-13NC x 5” Flatwasher 1/2” Locknut 1/2”-13NC Fitting, Grease Bolt 5/16”-18NC x 2 3/4” Pin, Attach Washer, Thrust Cover, Rotator Stud (Welded on Part) Slave Cylinder Assembly (Machines Built Prior to April 1992) (See Section 5 for Breakdown) Slave Cylinder Assembly - TUV (Machines Built April 1992 to Present) (See Section 5 for Breakdown) Pin, Attach (Lower) Pin, Attach (Upper) Plate, Retainer Bolt 5/16”-18NC x 3/4” Shield, Hose (3/16” Flexguard) 135 136 137 138 139 4070707 3520035 0641816 4761800 3311505 Shim 1/32” Plug Bolt 1/2”-13NC x 2” Lockwasher 1/2” Locknut 5/16”-18NC 1682742 4 P L A T F O R M 0235238 4-4 201 3160083 202 203 204 205 206 207 208 209 210 211 212 213 214 215 0080099 2760064 0440134 4740199 0440120 2440043 3440816 0080098 2440044 4740256 0440135 1760068 Not Used 3931010 ROTATOR ASSEMBLY Note: For Machines Built Prior to September 1991 refer to Service Information Bulletin #91-5 for Required Upgrade. REV. 1 1 1 1 2 10 in/ 28cm A/R 1 2 2 2 Ref. Ref. Rotator Motor Assembly (See Figure 4-3 for Breakdown) Adapter, Motor Housing, Gear Bearing, Sleeve Washer, Thrust Bearing, Thrust Gear, Worm Rollpin 1/4” x 1” Adapter, Motor to Worm Gear Gear, Worm Washer, Thrust Bearing, Sleeve Disc, Brake 1 Bolt, Socket Head #10-24NC x 5/8” 5 E 1 1 2 4 2 1 4 1 1 2 1 1 3120806 SECTION 4 PLATFORM FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 216 217 218 219 220 221 222 223 224 225 226 3441228 3931620 4761600 3931612 4070585 4070586 4070587 0100019 0100021 2160001 3020025 DESCRIPTION Rollpin 3/8” x 1 3/4” Bolt, Socket Head 3/8”-16NC x 1 1/4” Lockwasher 3/8” Bolt, Socket Head 3/8”-16NC x 3/4” Shim .010 Shim .005 Shim .002 Loctite #271 (Not Shown) Primer (Not Shown) Fitting, Grease - 90° Grease (Not Shown) PLATFORM WELDMENTS Note: Replacement decals must be ordered separately - See Section 8. 301 3510308 3510309 3510310 3510311 302 303 304 305 306 307 2600143 3311805 2160006 1780254 2940006 2560010 0237963 401 3120806 0641408 3311405 4740362 4360031 7000625 4460071 Standard Platform Options: 30” x 48” Platforms: 30” x 60” Platforms: 30” x 72” Platforms: 30” x 96” Platforms: Standard Platform Components Pin, Hinge Locknut 1/2”-13NC Fitting, Grease Door Weldment Latch, Door Handle FOOTSWITCH INSTALLATION Bolt 1/4”-20NC x 1” Locknut 1/4”-20NC Washer, Fender Footswitch Block, Contact Connector, Strain Relief QTY. REV. 2 2 6 4 A/R A/R A/R A/R A/R 1 A/R S E C T I O N Ref. Ref. 1 4 P L A T F O R M A/R 2 2 2 1 1 1 Ref. 7 3 3 3 1 2 1 4-5 SECTION 4 PLATFORM FIGURE 4-2. LOW MOUNT PLATFORMS AND FOOTSWITCH INSTALLATIONS S E C T I O N 4 P L A T F O R M 4-6 3120806 SECTION 4 PLATFORM FIGURE 4-2. LOW MOUNT PLATFORMS AND FOOTSWITCH INSTALLATIONS FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0250593 ROTATING SUPPORT INSTALLATION (PRIOR TO AUGUST 1990) ROTATING SUPPORT INSTALLATION (AUG. 1990 TO FEBRUARY 1991) ROTATING SUPPORT INSTALLATION (FEBRUARY 1991 TO APRIL 1992) ROTATING SUPPORT INSTALLATION (APRIL 1992 TO PRESENT) Ref. H Ref. C Ref. A Ref. _ 1281433 0251711 0253115 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 0238540 0239512 0961257 0960565 4040222 1120299 0235238 3340454 2880404 4160026 4752000 0652014 0641836 4751800 3311805 0901756 0641811 4761800 0641404 4761400 4751400 0641408 4562083 1670519 1670630 3421829 0641522 3311505 3421600 3421612 1682057 1682793 28 29 30 31 32 33 to 35 3120806 3532054 0641506 4761500 2160002 4740158 Not Required Pivot Attach Weldment (Prior to August 1990) Pivot Attach Weldment (August 1990 to Present) Bushing, Bronze (0238540 Pivot) Bushing, Bronze (0239512 Pivot) Shaft Weldment Cap Rotator Assembly (See Items 101-126 for Breakdown) Pad, Brake Key Washer, Belleville Flatwasher 5/8” Bolt 5/8”-18NF x 1 3/4” Bolt 1/2”-13NC x 4 1/2” Flatwasher 1/2” Locknut 1/2”-13NC Bracket Bolt 1/2”-13NC x 1 3/8” Lockwasher 1/2” Bolt 1/4”-20NC x 1/2” Lockwasher 1/4” Flatwasher 1/4” Bolt 1/4”-20NC x 1” Tube, Spacer Cover (Prior to January 1992) Cover (January 1992 to Present) Pin, Nose Bolt 5/16”-18NC x 2 3/4” Locknut 5/16”-18NC Pin, Attach (Lower) Pin, Attach (Upper) Slave Cylinder Assembly (Machines Built August Prior to April 1992) (See Section 5 for Breakdown) Slave Cylinder Assembly - TUV (Machines Built April 1992 to Present) Plate, Retainer Bolt 5/16”-18NC x 3/4” Lockwasher 5/16” Fitting, Grease Washer, Thrust S E C T I O N 1 1 2 2 1 1 1 2 1 8 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 2 2 1 1 1 4 P L A T F O R M 1 1 2 2 3 1 4-7 SECTION 4 PLATFORM FIGURE 4-2. LOW MOUNT PLATFORMS AND FOOTSWITCH INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 36 37 1380137 4920986 0251254 0253116 S E C T I O N 1 2 3 to 9 10 11 12 13 to 21 22 23 24 25 26 27 4 P L A T F O R M 0239512 0960565 4564579 Not Required 0641836 4751800 3311805 Not Required 3421613 0641522 3311505 3421600 3421612 1682057 1682742 28 29 30 31 32 33 34 35 4-8 3532054 0641506 4761500 2160002 4740158 4220137 1320160 3520035 DESCRIPTION Clip Retainer Wire, Mechanics FIXED SUPPORT INSTALLATION (PRIOR TO APRIL 1992) (NOT SHOWN) FIXED SUPPORT INSTALLATION (APRIL 1992 TO PRESENT) (NOT SHOWN) QTY. 1 1 ft./.3m Ref. B Ref. - Pivot Attach Weldment Bushing, Bronze Shaft 1 2 1 Bolt 1/2”-13NC x 4 1/2” Flatwasher 1/2” Locknut 1/2”-13NC 1 1 1 Pin, Nose Bolt 5/16”-18NC x 2 3/4” Locknut 5/16”-18NC Pin, Attach (Lower) Pin, Attach (Upper) Slave Cylinder Assembly (Machines Built Prior to April 1992) (See Section 5 for Breakdown) Slave Cylinder Assembly - TUV (Machines Built April 1992 to Present) Plate, Retainer Bolt 5/16”-18NC x 3/4” Lockwasher 5/16” Fitting, Grease Washer, Thrust Bar, Stop Clamp (Not Shown) Plug 1 2 2 1 1 1 0235238 ROTATOR ASSEMBLY: Note: For Machines Built Prior to September 1991 refer to Service Information Bulletin #91-5 for required upgrade. 101 3160083 102 103 104 105 106 107 108 109 110 0080099 2760064 0440134 4740199 0440120 2440043 3440816 0080098 2440044 Rotator Motor Assembly (See Figure 4-3 for Breakdown) Adapter, Motor Housing, Gear Bearing, Sleeve Washer, Thrust Bearing, Thrust Gear, Worm Rollpin 1/4” x 1” Adapter, Motor to Worm Gear Gear, Worm REV. 1 1 2 2 3 1 2 1 1 Ref. Ref. E 1 1 1 2 4 2 1 4 1 1 3120806 SECTION 4 PLATFORM FIGURE 4-2. LOW MOUNT PLATFORMS AND FOOTSWITCH INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 4740256 0440135 1760068 Not Used 3931010 3441228 3931620 4761600 3931612 4070585 4070586 4070587 0100019 0100021 2160001 3020025 DESCRIPTION Washer, Thrust Bearing, Sleeve Disc, Brake Bolt, Socket Head #10-24NC x 5/8” Rollpin 3/8” x 1 3/4” Bolt, Socket Head 3/8”-16NC x 1 1/4” Lockwasher 3/8” Bolt, Socket Head 3/8”-16NC x 3/4” Shim .010 Shim .005 Shim .002 Loctite #271 Primer Fitting, Grease - 90° Grease PLATFORM WELDMENTS Note: Replacement decals must be ordered separately - See Section 8. 201 3510376 3510377 3510378 3510379 202 203 204 205 206 207 208 209 2600143 3311805 2160006 1780254 2940006 2560010 0961450 0961259 0237963 301 3120806 0641408 3311405 4740362 4360031 7000625 4460071 Low Mount Platform Options: 30” x 48” Platforms: 30” x 60” Platforms: 30” x 72” Platforms: 30” x 96” Platforms: Standard Platform Components Pin, Hinge Locknut 1/2”-13NC Fitting, Grease Door Weldment Latch, Door Handle Bushing, Bronze (Top) Bushing, Bronze (Bottom) FOOTSWITCH INSTALLATION Bolt 1/4”-20NC x 1” Locknut 1/4”-20NC Washer, Fender Footswitch Block, Contact Connector, Strain Relief QTY. REV. 2 1 1 5 2 2 6 4 A/R A/R A/R A/R A/R 1 A/R S E C T I O N 4 Ref. Ref. P L A T F O R M 1 A/R 2 2 2 1 1 1 1 1 Ref. 7 3 3 3 1 2 1 4-9 SECTION 4 PLATFORM FIGURE 4-3.ROTATOR MOTOR ASSEMBLY S E C T I O N 4 P L A T F O R M 4-10 3120806 SECTION 4 PLATFORM FIGURE 4-3. ROTATOR MOTOR ASSEMBLY FIG & ITEM # PART NUMBER 3160083 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 7002105 7002123 Kit 7002104 7002111 7002117 Kit Kit 7002116 7002103 Kit 7009992 Kit 7002112 7002107 7002100 7000166 7002125 7002110 2900455 2900733 DESCRIPTION ROTATOR MOTOR ASSEMBLY Flange, Mounting Screw, Cap Seal, Dust Key, Woodruff Bearing, Thrust Needle Thrust, Bearing Race Seal, O-Ring Seal, Pressure Shaft, Output Housing Seal Plug, Housing Seal, O-Ring Drive Cap, End Screw, Cap Lockwasher Gerotor Sub-Assembly Plate, Spacer —————————— Seal Kit (Includes Items 3,7,8,11 and 13) (P/N 101-1009-007) Seal Kit (Includes Items 3,7,8,11 and 13) (P/N’s 101-1009-008 and 101-1009-009) Note: Identify by P/N stamped on nameplate located on Item 10. 3120806 QTY. REV. Ref. B 1 4 1 1 1 1 1 1 1 1 1 1 3 1 1 7 7 1 1 S E C T I O N 4 P L A T F O R M 1 1 Ref. 4-11 SECTION 4 PLATFORM FIGURE 4-4.CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993) S E C T I O N 4 P L A T F O R M 4-12 3120806 SECTION 4 PLATFORM FIGURE 4-4. CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993) FIG & ITEM # PART NUMBER 1281397 0860686 0860706 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3120806 3252043 0751006 4740120 3300177 4420038 0100001 0860538 3311505 4751500 0641508 2940052 2600132 2600105 1600094 7011903 2560038 2560040 4360274 3790015 4360132 4360131 4360108 Not Used 4360274 3790015 4360200 3790012 3251872 2920015 2920029 2920015 4360200 3790012 4060229 4360199 3790012 3520028 4360202 4060229 3790012 DESCRIPTION QTY. REV. Ref. E CONSOLE BOX ASSEMBLY - PQ CONTROLLERS AND VICKERS (2WS) CONSOLE BOX ASSEMBLY - PQ CONTROLLERS AND VICKERS (4WS) Ref. G Ref. D Lid (International Symbols) (Prior to January 1993) Screw, Pan Head #10-24NC x 3/4” Washer, Nylon Nut, Tinnerman Tape, Insulation Adhesive Box, Control (Includes Items 10-12) Nut 5/16”-18NC Flatwasher 5/16” Bolt 5/16”-18NC x 1” Latch Hinge Hinge (Access Door) Controller, PQ Electrical Assembly Knob (Lift) Knob (Swing) Switch, Push Button (Horn) O-Ring Switch, Push-pull (Emergency Stop) Lens, Red Switch (Emergency Stop) Block, Contact - 2 P.N.C. 1 18 18 18 1m A/R 1 4 4 4 2 1 1 3 3 2 A/R 1 1 1 1 1 CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993) Switch, Push Button (Start) O-Ring Switch, Toggle (Glow Plug - Optional) O-Ring (Glow Plug - Option) Nameplate (Glow Plug Option) Lamp (Engine Distress) Bulb Lamp (Chassis Out of Level) Switch, Toggle (Auxiliary Power) O-Ring Shield Switch, Toggle (Lights) (Optional) O-Ring Plug, Hole Switch, Toggle (Rotate) (Optional) Shield O-Ring S E C T I O N 4 P L A T F O R M 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-13 SECTION 4 PLATFORM FIGURE 4-4. CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993) (CONTINUED) FIG & ITEM # PART NUMBER 25 4360202 4060229 3790012 4360202 4060229 3790012 4360202 4060229 3790012 4360199 3790012 4360199 3790012 4360199 3790012 4360209 3640500 3910608 4750600 4760600 3310601 4460299 4460300 4460298 4460301 4460311 4460305 4460306 4460307 Not Used 4460244 0960238 3300048 4460071 0960238 3300048 3740049 3311001 4761000 1060309 Not Used 4360202 4060229 3790012 1600094 7011903 2560041 1600134 26 S E C T I O N 27 28 29 30 31 32 4 P L A T F O R M 33 34 35 36 37 38 39 40 41 42 43 44 45 4-14 DESCRIPTION QTY. Switch, Toggle (Level) Shield O-Ring Switch, Toggle (Steer) Shield O-Ring Switch, Toggle (Main Tele) Shield O-Ring Switch, Toggle (Engine Speed) O-Ring Switch, Toggle (Pump Volume) O-Ring Switch, Toggle (Wheel Speed) O-Ring Breaker, Circuit - 20 Amp Rail, Mounting Screw, Round head 36-32NC x 1/2” Flatwasher #6 Lockwasher #6 Nut #6-32NC Stop, Terminal Strip Barrier, Terminal End Block, Terminal Strip, Marking Bar, Buss Screw, Terminal Block Washer, Terminal Block Sleeve, Terminal Block 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 42 1 1 3 3 3 Connector Bushing, Insulating Nut, Conduit Connector Bushing, Insulating Nut, Conduit Relay Nut #10-24NC Lockwasher #10 Cable, Control - 12/4 (To Footswitch) 2 2 2 1 1 1 A/R A/R A/R 2.4m Switch, Toggle (Tower Tele) Shield O-Ring Controller, PQ (2WD) Electrical Assembly Knob, Controller (2WD) Controller, PQ (4WD) REV. 1 1 1 1 1 1 1 3120806 SECTION 4 PLATFORM FIGURE 4-4. CONSOLE BOX ASSEMBLY (PRIOR TO JANUARY 1993) (CONTINUED) FIG & ITEM # PART NUMBER 0253077 101 0140026 DESCRIPTION TILT ALARM INSTALLATION Alarm QTY. REV. Ref. - 1 S E C T I O N 4 P L A T F O R M 3120806 4-15 SECTION 4 PLATFORM FIGURE 4-5.CONSOLE BOX ASSEMBLY (JANUARY 1993 TO PRESENT) S E C T I O N 4 P L A T F O R M 4-16 3120806 SECTION 4 PLATFORM FIGURE 4-5. CONSOLE BOX ASSEMBLY (JANUARY 1993 TO PRESENT) FIG & ITEM # 1 PART NUMBER 0860739 2940052 2600105 2600132 3531023 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 3120806 3252224 3252382 3538392 1702402 4420008 0100001 1600141 7011907 7003751 2560112 4360199 4360202 4360200 3790012 4060229 2720015 4360274 4360289 7012611 7012612 4360282 0751006 4740120 3300177 4460386 3300147 0960905 4460052 3300047 0960239 4360202 3790012 4060229 0901796 4751000 4761000 3311001 3740085 3740086 3911012 DESCRIPTION QTY. CONSOLE BOX ASSEMBLY (STANDARD PARTS) Ref. Box Weldment Latch Hinge (Top) Hinge (Bottom) Rear Inner Reinforcement Lid Nameplate Options: Nameplate, Lid (January 1993 to May 1994) Nameplate, Lid (May 1994 to November 1994) Plate, Cover (November 1994 to Present) Decal, Lid (November 1994 to Present) Tape, Insulation Adhesive Controller, PQ Electrical Assembly Potentiometer Knob Switch, Toggle Switch, Toggle Switch, Toggle O-Ring Shield Lamp Switch, Push Button Switch, Emergency Stop Mushroom Head Boot Block, Contact - N.C. Screw #10-24NC x 3/4” Washer, Nylon Nut, Tinnerman Connector, Strain Relief Nut, Conduit Bushing Connector, Strain Relief Nut, Conduit Bushing Switch, Toggle O-Ring Shield Bracket Flatwasher #10 Lockwasher k#10 Nut #10-24NC Socket, Micro Switch Relay, Micro Switch Screw #10-24NC x 3/4” 1 2 1 1 1 1 REV. S E C T I O N 1 1 6 ft/2.5m A/R 3 3 3 3 4 4 1 9 5 2 2 1 1 1 1 21 21 21 1 1 1 2 2 2 1 1 1 1 8 8 8 A/R A/R 8 4 P L A T F O R M 4-17 SECTION 4 PLATFORM FIGURE 4-5. CONSOLE BOX ASSEMBLY (JANUARY 1993 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 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 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Not Used 3910608 4750600 4760600 3310601 4460299 4460298 4460301 4460311 4460305 4460306 4460307 4460300 4120013 3740058 3740063 0140019 0641508 4751500 3311505 Not Used 3560034 4761000 3311001 4360232 Not Used Not Used 4120012 3740057 3740066 4460404 4460405 4460423 0720803 4750800 4760800 Not Used Not Used 4420037 4460071 3300048 0960238 S E C T I O N 4 P L A T F O R M 0860825 101 4-18 1600141 7011907 DESCRIPTION QTY. Screw #6-32NC x 1/2” Flatwasher #6 Lockwasher #6 Nut #6-32NC Stop, Terminal Block, Terminal Strip, Marking Bar, Buss Screw, Terminal Washer, Terminal Sleeve, Terminal Barrier, Terminal Socket, Relay Relay Spring, Relay Alarm Bolt 5/16”-18NC x 1” Flatwasher 5/16” Locknut 5/16”-18NC 2 2 2 2 2 54 1 2 10 10 10 3 1 1 1 1 4 8 4 Plug, Hole (Not Shown) Lockwasher #10 Nut #10-24NC Breaker, Circuit - 15 AMP 8 1 1 1 Socket, Relay Relay Spring, Relay Strip, Terminal - #8 Strip, Terminal - #9 Strip, Terminal - #7 Screw, Machine #8-32NC x 3/8” Flatwasher #8 Lockwasher #8 1 1 1 10 32 2 16 16 16 Tape, Insulation Connector, Strain Relief Locknut, Conduit Bushing CONSOLE BOX ASSEMBLY - 2WS (2WD- JANUARY 1993 TO PRESENT/4WD - JANUARY 1993 TO JANUARY 1995) (VARIABLE PARTS) Controller, PQ Electrical Assembly REV. 14 ft/4m 1 1 1 Ref. B 1 1 3120806 SECTION 4 PLATFORM FIGURE 4-5. CONSOLE BOX ASSEMBLY (JANUARY 1993 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 102 103 104 2560112 3640752 Not Required 0860826 101 102 1600140 Not Required 0860974 101 102 103 104 1600141 7011907 2560112 3641032 0610111 7016307 0860826 101 102 103 104 1600140 7011903 7003789 Not Required 3640752 Not Required 0860976 101 102 103 104 1600140 7011903 7003789 Not Required 3641032 0610111 7016307 DESCRIPTION Knob Track CONSOLE BOX ASSEMBLY - 4WS (VARIABLE PARTS) Controller, PQ CONSOLE BOX ASSEMBLY - 2WS (4WD - JANUARY 1995 TO PRESENT) (VARIABLE PARTS) Controller, PQ Electrical Assembly Knob Track Board, PC Fuse - 7 Amp CONSOLE BOX ASSEMBLY - 4WS (2WD - JANUARY 1993 TO PRESENT/4WD - JANUARY 1993 TO JANUARY 1995) (VARIABLE PARTS) 3120806 Ref. Ref. B 1 1 1 1 1 1 Ref. Track 1 Ref. Controller, PQ Electrical Assembly Switch, Rocker 1 1 1 Track Board, PC Fuse - 7 Amp 1 1 1 Switch, Toggle - SPST (Glow Plug - Diesel Option) Switch, Toggle - SPST (Work Lights - Option) A 1 1 1 1 CONSOLE BOX ASSEMBLY - 4WS (4WD - JANUARY 1995 TO PRESENT) (VARIABLE PARTS) REV. 1 1 Controller, PQ Electrical Assembly Switch, Rocker OPTIONAL COMPONENTS (NOT SHOWN) 4360200 4360199 QTY. S E C T I O N 4 B B Ref. 1 1 4-19 P L A T F O R M SECTION 4 PLATFORM FIGURE 4-6.OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS S E C T I O N 4 P L A T F O R M 4-20 3120806 SECTION 4 PLATFORM FIGURE 4-6. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS FIG & ITEM # PART NUMBER 0252054 0251203 0252848 1 2 1670607 1670526 3941406 4751400 Not Used 0253558 3 4 3536566 0641406 4751400 3311405 DESCRIPTION CONSOLE BOX COVER INSTALLATION (BLACK) CONSOLE BOX COVER INSTALLATION (YELLOW) CONSOLE BOX COVER INSTALLATION (CLEAR PLEXI-GLASS) Cover (Black) Cover (Yellow) Screw, Self-Tapping 1/4-20 Flatwasher 1/4” RECEPTACLE PLATE INSTALLATION (AUSTRALIAN SPEC) Plate, Mounting Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Locknut 1/4”-20NC BEACON LIGHT OPTIONS 5 0252210/0252211 2920009 2920018 6 0238864/0238865 7 2920009 2920018 0901449 8 3120806 REV. Ref. Ref. Ref. 2 2 - Ref. A/R 3/3 A/R -/- F 4 2920013 2920111 Floodlight (Electric/Gas/Diesel Machines) Halogen Light (Electric/Gas/Diesel Machines) (Uses P/N 3536089 Mounting Plate) 2 2 Spring Bracket (Door Mounted) Bracket (Platform Mounted) Stop, Door 4 Ref. Ref. Ref. 4160028 0900232 0901056 4220007 - 1 2 4 2 WORKLIGHT OPTIONS (PRIOR TO NOVEMBER 1992) WORKLIGHT OPTIONS (NOVEMBER 1992 TO PRESENT) SELF-CLOSING GATE INSTALLATION S E C T I O N 1 1 4 4 2900068 0253987 0250143 9 Beacon Mounted Under Console Beacon (Red) Beacon (Amber) Beacon Mounted in Front of Console Beacon (Red) Beacon (Amber) Bracket, Mounting QTY. Ref. A 1 1 1 1 4-21 P L A T F O R M SECTION 4 PLATFORM FIGURE 4-6. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM # PART NUMBER 0253846 0254130 10 S E C T I O N 11 0480083 0480086 0480084 0251180 12 4 P L A T F O R M 4360263 0721016 4751000 4761000 3311001 3534494 1100054 0251921 1692405 13 14 15 16 17 18 19 20 21 22 23 24 25 26 4-22 1692959 0641820 1692980 4751800 3311805 0641616 4751600 4761600 3311601 4460071 0960238 3300048 0860619 3911012 4751000 4761000 3311001 3533904 0750806 4740120 3300177 4420008 DESCRIPTION MESH TO MIDRAIL INSTALLATION (LOW MOUNT PLATFORM) MESH TO MIDRAIL INSTALLATION (STANDARD PLATFORM) Mesh (Sides) (Low-Mount Platform) Mesh (Sides) (Standard Platform) Mesh (Door) PLATFORM INTERLOCK SWITCH INSTALLATION (FRENCH SPEC) Switch, Limit Screw, Machine #10-24NC x 2” Flatwasher #10 Lockwasher #10 Nut #10-24NC Plate, Mounting Cam, Activator SAFE LOAD INDICATOR SYSTEM INSTALLATION (STANDARD CONTROLS) (FRENCH SPEC) Safe Load Indicator System Amplifier Box, Junction Cell, Load (Front of Basket) Spacer (Rear of Basket) Bolt 1/2”-13NC x 2 1/2” Spacer Flatwasher 1k/2” Locknut 1/2”-13NC Bolt 3/8”-16NC x 2” Flatwasher 3/8” Lockwasher 3/8” Nut 3/8”-16NC Connector, Strain Relief Bushing Nut, Conduit Box Screw, Round Head #10-24NC Flatwasher #10 Lockwasher 310 Nut #10-24NC Lid Screw, Self-Tapping, #8 x 3/4” Washer, Nylon Nut, Tinnerman Tape, Insulating QTY. REV. Ref. - Ref. - 2 2 1 Ref. - 1 2 2 2 2 1 1 Ref. A 1 1 1 2 2 1 1 1 1 2 2 2 2 1 1 1 1 4 8 4 4 1 4 4 4 75.8cm 3120806 SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (Prior to September 1992) . . . . . . . . . . . . AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (September 1992 to Present) . . . . . . . . . . AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (Prior to September 1992) . . . . . . . . . . AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (September 1992 to Present) . . . . . . . AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (Prior To September 1992) . . . . . . . . . AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (September 1992 to Present) . . . . . . . LEVEL (UPRIGHT) CYLINDER ASSEMBLY (Prior to April 1992) . . . . . . . . . . . . . . . . . . . . . . . LEVEL (UPRIGHT) CYLINDER ASSEMBLY (April 1992 to Present) . . . . . . . . . . . . . . . . . . . . . MAIN LIFT CYLINDER ASSEMBLY (Prior To April 1992). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN LIFT CYLINDER ASSEMBLY (April 1992 To Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWER LIFT CYLINDER ASSEMBLIES (Prior To April 1992) . . . . . . . . . . . . . . . . . . . . . . . . . TOWER LIFT CYLINDER ASSEMBLIES (April 1992 To Present) . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLIES (Prior to April 1992). . . . . . . . . . . . . . SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY (April 1992 To Present) . . . . . . . . . . . . . STEER CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPE CYLINDER ASSEMBLIES - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BELLOWS INSTALLATION (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 5-2 5-4 5-6 5-8 5-10 5-12 5-14 5-16 5-18 5-20 5-22 5-24 5-26 5-28 5-30 5-32 5-34 5-36 5-40 S E C T I O N 5 C Y L I N D E R 3120806 5-1 SECTION 5 CYLINDER FIGURE 5-1.AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-2 3120806 SECTION 5 CYLINDER FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER DESCRIPTION QTY. REV. 1682376 AXLE LOCKOUT CYLINDER ASSEMBLY - 2WD (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) Ref. A 1682377 4640273 3300187 3300273 0100011 0100038 3951403 3900170 Kit Kit Kit 3480116 4562859 Kit Kit 1681322 Kit Kit 1120108 0100035 1681462 2160002 4640438 2900770 2220237 2900379 3120806 Barrel Bleeder Nut, Special (Prior to August 1992) Nut, Hex (August 1992 to September 1992) Loctite #242 Primer, Locking Setscrew 1/4”-20NC x 3/8” Setscrew 3/8”-16NC x 3/8” Ring, Guidelock Seal O-Ring Piston Spacer O-Ring Ring Head Seal, Rod Seal, Wiper Retainer, Head Loctite #222 Rod Fitting, Grease Cartridge, Check Valve Seal Kit - 4640438 Valve (1 Per Valve) Plug —————————— Kit, Seal (Includes Items 5,6,7,10,11,13 and 14) 1 3 1 1 A/R A/R 3 1 2 2 1 1 1 1 1 1 1 1 1 A/R 1 1 2 2 2 S E C T I O N 5 C Y L I N D E R 1 5-3 SECTION 5 CYLINDER FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-4 3120806 SECTION 5 CYLINDER FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLIES - 2WD (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # PART NUMBER 1682724 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1682725 1681462 1120108 1681322 4562859 3480116 3300273 Kit Kit Kit Kit Kit Kit Kit 3900170 2160003 2160002 3900175 3960416 3321401 0100011 0100038 0100035 4640509 2900792 2900379 3120806 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLY (STANDARD PARTS) Barrel Assembly Rod Retainer Head Spacer Piston Nut, Hex Seal, Wiper Seal, Rod Ring, Wear O-Ring Ring, Lock Seal, Piston O-Ring Setscrew 3/8”-16NC x 3/8” Fitting, Grease - 45° Fitting, Grease - 45° Setscrew 1/4”-28NF x 3/4” Seal, Thread Nut 1/4”-28NF Loctite #242 Primer, Locking Loctite #222 Valve, Cartridge (Counterbalance) Seal Kit - 4640509 Valve (1 Per Cartridge) —————————— Seal Kit - Lockout Cylinder (Includes Items 8-14) QTY. REV. Ref. C 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 3 3 3 A/R A/R A/R 2 2 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.AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-6 3120806 SECTION 5 CYLINDER FIGURE 5-3. AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NUMBER DESCRIPTION QTY. REV. 1682452 AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) Ref. A 1682453 4640273 3900175 3960416 3321401 3300273 0100011 3900170 Kit Kit Kit 3480134 4562859 3900141 0100011 Kit Kit 1681322 Kit Kit 1120108 0100035 1681460 2160002 4640438 2220885 2901148 3120806 Barrel Bleeder (Prior to April 1992) Setscrew 1/4”-28NF x 3/4” Seal, Thread (April 1992 to Present) Nut 1/4”-28NF (April 1992 to Present) Nut, Hex Loctite #242 Setscrew 3/8”-16NC x 3/8” Seal O-Ring Ring, Wear Piston Spacer Setscrew 1/4”-20NC X 3/8” Loctite #242 O-Ring Ring, Wear Head Seal, Rod Seal, Wiper Retainer, Head Loctite #222 Rod Fitting, Grease Cartridge, Check Valve Plug —————————— Kit, Seal (Includes Items 5,6,7,10,11,13 and 14) 1 3 3 3 3 1 A/R 3 1 1 1 1 1 1 A/R 1 1 1 1 1 1 A/R 1 1 2 2 S E C T I O N 5 C Y L I N D E R 1 5-7 SECTION 5 CYLINDER FIGURE 5-4.AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-8 3120806 SECTION 5 CYLINDER FIGURE 5-4. AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # PART NUMBER 1682727 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1682728 1682730 1120108 1681332 4565816 3480116 3300273 Kit Kit Kit Kit Kit Kit Kit 3900170 3900175 3321401 3960416 4640509 2900792 0100011 0100038 0100035 2160002 2900379 3120806 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) Barrel Weldment Rod Weldment Retainer Head Spacer Piston Nut, Hex Seal, Wiper Seal, Rod Ring, Wear O-Ring Ring, Lock Seal, Piston O-Ring Setscrew 3/8”-16NC x 3/8” Setscrew 1/4”-28NF x 3/4” Nut 1/4”-28NF Seal, Thread Valve, Cartridge (Counterbalance) Seal Kit - 4640509 Valve (1 Per Cartridge) Loctite Primer, Locking Locking Compound Fitting, Grease —————————— Seal Kit - Lockout Cylinders (Includes Items 8-14) QTY. REV. Ref. B 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 3 3 3 2 2 A/R A/R A/R 1 S E C T I O N 5 C Y L I N D E R 1 5-9 SECTION 5 CYLINDER FIGURE 5-5.AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-10 3120806 SECTION 5 CYLINDER FIGURE 5-5. AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NUMBER DESCRIPTION QTY. REV. 1682406 AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/4WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE) Ref. C 1682407 4640273 3900175 3960416 3321401 3300187 3300273 3900141 3900170 Barrel Bleeder (Prior to April 1992) Setscrew 1/4”-28NF x 3/4” (April 1992 to Present) Seal, Thread (April 1992 to Present) Nut 1/4”-28NF (April 1992 to Present) Nut, Special (Prior to August 1992) Nut, Hex (August 1992 to September 1992) Setscrew 1/4”-20NC x 3/8” (Prior to August 1992) Setscrew 3/8”-16NC x 3/8” (August 1992 to September 1992) Loctite #242 Primer, Locking Seal O-Ring Ring, Wear Piston Spacer O-Ring Ring, Backup Ring, Wear Head Seal, Rod Seal, Wiper Retainer, Head Loctite #242 Rod Fitting, Grease Cartridge, Check Valve Seal Kit (1 Per Valve) Plug —————————— Kit, Seal (Includes Items 5,6,7,10,11,13 and 14) 0100011 0100038 Kit Kit Kit 3480120 4563647 Kit Kit Kit 1680892 Kit Kit 1120179 0100035 1681787 2160002 4640438 2900770 2220885 2900381 3120806 1 2 2 2 2 1 1 2 1 S E C T I O N A/R A/R 1 1 1 1 1 1 1 1 1 1 1 1 A/R 1 1 2 2 2 5 C Y L I N D E R 1 5-11 SECTION 5 CYLINDER FIGURE 5-6.AXLE LOCKOUT CYLINDER ASSEMBLIES - 4WD/4WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) S E C T I O N 5 C Y L I N D E R 5-12 3120806 SECTION 5 CYLINDER FIGURE 5-6. AXLE LOCKOUT CYLINDER ASSEMBLIES - 4WD/4WS (SEPTEMBER 1992 TO PRESENT) (USE WITH OPTIONAL OSCILLATING AXLE) FIG & ITEM # PART NUMBER 1682757 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1681787 1682758 1120179 1680892 3480120 3300187 3300273 4563647 Kit Kit Kit Kit Kit Kit Kit Kit 3900141 3900170 0100011 3900175 3960416 3321401 2160002 0100035 0100038 4640509 2900792 2900381 3120806 DESCRIPTION QTY. AXLE LOCKOUT CYLINDER ASSEMBLIES - 4WD/ 4WS (SEPTEMBER 1992 TO PRESENT Rod Barrel Retainer Head Piston Nut (Prior to April 1992) Nut, Hex (April 1992 to Present) Tube, Spacer Seal, Wiper Seal, Rod Ring, Wear O-Ring Ring, Back-up O-Ring Seal, Piston Ring, Wear Setscrew 1/4”-20NC x 3/8” (Prior to April 1992) Setscrew 3/8”-16NC x 3/8” (April 1992 to Present) Loctite #242 Setscrew 1/4”-28NF x 3/4” Seal, Thread Nut 1/4”-28NF Note: Replace existing bleeders with these components when ordering parts. Fitting, Grease Compound, Locking Primer, Locking Valve, Holding Seal Kit - 4640509 Valve —————————— Seal Kit (Includes Items 8-15) REV. A 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 A/R 2 2 2 Ref. S E C T I O N 5 C Y L I N D E R 2 A/R A/R 2 2 1 5-13 SECTION 5 CYLINDER FIGURE 5-7.LEVEL (UPRIGHT) CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) S E C T I O N 5 C Y L I N D E R 5-14 3120806 SECTION 5 CYLINDER FIGURE 5-7. LEVEL (UPRIGHT) CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PART NUMBER DESCRIPTION QTY. REV. 1682019 LEVEL (UPRIGHT) CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) Ref. E 1682042 0961338 0961762 4640509 2900792 3300281 3900170 0100011 0100038 Kit Kit 3480105 Kit 4564158 Not Used Kit Kit 1682027 Kit Kit 1120160 0100035 1682028 0961329 0961763 2160002 2200201 2200213 0100020 2900375 3120806 Barrel Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Valve Seal Kit - 4640509 Valve Nut, Special Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Lock-Ring Seal, Piston Piston O-Ring Spacer, Tube 1 2 2 2 2 1 1 A/R A/R 2 2 1 1 1 O-Ring Ring, Wear Head Seal, Rod Wiper, Rod Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Fitting, Grease Plug 1/8” Plug 3/8” Sealant, Pipe —————————— Seal Kit (Includes Items 6,7,9,12,13,15 and 16) 1 1 1 1 1 1 A/R 1 2 2 1 4 2 A/R S E C T I O N 5 C Y L I N D E R 1 5-15 SECTION 5 CYLINDER FIGURE 5-8.LEVEL (UPRIGHT) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) S E C T I O N 5 C Y L I N D E R 5-16 3120806 SECTION 5 CYLINDER FIGURE 5-8. L EVEL (UPRIGHT) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1682745 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1682746 0961338 0961762 4640634 2900770 3300281 3900170 0100011 0100038 Kit Kit 3480105 Kit 4564158 Not Used Kit Kit 1682027 Kit Kit 1120160 0100035 1682028 0961329 0961763 2160002 4640812 2220885 3780185 2900375 3120806 DESCRIPTION LEVEL (UPRIGHT) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) QTY. REV. Ref. B Barrel Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Valve, Counterbalance Seal Kit - 4640634 Valve Nut Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Lock Ring Seal, Piston Piston O-Ring Spacer, Tube 1 2 2 2 2 1 1 A/R A/R 2 2 1 1 1 O-Ring Ring, Wear Head Seal, Rod Wiper, Rod Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior to February 1992) Bushing, Bronze (February 1994 to Present) Fitting, Grease Valve, Relief Fitting (February 1994 to Present Only) Plug, O-Ring O-Ring (February 1994 to Present Only) —————————— Seal Kit (Includes Items 6,7,9,12,13,15 and 16) 1 1 1 1 1 1 A/R 1 2 2 1 1 2 4 S E C T I O N 5 C Y L I N D E R 1 5-17 SECTION 5 CYLINDER FIGURE 5-9.MAIN LIFT CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) S E C T I O N 5 C Y L I N D E R 5-18 3120806 SECTION 5 CYLINDER FIGURE 5-9. MAIN LIFT CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 101 102 103 104 105 106 107 3120806 PART NUMBER DESCRIPTION QTY. REV. 1682072 MAIN LIFT CYLINDER ASSEMBLY (PRIOR TO APRIL 1992) Ref. F 1682073 0961361 4640452 2900770 Not Used 3300287 3900170 0100011 0100038 Kit Kit Kit 3480136 4564473 Not Used Kit Kit Kit 1682076 Kit 1120358 0100035 1682074 0961361 2160001 2180448 0100034 Barrel Assembly Bushing, Bronze Valve, Holding Seal Kit - 4640452 Valve 1 2 1 1 Nut Hex Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Ring, Guidelock Seal O-Ring Piston Spacer 1 1 A/R A/R 2 2 1 1 1 1 1 1 1 1 1 A/R 1 2 2 1 A/R 2901144 Ring, Wear Seal O-Ring Head Ring, Wiper Cap Loctite #222 Rod Assembly Bushing, Bronze Fitting, Grease - 90° Orifice (.062) Sealant —————————— Seal Kit (Includes items 7,8,9,13,14,15 and 17) 0251387 MANUAL DESCENT INSTALLATION (OPTIONAL) Ref. 1060373 4640677 2220820 4240033 0080189 0080226 2560109 3951403 3900230 Cable, Flex Valve Fitting, 90° Strap, Hose Adapter (Prior to S/N 047563) Adapter (S/N 047563 to Present) Knob Setscrew 1/4-20NC x 3/8” (Prior to S/N 047563) Setscrew #10-32NC x 3/8” (S/N 047563 to Present) S E C T I O N 5 C Y L I N D E R 1 E 1 1 1 8 1 1 1 1 1 5-19 SECTION 5 CYLINDER FIGURE 5-10.MAIN LIFT CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) S E C T I O N 5 C Y L I N D E R 5-20 3120806 SECTION 5 CYLINDER FIGURE 5-10. MAIN LIFT CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1682764 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1682765 0961361 0961760 4640634 2900770 Not Used 3300295 3900172 0100011 0100038 Kit Kit Kit 3480103 4565846 Not Used Kit Kit Kit 1682076 Kit 1120358 0100035 1682767 0961361 0961760 2160001 4640812 3780184 2901227 0253167 110 3120806 4640747 7010545 DESCRIPTION MAIN LIFT CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) Barrel Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Valve, Holding Seal Kit - 4640634 Valve QTY. REV. Ref. A 1 2 2 1 1 Nut, Special Setscrew 1/4”-20NC x 3/8” Loctite #242 Primer, Locking Ring, Guidelock Seal O-Ring Piston Spacer 1 1 A/R A/R 2 2 1 1 1 Ring, Wear Seal O-Ring Head Ring, Wiper Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Fitting, Grease 90° Valve, Relief Valve (February 1994 to Present) O-Ring —————————— Seal Kit (Includes Items 7,8,9,13,14,15 and 17) 1 1 1 1 1 1 A/R 1 2 2 2 2 4 MANUAL DESCENT INSTALLATION Valve, Lowering Seal Kit - 4640747 Valve S E C T I O N 5 C Y L I N D E R 1 Ref. - 1 1 5-21 SECTION 5 CYLINDER FIGURE 5-11.TOWER LIFT CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) S E C T I O N 5 C Y L I N D E R 5-22 3120806 SECTION 5 CYLINDER FIGURE 5-11. TOWER LIFT CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) FIG & ITEM # PART NUMBER 1682053 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1682054 0961361 4640509 2900792 2200201 0100020 3300287 3300170 0100011 0100038 Kit Kit Kit 3480136 Not Used 2200213 0100020 Kit Kit Kit 1682083 Kit 1120160 0100035 1682078 0961361 0961760 2160002 2160001 2900375 3120806 DESCRIPTION TOWER LIFT CYLINDER ASSEMBLY QTY. REV. Ref I Barrel Assembly Bushing, Bronze Valve, Cartridge Seal Kit - 4640509 Valve Plug 1/8” Sealant Nut, Hex Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Ring, Guidelock Seal O-Ring Piston 1 2 2 2 4 A/R 1 1 A/R A/R 2 2 1 1 Plug 3/8” Sealant Ring, Wear Seal O-Ring Head Ring, Wear Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Fitting, Grease (Prior to September 1991) Fitting, Grease - 90° (September 1991 to April 1992) —————————— Seal Kit (Includes Items 7,8,9,13,14,15 and 17) 2 A/R 1 1 1 1 1 1 A/R 1 2 2 1 1 S E C T I O N 5 C Y L I N D E R 1 5-23 SECTION 5 CYLINDER FIGURE 5-12.TOWER LIFT CYLINDER ASSEMBLIES (APRIL 1992 TO PRESENT) S E C T I O N 5 C Y L I N D E R 5-24 3120806 SECTION 5 CYLINDER FIGURE 5-12. TOWER LIFT CYLINDER ASSEMBLIES (APRIL 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1682739 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1682740 0961361 0961760 4640634 2900770 2220885 3300287 3300170 0100011 0100038 Kit Kit Kit 3480136 Not Used Not Used Kit Kit Kit 1682083 Kit 1120160 0100035 1682078 0961361 0961760 2160001 4640812 3780184 2900375 3120806 DESCRIPTION TOWER LIFT CYLINDER ASSEMBLY (STANDARD) QTY. REV. Ref. B Barrel Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Valve, Counterbalance Seal Kit - 4640634 Valve Plug, O-Ring Nut, Special Setscrew 3/8”-16NC x 3/8 Loctite #242 Primer, Locking Ring, Guidelock Seal O-Ring Piston 1 2 2 2 2 2 1 1 A/R A/R 2 2 1 1 Ring, Wear Seal O-Ring Head Ring, Wiper Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior To February 1994) Bushing, Bronze (February 1994 to Present) Fitting, Grease - 90° Valve, Relief Fitting O-Ring —————————— Seal Kit (Includes Items 7,8,9,13,14,15 and 17 1 1 1 1 1 1 A/R 1 2 2 1 2 4 S E C T I O N 5 C Y L I N D E R 1 5-25 SECTION 5 CYLINDER FIGURE 5-13.MASTER CYLINDER ASSEMBLY S E C T I O N 5 C Y L I N D E R 5-26 3120806 SECTION 5 CYLINDER FIGURE 5-13. MASTER CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1682013 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1682016 0960846 0961328 0961356 0961758 Not Used Not Used 3300190 3300281 3900139 3900170 0100011 0100038 Kit 3480102 Kit Kit 4564132 3900141 0100011 1681294 Kit Kit Kit Kit 1120286 0100035 1682014 0961328 0961759 2160001 4640812 3780183 2900340 3120806 DESCRIPTION MASTER CYLINDER ASSEMBLY Barrel Assembly Bushing (Prior to June 1989) Bushing, Bronze (June 1989 to October 1990) Bushing, Bronze (October 1990 to February 1994) Bushing, Bronze (February 1994 to Present) Nut, Special (Prior to February 1991) Nut, Hex (February 1991 to Present) Setscrew 1/4”-20NC x 1/2” (Prior to February 1991) Setscrew 3/8”-16NC x 3/8” (February 1991 to Present) Loctite #242 Primer, Locking O-Ring Piston Guidelock Ring Seal, Piston Spacer Setscrew 1/4”-20NC x 3/8” Loctite Head O-Ring Ring, Wear Wiper, Rod Seal, Rod Cap Loctite #222 Rod Assembly Bushing (Prior to February 1994) Bushing (February 1994 to Present) Fitting, Grease Valve, Relief Fitting O-Ring —————————— Seal Kit (Includes Items 7,9,10,14,15,16 and 17) QTY. REV. Ref. F 1 2 2 2 2 S E C T I O N 1 1 2 1 A/R A/R 1 1 2 2 1 1 A/R 1 1 2 1 1 1 A/R 1 1 1 2 2 4 5 C Y L I N D E R 1 5-27 SECTION 5 CYLINDER FIGURE 5-14.SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) S E C T I O N 5 C Y L I N D E R 5-28 3120806 SECTION 5 CYLINDER FIGURE 5-14. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLIES (PRIOR TO APRIL 1992) FIG & ITEM # PART NUMBER 1682057 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1682058 0960613 4640509 2900792 2200202 2200201 0100020 3300271 3300170 0100011 0100038 Kit Kit Kit 3480130 4563771 3951403 0100011 Kit Kit Kit 1681847 Kit 1120336 0100035 1682060 0961254 0961765 2160002 2901103 3120806 DESCRIPTION SLAVE CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO APRIL 1992) Barrel Assembly (1682057 Cylinder) Bushing, Bronze Valve Seal Kit - 4640509 Valve Plug 1/4” (Location may vary) Plug 1/8” (Location may very) Sealant Nut, Hex Setscrew 3/8”-16NC x 3/8” Loctite k#242 Primer, Locking Ring, Guidelock Seal O-Ring Piston Spacer Setscrew 1/4”-20NC x 3/8” Loctite Ring, Wear Seal T-Seal Head Ring, Wiper Cap Loctite #222 Rod Assembly Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Fitting, Grease —————————— Seal Kit (Includes Items 7,8,9,13,14,15 and 17) QTY. REV. Ref. B 1 2 2 2 2 4 A/R 1 1 A/R A/R 2 2 1 1 1 1 A/R 1 1 1 1 1 1 A/R 1 2 2 2 S E C T I O N 5 C Y L I N D E R 1 5-29 SECTION 5 CYLINDER FIGURE 5-15.SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) S E C T I O N 5 C Y L I N D E R 5-30 3120806 SECTION 5 CYLINDER FIGURE 5-15. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1682742 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1682793 0960613 0961764 1682060 0961254 0961765 1120336 0100035 1681847 3480130 3300271 0100011 0100038 4563771 4640634 2900770 3900170 3951403 0100011 2160002 2220885 Kit Kit Kit Kit Kit Kit Kit 4640812 3780183 2901103 3120806 DESCRIPTION SLAVE CYLINDER ASSEMBLY (APRIL 1992 TO PRESENT) Barrel Weldment Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Rod Weldment Bushing, Bronze (Prior to February 1994) Bushing, Bronze (February 1994 to Present) Cap Loctite #222 Head Piston Nut, Hex Loctite #242 Primer, Loctite Spacer Cartridge, Vented Valve Seal Kit - 4640634 Valve Setscrew 3/8”-16NC x 3/8” Setscrew 1/4”-20NC x 3/8” Loctite #242 Fitting, Grease Plug, O-Ring Wiper, Rod Seal, Rod Ring, Wear T-Seal Ring, Lock Seal O-Ring Valve, Relief Fitting (February 1994 to Present Only) O-Ring (February 1994 to Present Only) —————————— Seal Kit - Cylinder (Includes Item 13-19) QTY. REV. Ref. B 1 2 2 1 2 2 1 A/R 1 1 1 A/R A/R 1 1 1 1 1 A/R 2 2 1 1 1 1 2 2 1 2 4 S E C T I O N 5 C Y L I N D E R 1 5-31 SECTION 5 CYLINDER FIGURE 5-16.STEER CYLINDER ASSEMBLIES S E C T I O N 5 C Y L I N D E R 5-32 3120806 SECTION 5 CYLINDER FIGURE 5-16. STEER CYLINDER ASSEMBLIES FIG & ITEM # PART NUMBER 1681562 1682203 1681555 1 2 1681433 1681413 3300273 3300187 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0100011 0100038 Kit Kit 3480134 Kit 4562687 4564637 4562851 Not Used Kit Kit Kit 1681322 1681344 Kit 1120108 1681435 1682202 1681411 2160002 2160001 2160006 3900141 3900170 0100011 2901148 2901123 3120806 DESCRIPTION STEER CYLINDER ASSEMBLY (2WD FRONT AXLE) STEER CYLINDER ASSEMBLY (2WD REAR AXLE) STEER CYLINDER ASSEMBLY (4WD FRONT AND REAR AXLE) Barrel (1681562 Cylinder) Barrel (1682203/1681555 Cylinders) Nut, Hex (1681562/1681555 February 1991 to Present and 1682203 - August 1992 to Present) Nut, Special (1681562/1681555 - Prior to February 1991 and 1682203 - Prior to August 1992) Loctite #242 Primer, Locking Seal O-Ring Piston Ring, Wear Spacer (1681562 Cylinder) Spacer (1682203 Cylinder) Spacer (1681555 Cylinder) O-Ring Ring, Wear Seal, Rod Head, Cylinder (1681562 Cylinder) Head, Cylinder (1682203/1681555 Cylinder) Wiper, Rod Cap Rod (1681562 Cylinder) Rod (1682203 Cylinder) Rod (1681555 Cylinder) Fitting, Grease - Straight Fitting, Grease - 90° Fitting, Grease (4WD/4WS Only) Setscrew 1/4”-20NC x 3/8” (1681562/1681555 - Prior to February 1991 and 1682203 - Prior to August 1992) Setscrew 3/8”-16NC x 3/8” (1681562/168155 - February 1991 to Present and 1682203 - August 1992 to Present) Loctite #242 —————————— Kit, Seal (Includes Items 3,4,6,9,10,11 and 13) (1681562 Cylinder) Kit, Seal (Includes Items 3,4,6,9,10,11 and 13) (1682203/1681555 Cylinders) QTY. REV. Ref. Ref. Ref. H C D 1 1 1 S E C T I O N 1 A/R A/R 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 3 C Y L I N D E R 1 A/R 1 1 5-33 SECTION 5 CYLINDER FIGURE 5-17.TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM S E C T I O N 5 C Y L I N D E R 5-34 3120806 SECTION 5 CYLINDER FIGURE 5-17. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM FIG & ITEM # PART NUMBER 1682415 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 1682416 Not Used 1120108 0100035 1681283 Kit Kit Kit Kit 4564275 3951603 0100011 3480092 3300282 0100011 0100038 3900170 Kit Kit Kit 1682039 2200201 2200222 0100020 0560810 0641628 0641632 4751600 3311601 Not Used 4640675 0641520 0100011 2900396 3120806 DESCRIPTION TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM Barrel Assembly End Cap Loctite #222 Head Ring, Wear Seal, Wiper Seal, Rod O-Ring Spacer, Tube Setscrew 3/8”-26NC x 3/8” Loctite #242 Piston Nut, Hex (February 1991 to Present) Loctite #242 Primer, Locking Setscrew 3/8”-16NC x 3/8” O-Ring Ring, Guidelock Seal, Piston Rod Assembly Plug 1/8” Plug 1/4” Sealant, Pipe Block, Support Bolt 3/8”-16NC x 3 1/2” Bolt 3/8”-16NC x 4” Flatwasher 3/8” Nut 3/8”-16NC Valve, Dual Counterbalance (Not Field Repairable Replace Complete Valve) Bolt 5/16”-18NC x 2 1/2” Loctite #242 —————————— Seal Kit (Includes Items 5,6,7,8,13,14 and 15) QTY. REV. Ref. B 1 1 A/R 1 1 1 1 1 1 2 A/R 1 1 A/R A/R 1 1 2 2 1 1 2 A/R 1 1 1 4 2 S E C T I O N 5 C Y L I N D E R 1 4 A/R 5-35 SECTION 5 CYLINDER FIGURE 5-18.TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM S E C T I O N 5 C Y L I N D E R 5-36 3120806 SECTION 5 CYLINDER FIGURE 5-18. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NUMBER DESCRIPTION QTY. REV. 1681997 TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM Ref. H 1682001 1120108 0100035 1681283 Kit Kit Kit Kit 4564117 3480126 Kit Kit Kit 3300277 3900170 0100011 0100038 2200201 0100020 1682051 3300287 Rod - 2” (Top) Cap, End Loctite #222 Head - 3” Cylinder Bore (Top) Seal, Wiper Seal, Rod Ring, Wear O-Ring Spacer, Tube - 3” Cylinder Bore (Top) Piston - 3” Cylinder Bore (Top) O-Ring Ring, Lock Seal, Piston Nut, Hex Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Plug, Pipe -1/8” Sealant Barrel Nut, Hex (Uses 3/8” Setscrew) (Prior to August 1991 Use 3300302 as replacement) Nut, Hex (Uses 3/8” Setscrew) (August 1991 to Present) Setscrew 3/8”-16NC x 3/8” Loctite #242 Primer, Locking Piston - 3 1/2” Cylinder Bore (Bottom) Ring, Lock Seal, Piston O-Ring Spacer Setscrew 1/4”-20NC x 5/8” Head - 3 1/2” Cylinder Bore (Bottom) O-Ring Ring, Wear Z-Seal Seal, Wiper Cap, End Bolt, Socket Head 5/8”-11NC x 2” Lockwasher 5/8” Rod - 2 1/2” (Bottom) Valve Seal Kit - 4640509 Valve Plug, Pipe - 1/8” Sealant Plug, Pipe - 1/16” 1 1 A/R 1 1 1 1 1 1 1 1 2 2 1 1 A/R A/R 2 A/R 1 1 3300302 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 3120806 3900170 0100011 0100038 3480113 Kit Kit Kit 4563636 3951405 1681423 Kit Kit Kit Kit 1120351 3932032 4762000 1682005 4640509 2900792 2200201 0100020 2180527 S E C T I O N 5 C Y L I N D E R 1 1 A/R A/R 1 2 2 1 1 2 1 1 1 1 1 1 6 6 1 1 1 1 1 A/R 5-37 SECTION 5 CYLINDER FIGURE 5-18. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (CONTINUED) FIG & ITEM # PART NUMBER 0100020 2901143 DESCRIPTION Sealant —————————— Seal Kit (Includes Items 4,5,6,7,10,11,12,20, 21,22,26,27,28 and 29) QTY. REV. 3 1 S E C T I O N 5 C Y L I N D E R 5-38 3120806 SECTION 5 CYLINDER FIGURE 5-18. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 5 C Y L I N D E R 3120806 5-39 SECTION 5 CYLINDER FIGURE 5-19.CYLINDER BELLOWS INSTALLATION (OPTIONAL) S E C T I O N 5 C Y L I N D E R 5-40 3120806 SECTION 5 CYLINDER FIGURE 5-19. CYLINDER BELLOWS INSTALLATION (OPTIONAL) FIG & ITEM # PART NUMBER 1281146 1 2 0460092 0460090 3 4 5 0460091 0460085 0460073 0460075 0460077 6 0460083 7 0460075 8 9 1320122 1320059 DESCRIPTION BELLOWS INSTALLATION Bellows (With Zipper) (Master Cylinder) Bellows (With Zipper) (Tower Lift and Upright Level Cylinders) Bellows (With Zipper) (Main Lift Cylinder) Bellows (With Zipper) (Slave Cylinder) Bellows (With Zipper) (2WD - Front Steer Cylinder) Bellows (With Zipper) (4WD - Front Steer Cylinder) Bellows (With Zipper) (Optional on 2WD/2WS, 2WD/4WS and 4WD/2WS with Oscillating Axle) Bellows (With Zipper) (Optional on 4WD/4WS with Oscillating Axle) Bellows (With Zipper) (Optional on 4WS - Rear Steer Cylinder) Clamp, Worm Gear (5 1/8”-6” Dia.) Clamp, Worm Gear (2 1/2”-12 1/2” Dia.) QTY. REV. Ref. C 1 2 1 1 1 1 2 S E C T I O N 2 1 A/R 4 5 C Y L I N D E R 3120806 5-41 SECTION 5 CYLINDER FIGURE 5-19. CYLINDER BELLOWS INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 5 C Y L I N D E R 5-42 3120806 SECTION 6 HYDRAULIC TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 DESCRIPTION HYDRAULIC DIAGRAM LIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - AXLE LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - DRIVE (4WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - LIFT (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - LIFT (TOWER BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - ROTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - TELESCOPE - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - TELESCOPE - TOWER BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 6-2 6-4 6-6 6-10 6-14 6-16 6-18 6-22 6-24 6-26 6-28 6-30 6-32 S E C T I O N 6 H Y D R A U L I C 3120806 6-1 SECTION 6 HYDRAULIC FIGURE 6-1.HYDRAULIC DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk(*) are shown in the following pages. Information on diagrams not shown is available from JLG service/parts departments. Ref. Ref. Ref. Ref. 2791851 2791852 Axle Lockout Hydraulic Diagrams: All Machines Built Prior to April 1992 except 4WD/ 4WS All Machines Built April 1992 to Present except 4WD/4WS 4WD/4WS Machines Built Prior to April 1992 4WD/4WS Machines Built April 1992 to Present Ref. 2791549 2791692 4640632 4640523 2900698 Brake With Pressure Reducing Valve Hydraulic Diagrams: 2WD Machines with Ausco Brake 4WD Machines with Ausco Brake Valve, Pressure Reducing Cartridge Seal Kit Ref. Ref. B B 2791496* 2791796 2791593* 2791795 Drive Hydraulic Diagrams: 2WD/2WS 2WD/4WS 4WD/2WS 4WD/4WS Ref. Ref. Ref. Ref. Ref. E 6 I F 2791595 2791949* Lift and Level (Tower Boom) Hydraulic Diagrams: Prior to April 1992 April 1992 to Present Ref. Ref. Ref. D B/3 2791498 2791950* Lift and Slave (Main Boom) Hydraulic Diagrams: Prior to April 1992 April 1992 to Present Ref. Ref. Ref. C B Ref. 2791780 2791954 Manual Descent Hydraulic Diagrams (French, Italian and Australian Specs): Prior to April 1992 April 1992 to Present Ref. Ref. B A 0253433 Oil Cooler Hydraulic Diagram Ref. - 2792149 2791648 Power Tool Hydraulic Diagram - 1/2” Lines Power Tool Hydraulic Diagram - 3/8” LInes Ref. Ref. A A 2791608* 2791494* Pump Hydraulic Diagrams: Deutz Machines Ford Machines Ref. Ref. Ref. E E 2791760 2791947* S E C T I O N 6 H Y D R A U L I C 6-2 REV. Ref. A Ref. Ref. A 3120806 SECTION 6 FIG & ITEM # PART NUMBER HYDRAULIC QTY. REV. Rotate Hydraulic Diagram Ref. B Sequence Line Hydraulic Diagram (Ford Machines) Ref. A/B Steer Hydraulic Diagrams: 2WS Machines with Fixed Axle 2WS Machines with Oscillating Axle 4WS Machines with Fixed Axle 4WS Machines with Oscillating Axle Ref. Ref. Ref. Ref. Ref. A/C B/C A/A B/A 2791501* Swing Hydraulic Diagram Ref. A 2791500* Telescope (Main Boom) Hydraulic Diagram Ref. 6/E 2791499* Telescope (Tower Boom) Hydraulic Diagram Ref. C 2791542 Tow Hydraulic Diagram Ref. - 2791503* 2791696/1281353* 2791505/1281049* 2791579/1281049* 2791798/1281519 2791797/1281519 DESCRIPTION S E C T I O N 6 H Y D R A U L I C 3120806 6-3 SECTION 6 HYDRAULIC FIGURE 6-2.AXLE LOCKOUT HYDRAULIC DIAGRAM S E C T I O N 6 H Y D R A U L I C 2791947 - Rev A 6-4 3120806 SECTION 6 HYDRAULIC FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM FIG & ITEM # PART NUMBER 2791947 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2220711 2750756 2220466 2751026 2220504 2750900 2751010 2220472 2220473 2751003 2750921 2220490 2750786 2220235 2220609 2751122 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAM Fitting, Tee Hose Fitting, Straight Hose Fitting, Tee Hose Hose Fitting, 90° Fitting, 90° Hose Hose Fitting, Tee Hose Plug Fitting, Reducer Hose QTY. REV. Ref. A 1 1 3 1 1 1 2 2 2 1 1 2 1 1 1 1 S E C T I O N 6 H Y D R A U L I C 3120806 6-5 SECTION 6 HYDRAULIC FIGURE 6-3.HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) S E C T I O N 6 H Y D R A U L I C 2791496 - Rev E 6-6 3120806 SECTION 6 HYDRAULIC FIGURE 6-3. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) FIG & ITEM # PART NUMBER 2791496 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 3120806 2220451 Not Used 2220356 2220347 2750692 2220465 2220800 Not Used 2220466 2751397 2220504 2751014 Not Used 2220375 Not Used Not Used 2220415 2751010 2751428 2220414 Not Used 2220585 2751483 Not Used Not Used 2220673 4640197 Not Used 2750774 2220362 Not Used Not Used 2750902 Not Used Not Used Not Used Not Used Not Used 2751415 2220822 Not Used Not Used Not Used Not Used 2220355 2220417 DESCRIPTION HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) QTY. REV. Ref. E Fitting, Straight 2 Fitting, 45° Fitting, Straight Hose Fitting 90° Fitting, Straight 2 2 2 2 5 Fitting, 90° Hose Fitting, Tee Hose 2 1 2 2 Fitting 2 Fitting, Straight Hose Hose Fitting, Straight 2 2 1 3 Fitting, 90° Hose 1 1 Fitting, 90° Valve, Check 1 1 Hose Fitting, Tee 2 3 Hose 1 Hose Fitting 1 1 Fitting, 45° Fitting, Straight 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 6-3. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) (CONTINUED) FIG & ITEM # PART NUMBER 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 2220909 Not Used Not Used 2751341 Not Used Not Used Not Used 0100020 2220374 2751357 2751491 2751391 2220582 2750776 2220659 2750929 2220345 2750970 2220517 S E C T I O N DESCRIPTION QTY. Fitting, Straight 1 Hose 1 Sealant, Thread (Not Shown) Fitting, Straight Hose Hose Hose Fitting, Straight Hose Fitting, 90° Hose Fitting, Straight Hose Cap REV. A/R 2 1 1 1 1 1 1 4 1 1 1 6 H Y D R A U L I C 6-8 3120806 SECTION 6 HYDRAULIC FIGURE 6-3. HYDRAULIC DIAGRAM - DRIVE (2WD/2WS) (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 3120806 6-9 SECTION 6 HYDRAULIC FIGURE 6-4.HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) S E C T I O N 6 H Y D R A U L I C 2791593 - Rev I 6-10 3120806 SECTION 6 HYDRAULIC FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) FIG & ITEM # PART NUMBER 2791593 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 3120806 2220451 2750692 2751357 2220356 2220347 2751341 2220465 2220375 2750969 2220800 2750972 Not Used 2220602 2751502 2751517 Not Used 2750902 2751391 2220582 2220466 Not Used Not Used 2750792 2220362 2750771 2220366 2750777 2751484 2220596 2750774 2751483 Not Used 2220345 2750762 2751472 2220415 2751010 2220504 2751428 2220833 2220605 Not Used 2751011 2220711 2751397 2751014 DESCRIPTION HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) QTY. REV. Ref. I Fitting Hose Hose Fitting, 45° Fitting Hose Fitting Fitting Hose Fitting, Straight Hose 2 2 1 2 2 1 2 9 1 2 2 Fitting, Tee Hose Hose 1 1 2 Hose Hose Fitting, Straight Fitting, 90° 1 1 1 2 Hose Fitting, Tee Hose Fitting, 90° Hose Hose Fitting, 90° Hose Hose 1 4 2 6 2 1 4 2 2 Fitting, Straight Hose Hose Fitting Hose Fitting, Tee Hose Fitting, Reducer Fitting, Tee 1 1 2 6 2 4 1 1 1 Hose Fitting, Tee Hose Hose 2 1 1 2 S E C T I O N 6 H Y D R A U L I C 6-11 SECTION 6 HYDRAULIC FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) (CONTINUED) FIG & ITEM # PART NUMBER 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 2750904 Not Used 2220414 4640197 2220673 2751415 2220585 2220822 2220417 2220909 Not Used 2220355 2220679 2220618 2220070 Not Used Not Used 2751398 2220235 Not Used 2220469 2750970 2220517 S E C T I O N 6 0100020 H Y D R A U L I C 6-12 DESCRIPTION QTY. Hose 1 Fitting Valve, Check Fitting, 90° Hose Fitting, 90° Fitting Fitting, Reducer Fitting, Straight 3 1 1 1 1 1 1 1 Fitting, 45° Fitting, Tee Fitting, Reducer Fitting, 90° 1 1 1 1 Hose Fitting, Plug 3 3 Fitting, 4 Way Hose Cap —————————— Sealant, Thread 1 1 1 REV. A/R 3120806 SECTION 6 HYDRAULIC FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (4WD/2WS) (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 3120806 6-13 SECTION 6 HYDRAULIC FIGURE 6-5.HYDRAULIC DIAGRAM - LIFT (MAIN BOOM) S E C T I O N 6 H Y D R A U L I C 2791950 - Rev B 6-14 3120806 SECTION 6 HYDRAULIC FIGURE 6-5. HYDRAULIC DIAGRAM - LIFT (MAIN BOOM) FIG & ITEM # PART NUMBER 2791950 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2751452 2220221 2220501 2220609 2180699 2751450 2220582 2220472 2751412 2220899 2220657 2750997 2180379 2180615 2220591 2220473 Not Used 2750778 2180448 2180380 2752468 2220582 0100020 3120806 DESCRIPTION HYDRAULIC DIAGRAM - LIFT (MAIN BOOM) QTY. REV. Ref. B Hose Fitting, Reducer Fitting, 45° Fitting, Reducer Fitting, Modified Hose Fitting Fitting, 90° Hose Fitting, Tee Fitting, 45° Hose Fitting, Tee Orifice (.047) Fitting, Reducer Fitting, 90° 1 2 2 2 1 1 1 1 1 2 1 2 2 2 2 4 Hose Orifice (.062) Options: Prior to May 1995 May 1995 to Present Hose Fitting, Straight —————————— Sealant, Thread 2 1 S E C T I O N 6 2 1 H Y D R A U L I C A/R 6-15 SECTION 6 HYDRAULIC FIGURE 6-6.HYDRAULIC DIAGRAM - LIFT (TOWER BOOM) S E C T I O N 6 H Y D R A U L I C 2791949 - Rev B 6-16 3120806 SECTION 6 HYDRAULIC FIGURE 6-6. HYDRAULIC DIAGRAM - LIFT (TOWER BOOM) FIG & ITEM # PART NUMBER 2791949 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 3120806 2220577 2750921 2751111 2220635 2220371 2750999 2180379 2180448 2180380 2220606 2750911 2220344 2220703 2751142 2220372 2751006 Not Used 2751166 2180379 2180621 2220591 2751906 2220472 2220628 2750997 2220609 2750760 2220582 2220473 2750786 2220773 2220579 2220702 2220605 2751412 4100026 DESCRIPTION HYDRAULIC DIAGRAM - LIFT (TOWER BOOM) Fitting, Straight Hose Hose Fitting, Tee Fitting Hose Fitting, Modified Orifice (.062) Options: Prior to May 1995 May 1995 to Present Fitting Hose Fitting Fitting, 90° Hose Fitting Hose Hose Fitting, Modified Tee Orifice (.031) Fitting, Reducer Hose Fitting Fitting, 90° Hose Fitting, Reducer Hose Fitting Fitting, 90° Hose Fitting, 90° Fitting, Tee Fitting, Tee Fitting, Tee Hose Sleeve, Nylon QTY. REV. Ref. B 2 2 1 2 1 1 1 1 S E C T I O N 2 1 1 1 1 1 1 2 2 2 2 2 4 1 1 7 1 1 3 1 1 1 1 2 2 5ft/1.5m 6 H Y D R A U L I C 6-17 SECTION 6 HYDRAULIC FIGURE 6-7.HYDRAULIC DIAGRAM - PUMPS S E C T I O N 6 H Y D R A U L I C 6-18 3120806 SECTION 6 HYDRAULIC FIGURE 6-7. HYDRAULIC DIAGRAM - PUMPS FIG & ITEM # PART NUMBER 2791494 2791608 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 3120806 4640575 2220622 2220385 2220409 2220602 2220619 2751331 2220372 2220618 Not Used 2220375 2750757 2750792 2220373 2220373 2220500 2750763 2751489 Not Used 2220578 2220451 Not Used Not Used 2220695 Not Used Not Used 2220428 2220429 Not Used 2220582 Not Used Not Used Not Used 2220710 2220624 2220349 2210014 Not Used 2220621 2751004 2750908 2220371 2751373 Not Used DESCRIPTION HYDRAULIC DIAGRAM - PUMO (FORD) HYDRAULIC DIAGRAM - PUMP (DEUTZ) QTY. REV. Ref. Ref. E E Valve, Check Fitting, Reducer Fitting, Tee Fitting, 45° (Ford and Deutz) Fitting, Tee Fitting, Reducer Hose Fitting Fitting, Reducer 2 3 2 1 1 1 1 2 1 Fitting, Straight Hose (Ford) Hose (Deutz) Fitting (Ford) Fitting (Deutz) Fitting, 45° (Deutz) Hose (Ford) Hose (Deutz) 1 1 1 5 4 1 1 1 Fitting, 90° Fitting 1 1 Fitting, Tee 1 Fitting, Quick Disconnect Cap, Dust 3 3 Fitting 3 Fitting, Reducer Fitting, Reducer Fitting Fitting, 90° Barbed 1 1 2 2 Fitting, Reducer Hose (Ford) Hose (Deutz) Fitting Hose 2 1 1 1 1 S E C T I O N 6 H Y D R A U L I C 6-19 SECTION 6 HYDRAULIC FIGURE 6-7. HYDRAULIC DIAGRAM - PUMPS (CONTINUED) FIG & ITEM # PART NUMBER 40 2220603 2220473 2220603 2220738 2220377 2210003 2210028 2220379 Not Used 1320033 Not Used 2750777 2220346 Not Used 2751931 2220329 2180683 Not Used 2751469 2220820 2750757 2220384 2220642 2751331 2751322 2751113 2220237 2751509 2751839 2751002 2750908 2220671 2220596 2751010 2220727 2220584 2220414 2751391 2220507 2220386 2750928 2720332 2720343 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 S E C T I O N 6 H Y D R A U L I C 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 0100020 6-20 DESCRIPTION QTY. Fitting (Ford) Fitting, 90° (Deutz) Fitting Fitting, Tee Fitting Fitting, Barbed (Ford) Fitting, Barbed (Deutz) Fitting 1 1 1 1 3 2 2 1 Clamp 8 Hose Fitting 1 1 Hose Fitting, Reducer Fitting, Modified Tee 1 1 2 Hose Fitting, 90° Hose Fitting, Tee Fitting, Tee Hose (Ford) Hose (Deutz) Hose Fitting Hose Hose Hose (Ford) Hose (Deutz) Fitting, 90° (Ford) Fitting, 90° (Deutz) Hose Fitting Fitting, Tee Fitting Hose Fitting, 90° Fitting, 90° Hose Hose, Suction (Ford) Hose, Suction (Deutz) —————————— Sealant, Thread 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 REV. A/R 3120806 SECTION 6 HYDRAULIC FIGURE 6-7. HYDRAULIC DIAGRAM - PUMPS (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 3120806 6-21 SECTION 6 HYDRAULIC FIGURE 6-8.HYDRAULIC DIAGRAM - ROTATOR S E C T I O N 6 H Y D R A U L I C 2791503 - Rev B 6-22 3120806 SECTION 6 HYDRAULIC FIGURE 6-8. HYDRAULIC DIAGRAM - ROTATOR FIG & ITEM # PART NUMBER 2791503 1 2 3 4 5 6 7 8 9 10 11 12 2220218 Not Used 2220895 4640778 Not Used Not Used Not Used Not Used 2220214 2220502 2751920 2220466 0100020 DESCRIPTION HYDRAULIC DIAGRAM - ROTATOR QTY. REV. Ref. B Fitting, Adapter 2 Fitting, Straight Valve, Restricter 2 2 Fitting, Reducer Fitting, 45° Hose Fitting, 90° —————————— Sealant, Thread 2 2 2 2 S E C T I O N A/R 6 H Y D R A U L I C 3120806 6-23 SECTION 6 HYDRAULIC FIGURE 6-9.HYDRAULIC DIAGRAM - SEQUENCE S E C T I O N 6 H Y D R A U L I C 2791696 - Rev A 6-24 3120806 SECTION 6 HYDRAULIC FIGURE 6-9. HYDRAULIC DIAGRAM - SEQUENCE FIG & ITEM # PART NUMBER 2791696 1 2 3 4 5 6 7 8 2220582 2220605 Not Used 2220909 Not Used 2751018 2220618 2220385 DESCRIPTION HYDRAULIC DIAGRAM - SEQUENCE QTY. REV. Ref. A Fitting, Adapter Fitting, Tee 1 1 Fitting, Restrictor (.015) 1 Hose Fitting, Reducer Fitting, Tee 1 1 1 S E C T I O N 6 H Y D R A U L I C 3120806 6-25 SECTION 6 HYDRAULIC FIGURE 6-10.HYDRAULIC DIAGRAM - STEER S E C T I O N 6 H Y D R A U L I C 1281049 - Rev C 6-26 3120806 SECTION 6 HYDRAULIC FIGURE 6-10. HYDRAULIC DIAGRAM - STEER FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 PART NUMBER DESCRIPTION QTY. REV. 2791505 2791579 HYDRAULIC DIAGRAM - STEER (FIXED AXLE) (2WS) HYDRAULIC DIAGRAM - STEER (OSCILLATING AXLE) (2WS) Ref. Ref. A B 2220468 Not Used 2220496 Not Used Not Used Not Used 2220416 Not Used 2750903 2750904 2751406 2751899 2751406 0100020 Fitting 2 Fitting, 45° 2 Fitting, 90° 4 Hose Hose (Fixed Axle) Hose (Oscillating Axle) Hose (Fixed Axle) Hose (Oscillating Axle) —————————— Sealant, Thread 2 1 1 1 1 S E C T I O N A/R 6 H Y D R A U L I C 3120806 6-27 SECTION 6 HYDRAULIC FIGURE 6-11.HYDRAULIC DIAGRAM - SWING S E C T I O N 6 H Y D R A U L I C 2791501 - Rev A 6-28 3120806 SECTION 6 HYDRAULIC FIGURE 6-11. HYDRAULIC DIAGRAM - SWING FIG & ITEM # PART NUMBER 2791501 1 2 3 4 5 6 7 8 9 10 11 12 13 2220221 Not Used 2220609 2751012 2220605 2180377 2750901 4640574 2750900 2220466 Not Used 2220472 2180732 0100020 DESCRIPTION HYDRAULIC DIAGRAM - SWING QTY. REV. Ref. A Fitting, Reducer 2 Fitting, Reducer Hose Fitting, Tee Fitting, Modified Hose Valve, Shuttle Hose Fitting, 90° 2 2 2 2 2 1 1 1 Fitting, 90° Fitting, Orifice (.093) —————————— Sealant, Thread 2 2 S E C T I O N A/R 6 H Y D R A U L I C 3120806 6-29 SECTION 6 HYDRAULIC FIGURE 6-12.HYDRAULIC DIAGRAM - TELESCOPE (MAIN BOOM) S E C T I O N 6 H Y D R A U L I C 2791499 - Rev C 6-30 3120806 SECTION 6 HYDRAULIC FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE (MAIN BOOM) FIG & ITEM # PART NUMBER 2791499 1 2 3 4 5 6 2220773 2220507 Not Used 2220372 Not Used 2750910 0100020 DESCRIPTION HYDRAULIC DIAGRAM - TELESCOPE (MAIN BOOM) QTY. REV. Ref. C Fitting, 90° Fitting, 90° 2 2 Fitting 2 Hose —————————— Sealant, Thread 2 A/R S E C T I O N 6 H Y D R A U L I C 3120806 6-31 SECTION 6 HYDRAULIC FIGURE 6-13.HYDRAULIC DIAGRAM - TELESCOPE (TOWER BOOM) S E C T I O N 6 H Y D R A U L I C 2791500 - Rev E 6-32 3120806 SECTION 6 HYDRAULIC FIGURE 6-13. HYDRAULIC DIAGRAM - TELESCOPE (TOWER BOOM) FIG & ITEM # PART NUMBER 2791500 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Not Used 2220501 2751114 2220343 Not Used 2220606 Not Used 2220703 4640774 2750998 Not Used 2220591 2750992 2220344 2750785 Not Used 2751110 4100026 0100020 DESCRIPTION HYDRAULIC DIAGRAM - TELESCOPE (TOWER BOOM) QTY. REV. Ref. E Fitting, 45° Hose Fitting 2 1 2 Fitting, Tee 2 Fitting, 90° Valve, Check Hose 1 1 1 Fitting, Reducer Hose Fitting Hose 2 1 1 1 Hose Sleeve, Hose —————————— Sealant, Thread 1 2 S E C T I O N 6 A/R H Y D R A U L I C 3120806 6-33 SECTION 6 HYDRAULIC FIGURE 6-13. HYDRAULIC DIAGRAM - TELESCOPE (TOWER BOOM) (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 6-34 3120806 SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 DESCRIPTION PAGE ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 S E C T I O N 7 E L E C T R I C A L 3120806 7-1 SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION ELECTRICAL DIAGRAM LIST Note: Diagrams with asterisks (*) are shown in the following pages. Diagrams not shown are available from the JLG Service Department. 4932024 0610091 3740049 4931947/1281985 0610091 3740049 4931946 3990010 3740049 0140016 4932063 4931954 4931950 0140016 3740049 4360089 4360229 S E C T I O N 7 4932637/1282091 E L E C T R I C A L 0610104 3740049 3990010 1060341 0253077 0140026 1540002 Card, Circuit Motion Electrical Diagram Relay Diode - 6 Amp Cable, Electrical - 16/2 Tilt Electrical Diagram Alarm Capacitor 4932490 4932639/1282091 REV. Ref. Ref. Ref. Ref. 1 1 Ref. 1 1 Ref. 2 1 1 Ref. Ref. Ref. 1 1 1 1 Ref. Ref. 1 Ref. 1 2 — G/G — A 3/C — 2/D 2/D 11ft./3.4m Ref. 1 1 A Australian Electrical Modification Ref. B 1281186 Cold Weather Electrical Diagram (Deutz) Ref. F 4932362/1281526 Collector Ring Electrical Diagram (4WS) Ref. A/C 1060042 4460260 0960239 3300047 7-2 Alarm Electrical Diagrams Options Machines Built Prior to January 1993: Back-up Alarm with Lights Electrical Diagram Card, Circuit Relay Travel/Back-up/Swing Descent Electrical Diagram Card, Circuit Relay Motion Electrical Diagram Diode - 6 Amp Relay, Bosch - SPDT Alarm, Horn Tilt Electrical Diagram (3°) Tilt Electrical Diagram (5º) Tilt Electrical Diagram (5° With Cut-Out) Alarm, Horn Relay, Bosch - SPDT Flasher - 12V (Without Cut-Out) Switch, Toggle - SPDT M/C Override) (With CutOut) Machines Built January 1993 to Present: Travel Electrical Diagram QTY. Cable, Electrical - 16/5 Connector, Strain Relief (At Ground Control Box) Bushing Nut, Conduit 14 ft. 1 1 1 3120806 SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER QTY. REV. Drive Cut-Out (Above Horizontal) Electrical Diagram (Italian Spec) Drive Cut-Out (8 Meter) Electrical Diagram (Austrian, German and Dutch Spec) Relay - 2PDT Socket Relay Ref. B Ref. B Dual Fuel Electrical Diagram (Ford) (Prior to June 1995) Harness (M.T.B. to Gas and LP Solenoid Valves) Switch, Toggle - DPDT Ref. Dual Fuel Electrical Diagram (Ford) (June 1995 to Present) Harness (M.T.B. to Gas and LP Solenoid Valves) Switch, Toggle - DPDT Ref. Engine Distress Electrical Diagram - Deutz Machines Harness Switch, Pressure Lamp, Indicator (At Platform Console) Ref. Ref. 2920026 4360182 4360157 3740049 2920029 Engine Distress Electrical Diagram - Ford Machines Light (At Platform Console) Switch, Oil Pressure Switch, Water Temperature Relay Bulb 0251682 3990010 3740049 4360065 Engine Shutdown Electrical Diagram (Deutz) Diode - 6 Amp Relay, Bosch - SPDT Switch, Pressure - N.C. Ref. 1 1 1 — 4932492 1693405 1692927 French Electrical Modification Relay, Time Delay Socket, Relay Ref. 1 1 C 4931945 4931692 Generator Electrical Diagram (110V) (Deutz) Generator Electrical Diagram (110V) (Ford) (Prior to February 1995) Generator Electrical Diagram (110V) (Ford) (February 1995 to Present) Outlet, Electrical - Female Twist Lock Diode - 3.5 Amp (Deutz) Diode - 6.5 Amp (Ford) Relay, Bosch - SPDT Breaker, Circuit - 30 Amp Marine Type Ref. Ref. A D Ref. 3/B 4932314 4932315 3740057 4120012 4931444/1281738 4921305 4360201 4932813* 4921763 4360201 0251537/1281525 4921361 4360065 2920026 0252625 4932806 4460027 3990001 3990010 3740049 4360294 3120806 DESCRIPTION 1 1 E/H 1 1 — S E C T I O N 1 1 D/E 1 1 1 5/E 1 1 1 1 1 7 E L E C T R I C A L 1 1 3 2 1 7-3 SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER QTY. REV. Heaters Electrical Diagram Cable, Electrical - 16/3 (Heaters to Junction Box) Cable, Electrical - 12/4 (Thermostat to Junction Box) Ref. 20 ft. 3 ft. 2/A Ref. Ref. 1 1 Ref. Ref. B —/— Ref. D 2920111 Lights Electrical Diagram Options Back-up Lights Electrical Diagram Card, Circuit Relay Beacon Light On Hood Electrical Diagram Beacon Light On Platform Electrical Diagram (In Front of Console) Beacon Light On Platform Electrical Diagram (Under Console) Light, Beacon - Amber Light, Beacon - Red Headlights and Taillights Electrical Diagram Relay, Bosch - SPDT (At Ground Control Box) Switch, Toggle - SPST (At Platform Console Box) Nametag - Light On Cable, Electrical - 16/3 Taillight/Clearance Light Relay, Power Panel Lights Electrical Diagram Light, Panel Worklights Electrical Diagram (Prior to January 1993) Breaker, Circuit - 15 Amp Worklight Worklights Electrical Diagram - Without Platform Padding (January 1993 to Present) Worklights Electrical Diagram - With Platform Padding (January 1993 to Present) Worklight, Halogen 0253433 4921529 Oil Cooler Electrical Diagram Harness Ref. 1 Platform Electrical Diagrams Options PQ Controllers - Prior to January 1993 Platform Electrical Diagram - 2WS Platform Electrical Diagram - 4WS Diode - 6 Amp (2WS) Diode - 6 Amp (4WS) Capacitor - 1000MF/25VDC Cable, Electrical - 12/4 (To Footswitch) PQ Controllers - January 1993 to Present Platform Electrical Diagram - 2WS With Creep (2WD - Jan. 1993 to Present/4WD - Jan. 1993 to Jan. 1995) Ref. 4931998 1060016 1060012 4932024 0610091 3740049 4931942 0238864/0238865 1281671 2920018 2920009 4931941 3740049 4360199 3251019 1060016 2920019 3740002 S E C T I O N 0251619/1281525 2920024 4931943 7 4360232 2920013 0253987 E L E C T R I C A L 0254748 4932313/1281523 4932369/1281523 3990010 3990010 1540002 1060309 4932582/1281968 7-4 DESCRIPTION 1 1 Ref. 1 1 1 A/R 2 1 Ref. 3 Ref. — E A/E — 1 2 Ref. 4/C Ref. 2/— 2 — Ref. Ref. 9 11 1 8 ft./1.4m D/F B/F Ref. 2/A 3120806 SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER 4932787/1282388 4932583/1281968 1060515 3990010 4932089 3740049 4460049 1060300 4932340 Platform Electrical Diagram - 2WS With Creep (4WD - January 1995 to Present) Platform Electrical Diagram - 4WS With Creep (4WD - January 1995 to Present) Cable, Electrical - 12/4 (To Footswitch) (was p/n 1060309) Diode - 6 Amp Platform Gate Interlock Electrical Diagram (French Spec) Relay Connector, Strain Relief Cable, Electrical - 16/3 QTY. REV. Ref. —/— Ref. 1/A 8 ft/2.4m A/R Ref. G 1 2 15 ft./4.6m Ref. 3740049 3990010 1693405 Platform Safe-Load System Electrical Diagram (French Spec) Relay Diode - 6 Amp Timer 4932052 Power Tool Electrical Diagram Ref. — 4932034 Standard Electrical Diagram (Deutz) Harness - Engine Prior to S/N 34339 S/N 34339 to Present Harness - Valves Cable, Electrical - 16/3 (To LImit Switch) Cable, Electrical - 16/3 (To Limit Switch) Diode - 6 Amp Resistor - 7.5 Ohms/8 Watt Bar, Buss (Term 44 and 45) Ref. 1 J 4921208 4921767 4921161 1060300 1060300 3990010 3730095 4460308 4932438 4932762 3990010 4921161 1060300 4921162 4921721 3730095 3730004 1870004 3120806 DESCRIPTION Standard Electrical Diagram (Ford) (Prior to February 1995) Standard Electrical Diagram (Ford) (February 1995 to Present) Diode - 6 Amp Harness - Valves Cable, Electrical - 16/3 (To Limit Switch) Harness - Engine (Prior to February 1995) Harness - Engine (February 1995 to Present) Resistor - 7.5 Ohms/8 Watt (Prior to February 1995) Resistor - 7.5 Ohms/8 Watt (February 1995 to Present) Standard Electrical Schematic S E C T I O N C 2 1 1 7 1 20 ft/6m 23 ft/7m 8 1 1 Ref. C Ref. A E L E C T R I C A L 9 1 38 ft/116m 1 1 1 1 Ref. — 7-5 SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER QTY. REV. Steer Electrical Diagram (4WS) Cable, Electrical - 16/5 Connector, Strain Relief (At Ground Control Box) Bushing Nut, Conduit Ref. 15ft/4.5m 1 1 1 A/C Ref. — 4932793 Tilt Indicator Electrical Diagram - 4WD Machines Built After January 1995 Harness 4932052 4360199 Tool Circuit Electrical Diagram Switch, Toggle - SPST Ref. 1 4932362/1281526 1060042 4460260 0960239 3300047 4932793 DESCRIPTION 1 — S E C T I O N 7 E L E C T R I C A L 7-6 3120806 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 3120806 7-7 SECTION 7 ELECTRICAL FIGURE 7-2.ELECTRICAL SCHEMATIC S E C T I O N 7 E L E C T R I C A L 7-8 3120806 SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 1870004 - Rev 3120806 7-9 SECTION 7 S E C T I O N ELECTRICAL PAGE LEFT BLANK INTENSIONALLY. 7 E L E C T R I C A L 7-10 3120806 SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 8-2 DESCRIPTION PAGE DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 S E C T I O N 8 D E C A L S 3120806 8-1 SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) S E C T I O N 8 D E C A L S 8-2 3120806 SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PART NUMBER DESCRIPTION QTY. REV. 0239627 DECAL INSTALLATION (PRIOR TO FEBRUARY 1992) Ref. D 1700431 1700978 1700977 1700580 1700585 1701205 1700430 1700428 1700756 1700419 Not Available 3820001 1700584 1700593 1700979 1700640 1700981 1700975 1700976 3251813 1700980 0860520 3311405 4751400 1060279 0641408 4751400 3311405 1700157 1700037 0961127 0100010 3251243 1700643 1700582 3251028 3252347 3820001 1700477 1700476 1700818 Not Used 1700429 2900750 3120806 Decal - Stripe Decal - Arrow Decal - FWD Decal - Electrocution Decal - Crushing Decal - 60HA Decal - Fuel - Gasoline Decal - Fuel - Diesel Decal - Full/Add Decal - Hydraulic OIl Nameplate - Serial Number Rivet Decal - Patent Decal - Inspection Decal - Top Gun (Boom Location) Decal - Crushing Decal - JLG Decal - Lift Here Decal - Tie Down Nameplate - Made in USA Decal - Top Gun (Upright Location) Box, Manual Storage Locknut 1/4”-20NC Flatwasher 1/4” Cable, Lanyard Bolt 1/4”-20NC x 1” Flatwasher 1/4” Locknut 1/4”-20NC Decal - Manual Decal - Ground Controls Bushing, Snap Loctite Nameplate - 120V Decal - Important Decal - Ground Control Operation Decal - Dual Fuel Nameplate - Footswitch (was p/n 3251766) Rivet Decal - Attach Belt Decal - No Hands Decal - LP Gas Liquid Withdraw System Decal - LP Gas —————————— Decal Kit (Includes Latest Decals - See Figure 8-2) 57 ft. 4 4 5 5 3 1 1 1 1 1 4 1 1 2 3 2 4 4 1 1 1 4 4 1 1 2 1 1 1 1 A/R 1 1 1 1 1 4 2 1 1 S E C T I O N 8 D E C A L S 1 1 8-3 SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) (CONTINUED) FIG & ITEM # PART NUMBER 0251833 34 1701461 0251243 4420051 DESCRIPTION DECALS INSTALLATION - MANUAL DESCENT Decal - Manual Descent Instructions QTY. REV. Ref. - 1 Note: See Control Valves Installation or Hydraulic Diagram - Manual Descent for Number Nametag Call- Outs. Ref. STRIPES INSTALLATION - CORNER WARNING (NOT SHOWN) Ref. Tape, Safety - Black/Yellow A 9.3m S E C T I O N 8 D E C A L S 8-4 3120806 SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (PRIOR TO FEBRUARY 1992) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 8 D E C A L S 3120806 8-5 SECTION 8 DECALS FIGURE 8-2.DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) S E C T I O N 8 D E C A L S 8-6 3120806 SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1281796 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 3120806 1701505 1701542 1701504 Not Used 1701529 1701518 Not Used Not Used 1700584 Not Used Not Available Not Used 1701500 Not Used 1701543 Not Used Not Used Not Used Not Used 3820001 Not Used Not Used Not Used Not Used Not Used 0860520 4751400 3311405 1060279 0641408 17001509 0961127 0100010 Not Used 1701502 Not Used 3251028 3252356 3251813* 1700818 Not Used 1701503 Not Used Not Used Not Used DESCRIPTION DECALS INSTALLATION (STANDARD PARTS) QTY. REV. Ref. K Decal - Fuel Options: Diesel Gasoline Decal - Hydraulic Fluid 1 Decal - Arrow Decal - Crushing 4 8 Decal - Patent 1 1 Nameplate - Serial Number 1 Decal - Tie Down/Lift 8 Decal - LP Gas 1 1 Rivet A/R Box, Manual Storage Flatwasher 1/4” Locknut 1/4”-20NC Cable, Lanyard Bolt 1/4”-20NC x 1” Decal - Manual Bushing, Snap Loctite 1 6 5 1 1 1 1 A/R Decal - Full/Add 1 Decal - Dual Fuel (February 1992 to May 1994) Decal - Dual Fuel (May 1994 to Present) Decal - USA Decal - LP Gas Liquid Withdrawn System 1 1 1 1 Decal - Hydraulic Oil Level (Low) 1 S E C T I O N 8 D E C A L S 8-7 SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 44 45 46 1701555 4420052 Not Available 51 52 53 54 55 S E C T I O N 4 A/R 1 0252799 DECALS INSTALLATION - BROWN (VARIABLE PARTS) Ref. 1701703 1700981 1701205 1701443 1701444 Decal - Stripe (was p/n 1700431) Decal - JLG Decal - Model 60HA (Small) Decal - JLG Lift Decal - Model 60HA (Large) —————————— DECALS INSTALLATION - BLACK (VARIABLE PARTS) 40 ft./12.3m 1701334 1701321 1701724 1701551 1701595 0252801 8 101 102 1700037 3252347 103 1701460 1702280 1690696 1691483 1690697 104 105 106 D E C A L S 0252802 101 102 103 104 105 106 1701515 1693292 1701572 1693286 1693289 1701577 0252803 101 102 103 104 8-8 QTY. Decal - Tire Pressure (Prior to September 1995) Tape, Safety Decal - Bar Code 0252800 51 52 53 54 55 DESCRIPTION 1693285 1693294 1701573 1693288 Decal - Stripe Decal - JLG Decal - Model 60HA (Small) Decal - JLG Lift Decal - Model 60HA (Large) DECALS INSTALLATION - EURO ENGLISH AND AUSTRALIA Decal - Ground Control Nameplate - Footswitch (Machines Built Prior to July 1992) (was p/n 3251766) Decal - Caution (Prior to May 1994) Decal - Caution (May 1994 to Present) Decal - Caution Decal - Caution Decal - Capacity DECALS INSTALLATION - FRENCH Decal - Commandes Sol Nameplate - Attention Decal - Attention Decal - Attention Decal - Attention Decal - Capacity DECALS INSTALLATION - GERMAN AND AUSTRIAN Decal - Bodenkontrolle Nameplate - Achtung Decal - Vorsicht Decal - Achtung REV. C 2 1 2 2 Ref. C 40 ft./12.2m 2 1 2 2 Ref. B 1 1 2 2 1 1 1 Ref. - 1 1 2 1 1 1 Ref. - 1 1 2 1 3120806 SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 105 106 1693291 1690697 0252805 101 102 103 104 105 1701616 Not Required 1701574 Not Required 1701596 0252804 101 102 103 104 105 106 1701599 101600 1701571 1701601 1701602 1690697 0253258 101 102 103 104 105 106 1701789 1701791 1701796 1701794 1701798 1690697 0253554 201 202 203 3252197 1702958 3820001 1701818 0251833 0253163 301 3120806 1701461 1701779 DESCRIPTION Decal - Achtung Decal - Capacity DECALS INSTALLATION - DUTCH QTY. 1 1 Ref. Decal - Noodbeniening 1 Decal - Waarschuwing 2 Decal - Belangryk 2 DECALS INSTALLATION - ITALIAN Decal - Comando A Terra Nameplate - Attenzione Decal - Attenzione Decal - Attenzione Decal - Attenzione Decal - Capacity DECALS INSTALLATION - SPANISH Decal - Clontrol De Tierra Nameplate - Precaucion Decal - Precaucion Decal - Precaucion Decal - Precaucion Decal - Capacity DECALS INSTALLATION - AUSTRALIAN ONLY Nameplate - Important Production Post Production Alternative Rivet Decal - Access Forbidden MANUAL DESCENT DECALS INSTALLATION (PRIOR TO APRIL 1992) MANUAL DESCENT DECALS INSTALLATION (APRIL 1992 TO PRESENT) Decal - Instructions (Prior to April 1992) Decal - Instructions (April 1992 to Present) REV. Ref. - - 1 1 2 1 1 1 Ref. S E C T I O N A 1 1 2 2 1 1 Ref. 8 C D E C A L S 1 4 2 Ref. A Ref. - 1 1 8-9 SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION (FEBRUARY 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S E C T I O N 8 D E C A L S 8-10 3120806 SECTION 9 RECOMMENDED SERVICE PARTS STOCK Model 60HA EURO The following lists will service fleets of machines (built to current production per date on the front cover with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department. JLG PART NUMBER 7000418 4360171 4360280 7012339 7002450 7004214 2120107 1340046 4360284 7010698 4360267 4360281 4360199 4360202 4360200 4360274 3740049 4360216 4360232 3740058 3740059 3740067 1600110 7006139 7006152 2940006 4360031 1600141 7011907 7003751 4360289 4360282 3740086 3990010 STANDARD PARTS Coil (Figures 1-14, 2-5 and 2-7) Sensor, Level - 5° (Figure 2-1) Sensor, Level - 3° (Figure 2-1) Coil (Figure 2-3) Coil (Figure 2-5) Element, Air Cleaner (Figure 2-14 and 2-20) Element, Hydraulic Oil (Figure 2-24) Breather, Hydraulic OIl (Figure 2-24) Switch, Key (Figure 2-26) Key, Replacement (Figure 2-26) Block, Contact (Figure 2-26) Block, Contact (Figure 2-26) Switch, Toggle (Figures 2-26 and 4-5) Switch, Toggle (Figures 2-26 and 4-5) Switch, Toggle (Figures 2-26 and 4-5) Switch, Push Button (Figures 2-26 and 4-5) Relay (Figure 2-26) Breaker, Circuit (Figure 2-26) Breaker, Circuit (Figures 2-26 and 4-5) Relay (Figure 2-26 and 4-5) Relay (Figure 2-26) Relay (Figure 2-26) Sensor, Level (Figure 3-1) Powertrack - 1 Foot Section (Figures 3-2 and 3-3) Pin Kit - Powertrack (Figures 3-2 and 3-3) Latch, Platform Door (Figures 4-1 and 4-2) Footswitch (Figures 4-1 and 4-2) Controller, PQ (Figure 4-5) Electrical Assembly - 1600141 Controller (Figure 4-5) Potentiometer - 1600141 Controller (Figure 4-5) Switch, Emergency Stop (Figure 4-5) Block, Contact (Figure 4-5) Relay, Micro Switch (Figure 4-5) Diode - 6 Amp (Figure 7-1) 4360386 1660184 7014502 7012598 7012656 7021869 VARIABLE PARTS Switch, Level Sensor (4WD) (Figure 2-1) Coupling, Engine (Deutz Machines) (Figure 2-14) Engine Oil Filters (Deutz Machines) (Figure 2-14) Engine Fuel Filters (Deutz Machines) (Figure 2-14) Coupling, Engine (Ford Machines) (Figure 2-20) Engine Oil Filters (Ford Machines) (Figure 2-20) 3120806 QTY PER FLEET DESCRIPTION 1-4 5-9 10 OR MORE 1 1 1 1 1 12 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1 1 2 1 1 1 1 1 12 8 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1 1 2 1 1 1 1 1 12 12 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1 1 2 1 1 1 case 1 1 1 case 1 1 1 case 1 1 1 case 1 1 1 case 1 1 1 case 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 STOCK Model 60HA EURO The following lists will service fleets of machines (built to current production per date on the front cover with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department. JLG PART NUMBER 3740080 1600211 7008829 7008828 4360212 3740077 4360277 7016307 9-2 QTY PER FLEET DESCRIPTION Relay (Ford Machines) (Figure 2-20) Controller, Engine (Ford Machines) (Figure 2-26) Adeco PC Board (Deutz Machines) (Figure 2-26) Adeco Cable (Deutz Machines) (Figure 2-26) Breaker, Circuit (Deutz Machines) (Figure 2-26) Relay, Bosch (Deutz Machines) (Figure 2-26) Switch, Limit (Figure 3-1) Fuse (4WD Machines) (Figure 4-5) 1-4 5-9 10 OR MORE 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 3120806 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. REV. Ref. 0250400 AIRLINE INSTALLATION - 1/2” Ref. C 0270723 AMBER BEACON ON PLATFORM INSTALLATION Ref. 1 0256789 CAMERA MOUNT ASSEMBLY Ref. ELECTRICAL CONNECTOR KITS Amp Connector Kit Deutsch DT Connector Kit Deutsch HD Connector Kit Packard Connector Kit Various Connector Kit Ref. Ref. Ref. Ref. Ref. Ref. 0251682 ENGINE SHUTDOWN INSTALLATION - DEUTZ MACHINES Ref. - 0254213 Ref. - 4844592 4566267 3220053 EXHAUST PURIFIER INSTALLATION - FORD MACHINES BUILT PRIOR TO FEBRUARY 1995) (ONLY NON-STANDARD ITEMS LISTED BELOW) Exhaust Weldment (Mounted to Engine) Tube, Exhaust (Before Purifier) Purifier, Exhaust 0253433 3620003 2060012 OIL COOLER INSTALLATION Oil Cooler Assembly Fan Ref. 1 1 - 0251693 OXY-ACETYLENE LINE INSTALLATION Ref. - PANEL LIGHTS INSTALLATION Light, Panel Ref. 3 A/D POWER TOOL CIRCUIT - 1/2” LINE POWER TOOL CIRCUIT - 3/8” LINE POWER TOOL VALVES INSTALLATION Valve, Relief Relief Cartridge (1 Per Assembly) Valve, Solenoid VAlve, Flow Divider Ref. Ref. Ref. 2 2 1 1 -/D -/D B RECEPTACLE INSTALLATION (AT PLATFORM) Ref. A/C SPARK ARRESTOR INSTALLATION - DEUTZ ENGINES Arrestor, Spark Ref. A 1001148902 1001148903 1001148904 1001148905 1001148906 0251619/1281525 2920024 0254873/1281218 0250827/1281218 0250838 4640047 7004146 4640123 4640151 0254443/1282163 0251675 3220036 3120806 DESCRIPTION S E C T I O N 1 0 S P E C I A L 1 1 1 1 10-1 O P T I O N S 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 3120044 3120089 3120048 3120046 3120344 3120351 3120322 REV. 1 1 1 1 1 1 1 Ref. 1 1 1 7016654 7004275 7004276 7002826 0256436 0257728 TUBE RACK INSTALLATIONS PRODUCTION POST PRODUCTION ALTERNATIVE Ref. Ref. Ref. 2 2 WELD LEADS INSTALLATION Ref. C/D 1 0 S P E C I A L 7002822 0250401/1281218 10-2 TECHNICAL PUBLICATION SUPPLEMENTS Engine Manual - Deutz FL1011 Engine Manual - Ford LSG-423 Engine Manual - Ford LRG-423 Engine Manual - Kubota V1902 OEM Controller Supplement PQ Controller Supplement Spec Data Handbook QTY. Tools for Service Wire Stripper Wire Crimper (To install wire ends to wires) Pin/Socket Extractor - Universal (To Remove Pins/ Sockets from Connectors) Screwdriver, Potentiometer (To Adjust Drive Controllers) Screwdriver, Magnetic Seal Installation Tool - 1” Seal Installation Tool - 1 1/2” Seal Installation Tool - 2” 7002828 7002821 7002823 O P T I O N S DESCRIPTION 1 1 1 1 1 3120806 3120806 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

Parts 3120806 10-05

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