JLG 26MRT Parts Manual

Illustrated Parts Manual

Model

26MRT

P/N

3120792

October 17, 2013

REVISION LOG

February 4, 2000 - Original Issue Of Manual (Was part of complete Manual #3123003) (Edited to 0010520 Revision 37)

October 30, 2000 - Revised (Edited to 0010520 Revision 37)

February 25, 2004 - Revised

September 15, 2007 - Revised

June 24, 2011 - Revised

October 17, 2013 - Revised

3120792 A

REVISION LOG

B 3120792

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 FRAME AND STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 REAR DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-3 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-4 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-5 DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-6 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-7 HYDRAULIC DRIVE GENERATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

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

2-1 CONTROL VALVES & TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 CONTROL VALVES ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 VANGUARD GAS ENGINE INSTALLATION (PRIOR TO S/N 48113) . . . . . . . . . . . . . . .2-8

2-4 VANGUARD GAS ENGINE INSTALLATION (S/N 48113 TO PRESENT). . . . . . . . . . . . .2-14

2-5 DUAL FUEL INSTALLATION (VANGUARD MACHINES ONLY) . . . . . . . . . . . . . . . . . . .2-18

2-6 YANMAR DIESEL ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-7 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-8 GEAR PUMP ASSEMBLY (YANMAR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-9 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-10 HOOD INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

SECTION 3 - SCISSOR ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SCISSOR ARMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

4-1 PLATFORM COMPONENTS INSTALLATION - MANUALLY OPERATED

EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 STANDARD HANDRAILS & EXTENSION INSTALLATION (MANUALLY

OPERATED PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 WIDE PLATFORM HANDRAILS & EXTENSION INSTALLATION (MANUALLY

OPERATED PLATFORM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-4 FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY

OPERATED PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-5 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-6 CONTROLLER ASSEMBLY (PRIOR TO S/N 58990) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-7 CONTROLLER ASSEMBLY (S/N 58990 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . .4-24

SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 LIFT CYLINDER COMPONENTS ASSEMBLY (PRIOR TO S/N 26916) . . . . . . . . . . . . .5-2

5-2 LIFT CYLINDER COMPONENTS ASSEMBLY (S/N 26916 TO PRESENT) . . . . . . . . . . .5-6

5-3 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

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

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

6-2 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

3120792 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

7-2 ELECTRICAL SCHEMATIC - VANGUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 ELECTRICAL SCHEMATIC - YANMAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-4 HARNESS AND CABLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

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

8-1 DECALS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

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

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

ii 3120792

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 Frame And Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Rear Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-5 Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-6 Frame Mounted Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-7 Hydraulic Drive Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

E C T

I O N

3120792 1-1

SECTION 1 FRAME

910201201

101

102

105

107

104

204

203205

103

2181616

81113

151

41217

S E C T

I O N

FIGURE 1-1. FRAME AND STEERING INSTALLATION

1-2 3120792

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME WELDMENT OPTIONS: 1 2360388 Prior to S/N 27658 2360413 S/N 27658 to Present

0255118 STEERING & SPINDLES INSTALLATION Ref. 8

1 2780221 Hub Assembly (Includes Items 101-107) 2 2 4130286 Spindle Weldment (Includes Items 201-205) 2 3 3422610 Kingpin 2 4 3450810 Pin, Cotter 1/4” x 2 1/2” 2 5 3313003 Nut, Slotted 1 1/4”-7NC 2 6 0440162 Washer, Thrust 2 7 0642016 Bolt 5/8”-16NC x 2” 2 8 3312005 Locknut 5/8”-16NC 2

9 3841146 Rod-End 2 10 3322002 Nut, Jam 5/8”-16NC 2 11 Steer Cylinder Assembly (See Section 5 For Breakdown)

Options: 1683239 Prior to S/N 46538 1683697 S/N 46538 to Present

12 3340644 Pad, Wear 1 13 0641508 Bolt 5/16”-18NC x 1” 1 14 3311505 Locknut 5/16”-18NC 1 15 4751500 Flatwasher 5/16” 2 16 3020022 Grease A/R 17 4070809 Shim A/R 18 3780182 O-Ring 4 19 Nut, Wheel Options: 10

3300255 Prior to S/N 32539 3300407 S/N 32539 to Present

20 4752200 Flatwasher 3/4” 2

S E

I O N

2780221 HUB ASSEMBLY Ref.

101 7012519 Cup, Bearing - Inner (1 Per Hub) 2 102 7012520 Cone, Bearing - Inner (1 Per Hub) 2 103 7012521 Cup, Bearing - Outer (1 Per Hub) 2 104 7012522 Cone, Bearing - Outer (1 Per Hub) 2 105 7012523 Seal (1 Per Hub) 2 106 7012524 Cap, Dust (1 Per Hub) 2 107 7016360 Stud, Wheel (5 Per Hub) 10

4130286 SPINDLE WELDMENT Ref.

201 0961621 Bushing, Bronze (2 Per Spindle) 4 202 Not Used 203 7012542 Washer (1 Per Spindle) 2 204 7012541 Nut, Slotted (1 Per Spindle) 2 205 7012543 Pin, Cotter (1 Per Spindle) 2

3120792 1-3

⎯

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. REAR DRIVE INSTALLATION

1-4 3120792

SECTION 1 FRAME

FIGURE 1-2. REAR DRIVE INSTALLATION

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

REAR DRIVE AXLE INSTALLATION OPTIONS: Ref. 0255113 Prior to S/N 27815 Ref. E 0256927 S/N 27815 to Present Ref. 3

1 3160202 Drive Motor Assembly (See Figure 1-3 for Break-

down)

2 0920103 Drive Brake Assembly (See Figure 1-4 for Break-

down)

3 1360265 Drive Shaft Assembly 1 3A 7011120 Journal & Bearing Kit 2 3B 7011121 U-Bolt Assembly 1 3C 7011122 Yoke 2 3D 7011123 Yoke, Splined 1

4 Drive Axle Assembly Options: (See Figure 1-5 for

Breakdown) 0280148 Prior to S/N 27815 0280150 S/N 27815 to Present

5 0630488 U-Bolt 4 6 4711800 Flatwasher 1/2” (Narrow) 14 7 3321805 Locknut 1/2”-20NF 8 8 0641844 Bolt 1/2”-13NC x 5 1/2” 4

9 3311805 Locknut 1/2”-13NC 4 10 3931824 Capscrew, Socket Head 1/2”-13NC x 1 1/2” 2 11 3300255 Nut, Wheel 1/2”-20NF 10 12 0100011 Loctite #242 (Not Shown) A/R 13 3020008 Lube, Gear (Not Shown) A/R 14 1120064 Cap, Grease Fitting (Not Shown) 2

I O N

TIRE AND WHEEL INSTALLATIONS OPTIONS: Ref. 0255961 Standard Pneumatic (26 x 12.00) Ref. 3 0256586 Lug Pneumatic (26 x 12.00) Ref. 2 0257224 Pneumatic 27 x 10.50 - 15NHS Ref. 2 0256694 Standard Foam Filled (26 x 12.00) Ref. 2 0256696 Lug Foam Filled (26 x 12.00) Ref. 2

Tire & Wheel Assembly Options: A/R 4520168 26 x 12.00 Multi-Trac (Pneumatic) 4520169 26 x 12.00 Tru-Power (Right Side) (Pneumatic) 4520170 26 x 12.00 Tru-Power (Left Side) (Pneumatic) 4520194 27 x 10.50 Lug Tread (Right Side) (Pneumatic) 4520195 27 x 10.50 Lug Tread (Left Side) (Pneumatic) 4520185 26 x 12.00 Multi-Trac (Foam Filled) 4520186 26 x 12.00 Tru-Power (Right Side) (Foam Filled) 4520187 26 x 12.00 Tru-Power (Left Side) (Foam Filled)

3120792 1-5

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. REAR DRIVE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

TIRE AND WHEEL ASSEMBLY COMPONENTS Ref.

101 Tire Options: A/R

7018701 Tire - Multi Trac C/S 26 x 12.00 7018702 Tire - Tru Power TL 26 x 12.00 7020112 Tire - Lug Tread 27 x 10.50

102 Rim Options: A/R

7018700 Rim - 12.00

7020113 Rim - 10.50 103 4640113 Valve, Air A/R 104 1703067 Decal - Tire Pressure (40PSI) A/R 105 3300407 Nut, Wheel 1/2*”-20NF (S/N 44598 to Present) 10

Ref.

1-6 3120792

SECTION 1 FRAME

FIGURE 1-2. REAR DRIVE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120792 1-7

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

1-8 3120792

SECTION 1 FRAME

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160202 DRIVE MOTOR ASSEMBLY Ref. A

1 7014901 Shaft Sub-Assembly 1 2KitSeal 3 3 7014902 Plate, Valve 1 4KitSeal 1 5 7014903 Valve 1 6 7009913 Spring, Compression 2 7 7014904 Ring, Balance 1 8 Pin, Spring (Part of Item #7) 2

9 Kit O-Ring 1 10 Kit Ring, Back-Up 1 11 Kit O-Ring 1 12 Kit Ring, Back-Up 1 13 Kit O-Ring 1 14 Kit Ring, Back-Up 2 15 Kit Seal, Dust 1 16 Kit Seal, Shaft 1 17 Kit Ring, Back-Up 1 18 7009918 Housing, Bearing 1 19 7009979 Drive 1 20 Kit Seal, Face 1 21 7014905 Plate, Wear 1 22 7009980 Geroler Assembly 1 23 7009905 Drive, Valve 1 24 Not Serviced Housing, Valve 1 25 7000191 Ball, Steel 2 26 7002159 Plug/O-Ring Assembly 2 27 7000192 Spring, Compression 2

28 to 36 Not Used

37 7002157 Plug/O-Ring Assembly 1 38 7014906 Plug/O-Ring Assembly 1 39 7014907 Spool, Control 1 40 7014908 Spring, Compression 1 41 7014909 Spring, Compression 1 42 7014910 Plug/O-Ring Assembly 1 43 Kit Seal 1 44 Not Serviced Bolt 4 45 7009940 Plug/O-Ring Assembly (Not Shown) 1

S E

I O N

7014911 Seal Kit (Includes Items 2, 4, 9-14, 20, 43 & O-Rings on Plug

Assemblies)

3120792 1-9

SECTION 1 FRAME

21 31

S E

I O N

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

1-10 3120792

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920103 DRIVE BRAKE ASSEMBLY Ref.

1 7011740 Shaft 1 2 7011739 Plate, Cover 1 3 7007941 Bearing 1 4 Kit Seal, Oil 1 5 7011738 Spline, Outer 1 6 7007937 Capscrew, Socket Head 4 7 7011737 Plate, Spring 1 8 7011736 Piston 1

9 Kit Ring, Back-Up 1 10 7009774 Screw, Bleeder 1 11 Kit O-Ring 1 12 7011735 Plate, Pressure 1 13 7011734 Ring, Retainer 1 14 7007943 Ring, Retainer 1 15 7007954 Ring, Retainer 1 16 Kit Primary 1 17 Kit Rotor 5 18 Kit Stator 4 19 7018601 Bolt, Shoulder 4 20 Kit Seal, Case 2 21 Kit Spring (Red) 4 22 Kit Ring, Back-Up 1 23 Kit O-Ring 1 24 7018600 Capscrew, Socket Head 2

25 to 29 Not Used

30 7011710 Gasket (Not Shown) 1 31 Kit Spring (Blue) 2

⎯

S E

I O N

7011741 Lining Repair Kit (Includes Items 16, 17, 18, 20 & 30) 1 7011742 Bearing Repair Kit (Includes Items 3, 4, 20 & 30) 1 7011743 O-Ring Repair Kit (Includes Items 4, 9, 11, 20, 22, 23 & 30) 1 7011744 Spring Repair Kit (Includes Items 20, 21, 30 & 31) 1

3120792 1-11

SECTION 1 FRAME

S E

I O N

FIGURE 1-5. DRIVE AXLE ASSEMBLY

1-12 3120792

SECTION 1 FRAME

FIGURE 1-5. DRIVE AXLE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE AXLE ASSEMBLY OPTIONS: Ref.

0280148 Prior to S/N 27815 Ref.

0280150 S/N 27815 to Present Ref.

1 7019033 Housing 1 2 7019000 Drive Gear & Pinion 1 3 7019001 Bearing, Inner Pinion 1 4 Kit Shim, Drive Pinion Adjusting A/R 5 7019003 Baffle, Pinion Bearing 1 6 Kit Shim, Pinion Bearing Adjusting A/R 7 7019004 Bearing, Outer Pinion 1 8 7019005 Slinger, Outer Pinion Bearing 1

9 7019006 Seal, Pinion 1 10 7019007 Yoke Assembly 1 11 7019008 Washer, Pinion Nut 1 12 7019009 Nut, Pinion 1 13 Not Used 14 7019010 Cover, Carrier 1 15 7019011 Gasket 1

7019012 Sealant (Not Shown) A/R 16 7019013 Plug 1 17 7019014 Bolt, Carrier Cover 10 18 7019015 Cap, Differential Bearing 2 19 7019016 Bolt, Differential Bearing Cap 4 20 7019017 Bearing, Differential 2 21 Kit Shim, Differential Bearing A/R 22 Not Used 23 7019019 Bolt, Differential Case 10

24 to 29 Not Used

30 7019020 Bolt, Axle Shaft 8 31 7019021 Nut, Axle Shaft 8 32 7019022 Seal, Inboard Shaft 2 33 7019023 Ring, Wheel Bearing Retaining 2 34 7019024 Bearing, Axle Shaft Wheel 2 35 7019025 Seal, Outboard Shaft 2 36 7019026 Retainer, Axle Shaft 2 37 7019027 Shaft, Axle 2 38 7019034 Bolt, Wheel 10 39 7019029 Differential & Case Assembly (Sold as an Assembly Only) 1

⎯ ⎯

S E

I O N

7019002 Pinion & Bearing Adjusting Shims Kit (Includes Items 4, 6,

11, 12 & 15)

7019018 Differential Adjusting Shims Kit (Includes Items 15 & 21) 1

3120792 1-13

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION

1-14 3120792

SECTION 1 FRAME

FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LIMIT SWITCH INSTALLATIONS Ref. 0256354 Hi-Drive (Prior to S/N 37222) Ref. A 0257590 Hi-Drive (S/N 37222 to Present) Ref. 1 0256692 Overload Protection Ref.

1 4360397 Switch, Limit 1 2 3911024 Screw, Machine #10-24NC x 1 1/2” 2 3 4751000 Flatwasher #10 2 4 3311005 Locknut #10-24NC 2 5 4845077 Actuator, Weldment (Prior to S/N 37222) 1 6 0641508 Bolt 5/16”-18NC x 1” (Prior to S/N 37222) 2 7 3311505 Locknut 5/16”-18NC (Prior to S/N 37222) 2 8 4460052 Connector, Strain Relief 1 9 Not Used

10 1060341 Cable, Electrical - 16/2 A/R

TILT SWITCH INDICATOR INSTALLATIONS Ref. 0256426 Common (Prior to S/N 38569) Ref. A 0257219 Common (S/N 38569 to Present) Ref. 2 0256543 Latin American & Japanese (Prior to S/N 38569) Ref. A 0257217 Latin American & Japanese (S/N 38569 to Present) Ref. 2

⎯

S E

I O N

101 Switch, Tilt Indicator Options: 1

4360362 Prior to S/N 38569

4360348 S/N 38569 to Present 102 0641407 Bolt 1/4”-20NC x 7/8” 2 103 4761400 Lockwasher 1/4” 2 104 3311401 Nut 1/4”-20NC 2 105 1060330 Cable, Electrical - 16/3 6ft/1.8m

106 to 110 Not Used

111 4460445 Connector - 3 Pin 1 112 4460227 Pin 3

113 to 117 Not Used

118 4460326 Connector - 3 Pin 1 119 4460226 Socket, Female 3

0256353 LP TANK & BRACKETS INSTALLATION Ref.

200 4400040 Tank, LP 2 201 4844185 Bracket, Tank Mounting 2 202 0641522 Bolt 5/16”-18NC x 2 3/4” 2 203 4751500 Flatwasher 5/16” 2 204 3311505 Locknut 5/16”-18NC 2 205 1320023 Clamp 2 206 0641608 Bolt 3/8”-16NC x 1” 8 207 4751600 Flatwasher 3/8” 8 208 3311605 Locknut 3/8”-16NC 8

⎯

3120792 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0256684 BEACON LIGHT INSTALLATION (OPTIONAL) Ref. 3

301 2920146 Beacon Light Assembly 1 301A 7016319 Bulb, Flash 1 301B 7016372 Lens 1

302 0721006 Bolt #10-24NC x 3/4” 2

303 4761000 Lockwasher #10 4

304 3311001 Nut #10-24NC 2

305 1060341 Cable, Electrical - 16-2 10ft/3m

306 4460035 Terminal, Butt 2

307 0902322 Bracket, Beacon 1

308 2820036 Loom (S/N 48790 to Present) 2ft/.6m

0256722 LADDER INSTALLATION Ref. 2

401 Ladder Weldment Options: 1

4845388 Prior to S/N 58034

4845911 S/N 58034 to Present 402 3520071 Cap 4 403 0641624 Bolt 3/8”-16NC x 3” 4 404 4751600 Flatwasher 3/8” 8 405 3311605 Locknut 3/8”-16NC 4

ALARM INSTALLATIONS

0256492 Descent Ref. 2

0256493 Motion Ref. 3

0256491 Travel Ref. 3

501 0140024 Alarm 1 502 Bolt Options: 2

0641408 Bolt 1/4”-20NC x 1” (Prior to S/N 48790)

0641508 Bolt 5/16”-18NC x 1” (S/N 48790 to Present) 503 4751400 Flatwasher 1/4” 4 504 3311405 Locknut 1/4”-20NC 2 505 3990010 Diode 6 Amp (Motion Alarm Only) 2 506 4460035 Terminal, Electrical 2 507 1060341 Cable, Electrical - 16/2 4ft/1.2m 508 2820036 Loom (S/N 48790 to Present) 2ft/.6m

1-16 3120792

SECTION 1 FRAME

FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120792 1-17

SECTION 1 FRAME

FRAME REF.

103

104

107

109

107

109

105

10810105

108

201

203

202

106

109

106

109

LOCATED UNDER HOOD

USE EXISTING BOLT

302

307

303

304

305 306

FIGURE 1-7. HYDRAULIC DRIVE GENERATOR INSTALLATION

I O N

1-18 3120792

SECTION 1 FRAME

FIGURE 1-7. HYDRAULIC DRIVE GENERATOR INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258756 HYDRAULIC DRIVE GENERATOR INSTALLATION Ref. B

1 Not Used 2 0480034 V-Belt 1 3 0641408 Bolt 1/4”-20NC x 1” 4 4 0641430 Bolt 1/4”-20NC x 3 3/4” 2 5 0641507 Bolt 5/16”-18NC x 7/8” 2 6 0641609 Bolt 3/8”-16NC x 1 1/8” 5 7 0681610 Bolt 3/8”-16NC x 1 1/4” 2 8 Not Used 9 0901650 Bracket, Mounting 1

10 2460011 110 Volt Generator 1

7003657 Control Box Assembly 1 7010699 Voltmeter 1 7020194 Breaker, Circuit 1 7012558 Generator Assembly 1 7026199 Armature with Slip Rings 1 7020108 Brushes 4 7020109 Holders, Brush 4 7012513 Cap, Brush Holder 4

3580134 Pulley 1 11 Not Used 12 3160235 Motor 1 13 3311405 Locknut 1/4”-20NC 6 14 3311505 Locknut 5/16”-18NC 1 15 3311605 Locknut 3/8”-16NC 5 16 3580273 Pulley 1 17 4340569 Support, Mounting 1 18 4641100 Valve (See Items 301 to 307 for Breakdown) 1 19 4711400 Flatwasher 1/4” (Narrow) 4 20 4740468 Washer (Special) 1 21 4751500 Flatwasher 5/16” (Wide) 3 22 4751600 Flatwasher 3/8” (Wide) 12 23 4845865 Weldment, Generator Mount 1

24 to 25 Not Used

26 0100011 Loctite #242 (Not Shown) A/R

S E

I O N

0259057 110VOLT GENERATOR CONTROL BOX INSTALLATION Ref. 2

101 Not Used 102 Not Used 103 0902515 Bracket 1 104 3911016 Screw, Round Head #10-24NC x 1” 2 105 3311001 Nut #10-24NC 2 106 4761000 Lockwasher #10 2 107 0641406 Bolt 1/4”-20NC x 3/4” 4 108 3311405 Locknut 1/4”-20NC 4 109 4751400 Flatwasher 1/4” 8

3120792 1-19

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. HYDRAULIC DRIVE GENERATOR INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4922232 CABLE HARNESS 110VOLT Ref. 1

201 4460138 Plug, Male 1 202 4460779 Plug, Female 1 203 1060308 Cable 12/3 7ft/2.1m

4641100 HYDRAULIC VALVE ASSEMBLY Ref. A

301 Not Serviced Manifold Assembly 1 302 7021617 Cartridge 1

7012942 Seal Kit - 7021617 Cartridge 1

303 7017453 Cartridge Less Coil 1

7017402 Seal Kit - 7017453 Cartridge 1

7012539 Coil 1 304 7021370 Cartridge 1 305 7021372 Orifice (0.4mm) 1 306 7018905 Plug 1 307 7021371 Screw #8-32 x 1 3/4” 4

1-20 3120792

SECTION 2 GROUND COMPONENTS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

2-1 Control Valves & Tanks Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 Vanguard Gas Engine Installation (Prior to S/N 48113) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 Vanguard Gas Engine Installation (S/N 48113 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-5 Dual Fuel Installation (Vanguard Machines Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-6 Yanmar Diesel Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-7 Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-8 Gear Pump Assembly (Yanmar Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-9 Ground Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-10 Hood Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

S E C T

I O N

G R O U N D

C O

P O N

E N

3120792 2-1

17 16

22C

22B

22A

22D

3435193121

NOTE:

LOCATED IN ENGINE TRAY

21A

21B

E C T

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION

U N D

C O

P O N

E N

2-2 3120792

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0256120 VALVES & TANKS INSTALLATION Ref. 13

1 Tank, Fuel Options: 1

4400371 Prior to S/N 37163 4400401 S/N 37163 to Present

1A 1120477 Cap, Fuel 1

2 4400383 Hydraulic Tank Assembly 1 2A 7014802 Gauge, Sight 1 2B 7014803 Breather/Filler 1

2C 7026544 Elbow, W/Drain Plug 1

3 2120157 Filter, Oil Return 1

3A 2120158 Element, Filter 1 3B 7016313 Switch, Pressure 1

4 4240118 Strap, Hold-Down (Hydraulic Tank) 1

5 4240117 Strap, Hold-Down (Fuel Tank) 1

6 Not Used

7 3311601 Nut 3/8”-16NC 5

8 4751600 Flatwasher 3/8” 7

9 0100011 Loctite #242 (Not Shown) A/R 10 Molding Options:

4280295 Strip, Bumper (Prior to S/N 37163) 5ft/1.5m 4420037 Molding, Rubber 1” (S/N 37163 to Present) 7ft/2.1m

11 4420038 Molding, Rubber 2” 2ft/0.6m

12 to 14 Not Used

15 0641506 Bolt 5/16”-18NC x 3/4” 3 16 4751500 Flatwasher 5/16” 13 17 4761500 Lockwasher 5/16” 3 18 4640977 Control Valve Assembly (See Figure 2-2 for Breakdown) 1 19 0902289 Bracket, Mounting - Filter 1 20 4845337 Bracket, Mounting - Battery 1 21 2120146 Filter, Oil - Pressure 1

21A 2120150 Element, Filter 1 21B 7016312 Switch, Indicator 1

22 4640859 Manual Descent Valve Assembly 1

22A 7012952 Cartridge, Pump 1 22B 7012954 Cartridge, Needle Valve 1

7012953 Seal Kit - 7012954 Cartridge 1 22C 7012961 Knob 1 22D 7012955 Cartridge, Check 1

7012940 Seal Kit - 7012955 Cartridge 1

23 0400003 Battery 1 24 0400002 Hold-Down, Battery 1

24A 2910479 Clips, Hold-Down (Not Shown) 4

25 3980003 Seat, Battery 1 26 0630370 Rod, Tie-Down 2 27 3300029 Wingnut 3/8”-16NC 2 28 2560123 Grip, Handle 1 29 2560122 Handle, Manual Descent Valve 1

S E

I O N

G R O U N D

C O

P O N

E N

3120792 2-3

S E C T

I O N

U N D

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

30 1380136 Clip, Mounting 2 31 0641508 Bolt 5/16”-18NC x 1” 5 32 3311505 Locknut 5/16”-18NC 7 33 0641530 Bolt 5/16”-18NC x 3 3/4” 2 34 0651404 Bolt 1/4”-28NF x 1/2” 2 35 4711400 Flatwasher 1/4” (Narrow) 2 36 3820019 Rivet 2 37 4566987 Tube, Spacer 2 38 0140001 Horn 1 39 0641406 Bolt 1/4”-20NC x 3/4” 1 40 3311405 Locknut 1/4”-20NC 1 41 1060360 Cable, Battery (Battery to Ground) 1 42 1060632 Cable, Battery (Battery to Starter Relay) 1 43 2220240 Plug, O-Ring 2 44 4060807 Flex-Trim 9ft/2.7m 45 1701504 Decal - Hydraulic Fluid 1 46 3300233 Plug, O-Ring 2 47 1701502 Hydraulic Oil Level (High) 1 48 1701503 Hydraulic Oil Level (Low) 1 49 0100001 Adhesive (Not Shown) A/R 50 4711500 Flatwasher (Narrow) (S/N 62148 to Present) 4

C O

P O N

E N

2-4 3120792

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