JLG 1250AJP Parts Manual

Illustrated Parts Manual

Model

1250AJP

3121172

August 15, 2013

REVISION LOG

MODULE ON MACHINES

“WITHOUT UGM”

(UNIVERSAL

GROUND MODULE)

MODULE ON MACHINES

“WITH UGM” (UNIVERSAL

GROUND MODULE)

GROUND MODULE MODULE IDENTIFICATION

March 30, 2004 - Original Issue Of Manual (Edited to B/M 0010609 Revision 3)

July 15, 2004 - Revised Manual (Edited to B/M 0010609 Revision 4)

October 28, 2004 - Revised Manual (Edited to B/M 0010609 Revision 5)

February 24, 2005 - Revised Manual (Edited to B/M 0010609 Revision 7)

January 5, 2006 - Revised Manual (Edited to B/M 0010609 Revision 14)

April 30, 2006 - Revised Manual (Edited to B/M 0010609 Revision 15)

August 15, 2006 - Revised Manual (Edited to B/M 0010609 Revision 16)

January 15, 2007 - Revised Manual (Edited to B/M 0010609 Revision 17)

June 1, 2007 - Revised Manual (Edited to B/M 0010609 Revision 21)

October 20, 2007 - Revised Manual (Edited to B/M 0010609 Revision 25)

January 15, 2008 - Revised Manual (Edited to B/M 0010609 Revision 26)

July 31, 2008 - Revised Manual (Edited to B/M 0010609 Revision 32)

January 25, 2009 - Revised Manual (Edited to B/M 0010609 Revision 32)

July 27, 2009 - Revised Manual (Edited to B/M 0010609 Revision 41)

December 15, 2009 - Revised Manual (Edited to B/M 0010609 Revision 48)

July 22, 2010 - Revised Manual (Edited to B/M 0010609 Revision 52)

February 23, 2011 - Revised Manual (Edited to B/M 0010609 Revision 58)

May 25, 2011 - Revised Manual (Edited to B/M 0010609 Revision 58)

August 19, 2011 - Revised Manual (Edited to B/M 0010609 Revision 60)

January 23, 2012 - Revised Manual (Edited to B/M 0010609 Revision E)

June 22, 2012 - Revised Manual (Edited to B/M 0010609 Revision E)

August 17, 2012 - Revised Manual (Edited to B/M 0010609 Revision E)

December 20, 2012 - Revised Manual (Edited to B/M 0010609 Revision E)

April 19, 2013 - Revised Manual (Edited to B/M 0010609 Revision E)

3121172 1250AJP A

REVISION LOG

August 15, 2013 - Revised Manual (Edited to B/M 0010609 Revision E)

B 1250AJP 3121172

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667) . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE MOTOR ASSEMBLY (PRIOR TO S/N 0300079667) . . . . . . . . . . . . . . . . . . . . 1-18

1-6 HUB AND MOTOR ASSEMBLY (S/N 0300079667 TO S/N 0300083556). . . . . . . . . . 1-20

1-7 HUB AND MOTOR ASSEMBLY (S/N 0300083556 TO S/N 0300103907). . . . . . . . . . 1-26

1-8 DRIVE HUB ASSEMBLY - BONFIGLIOLI (S/N 0300103907 TO PRESENT) . . . . . . . 1-32

1-9 DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI (S/N 0300103907 TO

PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

1-10 DRIVE MOTOR ASSEMBLY (S/N 0300103907 TO PRESENT) . . . . . . . . . . . . . . . . . 1-40

1-11 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1-12 TRACTION VALVE ASSEMBLY (PRIOR TO S/N 0300103907) . . . . . . . . . . . . . . . . . 1-46

1-13 TRACTION VALVE ASSEMBLY (S/N 0300103907 TO PRESENT) . . . . . . . . . . . . . . 1-48

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

2-1 VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . 2-2

2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3 TURNTABLE SWING DRIVE AND BEARING INSTALLATION . . . . . . . . . . . . . . . . . . 2-12

2-4 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-5 CATERPILLAR DIESEL ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-6 DEUTZ TIER II & TIER III ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-7 DEUTZ TIER IVi & TIER IVi-PRE ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . 2-38

2-8 PUMP ASSEMBLY (REXROTH) (CATERPILLAR ENGINE MACHINES) . . . . . . . . . 2-46

2-9 PUMP ASSEMBLY (REXROTH) (DEUTZ ENGINE MACHINES) . . . . . . . . . . . . . . . . 2-52

2-10 PUMP ASSEMBLY (SAUER TANDEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2-11 PUMP ASSEMBLY (SAUER PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-12 PUMP ASSEMBLY (SAUER GEAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-13 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

2-14 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . 2-72

2-15 HYDRAULIC OIL COOLER INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 2-74

2-16 GROUND CONTROLS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . 2-76

2-17 GROUND CONTROLS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . 2-80

2-18 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

2-19 ENGINE TRAY JACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

2-20 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

2-21 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-98

2-22 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-102

2-23 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR

MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

2-24 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112

2-25 CLEARSKY TELEMATICS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . . . 2-118

2-26 CLEARSKY TELEMATICS INSTALLATION (WITH UGM) (OPTIONAL) . . . . . . . . . . . 2-122

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

3-1 BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 MAIN BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4 ACTUATOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3121172 1250AJP i

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FIGURE NO. TITLE PAGE NO.

3-5 POWER TRACK & BOOM CLAMPS INSTALLATION (TOWER BOOM) . . . . . . . . . . .3-20

3-6 POWER TRACK & BOOM CLAMPS INSTALLATION (MAIN BOOM & JIB) . . . . . . . .3-22

3-7 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS. . . . . . . . . . . . . . . .3-30

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

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

4-2 PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM) . . . . . . .4-8

4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-4 CONTROLLER ASSEMBLY (LIFT & SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-5 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-6 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . .4-22

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

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

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

5-3 PLATFORM LEVEL CYLINDER ASSEMBLY (PRIOR TO S/N 0300080030). . . . . . . .5-6

5-4 PLATFORM LEVEL CYLINDER ASSEMBLY (S/N 0300080030 TO PRESENT) . . . . .5-8

5-5 LIFT CYLINDER ASSEMBLY (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6 LIFT CYLINDER ASSEMBLY (TOWER BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 JIB CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-9 TELESCOPE CYLINDER ASSEMBLY (MAIN BOOM) . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-10 TELESCOPE CYLINDER ASSEMBLY (TOWER BOOM). . . . . . . . . . . . . . . . . . . . . . .5-22

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

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

6-2 HYDRAULIC DIAGRAM - DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-3 HYDRAULIC DIAGRAM - OSCILLATING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-4 HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-5 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-6 HYDRAULIC DIAGRAM - AUXILIARY POWER MOTOR . . . . . . . . . . . . . . . . . . . . . . .6-18

6-7 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

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

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

7-2 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (PRIOR TO

S/N 0300087575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (S/N 0300087575

TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

7-4 HARNESS COMPONENTS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . .7-46

ii 1250AJP 3121172

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

8-1 DECAL INSTALLATION - ANSI SPEC (PRIOR TO S/N 0300089066) . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION - ANSI SPEC (S/N 0300089066 TO PRESENT). . . . . . . . . . 8-6

8-3 DECAL INSTALLATION - ANSI EXPORT SPEC (PRIOR TO S/N 0300089066) . . . . 8-10

8-4 DECAL INSTALLATION - ANSI EXPORT SPEC (S/N 0300089066 TO PRESENT) . . 8-16 8-5 DECAL INSTALLATION - AUSTRALIAN & CE SPEC (PRIOR TO

S/N 0300089066). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-6 DECAL INSTALLATION - AUSTRALIAN & CE SPEC (S/N 0300089066 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

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

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

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

3121172 1250AJP iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 1250AJP 3121172

SECTION 1

FRAME

3121172 1250AJP 1-1

SECTION 1 FRAME

47 13

115

105

254

144

145

2817483216

225

220

246

231

212

217

226

5043329145126

4247264142

4777

4142422626

525356

255043

433147

2641424741

234747

301 302 303

37 38

FIGURE 1-1. AXLE INSTALLATIONS

1-2 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. AXLE INSTALLATIONS - COMMON PARTS 0271934 Ref. Fixed Axle J 0271521 Ref. Oscillating Axle J

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100081 A/R Adhesive #454 4 0363037 4 Bar, Stop 5Not Used 6 0641606 40 Bolt 3/8"-16NC x 3/4" 7 0641608 48 Bolt 3/8"-16NC x 1" 8 0641609 32 Bolt 3/8"-16NC x 1 1/8"

9 0641611 16 Bolt 3/8"-16NC x 1 3/8" 10 Not Used 11 0641613 8 Bolt 3/8"-16NC x 1 5/8”" 12 Not Used 13 4 Bolt Options:

0641620 Fixed Axle - Bolt 3/8”-16NC x 2 1/2”

0641624 Oscillating Axle - Bolt 3/8”-16NC x 3" 14 0641808 8 Bolt 1/2”-13NC x 1” 15 Not Used 16 0642214 1 Bolt 3/4”-10NC x 1 3/4” 17 0962033 2 Bushing 18 1180358 4 Carrier

7024365 A/R 24 in Section Repair Kit (Includes Inner & Outer Links, Joining

Bars & Rollers, and Assembling Hardware)

7024366 1 Mounting Bracket Kit (Includes Mounting Brackets for Both

Ends, 1 Roller Assembly and Assembling Hardware) 19 1320263 4 Clamp, Cable 20 1320298 4 Clamp, Hose 21 1684102 4 Axle Extension Cylinder Assembly (See Section 7 for

Breakdown) 22 3310805 8 Locknut #8-32NC 23 3340881 8 Pad, Wear 24 3340907 2 Pad, Axle 25 3340946 8 Pad, Wear 26 3340932 32 Pad, Wear 27 3340939 8 Pad, Rubber 28 3422918 1 Pin 29 3422960 4 Pin 30 3573294 4 Plate 31 3573335 8 Plate 32 3841287 1 Keeper, Pin 33 3900270 4 Bolt, Shoulder 1/2” -13NC x 1 1/2” 34 3930820 8 Capscrew #8-32NC x 1 1/4”

35 to 36 Not Used

37 4071035 2 Shim #18 Gauge 38 4071036 4 Shim #11 Gauge 39 4071054 8 Shim #18 Gauge

3121172 1250AJP 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

40 4071055 12 Shim #11 Gauge 41 4071039 24 Shim #18 Gauge 42 4071040 36 Shim #11 Gauge 43 4071042 24 Shim #16 Gauge

44 to 45 Not Used

46 4 Switch, Limit Options:

Use 4360578 Prior to S/N 0300074420 (was p/n 4360322) Use 4360578 S/N 0300074420 to S/N 0300080869 (was p/n 4360549)

4360578 S/N 0300080869 to Present 47 4711600 140 Flatwasher 3/8” Thin 48 4740461 1 Thrustwasher 49 4750800 8 Flatwasher #8 Regular 50 4846637 4 Extension, Axle 51 4846383 1 Box, Axle Pivot 52 0681813 12 Bolt 1/2”-13NC x 1 5/8” (Grade 8) 53 0681814 18 Bolt 1/2”-13NC x 1 3/4” (Grade 8) 54 0681815 12 Bolt 1/2”-13NC x 1 7/8” (Grade 8) 55 0681816 6 Bolt 1/2”-13NC x 2” (Grade 8) 56 4711800 48 Flatwasher 1/2” Thin 57 4460968 4 Connector, Strain Relief (Not Shown)

Ref. AXLE INSTALLATION - OPTIONAL PARTS

0271934 Ref. Fixed Axle J

101 to 104 Not Used

105 0363076 2 Bar, Stop

106 to 114 Not Used

115 0641814 4 Bolt 1/2”-13NC x 1 3/4”

116 to 143 Not used

144 4071049 6 Shim 11 Gauge 145 4071050 4 Shim 16 Gauge

0271521 Ref. Oscillating Axle J

201 to 211

212 0642020 4 Bolt 5/8”-11NC x 2 1/2”

213 to 216 Not Used

217 1684081 2 Oscillating Axle Cylinder Assembly (See Section 5 for Break-

down)

218 to 219 Not Used

220 3312005 4 Locknut 5/8”-11NC

221 to 224 Not Used

225 3422833 2 Pin 226 3422915 2 Pin

227 to 230 Not Used

231 3841258 4 Keeper, Pin

232 to 245 Not Used

246 4712000 4 Flatwasher 5/8” Thin

247 to 253 Not Used

254 3520054 4 Plug

1-4 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274106 Ref. AXLE STOP BLOCKS INSTALLATION A

301 0100019 A/R Compound, Locking 302 3931816 4 Capscrew, Socket Head 1/2”-13NC x 1” 303 4220235 2 Block, Stop

3121172 1250AJP 1-5

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION

1-6 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271520 Ref. STEER INSTALLATION H

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100035 A/R Compound, Locking 4Not Used 5 0630464 4 Screw, Button Head #10-24NC x 1/2” 6 0641505 4 Bolt 5/16”-18NC x 5/8” 7 0641511 4 Bolt 5/16”-18NC x 1 3/8” 8Not Used

9 0641634 4 Bolt 3/8”-16NC x 4 1/4” 10 0642016 4 Bolt 5/8”-11NC x 2” 11 0962423 8 Bushing 12 1671040 4 Cover, Sensor 13 1684314 4 Steer Cylinder Assembly 14 3311505 4 Locknut 5/16”-18NC 15 3300464 4 Nut, Slotted 16 Not Used 17 3422917 4 Kingpin 18 3422940 4 Pin, Steer Cylinder (Outer) 19 3422941 4 Pin, Steer Cylinder (Inner) 20 4 Pin, Sensor Options:

Use 3423256 Prior to S/N 0300090594 (was p/n 3422942)

3423256 S/N 0300090594 to Present 21 3451214 4 Pin, Cotter 3/8” x 3 1/2” 22 3760383 4 Ring, Retaining 23 3841258 4 Keeper, Pin 24 Not Used 25 3931020 8 Capscrew #10-24NC x 1 1/4” 26 3931412 16 Capscrew 1/4”-20NC x 3/4” 27 3932024 8 Capscrew 5/8”-11NC x 1 1/2” 28 4 Spindle Options:

Use 1001099632 Prior to S/N 0300100131 (was p/n 4130387)

1001099632 S/N 0300100131 to Present (was p/n 4130416) 29 4360505 4 Switch, Rotary Angle Sensor (Steer) 30 4460914 4 Terminal 31 4711500 12 Flatwasher 5/16” Thin 32 4711800 4 Flatwasher 1/2” Thin 33 4740181 4 Thrustwasher 34 4740229 4 Thrustwasher 35 4740505 8 Thrustwasher 36 4751600 4 Flatwasher 3/8” Regular 37 4755000 4 Flatwasher 2 1/2” Regular 38 4 Arm, Steer Options:

Use 0200833 Prior to S/N 0300090594 (was p/n 4846494)

0200833 S/N 0300090594 to Present 39 0741606 8 Screw, Countersunk 3/8”-16NC x 3/4” 40 1120549 4 Cap, Seal (Outer) 41 1120550 4 Cap, Seal (Inner)

3121172 1250AJP 1-7

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

42 3960551 4 Seal (Outer) 43 3960552 4 Seal (Inner) 44 0080277 4 Adapter, Angle Sensor Pilot (S/N 0300090594 to Present) 45 4750800 8 Flatwasher #8 Regular

1-8 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121172 1250AJP 1-9

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

1-10 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE INSTALLATION 0271522 Ref. With Bonfiglioli Drive Hub (Prior to S/N 0300103907) E 0275685 Ref. With Bonfiglioli Drive Hub (S/N 0300103907 to Present) B

1001104324 Ref. With Reggiana Riduttori Drive Hub A

1 0100019 A/R Compound, Locking 2Not Used 3 0701617 48 Bolt M16 x 45mm (12 Per Wheel) 4 4892000 48 Flatwasher 5/8in Hardened (12 Per Wheel)

0272258 Ref. HUB AND MOTOR ASSEMBLY (PRIOR TO S/N 0300079667) B

Ref. Note: Original Equipment hub may have been replaced with

Service Replacement. Refer to tag on hub for identification before ordering parts.

101 Use 2780283 4 Drive Hub Assembly (Was p/n 2780248 - See Figure 1-4 for

Breakdown. See Figure 1-7 for replacement components for Service Replacement p/n 2780283.)

102 3160291 4 Drive Motor Assembly (See Figure 1-5 for Breakdown)

131 Ref. HUB AND MOTOR ASSEMBLY (S/N 0300079667 TO

S/N 0300103907)

Ref. Note: For Machines Built S/N 0300079596 to S/N 0300083552,

Original Equipment may have been replaced with Service Replacement. Refer to tag on hub for identification before ordering parts.

Use 2780284 4 S/N 0300079667 to S/N 0300083556 (Was p/n 2780279 -

See Figure 1-6 for Breakdown. See Figure 1-7 for replacement components for Service Replacement p/n 2780284.)

2780284 4 S/N 0300083556 to S/N 0300103907 (See Figure 1-7 for

Breakdown)

Ref. HUB AND MOTOR ASSEMBLY (S/N 0300103907 TO PRESENT) 2780286 Ref. With Bonfiglioli Drive Hub

1001104315 Ref. With Reggiana Riduttori Drive Hub

151 4 Drive Hub Assembly Options:

Ref. Note: Various brands used on Machines Built S/N 0300103907

to Present. When replacing complete hub, note that all 4 hubs must be the same brand.

Ref. Note: Various brands used on Machines Built S/N 0300103907

to Present. Identify brand before ordering replacement parts.

Use 1001093243 Bonfiglioli Hub (was p/n 2780290) (See Figure 1-8 for

Breakdown)

1001104325 Reggiana Riduttori Hub (See Figure 1-9 for Breakdown)

152 3160339 4 Drive Motor Assembly (See Figure 1-10 for Breakdown)

3121172 1250AJP 1-11

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. TIRE AND WHEEL INSTALLATIONS

0271852 Ref. Foam-Filled Tires B

1001115961 Ref. Solid Tires A

Ref. Note: Assemblies may require ballast/foam filling to manu-

facturer’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.

201 2 Right Side Tire & Wheel Assembly Options:

0272055 Foam-Filled Tire and Wheel Assembly

1001112716 Solid Tire and Wheel Assembly

202 2 Left Side Tire & Wheel Assembly Options:

0272056 Foam-Filled Tire and Wheel Assembly

1001112669 Solid Tire and Wheel Assembly 203 0701619 64 Bolt M16 x 55mm (16 Per Wheel) 204 4892000 64 Flatwasher 5/8in Hardened (16 Per Wheel)

1-12 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121172 1250AJP 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667)

1-14 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780248 Ref. DRIVE HUB ASSEMBLY C

Ref. Note: Unless there is capability to torque shaft (item 4) to 626

ft/lbs. (850Nm) Repair beyond this level is NOT advised.

Ref. Note: Original Equipment p/n 2780248 hub may have been

replaced with Service Replacement p/n 2780283. - See Figure 1-7 for Breakdown. Refer to tag on hub for identification before ordering parts.

1 Use Item 252 4 Gear, Planet 2 Use Item 252 3 Gear, Planet 3 7022535 1 Gear, Sun 4 Use Item 252 1 Nut, Shaft 5 7021388 3 Pin, Planet 6Not Used 7 7022537 1 Carrier, Planet 8 7022538 1 Cover

9 7024967 1 Button, Thrust 10 Use Item 252 3 Bearing, Roller 11 Use Item 252 4 Bearing, Roller 12 Use Item 252 1 Bearing, Ball 13 Use Item 252 2 Bolt, Hex 14 Use Item 252 3 Ring, Retaining 15 Use Item 252 4 Ring, Retaining 16 7022546 1 Ring, Retaining 17 Use Item 252 3 Ring, Stay 18 Not Used 19 7024966 1 O-Ring 20 7024968 1 Seal, Face 21 7022550 2 Plug 22 Use Item 252 2 Seal, Ring 23 Use Item 252 2 Bolt 24 Not Available 2 Ball

25 to 26 Not Used

27 Not Available 2 Bolt 28 Not Available 2 Washer 29 Not Used 30 7022556 1 Gear, Ring

31 to 32 Not Used

33 Use Item 252 1 O-Ring

34 to 39 Not Used

40 Use Item 252 3 Gear, Planet 41 7022559 1 Carrier, Planet 42 7022560 1 Gear, Sun 43 Use Item 252 1 Gear, Sun 44 Use Item 252 1 Shaft, Input 45 7011326 3 Pin, Planet 46 Use Item 252 3 Bearing, Roller 47 7022564 1 Ring, Retaining 48 Use Item 252 3 Ring, Retaining 49 Not Used

3121172 1250AJP 1-15

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

50 Use Item 252 3 Ring, Stay 51 7022567 1 Cover 52 7022568 1 Thrustwasher 53 Use Item 252 2 Bolt 54 Use Item 252 1 O-Ring 55 Use Item 252 1 Spring, Pressure

56 to 59 Not Used

60 7022572 1 Spindle 61 7022573 1 Piston 62 7022574 1 Coupler 63 7022575 1 Ring, Locator 64 7021354 1 Plate, Back-up 65 7022576 1 Plate, Back-up 66 7022577 1 Ring, Retaining 67 7022578 1 Ring, Retaining 68 7022509 1 Ring, Retaining 69 7022579 2 Bolt

70 to 71 Not Used

72 Use Item 252 4 Disc, Brake 73 Use Item 252 5 Disc, Brake 74 Use Item 252 16 Spring 75 Use Item 251 2 Ring, Back-up 76 Use Item 251 1 Seal 77 Use Item 251 2 Ring, Back-up 78 Use Item 251 1 Seal

79 to 86 Not Used

87 7024032 1 O-Ring

88 to 119 Not Used

120 See Note 1 Motor Assembly (Note: See Separate Parts List) 121 7024031 1 O-Ring (Not Shown)

122 to 223 Not Used

224 7024969 2 Pin, Slotted (Not Shown)

225 to 250 Not Used

— — — — — — — — — — 251 7022581 1 Kit 1 - Brake Seal Kit (Includes Items 75-78) 252 7022580 1 Kit 2 - Brake Disc Kit (Includes Items 72-74)

7022536 1 Kit 3 - Bearing Kit (Includes Items 4, 12, 23 & 53) 7024030 1 Kit 4 - Planet Gear & Bearing Kit (Includes Items 40, 46, 48 &

50) 7024029 1 Kit 5 - Planet Gear & Bearing Kit (Includes Items 2, 10, 14 & 17) 7024028 1 Kit 6 - Planet Gear & Bearing Kit (Includes Items 1, 11 & 15) 7022540 1 Kit 7 - Mechanical Disconnect Kit (Includes Items 13, 22, 33, 43,

44, 54 & 55)

1-16 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (PRIOR TO S/N 0300079667) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121172 1250AJP 1-17

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (PRIOR TO S/N 0300079667)

1-18 1250AJP 3121172

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (PRIOR TO S/N 0300079667)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160291 Ref. DRIVE MOTOR ASSEMBLY C

1 7012716 1 Rotary Group Assembly 2 Not Available 1 Piston, Control 3 Not Available 1 Rod, Piston 4Not Used 5 Not Available 1 Housing 6 Not Available 1 Plate, Port 7 7024036 1 Plate, Swash 8 7024037 1 Driveshaft 9 Not Available 1 Plug, Screw

10 to 11 Not Used

12 7012704 1 Shim 13 Not Available 1 Stop Screw 14 Not Used 15 7024038 1 Bearing 16 7012706 1 Bearing 17 7024039 2 Shell, Cradle

18 to 19 Not Used

20 Use Item 51 1 Seal, Shaft 21 Use Item 51 1 O-Ring 22 Use Item 51 1 O-Ring 23 Use Item 51 2 O-Ring 24 Use Item 51 1 Seal 25 7012715 1 V-Ring 26 Not Used 27 7024040 4 Screw, Sockethead M12 x 60 28 Not Used 29 Not Available 1 Ring, Stop 30 Not Available 1 Plug

31to 32 Not Used

33 Not Available 1 Pin, Dowel 34 Not Used 35 Not Available 1 Nut M10 36 Not Available 1 Nut, Cap M10 37 Use Item 51 1 Plug 38 7024041 1 Orifice 39 Use Item 51 1 O-Ring

40 to 50 Not Used

51 7024034 1 Seal Kit (Includes Items 20-24, 37 & 39)

3121172 1250AJP 1-19

SECTION 1 FRAME

88 68 66 64 75 78 79 62 77

76747328292

521215361441514749461518115352105554454456484317223423942

318

6763696

2013242161

7978 78 76

FIGURE 1-6. HUB AND MOTOR ASSEMBLY (S/N 0300079667 TO S/N 0300083556)

1-20 1250AJP 3121172

SECTION 1 FRAME

3121172 1250AJP 1-21

SECTION 1 FRAME

FIGURE 1-6. HUB AND MOTOR ASSEMBLY (S/N 0300079667 TO S/N 0300083556)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780279 Ref. DRIVE HUB AND MOTOR ASSEMBLY B

Ref. Note: For Machines Built S/N 0300079667 to S/N 0300083556,

Original Equipment p/n 2780279 may have been replaced with Service Replacement p/n 2780284 - See Figure 1-7 for Breakdown. Refer to tag on hub for identification before ordering parts.

Ref. Note: Unless there is capability to torque shaft (item 5) to 626

ft/lbs. (850Nm) Repair beyond this level is NOT advised.

1 2780248 1 Hub, Torque 2 Use Item 98 4 Gear, Planet 3 Use Item 98 3 Gear, Planet 4 7022535 1 Gear, Sun 5 Use Item 98 1 Nut, Shaft 6 7021388 3 Pin, Planet 7 Not Used 8 7022537 1 Carrier, Planet

9 7022538 1 Cover 10 7024967 1 Button, Thrust 11 Use Item 98 3 Bearing, Roller 12 Use Item 98 4 Bearing, Roller 13 Use Item 98 1 Bearing, Ball 14 Use Item 98 2 Bolt, Hex 15 Use Item 98 3 Ring, Retaining 16 Use Item 98 4 Ring, Retaining 17 7022546 1 Ring, Retaining 18 Use Item 98 3 Ring, Stay 19 Not Used 20 7024966 1 O-Ring 21 7024968 1 Seal, Face 22 7022550 2 Plug 23 Use Item 98 2 Seal, Ring 24 Use Item 98 2 Bolt 25 Not Available 2 Ball

26 to 27 Not Used

28 Not Available 2 Bolt 29 Not Available 2 Washer 30 Not Used 31 7022556 1 Gear, Ring

32 to 33 Not Used

34 Use Item 98 1 O-Ring

35 to 40 Not Used

41 Use Item 98 3 Gear, Planet 42 7022559 1 Carrier, Planet 43 7022560 1 Gear, Sun 44 Use Item 98 1 Gear, Sun 45 Use Item 98 1 Shaft, Input 46 7011326 3 Pin, Planet 47 Use Item 98 3 Bearing, Roller 48 7022564 1 Ring, Retaining

1-22 1250AJP 3121172

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