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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
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
A
A
1
10
1
2
10
8
7
6
9
2
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.
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
3121620 1850SJ i
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
5
1
13
26
20
12
12
9
4
4
8
8
14
10
10
15
23
23
25
1
25
1
24
17
7
2
6
11
3
16
19
18
22
21

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
6
11
26
9
2
20
1
29
1 5
8
1726252424
12
1
14
7
7
36361031911832128353430
22
31
4
131627
382713
23
23
16
4
37
33
33
32
32
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
3
5
5
5
4
4
4
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
RH
1001157849 Ref HUB/MOTOR ASSEMBLY WITH FITTINGS - FRONT RH & REAR
LH
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)
D
D
3121620 1850SJ 1-7
SECTION 1 FRAME
1
2
3
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
18
19
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
34
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
46
45
37
36
343530
29
27
28
17
16
1514131211181087619432
5
19
20
21
24
23
22
26
313233
33
25
42
39
39
41
40
38
49
55
545352
50
51
47
48
49
48
56
43
44
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
1
2
101
102
103
3

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
31
5
5
5
19
19
19
15
2
26
26
22
21
21
10
1 6
1 7
20
29
31
31
19
35
5
5

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
14
9
104 105
104 105
2
13
1
13
102
102
106
103
3
102
102
4
1001157198
7
10
102
12
15
6
8
102
102
106
102
11
101
5
16

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
4
8
11
11
11
104
104
104
104
104
104
104
104
102
103
105
105
10
11
11
11
5
7
9
101
1
2
3
1001157207

FIGURE 1-9. STEER/AXLE EXTEND VALVE ASSEMBLY

1-20 1850SJ 3121620
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