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

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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
				E
	TABLE OF CONTENTS
				C
FIGURE	DESCRIPTION	PAGE		T
				I
1-1 Frame And Steering Installation		1-2
1-2	Rear Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1-4. .		O
1-3	Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1-6. .
1-4	Drive Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1-8. .		N
1-5	Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1-10. .
1-6 Frame Mounted Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. 1-12. .		1
				F
				R
				A
				M
				E

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1-1

S E C T I O N

1

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SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION

13	15	14
	12	17
	11

10

9

3	18	16 201	2	16	201	18	6	4	5
	6						102
	7	8	105
								101
				107	1				103	104
						19				204
							20	203
								205		106

1-2

3120893

SECTION 1 FRAME

.

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)	1
		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
	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

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1-3

	SECTION 1 FRAME
S	FIGURE 1-2. REAR DRIVE INSTALLATION
E
C
T
I
O
N

1

F

R

A

M

E

1-4

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SECTION 1 FRAME

FIGURE 1-2. REAR DRIVE INSTALLATION

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
	0256794	TIRE AND WHEEL INSTALLATION	Ref.	2
101	4520188	Tire and Wheel Assembly - 27 x 10.50 NHS -6 Ply	2
		(Right Side) (Foam Filled)
	4520189	Tire and Wheel Assembly - 27 x 10.50 NHS -6 Ply	2
		(Left Side) (Foam Filled)
		Note: Assemblies may require ballast/foam filling	Ref.
		to manufacturer’s specifications prior to installing
		on a machine. Refer to Operation & Safety or Ser-
		vice & Maintenance Manuals. Purchase individual
		tire and/or rim only if able to foam fill tire & wheel
		assembly, otherwise, purchase complete assem-
		bly.
	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

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	SECTION 1 FRAME
S	FIGURE 1-3. DRIVE MOTOR ASSEMBLY
E
C
T
I
O
N

1

F

R

A

M

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1-6

3120893

SECTION 1 FRAME

.

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
	2900699	Seal Kit (Includes Items 3, 4 & 7)	1

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	SECTION 1 FRAME
S	FIGURE 1-4. DRIVE BRAKE ASSEMBLY
E
C
T
I
O
N
1
F
R
A
M
E

1-8

3120893

SECTION 1 FRAME

.

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	Ref.
		here for reference.
1	7016631	O-Ring	1
2	7016632	Cam	1
3	7016633	Shoe Assembly - Single (Requires 2 per side/4 per	A/R
		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

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SECTION 1 FRAME

FIGURE 1-5. DRIVE AXLE ASSEMBLY

12

11

10

9
8
7	5
	6

4

3

1

			2
32	30
33
34
35	23	39	15
36		21
	20		14
31	39
37
	18	17	16
38		19

1-10

3120893

SECTION 1 FRAME

.

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
	7019002	Pinion & Bearing Adjusting Shims Kit (Includes Items 4, 6, 11,	1
		12 & 15)
	7019018	Differential Adjusting Shims Kit (Includes Items 15 & 21)	1

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SECTION 1 FRAME

FIGURE 1-6. FRAME MOUNTED COMPONENTS INSTALLATION

6

7

4

3

1

2

501

502

602 603

10

8

505

504

	B104		A104		204	704	304	404	101	501
	5	104		504 604 804						201
604	601	605	606	607	608

504	020
503	502

	301	401		314 315
		311	303
			304	313
308	307

	312
301	305
	306
302	LOCATED ON PIVOT PIN

2 50

102

202

			302
602	702	802	402

1-12

3120893

SECTION 1 FRAME

.

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
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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SECTION 1 FRAME

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:	9ft/2.74m
	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
	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

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3120893

2-1

S E C T I O N

2

G R O U N D

C O M P O N E N T S

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. CONTROL VALVES & TANKS INSTALLATION

4

34

35

19

32

16

31

		3		2B		21B
				45
		3B			21A
				10		21
	24	3A
27				43
				2A	NOTE: LOCATED
8				47	IN ENGINE TRAY
			2C	48
		41
25
23				2
42				1A	1
26			44
20
31				46
	32
16				18
38			8
39
40			7
35
32		16
22A	22B
		31
37	22C		17	11
22			16
22D				28
50
	33		15	29
				30
				36
	5
	10			7
				8

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

C O M P O N E N T S

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

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

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 2-2. CONTROL VALVES ASSEMBLY

	4
	9A
6	9B
5	9
3

8

10A

10B

106

113

101

105

110

108 109A

111

1

7

2

6

12

5

108 112

109

11

110 103

104

102

104

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.
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	Fitting 90°	1
113	Not Serviced	Capscrew, Socket Head M4 x 45mm	8

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

2-7

8-2

3120893

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
				45
				46	12
					22	11D
					23	11B
				11A
							11C							31
6
				11				13		49
			5
44				45				4
				46						19
84					45							INSTALL BETWEEN STARTER
										104		MTG BOLT AND ENGINE MTG
												67 BOLT TO TRAY
								106 101B		107
							126					121	127	77
								101C					128	78
42								101						79
43														17
								132
													124
								101A					114
							69	82
								83
							70
				36			20							123
				22			68
				23			23	103						129	80	81
							36
						36		112								1
				29			86
					35		40
							41							125
								105						115
								7	122							73
																75
					10		24	8
						26
							25
						27	34	36
						33
		4						35
		0						71			33				74
												10			75
50
												24
51	85									9	26
52												25
	116										27	34			47
118									32	119					41
	51
87															24
	41			64
					FUEL TANK
				65												21
					LOCATED IN

HYDRAULIC TRAY

130

59

51 53

30

57 51 56 48

53

76	29
131

72

60

61

62

16

66

38

2336

39

3

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

COMPONENTS GROUND 2 SECTION

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	Ref.	14
		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-	1
		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.	Ref.
		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	1
		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

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	°	1
		Fitting, 90
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	1
		replacement)
77	1320061	Clamp, Hose	1
78	0700808	Bolt, Metric 8mm x 16mm	1
79	4751500	Flatwasher 5/16”	1

2-10

3120893