JLG 120HX Parts Manual

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Page 1

Illustrated Parts Manual

Model

120HX

P/N

3120687

August 31, 2011

Page 2

Page 3

REVISION LOG

May 1992 - Original Issue Of Manual

May 1995 - Revised

June 1997 - Revised

May 1998 - Revised

December 1998 - Revised

November 12, 1999 - Revised (Manual edited to 0010448 Revision 32)

March 2, 2000 - Revised (Manual edited to 0010448 Revision 32)

October 1, 2000 - Revised (Manual edited to 0010448 Revision 33)

February 24, 2004 - Revised

January 4, 2008 - Revised

August 31, 2011 - Revised

3120687 A

Page 4

REVISION LOG

B 3120687

Page 5

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 FRAME, VALVES AND SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3 STEERING AND AXLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-5 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-6 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-7 DRIVE MOTOR ASSEMBLY - REXROTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

1-8 JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

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

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

2-2 VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 VALVES ASSEMBLY - HYDRO AIR (PRIOR TO S/N 38697) . . . . . . . . . . . . . . . . . . . . . .2-8

2-4 VALVES ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . . .2-10

2-5 ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . .2-14

2-6 SWING DRIVE AND BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-7 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-8 SWING BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-9 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-10 LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-11 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-12 REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992) . . . . . . . . . . . . .2-34

2-13 REMOTE DRIVE CONTROL BOX ASSEMBLY (JULY 1992 TO PRESENT) . . . . . . . . . .2-36

2-14 DEUTZ F4L-912 ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

2-15 GENERATOR INSTALLATION- DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

2-16 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

2-17 PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

2-18 PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697) . . . . . . . . . . . . . . . . . .2-56

2-19 PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . . . . .2-58

2-20 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

2-21 HOOD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

2-22 OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

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

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

3-2 CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-3 JIB BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-4 EXTEND-A-REACH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-5 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION. . . . . . . . . . . . . .3-18

3-6 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

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

4-1 PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) . . . . . . . . . . . . . . . . . . . .4-2

4-2 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-4 OPTIONAL PLATFORM MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

3120687 i

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

5-3 EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4 EXTEND-A-REACH LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-5 JACK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-8 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-9 CYLINDER BELLOWS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

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

6-1 HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE)

(PRIOR TO S/N 38697). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE)

(S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-3 HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697). . . . . . . . . . . . . . . . . . . .6-10

6-4 HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) . . . . . . . . . . . . . . . . .6-14

6-5 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

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

7-1 ELECTRICAL DIAGRAM - BOOM LENGTH INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL DIAGRAM - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7-3 ELECTRICAL DIAGRAM - FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-4 ELECTRICAL DIAGRAM - PLATFORM. (PRIOR TO S/N 38697). . . . . . . . . . . . . . . . . . .7-5

7-5 ELECTRICAL DIAGRAM - PLATFORM (S/N 38697 TO PRESENT) (SHEET 1 OF 2) . . . 7-6

7-6 ELECTRICAL DIAGRAM - STANDARD (PRIOR TO S/N 38697) (SHEET 1 OF 4) . . . . .7-8

7-7 ELECTRICAL DIAGRAM - STANDARD (S/N 38697 TO PRESENT) (SHEET 1 OF 4) . . . 7-12

7-8 ELECTRICAL COMPONENTS AND DIAGRAM CHART . . . . . . . . . . . . . . . . . . . . . . . . .7-16

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

8-1 DECALS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

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

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

ii 3120687

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SECTION 1 FRAME

S E

TABLE OF CONTENTS

FIGURE DESCRIPTION

1-1 FRAME, VALVES AND SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 STEERING AND AXLES INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-6 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-7 DRIVE MOTOR ASSEMBLY - REXROTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

C T

I O N

3120687 1-1

Page 8

SECTION 1 FRAME

E C T

I O N

FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION

1-2 3120687

Page 9

SECTION 1 FRAME

FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME, VALVES AND SHIELDS INSTALLATION Ref.

1 2360353 Frame Weldment (Prior to June 1993) 1

2360369 Frame Weldment (June 1993 to Present) 1

VALVES INSTALLATION - FRAME MOUNTED Ref. 0252709 Prior To S/N 38697 Ref. 4 0258677 S/N 38697 To Present Ref. 1

101 Not Used 102 4640739 Valve Assembly - Hydro Air (See Figure 1-2 for 1

Breakdown) (Prior to S/N 38697)

4641066 Valve Assembly - Hydro Air (See Figure 1-2 for 1

Breakdown) (S/N 38697 to Present)

103 4640260 Valve Assembly - Flow Divider (Prior to S/N 38697) 2

Not Available Cartridge (Vickers/Modular Controls Version)

7009739 Seal Kit (Vickers/Modular Controls Version) 7007321 Cartridge (Fluid Controls Version) 7007323 Seal Kit (Fluid Controls Version)

4640923

7012992 Cartridge 7012980 Seal Kit 7012993 Plug, Orifice

104 4640629 Valve Assembly - Flow Divider (Prior to S/N 38697

2900745 Seal Kit - Cartridge (Includes O-Rings and Back-

105 4640743 Valve Assembly - Hydraforce 3-Way Solenoid 1

7000645 Coil 1 7012905 Seal Kit 1

106 Not Used 107 Not Used 108 Not Used 109 4711600 Flatwasher 3/8" Narrow 4 110 4761600 Lockwasher 3/8" 7 111 0641609 Bolt 3/8"-16NC x 1 1/8" 4 112 4711500 Flatwasher 5/16" Narrow A/R 113 4761500 Lockwasher 5/16" A/R 114 0641520 Bolt 5/16"-18NC x 2 1/2" 4 115 0641524 Bolt 5/16"-18NC x 3" (Prior to S/N 38697) 3 116 4300036 Stud (Welded on Part) 2 117 4711400 Flatwasher 1/4" Narrow 4 118 4761400 Lockwasher 1/4" 2 119 3311401 Nut 1/4"-20NC 2

Valve Assembly - Flow Divider (S/N 38697 to Present)

Only)

Up Rings) (2 Per Valve)

I O N

F R A

3120687 1-3

Page 10

SECTION 1 FRAME

I O N

FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252684 FRAME SHIELDS INSTALLATION Ref. 2

201 4060824 Shield 2 202 4300031 Stud (Welded on Part) 8 203 4751400 Flatwasher 1/4" 8 204 3300151 Nut, Acorn 1/4"-20NC 8

— — — — — — — — — —

0100011 Loctite #242 A/R

1-4 3120687

Page 11

SECTION 1 FRAME

FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120687 1-5

Page 12

SECTION 1 FRAME

I O N

FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR

1-6 3120687

Page 13

SECTION 1 FRAME

FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

VALVE ASSEMBLY - HYDRO AIR Ref. 4640739 Prior To S/N 38697 Ref. A 4641066 S/N 38697 To Present Ref. A

1 Rexroth Valve Section - Complete (Jack) Options: A/R

Prior to S/N 38697 Components: 7012723 Rexroth Valve Section - Complete (Jack) 2 7012730 Coil, Solenoid (2 Per Section) 4 7012725 Seal Kit - Rexroth Valve Section 1 7012731 Orifice 1.5mm (Located in B Port) 2

S/N 38697 to Present Components: 7017491 Rexroth Valve Section - Complete (Jack) 2 7021404 Spool (2 Per Section) 4 7021401 Coil (2 Per Section) 4 7021402 Seal Kit 2 7021403 End Cap (2 Per Section) 4

2 Rexroth Valve Section - Complete (Steer) Options: A/R

Prior to S/N 38697 Components: 4640788 Rexroth Valve Section - Complete (Steer) 2 7012730 Coil, Solenoid (2 Per Section) 4 7012725 Seal Kit - Rexroth Valve Section 1

S/N 38697 to Present Components: 7017490 Rexroth Valve Section - Complete (Steer) 2 7021400 Spool (2 Per Section) 4 7021401 Coil (2 Per Section) 4 7021402 Seal Kit 2 7021403 End Cap (2 Per Section) 4

3 Rexroth Valve Section - Complete (Extend) Options: A/R

Prior to S/N 38697 Components: 7012724 Rexroth Valve Section - Complete (Extend) 2 7012725 Seal Kit - Rexroth Valve Section 1 7012730 Coil, Solenoid (2 Per Section) 4

S/N 38697 to Present Components: 7017491 Rexroth Valve Section - Complete (Jack) 2 7021404 Spool (2 Per Section) 4 7021401 Coil (2 Per Section) 4 7021402 Seal Kit 2 7021403 End Cap (2 Per Section) 4

4 7012914 Cartridge, Valve - Hydraforce 4 5 7012912 Cartridge, Valve - Hydraforce 8

— — — — — — — — — — 7012918 Seal Kit - 7012914 Cartridge Valve (1 Per Cartridge) 4 7012998 Seal Kit - 7012912 Cartridge Valve (1 Per Cartridge) 8

I O N

F R A

3120687 1-7

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SECTION 1 FRAME

I O N

FIGURE 1-3. STEERING AND AXLES INSTALLATION

1-8 3120687

Page 15

SECTION 1 FRAME

FIGURE 1-3. STEERING AND AXLES INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

STEERING AND AXLES INSTALLATIONS Ref. 0252605 Standard Machines Ref. 4 0253603 CSA Machines Ref. 3

1 4130282 Spindle Weldment 2 2 4130283 Spindle Weldment 2 3 0252674 Tie-Rod Assembly 2 A

3841167 Rod, Inner - Tie-Rod (1 Per Assembly) 2 3841166 Tube, Outer - Tie-Rod (1 Per Assembly) 2 3421990 Pin, Extension Lock (1 Per Assembly) 2 3420372 Hairpin (1 Per Assembly) 2 1260017 Chain - #3 (1 Ft./2.5cm Per Assembly) 2 Ft./5cm

4 3323002 Nut, Jam 1 1/4"-12NF (RH Threads) 2 5 1660202 Rod, End (RH Threads) 2 6 3300229 Nut, Jam 1 1/4"-12NF 2 7 1660203 Rod, End (LH Threads) 2 8 3421972 Pin (Tie-Rod) 4

9 0641506 Bolt 5/16"-18NC x 3/4" 12 10 4761500 Lockwasher 5/16" 12 11 3532054 Plate, Retainer 4 12 Not Used Kingpin Options: 4

3421948 Standard

3422168 CSA 13 3324203 Nut, Slotted 2"-9NF 4 14 3451012 Pin, Cotter 5/16" x 3" 4

15 1682605

16 3422044 Pin (Steer Cylinder) 2 17 3531946 Plate, Retainer 2 18 4740130 Washer, Thrust 2 19 4740314 Washer, Thrust 4 20 3422023 Pin (Steer Cylinder) (Prior to S/N 33213) 2

3422633 Pin (Steer Cylinder) (S/N 33213 to Present) 2 21 3420592 Hairpin 2 22 4713000 Flatwasher 1 1/4" Narrow 2 23 3760170 Ring 4 24 1260017 Chain - #3 (7.25 in./18.5cm Per Location) 25 2160001 Fitting, Grease - 90° 2 26 2160003 Fitting, Grease - 45° 1 27 4220174 Weldment, Stop (Prior to S/N 47227) 4 28 3450808 Cotter Pin (S/N 47227 to Present) 4

Steer Cylinder Assembly (See Section 5 for Breakdown)

14.5 in/37cm

I O N

F R A

3120687 1-9

Page 16

SECTION 1 FRAME

I O N

FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

EXTENDABLE AXLES INSTALLATION Ref. 0252604 Prior To June 1993 Ref. B 0253776 June 1993 To Present Ref. 3

101 4844090 Axle Weldment 2

0960821 Bushing (2 Per Axle) (Kingpin Pivot) 4

102 4844089 Axle Weldment 2

0960821 Bushing (2 Per Axle) (Kingpin Pivot) 4

103 Axle Extension Cylinder Assembly Options (See

Section 5 for Breakdown): 1682618 Prior to S/N 33105 1683532 S/N 33105 to Present

104 3421953 Pin (Extension Cylinder) 4 105 3760133 Ring, Retaining 8 106 3340197 Pad, Wear (Rear Top) 4 107 4070810 Shim A/R 108 4070811 Shim A/R 109 0641618 Bolt 3/8"-16NC x 2 1/4" 8 110 4761600 Lockwasher 3/8" 8 111 Not Used 112 0641809 Bolt 1/2"-13NC x 1 1/8" 12 113 4711800 Lockwasher 1/2" 12 114 0560675 Block, Axle Shim (Bottom) 4 115 0560674 Block, Axle Shim (Bottom) 4 116 0560673 Block, Axle Shim (Top) 8 117 3535884 Plate, Axle Stop 4 118 4070803 Shim 1/16"/1.6mm A/R 119 4070804 Shim 1/32"/.8mm A/R 120 3972218 Setscrew 3/4"-10NC x 2 1/4" 24 121 3312202 Nut, Jam 3/4"-10NC 24 122 3535883 Plate, Cylinder Retaining 2 123 0641609 Bolt 3/8"-16NC x 1 1/8" 4 124 3311605 Locknut 3/8"-16NC 4 125 4360277 Switch, Limit 4 126 4360236 Head, Actuator 4 127 3900168 Bolt, Socket Head #10-24NC 8 128 4920140 Lockwire 4 129 4360237 Switch, Arm 4 130 4460052 Connector, Strain Relief 4 131 2160002 Fitting, Grease 4 132 4060807 Flex-Trim 133 3311505 Nut 5/16"-18NC 16 134 4070845 Shim (June 1993 to Present Only) A/R 135 0641807 Bolt 1/2"-13NC x 7/8" (June 1993 to Present Only) 12 136 4761800 Lockwasher 1/2" (June 1993 to Present Only) 12 137 3536794 Plate (June 1993 to Present Only) 2 138 0641605 Bolt 3/8"-16NC x 5/8" (June 1993 to Present Only) 4 139 4070849 Shim (June 1993 to Present Only) A/R

— — — — — — — — — — 0100011 Loctite #242 A/R

92 in/2.34cm

1-10 3120687

Page 17

SECTION 1 FRAME

FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120687 1-11

Page 18

SECTION 1 FRAME

I O N

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

1-12 3120687

Page 19

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

TIRE AND WHEEL DRIVE INSTALLATIONS Ref.

0252606 WHEEL DRIVE INSTALLATION Ref. 3

1 2780189 Drive Hub Assembly (See Figure 1-5 for Breakdown) 4

0920084 Prior to S/N 33476 0920110 S/N 33476 to Present

See Note

3160213

4 4300092 Stud 1/2"-13NC x 5 1/2" (2 Per Wheel) 8 5 4761800 Lockwasher 1/2" (2 Per Wheel) 8 6 4751800 Flatwasher (2 Per Wheel) 8 7 3311801 Nut 1/2"-13NC (2 Per Wheel) 8 8Not Used

9 0642216 Bolt 3/4"-10NC x 2" (12 Per Wheel) 48 10 4762200 Lockwasher 3/4" (12 Per Wheel) 48 11 3300007 Lugnut 3/4"-16NC (12 Per Wheel) 48

0100011 Loctite #242 A/R

Drive Brake Assembly Options (See Figure 1-6 for Breakdown):

Drive Motor Assembly Options (See Figure 1-7 for Breakdown):

Prior to July 1995 (was p/n 3160176) Note: Use p/n 3160213 Motor Plus p/n 2900869 Conversion Kit as Replacement.

July 1995 to Present (See Figure 1-7 for Breakdown)

— — — — — — — — — —

I O N

F R A

TIRE AND WHEEL INSTALLATION (FOAM-FILLED) Ref. 0251590 Prior To S/N 43718 Ref. 2 0259545 S/N 43718 To Present Ref. A

12 Tie and Wheel Assembly (Foam-Filled) Options: A/R

0251589 Prior To S/N 43718 4

S/N 43718 To Present 0259444 Right Side (Foam-Filled) 2 0259445 Left Side (Foam-Filled) 2

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

Tire Options: 4

4520136 Tire 445/65R x 22.5 (Prior to S/N 43718)

4520218

Tire 445/65 x 22.5 (S/N 43718 To Present)

3120687 1-13

Page 20

SECTION 1 FRAME

I O N

FIGURE 1-5. DRIVE HUB ASSEMBLY

1-14 3120687

Page 21

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780189 DRIVE HUB ASSEMBLY Ref. —

1 7007698 Hub and Spindle Assembly (See Items 101-110 for 1

Breakdown) 2 7007657 Gear, Internal 1 3 7001910 Carrier Assembly (See Items 201-208 for Breakdown) 1 4 7001963 Gear, Ring 1 5 Kit O-Ring 2 6 7001965 Cover Assembly (See Items 301-309 for Breakdown) 1 7 7000282 Washer, Thrust 2 8 7000283 Spring 1 9 7000284 Ring, Retaining - Internal 1

10 7000285 Ring, Retaining - External 1 11 7010472 Shaft, Input 1 12 7001995 Spacer, Input 1 13 7010471 Gear, Sun 1 14 7001993 Spacer, Input 1 15 7001972 Washer, Thrust 4 16 7001973 Bearing, Thrust 2 17 7001974 Bolt 1/2"-13NC x 3 3/4" 16 18 7001975 Bolt, Socket Head 3/8"-16NC x 3 1/2" 4 19 7000290 Coupling 1 20 Not Used 21 Not Used 22 Not Used 23 7001976 Lockwasher 20 24 Not Used 25 7001977 Ring, Keeper 1

I O N

F R A

7007698 HUB AND SPINDLE ASSEMBLY Ref.

101 7007699 Spindle 1 102 Kit Seal, Lip 1 103 7001947 Cup, Bearing 2 104 7001948 Cone, Bearing 2 105 7001949 Washer, Thrust 1 106 7001950 Ring, Retaining - External 1 107 7001951 Housing 1 108 7001928 Plug, Pipe 2 109 7000265 Stud 3/4"-16NF 12 110 7001952 Plug, Pipe 2

3120687 1-15

Page 22

SECTION 1 FRAME

I O N

FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

7001910 CARRIER ASSEMBLY Ref.

201 7001955 Carrier 1 202 7001956 Rollpin 3 203 7001957 Cup, Bearing 6 204 7001958 Cone, Bearing 6 205 7001959 Shaft, Planet 3 206 7017003 Gear, Cluster 3 207 7001961 Spacer, Thrust 3 208 7001962 Ring, Retainer - External 3

7001965 COVER ASSEMBLY Ref.

301 7001966 Plate, Cover 1 302 7001967 Cap, Cover 1 303 7000220 Bolt 1/4"-20NC x 3/4" 4 304 7000231 Cap, Disengage 1 305 7001968 Rod, Disengage 1 306 Kit O-Ring 1 307 Kit O-Ring 1 308 7000243 Plug, Pipe - 1/8" 1 309 7001928 Plug, Pipe - 3/8" 1

— — — — — — — — — —

2900560 Seal Kit (Includes Items 5, 102, 306 and 307) 1

1-16 3120687

Page 23

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120687 1-17

Page 24

SECTION 1 FRAME

I O N

FIGURE 1-6. DRIVE BRAKE ASSEMBLY

1-18 3120687

Page 25

SECTION 1 FRAME

FIGURE 1-6. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE BRAKE ASSEMBLY 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

I O N

F R A

26 Not Used 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

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

3120687 1-19

Page 26

SECTION 1 FRAME

I O N

FIGURE 1-6. DRIVE BRAKE ASSEMBLY (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

1-20 3120687

Page 27

SECTION 1 FRAME

FIGURE 1-6. DRIVE BRAKE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

F R A

3120687 1-21

Page 28

SECTION 1 FRAME

I O N

FIGURE 1-7. DRIVE MOTOR ASSEMBLY - REXROTH

1-22 3120687

Page 29

SECTION 1 FRAME

FIGURE 1-7. DRIVE MOTOR ASSEMBLY - REXROTH

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE MOTOR ASSEMBLY - REXROTH Ref. 3160176 Prior to July 1995 Ref. — 3160213 July 1995 to Present Ref. —

1 7012701 Shaft - 13 Teeth 1 2 Kit Seal, Shaft 1 3 7012702 Bearing, Cradle 2 4 Not Available Housing 1 5 7012703 Rod, Piston 1 6 7012704 Piston, Stroking 1 7 Kit O-Ring 1 8 7012705 Nut, Adaptor 1

9 7012706 Bearing, Roller 1 10 7012707 Bolt, Metric Socket Head M12 x 65 4 11 7012708 Block, Port 1 12 7012709 Shim 1 13 7012710 Pin, Dowel M6 x 18 1 14 Kit O-Ring 1 15 7012711 Nut, Cap M10 x 1 1 16 7012712 Screw, Adjusting 1 17 Kit O-Ring 2 18 7012713 Nut, Jam M10 x 1 1 19 Kit Rotary Group Assembly 1 20 Not Available Plug 1 21 Kit Plate, Swash 1 22 7012714 Bearing, Roller 1 23 7012715 V-Ring 1 24 7012700 Control Plate Assembly 1

— — — — — — — — — —

2900788

7012716 Rotary Group Kit (Includes Items 19 and 21) 1

Seal Kit (Includes Items 2,7,14,17 and O-Rings under

Item 24)

I O N

F R A

3120687 1-23

Page 30

SECTION 1 FRAME

I O N

FIGURE 1-8. JACK CYLINDER INSTALLATION

1-24 3120687

Page 31

SECTION 1 FRAME

FIGURE 1-8. JACK CYLINDER INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252607 JACK CYLINDER INSTALLATION Ref. 2

1 1682511 Jack Cylinder Assembly (See Section 5 for Breakdown) 2 2 0641812 Bolt 1/2"-13NC X 1 1/2" (4 Per Cylinder) 8 3 4761800 Lockwasher 1/2" (4 Per Cylinder) 8 4 3535906 Plate, Mounting (1 Per Cylinder) 2 5 0641816 Bolt 1/2"-13NC x 2" (4 Per Cylinder) 8 6 4711800 Flatwasher 1/2" Narrow (4 Per Cylinder) 8 7 3311805 Locknut 1/2"-13NC (4 Per Cylinder) 8 8 3252185 Nameplate - Jack Operator (1 Per End of Machine) 2

9 4360314

10 4740397 Washer, Special (2 Per Nameplate) 4

11 0630448

12 4761400 Lockwasher 1/4" (4 Per Nameplate) 8 13 Not Used 14 3340630 Jack Pad Weldment 2 15 0641852 Bolt 1/2" -13 NC x 6 1/2" 4 16 3311801 Nut 1/2" - 13 NC 4

0100011 Loctite A/R

Switch, Toggle - Extend and Retract of Jack Cylinder and Axles (2 Per Nameplate)

Screw, Button Head 1/4"-20NC x 3/4" (4 Per Nameplate)

— — — — — — — — — —

I O N

F R A

3120687 1-25

Page 32

SECTION 1 FRAME

I O N

FIGURE 1-8. JACK CYLINDER INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-26 3120687

Page 33

SECTION 2 TURNTABLE

S E

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

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

2-2 VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 VALVE ASSEMBLY - HYDRO-AIR (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 VALVE ASSEMBLY - HYDRO-AIR (S/N 38697 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . . . . . . . 2-14

2-6 SWING DRIVE AND BEARING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-7 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-8 SWING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-9 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-10 LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-11 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-12 REMOTE DRIVE CONTROL BOX ASSEMBLY (Prior to July 1992). . . . . . . . . . . . . . . . . . . . . . 2-34

2-13 REMOTE DRIVE CONTROL BOX ASSEMBLY (July 1992 to Present) . . . . . . . . . . . . . . . . . . . 2-36

2-14 DEUTZ F4L-912 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-15 GENERATOR INSTALLATION - DEUTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-16 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

2-17 PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

2-18 PUMP ASSEMBLY - BARNES (October 1992 to S/N 38697). . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

2-19 PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2-20 TANKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2-21 HOODS AND ALARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

2-22 OIL COOLER INSTALLATION (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

I O N

T U R N

3120687 2-1

Page 34

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION

2-2 3120687

Page 35

SECTION 2 TURNTABLE

FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

TURNTABLE, BOOM AND SWITCHES INSTALLATION Ref.

4620078 TURNTABLE ASSEMBLY Ref. F/6

1 0252852 Boom Pivot Assembly 2

0960594 Bushing, Self-Aligning (1 Per Assembly) 2

2 0961392 Bushing, Bronze (Base Pivot) 2

1281825 BOOM AND CYLINDERS INSTALLATION Ref. C

101 Boom Assembly (See Section 3 for Breakdown) 1

102 1682630

1682895

103 1681580

104 3952014 Setscrew 5/8"-11NC x 1 3/4" 2 105 3312002 Nut, Jam 5/8"-11NC 2 106 2160002 Fitting, Grease 3 107 0681812 Bolt 1/2"-13NC 4 108 4740171 Washer, Special Hardened 4 109 Not Used 110 1120368 Cap, Boom Pivot 2 111 Not Used 112 Not Used 113 0236548 Pin, Top Master Cylinder 1 114 4740006 Washer, Special 1 115 0651608 Bolt 3/8"-24NF x 1" 1 116 4761600 Lockwasher 3/8" 1 117 4300038 Stud (Welded on Part) (Prior to July 1995) 1

4300034 Stud (Welded on Part) (July 1995 to Present) 1

118 4751500 Flatwasher 5/16" (Prior to July 1995) 1

4751600 Flatwasher 3/8" (July 1995 to Present) 1

119 4761500 Lockwasher 5/16" (Prior to July 1995) 1

4761600 Lockwasher 3/8" (July 1995 to Present) 1

120 3311501 Nut 5/16"-18NC (Prior to July 1995) 1

3311601 Nut 3/8"-16NC (July 1995 to Present) 1 121 3420085 Pin, Bottom Master Cylinder 1 122 3450610 Pin, Cotter 3/16" x 2 1/2" 2 123 Not Used 124 4712200 Flatwasher 3/4" 2 125 4762200 Lockwasher 3/4" 2 126 0682213 Bolt 3/4"-10NC x 1 5/8" (Grade 8) 2 127 Not Used 128 4740361 Washer, Special 2 129 3900159 Screw, Countersunk 1/2"-13NC x 3/4" 4 130 0641840 Bolt 1/2"-13NC x 5" 1 131 3311805 Locknut 1/2"-13NC 1

Lift Cylinder Assembly (See Section 5 for Breakdown) (Prior to November 1992)

Lift Cylinder Assembly (See Section 5 for Breakdown) (November 1992 to Present)

Master Cylinder Assembly (See Section 5 for Breakdown)

I O N

T U R N

T A B

3120687 2-3

Page 36

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

132 2160001 Fitting, Grease - 90° 1 133 4740040 Flatwasher, Special 2

— — — — — — — — — —

0100019 Loctite #271 A/R

BOOM AND CYLINDERS INSTALLATION (VARIABLE PARTS)

0252780 ANSI Spec Prior to S/N 37026 Ref. F 0252931 ANSI Spec with Chip Covers Prior To S/N 37026 Ref. D 0258412 ANSI Spec S/N 37026 To Present Ref. 1 0258417 ANSI Spec with Chip Covers (S/N 37026 To Present Ref. 1 0253601 CSA Spec Prior To S/N 37026) Ref. C 0258419 CSA Spec S/N 37026 To Present Ref. 1

151 Pin, Boom Pivot Options: 1

3421555 ANSI Spec 3422151 CSA Spec

152 Pin, Bottom Lift Cylinder Options: 1

3421676 ANSI Spec 3422149 CSA Spec

153 Pin, Top Lift Cylinder Options: 1

3421678 ANSI Spec 3422150 CSA Spec

Ref.

0236629 HORIZONTAL CUTOUT LIMIT SWITCH

INSTALLATION (RIGHT SIDE)

201 4360057 Switch, Limit 1 202 4761000 Lockwasher #10 2 203 0721014 Bolt #10-24NC x 1 3/4" 2 204 Not Used 205 0200048 Arm, Actuator 1 206 4460049 Connector 1

0239844 LUBE LINES INSTALLATION Ref. 3

401 2160002 Fitting, Grease 3 402 2220001 Fitting 3 403 2751032 Hose 1 404 2750528 Hose 1 405 2750807 Hose 1 406 2200261 Fitting, Nipple 2 407 2750527 Hose 2 408 2220063 Fitting 3 409 4300031 Stud (Welded on Part) 1 410 4761400 Lockwasher 1/4" 1 411 3311401 Nut 1/4"-20NC 1 412 1320040 Clamp, Insulated 1

Ref. 3

2-4 3120687

Page 37

SECTION 2 TURNTABLE

FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-5

Page 38

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED

2-6 3120687

Page 39

SECTION 2 TURNTABLE

FIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

VALVES INSTALLATION - TURNTABLE MOUNTED Ref. 0252709 Prior To S/N 38697 Ref. 4 0258677 S/N 38697 To Present Ref. 2

1 Valve Assembly - Hydro-Air Options: 1

4640738 Prior to S/N 38697 (See Figure 2-3 for Breakdown)

4641065

4641181 Post Production (See Figure 2-4 for Breakdown)

2 to 5 Not Used

6 4640758 Valve Assembly - 3 - Way Solenoid 1

7012906 Coil 1 7012907 Seal Kit 1

7 Valve, Counterbalance Options: 1

4640626 Prior to S/N 38697 4641079 S/N 38697 to Present

8 4640543 Valve Assembly - Solenoid 1

7009745 Coil (Vickers/Modular Controls Version) 1 7004368 Coil (Hydraforce Version) 1

9 4711600 Flatwasher 3/8" 11 10 4761600 Lockwasher 3/8" 7 11 0641609 Bolt 3/8"-16NC x 1 1/8" 3

12 to 15 Not Used

16 4300036 Stud (Welded on Part) 4 17 4711400 Flatwasher 1/4" 17 18 4761400 Lockwasher 1/4" 11 19 3311401 Nut 1/4"-20NC 17 20 Not Used 21 0641616 Bolt 3/8"-16NC x 2" 4 22 3535942 Plate, Valve Mounting 1 23 0641420 Bolt 1/4"-20NC x 2 1/2" 2 24 3311605 Nut 3/8"-16NC 4 25 0140001 Horn 1 26 0641406 Bolt 1/4"-20NC x 3/4" 1

S/N 38697 to Production (See Figure 2-4 for Breakdown)

I O N

T U R N

T A B

TILT INDICATOR INSTALLATION Ref. 0239858 Prior To September 1994 Ref. B 0253159 September 1994 To Present Ref. 2

101 Switch, Level Sensor - 5° Options: 1

4360171 Prior To September 1994 4360362 September 1994 To Present

102 2820022

3120687 2-7

Tubing, Vinyl (6 in/14cm Per Switch) (Prior to September 1994)

6 in./14cm

Page 40

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-8 3120687

Page 41

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4640738

1 7012717 Rexroth Valve Section - Complete (Swing and Lift) 2

7012728 Coil, Solenoid (2 Per Section) 4

2 7012718

7012728 Coil, Solenoid (1 Per Section) 1

3 7012720 Rexroth Valve Section - Complete (Telescope) 1

7012730 Coil, Solenoid (2 Per Section) 2 7012734 Orifice 2.7mm (Located in T Port) 1

4 7012719 Rexroth Valve Section - Complete (Extend-A-Reach) 1

7012729 Coil, Solenoid (2 Per Section) 2 7012735 Diode Circuit Board (2 Per Section) 2 7012736 Orifice 1.2mm (Located in Port A Only) 1

5 4640788 Rexroth Valve Section - Complete (Rotate) 1

7012730 Coil, Solenoid (2 Per Section) 2

6 7012722 Rexroth Valve Section - Complete (Platform Level) 1

7012730 Coil, Solenoid (2 Per Section) 2 7012736 Orifice 1.2mm (Located in A and B Ports) 2

7 7012908 Cartridge, Valve 1

7012915 Seal Kit - 7012908 Cartridge 1

8 7012909 Cartridge, Valve 1

7012916 Seal Kit - 7012909 Cartridge 1

9 7012910 Cartridge, Valve (Without Coil) 1

2900756 Seal Kit - 7012910 Cartridge 1 7000645 Coil - 12V 1

10 7010542 Cartridge, Valve 4

7010543 Seal Kit - 7010542 Cartridge (1 Per Cartridge) 4

11 7012912 Cartridge, Valve 7

7010541 Seal Kit - 7012912 Cartridge (1 Per Cartridge) 7

12 7012913 Cartridge, Valve 1

2900708 Seal Kit - 7012913 Cartridge (1 Per Cartridge) 1

13 7012914 Cartridge, Valve 2

7012918 Seal Kit - 7012914 Cartridge (1 Per Cartridge) 2

14 7018942 Capscrew, Socket Head #10-24NC x 2” A/R

7012725 Seal Kit - Rexroth Valve Sections (1 Per Valve Section) 7

VALVE ASSEMBLY - HYDRO-AIR (PRIOR TO S/N

38697)

Rexroth Valve Section - Complete (Flow) (was p/n

4640782)

— — — — — — — — — —

Ref. —

I O N

T U R N

T A B

3120687 2-9

Page 42

16 25

18 24

324

14151313121110

51725

26827

SECTION 2 TURNTABLE

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

I O N

T U R N

A B

2-10 3120687

Page 43

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

VALVE ASSEMBLIES Ref. 4641065 PRODUCTION Ref. E 4641181 POST PRODUCTION Ref. B

1 7017482 Cartridge, Valve 1

7012518 Seal Kit - 7017482 Cartridge 1

2 7012997 Cartridge, Flow Control (Lift Down Speed Control) 1

7010545 Seal Kit - 7012997 Cartridge 1

3 7017483 Cartridge, Flow Control 2

7012953 Seal Kit - 7017483 Cartridge 2

4 7010542 Cartridge, Load Shuttle 4

7010543 Seal Kit - 7010542 Cartridge (1 Per Cartridge) 4

5 7012914 Cartridge, Pilot Check 2

7012918 Seal Kit - 7012914 Cartridge (1 Per Cartridge) 2

6 7017484 Cartridge, Pilot Directional 2

7012942 Seal Kit - 7017484 Cartridge (1 Per Cartridge) 2

7 7017485 Cartridge, Proportional Valve (Without Coil) (Lift,

Swing, Tele, EAR & Rotate)

Not Available Seal Kit - 7017485 Cartridge 3

8 7021637 Cartridge, Relief Valve (Main Pressure Adjustment) 1

7012972 Seal Kit - 7021637 Cartridge 1

9 7017487 Cartridge, Relief Valve (Lift Down Pressure) 1

7017496 Seal Kit - 7017487 Cartridge 1

10 7017421 Cartridge, Relief Valve (Swing Pressure) 1

7012998 Seal Kit - 7017421 Cartridge 1

11 7017418 Cartridge, Relief Valve (EAR Up Pressure) 1

7012998 Seal Kit - 7017418 Cartridge 1

12 7017488 Cartridge, Relief Valve (EAR Down Pressure) 1

7012998 Seal Kit - 7017488 Cartridge 1

13 7017422 Cartridge, Relief Valve (Rotate Right, Rotate Left) 2

7012998 Seal Kit - 7017422 Cartridge 2

14 7017489 Cartridge, Relief Valve (Level Down Pressure) 1

7012998 Seal Kit - 7017489 Cartridge 1

15 7017422 Cartridge, Relief Valve (Level Up Pressure) 1

7012998 Seal Kit - 7017489 Cartridge 1

16 7012910

2900708 Seal Kit - 7012910 Cartridge 1

17 7010635 Cartridge, Solenoid Valve (Without Coil) (Lift Down) 1

2900708 Seal Kit - 7010635 Cartridge 1

18 7017452 Cartridge, Solenoid Valve (Without Coil) (Telescope) 1

7017402 Seal Kit - 7017452 Cartridge 1 7012944 Coil - 12V 2

19 7021622 Bosch Valve Section - Complete (Lift) 1

7021405 Spool (2 Per Section) 1 7021401 Coil (2 Per Section) 1 7021402 Seal Kit (2 Per Section) 1 7021406 Cap, End (2 Per Section) 1 7024826 Bolt 4

Cartridge, Solenoid Valve (Without Coil) (Main Dump)

I O N

T U R N

T A B

3120687 2-11

Page 44

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-4. VALVES ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

20 7017491 Bosch Valve Section - Complete (Swing) 1

7021404 Spool (2 Per Section) 1 7021401 Coil (2 Per Section) 1 7021402 Seal Kit (2 Per Section) 1 7021403 Cap, End (2 Per Section) 1 7024826 Bolt 4

21 7017491 Bosch Valve Section - Complete (EAR) 1

7021404 Spool (2 Per Section) 1 7021401 Coil (2 Per Section) 1 7021402 Seal Kit (2 Per Section) 1 7021403 Cap, End (2 Per Section) 1 7024826 Bolt 4

22 7017490 Bosch Valve Section - Complete (Rotate) 1

7021400 Spool (2 Per Section) 1 7021401 Coil (2 Per Section) 1 7021402 Seal Kit (2 Per Section) 1 7021403 Cap, End (2 Per Section) 1 7024826 Bolt 4

23 7017491 Bosch Valve Section - Complete (Level) 1

7021404 Spool (2 Per Section) 1 7021401 Coil (2 Per Section) 1 7021402 Seal Kit (2 Per Section) 1 7021403 Cap, End (2 Per Section) 1

7024826 Bolt 4 24 7012944 Coil 2 25 7012943 Coil 2 26 7017451 Coil 3 27 7017492 Orifice 1 28 7017493 Orifice 1 29 7017494 Orifice 2

2-12 3120687

Page 45

SECTION 2 TURNTABLE

FIGURE 2-4. VALVES ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-13

Page 46

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-14 3120687

Page 47

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION OPTIONS:

0250611 PRIOR TO SEPTEMBER 1994 Ref. B 0254882 SEPTEMBER 1994 TO PRESENT Ref. 3

ROTARY OIL COUPLING INSTALLATIONS Ref.

1 Rotary Oil Coupling Assembly Options:

1660185 Prior To September 1994 1 —

(See Items 101-105 For Breakdown 1660213 September 1994 to Present 1 A 7013175 Seal Kit - 1660213 Coupling 1

2 3530403 Plate, Retaining 1 3 3951820 Setscrew 1/2"-13NC x 2 1/2" 2 4 0641807 Bolt 1/2"-13NC x 7/8" 2 5 4761800 Lockwasher 1/2" 2 6 1440154 Collar 1 7 0641512 Bolt 5/16"-18NC x 1 1/2" (Prior to S/N 36536) 4

0641514 Bolt 5/16"-18NC x 1 3/4" (S/N 36536 to Present) 4

8 4761500 Lockwasher 5/16" 4

0100011 Loctite #242 A/R 0100019 Loctite #271 A/R

Ref.

I O N

T U R N

T A B

1660185 ROTARY OIL COUPLING ASSEMBLY Ref. —

101 0620106 Body, Swivel 1 102 2760091 Housing, Swivel 1 103 Kit T-Seal 7 104 3760004 Ring, Retaining 1 105 Kit O-Ring 1

— — — — — — — — — —

Seal Kit Options: 1

2901146 1660185 Coupling (Includes Items 103 and 105)

Use 1660213EX 1660213 Coupling (was p/n 7013175)

Note: Due to complexity of repair, seal kit no longer available. Use rebuilt unit as replacement.

0252284

201 4843822 Bracket Weldment 1 202 0960224 Bushing 2 203 0641418 Bolt 1/4"-20NC x 2 1/4" 2 204 2180763 Pipe 1 205 0961531 Bushing 1 206 3760108 Collector Ring Assembly 1 207 3311801 Nut 1/2"-13NC 2 208 3420290 Pin, Drive 2 209 0231047 Guide, Drive 2 ` 210 0234721 Cover 1

COLLECTOR RING INSTALLATION (FOUR WHEEL STEER ONLY)

Ref. 3

3120687 2-15

Page 48

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

211 0721004 Screw, Machine #10-24NC x 1/2" 4 212 4761400 Lockwasher 1/4" 2 213 1320040 Clamp, Cable 2 214 3911012 Screw, Machine 2 215 4751000 Flatwasher #10 6 216 4761000 Lockwasher #10 6 217 3311001 Nut #10-24NC 6 218 4751400 Flatwasher 1/4" 2

2-16 3120687

Page 49

SECTION 2 TURNTABLE

FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-17

Page 50

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION.

2-18 3120687

Page 51

SECTION 2 TURNTABLE

FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION.

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252675 SWING DRIVE INSTALLATION Ref. 5

1 3160184 Swing Motor Assembly (See Figure 2-7 for Breakdown) 1 2 Swing Brake Assembly Options (See Figure 2-8 for

Breakdown): 0920083 Prior to S/N 33476 0920109 S/N 33476 to Present

3 2780116 Swing Hub Assembly (See Figure 2-9 for Breakdown) 1 4 4844109 Mounting Weldment - Swing Drive 1 5 2440058 Gear, Pinion 1 6 3533337 Plate, Retaining 1 7Not Used 8 3900164 Screw, Countersunk 1/2"-20NF x 1" 2

9 0642216 Bolt 3/4"-10NC x 2" 8 10 0641810 Bolt 1/2"-13NC x 1 1/4" 2 11 4761800 Lockwasher 1/2" 2 12 3931864 Bolt, Socket Head 1/2"-13NC x 4" (Grade 8) 2 13 4740189 Washer, Special 2 14 Not Used 15 4740171 Washer, Special Hardened 2 16 4640741 Motor Control Valve Assembly 1

7011320 Cartridge 2

2900770 Seal Kit 2 17 0641520 Bolt 5/16"-18NC x 2 1/2" 4 18 4761500 Lockwasher 5/16" 4 19 3790155 O-Ring (S/N 40756 to Present) 1

— — — — — — — — — — 0100019 Loctite #271 A/R 0100009 Sealant, Pipe A/R

I O N

T U R N

T A B

0250348 TURNTABLE BEARING INSTALLATION Ref. 7/F

101 0440193 Bearing 1 102 0682016 Bolt 5/8"-11NC x 2" 40 103 4740004 Washer, Special Hardened 80 104 0100019 Loctite #271 (Not Shown) A/R 105 Not Used 106 Bolt Options: 40

0682016 Prior to S/N 53244 Use Bolt 5/8”-11NC x 2” 0682026 Prior to S/N 53244 Use Bolt 5/8”-11NC x 3 1/4”

0239842 TURNTABLE LOCK INSTALLATION Ref. 2

201 4843318 Bushing Weldment 1 202 3421565 Pin, Snap 1 203 1260017 Chain - #3 9 in/23cm 204 3760170 Ring, Quick Release 2 205 3421563 Pin, Turntable Lock 1

3120687 2-19

Page 52

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-7. SWING MOTOR ASSEMBLY

2-20 3120687

Page 53

SECTION 2 TURNTABLE

FIGURE 2-7. SWING MOTOR ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160184 SWING MOTOR ASSEMBLY Ref. B

1 Kit Seal, Dust 1 2 Kit Ring, Back-Up 1 3 Kit Seal, Lip 1 4 7004196 Valve, Rotary 1 5 7004167 Ball, Check Valve 2 6 7004179 IGR Assembly 1 7 Kit Ring, Snap 1 8 Kit Seal, Ring 3

9 7004171 Plug, Vent (Includes O-Ring) 1 10 7010780 Bolt 8 11 Not Used 12 7010781 Shaft, Spline 1 13 Not Used 14 Not Used 15 7010782 Body/Bearing Assembly 1 16 Not Used 17 7004192 Cover/Bearing Assembly 1 18 Not Used 19 Not Used 20 Not Used 21 Kit Ring, Retaining 1 22 7010776 Plate, Commutator 1

— — — — — — — — — —

2900798 Seal Kit (Includes Items 1,2,3,7,8 and 21)) 1

I O N

T U R N

T A B

3120687 2-21

Page 54

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-8. SWING BRAKE ASSEMBLY

2-22 3120687

Page 55

SECTION 2 TURNTABLE

FIGURE 2-8. SWING BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

SWING BRAKE ASSEMBLY Ref.

1 Kit Seal, Oil 1 2 Kit Bearing 1 3 7007977 Ring, Retaining 1

4 to 10 Not Used

11 Kit Seal, Case 1 12 Not Used 13 7011719 Cover 1 14 Not Used 15 7007987 Pin, Dowel 2 16 Kit Ring, Back-up (Inner) 1 17 Kit O-Ring (Inner) 1 18 Kit Ring, Back-up (Outer) 1 19 Kit O-Ring (Outer) 1 20 Kit Rotor 2 21 Kit Stator 2 22 Not Used 23 Not Used 24 Not Used 25 Not Used 26 Kit O-Ring 2 27 7007934 Gasket 2

I O N

T U R N

T A B

2900766 Seal Kit (Includes items 1,11,16,17,18,19,26 and 27) 1 2900768 Bearing Kit (Includes Items 1,2,11,26 and 27) 1

SWING BRAKE ASSEMBLY (VARIABLE PARTS)

0920083 Machines Built Through 1992 Ref. — 0920083 Machines Built 1993 to S/N 33476 Ref. A 0920109 Machines Built S/N 33476 to Present Ref. B

51 Shaft Options: 1

7011718 Machines Built Through 1992 7011720 Machines Built Through 1993 to Present

52 Spring Options: A/R

0920083 Brake Components: 7007979 Spring (Small) 6 7007980 Spring (Large) 6

Not Required 0920109 Brake 0

53 Spring Options: A/R

Not Required 0920083 Brake 0

0920109 Brake Components: 7007970 Spring (Red) 6 7018602 Spring (Blue) 3

54 Housing Options: 1

7007981 Machines Built Through 1992 7011713 Machines Built Through 1993 to S/N 33476 7018605 Machines Built S/N 33476 to Present

3120687 2-23

Page 56

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-8. SWING BRAKE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

55 Bolt, Washer Head 4

7007985 0920083 Brake 7018607 0920109 Brake

56 Guide, Spring 1

Not Required Machines Built Through 1992

7011717 Machines Built Through 1993 to S/N 33476 7018606 Machines Built S/N 33476 to Present

57 7007923 Piston 1

7007923 0920083 Brake 7018603 0920109 Brake

58 Return Plate/Separator Assembly Options: A/R

0920083 Brake Components:

Kit Plate, Return 1 7011715 Separator Assembly 2 7011714 Pin 4 7007983 Separator 2 7018604 0920109 Brake (1 Welded Component) 1

59 Screw, Bleeder/Plug Options: 1

7007914 0920083 Brake (Screw, Bleeder) 7018609 0920109 Brake (Plug)

60 Ring, Retaining Options: A/R

Not Required Machines Built Through 1992

7011716 Machines Built Through 1993 to Present

— — — — — — — — — —

Lining Kit Options (Includes Items 11,20,21,26, 27 &

58): 2900767 0920083 Brake 7018608 0920109 Brake

2-24 3120687

Page 57

SECTION 2 TURNTABLE

FIGURE 2-8. SWING BRAKE ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-25

Page 58

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-9. SWING HUB ASSEMBLY

2-26 3120687

Page 59

SECTION 2 TURNTABLE

FIGURE 2-9. SWING HUB ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780116 SWING HUB ASSEMBLY Ref. —

1 7001916

2 7001917 Gear, Internal 1 3 7001918 Carrier Assembly (See items 201-207 for Breakdown) 1 4 7000279 Gear, Ring 1 5 Kit O-Ring 2 6 7001920 Cover 1 7Not Used 8 7001922 Washer, Thrust 1

9Not Used 10 Not Used 11 Not Used 12 Not Used 13 7001921 Gear, Input 1 14 Not Used 15 7000287 Washer, Thrust 4 16 7000288 Bearing, Thrust 2 17 7001923 Bolt 8 18 7001924 Bolt, Shoulder 4 19 7001929 Lockwasher 4 20 7001926 Plug, Pipe 1

Hub and Spindle Assembly (See Items 101-111 for Breakdown)

I O N

T U R N

T A B

7001916 HUB AND SPINDLE ASSEMBLY Ref.

101 7001982 Shaft, Output 1 102 Kit Seal, Lip 1 103 7000272 Cup, Bearing 1 104 7000273 Cone, Bearing 1 105 7000274 Cup, Bearing 1 106 7000275 Cone, Bearing 1 107 Not Available Hub 1 108 Kit Spacer 1 109 Kit Ring, Retaining 1 110 7001928 Plug, Pipe 1 111 7001926 Plug, Pipe 2

7001918 CARRIER ASSEMBLY Ref.

201 Not Available Housing, Carrier 1 202 Kit Washer, Thrust 6 203 7001902 Bearing, Needle 84 204 Kit Spacer 3 205 7001904 Shaft, Planet 3 206 Kit Gear, Cluster 3 207 Kit Rollpin 3

— — — — — — — — — — 2900202 Seal Kit (Includes Items 5, 102, 108 and 109) 1 7001927 Cluster Gear Kit (Includes Items 202, 204,206 and 207) 1

3120687 2-27

Page 60

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-10. LOAD MANAGEMENT INSTALLATION

2-28 3120687

Page 61

SECTION 2 TURNTABLE

FIGURE 2-10. LOAD MANAGEMENT INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0239868 LOAD MANAGEMENT INSTALLATION Ref. 7

1 Base Weldment Options: 1

4843310 Prior to May 1992 4844080 May 1992 to September 1992

4844272 September 1992 to Present 2 4160099 Spring 5 3 0630422 Bolt 1 1/4"-&NC x 14" 5 4 3313002 Nut, Jam 1 1/4"-7NC 5 5 3273001 Nut 1 1/4"-7NC (Grade 8) 5 6 4360263 Switch, Limit 1 7 4360259 Switch, Proximity 1 8 3841004 Rod, Actuator 1 9 3321501 Nut 5/16"-18 1

10 3533414 Plate, Actuator Mounting 1 11 4843128 Actuator, Switch (Prior to S/N 27316) 1

0630510 Bolt, Leveler (S/N 27316 to Present) 1

12 3321405 Locknut 1/4"-28NF 1 13 3900104 Screw, Drilled Head #10-24NC x 2 1/4" 4 14 4920140 Lockwire 2 15 4460342 Connector, Strain Relief 2 16 3421677 Pin, Load Moment Pivot 1 17 0642252 Bolt 3/4"-10NC x 6 1/2" 1 18 3312205 Locknut 3/4"-10NC 1 19 2160002 Fitting, Grease 2 20 4220120 Stop, Turntable 2 21 4220121 Stop, Turntable A/R 22 4070729 Shim 11 GA x 1 1/2" x 4" A/R 23 4070728 Shim 16 GA x 1 1/2" x 4" A/R 24 Not Used 25 Not Used 26 Not Used 27 Not Used 28 4220157 Stop, Turntable 1/2" x 1 1/2"" x 4" A/R 29 4220158 Stop, Turntable 1/4" x 1 1/2" x 4" A/R

— — — — — — — — — —

0100019 Loctite A/R

I O N

T U R N

T A B

3120687 2-29

Page 62

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-11. GROUND CONTROLS INSTALLATION

2-30 3120687

Page 63

SECTION 2 TURNTABLE

FIGURE 2-11. GROUND CONTROLS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

GROUND CONTROLS INSTALLATION Ref. 0252713 Prior To S/N 38697 Ref. 2 0258613 S/N 38697 To Present Ref. 1

1 Ground Control Box Assembly - Deutz Options (See

Items 101-181 for Breakdown) 0860775 Prior to S/N 38697 7 0861220 S/N 38697 to Present 1

2 2600148 Hinge 1 3 1780227 Door, Ground Control 1 4 4751400 Flatwasher 1/4" 14 5 3311405 Locknut 1/4"-20NC (Prior to S/N 38697) 14

3311401 Nut 1/4"-20NC (S/N 38697 to Present) 14

6 4300031 Stud (Welded on Part) (Prior to S/N 38697) 5 7 2940042 Latch 1 8Not Used 9 4300032 Stud (Welded on Part) 4

10 4751500 Flatwasher 5/16" 8

— — — — — — — — — —

0100011 Loctite #242 A/R

I O N

T U R N

T A B

GROUND CONTROL BOX ASSEMBLY Ref. 0860775 Prior To S/N 38697 Ref. 7 0861220 S/N 38697 To Present Ref. 4

101 Lid/Nameplate Options: 1

3252182 Prior to May 1994 3252354 May 1994 to S/N 45584 3252647 S/N 45584 to Present

102 0860562 Box 1 103 0140019 Alarm 1 104 4420037 Gasket 105 0610084 Card, Circuit (Engine Relay) 1 106 0610080 Card, Circuit (Select) 1 107 Card, Circuit (Load Radius) Options: 1

0610083 Prior to April 1993 0610106 April 1993 to S/N 44577 0610130 S/N 44577 to Present

108 0610100 Card, Circuit (Overload) 2 109 3740070 Relay - SPDT 16 110 3740016 Relay - 3PDT 6 111 3740057 Relay - 2PDT (Prior to S/N 38697) 2

3740122 Relay - 2PDT (S/N 38697 to S/N 41162) 2 3740057 Relay - 2PDT (S/N 41162 to Present) 2

112 3740049 Relay - 5PDT (With Skirt) A/R 113 Not Used 114 4460301 Marker, Terminal (1-50) 1 115 3640686 Rail 1 116 4460442 Stop, Terminal 1

15 ft./4.5m

3120687 2-31

Page 64

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

117 4460387 Block, Terminal 35 118 4460388 Barrier, Terminal 4 119 4460307 Sleeve, Terminal 20 120 4460441 Bar, Buss - 5 Position 4 121 4460306 Washer, Terminal 20 122 4460305 Screw, Terminal 20 123 4360216 Breaker, Circuit - 30 Amp 1 124 4360232 Breaker, Circuit - 15 Amp 2 125 Switch, Key (Master Select) Options: 1

4360319 Prior to S/N 38697 4360315 S/N 38697 to S/N 45584 4360469 S/N 45584 to Present

Key, Replacement Options: 1 7012560 Use with 4360319 & 4360315 Switches 2860030 Use with 4360469 Switch

126 4460299 Stop, Terminal 1 127 2920027 Light, Indicator - Green (Axles Set) 1 128 2920029 Bulb, Light 3 129 4360212 Breaker, Circuit - 3 Amp 1 130 2920026 Light, Indicator - Red (Radius Limit) 1 131 4360274 Switch, Push Button (Start) 1 132 Not Used 133 2920090 Light, Indicator - Blue (Capacity Limit) 1

134 4360314

135 4760600 Lockwasher #6 A/R 136 4751400 Flatwasher 1/4" A/R 137 3311401 Nut 1/4"-20NC A/R 138 4751000 Flatwasher #10 4 139 3311001 Nut #10-24NC 4 140 4460051 Connector, Strain Relief 6 141 3300048 Nut, Conduit 6 142 0960238 Bushing, Reducer 6 143 Connector, Strain Relief Options: 2

4460071 Prior to S/N 31870 4460051 S/N 31870 to S/N 34119 4460071 S/N 34119 to S/N 41162

144 4460386 Connector, Strain Relief 1 145 3300177 Nut, Tinnerman 3 146 0750806 Screw, Self-Tapping #8 x 3/4" 3 147 0720804 Screw, Hex #8-32NC x 1/2" 6 148 4760800 Lockwasher #8 6 149 3310801 Nut #8-32NC 6 150 3910606 Screw, Hex #6-32NC x 3/8" 2 151 4460451 Strip, Terminal Marking - #98 20 152 3790012 O-Ring 8 153 4460234 Clamp, Cable 10 154 4460452 Strip, Terminal marking - #99 20 155 4120012 Base, Relay 2 156 3300147 Nut, Conduit 1

Switch, Toggle (Extend-A-Reach, Lift, Swing, Level, Telescope and Rotate)

2-32 3120687

Page 65

SECTION 2 TURNTABLE

FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

157 3740066 Spring, Relay 2 158 3910616 Screw, Hex #6-32NC x 1" 10 159 4564088 Stand-Off #6-32NC x 1/4" A/R 160 3310601 Nut #6-32NC A/R 161 Not Used 162 2420009 Hourmeter 1 163 2420091 Voltmeter 1 164 2420074 Gauge, Oil Pressure 1 165 3520070 Plug, Hole 1 166 0960905 Bushing 1 167 4360330 Switch, Toggle (Auxiliary Power) 1 168 4360328 Switch, Toggle (Proximity Manual Test) 1 169 4060229 Guard, Switch 1 170 0610091 Card, Circuit (Prior to S/N 38697) 1 171 4120013 Socket, Relay (Prior to S/N 38697) 1 172 3740058 Relay (Prior to S/N 38697) 1 173 3740063 Spring, Relay (Prior to S/N 38697) 1 174 Block, Contact Options: 1

4360282 Prior to S/N 45584 4360476 S/N 45584 to Present

175 Switch, Emergency Stop Options: 1

4360289 Prior to S/N 45584 4360475 S/N 45584 to Present

Cap Options: 1

7012611 Cap, Mushroom Head (Used on Switch p/n

4360289) 7012612 Boot (Used on Switch p/n 4360289) 1 7020175 Cap, Red (Used on Switch p/n 4360475) 7020176 Contact Block (Used on Switch p/n 4360475)

176 Not Used 177 4740120 Washer, Nylon 3 178 4750800 Washer, Flat 6 179 4070991 Shim .125 (S/N 45584 to Present) 1 180 4070987 Shim .015 (S/N 45584 to Present) 1 181 3910804 Screw #8-32NC x 1/4” (S/N 45584 to Present) 6

I O N

T U R N

T A B

3120687 2-33

Page 66

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-34 3120687

Page 67

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252717

1 3503928 Lid, Control Box 1 2 4420037 Tape, Insulation 3 3251831 Nameplate - Emergency Stop 1 4 3251830 Nameplate - Drive/Steer Functions 1 5 3251829 Nameplate - Caution 1 6 4460052 Connector, Strain Relief 1 7 3300047 Locknut, Conduit 1 8 0960239 Bushing 1

9 1060304 Cable, Electrical - 16/10 10 3941004 Screw #10 x 1/2" 4 11 4360074 Switch, Toggle 2 12 4843020 Control Box Weldment 1 13 4360071 Switch, Toggle 1 14 4360141 Guard, Switch 1 15 4060802 Shield 4 16 Not Used 17 Not Used 18 Not Used 19 Not Used 20 2560116 Knob, Speed Control 1 21 3300352 Nut, Special 1 22 4360340 Switch, Potentiometer 1 23 3730091 Resistor 1 24 3990001 Diode 6

REMOTE DRIVE CONTROL BOX ASSEMBLY (PRIOR TO JULY 1992)

Ref. A

21 in./53cm

23 ft./7.62m

I O N

T U R N

T A B

3120687 2-35

Page 68

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-36 3120687

Page 69

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

REMOTE DRIVE CONTROL BOX ASSEMBLY OPTIONS:

0253148 2WS (July 1992 To October 1992) Ref. — 0253604 4WS (October 1992 To Present) Ref. 6

1 Box, Remote Options: 1

0860798 2WS 0860831 4WS

2 Plate, Remote Box Lid Options: 1

3536234 2WS

3536613 4WS 3 4420037 Tape, Insulation A/R 4 Decal, Remote Box Options:

1701774 2WS 1

1701872 4WS (October 1992 to March 1994) 1

1702291 4WS (March 1994 to Present) 1 5 1701775 Decal, Potentiometer 1 6 Switch, Emergency Stop Options: 1

4360289 Prior to S/N 44577

4360475 S/N 44577 to Present 7 4060802 Shield, Toggle A/R 8 4360074 Switch, Toggle A/R 9 4360340 Switch, Potentiometer 1

10 3300352 Nut, Special 1 11 4460052 Connector, Strain 1 12 3300047 Locknut 1 13 0960239 Bushing 1 14 Use 1060018 Cable, Control 16/10 (was p/n 1060304) 25 ft. 15 4740120 Washer, Nylon 4 16 3300177 Nut, Tinnerman #8 4 17 0750804 Screw #8 x 1/2 Lg. 4 18 2560116 Knob, Speed Control (Black) 1 19 4711600 Flatwasher 3/8" 1

— — — — — — — — — — 3730091 Resistor (Not Shown) 1 3990001 Diode (Not Shown) A/R

Ref.

I O N

T U R N

T A B

3120687 2-37

Page 70

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION

2-38 3120687

Page 71

SECTION 2 TURNTABLE

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DEUTZ F4L-912 ENGINE INSTALLATION Ref. 0252496 Standard Engine - Prior To October 1992 Ref. B 0253353 Standard Engine October 1992 To S/N 38697 Ref. E 0258730 Standard Engine S/N 38697 To Present Ref. 4 0252500 Clean Burn Engine Prior To October 1992 Ref. B 0253355 Clean Burn Engine October 1992 To S/N 38697 Ref. E 0258731 Clean Burn Engine S/N 38697 To S/N 43911 Ref. 4

1 Engine - Deutz Diesel F4L-912 Options: 1

2000083 Standard Engine 1 2000115 Clean Burn Engine 1

3600164 13 Tooth Spline (Prior to S/N 28163) 3600260 15 Tooth Spline (S/N 28163 to Present)

3 3200229 Motor Support Weldment (Front) 1 4 3200228 Motor Support Weldment (Rear) 2 5 3200133 Mount, Rubber Motor (Front) 1 6 3200183 Mount, Rubber Motor (Rear) 2 7 3200227 Plate, Engine Mounting (Front) 1 8 3200306 Plate, Engine Mounting (Rear) 1 9 Pump Assembly Options: 1

3600191

2900660 Shaft Seal Kit - 3600191 Pump 1

3600205

3600286

10 0901829 Bracket, Filter 1 11 2120135 Filter - Charge Pump 1

2120136 Element 1

12 1060044 Cable, Battery (Starter to Ground) 1 13 0641812 Bolt 1/2"-13NC x 1 1/2" 2 14 4761800 Lockwasher 1/2" 2 15 0250069 Fuel Shutdown Kit (Includes Mounting Hardware) 1 16 0642032 Bolt 5/8"-11NC x 4" 3 17 3312005 Locknut 5/8"-11NC 3 18 4740242 Flatwasher, Special 3 19 0701427 Bolt, Metric 14mm x 100mm 4 20 4740191 Lockwasher, Metric 14.2mm 4 21 0701215 Bolt, Metric 12mm x 35mm 8 22 4832100 Lockwasher 12mm 8 23 4751600 Flatwasher 3/8" (Prior to S/N 38697) 2

4891600 Flatwasher 3/8" (S/N 38697 to Present) 2

24 0641610 Bolt 3/8"-16NC x 1 1/4" (Prior to S/N 38697) 2

0641620 Bolt 3/8"-16NC x2 1/2" (S/N 38697 to Present) 2

25 4761600 Lockwasher 3/8" (Prior to S/N 38697) 2

0100011 Loctite #242 (S/N 38697 to Present) A/R

26 0701015 Bolt, Metric 10mm x 35mm 2

Pump Assembly - Sunstrand (See Figure 2-17 for Breakdown)

Pump Assembly - Barnes (Not Field Serviceable) (Prior to October 1992)

Pump Assembly - Barnes (October 1992 to S/N 38697) (See Figure 2-18 For Breakdown)

Pump Assembly - Barnes (S/N 38697 to Present) (See Figure 2-19 For Breakdown)

I O N

T U R N

T A B

3120687 2-39

Page 72

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

27 4831700 Lockwasher 6mm 1 28 3311401 Nut 1/4"-20NC 3 29 0641405 Bolt 1/4"-20NC x 5/8" 4 30 4761400 Lockwasher #1/4" 4 31 Not Used 32 0700617 Bolt, Metric 6mm x 45mm 5 33 0237627 Electrical Panel Assembly (See Items 201-211 for

(Breakdown)

34 0237635 Throttle Cable Installation (See Items 301-315 for

Breakdown) 35 0901402 Bracket, Terminal Strip 1 36 1320070 Clamp, Wire 1 37 1670414 Cover, Terminal Strip 1 38 3910812 Screw, Machine #8-32NC x 3/4" 2 39 4770800 Starwasher #8 2 40 3310801 Nut #8-32NC 2 41 1700821 Decal, Wire Identification 1 42 4843384 Air Intake Weldment 1 43 4565269 Adapter, Exhaust (S/N 38697 to Present) 1 44 Not Used 45 4921414 Harness, Wiring 1 46 2420073 Gauge, Sender Unit 1 47 Coupling Installations (See Figure 2-16 for

Breakdown) 48 4811700 Flatwasher 6mm 9 49 Not Used 50 Not Used 51 4640742 Valve, Oil Drain 1 52 2720042 Hose, Heater 53 4832000 Lockwasher, Metric 10mm 2

54 to 56 Not Used

57 3290607 Locknut, Metric 6mm (S/N 38697 to Present) 4 58 Not Used 59 1320222 Clamp (Not Shown) (S/N 38697 to Present) 1 60 3790152 O-Ring 1

— — — — — — — — — —

4420001 Tape, Sealant A/R

6 in./15cm

DEUTZ ENGINE INSTALLATION Ref. 0252495 Standard Engine Prior To October 1992 Ref. B 0253354 Standard Engine October 1992 To S/N 38697 Ref. 3 0258723 Standard Engine S/N 38697 To Present Ref. 1 0252499 Clean Burn Engine Prior To October 1992 Ref. B 0253356 Clean Burn Engine October 1992 To S/N 38697 Ref. 2 0258729 Clean Burn Engine S/N 38697 To S/N 43911 Ref. 2

78 Tube Weldment Options: 1

4844165 Prior to October 1992 4844238 October 1992 to Present

79 1670627 Cover, Base Plate 1

2-40 3120687

Page 73

SECTION 2 TURNTABLE

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

80 1340020 Air Cleaner Assembly 1

7004214 Element 1 81 0340002 Band, Mounting 2 82 0080046 Elbow 1 83 0080039 Elbow 2 84 4565655 Tube 1 85 2720224 Hose 2 3/4" ID x 3" Lg. 1 86 1320058 Clamp 8 87 4300031 Stud (Welded on Part) 8 88 4761400 Lockwasher 1/4" 6 89 3311401 Nut 1/4"-20NC 12 90 0400020 Battery (Large) 1 91 0236768 Rod, Tie-Down 4 92 0361027 Bar, Hold-Down 1 93 3980006 Seat, Battery 1 94 0400003 Battery (Small) 1 95 0400002 Hold-Down 1 96 3980003 Seat, Battery 1 97 4751400 Flatwasher 1/4" A/R 98 3300029 Wingnut 1/4"-20NC 4 99 1060031 Cable, Battery (Large Battery to Ground) 1

100 1060109 Cable, Battery (Large Battery to Starter) 1 101 1060149 Cable, Battery (Starter to Aux. Relay) 1 102 1060132 Cable, Battery (Aux. Relay to Aux. Pump) 1 103 4300034 Stud (Welded on Part) A/R 104 4921139 Cable, Battery (Positive to Positive - Batteries) 1 105 0642022 Bolt 5/8"-11NC x 2 3/4" 2 106 4752000 Flatwasher 5/8" 2 107 4762000 Lockwasher 5/8" 2 108 3312001 Nut 5/8"-11NC 2 109 0641622 Bolt 3/8"-16NC x 2 3/4" 2 110 4751600 Flatwasher 3/8" A/R 111 4761600 Lockwasher 3/8" A/R 112 3311601 Nut 3/8"-16NC A/R 113 Auxiliary Pump Assembly Options: 1

3600050

3600208

114 0641620 Bolt 3/8"-16NC x 2 1/2" 2 115 2720271 Fuel Line (Return) 8 ft./2.4m 116 2750532 Fuel Line (Supply) 10 ft./3m 117 2220063 Fitting, 90° 2 118 2220720 Fitting, Barbed 2 119 0641414 Bolt 1/4"-20NC x 1 3/4" 13 120 1320022 Clamp 4 121 Air Inlet Box Assembly Options: 1

0252866 Prior to October 1992

0253194 October 1992 to Present

122 4280002 Neoprene 1/8" x 2"

Pump Used Prior to April 1993 (See Items 501-503 for Breakdown)

Pump Used April 1993 to Present (See Items 504506 for Breakdown)

30 in./76cm

I O N

T U R N

T A B

3120687 2-41

Page 74

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

123 1320059 Clamp 1 124 2180536 Fitting, Coupling 1 125 3311405 Locknut 1/4"-20NC 13 126 1060031 Cable, Battery (Small Battery to Ground) 1 127 4751500 Flatwasher 5/16" 2 128 4740362 Washer, Fender 6 129 4761500 Lockwasher 5/16" 2 130 3535949 Plate, Hose Cover 1 131 0362101 Bar, Spacer 1 132 3536008 Plate, Shield 1 133 1320021 Clamp, Muffler 1

133 to 137 Not Used

138 4751700 Flatwasher 7/16" (S/N 38697 to Present) 1

0237627 ELECTRICAL PANEL ASSEMBLY Ref. 7

201 3740059 Relay 1 202 3321001 Nut #10-32NF 3 203 3310801 Nut #8-32NC 1 204 3530425 Plate, Mounting 1 205 3740080 Relay, Sealed 1 206 3740067 Relay 2 207 3300220 Nut, Special 6 208 0641405 Bolt 1/4"-20NC x 5/8" 7 209 4761400 Lockwasher 1/4" (Prior to S/N 37522) 7

4791400 Starwasher 1/4" (S/N 37522 to Present) 7 210 3311401 Nut 1/4"-20NC 7 211 4711400 Flatwasher 1/4" 6

0237635 THROTTLE CABLE INSTALLATION Ref. 4

301 0060023 Actuator 1

7008804 Bellows, Rubber 1

7008829 Board, Circuit 1

7008821 Motor, Drive 1

7008828 Cable, Throttle 1 302 0901389 Bracket, Throttle Cable 1 303 4460302 Stop, Terminal 1 304 3450203 Pin, Cotter 1/16" x 3/4" 1 305 4711400 Flatwasher 1/4" Narrow 1 306 0641409 Bolt 1/4"-20NC x 1 1/8" 2 307 4751400 Flatwasher 1/4" 2 308 0630400 Bolt, Metric 8mm - 1.25 x 90mm 2 309 4761500 Lockwasher 5/16" (Prior to S/N 37522) 2

4831900 Lockwasher 8mm (S/N 37522 to Present) 2 310 3290801 Nut, Metric 8mm - 1.25 2 311 1320041 Clamp 1 312 4761400 Lockwasher 1/4" 3 313 4751600 Flatwasher 3/8" 2

2-42 3120687

Page 75

SECTION 2 TURNTABLE

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

314 0641406 Bolt 1/4"-20NC x 3/4" 1 315 3311401 Nut 1/4"-20NC 1

0252694

401 3220080 Muffler 1 402 0340041 Band, Mounting 2 403 0641406 Bolt 1/4"-20NC x 3/4" 8 404 4751400 Flatwasher 1/4" 4 405 4761400 Lockwasher 1/4" 8 406 3311401 Nut 1/4"-20NC 8 407 4565269 Adaptor, Exhaust 1 408 Not Used 409 4565663 Tube, Exhaust 1 410 4844169 Snorkel 1 411 4565267 Elbow, Exhaust 1 412 4565664 Tube, Flex Exhaust 1 413 1320011 Clamp, Muffler - 2 1/2" 4 414 4100025 Sleeve, Fiberglass 42 in./1m

0255613

EXHAUST INSTALLATION (PRIOR TO OCTOBER

1992)

EXHAUST INSTALLATION (OCTOBER 1992 TO PRESENT)

Ref. —

Ref. 2

I O N

T U R N

T A B

451 1320011 Clamp, Muffler 2 452 3220082 Muffler (Standard) 1

3220088 Muffler (Exhaust Purifier - Optional Not Shown) 1 453 0340041 Band, Mounting 1 454 0641408 Bolt 1/4"-20NC x 1" 2 455 4751400 Flatwasher 1/4" 4 456 3311405 Locknut 1/4"-20NC 2 457 0901849 Bracket, Exhaust Mounting 1 458 4565751 Tube, Exhaust 1 459 3311405 Locknut 1/4"-20NC 4 460 4751400 Flatwasher 1/4" 4 461 4844235 Stack, Exhaust 1 462 1120423 Cap, Rain 1 463 Not Used 464 0641408 Bolt 1/4"-20NC x 1" 4

3600050

501 Coupling Options: 1

7004249 Barnes Brand Pump

7004412 Stone Brand Pump 502 Motor Options: 1

7004248 Barnes Brand Pump

7000482 Stone Brand Pump

AUXILIARY PUMP ASSEMBLY - BARNES OR STONE PUMP (PRIOR TO APRIL 1993)

Ref. D

3120687 2-43

Page 76

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

503 Pump Options: 1

7010923 Barnes Brand Pump 7004414 Stone Brand Pump

3600208

504 7013711 Coupling 1 505 7013710 Motor 12VDC 1

7013753 Brush Kit 1

506 7013712 Pump 1

0255152 Engine Distress Installation Ref. 3 0255274 Low Oil Pressure Shutdown Installation (Prior to

0270566 Low Oil Pressure Shutdown Installation

0239119 Generator Installation - 110 Volt Ref. 11

601 4360179 Switch, Temp Head (Located Under Top Engine

602 2180360 Fitting, Tee 1 603 Switch, Oil Pressure Options: 1

4360065 Engine Distress Installation 4360065 Low Oil Pressure Shutdown Installation 4360037 Generator Installation - 110 Volt

604 Fitting Options: A/R

2180749 Fitting, 45° (Engine Distress Installation and Low

Not Required Low Oil Pressure Shutdown Installation Prior to

2180730 Fitting, Adapter (Generator Installation - 110V) 1

AUXILIARY PUMP ASSEMBLY (APRIL 1993 TO PRESENT)

ENGINE DISTRESS INSTALLATION Ref.

S/N 54482)

(S/N 54482 to Present)

Cover) (Engine Distress Installation Only)

Oil Pressure Shutdown S/N 54482 to Present)

S/N54482

Ref. A

Ref. 4

Ref. 1/B

ENGINE COMPONENTS Ref.

7000663 Alternator (Bosch) 1 7000872 Alternator (Delco-Remy) 1

Starter Options: 1

Use 7020413 Starter (New) ( was p/n 7000661) 1

7020420 Starter ( Remanufactured) 1

70001927 Manifold, Exhaust 1

7000697 Belt, Blower 1 7000698 Belt, Alternator 1

7026125 Flange, Exhaust 1 Use 7029274 Filter, Fuel (was p/n 7000649) 1 Use 7029276 Filter, Oil (was p/n 7000648) 1

7014503 Filter, Oil (Case of 12) 1

7016309 Washer, Copper Sealing 1

7016330 Switch, Oil Pressure 1

2-44 3120687

Page 77

SECTION 2 TURNTABLE

FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Use 7019607 Switch, Solenoid (was p/n 7016341) 1

7016364 Pump, Fuel Lift 2 7019607 Solenoid, Fuel Shutdown 1 7020208 Gear, Ring 1 7020400 Washer, Fuel Line 1 7020401 Washer 1 7020402 Washer, Fuel Line 1 7020403 Washer, Fuel Line 1 7020405 Washer, Oil Plug 1 7020407 Gasket, Lift Pump 1 7020409 Dipstick 1 7020421 Nozzle, Injector 1 7020422 Injector 1 7020423 Gasket, Injector Tip 1 7020432 Kit, Lift Pump Repair 1 7020433 Gasket 1 7020498 Fan 1 7026173 Switch, Broken Belt 1

7027250 Spring, Tension (Actuator) 1 70001361 Pump, Fuel Injection 4 70001928 Gasket, Exhaust Manifold 4 70002252 Ring, Head Fire 4 70002253 Gasket Set, Complete Engine 1 70002254 Kit, Piston/Cylinder 4 70002258 Bolt, Cylinder Head 4 70002259 Washer, Cylinder Head Bolt 4

I O N

T U R N

T A B

3120687 2-45

Page 78

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ

2-46 3120687

Page 79

SECTION 2 TURNTABLE

FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0239119 GENERATOR INSTALLATION- DEUTZ Ref. 11

1 4843133 Bracket, Generator Mounting 1 2Not Used 3 2460011 Generator and Control Box Assembly 1

7012558 Generator 1 7020193 Cord, Power 1 7026199 Armature 1 7020108 Brush 4 7020109 Holder, Brush 4 7012513 Cap, Brush Holder 4 7012514 Fan 1 7020110 End, Bell Front 1 7020111 End, Bell Rear 1 7020190 Bearings 2 7003657 Box, Control 1

Note: Replacement Generator p/n 7012558 comes standard with Pulley p/n 3580134. This Pulley may not be correct for all applications. Refer to Pulley options below.

Use 2420203 Voltmeter (was p/n 7010699) 1 Use 4360542 Breaker, Circuit (was p/n 7020194) 1

4460190 Receptacle 2 2920162 Lamp 1 7020191 Switch, Toggle 1

3520028 Plug, Hole 1 4 0480050 V-Belt 1 5 4340511 Support, Adjustment 1 6 3580109 Pulley 1 7Not Used 8 2860012 Key, Woodruff 1 9 0700821 Bolt, Metric 8m x 65mm 4

10 4761500 Lockwasher 5/16" 6 11 0681610 Bolt 3/8"-16NC x 1 1/4" (Grade 8) 2 12 4751500 Flatwasher 5/16" A/R 13 0641507 Bolt 5/16"-18NC x 7/8" 2 14 3251476 Nameplate - On/Off 1 15 4460023 Connector 1 16 4300031 Stud (Welded on Part) 2 17 4761400 Lockwasher 1/4" 2 18 Not Used 19 4920039 Wire - Red 12ft/3.7m 20 Not Used 21 Not Used 22 2180360 Fitting, Tee (Not Shown - Located on Engine) 1 23 Not Used 24 Not Used 25 4360037 Switch, Oil Pressure (Not Shown - Located on Engine) 1 26 3311401 Nut 1/4"-20NC 2

I O N

T U R N

T A B

3120687 2-47

Page 80

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

27 2180730 Fitting, Adapter (Not Shown - Located on Engine) 1 28 4761600 Lockwasher 3/8" 2 29 4751600 Flatwasher 3/8" 4

2-48 3120687

Page 81

SECTION 2 TURNTABLE

FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-49

Page 82

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-16. PUMP COUPLING INSTALLATION

2-50 3120687

Page 83

SECTION 2 TURNTABLE

FIGURE 2-16. PUMP COUPLING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PUMP COUPLING INSTALLATIONS Ref.

0239954

1 1660170 Coupling, Pump - Lovejoy 1

1660174 Disc, Coupling 1

1660175 Hub, Coupling 1 2 0701014 Bolt, Metric 10mm x 30mm 18 3 4832000 Lockwasher, Metric 10mm 18 4 0080164 Adaptor, Pump Mounting Plate 1

0250600 13 Tooth Pump Ref. —

0256849 15 Tooth Pump Ref. —

101 Coupling, Pump - Hayes Options: 1

1660183 13 Tooth Pump

1660233 15 Tooth Pump

102 0701014 Bolt, Metric 10mm x 30mm 12 103 4832000 Lockwasher 10mm 18 104 0080164 Plate, Adaptor 1 105 0701010 Bolt, Metric 10mm x 20mm 6

3020021 Grease A/R

PUMP COUPLING INSTALLATION - LOVEJOY (STANDARD PARTS WHEN EQUIPPED)

Note: Used with 13 tooth pump.

PUMP COUPLING INSTALLATION - HAYES Ref.

— — — — — — — — — — —

Ref. —

I O N

T U R N

T A B

3120687 2-51

Page 84

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND

2-52 3120687

Page 85

SECTION 2 TURNTABLE

FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PISTON PUMP ASSEMBLY - SUNSTRAND Ref. 3600164 13 Tooth Pump Spline (Prior to S/N 28163) Ref. A 3600260 15 Tooth Pump Spline (S/N 28163 to Present) Ref. B

1 7007413 Shim Kit - Relief Valve 1 2 7007414 Plug 1 3 Kit O-Ring 1 4 7007416 Spring, Relief Valve 1 5 7007417 Valve, Relief 1 6 Kit O-Ring 2 7 7007419 Plug 2 8Not Used

9Not Used 10 7007420 Plug 2 11 7007208 Plug 2 12 7007421 Screw 10 13 Not Used 14 7007422 Gasket, Servo Cover 2 15 7007423 Nut, Special 1 16 7007424 Cover, Adjustment 1 17 Not Used 18 7007425 Bearing, Needle 1 19 Kit Ring, Retaining 1 20 Kit Washer 1 21 Kit Spring 1 22 Not Used 23 Kit Washer 1 24 Kit Retainer 1 25 Kit Pin, Slipper Holddown 3 26 Kit Piston Assembly 7 27 Kit Guide, Slipper 1 28 Kit Guide, Retainer 1 29 7007435 Pin, Spring 1 30 7007436 Screw - 12 Point Head 1 31 7007437 Bearing, Ball 1 32 7007438 Ring 2 33 7007439 Ring 2 34 7007440 Pin, Spring 2 35 7007441 Handle, Pin 1 36 7007442 Sleeve, Bearing 1 37 Kit Gasket, Front Cover 1 38 7007444 Pin 1 39 7007445 Plug, Expansion 1 40 Kit Pin 1 41 Kit O-Ring 1 42 Kit Ring, Load Temper 1 43 7007449 Housing, Pump 1 44 Kit Ring, Back-Up 1

I O N

T U R N

T A B

3120687 2-53

Page 86

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

45 Kit O-Ring 1 46 Kit Cover, Gerotor 1 47 7007453 Bolt, Hex 3 48 7007208 Plug 1 49 7007454 Cover, Front 1 50 Kit Block, Cylinder 1 51 7007456 Screw - 12 Point Head 6 52 7001438 Washer 10 53 Kit Swashplate 1 54 7007458 Journal, Bearing 1 55 Kit Seal, Lip 1 56 Kit O-Ring 1 57 Shaft, Main Pump 1

7007461 13 Tooth Spline (Prior to S/N 30660)

7010121 15 Tooth Spline (S/N 30660 to Present) 58 Kit Plate, Valve 1 59 Kit Gerotor Assembly 1 60 Kit Pin 1 61 Kit Key, Woodruff 1 62 7007466 Adaptor, Remote Filtration (Without Bypass) 1 63 Kit O-Ring 3 64 7007468 Screw 2 65 7007469 Screw 2 66 7007470 Plug 1 67 7007471 Cover, Servo (With Adjuster) 1

7007490 Stop, Servo (Not Shown) 2

7007491 Nut, Special (Not Shown) 2

7007492 Ring, External (Not Shown) 2 68 7007482 Cover, Servo (Without Adjuster) 1 69 7007483 Guide, Spring 1 70 7007484 Stop, Servo 1 71 7007485 Spring 1 72 7007486 Screw 1 73 7007487 Guide, Spring 1 74 7007488 Ring, Retaining 1 75 7007499 Locknut 1 76 Kit Ring, Piston 2 77 7007494 Piston, Servo 1 78 Kit O-Ring 2 79 7007472 Valve, By-Pass 1 80 7007473 Valve, Pressure Release (Includes Item 6) 2 81 7007474 Control, Dual Oil-Filled 1

7007496 Coil Assembly (Pilot) 1

7007497 Plug (Pump) 1

7007498 Plug (Valve Harness) 1 82 7007478 Screw 2 83 7001498 Screw 2 84 Kit O-Ring 2 85 Kit O-Ring 1

2-54 3120687

Page 87

SECTION 2 TURNTABLE

FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

86 7007475 Plug, Orifice/Screen -.156 1 87 7007477 Plug, Orifice -.37 2 88 7007476 Adapter, Auxiliary Pump 1 89 7010120 Spacer/Gasket 1

— — — — — — — — — —

2900752

7007412 Seal Kit - Servo Piston (Includes Items 76 and 78) 1 2900826 Charge Pump Kit (Includes Items 41,42,46,59,60,61) 1

2900827

Seal Kit - Complete (Includes Items 3,6,14,15,37,41,42,

44,45,55,56,63,76,78,84 and 85)

Cylinder Block Kit (Includes Items 19-28, 40,50,53,55,58)

I O N

T U R N

T A B

3120687 2-55

Page 88

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-56 3120687

Page 89

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3600205

1 7010955 Ring, Retaining 1 2Kit 3 7010956 Flange, Mounting 1 4Kit 5Kit 6 7010957 Bearing 2 7 Kit O-Ring 2 8 7010996 Housing, Gear 1

9 7010959 Pin, Dowel 4 10 Not Used 11 7010997 Gear, Idler 1 12 7010998 Gear, Drive 1 13 7010960 Cover, End 1 14 7010961 Bolt 4

7010953 Seal Kit (Includes Items 2,4,5 and 7) 1

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

— — — — — — — — — —

Ref. —

I O N

T U R N

T A B

3120687 2-57

Page 90

SECTION 2 TURNTABLE

I O N

T U R N

A B

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

2-58 3120687

Page 91

SECTION 2 TURNTABLE

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3600286

1 7010105 Bearing/Bushing 2 2 Not Serviced Housing 1 3 Not Serviced Flange, Mounting 1 4 7010103 Cover, End 1 5 7010126 Gear, Drive 1 6 7010125 Gear, Idler 1 7 Kit Ring, Anti-Extrusion 2 8 Kit Seal 2

9 7010124 Bolt 4 10 7010104 Ring, Retaining 1 11 7010127 Pin, Dowel 4 12 Kit Seal, O-Ring 2 13 Kit Seal, Shaft 1

7007489 Seal Kit (Includes Items 7,8,12 and 13) 1

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

— — — — — — — — — —

Ref. —

I O N

T U R N

T A B

3120687 2-59

Page 92

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-20. TANKS INSTALLATION

2-60 3120687

Page 93

SECTION 2 TURNTABLE

FIGURE 2-20. TANKS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252524 TANKS INSTALLATION Ref. 5

1 4400279

4400386

2 4400340

3 0641614 Bolt 3/8"-16NC x 1 3/4" 4 4 4711600 Flatwasher 3/*’ 15 5 3311605 Locknut 3/8"-16NC 8 6 0641616 Bolt 3/8"-16NC x 2" 3 7 1340046 Breather 1 8 2220893 Fitting 1 9 2120134 Filter, Hydraulic 1

2120129 Element 1

4300034 Stud, Weld 4

4400279 Prior To June 1995 Ref. B 4400386 June 1995 To Present Ref. 2

Fuel Tank Assembly (See Items 101-112 for Breakdown) (Prior to June 1995)

Fuel Tank Assembly (See Items 101-112 for Breakdown) (June 1995 to Present)

Hydraulic Oil Tank Assembly (See Items 201-216 for Breakdown)

— — — — — — — — — —

FUEL TANK ASSEMBLY Ref.

I O N

T U R N

T A B

101 4400280 Tank Weldment (Prior to June 1995) 1

4400387 Tank Weldment (June 1995 to Present) 1 102 Not Used 103 2180467 Fitting, 90° 2 104 4562663 Tube, Sight (Prior to February 1993)

4562516 Tube, Sight (February 1993 to Present) 105 1320022 Clamp 2 106 2200052 Plug, Pipe - 1/4" 1 107 0100020 Sealant, Thread (Not Shown) A/R 108 4060574 Protector, Gage 1 109 3311401 Nut 1/4"-20NC 3 110 4761400 Lockwasher 1/4" 3 111 4751400 Flatwasher 1/4" 3 112 3300205 Nut, Retainer 5/16"-18NC 3

4400340 HYDRAULIC OIL TANK ASSEMBLY Ref. B

201 4400341 Tank Weldment 1 202 Not Used 203 4740338 Washer, Sealing 6 204 2420080 Gage, Level 1

7016664 Washer, Sealing 2 205 1670625 Lid 1 206 Not Used 207 3520022 Plug, Magnetic 1 208 1340045 Basket, Strainer 1

15 in./38cm

3120687 2-61

Page 94

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-20. TANKS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

209 3960371 Gasket 1 210 3300205 Nut, Retainer 5/16"-18NC 3 211 2180606 Nipple, Pipe 1 212 2120104 Filter 1 213 3311401 Nut 1/4"-20NC 14 214 4761400 Lockwasher 1/4" 14 215 0100020 Sealant, Thread (Not Shown) A/R 216 4751400 Flatwasher 1/4" 14

0255869 FUEL FILL EXTENSION KIT Ref. —

Note: For use on fuel tanks built prior to June

1995. Tanks built June 1995 to present are already equipped with extension.

301 4845158 Fill Tube Extension Weldment 1 302 3960465 Seal 1

FUEL CAP ASSEMBLY - STANDARD Ref. 4400279 Prior To June 1995 Ref. B 4400386 June 1995 To S/N 30382 Ref. 2 0257365 S/N 30382 to Present with Standard Cap Ref. 1 0257366 S/N 30382 to Present with Red Protectoseal Cap Ref. 2 0258626 S/N 30382 to Present with Blue Protectoseal Cap Ref. 1

401 Cap, Fill Options: 1

1120314 Standard Cap 1120367 Red Protectoseal Cap 1120512 Blue Protectoseal Cap

2-62 3120687

Page 95

SECTION 2 TURNTABLE

FIGURE 2-20. TANKS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-63

Page 96

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-21. HOOD INSTALLATION

2-64 3120687

Page 97

SECTION 2 TURNTABLE

FIGURE 2-21. HOOD INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

HOOD INSTALLATIONS Ref. 0252589 Prior To October 1992 Ref. B 0253362 October 1992 To Present Ref. 5

Note: Replacement Decals Must be Ordered Separately - See Section 8.

1 Panel - Hood Top (Engine Side) Options: 1

3380399 Prior to October 1992 3536417 October 1992 to Present

2 Panel - Hood Top (Valve Side) Options: 1

4844115 Prior to October 1992 4844390 October 1992 to Present

3 Panel - Hood (Valve Side) Options: 1

3380378 Prior to June 1995 3380419 June 1995 to Present

4 3380400 Panel - Hood (Engine Side) 1 5 4844087 Panel - Door (Engine Side) 1 6 1780172 Door (Valve Side) 1 7 Duct, Discharge (Engine Side) Options: 1

4844078 Prior to October 1992 4844236 October 1992 to Present

8 3535948 Plate, Baffle (Engine Side) 1

9 2940051 Latch 1 10 4844113 Door (Valve Side) 1 11 3380379 Panel - Hood Top (Valve Side) 1 12 4844074 Door (Engine Side) 1 13 Not Used 14 4843334 Mounting, Gas Spring 1 15 3941405 Screw, Self-Tap 1/4" x 5/8" 8 16 4761400 Lockwasher 1/4" 8 17 4300034 Stud (Welded on Part) 16 18 4751600 Flatwasher 3/8" 16 19 3311605 Locknut 3/8"-16NC 16 20 4160081 Spring, Gas 2 21 0630383 Bolt, Carriage 5/16"-18NC x 3/4" 4 22 4751500 Flatwasher 5/16" 10 23 3311505 Locknut 5/16"-18NC 6 24 0641406 Bolt 1/4"-20NC x 3/4" 40 25 3311405 Locknut 1/4"-20NC 70 26 4751400 Flatwasher 1/4" 48 27 0901500 Bracket, Mounting - Hood 1 28 4843324 Bracket, Mounting - Hood 1 29 0901502 Bracket, Mounting - Hood 3 30 Not Used 31 1670516 Cover, Front 1 32 4844083 Hood (Front) 1 33 4740362 Washer, Fender 41 34 0641408 Bolt 1/4"-20NC x 1" 22 35 3537819 Plate, Extension - Base 1

Ref.

I O N

T U R N

T A B

3120687 2-65

Page 98

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-21. HOOD INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

36 0641512 Bolt 5/16"-18NC x 1 1/2" (October 1992 to Present) 5 37 0940036 Bumper, Door 2 38 0901197 Bracket, Door Stop 2 39 Not Used 40 0641508 Bolt 5/16"-18NC x 1" 4 41 4761500 Lockwasher 5/16" 4 42 3200222 Mounting, Gas Spring 2 43 2940042 Mounting, Latch 5 44 Not Used 45 Not Used 46 4300032 Stud (Welded on Part) 5 47 3536414 Plate, Seal (October 1992 to Present) 1 48 3536415 Plate, Seal (October 1992 to Present) 1 49 3535951 Plate, Hinge Shield 1 50 3820018 Rivet 10 51 2820059 Acoustical Foam - 33 x 20 (October 1992 to Present) 1 52 2820058 Acoustical Foam - 20 x 17 (October 1992 to Present) 1

53 2820053

54 2820057

0100011 Loctite #242 A/R

Acoustical Foam - 6 3/4" x 14 3/4" (October 1992 to Present)

Acoustical Foam - 24" x 16 3/4" (October 1992 to Present)

— — — — — — — — — —

0252652 HOOD SEALS INSTALLATION Ref. A

101 3960418 Seal 13 ft./4m 102 3960389 Seal, Door 8 ft./2.4m 103 3960429 Tape, Sealant 7 ft./2.1m 104 3960433 Seal 6 ft./1.8m

0251543 ALARM INSTALLATION (OPTIONAL) Ref. 2

201 0140032 Alarm 1 202 0641406 Bolt 1/4"-20NC x 3/4" 2 203 4751400 Flatwasher 1/4" 4 204 3311405 Locknut 1/4"-20NC 2

2-66 3120687

Page 99

SECTION 2 TURNTABLE

FIGURE 2-21. HOOD INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

I O N

T U R N

T A B

3120687 2-67

Page 100

SECTION 2 TURNTABLE

I O N

T U R N

A B

FIGURE 2-22. OIL COOLER INSTALLATION

2-68 3120687

JLG 120HX Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual