JLG 1230ES Parts Manual

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Illustrated Parts Manual

Model

1230ES

P/N

3121223

October 8, 2013

REVISION LOG

P/N

1600346

(Color: Blue)

P/N

1001092456

(Color: Black)

NOTES:

NOTE: Country of Manufacture - The 1230ES Scissor Lifts are manufactured by JLG Industries in the following

countries: USA, France and China. Refer to the Serial Number Tag to identify the country of manufacture. Machines manufactured in the USA will have a serial number prefix of 02 (i.e. 02XXXXXXXX), machines manufactured in France will have a prefix of A2 (i.e. A2XXXXXXXX) and machines manufactured in China will have a prefix of B2 (i.e. B2XXXXXXXX).

NOTE: Production in France starts August 2006 & ends February 2010 with S/N A200009897.

NOTE: Drive Module Identification - The module is located inside the frame. Open the left side battery door and identify

the drive module by part number or visual identification before ordering parts. (See illustration below). Also, identify the country of manufactured by referring to the S/N nameplate before ordering parts (See note above). USA built machines: Machines built prior to S/N 0200203195 use the 1600346 Drive Module. Machines with S/N 0200203195 to Present use the 1001092456 Drive Module.

French built machines: All machines use the 1600346 Drive Module. China built machines: All machines use the 1001092456 Drive Module.

MANUAL REVISION LOG:

April 12, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19)

July 31, 2006 - Original Issue of Manual (Edited to B/M 0010670 Revision 4)

January 15, 2007 - Revised Manual (Edited to B/M 0010670 Revision 6)

August 1, 2007 - Revised Manual (Edited to B/M 0010670 Revision 8)

February 15, 2008 - Revised Manual (Edited to B/M 0010670 Revision 8)

August 15, 2008 - Revised Manual (Edited to B/M 0010670 Revision 11)

August 12, 2009 - Revised Manual (Edited to B/M 0010670 Revision 11)

March 1, 2010 - Revised Manual (Edited to B/M 0010670 Revision 12)

November 1, 2010 - Revised Manual (Edited to B/M 0010670 Revision 17)

April 8, 2011 - Revised Manual (Edited to B/M 0010670 Revision 18)

July 14, 2011 - Revised Manual (Edited to B/M 0010670 Revision 19)

October 7, 2011 - Revised Manual (Edited to B/M 0010670 Revision 19)

January 12, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19)

3121223 1230ES A

REVISION LOG

June 22, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19)

August 21, 2012 - Revised Manual (Edited to B/M 0010670 Revision 19)

January 7, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19)

April 12, 2013 - Revised Manual (Edited to B/M 0010670 Revision 19)

July 9, 2013 - Revised Manual (Edited to B/M 0010670 Revision B)

October 8, 2013 - Revised Manual (Edited to B/M 0010670 Revision B)

B 1230ES 3121223

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 STEERING AND DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 WHEEL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 POTHOLE PROTECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS . . . . . . . . . . . . . . 1-14

1-5 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE

MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE

MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 BATTERIES AND COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 - MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 MAST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM CONSOLE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 DRIVE/STEER P/Q CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 4-12

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

5-1 LIFT CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

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

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

7-1 ELECTRICAL SCHEMATIC (MACHINES WITH 1600346 DRIVE MODULE). . . . . . . . . 7-2

7-2 ELECTRICAL SCHEMATIC (MACHINES WITH 1001092456 DRIVE MODULE) . . . . . 7-4

7-3 ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346

DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-4 ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456

DRIVE MODULE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

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

8-1 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

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

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3121223 1230ES i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

ii 1230ES 3121223

SECTION 1

FRAME

3121223 1230ES 1-1

SECTION 1 FRAME

208

207

206

205

204

203

202

201

102

105

101

107

106

104

103

105

161014

FIGURE 1-1.STEERING AND DRIVE INSTALLATION

1-2 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-1. STEERING AND DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274549 Ref. STEERING AND DRIVE INSTALLATION E

1 0100019 A/R Compound, Locking 2 0761016 4 Bolt M10 x 40mm 3 0630606 2 Capscrew M12 x 25mm 4 0903594 1 Bracket, Steering Knuckle (Right) 5 0903595 1 Bracket, Steering Knuckle (Left) 6 1684458 1 Steer Cylinder Assembly (See Section 5 for Breakdown) 7 3010164 1 Link, Steering

7A 0440263 2 Bushing, Flange

8 3010165 1 Arm, Steering (Left)

8A 0440263 2 Bushing, Flange

9 3010166 1 Arm, Steering Right) 9A 0440263 2 Bushing, Flange 10 3291005 2 Locknut M10 11 3423303 4 Pin, Linkage 12 3423230 1 Pin, Clevis 13 3423235 1 Pin, Clevis 14 3423236 1 Pin, Clevis 15 3760348 5 Ring, Retaining 16 3841143 1 Keeper

Ref. DRIVE INSTALLATION Ref. Note: For Module Identification, see note on Revision Log

Page A before ordering parts.

0274550 Ref. Machines with 1600346 Drive Module I

1001118433 Ref. Machines with 1001092456346 Drive Module A

101 0630580 20 Bolt, Wheel 102 2780266 2 Hub Assembly (See Items 201-208 for Breakdown) 103 2 Wheel Drive Assembly Options (See Figure 1-2 for Breakdown):

Ref. Note: Requires identification of drive module before

ordering parts. Refer to Revision Log Page A of this manual.

1001092743 USA Built Machines with 1600346 Drive Module 1001118359 USA Built Machines with 1001092456 Drive Module

Use 1001092743 French Built Machines Prior to S/N A200007624 with

1600346 Drive Module (was p/n 3160329)

1001092743 French Built Machines S/N A200007624 to S/N A200009897

with 1600346 Drive Module

1001118359 China Built Machines 104 3760463 2 Ring, Retaining 105 Use 2915012 4 Tire & Wheel Assembly Kit (includes qty 5 of item 101) (Was

p/ns 4520565, 1001100840 & 1001114467)

Note: Must replace Tire & Wheel Assemblies in pairs per axle.

106 4740523 2 Washer 107 4740524 2 Washer 108 4240018 2 Tie-Strap (Not Shown) 109 1321682 2 Clamp, Worm (Not Shown - Used on Drive Motor Cable)

3121223 1230ES 1-3

SECTION 1 FRAME

FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

110 4923602 1 Harness, Field Wire Connection (Not Shown - See Section 7

for Breakdown)

2780266 Ref. HUB ASSEMBLY D

Ref. Note: Quantities shown are for 1 assembly. Two Assemblies

are required per machine.

201 Use 1001102354 1 Cap, Dust (was p/n 7012524) 202 Use 3300423 1 Nut, Slotted (was p/n 7010641) 203 Use 3450406 1 Pin, Cotter 2” x 3/16” (was p/n 7010642) 204 Use 4740468 1 Washer (was p/n 7019697) 205 Use 1001102351 1 Bearing, Cone - Outer (was p/n 7026185) 206 Not Available 1 Hub (Purchase Complete Hub p/n 2780266) 207 Use 1001102353 1 Bearing, Cone - Inner (was p/n 7026183) 208 Use 1001102349 1 Seal (was p/n 7026184)

1-4 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-1. STEERING AND DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 1-5

SECTION 1 FRAME

26B

26A

26B

26A

202119

29424

104

103

105

109

110

111

112

106

107

114

113

FIGURE 1-2.WHEEL DRIVE ASSEMBLY

1-6 1230ES 3121223

SECTION 1 FRAME

127

125

128

126

STYLE “A”

151

153

154

152

STYLE “B”

108A

108B

202

201 203

204 205A 205B 205C 205D

206

GENUINE PARTS

207 208

209 210A 210B 211A 211B

3121223 1230ES 1-7

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE ASSEMBLY Ref. Note: Due to service updates, drive motors may use any of

the various parts listed below. Visual identification will be required.

Ref. Note: Requires identification of drive module before

ordering parts. Refer to Revision Log Page A of this manual.

Use 1001092743 Ref. French Built Machines Prior to S/N A200007624 with

1600346 Drive Module (was p/n 3160329)

1001092743 Ref. French Built Machines S/N A200007624 to S/N A200009897

with 1600346 Drive Module

1001092743 Ref. USA Built Machines with 1600346 Drive Module D 1001118359 Ref. USA Built Machines with 1001092456 Drive Module A 1001118359 Ref. China Built Machines with 1001092456 Drive Module A

Ref. HUB ASSEMBLY

1 Not Available 1 Spindle 2 Use Item 206 1 Hub 3 Use Item 204 1 Ring, Input 4 Use Item 203 1 Gear, Input Sun 5 Use Item 203 3 Gear, Input Planet 6 Use Item 203 3 Pin, Planet Gear 7 Use Item 203 1 Carrier 8 Use Item 203 1 Gear, Output Sun

9 Use Item 207 3 Gear, Output Planet 10 Use Item 207 3 Pin, Output Planet 11 Use Item 201 1 Cover 12 7024757 1 Bushing Kit, Kingpin (Includes 2 Bushings) 13 See Note 1 Motor, Electric (Note: Use item 205A, 205B or 205C) 14 See Note 2 Bearing, Main (Note: Use Item 202, 204, 206 or 207) 15 Use Item 207 1 Bearing, Shaft 16 70001739 1 Seal, Lip 17 7024786 1 Seal, Lip 18 Use Item 203 3 Ring, Retaining 19 Use Item 201 1 Ring, Retaining 20 70000191 1 O-Ring 21 Use Item 201 1 Thrustwasher 22 Not Used 23 Use Item 203 1 Plate, Thrust 24 Use Item 203 1 Ring, Retaining 25 See Note 9 Thrustwasher (Note: Use Item 203 or 207) 26 See Note A/R Bearing/Bushing Options (Note: Use Item 203 or 207):

26A 66 Bearing, Needle 26B 6 Bushing

27 See Note 1 Ring, Retaining (Note: Use Item 204, 206 or 207) 28 Use Item 207 1 Ring, Retaining 29 Use Item 201 2 Plug

30 to 31 Not Used

32 Use Item 207 3 Washer, Tanged

D/F

1-8 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BRAKE & MOTOR COMPONENTS

101 to 102 Not Used

103 Use Item 208 1 Brush & Terminal Assembly 104 70000790 2 Spring, Brush 105 70000791 1 Box, Brush 106 Use Item 208 1 Ring, Retaining 107 Use Item 208 1 Bearing 108 1 Harness, Electrical Cable Options:

Ref. Note: Requires identification of drive module before

ordering parts when equipped with item 108B style cable. Refer to Revision Log Page A.

108A Use 1001093652 Hub with Item 108A Style Cable (was p/n 7024770) 108B 1001093652 Hub with Item 108B Style Cable & 1600346 Drive Module 108B 1001118363 Hub with Item 108B Style Cable & 1001092456 Drive

Module 109 70000792 1 Commutator 110 Use Item 209 1 Disc, Reaction 111 7024785 1 Disc, Friction 112 Use Item 209 1 Brake Assembly 113 Use Item 210 2 Flatwasher 114 Use Item 210 2 Bolt

115 to 124 Not Used

— — — — — — — — — —

Ref. Style “A” Brake Cover 125 Use Item 211A 1 Plate, Cover 126 See Note 1 O-Ring (Note: Use Item 210 or 211A) 127 70000383 1 Connector, Strain Relief 128 Use Item 211A 1 Cover

129 to 150 Not Used

— — — — — — — — — —

Ref. Style “B” Brake Cover 151 Use Item 211B 1 Plate, Cover 152 70001949 1 Gasket, Cover 153 Use item 211B 1 Cover, Top 154 Use Item 211B 1 Cover, End

Ref. KIT OPTIONS 201 7024747 1 Cover Kit (Includes Items 11,19, 20,21 & 29) 202 7024748 1 Main Seal Kit (Includes Qty 1 of Items 14,16 & 20) 203 7024749 1 Input Carrier Kit (Includes Items 4-8,18,20 & 23-26) 204 7024758 1 Input Ring Kit (Includes Item 3,20,27 & Qty 1 of Item 14) 205 1 Motor Kit Options (Includes Items 13,17,103-114 & 151-154):

205A Use 1001100819 French Built Machines Prior to S/N A200007624 (was p/n

3160329)

205B French Built Machines Options S/N A200007624 to S/N

A200009897: 70001347 Wheel Drive Assembly 1001092743 70002308 Wheel Drive Assembly 1001118359

3121223 1230ES 1-9

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

205C USA Built Machines Options:

70001347 Wheel Drive Assembly 1001092743

70002308 Wheel Drive Assembly 1001118359 206 7024756 1 Hub Kit (Includes Items 2,16,20,27 & Qty 1 of Item 14) 207 7024750 1 Output Planet Kit (Includes Items 9,10,15,20,25-28,32 & Qty 1

of Item 14) 208 7024771 1 Motor Brush & Bearing Kit (Includes Items 103, 106 & 107) 209 7024772 1 Brake Kit (Includes Items 110, 111 & 112) 210 7024773 1 Motor Hardware Kit (Includes 113, 114 & 126) 211 1 Brake Cover Kit Options:

211A 7024787 Style “A” (Includes Items 125 - 128) 211B 70001265 Style “B” (Includes Items 151 - 154)

1-10 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-2. WHEEL DRIVE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 1-11

SECTION 1 FRAME

134A1911132123

FIGURE 1-3. POTHOLE PROTECTION INSTALLATION

1-12 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-3. POTHOLE PROTECTION INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274564 Ref. POTHOLE PROTECTION INSTALLATION G

1 0060084 1 Actuator 2 0100035 A/R Compound, Locking 3 0630587 2 Bolt, Carriage M6 x 25mm 4 3010145 1 Bar, Pothole (Left)

4A 0440263 2 Bushing, Flange

5 3010146 2 Link 6 3010147 2 Link, Actuator (Left)

6A 0440263 1 Bushing, Flange

7 3010152 1 Bar, Pothole (Right)

7A 0440263 2 Bushing, Flange

8 3010153 2 Link, Actuator (Right)

8A 0440263 1 Bushing, Flange

9 3290605 2 Locknut M6 10 3423189 2 Pin 11 3423230 2 Pin 12 3423231 2 Pin 13 3760348 10 Ring, Retaining 14 3841703 1 Rod, Actuator 15 4010415 4 Screw M4 x 35mm 16 4160160 1 Spring 17 4220258 1 Pad, Actuator 18 4569225 1 Tube, Actuator 19 4569238 4 Spacer 20 4811700 2 Flatwasher M6 21 3290405 4 Locknut M4 22 4031709 4 Capscrew M6 x 25mm 23 4220308 2 Spacer 24 4160222 1 Spring (Right) 25 4160223 1 Spring (Left) 26 4811400 2 Flatwasher M4 27 2 Switch, Limit Options:

Ref. Note: Requires identification of drive module before

ordering parts. Refer to Revision Log Page A of this manual.

Use 1001115448 Switch for Machines with 1600346 Drive Module (USA Built

Machines Prior to S/N 0200195926) (was p/n 4360633)

1001109088 Switch for Machines with 1600346 Drive Module (USA Built

Machines S/N 0200195926 to Present)

Use 1001115448 Switch for Machines with 1600346 Drive Module (French Built

Machines) (was p/n 4360633)

1001109088 Switch for Machines with 1001092456 Drive Module

3121223 1230ES 1-13

SECTION 1 FRAME

213

212

101

102

103

202

201 203

205

206

104

301

FIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS

1-14 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-4. BATTERY CHARGER/BEACON LIGHT/INVERTER INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274558 Ref. BEACON LIGHT INSTALLATION (OPTIONAL) D

1Not Used

2 2920161 1 Light, Beacon

7016319 1 Bulb, Replacement

7016372 1 Len, Replacement 3Not Used 4 4060865 1 Guard, Strobe 5Not Used 6 4191406 2 Screw M4 x 12mm 7 4191706 2 Screw M6 x 12mm 8 4341144 1 Mount, Beacon

0274562 Ref. BATTERY CHARGER INSTALLATION D

101 1 Battery Charger Assembly

Ref. Note: Cable ends are the only serviceable parts. See

Section 7 for call-outs.

Use 1001128737 USA Built Machines Prior to S/N 0200197381 (was p/n

0400238 - Kit p/n 1001128737 includes Charger and Battery Temperature Sensor Kit)

1001112111 USA Built Machines S/N 0200197381 to Present

Use 1001128737 French Built Machines (was p/n 0400238 - Kit

p/n 1001128737 includes Charger and Battery Temperature Sensor Kit)

1001112111 China Built Machines 102 4191706 2 Screw M6 x 12mm 103 4811700 2 Flatwasher M6

0274563 Ref. BATTERY CHARGER/INVERTER COMBINATION INSTALLA-

TION (ANSI & CSA SPECS OPTION)

201 0100011 A/R Compound, Locking 202 1001093839 1 Battery Charger/Inverter Assembly (was p/n 0400237) 203 0760812 4 Screw M8 x 25mm 204 Not Used 205 2820239 1 Pad, Insulator 206 4740562 4 Flatwasher

207 to 211 Not Used

212 1706749 1 Decal - Inverter 213 1706750 1 Decal - On/Off Inverter 214 1706765 1 Decal - Hazardous Voltage (Not Shown - Located on Mast Cover

Near AC Receptacle)

301 Use 2915230 1 BATTERY CHARGER REPROGRAM CONTROLLER KIT FOR

DELTA-Q CHARGER ONLY (WAS P/N 1600466)

3121223 1230ES 1-15

SECTION 1 FRAME

111

106

FIGURE 1-5.FRAME COVERS INSTALLATION

1-16 1230ES 3121223

SECTION 1 FRAME

FIGURE 1-5. FRAME COVERS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274560 Ref. FRAME COVERS INSTALLATION I

1Not Used 2 4191708 4 Bolt M6 x 20mm 3 0760614 4 Bolt M6 x 30mm 4 3290605 4 Locknut M6 5 3380604 1 Panel, Top Cover

6 to 7 Not Used

8 3380619 1 Cover, Charger

9 3575919 1 Plate, Step 10 Not Used 11 4420070 1 Tape, Anti-Skid 12 4811700 A/R Flatwasher 6mm

Ref. PLATFORM BUMPER INSTALLATION

1001098653 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0274552 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

1001100633 Ref. Australian Specs C

0274552 Ref. CE Specs Q

101 to 105 Not Used

106 1001008575 2 Bumper (was p/n 0940088)

Ref. Note: Recommend purchasing item 111 Nut when replacing

Bumper.

107 to 110 Not Used

111 3290805 2 Nut M8

3121223 1230ES 1-17

SECTION 1 FRAME

FIGURE 1-5. FRAME COVERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-18 1230ES 3121223

SECTION 2

GROUND COMPONENTS

3121223 1230ES 2-1

SECTION 2 GROUND COMPONENTS

201

5C55A91

107

101

10510

FIGURE 2-1.PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION

2-2 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PUMP/MOTOR/TANK ASSEMBLY

3600432 Ref. French Built Machines Prior to S/N A200009318 (Original

Equipment)

1001101832 Ref. French Built Machines Prior to S/N A200009318 (Service

Replacement)

1001101831 Ref. French Built Machines S/N A200009318 to S/N A200009897 C

3600432 Ref. USA Built Machines Prior to S/N 0200189255 (Original

Equipment)

1001101832 Ref. USA Built Machines Prior to S/N 0200189255 (Service

Replacement)

1001101831 Ref. USA Built Machines S/N 0200189255 to Present C 1001101831 Ref. China Built Machines S/N B20000100 to Present C

Ref. NOTE: ORIGINAL EQUIPMENT ASSEMBLY P/N 3600432 MAY

HAVE BEEN REPLACED WITH SERVICE REPLACEMENT ASSEMBLY P/N 1001101832. IDENTIFY P/N BEFORE ORDERING REPLACEMENT COMPONENTS.

Ref. NOTE: THE PARTS LIST BELOW (#1-13) IS FOR P/N 3600432

PUMP/MOTOR/TANK ASSEMBLY. NO SERVICE PARTS ARE AVAILABLE FOR THE 1001101831 AND 1001101832 PUMP/ MOTOR/TANK ASSEMBLIES.

1 Not Available 1 Adapter Assembly 1A 7011025 1 O-Ring

2 70000661 1 Pump Assembly

Not Available 1 Seal Kit

3 70000662 1 Motor Assembly

70000663 1 Brush Kit 70000664 2 Bearing, Ball

3A 70000665 1 Coupling

4 70000666 1 Cartridge, Relief

Not Available 1 Seal Kit

5 70000667 1 Tank Assembly 5A 70000668 1 Breather 5B 70000669 1 Filter 5C 70000670 1 Filter, Suction

6 Not Available 1 Valve Assembly 6A 70000671 1 Cartridge, Solenoid

Not Available 1 Seal Kit Not Available 1 Coil

6B 70000672 1 Cartridge, Solenoid

Not Available 1 Seal Kit Not Available 1 Coil

6C 70000666 2 Cartridge, Relief

Not Available 1 Seal Kit 7 70000673 2 O-Ring 8 70000674 3 Screw 9 70000675 1 Bracket, Mounting

10 70000676 2 Screw 11 2144605 2 Fitting, Straight

3121223 1230ES 2-3

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

12 2 Fitting Options:

2144610 Straight Fitting

1001101362 90° Fitting

13 2221086 1 Fitting, Pressure Check

0274581 Ref. PUMP/MOTOR/TANK INSTALLATION F

101 0761016 2 Bolt M10 x 40mm

102 to 104 Not Used

105 3291005 2 Locknut M10 106 1 Pump/Motor/Tank Assembly Options (See Items 1-13 for

Breakdown):

Use 1001101832 French Built Machines Prior to S/N A200009318 (was p/n

3600432)

1001101831 French Built Machines S/N A200009318 to S/N A200009897

Use 1001101832 USA Built Machines Prior to S/N 0200189255 (was p/n

3600432) 1001101831 USA Built Machines S/N 02001892558 to Present 1001101831 China Built Machines S/N 020000100 to Present

107 4240147 1 Strap, Anti-Static

Ref. KIT OPTIONS

201 1 Maintenance Kit Options (Includes Item 5B & 1 Gallon of

Hydraulic Oil):

1001101328 3600432 Assembly

Not Available 1001101831 & 1001101832 Assemblies

2-4 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. PUMP/MOTOR/TANK ASSEMBLY AND INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 2-5

SECTION 2 GROUND COMPONENTS

4A4B4C

FIGURE 2-2.ELECTRICAL COMPONENTS INSTALLATION

2-6 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-2. ELECTRICAL COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ELECTRICAL COMPONENTS INSTALLATION

0274555 Ref. ANSI & ANSI Export Specs with p/n 1600346 Drive Modules I

1001116638 Ref. ANSI & ANSI Export Specs with p/n 1001092456 Drive

Modules

0274778 Ref. Australian & CE Specs with p/n 1600346 Drive Modules I

1001116639 Ref. Australian & CE Specs with p/n 1001092456 Drive Modules A

1 0140043 1 Alarm 2 1 Ground Control Box Assembly Options:

Ref. Note: For Module Identification, see note on Revision Log

page A before ordering parts.

0272780 ANSI & ANSI Export Specs with p/n 1600346 Drive Module

(See Figure 2-3 for Breakdown)

1001114929 ANSI & ANSI Export Specs with p/n 1001092456 Drive

Module (See Figure 2-4 for Breakdown)

0273444 Australian & CE Specs with p/n 1600346 Drive Module

(See Figure 2-3 for Breakdown)

1001114931 Australian & CE Specs with p/n 1001092456 Drive Module

(See Figure 2-4 for Breakdown) 3 0700615 3 Bolt M6 x 35mm 4 1 Module, Drive Options:

Ref. Note: For Module Identification, see note on Revision Log

page A before ordering parts.

4A 1600346 Module - Identify by visual inspection or by p/n on Label 4B 1001092456 Module - Identify by visual inspection or by p/n on Label

A/R 1001092456 Replacement Components: 4C 70002683 1 Fuse 4D 70002682 1 Bussbar

5 3740150 1 Relay 6 4000010 1 Sensor, Proximity 7 4191706 2 Screw M6 x 12mm 8 4191708 5 Screw M6 x 20mm 9 1 Harness, Chassis (See Section 7 for Breakdown) (Not Shown)

Ref. Note: Requires identification of drive module before

ordering parts. Refer to Revision Log Page A of this manual.

4923301 Harness for Machines with 1600346 Drive Module (USA Built

Machines Prior to S/N 0200195926 )

1001110303 Harness for Machines with 1600346 Drive Module (USA Built

Machines S/N 0200195926 to Present )

4923301 Harness for French Built Machines with 1600346 Drive

Module

1001116640 Harness for USA/China Built Machines with 1001092456

Drive Module 10 4360387 1 Switch, Push Button 11 3290605 2 Locknut M6 12 3900392 2 Screw M6 x 30mm 13 0100048 A/R Grease, Dielectric 14 4220307 1 Block, Spacer 15 4240153 1 Strap, Clinch (Not Shown)

3121223 1230ES 2-7

SECTION 2 GROUND COMPONENTS

123

111213

FIGURE 2-3.GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE

MODULE)

2-8 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-3. GROUND CONTROL ASSEMBLY (MACHINES WITH 1600346 DRIVE MODULE)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: For Module Identification, see note on Revision Log

page A before ordering parts.

Ref. GROUND CONTROL ASSEMBLY 0272780 Ref. ANSI & ANSI Export Specs with p/n 1600346 Drive Modules AB 0273444 Ref. Australian & CE Specs with p/n 1600346 Drive Modules X

1 0380025 1 Box, Ground Control 2 0610161 1 Board, PC (Battery Charger LED) 3 1600419 1 Board, PC (Ground Control)

2915039 1 Upgrade Kit (Includes Cables, Programming Instructions & CD

Software)

Ref. Note: PC Board must be recalibrated when replaced.

4 1671105 1 Cover, Front 5 1 Decal - LED Options:

1705696 ANSI & ANSI Export Specs 1705697 CE & Australian Specs

6 1705698 1 Decal - Function 7 2420172 1 Hourmeter 8 3520193 1 Plug

9Not Used 10 4340739 1 Plate, Mounting 11 3900336 4 Screw, Torx #10-32NC x 1/2” 12 3900356 4 Screw, Torx M3.5 x 16mm 13 3900338 6 Screw, Torx M4 x 20mm 14 3900339 5 Screw, Plastite #6 x 1/2” 15 4360069 1 Breaker, Circuit - 10 Amp 16 4360328 1 Switch, Toggle 17 1 Keyswitch Options:

4360469 ANSI & ANSI Export Specs 4360470 Australian Specs (USA Built Machines Prior to S/N

0200203535 & All French Built Machines)

4360469 Australian Specs (USA Built Machines S/N 0200203535 to

Present & All China Built Machines) 4360470 CE Specs 2860030 1 Key, Replacement (Fits All Specs)

18 4360475 1 Switch, Emergency Stop

7020175 1 Cap 7020176 1 Block, Contact

19 1 Module, Tilt Options:

Use 1810140 1 TIlt Module (was p/n 4000006)

20 4922865 1 Harness, Control Box (See Section 7 for Breakdown):

0274791 Ref. ANTI-VANDELISM PACKAGE INSTALLATION (NOT SHOWN) A 1671124 1 Cover, Ground Control Box

3121223 1230ES 2-9

SECTION 2 GROUND COMPONENTS

FIGURE 2-4.GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE

MODULE)

2-10 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL ASSEMBLY (MACHINES WITH 1001112456 DRIVE

MODULE)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: For Module Identification, see note on Revision Log

page A before ordering parts.

Ref. GROUND CONTROL ASSEMBLY

1001114929 Ref. ANSI & ANSI Export Specs with p/n 1001092456 Drive

Modules

1001114931 Ref. Australian & CE Specs with p/n 1001092456 Drive Modules A

1 0380025 1 Box, Ground Control 2 0610161 1 Board, PC (Battery Charger LED) 3 1671105 1 Cover, Front 4 1 Decal - LED Options:

1705696 ANSI & ANSI Export Specs 1705697 CE & Australian Specs

5 1705698 1 Decal - Function 6 2420172 1 Hourmeter 7 3520193 1 Plug 8 3900336 6 Screw, Torx #10-32NC x 1/2”

9 3900338 6 Screw, Torx M4 x 20mm 10 3900339 2 Screw, Plastite #6 x 1/2” 11 3900356 4 Screw, Torx M3.5 x 16mm 12 4340739 1 Plate, Mounting 13 4360069 1 Breaker, Circuit - 10 Amp 14 4360328 1 Switch, Toggle 15 1 Keyswitch Options:

4360469 ANSI & ANSI Export Specs 4360470 Australian Specs (USA Built Machines Prior to S/N

0200203535 & All French Built Machines)

4360469 Australian Specs (USA Built Machines S/N 0200203535 to

Present & All China Built Machines) 4360470 CE Specs 2860030 1 Key, Replacement (Fits All Specs)

16 4360475 1 Switch, Emergency Stop

7020175 1 Cap 7020176 1 Block, Contact

17 1001114933 1 Module, Tilt 18 1001114937 1 Mount, Harness Bulkhead 19 3321005 4 Locknut #10-32NC 20 4751000 4 Flatwasher #10 21 1001114935 1 Harness, Control Box (See Section 7 for Breakdown):

0274791 Ref. ANTI-VANDELISM PACKAGE INSTALLATION (NOT SHOWN) A 1671124 1 Cover, Ground Control Box

3121223 1230ES 2-11

SECTION 2 GROUND COMPONENTS

NOTE: REPLACEMENT DECALS ON FRONT OF BATTERY BOXES MUST BE ORDERED SEPARATELY - SEE SECTION 8

202

206

208

207

205

101

102

105

106

107

108

201

FIGURE 2-5.BATTERIES AND COVERS INSTALLATION

2-12 1230ES 3121223

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. BATTERIES AND COVERS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BATTERIES AND COVERS INSTALLATION Ref. Note: For Module Identification, see note on Revision Log

page A before ordering parts.

0274561 Ref. Machines with 1600346 Drive Module & GC Type Batteries G

1001117838 Ref. Machines with 1001092456 Drive Module & GC Type Batteries B 1001155025 Ref. Machines with 1001092456 Drive Module & AGM & EVG Type

Batteries

1 1 Battery Box Assembly (Left) Options (See Items 101-108 for

Breakdown):

0861747 Ref. Box for GC Type Batteries

1001155029 Ref. Box for AGM & EVG Type Batteries

2 1 Battery Box Assembly (Right) Options (See Items 201-208 for

Breakdown):

0861748 Ref. Box for GC Type Batteries

1001155030 Ref. Box for AGM & EVG Type Batteries

3 1 Battery Cable Kit Options (Not Shown - See Section 7 for

Breakdown):

Ref. Note: Requires identification of drive module before

ordering parts. Refer to Revision Log Page A.

2902444 Machines with p/n 1600346 Drive Module

1001117837 Machines with p/n 1001092456 Drive Module 4 3391408 2 Pin, Split 5 8423243 2 Pin, Door Latch 6 4160214 2 Spring, Door Latch 7 4812100 A/R Flatwasher 12mm 8 3020039 A/R Lubricant 9 0100048 A/R Grease, Dielectric

10 Use 1001127269 1 Temperature Sensor Kit (Includes p/n 1001112113 Sensor,

Wire Nut & Instructions)

Ref. BATTERY BOX ASSEMBLY (LEFT)

0861747 Ref. Box for GC Type Batteries C

1001155029 Ref. Box for AGM & EVG Type Batteries A

101 2 Battery Options:

0400215 GC Type Battery

1001112112 AGM & EVG Type Battery

102 3380599 1 Tray (Left)

103 to 104 Not Used

105 0630587 1 Bolt, Carriage M6 x 25mm 106 3290605 1 Locknut M6 107 4220286 1 Block 108 4811700 1 Flatwasher M6

Ref. BATTERY BOX ASSEMBLY (RIGHT) Ref. Box for GC Type Batteries C

1001155030 Ref. Box for AGM & EVG Type Batteries A

201 2 Battery Options:

0400215 GC Type Battery

1001112112 AGM & EVG Type Battery

3121223 1230ES 2-13

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. BATTERIES AND COVERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

202 3380600 1 Tray (Right)

203 to 204 Not Used

205 0630587 1 Bolt, Carriage M6 x 25mm 206 3290605 1 Locknut M6 207 4220286 1 Block 208 4811700 1 Flatwasher M6

2-14 1230ES 3121223

SECTION 3

MAST

3121223 1230ES 3-1

SECTION 3 MAST

104 205

104 204

104 202

111 400

401

1 5

408

114

115

403

406

407

106

402

403

405

102227

209

208

209

208

207

201

301

307

310

306

102

106

PART OF PLATFORM

WELDMENT

209

207

201

208

109

108

116

209

208

209

404

122

119

121

123

106

122

119

106

FIGURE 3-1.MAST INSTALLATION

3-2 1230ES 3121223

SECTION 3 MAST

FIGURE 3-1. MAST INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. MAST INSTALLATION

1001098653 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0274552 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

1001100633 Ref. Australian Specs C

0274552 Ref. CE Specs Q

1 0100011 A/R Compound, Locking

2 to 3 Not Used

4 0761217 4 Bolt M12 x 45mm 5 0760812 2 Bolt M8 x 25mm

6 to 9 Not Used

10 4 Locknut Options:

8310625 3/8”-16NC 3291205 M12

11 to 14 Not Used

15 4071111 A/R Shim

16 to 17 Not Used

18 3820037 2 Rivnut M6

2080043 2 Rivnut 1/4in-20NC

19 to 21 Not Used

22 5241200 8 Flatwasher M12 Hardened

23 to 26 Not Used

27 1001102858 1 Clamp

Ref. MAST SUB-ASSEMBLY

1001098727 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0274567 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

0274567 Ref. Australian & CE Specs L

101 Not Used 102 0700618 1 Bolt M6 x 50mm 103 Not Used 104 1 Mast Assembly (See Items 201-210 for Breakdown)

1001098728 All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0801530 All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

0801530 Australian & CE Specs 105 Not Used 106 3290605 A/R Locknut M6 107 Not Used 108 3820019 12 Rivet 109 A/R Pad, Slide Options:

4700042 A/R Pad, Slide (8.7mm)

1001092165 A/R Pad, Slide (9.7mm) (Note: Identifiable by notch at top &

bottom of bolted on side)

3121223 1230ES 3-3

SECTION 3 MAST

FIGURE 3-1. MAST INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: Use p/n 1001092165 as replacement whenever

possible. Combination of both types of pads may be used.

110 Not Used 111 4923503 1 Powertrack & Cable Assembly (See Items 401-406 for

Breakdown)

112 to 113 Not Used

114 4191406 2 Setscrew M4 x 12mm 115 0760608 2 Bolt M6 x 16mm 9 (was p/n 0760610) 116 4160220 1 Spring, Mast Cable/Hose 117 0100040 A/R Adhesive (Not Shown) 118 Not Used 119 4811700 4 Flatwasher 6mm 120 1001156211 1 Bracket, Cable Support (S/N 0200221047 to Present) 121 1001102858 1 Clamp (S/N 0200221047 to Present) 122 0760610 3 Bolt M6 x 20mm (S/N 0200221047 to Present) 123 4811702 1 Flatwasher 6mm (S/N 0200221047 to Present)

Ref. MAST ASSEMBLY

1001098728 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0801530 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

0801530 Ref. Australian & CE Specs L

201 0700616 1 Bolt M6 x 40mm 202 1 Mast, Outer Mid Options:

1001098730 All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0801532 All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built

0801532 Australian & CE Specs

203 1 Mast, Inner Mid Options:

1001098731 All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0801533 All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

0801533 Australian & CE Specs

204 1 Mast, Inner Options:

1001098732 All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0801534 All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

0801534 Australian & CE Specs 205 1684469 1 Lift Cylinder Assembly (See Section 5 for Breakdown) 206 Not Used 207 3290605 2 Locknut M6 208 3820019 40 Rivet 209 A/R Pad, Slide Options:

4700042 A/R Pad, Slide (8.7mm)

1001092165 A/R Pad, Slide (9.7mm) (Note: Identifiable by notch at top &

bottom of bolted on side)

3-4 1230ES 3121223

SECTION 3 MAST

FIGURE 3-1. MAST INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. Note: Use p/n 1001092165 as replacement whenever

possible. Combination of both types of pads may be used.

210 0100040 A/R Adhesive (Not Shown)

— — — — — — — — — —

1 Mast Kit Options:

1001098733 Kit (Includes Items 202-204) for All Specs Except Australian

& CE Specs USA Built Machines Prior to S/N 0200196530 & All French Built Machines

2902439 Kit (Includes Items 202-204 & 208-210) for All Specs Except

Australian & CE Specs USA Built Machines S/N 0200196530 to Present & All China Built Machines

2902439 Kit (Includes Items 202-204 & 208-210) for Australian & CE

Specs

0274560 Ref. COVERS INSTALLATION I

301 3900357 2 Bolt M6 x 16mm

3900258 2 Screw 1/4in-20NC x 3/4in

302 to 305 Not Used

306 3380605 1 Panel, Front 307 3380612 1 Cover, Top

308 to 309 Not Used

310 4191406 2 Setscrew M4 x 12mm

4923503 Ref. POWERTRACK ASSEMBLY H

Ref. Note: See Section 7 for Additional Components.

400 1001100163 1 Carrier Assembly 401 1180404 1 Carrier, Power Track (No Repair Parts Available) 402 1271646 1 Channel, Push Tube 403 3290405 6 Locknut M4 404 4031509 4 Screw M4 x 25mm (was p/n 4010414) 405 1001095304 1 Shield, Power Track 406 1 Mounting Foot Options:

Use 1001103349 French Built Machines Prior to S/N A200007893 (was p/n

4341256)

1001100170 French Built Machines S/N A200007893 to

S/N A200009897 1001100170 USA Built Machines 1001100170 China Built Machines

407 2 Screw M4 Options:

4010412 French Built Machines Prior to S/N A200007893

1001100176 French Built Machines S/N A200007893 to S/N

A200009897 1001100176 USA Built Machines 1001100176 China Built Machines

408 4240033 3 Tie-Strap

3121223 1230ES 3-5

SECTION 3 MAST

FIGURE 3-1. MAST INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-6 1230ES 3121223

SECTION 4

PLATFORM

3121223 1230ES 4-1

SECTION 4 PLATFORM

207

213

212

219

302

303

304

SEE PAGE 2 FOR

GATE DOOR OPTIONS

NOTE: REPLACEMENT DECALS

MUST BE ORDERED SEPARATELY

– SEE SECTION 8

FIGURE 4-1. PLATFORM INSTALLATION

4-2 1230ES 3121223

SECTION 4 PLATFORM

16B128C

ALL SPECS EXCEPT

AUSTRALIAN SPECS

AUSTRALIAN SPECS ONLY

GENUINE PARTS

100

3121223 1230ES 4-3

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PLATFORM INSTALLATION

1001098653 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0274552 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & All China Built Machines

1001100633 Ref. Australian Specs C

0274552 Ref. CE Specs Q

1 0100011 A/R Compound, Locking 2 280013 6in/15cm Conduit (Australian Spec Only)

3 to 5 Not Used

6 1001008575 2 Bumper (was p/n 0940088) (Not Shown - Located on Frame)

Ref. Note: Recommend purchasing item 11 when replacing

Bumper.

7 2080040 16 Fastener, Huck

8 A/R Gate Options: 8A 2410021 2 All Specs Except Australian Spec 8B 1001100630 1 Australian Spec Left Side (from Operators Position) 8C 1001100631 1 Australian Spec Right Side (from Operators Position)

9 2600281 4 Hinge 10 3290606 2 Nut M6 (Australian Spec Only) 11 3290805 2 Nut M8 (Not Shown - Located on Frame) 12 3520072 A/R Cap-Plug 13 0700618 8 Bolt M6 x 50mm

0641416 8 Bolt 1/4in-20NC x 2in 14 4071095 A/R Shim 15 4010618 4 Screw M6 x 50mm (Australian Spec Only) 16 4 Stop Options:

16A 4220309 All Specs Except Australian Spec (Was p/n 4220233) 16B 1001100141 Australian Spec

17 4420072 3 Tape, Anti-Skid 18 3820037 8 Rivnut M6

2080043 8 Rivnut 1/4in-20NC 19 Not Used 20 3340962 2 Pad (was p/n 4420072) 21 4420070 1 Tape, Anti-Skid 22 4811700 4 Flatwasher M6 (Australian Spec Only) 23 4811900 2 Flatwasher M6 (Australian Spec Only) 24 1580050 1 Tray 25 4191406 3 Screw M4 x 12mm 26 1001091102 3 Flatwasher, Large

27 to 28 Not Used

29 1001100142 2 Handle (Australian Spec Only)

30 to 31 Not Used

32 1001100634 2 Spring 33 1001100918 2 Pin, Plunger 34 1001100947 2 Turnbuckle

4-4 1230ES 3121223

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. KIT OPTIONS

100 1001101322 1 Gate Latch Kit (Australian Spec Only) (Includes 1-2, 7, 10, 13-15,

16B, 18, 22, 23, 29 & 32-34)

Ref. PLATFORM SUB-ASSEMBLY

1001098727 Ref. All Specs Except Australian & CE Specs USA Built Machines

Prior to S/N 0200196530 & All French Built Machines

0274567 Ref. All Specs Except Australian & CE Specs USA Built Machines

S/N 0200196530 to Present & China Built Machines

0274567 Ref. Australian & CE Specs L

201 to 206 Not Used

207 1 Platform Weldment Options:

1001098729 USA Built Machines Prior to S/N 0200196530

3510876 USA Built Machines S/N 0200196530 to Present 3510876 French & China Built Machines

208 to 211 Not Used

212 2080040 3 Fastener, Huck 213 8990147 1 Box, Manual Storage

70003486 2 Clip, Holder

214 to 218 Not Used

219 4811700 3 Flatwasher 6mm

0274553 Ref. KICKPLATE INSTALLATION (AUSTRALIAN & CE SPECS ONLY) C

301 Not Used 302 3576089 1 Kickplate 303 2080040 4 Fastener, Huck 304 4420070 1 Tape, Anti-Skid

3121223 1230ES 4-5

SECTION 4 PLATFORM

201A

201B

201C

201D

100A 100B 100C

101 102

12 101 102

102

171717

18521

23 14

201

FIGURE 4-2.PLATFORM CONSOLE BOX INSTALLATION

4-6 1230ES 3121223

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM CONSOLE BOX INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274554 Ref. CONSOLE BOX INSTALLATION B

1001091153 Ref. Console Box Assembly (USA Built Machines) F

See Note Ref. Console Box Assembly (French Built Machines Prior to S/N

A200006146) (Was p/n 0272778)

1001091153 Ref. Console Box Assembly (French Built Machines S/N

A200006146 to Present)

1001091153 Ref. Console Box Assembly (China Built Machines S/N

B200000100 to Present)

Ref. Note: When replacing complete assy, use p/n 1001091153.

1 0140011 1 Alarm 2 Use Item 102 1 Platform Box Control Module (Was p/n 1600439) 3 1380156 1 E-Clip 4 1 Controller, Drive/Steer Options:

Use 1001134438 P/Q Controller, Drive/Steer (USA Built Machines Prior to

S/N 0200177164 & French Built Machines Prior to S/N A200006537) (Original Equipment was p/n 1600345 See Figure 4-3 for Breakdown) (For Service Replacement Components p/n 1600402 & 1001134438 - See Figure 4-4 for Breakdown)

Use 1001134438 J.R. Merritt Controller, Drive/Steer (USA Built Machines

S/N 0200177164 to Present & French Built Machines S/N A200006537 to S/N A200009897& China Built Machines S/N B20000100 to Present) (Original Equipment was p/n

1600402) 5 1671098 1 Latch 6 1 Decal - Icon Options:

See Note USA Built Machines (Was p/n 1001091272)

(Note: Use Item 100C, 101 or 102)

See Note French Built Machines Prior to S/N A200006146 (Was p/n

1705674) (Note: Use Item 100A, 101 or 102)

See Note French Built Machines S/N A20000 6146 to S/N A200009897

(was p/n 1001091272) (Note: Use Item 100B, 101 or 102)

Not Available China Built Machines S/N B20000 0100 to Present 7 1705676 1 Decal - Emergency Stop Ring 8 2560179 1 Handle, Latch 9 Use 1001091390 1 Housing, Joystick (Lower) (Was p/ns 2760113 & 1001091277)

10 Use 1001091390 1 Mount, Joystick (Was p/ns 2760114 & 1001091278) 11 1 Housing, Module Mounting (Lower) Options:

1001091279 USA Built Machines

Use 1001091279 French Built Machines Prior to S/N A200006146 (Was p/n

2760115) 1001091279 French Built Machines S/N A20000 6146 to S/N A200009897 1001091279 China Built Machines S/N B200000100 to Present

12 See Note 1 Housing, Module Mounting (Upper) (Was p/ns 2760116 &

1001091280) (Note: Use Item 101 or 102) 13 3300473 4 Nut M6 14 3340968 2 Button (Includes Black Button Only) 15 3380475 2 Panel, Side

3121223 1230ES 4-7

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM CONSOLE BOX INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

16 1 Plate, Decal Options:

See Note USA Built Machines (Was p/n 1001091283)

(Note: Use Item 100C, 101 or 102)

See Note French Built Machines Prior to S/N A200006146 (Was p/n

3574249) (Note: Use Item 100A, 101 or 102)

See Note French Built Machines S/N A200006146 to S/N A200009897

(Was p/n 1001091283) (Note: Use Item 100B, 101 or 102C)

Not Available China Built Machines S/N B20000 0100 to Present 17 3900333 4 Screw M6 x 190mm 18 4160203 1 Spring, Compression 19 4191306 5 Screw M3.5 x 12mm 20 4191407 8 Screw M4 x 16mm 21 4191409 6 Screw M4 x 25mm 22 4360475 1 Switch, Emergency Stop

7020175 1 Cap

7020176 1 Block, Contact 23 4360538 2 Strip, Switch & Membrane 24 4360539 1 Switch, Toggle 25 4568738 1 Tube, Spacer 26 4922870 1 Harness, Platform Box (Not Shown - See Section 7 for

Breakdown) 27 1703819 1 Decal - Directional Arrow 28 6 Screw M3.5 x 12mm Options:

1001091396 USA Built Machines

4191306 French Built Machines Prior to S/N A200006146 1001091396 French Built Machines S/N A200006146 to S/N A200009897 1001091396 China Built Machines S/N B20000 0100 to Present

Ref. KIT OPTIONS

100 A/R Decal Kit Options:

Not Available 1 Decal Kit for China Built Machines S/N B20000100 to Present

100A 1001091967 1 Decal Kit for French Built Machines Prior to S/N A200006146

(Includes Items 6, 16 & 28)

Ref. Note: Two of item 6 are included in the kit - Use p/n

1705674. Dispose of the other decal.

Ref. Note: If housing has been replaced with Kit p/n 1001091393

or Kit p/n 1001091965, use Decal Kit p/n 1001091968.

100B 1001091968 1 Decal Kit for French Built Machines S/N A200006146 to

S/N A200009897 (Includes Items 6, 16 & 28)

Ref. Note: Two of item 6 are included in the kit - Use p/n

1001091272. Dispose of the other decal.

100C 1001091968 1 Decal Kit for USA Built Machines (Includes Items 6, 16 & 28)

Note: Two of item 6 are included in the kit - Use p/n

1001091272. Dispose of the other decal.

101 1001091393 1 Decal & Housing Kit (Includes Items 6, 12, 16 & 28)

Ref. Note: Two of item 6 are included in the kit - Use p/n

1001091272. Dispose of the other decal.

102 1001091965 1 Decal, Housing & Module Kit (Includes Items 2, 6, 12, 14, 16, 19,

23, 24 & 28)

Ref. Note: Two of item 6 are included in the kit - Use p/n

1001091272. Dispose of the other decal.

4-8 1230ES 3121223

SECTION 4 PLATFORM

FIGURE 4-2. PLATFORM CONSOLE BOX INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. PLATFORM BOX COVER INSTALLATION

0273841 Ref. USA Built Machines Prior to S/N 0200196453 & All French

Built Machines

1001118216 Ref. USA Built Machines S/N 0200196453 to Present & All China

Built Machines

201 1001118215 Kit, Platform Box Shield (was p/n 2902341) 201A 0760808 4 Bolt, (Metric) 8 x 16LG 201B 1380159 4 Clip, Cover Mounting 201C 1001116154 1 Cover, Platform Box (was p/n 1671161) 201D 3290805 4 Locknut, M8 x 1.25

0274791 Ref. ANTI-VANDELISM PACKAGE INSTALLATION (NOT SHOWN) A 3380625 1 Cover, Lockable Platform Console Box

3121223 1230ES 4-9

SECTION 4 PLATFORM

1D1B1C1G1E1A2A

2C2D1F33A

FIGURE 4-3.DRIVE/STEER P/Q CONTROLLER ASSEMBLY

4-10 1230ES 3121223

SECTION 4 PLATFORM

FIGURE 4-3. DRIVE/STEER P/Q CONTROLLER ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

See Note Ref. P/Q CONTROLLER ASSEMBLY

Ref. Note: Original Equipment Assembly p/n 1600345 may have

been replaced with p/n 1001134438 as Service Replacement Assembly. Identify P/N before ordering replacement components. If equipped with p/n 1001134438 refer to next illustration.

1 7020551 1 Grip Assembly 1A 7020500 2 Switch, Steer Rocker 1B 7020501 1 Switch, Enable Push Button 1C 7003790 1 Cap, Rubber Rocker (Includes Lock RIng) 1D 7011997 1 Trigger 1E Not Available 1 Grip - Right Half 1F Not Available 1 Grip - Left Half 1G Not Available 1 Actuator, Switch

2 Not Available 1 Handle/Housing Assembly 2A 7020552 1 Bezel 2B 7020553 1 Gasket 2C 7020554 1 Spring, Centering 2D 7020555 1 Foot, Centering 2E 7020556 1 Boot, Rubber

3 Not Available 1 Electrical Assembly (Not Shown) 3A 4460266 1 Connector, Receptacle - 9 Pin

4460226 7 Socket, Female 4460265 1 Plug, Male-9 Position (Part of Platform Box Harness) 4460227 7 Pin, Male (Part of Platform Box Harness)

3121223 1230ES 4-11

SECTION 4 PLATFORM

341

FIGURE 4-4.DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY

4-12 1230ES 3121223

SECTION 4 PLATFORM

FIGURE 4-4. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

See Note 1 J.R. MERRITT CONTROLLER ASSEMBLY

Ref. Note: Use p/n 1001134438 as replacement. Original

Equipment was 1600402.

1 70001250 1 Boot, Panel

2 70001252 1 Gasket, Mounting

70001251 1 Bezel, Mounting

3 70003650 1 Handle Repair Kit (Includes handle gasket, item#4 push button

and item #4 lever installed in front handle half, back handle half,

top actuator, boot and hardware.) 70000084 1 Cap, Rubber 70000082 1 Microswitch

7027766 1 Ring, Retaining

7027365 1 Actuator, Handle 70001253 1 Gasket, Handle 70000683 4 Washer, Neoprene 70000685 2 Spacer, Plastic 70000686 2 Screw (Top) 70000684 2 Screw (Bottom)

4 7027367 1 Switch, Push Button

7027765 1 Lever, Enable

3121223 1230ES 4-13

SECTION 4 PLATFORM

FIGURE 4-4. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-14 1230ES 3121223

‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘‘

SECTION 5

CYLINDER

3121223 1230ES 5-1

SECTION 5 CYLINDER

141423

1616191718

1132B2A20D

20B

20C

20A

100

FIGURE 5-1.LIFT CYLINDER ASSEMBLY

5-2 1230ES 3121223

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1684469 Ref. LIFT CYLINDER ASSEMBLY H

1Not Used

2 A/R Rod Options: 2A 70000732 1 Rod (Cylinder #1) 2B 70000733 1 Rod (Cylinder #2)

3 70000734 1 Rod (Cylinder #3)

4 70000721 3 Head (Cylinders #1/#2/ #3)

5 70000722 3 Piston - Outer (Cylinders #1/#2/ #3)

6 Not Available 1 Barrel (Cylinder #1)

7 Not Available 1 Barrel (Cylinders #2/#3)

8 70000723 3 Ring, Retaining (Cylinders #1/#2/ #3)

9 4640858 3 Bleeder (Cylinders #1/#2/ #3) 10 Not Used 11 Use Item 100 3 Wiper (Cylinders #1/#2/ #3) 12 Use Item 100 3 Seal (Cylinders #1/#2/ #3) 13 70000725 3 Ring, Retaining (Cylinders #1/#2/ #3) 14 Use Item 100 3 Seal (Cylinders #1/#2/ #3) 15 Not Used 16 Use Item 100 2 O-Ring (Cylinder #2 Guide) 17 70000726 1 Cap (Cylinder #2) 18 70000727 1 Guide (Cylinder #2) 19 Use Item 100 1 O-Ring (Cylinder #2 Cap) 20 70000728 1 Valve Assembly

20A 70000737 1 Cartridge, Solenoid

Not Available 1 Seal Kit - 70000737 Valve Not Available 1 Coil

70002720 1 Knob Kit (Includes Knob, Coil Nut, Spacer, Retaining Nut &

Qty 2 Coil O-Rings)

20B 70001254 1 Cartridge, Check

Not Available 1 Seal Kit - 70001254 Valve 20C Not Available 1 Orifice 20D Not Available 1 O-Ring

21 70000729 3 Piston - Inner (Cylinders #1/#2/ #3) 22 70000730 3 Spring (Cylinders #1/#2/ #3) 23 70000731 1 Spacer (Cylinder #1) 24 Not Used 25 2144609 2 Fitting, Straight

— — — — — — — — — —

100 70000735 1 Seal Kit - 1684469 Cylinder (Includes Items 11, 12, 14, 16 & 19)

3121223 1230ES 5-3

SECTION 5 CYLINDER

1213156141617

10442100

FIGURE 5-2. STEER CYLINDER ASSEMBLY

5-4 1230ES 3121223

SECTION 5 CYLINDER

FIGURE 5-2. STEER CYLINDER ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1684458 Ref. STEER CYLINDER ASSEMBLY G

1 70000742 1 Barrel 2 70000741 1 Rod 3Not Used 4 0440236 3 Bushing 5 70000738 1 Piston 6 70000739 1 Head

7 to 9 Not Used

10 Use Item 100 2 Seal 11 Not Available 1 Setscrew 12 Use Item 100 1 Seal 13 Use Item 100 1 Ring, Back-up 14 Use Item 100 1 Seal 15 Use Item 100 1 O-Ring 16 Use Item 100 1 Seal 17 Use Item 100 1 O-Ring 18 2144605 2 Fitting, Straight

— — — — — — — — — —

100 70000743 1 Seal Kit - 1684458 Cylinder (Includes Items 10 & 12-17)

3121223 1230ES 5-5

SECTION 5 CYLINDER

FIGURE 5-2. STEER CYLINDER ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-6 1230ES 3121223

SECTION 6

HYDRAULIC

3121223 1230ES 6-1

SECTION 6 HYDRAULIC

101

201

313

312

311

STEER

CYLINDER

LIFT

CYLINDER

PUMP/

MOTOR/

TANK

FIGURE 6-1.HYDRAULIC DIAGRAM

6-2 1230ES 3121223

SECTION 6 HYDRAULIC

FIGURE 6-1. HYDRAULIC DIAGRAM

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. HYDRAULIC COMPONENTS

0274581 Ref. Hydraulic Installation F 1Not Used 2 2 Hose (Lift) Options:

See Note French Built Machines Prior to S/N A200009318

1001101833 French Built Machines S/N A200009318 to Present

See Note USA Built Machines Prior to S/N 0200189255

1001101833 USA Built Machines S/N 0200189255 to Present

Ref. Note: P/N was 2755002. Purchase p/ns 1001101833

Hose & 1001101362 Fitting as replacement.

3 2755003 2 Hose (Steer)

1684458 Ref. Steer Cylinder Components G

101 2144605 2 Fitting, Straight

1684469 Ref. Lift Cylinder Components H

201 2144609 2 Fitting, Straight

Ref. Pump/Motor/Tank Components

3600432 Ref. French Built Machines Prior to S/N A200009318 (Original

Equipment)

1001101832 Ref. French Built Machines Prior to S/N A200009318 (Service

Replacement)

1001101831 Ref. French Built Machines S/N A200009318 to Present C

3600432 Ref. USA Built Machines Prior to S/N 0200189255 (Original

Equipment)

1001101832 Ref. USA Built Machines Prior to S/N 0200189255 (Service

Replacement)

1001101831 Ref. USA Built Machines S/N 0200189255 to Present C

301 to 310 Not Used

311 2144605 2 Fitting, Straight 312 2 Fitting Options:

2144610 Straight Fitting

1001101362 90° Fitting

313 2221086 1 Fitting, Pressure Check

3121223 1230ES 6-3

SECTION 6 HYDRAULIC

FIGURE 6-1. HYDRAULIC DIAGRAM (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-4 1230ES 3121223

SECTION 7

ELECTRICAL

3121223 1230ES 7-1

SECTION 7 ELECTRICAL

ATTACH TO BRAKE RELEASE SWITCH

FIGURE 7-1. ELECTRICAL SCHEMATIC (MACHINES WITH 1600346 DRIVE MODULE)

7-2 1230ES 3121223

SECTION 7 ELECTRICAL

1870188 D

1870188 F

ATTACH TO #1 ON CHARG ER

NOTE: THIS SCHEMATIC USED WITH 1600346 DRIVE MODULE. SEE PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

REVISION LOG

3121223 1230ES 7-3

SECTION 7 ELECTRICAL

FIGURE 7-2. ELECTRICAL SCHEMATIC (MACHINES WITH 1001092456 DRIVE MODULE)

7-4 1230ES 3121223

SECTION 7 ELECTRICAL

1001114879 B

NOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE MODULE. SEE REVISION LOG PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

3121223 1230ES 7-5

SECTION 7 ELECTRICAL

7-6 1230ES 3121223

SECTION 7 ELECTRICAL

1001114879 B

NOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE MODULE. SEE PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

REVISION LOG

3121223 1230ES 7-7

SECTION 7 ELECTRICAL

1001114879 B

NOTE: THIS SCHEMATIC USED WITH 1001092456 DRIVE

MODULE. SEE PAGE A OF THIS MANUAL

FOR DRIVE MODULE IDENTIFICATION.

REVISION LOG

7-8 1230ES 3121223

SECTION 7 ELECTRICAL

THIS PAGE INTENTIONALLY LEFT BLANK

3121223 1230ES 7-9

SECTION 7 ELECTRICAL

408

407

POTHOLE

PROTECTION SWITCHES

ALARM

BEACON LIGHT

309L 601

301

601A

603A

603D

603

603B

603C

301A

309D

GROUND

CONTROL

BOX

PLATFORM

RECEPTACLE

MODULE

(JAPANESE

SPEC)

506A

109

309M

2 107 111 112 113 114 115 116

309C 201B

507C

507F

507G

507E

507K

507N

507P

507R

507M

507K

507D 507L

309J

309

407

407A

408

408A

108

111 113 116

201A

309G

309A

309

309F

701A

701B

701C

201B

201D

201

201C

309

309L

501A

BRAKE

DISCONNECT

SWITCH

DRIVE

MOTORS

501

508A

501D

508A

508

501D

502

501B

502

503

501C

503

501C

110

105

507H

507S

507J

105

PUMP/

MOTOR/

TANK

PLATFORM

CONSOLE

BOX

505A

505

110

506

NOTE: THIS ILLUSTRATION USED WITH 1600346 DRIVE MODULE. SEE

PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

REVISION LOG

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE)

7-10 1230ES 3121223

SECTION 7 ELECTRICAL

404

409

309

309H

501

602A

602E

602F

602P

602C

602D

602J

602H

602G

602M

602B

602K

602L

DRIVE

CONTROLLER

504C

504G

504H

504E

504D

309K

309E

309B

504B

504A

BATTERY

CHARGER

BATTERY

CHARGER/

INVERTER

POWER

SWITCH

TO AC

POWER

504J

504K

507A 509A

507B 507K

504L

406

406B

402

402A

401

602V

602U

401

402B

403 403A

403B

404

309

404A

405

405A

406A

406C

PROXIMITY

SENSOR

309J 306A

309J

306

LIFT

CYLINDER

602N

602S

602R

602T

408

407

407A

409A

CONTACTOR

RELAY

404A

409A

305A

305

309L

401

408B

BATTERIES

507J

507T

NOTE: THIS ILLUSTRATION USED WITH 1600346 DRIVE MODULE. SEE PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

REVISION LOG

405A

504F

BATTERY

TEMPERATURE

SENSOR

510A

510

3121223 1230ES 7-11

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONSOLE BOX COMPONENTS

1 4922870 1 Platform Box Harness B 2 4461016 1 Connector - 14 Position

4460464 9 Pin, Male 4460466 5 Plug, Sealing 4460496 1 Lockwasher 4460497 1 Nut, Panel

3 4460265 1 Plug, Male - 9 Position

4460267 8 Pin, Male 4 2540042 2 Grommet 90° 5 Not Available 1 Receptacle, Female - 3 Position (Molex 43640-0301) 6 4461057 1 Plug, Male - 16 Position

4923503 Ref. MAST CABLE ASSEMBLY H

101 to 104 Not Used

105 4240033 3 Tie-Strap 106 Not Used 107 4460754 1 Connector - 14 Position 108 4460930 1 Plug, Male - 8 Position (Gray) 109 4923504 28ft/8.5m Cable, Electrical -18/5C + 18/1STP 110 4923505 28ft/8.5m Cable, Electrical -14/3C 111 2820026 A/R Tubing, Clear 112 3730119 1 Resistor 120Ohm/.25Watt 113 4460465 10 Socket, Female 114 4460466 6 Plug, Sealing 115 4460493 1 Cap, Dust 116 4460944 6 Socket, Female

Ref. GROUND CONTROL BOX COMPONENTS

201 4922865 1 Control Box Harness F

201A 4460265 1 Plug, Male - 9 Position

4460268 9 Socket, Female

201B 4460761 2 Receptacle, Female - 4 Position

4460267 8 Pin, Male

201C Not Available 1 Grommet (Molded in Part of Harness) 201D 4460418 1 Connector, Female - 6 Position

4460419 3 Socket, Female

Ref. GROUND CONTROL COMPONENTS

301 0140043 1 Alarm and Harness (Separate Harness Not Available)

301A 4460536 1 Receptacle, Female - 3 Position

4460465 3 Socket, Female

302 to 304 Not Used

7-12 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

305 3740150 1 Contactor Relay Harness (Includes Relay)

305A 4460891 1 Plug, Male - 2 Position

4460465 2 Socket, Female

306 4000010 1 Proximity Harness (Includes Sensor)

306A 4460897 1 Receptacle, Female - 2 Position

4460464 2 Pin, Male

Not Available 1 Wedge Lock - 2 Position (Deutsch WM-2P)

307 to 308 Not Used

309 1 Chassis Harness Options

See Note Harness used on USA Built Machines Prior to S/N 0200195926

& All French Built Machines (Note: Was p/n 4923301 - Order both p/ns 1001110303 & 1001115448 as replacement.)

1001110303 Harness used on USA Built Machines S/N 0200195926 to

Present

Ref. Chassis Harness Wiring Diagram Options:

4933341 Ref. USA Built Machines Prior to S/N 0200195926 & All French

Built Machines

1001110304 Ref. USA Built Machines S/N 0200195926 to Present A

309A 2 Switch, Limit Options:

Use 1001115448 Switch used on USA Built Machines Prior to

S/N 0200195926 & All French Built Machines (was p/n 4360633)

1001109088 Switch used on USA Built Machines S/N 0200195926 to

Present 4460884 2 Plug, Male - 4 Position (Use with p/n 1001109088 Switch) 4460465 4 Socket, Female (Use with p/n 1001109088 Switch)

309B 4460320 1 Plug, Male - 2 Position (Note: Connection to this plug used

only when footswitch or battery interlock options are required)

4460226 2 Socket, Female

309C 4460321 1 Plug, Male - 4 Position

4460227 4 Pin, Male

309D 4460539 1 Plug, Male - 3 Position

4460464 3 Pin, Male

309E 4460648 1 Connector, Anderson

309F 4460761 1 Receptacle, Female - 4 Position

4460227 4 Pin, Male

309G 4460814 1 Plug, Male - 40 Position

4460465 25 Socket, Female 4460944 6 Socket, Female (Gold) 4460466 3 Seal, Plug 0840057 1 Boot

309H 4460870 1 Plug, Male - 12 Position

4460877 4 Pin, Male

309J 4460891 5 Plug, Male - 2 Position

4460465 10 Socket, Female

309K 4460894 1 Plug, Male - 6 Position

4460465 6 Socket, Female

309L 4460897 4 Receptacle, Female - 2 Position

4460464 8 Pin, Male 3990013 1 Diode 1 Amp (Right Brake Only)

3121223 1230ES 7-13

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

309M 4460931 1 Receptacle, Female -8 Position

4460464 2 Pin, Male 4460943 3 Pin, Male (Gold) 0840058 1 Boot

2902444 Ref. BATTERY CABLE KITS E

401 0840060 8 Boot, Terminal (Gray) (Covers only the Battery Terminal Base)

402 4923324 1 Cable, Battery (Battery Positive to Battery Negative) A 402A Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 402B 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

403 4923325 1 Cable, Battery (LH Side Batteries to RH Side Batteries) B 403A Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 403B 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

404 4923326 1 Cable, Battery (Contactor to RH Side Batteries) A 404A Not Available 2 Boot, Terminal (Black)

405 4923327 1 Cable, Battery (Drive Module B– to LH Side Batteries) A 405A Not Available 2 Boot, Terminal (Black)

406 4923328 1 Cable, Battery with Disconnect (Battery Positive to Battery

Negative) 406A Not Available 1 Connector, Anderson 406B Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 406C 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

407 4923329 1 Cable, Battery (Drive Module B+ to Pump Motor +) A

407A 0840041 2 Boot, Terminal (Red)

408 4923330 1 Cable, Battery (Drive Module P to Pump Motor –) D 408A Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 408B 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

409 4923331 1 Cable, Battery (Drive Module B+ to Contactor) A 409A 0840041 2 Boot, Terminal (Red)

Ref. STANDARD HARNESSES

501 1001093652 2 Drive Motor/Brake Harness (was p/n 7024770) 501A 4460891 2 Plug, Male - 2 Position (1 Per Harness)

4460465 4 Socket, Female (2 Per Harness)

501B Not Available 2 Plug, Male - 2 Position (1 Per Harness) (To Brake)

Not Available 4 Socket, Female (2 Per Harness) (To Brake)

501C Not Available 2 Plug, Male - 2 Position (1 Per Harness) (To Motor)

Not Available 4 Socket, Female (2 Per Harness) (To Motor)

501D 4461261 2 Plug, Male - 1 Position

4460509 2 Socket, Female

502 Not Available 2 Harness, Brake (Internal Connections - Purchase Complete

Brake) Not Available 2 Receptacle, Female - 2 Position (1 Per Harness) Not Available 4 Pin, Male (2 Per Harness)

7-14 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

503 Not Available 2 Harness, Motor (Internal Connections - Purchase Complete

Motor) Not Available 2 Receptacle, Female - 2 Position (1 Per Harness) Not Available 4 Pin, Male (2 Per Harness)

504 Ref. Battery Charger Components: 504A Not Available DC Harness/Cord Set 504B 4460648 1 Plug, Anderson 504C Not Available 1 Harness with Connector 504D 4460424 1 Connector, Female - 2 Position (Note: Connection to this plug

used only when battery interlock options are required)

4460227 2 Pin, Male

504E Not Available 1 Harness with Connector

504F 4460899 1 Connector, Female - 6 Position

4460464 6 Pin, Male 504G Not Available 1 Connector, Strain Relief 504H Not Available 1 Connector, Strain Relief

504J Not Available 1 Connector, Strain Relief

504K Not Available 1 AC Harness/Cord Set

504L Not Available 1 Connector, Female

505 4360539 1 Toggle Switch and Harness (No Separate Harness Available)

505A Not Available 1 Plug, Male - 3 Position (Molex P/N 43643-0300)

506 Not Available 1 Joystick Harness

506A 4460266 1 Receptacle, Female - 9 Position

4460226 8 Socket, Female

507 Ref. AC Power Components

0274556 Ref. ANSI/CSA/Japan Specs (Supplied with ANSI Spec Plug) E

0274802 Ref. ANSI Export/Australian Specs (No Plug Supplied. Plug Must Be

Purchased Locally) 0274802 Ref. CE Spec (No Plug Supplied. Plug Must Be Purchased Locally) D 0275772 Ref. CE Spec with 110V with IEC Yellow Receptacle & Plug & Circuit

Breaker 0275773 Ref. CE Spec with 220V with IEC Blue Receptacle & Plug & Circuit

Breaker 0275771 Ref. CE Spec with 220V with AFSINT 107 Keyed Ground

Receptacle & Plug & Circuit Breaker 0275769 Ref. CE Spec with 220V with CEE 7 Post Ground Receptacle & Plug

& Circuit Breaker (2x4 Box) 0275774 Ref. CE Spec with 220V with CEE 7 Post Ground Receptacle & Plug

& Circuit Breaker (70x70 Box) 0275770 Ref. CE Spec with 220V with CEE 7 Side Ground Receptacle & Plug

& Circuit Breaker (2x4 Box) 0275775 Ref. CE Spec with 220V with CEE 7 Side Ground Receptacle & Plug

& Circuit Breaker (70x70 Box)

1 Decal - AC Power (Not Shown - Located on Rear Cover)

120V AC (0274556 Installations) Options:

3252761 USA Built Machines Prior to S/N 0200194028, French

Built Machines Prior to S/N A200009503

1001103742 USA Built Machines S/N 0200194028 to Present, French

Built Machines S/N A200009503 to S/N A200009897

1703464 120V AC - 60HZ (0275772 Installations)

3121223 1230ES 7-15

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

507 cont’d 220V-50/60HZ (0274802, 0275769, 0275770, 0275771,

0275773, 0275774, 0275775 Installations) Options:

3252507 USA Built Machines Prior to S/N 0200194028, French

Built Machines Prior to S/N A200009503

1001103742 USA Built Machines S/N 0200194028 to Present, French

Built Machines S/N A200009503 to S/N A2000009897

507A 1 Harness, AC to Battery Charger (No Serviceable Parts)

ANSI/CSA/Japan Specs

1060688 French Built Machines Prior to S/N A200008736

1001098832 French Built Machines S/N A200008736 to S/N

A2000009897

1060688 USA Built Machines Prior to S/N 0200183666

1001098832 USA Built Machines S/N 0200183666 to S/N

0200189617

1001103257 USA Built Machines S/N 0200189617 to Present

ANSI Export/Australian/CE Specs

1060689 USA Built Machines Prior to S/N 0200194028, French

Built Machines Prior to S/N A200009503

1001103258 USA Built Machines S/N 0200194028 to Present, French

Built Machines S/N A200009503 to S/N A2000009897 507B 1321293 1 Clamp 507C A/R AC Receptacle Box Kit Options:

2902431 1 0274556 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507F & 507H)

Not Available 0 0274802 Installations (Purchase Components Locally)

0275216 1 0275772 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507G)

0275217 1 0275773 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507G)

0275454 1 0275771 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507G)

0275452 1 0275769 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507G)

Use 1001100343 1 0275774 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507F, 507H & 507J) (was p/n 0275218 &

1001141971)

0275453 1 0275770 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507G)

Use 1001100344 1 0275775 Installations Switch Box/Receptacle Kit (Includes

Items 507D-507F, 507H & 507J) (was p/n 0275219 &

1001141970)

507D A/R Box Options:

0861731 1 0274556, 0275769, 0275770, 0275771 Installations

Not Available 0 0274802 Installations (Purchase Components Locally)

0861781 1 0275772/0275773 Installations

See Note 1 0275774/0275775 Installations (Note: Was

p/n0861782 which is no longer available. Use p/n 1001100344 CEE 7 Side Ground Service Kit or p/n 1001100343 CEE 7 Post Ground Service Kit. Kits includes Box p/n 1001141967 & items 507D, 507E, 507F, 507H, 507J.)

7-16 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

507E A/R Cover Options:

1671207 1 0274556 Installations

Not Available 0 0274802 Installations (Purchase Components Locally)

4461198 1 0275772 Installations (Includes Receptacle) 4461201 1 0275773 Installations (Includes Receptacle) 4461246 1 0275771 Installations (Includes Receptacle)

4461244 1 0275769 Installations (Includes Receptacle) 1001141968 1 1001100343 & 1001141971 Service Kits 1001141969 1 1001100344 & 1001141970 Service Kits

Use 1001100343 1 0275774 Installations (Includes Receptacle) (was p/n

4461204)

4461245 1 0275770 Installations (Includes Receptacle)

Use 1001100344 1 0275775 Installations (Includes Receptacle) (was p/n

4461207)

507F A/R Receptacle Options:

4460346 1 0274556 Installations

Not Available 0 0274802 Installations (Purchase Components Locally)

4461198 1 0275772 Installations (Includes Cover)

4461201 1 0275773 Installations (Includes Cover)

4461246 1 0275771 Installations (Includes Cover)

4461244 1 0275769 Installations (Includes Cover) 1001141968 1 1001100343 & 1001141971 Service Kits 1001141969 1 1001100344 & 1001141970 Service Kits

Use 1001100343 1 0275774 Installations (Includes Cover) (was p/n

4461204)

4461245 1 0275770 Installations (Includes Cover)

Use 1001100344 1 0275775 Installations (Includes Cover) (was p/n

4461207)

507G A/R Connector, Strain Relief Options:

4460662 1 0274556, 0275769, 0275770, 0275771 Installations

Not Available 0 0274802 Installations (Purchase Components Locally)

4461257 1 0275774, 0275775 Installations (90°) (USA Built

Machines Prior to S/N 0200194028, French Built Machines Prior to S/N A200009503)

1001103471 1 0275774, 0275775 Installations (90°) (USA Built

Machines S/N 0200194028 to Present, French Built

Machines S/N A200009503 to S/N A2000009897) 4460633 1 0275772, 0275773 Installations 4461258 Adapter, Connector (0275774, 0275775 Installations

Only) (USA Built Machines Prior to S/N 0200194028, French Built Machines Prior to S/N A200009503)

507H A/R Plug, Male Options:

4460138 1 0274556 Installations

Not Available 0 0274802 Installations (Purchase Locally)

4461196 1 0275772 Installations 4461199 1 0275773 Installations 4461249 1 0275771 Installations 4461202 1 0275769/0275774 Installations & 1001100343/

1001141971 Service Kits

3121223 1230ES 7-17

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

507H cont’d 4461205 1 0275770/0275775 Installations & 1001100344/

1001141970 Service Kits

507J A/R Receptacle, Replacement Options:

Not Available 0 0274556/0274802 Installations (Purchase Components

Locally) 4461197 1 0275772 Installations 4461200 1 0275773 Installations 4461250 1 0275771 Installations 4461203 1 0275769/0275774 Installations & 1001100343/

1001141971 Service Kits 4461206 1 0275770/0275775 Installations & 1001100344/

1001141970 Service Kits

507K A/R Hardware Options:

4190406 Screw M4 x 12mm 4010408 Screw M4 x 16mm 4010414 Screw M4 x 30mm 0760606 Screw M6 x 12mm 0760608 Screw M6 x 16mm 0760612 Screw M6 x 25mm 3290405 Locknut M4 3290605 Locknut M6 4811400 Flatwasher M4 4811700 Flatwasher M6

507L A/R Bracket, Receptacle Box Mounting Options:

Not Required 0 0274556, 0274802, 0275769, 0275770, 0275771

Installations 0903551 1 0275772, 0275773, 0275774, 0275775 Installations

507M 3380766 1 Shield, Circuit Breaker Mounting (Required Only on CE Spec

Installations Except 0274802 Installation)

507N 2902559 A/R Circuit Breaker Kit D

Ref. Note: Required Only on CE Spec Installations Except

0274802 Installation

1 Breaker, Circuit Options:

240015 1 Prior to S/N A200006201

See Note A/R Breaker 16 Amp S/N A200006201 to S/N A200009455

(Note: Was p/n 2400093. Use qty 1 each of p/ns 1001109475 & 1001109482 as replacement)

1001109475 1 Breaker 16 Amp (S/N A200009455 to Present) 1001109482 1 Breaker 30 Amp (S/N A200009455 to Present)

240093 1 Breaker Box (Prior to S/N 6201)

0861880 1 Breaker Box (S/N A200006201 to S/N A2000009897)

250135 1 Terminal Block (Prior to S/N A200006201) 4460957 1 Terminal Block (S/N A200006201 to S/N A2000009897) 4460956 1 Barrier, Terminal Block (S/N A200006201 to Present Only)

507P 2 Connector, Strain Relief Options:

4460633 Prior to S/N A200006201

1001097150 S/N A200006201 to S/N A2000009897 507R 1060908 1000mm Cable, Electrical - 12/3 507S 1001103742 1 Decal - AC to Platform 507T 1001103743 1 Decal - AC to Charger

7-18 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

508 4923602 1 Field Wire Connection Harness B

508A 4461260 2 Receptacle, Female - 1 Position

4460508 2 Pin, Male

509 1 Charger Plug Installations

0274556 Ref. ANSI/CSA/Japan Specs (Supplied with ANSI Spec Plug) E 0274802 Ref. ANSI Export/Australian Specs (No Plug Supplied. Plug Must Be

Purchased Locally)

509 cont’d 0274802 Ref. CE Spec (No Plug Supplied. Plug Must Be Purchased Locally) C

0275666 Ref. CE Spec with 110V with IEC Yellow Receptacle D 0275667 Ref. CE Spec with 220V with IEC Blue Receptacle D 0275665 Ref. CE Spec with 220V with AFSINT 107 Keyed Ground

Receptacle 0275663 Ref. CE Spec with 220V with CEE 7 Post Ground Receptacle C 0275664 Ref. CE Spec with 220V with CEE 7 Side Ground Receptacle & E

509A A/R Plug, Male Options:

Use 1060688 1 0274556 Installations

Not Available 0 0274802 Installations (Purchase Locally)

4461196 1 0275666 Installations 4461199 1 0275667 Installations 4461249 1 0275665 Installations 4461202 1 0275663 Installations 4461205 1 0275664 Installations

510 Use 1001127269 1 Battery Temperature Sensor Harness (Includes Sensor and

Instructions) (was p/n 1001112113)

510A 4460465 2 Socket, Female

Ref. OPTIONAL HARNESSES

601 2920161 1 Beacon Light and Harness (Separate Harness Not Available)

601A 4460891 1 Plug, Male - 2 Position (1 Per Harness)

4460465 2 Socket, Female (2 Per Harness)

602 Ref. Battery Charger/Inverter Components (ANSI & CSA Option Only): 602A Not Available 1 AC Output Harness (Internal Part of Inverter) 602B Not Available 1 Receptacle, Female - 4 Position (Conxall T9014) 602C Not Available 1 AC Input Harness (Internal Part of Inverter) 602D Not Available 1 Receptacle, Female - 4 Position (Conxall T9016) 602E Not Available 1 Remote Control Harness (Internal Part of Inverter)

602F Not Available 1 Plug, Male - 8 Position (Conxall 7281-8PG-300)

602G Use 1001091479 1 AC Input Harness (was p/n 4923389 on French Built Machines

Prior to S/N A200006146)

602H 4460138 1 Plug, Male

602J Not Available 1 Plug, Male - 4 Position (Conxall T9017)

602K 1 AC Output Harness Options:

4923390 Harness French Built Machines Prior to S/N A200006146 D

Not Required Harness French Built Machines S/N A200006146 to

S/N A2000009897

Not Required Harness USA Built Machines

602L 4460779 1 Receptacle, Female (French Built Machines Prior to S/N

A200006146 Only)

3121223 1230ES 7-19

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

602M 1001091478 1 Plug, Male - 4 Position

602N 4923391 1 Data Interface Harness (Internal Part of Inverter) D 602P Not Available 1 Plug, Male - 8 Position (Conxall 6280-8SG-318) 602R 4460899 1 Receptacle, Female - 6 Position

4460464 4 Pin, Male 4460466 2 Plug, Seal

3990010 1 Diode 6A/600V 602S 4360336 1 Switch, Toggle 602T 4460424 2 Receptacle, Female - 2 Position

4460267 2 Pin, Male 602U 4923435 1 Cable, Battery + to Inverter + A 602V 4923436 1 Cable, Battery – to Inverter – A

603 4923355 1 Footswitch Module Harness (Japanese Spec Only) B

603A 4460908 1 Plug, Male - 12 Position (Gray) (Mini)

4460918 2 Socket, Female (Gold)

4460915 1 Wedge, Locking 603B 4460909 1 Plug, Male - 12 Position (Black) (Mini)

4460918 2 Socket, Female (Gold)

4460915 1 Wedge, Locking 603C 4460930 1 Plug, Male - 8 Position

4460465 4 Socket, Female

4460944 3 Socket, Female (Gold)

4460466 1 Plug, Seal 603D 4460931 1 Receptacle, Female - 8 Position

4460464 5 Pin, Male

4460943 3 Pin, Male (Gold)

Ref. TOOLS FOR SERVICE

701 2901443 1 Analyzer Kit 1 701A 1600244 1 Analyzer 701B 1060633 1 Cable, Analyzer 1/A 701C 4460321 2 Plug, Male - 4 Position

4460226 8 Socket, Female 702 7002821 1 Crimper, Wire (Not Shown) 703 7002823 1 Extractor, Pin - Universal (Not Shown) 704 4460467 A/R Extractor, Pin #16 Gauge (Not Shown) 705 4460510 A/R Extractor, Pin #12 Gauge (Not Shown) 706 7002828 1 Stripper, Wire (Not Shown) 707 1001137005 1 Software Cable Kit (Not Shown)

7-20 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-3. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1600346 DRIVE

MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121223 1230ES 7-21

SECTION 7 ELECTRICAL

POTHOLE

PROTECTION

SWITCHES

ALARM

BEACON LIGHT

309J 601

301

601A

301A

309C

GROUND

CONTROL

BOX

PLATFORM

RECEPTACLE

506A

109

309M

2 107 111 112 113 114 115 116

507C

507F

507G

507E

507K

507N

507P

507R

507M

507K

507D 507L

309G

309

407

407A

408

408A

108

111 113 116

309F

309

309P

701A

701B

701C

309

309S

501A

BRAKE

DISCONNECT

SWITCH

DRIVE

MOTORS

501

502

501B

502

503

501C

503

501C

408

407

110

105

507H

507S

507J

105

PUMP/

MOTOR/

TANK

PLATFORM

CONSOLE

BOX

505A

505

110

506

NOTE: THIS ILLUSTRATION USED WITH 1001092456 DRIVE MODULE. SEE REVISION LOG

PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

309R

201A

201B

201C

204A

203A

203

202

204

201

201D

FIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456

DRIVE MODULE)

7-22 1230ES 3121223

404

409

309

602A

602E

602F

602P

602C

602D

602J

602H

602G

602B

RELAY

504C

504G

504H

504E

504D

309H

309D

309A

504B

504A

BATTERY

CHARGER

BATTERY

CHARGER/

INVERTER

POWER

SWITCH

TO AC

POWER

504J

504K

507A 509A

507B 507K

504L

406

406B

402

402A

401

602V

602U

401

402B

403 403A

403B

404

309

404A

405

405A

406A

406C

PROXIMITY

SENSOR

309G 306A

309B

309J

306

LIFT

CYLINDER

602N

602S

602R

602T

CONTACTOR

RELAY

404A

409A

305A

305

309G

401

BATTERIES

507J

408

408A

407

405A

407A

405

409

409A

507T

NOTE: THIS ILLUSTRATION USED WITH 1001092456 DRIVE MODULE. SEE REVISION LOG

PAGE A OF THIS MANUAL FOR DRIVE MODULE IDENTIFICATION.

309

DRIVE

CONTROLLER

+BF1

+BF2

–B

–T

–P

309N

309E

504F

BATTERY

TEMPERATURE

SENSOR

510A

510

SECTION 7 ELECTRICAL

3121223 1230ES 7-23

SECTION 7 ELECTRICAL

FIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456

DRIVE MODULE)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONSOLE BOX COMPONENTS

1 4922870 1 Platform Box Harness B 2 4461016 1 Connector - 14 Position

4460464 9 Pin, Male 4460466 5 Plug, Sealing 4460496 1 Lockwasher 4460497 1 Nut, Panel

3 4460265 1 Plug, Male - 9 Position

4460267 8 Pin, Male 4 2540042 2 Grommet 90° 5 Not Available 1 Receptacle, Female - 3 Position (Molex 43640-0301) 6 4461057 1 Plug, Male - 16 Position

4923503 Ref. MAST CABLE ASSEMBLY H

101 to 104 Not Used

Ref. GROUND CONTROL BOX COMPONENTS

201 1001114935 1 Control Box Harness A

201A Not Available 1 Receptacle, Female - 18 Position

Not Available 16 Socket, Female

201B 4460961 1 Receptacle, Female - 4 Position

4460267 4 Pin, Male

201C 4461077 1 Plug, Male - 4 Position

4460928 4 Socket, Female

201D Use 4460418 1 Receptacle, Female - 3 Position

Use 4460419 3 Terminal 202 1001114937 1 Mount, Harness Bulkhead 203 Use 1001114933 1 Harness, Tilt Sensor (Includes Sensor) A

203A 4461076 1 Receptacle, Female - 4 Position

4460929 4 Pin, Male

204 Use 0610161 1 Harness, Charger LED (Includes PC Board

204A 4460321 1 Plug, Male - 4 Position

4460268 3 Socket, Female

7-24 1230ES 3121223

SECTION 7 ELECTRICAL

FIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456

DRIVE MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. GROUND CONTROL COMPONENTS

301 0140043 1 Alarm and Harness (Separate Harness Not Available)

301A 4460536 1 Receptacle, Female - 3 Position

4460465 3 Socket, Female

302 to 304 Not Used

305 3740150 1 Contactor Relay Harness (Includes Relay)

305A 4460891 1 Plug, Male - 2 Position

4460465 2 Socket, Female

306 4000010 1 Proximity Harness (Includes Sensor)

306A 4460897 1 Receptacle, Female - 2 Position

4460464 2 Pin, Male

Not Available 1 Wedge Lock - 2 Position (Deutsch WM-2P)

307 to 308 Not Used

309 1001116640 1 Chassis Harness E

1001116644 1 Wiring Diagram - Chassis Harness C

309A 4460320 1 Plug, Male - 2 Position (Note: Connection to this plug used only

when footswitch or battery interlock options are required)

4460226 2 Socket, Female

309B 1001097347 1 Relay

4460374 1 Plug, Relay 4460375 4 Terminal

309C 4460539 1 Plug, Male - 3 Position

4460464 3 Pin, Male 309D 4460648 1 Connector, Anderson 309E 4460873 1 Plug, Male - 35 Position

4460871 25 Socket, Female

309F 4460884 2 Plug, Male - 4 Position

4460465 4 Socket, Female 309G 4460891 5 Plug, Male - 2 Position

4460465 10 Socket, Female 309H 4460894 1 Plug, Male - 6 Position

4460465 4 Socket, Female

309J 4460897 2 Receptacle, Female - 2 Position

4460464 4 Pin, Male

309L Not Used

309M 4460931 1 Receptacle, Female - 8 Position

4460464 5 Pin, Male

4460943 3 Pin, Male (Gold)

0840058 1 Boot 309N 1001096138 1 Plug, Male - 23 Position

4460871 12 Socket, Female 309P 4460761 1 Receptacle, Female - 4 Position

4460227 4 Pin, Male 309R 1001115076 1 Plug, Male - 18 Position

4460465 14 Socket, Female

4460942 2 Socket, Female

3121223 1230ES 7-25

SECTION 7 ELECTRICAL

FIGURE 7-4. ELECTRICAL CONNECTORS INSTALLATION (MACHINES WITH 1001092456

DRIVE MODULE) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

309S 1001118322 2 Connector - 6 Position

91013191 4 Terminal

4460464 8 Pin, Male

1001117837 Ref. BATTERY CABLE KITS A

401 0840060 8 Boot, Terminal (Gray) (Covers only the Battery Terminal Base)

402 1060998 1 Cable, Battery (Battery Positive to Battery Negative) C 402A Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 402B 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

403 4923325 1 Cable, Battery (LH Side Batteries to RH Side Batteries) C 403A Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 403B 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

404 4923326 1 Cable, Battery (Contactor to RH Side Batteries) B 404A Not Available 2 Boot, Terminal (Black)

405 1001117840 1 Cable, Battery (Drive Module B– to LH Side Batteries) A 405A Not Available 2 Boot, Terminal (Black)

406 4923328 1 Cable, Battery with Disconnect (Battery Positive to Battery

Negative) 406A Not Available 2 Connector, Anderson 406B Not Available 1 Boot, Terminal (Black) (1 Per Cable Assembly) 406C 0840041 1 Boot, Terminal (Red) (1 Per Cable Assembly)

407 1001117841 1 Cable, Battery (Drive Module +BF2 to Pump Motor +) A

407A Not Available 2 Boot, Terminal (Black)

408 1001117842 1 Cable, Battery (Drive Module P– to Pump Motor –) A

408A Not Available 2 Boot, Terminal (Black)

409 1001117843 1 Cable, Battery (Drive Module B+ to Contactor) A

409A Not Available 2 Boot, Terminal (Black)

Ref. STANDARD HARNESSES

501 1001118363 2 Drive Motor/Brake Harness B

501A 1001118323 2 Connector - 6 Position

91013192 4 Socket, Female (2 Per Harness)

4460465 8 Socket, Female (4 Per Harness)

501A 4460891 2 Plug, Male - 2 Position (1 Per Harness)

4460465 4 Socket, Female (2 Per Harness)

501B Not Available 2 Plug, Male - 2 Position (1 Per Harness) (To Brake)

Not Available 4 Socket, Female (2 Per Harness) (To Brake)

501C Not Available 2 Plug, Male - 2 Position (1 Per Harness) (To Motor)

Not Available 4 Socket, Female (2 Per Harness) (To Motor)

502 Not Available 2 Harness, Brake (Internal Connections - Purchase Complete

Brake)

Not Available 2 Receptacle, Female - 2 Position (1 Per Harness) Not Available 4 Pin, Male (2 Per Harness)

503 Not Available 2 Harness, Motor (Internal Connections - Purchase Complete

Motor)

Not Available 2 Receptacle, Female - 2 Position (1 Per Harness) Not Available 4 Pin, Male (2 Per Harness)

7-26 1230ES 3121223