JLG 110HXER Parts Manual

Illustrated Parts Manual

Models

100HX 110HX

110HXER

100HX+6

3120637

July 29, 2011

REVISION LOG

February 1989 - Original Issue Of Manual

August 1989 - Revised (Added 100HX)

February 1991 - Revised

February 1997 - Revised (New Format)

September 1997 - Change 1

October 1999 - Revised (Manual edited to 0010375 Revision 41)

March 1, 2000 - Revised (Manual edited to 0010375 Revision 41)

October 1, 2000 - Revised (Manual edited to 0010375 Revision 42)

February 12, 2004 - Revised

December 14, 2007 - Revised

July 29, 2011 - Revised

3120637 A

REVISION LOG

B 3120637

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3 DRIVE BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-4 DRIVE BRAKE ASSEMBLY - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-5 DRIVE MOTOR ASSEMBLY - VICKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

1-6 DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

1-7 VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED). . . . . . . . . . . . . . . . .1-22

1-8 TOW PACKAGE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620038 TURNTABLE

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4 CONTROL VALVES AND TILT INDICATOR INSTALLATIONS . . . . . . . . . . . . . . . . . . . .2-14

2-5 CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) . . . . . . . . . .2-18

2-6 CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) . . . . . . .2-22

2-7 CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO

JUNE 1995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-8 CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995

TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-9 ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989) . . .2-34

2-10 ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT) . . . . . . . . .2-36

2-11 CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

2-12 SWING DRIVE, BEARING AND LOCK INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2-40

2-13 SWING MOTOR ASSEMBLY - CHAR-LYNN (4620038 TURNTABLE MACHINES). . . . .2-44

2-14 SWING MOTOR ASSEMBLY - NICHOLS (4620044 AND 4620078 TURNTABLE

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

2-15 SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992). . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2-16 SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . .2-52

2-17 SWING HUB ASSEMBLY (4620038 TURNTABLE MACHINES) . . . . . . . . . . . . . . . . . . .2-56

2-18 SWING HUB ASSEMBLY (4620044 AND 4620078 TURNTABLE MACHINES) . . . . . . .2-58

2-19 ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . .2-60

2-20 DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO

OCTOBER 1992). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

2-21 DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992

TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-22 ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES . .2-78

2-23 GENERATOR INSTALLATIONS - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . .2-80

2-24 FORD LSG-423 ENGINE INSTALLATIONS (PRIOR TO MARCH 1995) . . . . . . . . . . . . .2-82

2-25 PRECISION GOVERNOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR

TO MARCH 1995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

2-26 GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO

MARCH 1995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92

2-27 FORD LRG-423 ENGINE INSTALLATION - (MARCH 1995 TO S/N 35742) . . . . . . . . . .2-94

2-28 FORD LRG-425 ENGINE INSTALLATION - (S/N 35742 TO PRESENT) . . . . . . . . . . . . .2-100

3120637 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

2-29 GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT MARCH 1995

TO PRESENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-106

2-30 DUAL FUEL INSTALLATION - FORD ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . 2-110

2-31 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-114

2-32 MAIN PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

2-33 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

2-34 GROUND CONTROLS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124

2-35 LOAD MANAGEMENT INSTALLATION (4620038 TURNTABLE) . . . . . . . . . . . . . . . . . .2-132

2-36 LOAD MANAGEMENT INSTALLATION (4620044 AND 4620078 TURNTABLES) . . . . .2-134

2-37 HOODS AND ALARM INSTALLATION (4620038 TURNTABLE) . . . . . . . . . . . . . . . . . . . 2-136

2-38 HOODS AND ALARM INSTALLATION (FORD ENGINE MACHINES WITH 4620044 AND

4620078 TURNTABLE & DEUTZ ENGINE MACHINES WITH 4620044 TURNTABLE) . . . .2-140

2-39 HOODS AND ALARM INSTALLATION (DEUTZ ENGINE MACHINES WITH

4620078 TURNTABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144

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

3-1 BOOM ASSEMBLY COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-3 EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER

ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

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

ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-5 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION . . . . . . . . . . . . .3-24

3-6 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

SECTION 4 - PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 PLATFORM COMPONENTS INSTALLATION - 100HX/110HX . . . . . . . . . . . . . . . . . . . .4-2

4-2 PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO

MAY 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-4 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 CONSOLE BOX ASSEMBLY - OEM CONTROLLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-6 CONTROLLER ASSEMBLIES - OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-7 OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . .4-24

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 AXLE EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 AXLE LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992) . . . . . . 5-6

5-4 LEVEL CYLINDER ASSEMBLY (100HX & 110HX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992) 5-10

5-6 LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER) . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO MAY 1992) . . . . . . . . . . . . . . . . . . . . 5-14

5-8 LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT) . . . . . . . . . . . . . . . . .5-16

5-9 LIFT CYLINDER ASSEMBLY - BOOM (TUV STYLE) (MAY 1992 TO PRESENT) . . . . . . 5-18

5-10 LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (100HX+10 & 110HXER ONLY) . . .5-20

5-11 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-12 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-13 TELESCOPE CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-14 CYLINDER BELLOWS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

ii 3120637

TABLE OF CONTENTS

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SECTION 6 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE &

WITH DUAL FRAME JACKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH

AUSCO DRIVE BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4 HYDRAULIC DIAGRAM - DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-5 HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER) . . . . . . . . . .6-12

6-6 HYDRAULIC DIAGRAM - LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-7 HYDRAULIC DIAGRAM - LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-8 HYDRAULIC DIAGRAM - PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-9 HYDRAULIC DIAGRAM - ROTATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-10 HYDRAULIC DIAGRAM - SEQUENCE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-11 HYDRAULIC DIAGRAM - SWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

6-12 HYDRAULIC DIAGRAM - TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 WIRING DIAGRAM - BOOM INDICATOR PENDULUM.. . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-3 WIRING DIAGRAM - DUAL FUEL (FORD ENGINE OPTION).. . . . . . . . . . . . . . . . . . . . .7-9

7-4 WIRING DIAGRAM - GENERATOR (DUETZ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7-5 WIRING DIAGRAM - GENERATOR (FORD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7-6 WIRING DIAGRAM - PLATFORM (100HX &110HX). . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-7 WIRING DIAGRAM - PLATFORM (100HX+10 & 110HXER). . . . . . . . . . . . . . . . . . . . . .7-13

7-8 WIRING DIAGRAM - STANDARD (100HX & 110HX WITH DEUTZ ENGINE) . . . . . . . . .7-14

7-9 WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) . . .7-17

7-10 WIRING DIAGRAM - STANDARD (100HX & 110HX WITH FORD ENGINE) . . . . . . . . .7-20

7-11 WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) . . . .7-24

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

8-1 DECALS INSTALLATION - STANDARD BROWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION - COUNTRY SPEC BROWN . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-3 DECALS INSTALLATION - STANDARD BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

8-4 DECALS INSTALLATION - COUNTRY SPEC BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

3120637 iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 3120637

SECTION 1 FRAME

S E

TABLE OF CONTENTS

FIGURE DESCRIPTION

1-1 STEERING AND AXLE/WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 BRAKE ASSEMBLY - MICO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE MOTOR ASSEMBLY - VICKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 DRIVE MOTOR ASSEMBLY - VICKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 VALVES AND SWITCHES INSTALLATIONS (Frame Mounted) . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

C T

I O N

3120637 1-1

SECTION 1 FRAME

E C T

I O N

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

1-2 3120637

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2360280 FRAME WELDMENT Ref.

STEERING INSTALLATION Ref.

0239122 Standard Ref. 5

0259555

0253574 CSA Ref. 2

0259556

1 1681934

2 4843050 Tie-Rod Assembly 1

2A 3420620 Pin, Quick Release 1

3 3421553 Kingpin 2 4 4740314 Washer, Thrust 2 5 3960243 Seal, Hub 2 6 3300007 Nut, Wheel 24 7 0630078 Stud, Wheel 24 8 2780159 Hub Assembly (Includes Item 7) 2

9 1120347 Cap, Hub 2 10 0721003 Bolt #10-24NC x 3/8" 8 11 4761000 Lockwasher #10 8 12 4740347 Washer, Hardened 2 13 3323803 Nut, Slotted 1 3/4"-12NF 2 14 3324203 Nut, Slotted 2"-12NF 2 15 0440190 Cup, Bearing 4 16 0440191 Cone, Bearing 4 17 3451012 Pin, Cotter 5/16" x 3" 4 18 3421524 Pin, Steer Cylinder 1 19 3312602 Nut, Jam 1"- 8NC 2 20 4740111 Washer, Thrust 5 21 2160002 Fitting, Grease 3 22 0642644 Bolt 1"-8NCx 5 1/2" 2 23 0560605 Block 2 24 3323002 Nut, Jam 1 1/4" - 12 NF 2 25 0641507 Bolt 5/16"-18NC x 7/8" 2 26 4761500 Lockwasher 5/16" 2 27 3532561 Plate, Retainer 1 28 Spindle (Left Side) Options: 1

4130206 Standard 4130370 Standard (Machines With Tow Bar Package) 4130300 CSA 4130371 CSA (Machines With Tow Bar Package)

28A 0960821 Bushing, Bronze 2

29 Pin, Clevis Options: 1

3421330 Prior to S/N 33256 3422635 S/N 33256 to Present

See Note

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

CSA (Machines with Tow Bar Package) (S/N 47309 to Present)

Steer Cylinder Assembly (See Section 5 for Breakdown)

3421330 Pin (Prior to S/N 33256) (Note Recommend using 3422635 in place of original 3421330)

Ref. 1

I O N

F R A

3120637 1-3

SECTION 1 FRAME

I O N

FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

30 3420158 Hairpin 1 31 4712600 Flatwasher 1" 1 32 Spindle (Right Side) Options: 1

4130205 Standard 4130299 CSA

0960821 Bushing, Bronze 2 33 0100011 Loctite #242 (Not Shown) A/R 34 3760170 Ring, Quick Release 2 35 1260017 Chain 8in/20cm 36 2160001 Fitting, Grease - 90° 2 37 2160003 Fitting, Grease - 45° 1

0239089 AXLES INSTALLATION Ref. 10

101 4843031 Inner Axle Weldment (Front Right Side) 1 102 4843030 Inner Axle Weldment (Front Left Side) 1 103 3972218 Setscrew 3/4"-10NC x 2 1/4" 16 104 3312202 Nut, Jam 3/4"-10NC 16 105 0361632 Bar 2 106 4070576 Shim 1/32" 2 107 4070577 Shim 1/16" 2 108 0642008 Bolt 5/8"-11NC x 1" 8 109 4712000 Flatwasher 5/8" 8 110 3311505 Locknut 5/16"-18NC 12 111 4300032 Stud (Welded on Part) 4 112 4761400 Lockwasher 1/4" 4 113 4843032 Bushing Weldment 4 114 3760106 D-Ring 4 115 1260017 Chain #3 64in/1.6m 116 3421546 Pin, Axle Lock 4 117 3421565 Snap-Pin 4 118 3760170 Ring, Quick Release 4 119 3340527 Wear Pad 4 120 0560674 Block, Axle Shim 8 121 0560673 Block, Axle Shim 2

122 1681964

123 3760140 Ring, Retaining 8 124 3421549 Pin, Attaching (Front Axle Cylinder) 2 125 0560675 Block, Axle Shim 2 126 0641406 Bolt 1/4"-20NC x 3/4" 8 127 4751400 Flatwasher 1/4" 12 128 0100011 Loctite #242 (Not Shown) A/R 129 0361631 Bar, Wear 2 130 4070574 Shim 1/16" 2 131 4070575 Shim 1/32" 2 132 3421548 Pin, Attaching (Rear Axle Cylinder) 2 133 3532592 Plate, Cover 1 134 0641403 Bolt 1/4"-20NC x 5/8" 4 135 3532590 Plate, Cover 2

Axle Extension Cylinder Assembly Options (See Section 5 for Breakdown)

1-4 3120637

SECTION 1 FRAME

FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

136 3532591 Plate, Cover 2 137 3300151 Nut, Acorn 4 138 4843028 Inner Axle Weldment (Rear Right Side) 1 139 4843023 Inner Axle Weldment (Rear Left Side) 1 140 0641505 Bolt 5/16"-18NC x 5/8" 16 141 4761500 Lockwasher 5/16" 16 142 4070670 Shim 1/8" A/R 143 4070672 Shim 1/32" A/R 144 4070674 Shim 1/16" A/R

0239152 WHEEL DRIVE INSTALLATION Ref. 3/B 201 2780155 Hub Assembly (See Figure 1-2 for Breakdown) 2 202 Brake Assembly Options: 2

0920072 Prior to March 1992 (See Figure 1-3 for Breakdown)

0920084 March 1992 to S/N 33476 (See Figure 1-4 for

Breakdown)

0920110 S/N 33476 to Present (See Figure 1-4 for

Breakdown)

0920119 Optional Replacement (Note: Can be used as

suitable replacement. Requires P/N 4300097 5-1/8” long Stud) (was p/n 0920117)

Note: Repair Kit p/n 7018612 & Mounting Face Gasket p/n 7000731 are only Service Parts available for Brake p/ns 0920119 & 0920117.

203 Motor Assembly Options: 2

Use 1001096405 Original Equipment (was p/n 3160132 - See Figure

1-5 for Breakdown)

1001096405 Service Replacement Kit (See Figure 1-6 for

Breakdown) 204 4300092 Stud 1/2"-13NC x 5 1/2" 4 205 4751800 Flatwasher 1/2" 4 206 4761800 Lockwasher 1/2" 4 207 3311801 Nut 1/2"-13NC 4 208 0642216 Bolt 3/4"-10NC x 2" 24 209 4762200 Lockwasher 3/4" Narrow 24 210 3300007 Lugnut 3/4"-16NF 24

I O N

F R A

TIRE AND WHEEL INSTALLATIONS Ref.

Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/ or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

301 0239344

0253929

0259456

0259442

3120637 1-5

Tire and Wheel Assembly - 15 x 22.5 Foam-Filled (Prior to April 1993)

Tire and Wheel Assembly - 385/65R22.5 Foam-Filled (April 1993 to S/N 44997)

Tire and Wheel Assembly - 385/65R22.5 Foam-Filled L.H. (S/N 44997 to Present)

Tire and Wheel Assembly - 385/65R22.5 Foam-Filled R.H. (S/N 44997 to Present)

A/R

SECTION 1 FRAME

I O N

FIGURE 1-2. DRIVE HUB ASSEMBLY

1-6 3120637

SECTION 1 FRAME

FIGURE 1-2. DRIVE HUB ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780155 DRIVE HUB ASSEMBLY Ref. —

1 7001974 Bolt, Hex Head 16 2 7001975 Bolt, Hex Head Shoulder 4 3 7001976 Lockwasher 20

— — — — — — — — — —

7001965 Cover Assembly 1 4 7001966 Cover 1 5 7001928 Plug, Pipe 1 6 7000243 Plug, Pipe 1 7 7001967 Cap, Cover 1 8 Kit O-Ring 1 9 7001968 Rod, Disconnect 1

10 Kit O-Ring 1 11 7000231 Cap, Disconnect 1 12 7000220 Bolt 4 13 7001963 Gear, Ring 1 14 Kit O-Ring 2 15 7001972 Thrustwasher 4 16 7001973 Bearing, Thrust 2 17 7001971 Gear, Input (Sun Gear) 1 18 7001970 Spacer, Thrust 1 19 7000285 Ring, Retaining 1 20 7001919 Shaft, Input 1 21 7007657 Gear, Internal 1

— — — — — — — — — —

7001910 Carrier Assembly 1

22 7001955 Carrier 1 23 7001959 Shaft, Planet 3 24 7001956 Pin, Roll 3 25 7001962 Ring, Retaining 3 26 7001961 Spacer 3 27 7017003 Gear, Cluster 3 28 7001957 Cup, Bearing 6 29 7001958 Cone, Bearing 6

7007698 Hub and Spindle Assembly 1

30 7007699 Spindle 1 31 Kit Seal 1 32 7001948 Cup, Bearing 2 33 7001947 Cone, Bearing 2 34 7001949 Shim, Bearing 1 35 7001950 Ring, Retaining 1 36 7001951 Hub 1 37 7001928 Plug, Pipe 2 38 7001952 Plug, Magnetic 1 39 7000265 Stud 12 40 7001977 Ring, Keeper 1 41 7000284 Ring, Retaining 1 42 7000282 Washer 2

I O N

F R A

3120637 1-7

SECTION 1 FRAME

I O N

FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

43 7000283 Spring 1 44 Not Used 45 7000290 Coupling, Input 1

— — — — — — — — — —

2900560 Seal Kit (Includes Items 8, 10, 14 and 31)

1-8 3120637

SECTION 1 FRAME

FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120637 1-9

SECTION 1 FRAME

I O N

FIGURE 1-3. DRIVE BRAKE ASSEMBLY - AUSCO

1-10 3120637

SECTION 1 FRAME

FIGURE 1-3. DRIVE BRAKE ASSEMBLY - AUSCO

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920072 DRIVE BRAKE ASSEMBLY - AUSCO Ref. D

1 7003047 Housing 1 2 Kit Gasket 1 3 7003049 Bearing 1 4 Kit Seal, Oil 1 5 7003051 Retainer, Spring 1 6 7003052 Spring, Compression 8 7 7003070 Shaft, Splined 1 8 7000717 Pin, Torque 2

9 7003054 Disc, Primary 1 10 7003006 Spring, Separator 6 11 7003055 Disc, Rotating 3 12 7003056 Disc, Stationary 3 13 7003057 Piston 1 14 Kit Ring, Backup 1 15 Kit O-Ring 1 16 Kit Ring, Backup 1 17 Kit O-Ring 1 18 7000760 Bearing 1 19 7000796 Screw, Bleeder 1 20 7003071 Plate, Power 1 21 7003007 Screw 4 22 7003059 Valve, Pressure 1 23 7000728 Plug 1 24 Kit Gasket 2

— — — — — — — — — — 2900662 Seal Kit (Includes Items 2,4,14,15,16, 17 and 24) 1 7003069 Gasket Kit (Includes Item 24) 1

I O N

F R A

3120637 1-11

SECTION 1 FRAME

I O N

FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO

1-12 3120637

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE BRAKE ASSEMBLY - MICO Ref.

1 Kit Seal, Oil 1 2 Kit Bearing 1 3 7007977 Ring, Retaining 1 4Not Used 5Not Used 6Not Used 7Not Used 8Not Used

9Not Used 10 Not Used 11 Kit Seal, Case 1 12 Not Used 13 7007986 Cover 1 14 Not Used 15 7011716 Ring, Retainer 1 16 Not Used 17 7007987 Pin, Dowel 2 18 Kit Ring, Back-up 1 19 Kit O-Ring 1 20 Kit Ring, Back-up 1 21 Kit O-Ring 1 22 Kit Rotor 2 23 Kit Stator 2 24 Not Used 25 7007924 Plug, Pipe 1

26 and 27 Not Used

28 Kit O-Ring 2 29 7007933 Gasket 2

— — — — — — — — — —

2900766 Seal Kit (Includes Items 1,11,18,19,20,21,28 and 29) 1

2900768 Bearing Kit (Includes Items 1,2,11,28 and 29) 1

I O N

F R A

DRIVE BRAKE ASSY - MICO (VARIABLE PARTS)

0920084 Prior To S/N 33476 Ref. A 0920110 S/N 33476 To Present Ref. B

51 7011712 Shaft 1 52 Spring Options: A/R

7007979 Inner Spring - Prior To S/N 33476 6 7007980 Outer Spring - Prior To S/N 33476 6

Not Required S/N 33476 To Present 0

53 Spring Options: A/R

Not Required Prior To S/N 33476 0

7007970 Spring (Red) - S/N 33476 To Present 6 7018602 Spring (Blue) - S/N 33476 To Present 3

3120637 1-13

SECTION 1 FRAME

I O N

FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

54 Housing Options: 1

7011713 Prior To S/N 33476 7018605 S/N 33476 To Present

55 Bolt, Washer Head Options: 4

7007985 Prior To S/N 33476 7018607 S/N 33476 To Present

56 Guide, Spring Options: 1

7011717 Prior To S/N 33476 7018606 S/N 33476 To Present

57 Piston Options: 1

7007923 Prior To S/N 33476 7018603 S/N 33476 To Present

58 Plate, Return/Separator Assembly Options: 1

7007923 Prior To S/N 33476 Components:

Kit Plate, Return 1 7011715 Separator Assembly 2 7011714 Pin 4 7007983 Separator 2 7018603 S/N 33476 To Present Components:

Kit Plate, Return 1

59 Plug Options: 1

7007914 Bleeder Screw - Prior To S/N 33476 7018609 Plug - S/N 33476 To Present

Lining Kit Options (Includes Items 58, 11, 22, 23, 28

and 29): 2900767 Prior To S/N 33476 7018608 S/N 33476 To Present

1-14 3120637

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120637 1-15

SECTION 1 FRAME

I O N

FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS

1-16 3120637

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160132 DRIVE MOTOR ASSEMBLY - VICKERS Ref. B

1 7006766 Yoke 1 2 7006767 Roll Pin 1 3 7006768 Spherical Seat 1 4 7006769 Spring Seat 1 5 7006774 Yoke Spring 1 6 7006776 Yoke Stop 1 7 Kit Gasket 1 8 7006786 Housing 1

9 7006787 Washer 6 10 7006788 Screw 6 11 7006789 Screw 4 12 Shim (Included with Item 18) 1 13 7006721 Retaining Ring 1 14 7006796 Shaft 1 15 7006791 Bearing 2 16 7006792 Pintle Bearing 2 17 Kit O-Ring 2 18 7006794 Shim Kit (Includes Item 12) 1 19 7006795 Cover 2 20 7006719 Bearing 1 21 7006797 Piston 1 22 7006798 Piston Rod 1 23 7006703 Plug 1 24 Kit O-Ring 1 25 7009300 Screw 4 26 7009301 Control Block 1 27 Kit Gasket 1 28 Kit O-Ring 1 29 Kit Back-up Ring 1 30 7009305 Retaining Ring 1 31 7009306 Valve Block 1 32 7006706 Pin 1 33 7009307 Pin 2 34 7009308 Shaft 1 35 7006717 Piston and Shoes 9 36 7006716 Shoe Plate 1 37 7006715 Spherical Washer 1 38 7006714 Pin, Retainer 1 39 7006713 Pin 3 40 7006712 Cylinder, Block 1 41 7006711 Spring Washer 1 42 7006710 Spring 1 43 7006709 Spring Washer 1 44 7009309 Retaining Ring 1 45 7006707 Bearing Spacer Kit 1 46 7009310 Wafer Plate 1 47 7006704 Bearing S/A 1

I O N

F R A

3120637 1-17

SECTION 1 FRAME

I O N

FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

— — — — — — — — — —

2900659 Seal Kit (Includes 7,14,17,24,27,28 and 29) 1

1-18 3120637

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120637 1-19

401938

303433

313231

121310

119161517

100

SECTION 1 FRAME

I O N

FIGURE 1-6. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS

1-20 3120637

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1001096405 DRIVE MOTOR ASSEMBLY KIT - SAUER-DANFOSS Ref. 2

1001096406 Drive Motor Assembly - Sauer-Danfoss Ref. A 1 7022302 Bearing, Journal 2 2 7007446 Pin 1 3 7007438 Ring, Retaining 2 4 70000794 Swashplate 1 5 Not Available Pin 2 6 Use Item 100 Gasket 1 7 7027740 Cylinder Block Kit (Includes Items 9-17) 1 8 7024862 Plate, Valve 1 9 Use Item 7 Block, Cylinder 1

10 70000856 Guide, Slipper Retainer 1 11 7021275 Pin, Slipper Hold Down 3 12 7024865 Piston Assembly 9 13 70000857 Retainer, Slipper 1 14 7022311 Ring, Retaining 1 15 7024867 Spring 1 16 7024868 Washer 1 17 7022314 Retainer, Spring 1 18 7023910 Shaft 1 19 7007439 Ring, Retaining 1 20 70000795 Cap, End - Axial 1 21 7022368 Screw 5 22 7021249 Bearing, Needle 1 23 7022321 Plug (Includes Item 24) 1 24 7022322 O-Ring 1 25 7007420 Plug (Includes Item 26) 1 26 7021256 O-Ring 1 27 7007419 Plug (Includes Item 28) 2 28 7007418 O-Ring 2 29 Not Available Seat, Spring 1 30 Not Available Housing 1 31 7007420 Plug (Items Item 32) 2 32 7021256 O-Ring 2 33 7022321 Plug (Items Item 34) 1 34 7022322 O-Ring 1 35 7022324 O-Ring 1 36 7022325 Ring, Seal 1 37 7024871 Piston, Servo 1 38 7007437 Bearing 1 39 7022326 Spring 1 40 7007459 Seal, Lip 1 41 7022371 Washer, Support 1

100 7022328 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and

40)

Adapter Options: Ref. 201 70001098 Adapter 12x16 (Not Shown) 1 202 70001099 Adapter 8x10 (Not Shown) 1

I O N

F R A

3120637 1-21

SECTION 1 FRAME

I O N

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

1-22 3120637

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