JLG 1850SJ Parts Manual

Illustrated Parts Manual

Model

1850SJ

3121620

March 31, 2014

REVISION LOG

March 31, 2014 - Original Issue of Manual (Edited to B/M 1001154100 Revision E)

3121620 1850SJ A

REVISION LOG

B 1850SJ 3121620

GENERAL INFORMATION

Manual # Model Designation PG#

SECTION 6 CYLINDER

FIGURE 6-3. LIFT CYLINDER ASSEMBLY

PG# Model Designation Manual #

SECTION 6 CYLINDER

FIGURE 6-3. LIFT CYLINDER ASSEMBLY

1) MACHINE IDENTIFICATION

Machines are identified by model & in some cases a combination of model, serial number (SN) or regional standard (i.e. ANSI CE, CSA). Components may also be identified by SN or manufacturer. Common components that may be identified by these characteristics are engines & hydraulic components.

2) PARTS MANUAL ORGANIZATION

Product information in this manual is organized under section titles. Frame, Cylinder, Hydraulic & Electrical are a few examples. Each section is organized by figure & page number. The information within the Figure is then organized by item number, part number, description & corresponding illustration(s).

3) TABLE OF CONTENTS

A table of contents is found toward the beginning of the manual. Figure number, description & page number are provided for quick reference to the page containing the related information.

4) RECOMMENDED SPARE PARTS

The Recommended Spare Parts, located near the end of the manual, references most frequently used maintenance parts.

5) PART NUMBER INDEX

A numerical index listing all part numbers & the corresponding page number(s) appears at the back of the manual.

3121620 1850SJ i

GENERAL INFORMATION

6) NON-SERVICED PARTS

In some instances, it is necessary to display non-serviced parts, assemblies or installations. In the case of assemblies & installations there will be a Ref in the Qty column. In the case of parts that are not available for service within assemblies or components, there will be a NSS (Not Sold Separately) or NLA (No Longer Available) listed in the Qty column of the manual.

7) PARTS LIST ITEM NUMBERS

Numbers shown in the Item# column correspond to numbers used in the associated illustration(s). Item numbers which are missing from the sequence in the parts list are not used on that page.

8) INDENTED PART DESCRIPTION

An indented part description is included in the item under which it is indented.

9) ABBREVIATIONS & SYMBOLS

AC.............................................. Alternating Current

ADE............................Advanced Design Electronics

ANSI.............American National Standards Institute

AR.........................................................As Required

ASSY.........................................................Assembly

AUX.............................................................Auxiliary

AWG......................................American Wire Gauge

B/M.....................................................Bill of Material

CE...........................................European Conformity

CCW............................................Counter Clockwise

cm............................................................Centimeter

CW............................................................Clockwise

CSA.......................Canadian Standards Association

CYL..............................................................Cylinder

DIA..............................................................Diameter

DC.......................................................Direct Current

EMS................................................Emergency Stop

ENG...............................................................Engine

FT(ft)..................................................................Feet

GA(Ga)...........................................................Gauge

HYD............................................................Hydraulic

Hz.....................................................................Hertz

ID......................................................Inside Diameter

in.....................................................................inches

ISO............International Organization for Standards

JIC..........................................Joint Industry Council

KG...............................................................Kilogram

L.........................................................................Liter

LB..................................................................Pounds

LCD.........................................Liquid Crystal Display

LED.........................................Light Emitting Diodes

LH..............................................................Left Hand

LSS........................................Load Sensing System

M(m).....................................................Metric/Meter

MM (mm)....................................................Milimeter

mA...............................................................Miliamps

NLA...........................................No Longer Available

NPT........................................National Pipe Threads

NSS...........................................Not Sold Separately

OD.................................................Outside Diameter

ORB......................................................O-Ring Boss

ORFS............................................O-Ring Face Seal

OZ (oz)..........................................................Ounces

PG.....................................................................Page

P/N........................................................Part Number

qt....................................................................Quarts

QTY..............................................................Quantity

REF...........................................................Reference

REV....................................................Revision Level

RH...........................................................Right Hand

SAE.......................Society of Automotive Engineers

SN......................................................Serial Number

SPEC(S).............................................Specifications

T/T..............................................................Turntable

UGM.................................Universal Ground Module

V........................................................................Volts

W......................................................................Watts

#...................................................................Number

10) ILLUSTRATION REFERENCE LETTERS

When necessary, illustrations may contain reference letters that are intended to track information (i. e. hoses, harnesses) from one point to another or to track visual enlargement of components to show details that may be located in another area on the illustration.

Note: Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

ii 1850SJ 3121620

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 AXLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 WHEEL DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-5 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-6 TIRE/WHEEL INSTALLATION - IN445/50D710 FOAM-FILLED . . . . . . . . . . . . . . . . . 1-14

1-7 VALVES INSTALLATION - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-8 TRACTION VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-9 STEER/AXLE EXTEND VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-10 ELECTRICAL COMPONENTS INSTALLATION - FRAME. . . . . . . . . . . . . . . . . . . . . . 1-22

1-11 COVERS INSTALLATION - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

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

2-1 VALVES & HYDRAULIC FILTERS INSTALLATION - TURNTABLE . . . . . . . . . . . . . . 2-2

2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 TURNTABLE BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 TURNTABLE LOCK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-6 SWING HUB/BRAKE/ Motor ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-7 COUPLING/COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-8 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-9 HYDRAULIC TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-10 AUXILIARY POWER/BATTERIES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-11 AUXILIARY PUMP AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-12 TURNTABLE ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . 2-28

2-13 GROUND CONTROL CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2-14 KEY SWITCH - ANSI, ANSI EXPORT, AUSTRALIAN AND CSA SPECs . . . . . . . . . . 2-34

2-15 KEY SWITCH - CE SPECs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2-16 LIGHT PANEL - ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS . . . . . . . . . . . 2-38

2-17 LIGHT PANEL - AUSTRALIAN & CE SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-18 ELECTRICAL PANEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2-19 ALARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2-20 BEACON LIGHT INSTALLATION - OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-21 HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2-22 VENTURI INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

SECTION 3 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 DEUTZ LRC ENGINE INSTALLATION - NO COLD WEATHER PKG . . . . . . . . . . . . . 3-2

3-2 DEUTZ LRC ENGINE/PUMP ASSEMBLY - NO COLD WEATHER PKG . . . . . . . . . . 3-6

3-3 DEUTZ LRC ENGINE ASSEMBLY - NO COLD WEATHER PKG . . . . . . . . . . . . . . . . 3-8

3-4 DEUTZ LRC ENGINE INSTALLATION - WITH COLD WEATHER PKG . . . . . . . . . . . 3-14

3-5 DEUTZ LRC ENGINE/PUMP ASSEMBLY - WITH COLD WEATHER PKG . . . . . . . . 3-18

3-6 DEUTZ LRC ENGINE ASSEMBLY - WITH COLD WEATHER PKG . . . . . . . . . . . . . . 3-20

3-7 DEUTZ LRC ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-8 DEUTZ T4i ENGINE INSTALLATION - NO COLD WEATHER PKG . . . . . . . . . . . . . . 3-30

3-9 DEUTZ T4i ENGINE/PUMP ASSEMBLY - NO COLD WEATHER PKG . . . . . . . . . . . 3-34

3-10 DEUTZ T4i ENGINE ASSEMBLY - NO COLD WEATHER PKG . . . . . . . . . . . . . . . . . 3-36

3-11 DEUTZ T4i ENGINE INSTALLATION - WITH COLD WEATHER PKG . . . . . . . . . . . . 3-42

3-12 DEUTZ T4i ENGINE/PUMP ASSEMBLY - WITH COLD WEATHER PKG . . . . . . . . . 3-46

3-13 DEUTZ T4i ENGINE ASSEMBLY - WITH COLD WEATHER PKG . . . . . . . . . . . . . . . 3-48

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

3-14 DEUTZ T4i ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

3-15 PUMP COUPLING KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60

3-16 TANDEM PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62

3-17 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66

3-18 GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

3-19 SPARK ARRESTOR INSTALLATION - DEUTZ LRC (OPTIONAL) . . . . . . . . . . . . . .3-72

3-20 SPARK ARRESTOR INSTALLATION - DEUTZ T4i (OPTIONAL) . . . . . . . . . . . . . . .3-74

SECTION 4 - BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-3 JIB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-4 JIB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-5 PLATFORM ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-6 JIB ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-7 PLATFORM SUPPORT INSTALLATION - NO LSS . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-8 PLATFORM SUPPORT INSTALLATION - WITH LSS . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-9 POWER TRACK INSTALLATION - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

4-10 VALVES INSTALLATION - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

4-11 JIB VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

4-12 PLATFORM VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

4-13 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4-38

4-14 BOOM CABLES - ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS . . . . . . . . . .4-44

4-15 Boom CABLES (AUSTRALIAN AND CE SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

4-16 BOOM CABLES - SKYPOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

4-17 JIB ENCLOSURE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50

SECTION 5 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 PLATFORM ASSEMBLY - SIDE GATE ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 PLATFORM ASSEMBLY - DROP BAR ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-3 PLATFORM ASSEMBLY - FALL ARREST - ANSI SPEC . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4 PLATFORM ASSEMBLY - FALL ARREST - AUSTRALIAN AND CE SPECS . . . . . . .5-8

5-5 TRAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6 LCD DISPLAY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 PLATFORM CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-8 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-9 DECAL AND LIGHT PANEL - ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS .5-20

5-10 DECAL AND LIGHT PANEL - AUSTRALIAN AND CE SPECS . . . . . . . . . . . . . . . . . .5-22

5-11 LIFT AND SWING CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-12 DRIVE AND STEER CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

5-13 FOOTSWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

SECTION 6 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 AXLE EXTEND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 BOOM TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4 JIB LEVEL (SLAVE) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-5 JIB LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-6 JIB LOCK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-7 JIB TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-8 PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .6-16

ii 1850SJ 3121620

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

6-9 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

SECTION 7 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 BOOM AND JIB HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 CHASSIS HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 TURNTABLE HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-4 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

SECTION 8 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 AXLE SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3 CHASSIS HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-4 COUPLING/COLLECTOR RING HARNESS & COMPONENTS . . . . . . . . . . . . . . . . . 8-12

8-5 DRIVE PUMP HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-6 TURNTABLE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-7 GROUND CONTROL PANEL HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8-8 VALVE BANK HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

8-9 BLAM HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

8-10 FUEL PUMP & WIF HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

8-11 BATTERY CABLE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

8-12 TILT SENSOR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

8-13 MTS CONNECTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

8-14 LOAD SENSOR CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

8-15 ALARM HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

8-16 BEACON LIGHT (AMBER) HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

8-17 ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

8-18 ENGINE CAN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62

8-19 PROXIMITY SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 8-64

8-20 PROXIMITY SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 8-66

8-21 ANGLE SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

8-22 SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

8-23 BOOM LENGTH SENSOR HARNESS AND COMPONENTS . . . . . . . . . . . . . . . . . . 8-72

8-24 BOOM SENSOR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74

8-25 BOOM HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76

8-26 TRANSPORT SWITCH HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78

8-27 PLATFORM VALVE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80

8-28 MAIN BOOM CONTROL CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84

8-29 JIB CONTROL CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86

8-30 MAIN BOOM 16/4 CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88

8-31 BOOM AC CABLE - ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS . . . . . . . 8-90

8-32 BOOM AC CABLE - AUSTRALIAN & CE SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92

8-33 JIB AC CABLE - ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS . . . . . . . . . . 8-94

8-34 JIB AC CABLE - AUSTRALIAN AND CE SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96

8-35 BOOM AC CABLE - SKYPOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98

8-36 JIB AC CABLE - SKYPOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

8-37 JIB VALVE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102

8-38 LCD DISPLAY HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108

8-39 PLATFORM CONSOLE Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110

8-40 RECEPTACLE & CLAMP INSTALLATION - SUPPLIED LOCALLY . . . . . . . . . . . . . 8-120

8-41 RECEPTACLE & CLAMP INSTALLATION - 110V - ANSI SPEC . . . . . . . . . . . . . . . . 8-122

8-42 RECEPTACLE & CLAMP INSTALLATION - 220V - ANSI SPEC . . . . . . . . . . . . . . . . 8-124

3121620 1850SJ iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

8-43 BREAKER BOX ASSEMBLY - CE SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-126

8-44 KIT - BREAKER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-128

SECTION 9 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

9-1 DECAL INSTALLATION - ANSI SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

9-2 DECAL INSTALLATION - ANSI EXPORT SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

9-3 DECAL INSTALLATION - AUSTRALIAN SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

9-4 DECAL INSTALLATION - BRAZIL SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

9-5 DECAL INSTALLATION - CE SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16

9-6 DECAL INSTALLATION - CHINESE SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18

9-7 DECAL INSTALLATION - CSA SPEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22

9-8 DECAL INSTALLATION - JAPANESE SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26

9-9 DECAL INSTALLATION - KOREAN SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30

9-10 DECAL INSTALLATION - OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 11 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

SECTION 12 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

iv 1850SJ 3121620

SECTION 1

FRAME

3121620 1850SJ 1-1

SECTION 1 FRAME

1001156464

FIGURE 1-1. AXLES INSTALLATION

1-2 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-1. AXLES INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001156464 Ref AXLES INSTALLATION D

1 0100011 AR Compound, Locking 2 0100071 AR Compound, Locking 3 0440273 8 Bushing 4 0701420001 8 Bolt M14 x 60 5 0761015001 8 Bolt M10 x 35 6 0762418001 8 Bolt M24 x 50 7 3020039 AR Lubricant 8 3291407001 8 Nut M14

9 3422912 4 Pin 10 3841258 8 Keeper, Pin 11 3841356 4 Keeper, Pin 12 4740229 8 Washer, Thrust 13 1001172358 8 Washer M10 14 4812200001 8 Washer M14 15 1001120000 4 Pin 16 1001155133 4 Washer, Thrust 17 1001155363 4 Pin 18 1001155619 1 Axle - Front RH 19 1001155690 1 Axle - Front LH 20 1001156648 4 Axle Extend Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 21 1001156862 1 Axle - Rear RH 22 1001156863 1 Axle - Rear LH 23 1001157007 8 Sleeve 24 1001157084 4 Sensor Assembly (See ELECTRICAL SECTION for Breakdown) 25 1001157466 8 Bolt M10 x 30 26 1001158017 AR Shim

3121620 1850SJ 1-3

SECTION 1 FRAME

1 5

1726252424

36361031911832128353430

131627

382713

1001156606

FIGURE 1-2. STEERING INSTALLATION

1-4 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-2. STEERING INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001156606 Ref STEERING INSTALLATION D

1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 3 0100035 AR Compound, Locking 4 0701422001 8 Bolt M14 x 70 5 0760808001 4 Bolt M8 x 16 6 0760815001 4 Bolt M8 x 35 7 0962423 8 Bushing 8 1120549 4 Cap

9 1671040 4 Cover 10 2080091 4 Screw M4 x 16 11 3290805001 4 Nut M8 12 3300464001 4 Nut 13 3291214001 8 Nut M14 14 3451214 4 Pin, Cotter 15 3760383 4 Ring 16 3841258 8 Keeper, Pin 17 3960551 4 Seal 18 4031512 8 Capscrew M4 x 40 19 4031707 16 Capscrew M6 x 16 20 4032311001 8 Capscrew M16 x 35 21 4460914 4 Base, Terminal 22 4711800 4 Washer 1/2 23 4740229 8 Washer, Thrust 24 4740505 8 Washer, Thrust 25 4755000001 AR Washer 2-1/2 26 4811900001 12 Washer M8 27 4812200001 8 Washer M14 28 1001146963 4 Sensor Assembly (See ELECTRICAL SECTION for Breakdown) 29 1001174345 4 Screw M20 x 20 30 1001155836 4 Adapter 31 1001155986 4 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 32 1001156678 2 Spindle - Front LH & Rear RH 33 1001156679 2 Spindle - Front RH & Rear LH 34 1001156778 4 Pin 35 1001156785 4 Link 36 1001156815 4 Kingpin 37 1001156991 4 Pin 38 1001156996 4 Pin 39 1001155817 4 Harness, Steer (See ELECTRICAL SECTION for Breakdown)

3121620 1850SJ 1-5

SECTION 1 FRAME

1 2

201 202

206

207

205

204

101

105

106

104

103

102

1001157850

FIGURE 1-3. WHEEL DRIVE INSTALLATION

1-6 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157850 Ref WHEEL DRIVE INSTALLATION D

1 0100019 AR Compound, Locking 2 0762018001 64 Bolt M20 x 50 3 5242000001 64 Washer M20 4 1001154759 2 Drive Hub/Motor with Fittings - Front LH & Rear RH (See Items

101-106 for Breakdown)

5 1001157849 2 Drive Hub/Motor with Fittings - Front RH & Rear LH (See Items

101-106 for Breakdown)

1001154759 Ref HUB/MOTOR ASSEMBLY WITH FITTINGS - FRONT LH & REAR

1001157849 Ref HUB/MOTOR ASSEMBLY WITH FITTINGS - FRONT RH & REAR

101 2110808 1 Fitting, Straight ORFS/ORB 102 2220415 1 Fitting, Straight JIC/ORB 103 2220472 1 Fitting, 90 JIC/ORB 104 2111012 1 Fitting, Straight ORFS/ORB 104 2131012 1 Fitting, 90 ORFS/ORB 105 2111012 1 Fitting, Straight ORFS/ORB 105 2131012 1 Fitting, 90 ORFS/ORB 106 1001154772 1 Drive Hub/Motor (See Items 201-207 for Breakdown)

1001154772 Ref DRIVE HUB/MOTOR ASSEMBLY B

201 0100011 AR Compound, Locking 202 0761214 2 Bolt M12 x 30 203 3020008 2.6qt/2.5L Lube, Gear (Not Shown) 204 3160339 1 Motor - Drive (See DRIVE MOTOR ASSEMBLY for Breakdown) 205 3790158 1 O-Ring 206 5241200 2 Washer M12 207 1001149921 1 Hub - Drive (See DRIVE HUB ASSEMBLY for Breakdown)

3121620 1850SJ 1-7

SECTION 1 FRAME

51 52

3160339

FIGURE 1-4. DRIVE MOTOR ASSEMBLY

1-8 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-4. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160339 Ref DRIVE MOTOR ASSEMBLY B

1 7022368 4 Bolt 2 70000859 1 End Cap, Motor 3 70003628 2 Locating Pin 4 See Note 1 O-Ring (Note: Use p/n 70000862) 5 7007420 1 Plug (Includes Item 4) 6 7007446 1 Pin, Dowel 7 7021249 1 Bearing, Needle 8 70000854 1 Plate, Valve

9 7022311 1 Snap Ring 10 7022314 1 Retainer, Spring 11 7024867 1 Spring 12 7024868 1 Washer (was p/n 7022313) 13 70000855 1 Block, Cylinder 14 7021275 3 Pin, Slipper 15 70000856 1 Guide 16 70000857 1 Retainer, Slipper 17 7024865 9 Piston, Cylinder 18 See Note 1 Ring, Piston (Note: Use p/n 70000862) 19 See Note 1 O-Ring (Note: Use p/n 70000862) 20 70000860 1 Piston, Servo (Includes Items 18 & 19) 21 70000861 1 Spring 22 See Note 1 Pin (Note: Not Available for Purchase) 23 70000853 1 Swashplate 24 70000852 1 Kit, Bearing 25 See Note 1 Gasket (Note: Use p/n 70000862) 26 See Note 1 Plug (Note: Not Available for Purchase) 27 See Note 1 O-Ring (Note: Use p/n 70000862) 28 7022321 1 Plug (Includes Item 29) 29 See Note 1 O-Ring (Note: Use p/n 70000862) 30 See Note 1 Housing (Note: Not Available - Purchase Complete Motor) 31 70000858 1 Shaft 32 7007437 1 Bearing 33 7007439 1 Snap Ring 34 7007438 2 Snap Ring 35 See Note 1 Seal (Note: Use p/n 70000862) 36 7022371 1 Washer, Seal Support 51 70000862 1 Kit, Motor Seal (Includes Items 4,18,19,25,27,29 & 35) 52 7027740 1 Kit, Cylinder Block (Includes Items 9 - 17)

3121620 1850SJ 1-9

SECTION 1 FRAME

343530

1514131211181087619432

313233

545352

101 102

100

1001149921

FIGURE 1-5. DRIVE HUB ASSEMBLY

1-10 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001149921 Ref DRIVE HUB ASSEMBLY F

1 70004429 1 Ring

2 See Note 2 Screw M6x20 (Note: Use p/n 70004452)

3 See Note 1 Cover (Note: Use p/n 70004452)

4 See Note 1 Gasket (Note: Use p/n 70004452 or 70004451)

5 See Note 2 Plug (Includes O-Ring) (Note: Use p/n 70004452)

6 See Note 1 Cover (Note: Use p/n 70004452)

7 See Note 1 O-Ring (Note: Use p/n 70004452 or 70004451)

8 See Note 1 Shim (Note: Use p/n 70004452)

9 See Note 1 Pin (Note: Use p/n 70004452) 10 See Note 1 O-Ring (Note: Use p/n 70004452 or 70004451) 11 70004430 1 Pinion 12 70004431 1 Ring, Retaining 13 70004432 1 Assembly, Gear Reduction 14 70004433 1 Pinion 15 70004434 1 Ring 16 70004435 1 Assembly, Gear Reduction 17 70004436 1 Pinion 18 NSS Housing, Hub 19 70002052 2 Screw M10 x 25 20 70004437 6 Screw M6 x 14 21 70004437 1 Plug 22 70002032 4 Ring, Retaining 23 70002031 4 Bearing 24 70004439 4 Wheel, Planet 25 70004440 1 Flange 26 See Note 1 O-Ring (Note: Use p/n 70004451) 27 70004441 1 Nut 28 70004363 2 Screw M6 x 10 29 70004442 1 Bearing 30 NSS Support, Hub 31 See Note 1 O-Ring (Note: Use p/n 70004451) 32 70004443 1 Bearing 33 See Note 1 Seal (Note: Use p/n 70004451) 34 70004444 1 Coupling 35 70002036 1 Spring 36 70004445 1 Ring, Retaining 37 70004446 1 Bearing 38 NSS Axle 39 70004447 3 Plug 40 70002057 3 Plug (Includes O-Ring) 41 70002028 1 Plug, Plastic 42 70004448 1 Shaft, Input 43 See Note 9 Disc, Iron (Note: Use p/n 70004453) 44 See Note 8 Disc, Brake (Note: Use p/n 70004453) 45 See Note 1 Spacer (Note: Use p/n 70004453) 46 See Note 1 Seal (Note: Use p/n 70004453 or 70004451) 47 See Note 1 O-Ring (Note: Use p/n 70004453 or 70004451)

3121620 1850SJ 1-11

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

48 See Note 2 Seal (Note: Use p/n 70004453 or 70004451) 49 See Note 2 O-Ring (Note: Use p/n 70004453 or 70004451) 50 See Note 1 Piston, Brake (Note: Use p/n 70004453) 51 See Note 5 Spring, Brake (Note: Use p/n 70004453) 52 See Note 1 Spacer (Note: Use p/n 70004453) 53 See Note 1 Ring, Retaining (Note: Use p/n 70004453) 54 See Note 1 O-Ring (Note: Use p/n 70004451) 55 70004449 1 Support, Motor

56 70004450 6 Screw M8 x 25 100 70004451 1 Kit, Seal (Includes Items 4, 7, 10, 26, 31, 33, 46-49 & 54) 101 70004452 1 Kit, Cover (Includes Items 2-10) 102 70004453 1 Kit, Brake (Includes Items 43-53)

1-12 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121620 1850SJ 1-13

SECTION 1 FRAME

1001157216

101

102

103

FIGURE 1-6. TIRE/WHEEL INSTALLATION - IN445/50D710 FOAM-FILLED

1-14 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-6. TIRE/WHEEL INSTALLATION - IN445/50D710 FOAM-FILLED

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157216 Ref TIRE/WHEEL INSTALLATION - IN445/50D710FOAM-FILLED B

Ref Note: Requires ballast/foam filling to manufacturer’s

specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete.

1 0701619001 80 Bolt M16 x 55 (20 Per Wheel) 2 1001172356 80 Washer 5/8 (20 Per Wheel) 3 1001147616 2 Tire/Wheel (RH Side) (See Items 101-103 for Breakdown) 3 1001149711 2 Tire/Wheel (LH Side) (See Items 101-103 for Breakdown)

1001147616 Ref TIRE/WHEEL ASSEMBLY (RH SIDE) D 1001149711 Ref TIRE/WHEEL ASSEMBLY (LH SIDE) D

101 1001147617 4 Wheel (1 per Tire/Wheel) 102 1001147618 4 Tire (1 per Tire/Wheel) 103 1001157467 4 Valve (1 per Tire/Wheel)

3121620 1850SJ 1-15

SECTION 1 FRAME

1001157706_PG 1 OF 3

1 6

1 7

FIGURE 1-7. VALVES INSTALLATION - FRAME

1-16 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-7. VALVES INSTALLATION - FRAME

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157706 Ref VALVES - FRAME G

1 0100011 AR Compound, Locking 2 0641422 2 Bolt 1/4 x 2-3/4 5 0760812 8 Bolt M8 x 25 6 0761012 4 Bolt M10 x 25

7 0761218001 4 Bolt M12 x 50 10 3291205001 4 Nut M12 11 3311405 4 Nut 1/4 15 4641155 1 Manifold, Junction 16 4711400 4 Washer 1/4 19 4811900001 8 Washer M8 20 4812000 4 Washer M10 21 4812100001 4 Washer M12 29 1001164354 1 Bracket 30 1001157198 1 Valve, Traction (See TRACTION VALVE ASSEMBLY for

Breakdown)

31 1001157207 2 Valve, Steer/Axle Extend (See STEER/AXLE EXTEND VALVE

ASSEMBLY for Breakdown)

35 1001118274 8 Nut M8

3121620 1850SJ 1-17

SECTION 1 FRAME

104 105

102

106

103

102

1001157198

102

106

102

101

FIGURE 1-8. TRACTION VALVE ASSEMBLY

1-18 1850SJ 3121620

SECTION 1 FRAME

FIGURE 1-8. TRACTION VALVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157198 Ref TRACTION VALVE ASSEMBLY E

1 7012941 1 Cartridge, Solenoid Less Coil

1 7010543 1 Kit, Seal

2 7012941 1 Cartridge, Solenoid Less Coil

2 7010543 1 Kit, Seal

3 70004383 1 Cartridge, Relief

3 7012998 1 Kit, Seal

4 70004384 1 Cartridge, Load Shuttle

4 7012973 1 Kit, Seal

5 70004385 1 Cartridge

5 70002978 1 Kit, Seal

6 70004017 1 Cartridge, Flow Divider

6 7021625 1 Kit, Seal

7 70004017 1 Cartridge, Flow Divider

7 7021625 1 Kit, Seal

8 70003408 1 Cartridge, Check

8 7022399 1 Kit, Seal

9 70003408 1 Cartridge, Check

9 7022399 1 Kit, Seal 10 70003408 1 Cartridge, Check 10 7022399 1 Kit, Seal 11 70003408 1 Cartridge, Check 11 7022399 1 Kit, Seal 12 70000803 1 Cartridge, Pressure Switch 13 70002386 2 Coil 14 7017493 1 Orifice 15 7017493 1 Orifice 16 70004386 1 Orifice

101 2111016 2 Fitting, Straight ORB/ORFS 102 2111012 10 Fitting, Straight ORB/ORFS 103 2110810 1 Fitting, Straight ORB/ORFS 104 2220415 2 Fitting, Straight JIC/ORB 105 2220861 2 Fitting, Tee JIC/ORB 106 2221086 2 Fitting, Test

3121620 1850SJ 1-19

SECTION 1 FRAME

104

102

103

105

101

1001157207

FIGURE 1-9. STEER/AXLE EXTEND VALVE ASSEMBLY

1-20 1850SJ 3121620

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