JLG 26MRT Parts Manual
Illustrated Parts Manual
Model
26MRT
P/N
3120893
October 17, 2013
REVISION LOG
February 4, 2000 - Original Issue Of Manual (Was part of complete Manual #3120844) (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
3120893 A
REVISION LOG
B 3120893
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-4 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-5 DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-6 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
SECTION 3 - SCISSOR ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 SCISSOR ARMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 ARM GUARDS INSTALLATION (PRIOR TO S/N 54142) . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-3 ARM GUARDS INSTALLATION (S/N 54142 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . .3-10
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 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4-4 CONTROLLER ASSEMBLY (PRIOR TO S/N 58990) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-5 CONTROLLER ASSEMBLY (S/N 58990 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . .4-16
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
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
3120893 i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
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 3120893
SECTION 1 FRAME
S
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-4 Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-5 Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-6 Frame Mounted Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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3120893 1-1
SECTION 1 FRAME
1
3
7
8
6
91020
120
1
101
106
102
105
107
104
204
203205
103
218161
6
19
20
1811131
5141217
4
5
6
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FIGURE 1-1. FRAME AND STEERING INSTALLATION
1-2 3120893
SECTION 1 FRAME
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FIGURE 1-1. FRAME AND STEERING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
2360420 FRAME WELDMENT 1
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
1
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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
3120893 1-3
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FIGURE 1-2. REAR DRIVE INSTALLATION
1-4 3120893
SECTION 1 FRAME
FIGURE 1-2. REAR DRIVE INSTALLATION
S
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FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0256775 REAR DRIVE AXLE INSTALLATION Ref. 3
1 3160215 Drive Motor Assembly (See Figure 1-3 for Breakdown) 1
2 0920107 Drive Brake Assembly (See Figure 1-4 for Breakdown) 2
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 0280150 Drive Axle Assembly (See Figure 1-5 for Breakdown) 1
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 Nut, Wheel 1/2”-20NF Options: 10
3300255 Prior to S/N 32539
3300407 S/N 32539 to S/N 46538
12 0100011 Loctite #242 (Not Shown) A/R
13 3020008 Lube, Gear (Not Shown) A/R
14 0920108 Drum, Brake 2
15 0080227 Adapter, Motor 1
16 1360269 Clevis (Right Side) 1
17 1360270 Clevis (Left Side) 1
18 0060036 Actuator 2
19 0641710 Bolt 7/16”-14NC x 1 1/4” 4
20 4060926 Shield, Actuator 2
21 3311705 Locknut 7/16”-14NC 4
22 4070957 Shim, Axle 2
23 1120064 Cap, Grease Fitting (Not Shown) 4
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0256794 TIRE AND WHEEL INSTALLATION Ref. 2
101 4520188 Tire and Wheel Assembly - 27 x 10.50 NHS -6 Ply
(Right Side) (Foam Filled)
4520189 Tire and Wheel Assembly - 27 x 10.50 NHS -6 Ply
(Left Side) (Foam Filled)
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.
7020112 Tire, 27 x 10.50 x 15 A/R
7020113 Wheel, 15 x 8 A/R
102 3300255 Nut, Wheel 1/2”-20NF (S/N 46538 to Present) 20
3120893 1-5
2
2
Ref.
SECTION 1 FRAME
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FIGURE 1-3. DRIVE MOTOR ASSEMBLY
1-6 3120893
SECTION 1 FRAME
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FIGURE 1-3. DRIVE MOTOR ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
3160215 DRIVE MOTOR ASSEMBLY Ref.
1 7014901 Shaft Sub-Assembly 1
2 7014912 Seal 4
3 Kit Seal, Exclusion 1
4 Kit Seal, Shaft 1
5 7009919 Ring, Back-Up 1
6 Not Serviced Housing, Bearing 1
7 Kit Seal, Shaft Face 1
8 7009982 Plate, Wear 1
9 7009936 Drive 1
10 7009937 Geroler Assembly 1
11 7009983 Plate, Valve 1
12 7009905 Drive, Valve 1
13 7009927 Valve 1
14 7009909 Ring, Balance 1
15 7009912 Pin, Balance Ring 2
16 7009913 Spring, Compression 2
17 7009910 Seal, Inner Face 1
18 7009928 Seal, Outer Face 1
19 7014913 Housing, Valve 1
20 7002157 Plug/O-Ring Assembly 1
7002158 O-Ring 1
21 Not Serviced Bolt 4
22 to 23 Not Used
24 7014914 Piston, Shuttle 1
25 7014915 Poppet 2
26 7014916 Spring 2
27 7014917 Sleeve 2
28 7009940 Plug/O-Ring Assembly 2
7009941 O-Ring 2
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2900699 Seal Kit (Includes Items 3, 4 & 7) 1
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FIGURE 1-4. DRIVE BRAKE ASSEMBLY
1-8 3120893
SECTION 1 FRAME
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FIGURE 1-4. DRIVE BRAKE ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0920107 DRIVE BRAKE ASSEMBLY Ref.
Note: Drum not included in Brake Assembly but shown
here for reference.
1 7016631 O-Ring 1
2 7016632 Cam 1
3 7016633 Shoe Assembly - Single (Requires 2 per side/4 per
machine)
4 7016634 Plate, Backing 1
5 7016635 Spring, Return 2
6 7016636 Lever 1
7 7016637 Rollpin 1
8 0920108 Drum (was p/n 0920218) 1
Ref.
A/R
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3120893 1-9
SECTION 1 FRAME
16
17
19
18
20
30
32
33
34
35
36
31
38
39
37
23
39
21
14
15
2
3
1
4
5
6
8
9
11
12
7
10
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FIGURE 1-5. DRIVE AXLE ASSEMBLY
1-10 3120893
SECTION 1 FRAME
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FIGURE 1-5. DRIVE AXLE ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0280150 DRIVE AXLE ASSEMBLY 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
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7019002 Pinion & Bearing Adjusting Shims Kit (Includes Items 4, 6, 11,
12 & 15)
7019018 Differential Adjusting Shims Kit (Includes Items 15 & 21) 1
3120893 1-11
1
SECTION 1 FRAME
1
0
1
1
0
5103104
1
0
2
2
0
0
2
0
5
2
0
1
2
0
2
2
0
6
2
0
7
2
0
8
2
0
4
2
0
3
2
0
5
5
6
7
40440
340
7
4
0
2
4
0
1
4
0
1
A
4
0
1
B
405406408
1
8
2
3
4
10
602
603
601
608
604
605
606
607
501
502
503
504
504
505
LOCATED O
N
PIVOT PIN307308306303
304309310311305313301302314
31531
2
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FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION
1-12 3120893
SECTION 1 FRAME
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FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0256692 OVERLOAD PROTECTION INSTALLATION 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.
0256427 Euro Spec (Prior to S/N 38569) Ref. A
0257220 Euro Spec (S/N 38569 to Present) Ref. 2
0256544 Australian Spec (Prior to S/N 38569) Ref. A
0257218 Australian Spec (S/N 38569 to Present) Ref. 2
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101 4360354 Switch, Tilt Indicator 1
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
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
0256833 HI-DRIVE LIMIT SWITCH INSTALLATION Ref. 3
301 1440325 Collar 1
302 3951603 Setscrew 3/8”-16NC x 3/8” 2
303 3570030 Bracket 1
304 3570029 Plate 1
305 4360321 Switch, Limit 1
306 3911020 Screw, Machine #10-24NC x 1 1/4” 2
307 4751000 Flatwasher #10 2
308 3311005 Locknut #10-24NC 2
309 0641405 Bolt 1/4”-20NC x 5/8” 2
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FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
310 4751400 Flatwasher 1/4” 4
311 3311405 Locknut 1/4”-20NC 2
312 4460428 Connector, Strain Relief 1
313 Cable, Electrical Options:
1060341 Cable, Electrical - 16/2 (Prior to S/N 55491)
1060680 Cable, Electrical - 18/2 (S/N 55491 to Present)
314 4460320 Connector, Terminal 1
315 4460268 Socket, Female 2
316 0100011 Loctite #242 (Not Shown) A/R
0256684 BEACON LIGHT INSTALLATION (OPTIONAL) Ref. 3
401 2920146 Beacon Light Assembly 1
401A 7016319 Bulb, Flash 1
401B 7016372 Lens 1
402 0721006 Bolt #10-24NC x 3/4” 2
403 4761000 Lockwasher #10 4
404 3311001 Nut #10-24NC 2
405 1060341 Cable, Electrical - 16-2 10ft/3m
406 4460035 Terminal, Butt 2
407 0902322 Bracket, Beacon 1
408 2820036 Loom (S/N 48790 to Present) 2ft/.6m
9ft/2.74m
0256722 LADDER INSTALLATION Ref. 2
501 Ladder Weldment Options: 1
4845388 Prior to S/N 58034
4845911 S/N 58034 to Present
502 3520071 Cap 4
503 0641624 Bolt 3/8”-16NC x 3” 4
504 4751600 Flatwasher 3/8” 8
505 3311605 Locknut 3/8”-16NC 4
ALARM INSTALLATIONS Ref.
0256492 Descent Ref. 2
0256493 Motion Ref. 3
0256491 Travel Ref. 3
601 0140024 Alarm 1
602 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)
603 4751400 Flatwasher 1/4” 4
604 3311405 Locknut 1/4”-20NC 2
605 3990010 Diode 6 Amp (Motion Alarm Only) 2
606 4460035 Terminal, Electrical 2
607 1060341 Cable, Electrical - 16/2 4ft/1.2m
608 2820036 Loom (S/N 48790 to Present) 2ft/.6m
1-14 3120893
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120893 2-1
S
4
2B
45
10
44
28
38
25
8
31
16
8
8
18
46
32
7
7
31
11
17
16
15
22C
22B
22A
37
22
22D
50
33
16
29
39
26
42
20
41
30
40
23
27
24
36
35
32
3
3B
3A
2A
47
48
43
2
1
1A
5
10
3435193121
NOTE:
LOCATED
IN ENGINE TRAY
21A
21B
32
16
2C
E
C
T
I
O
N
2
G
R
SECTION 2 GROUND COMPONENTS
FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION
M
O
U
N
D
C
O
P
O
N
E
N
T
S
2-2 3120893
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
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120893 2-3
S
E
C
T
I
O
N
2
G
R
O
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
M
P
O
N
E
N
T
S
2-4 3120893
SECTION 2 GROUND COMPONENTS
FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120893 2-5
SECTION 2 GROUND COMPONENTS
126
5
111
113
106
107
108
109A
110
101
105
102
104
103
104
110
108
109
11
112
12
10A
10B
10
8
3
5
6
4
9A
9
9B
7
FIGURE 2-2. CONTROL VALVES ASSEMBLY
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-6 3120893
SECTION 2 GROUND COMPONENTS
.
FIGURE 2-2. CONTROL VALVES ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4640977 CONTROL VALVE ASSEMBLY Ref. C
1 Not Serviced Manifold 1
2 7012966 Cartridge With Coil 1
7012967 Seal Kit - 7012966 Cartridge 1
7012944 Coil 1
3 7017415 Cartridge 1
7012998 Seal Kit - 7017415 Cartridge 1
4 7017416 Cartridge 1
7012998 Seal Kit - 7017416 Cartridge 1
5 7017417 Cartridge 2
7012998 Seal Kit - 7017417 Cartridge (1 Per Cartridge) 2
6 7018900 Orifice 1/16”/1.2mm 2
7 7012941 Cartridge Less Coil 1
7010543 Seal Kit - 7012941 Cartridge 1
7012944 Coil 1
8 7018901 Valve Assembly (See Items 101-113 for Breakdown) 1
9 7012770 Valve Assembly 1
7012773 Seal Kit 2
9A 7018912 Nut 2
9B 7012772 Coil 2
10 7012795 Valve Assembly 1
7012773 Seal Kit 2
10A 7018912 Nut 2
10B 7012772 Coil 2
11 7018903 Tube Assembly 1
12 7018905 Plug 1
7018901 VALVE ASSEMBLY Ref.
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
101 Not Serviced Housing 1
102 7018911 Spool 1
103 Not Serviced Detent 1
104 7018906 O-Ring 2
105 7018907 O-Ring 4
106 Not Serviced Nameplate 1
107 Not Serviced Rivet 4
108 7018908 O-Ring 2
109 7018909 Spool 1
109A 7018910 Pin, Push 1
110 Not Serviced Housing 2
111 Not Serviced Plug 1
112 7018904
113 Not Serviced Capscrew, Socket Head M4 x 45mm 8
3120893 2-7
Fitting 90
°
1
N
E
N
T
S
S
17
101B
101C
101
101A
83
82
103
126
112
105
31
49
4
121
114
124
127
128
104
106
107
67
INSTALL BETWEEN STARTER
MTG BOLT AND ENGINE MTG
BOLT TO TRAY
7
9
50
64
71
122
51
65
FUEL TANK
LOCATED IN
HYDRAULIC TRAY
52
115
125
8
10
10
29
40
119
11
45
46
11B
11C
19
13
11D
11A
122223
24
24
36
41
26
26
20
68
25
25
22
27
27
35
35
32
34
34
23
33
33
36
36
2
123
129
113
1
808
16638164774734175752433
921
362
3
777879
5
6
44
42
84
43
SUPPLIED
WITH ENGINE
76
72
56
30
130
29
57
514853
595153
60616
2
69
70
132
45
45
46
233686
40
41
85
118
116
51
87
E
C
T
I
O
N
SECTION 2 GROUND COMPONENTS
FIGURE 2-3. VANGUARD GAS ENGINE INSTALLATION (PRIOR TO S/N 48113)
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-8 3120893
SECTION 2 GROUND COMPONENTS
.
FIGURE 2-3. VANGUARD GAS ENGINE INSTALLATION (PRIOR TO S/N 48113)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0255959 VANGUARD ENGINE ASSEMBLY & INSTALLATION (PRIOR
TO S/N 48113)
1 3539676 Shroud, Fan 1
2 1340033 Cap, Air Intake 1
3 3539465 Plate, Mounting (Radiator) 1
4 2000140 Engine - Vanguard DM700G (See Items 101-130 for Break-
down)
5 3600256 Piston Pump Assembly (See Figure 2-7 for Breakdown) 1
6 See Note Gear Pump Assembly (was p/n 3600257) 1
Note: P/N 3600257 no longer available. Use p/n 3600466.
New pump includes required fitting.
7018924 Seal Kit (Includes Shaft Seal) 1
7018923 Seal, Shaft 1
7 3539459 Plate, Mounting (Rear Right Side) 1
8 3539460 Plate, Mounting (Rear Left Side) 1
9 3539461 Plate, Mounting (Front) 1
10 3200381 Mount, Motor 3
11 1340057 Air Cleaner Assembly 1
11A 7015004 Element, Filter 1
11B 7015005 Cover Assembly 1
11C 7015006 Valve, Vacuator 1
11D 7015007 Latch 2
12 0340045 Band, Mounting 1
13 3539484 Plate, Mounting (Air Cleaner) 1
14 to 15 Not Used
16 3620035 Radiator 1
7016606 Cap, Radiator 1
7019618 Draincock 1
17 2901414 Fan Kit 1
18 1700430 Decal - Gas (Not Shown - Located on Hood) 1
19 4567104 Pipe, Exhaust 1
20 0902270 Bracket 1
21 2540032 Grommet 2
22 0641506 Bolt 5/16”-18NC x 3/4” 2
23 3311505 Locknut 5/16”-18NC 5
24 0641608 Bolt 3/8”-16NC x 1” 7
25 3311605 Locknut 3/8”-16NC 6
26 0641818 Bolt 1/2”-13NC x 2 1/4” 3
27 3311805 Locknut 1/2”-13NC 3
28 Not Used
29 Use 2910000 Actuator Assembly (Was p/n 0060037) (See Section 7 for
Breakdown)
30 3841315 Rod, Throttle 1
31 3220109 Muffler 1
32
33 4740274 Washer, Snubbing 3
34 4751600 Flatwasher 3/8” 6
35 0700810 Bolt Metric 8mm x 20mm 12
Ref. 14
1
Ref.
1
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120893 2-9
S
E
C
T
I
O
N
2
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
SECTION 2 GROUND COMPONENTS
FIGURE 2-3. VANGUARD GAS ENGINE INSTALLATION (PRIOR TO S/N 48113) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
36 4751500 Flatwasher 5/16” 23
37 0100011 Loctite #242 (Not Shown) A/R
38 0760605 Bolt, Metric 6mm x 10mm 6
39 0641508 Bolt 5/16”-18NC x 1” 3
40 2720015 Hose, Fuel Line (1/4”) 6ft/1.8m
41 1320022 Clamp, Hose 8
42 0641812 Bolt 1/2”-13NC x 1 1/2” 2
43 4751800 Flatwasher 1/2” 2
44 0701012 Bolt, Metric 10mm x 25mm 2
45 1320031 Clamp, Hose 4
46 2720063 Hose, Air Intake 2ft/0.6m
47 Hose (3/8”) Options:
2750532 Prior to S/N 44924 2ft/0.6m
2720058 S/N 44924 to Present 5ft/1.5m
48 0651405 Bolt 1/4”-28NF x 5/8” 1
49 1320026 Clamp, U-Bolt 1
50 0641406 Bolt 1/4”-20NC x 3/4” 5
51 4751400 Flatwasher 1/4” 9
52 3311405 Locknut 1/4”-20NC 3
53 4567086 Tube, Spacer - Throttle Linkage 2
54 to 55 Not Used
56 1660222 Coupling, Throttle 1
57 3321402 Nut, Jam 1/4”-28NF 1
58 Not Used
59 1660220 Coupling, Throttle 1
60 4740442 Washer, Belleville 1
61 3900217 Bolt, Socket Head Shoulder 3/8”-16NC x 7/8” 1
62 0962031 Bushing, Flanged 1
63 Not Used
64 2220250 Fitting, Reducer 1
65 2220317
66 4811700 Flatwasher, Metric 6mm 6
67 1060221 Cable, Solenoid 1
68 3740049 Relay 2
69 0721008 Bolt #10-24NC x 1” 2
70 3311005 Locknut #10-24NC 2
71 0700812 Bolt, Metric 8mm x 25mm 3
72 3539929 Plate, Mounting 1
73 2720420 Hose, Radiator (Top) 1
74 2720421 Hose, Radiator (Bottom) 1
75 Clamp, Hose Options: 4
1320014 Prior to S/N 44432
1320033 S/N 44432 to Present
76 4160150 Spring (Used Prior to S/N 28511 - Recommend #131 as
77 1320061 Clamp, Hose 1
78 0700808 Bolt, Metric 8mm x 16mm 1
79 4751500 Flatwasher 5/16” 1
Fitting, 90
replacement)
°
1
1
2-10 3120893
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