JLG 120HX Parts Manual

Illustrated Parts Manual

Model

120HX

P/N

3120687

August 31, 2011

REVISION LOG

May 1992 - Original Issue Of Manual

May 1995 - Revised

June 1997 - Revised

May 1998 - Revised

December 1998 - Revised

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

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

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

February 24, 2004 - Revised

January 4, 2008 - Revised

August 31, 2011 - Revised

3120687 A

REVISION LOG

B 3120687

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

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

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

SECTION 1 FRAME

E C T

I O N

FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION

1-2 3120687

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

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

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

SECTION 1 FRAME

I O N

FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR

1-6 3120687

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

SECTION 1 FRAME

I O N

FIGURE 1-3. STEERING AND AXLES INSTALLATION

1-8 3120687

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

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

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

SECTION 1 FRAME

I O N

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

1-12 3120687

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

SECTION 1 FRAME

I O N

FIGURE 1-5. DRIVE HUB ASSEMBLY

1-14 3120687

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

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

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

SECTION 1 FRAME

I O N

FIGURE 1-6. DRIVE BRAKE ASSEMBLY

1-18 3120687

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

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

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

SECTION 1 FRAME

I O N

FIGURE 1-7. DRIVE MOTOR ASSEMBLY - REXROTH

1-22 3120687

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

SECTION 1 FRAME

I O N

FIGURE 1-8. JACK CYLINDER INSTALLATION

1-24 3120687

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