JLG 3969 Parts Manual

Illustrated Parts Manual

Model
3369electric
3969electric

3120882

May 31, 2013

REVISION LOG

March 22, 1999 - Original Issue Of Manual (Was part of complete Manual #3120835)

(Model 3369 Manual edited to 0010498 Revision 22)

(Model 3969 Manual edited to 0010487 Revision 24)

September 29, 2000 Revised - (Model 3369 Manual edited to 0010498 Revision 31)

(Model 3969 Manual edited to 0010487 Revision 27)

August 15, 2003 Revised - (Model 3369 Manual edited to 0010498 Revision 34)

(Model 3969 Manual edited to 0010487 Revision 32)

September 1, 2003 Revised - Updated Section 3

January 31, 2007 Revised

November 1, 2010 Revised

May 31, 2013 Revised

3120882 A

REVISION LOG

B 3120882

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME

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

1-2 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

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

1-5 ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) . . . . . . . . . . . . .1-12

1-6 BATTERY CHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

1-7 BATTERY CHARGER ASSEMBLY - UK ONLY (110/220 DUAL VOLTAGE)

(S/N 43921 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

1-8 BATTERY CHARGER ASSEMBLY - EURO SPEC (SERVICE REPLACEMENT) . . . . . . .1-26

1-9 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

SECTION 2 - GROUND COMPONENTS

2-1 HYDRAULIC COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3 PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4 GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5 COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

SECTION 3 - SCISSOR ARMS

3-1 SCISSOR ARMS INSTALLATION - MODEL 3369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 SCISSOR ARMS INSTALLATION - MODEL 3969 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3 ARM GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

SECTION 4 - PLATFORM

4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 MANUAL PLATFORM EXTENSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-3 PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506) . . . . . . . . . . . . . . . . .4-12

4-4 PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT) . . . . . . . . . . . . . .4-16

4-5 CONTROLLER ASSEMBLY - PQ (PRIOR TO S/N 71506). . . . . . . . . . . . . . . . . . . . . . . .4-20

4-6 CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT) . . . . . . . . . . . . . . . . . . . . .4-22

SECTION 5 - CYLINDER

5-1 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

SECTION 6 - HYDRAULIC

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

SECTION 7 - ELECTRICAL

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

7-2 STANDARD ELECTRICAL SCHEMATIC (PRIOR TO S/N 72550) . . . . . . . . . . . . . . . . . .7-6

7-3 STANDARD ELECTRICAL DIAGRAM - EURO SPEC (S/N 72550 TO PRESENT). . . . . .7-8

7-4 STANDARD ELECTRICAL DIAGRAM - AUSTRALIAN SPEC (S/N 72550 TO PRESENT)7-9

7-5 MAIN ELECTRICAL CONNECTOR AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

3120882 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.
SECTION 8 - DECALS

8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK

SECTION 10 - SPECIAL OPTIONS

ii 3120882

SECTION 1 FRAME

S

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 FRAME AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 TIRE AND WHEEL DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

1-5 ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED).. . . . . . . . . . . . . . . . . . 1-12

1-6 BATTERY CHARGER ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 BATTERY CHARGER ASSEMBLY - UK ONLY (110/220 DUAL VOLTAGE)(S/N 43921 TO

PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-8 BATTERY CHARGER ASSEMBLY - EURO SPEC (SERVICE REPLACEMENT). . . . . . . . . . . . 1-26

1-9 FRAME MOUNTED COMPONENTS INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

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FIGURE 1-1. FRAME AND STEERING INSTALLATION

1-2 3120882

SECTION 1 FRAME

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FIGURE 1-1. FRAME AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME AND STEERING INSTALLATION Ref.

2360370 Frame Weldment 1

STEERING AND SPINDLES INSTALLATION

0252243 Steering and Spindles - Standard Ref. 8

1 2780186 Hub Assembly (Includes Items 101-106) 2
2 4130286 Spindle 2
3 3421988 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”-18NC x 2” 2
8 3312005 Locknut 5/8”-18NC 2

9 3841146 Rod-End 2
10 3322002 Nut, Jam 5/8”-18NC 2
11 Use 1683695 Steer Cylinder Assembly (See Section 5 for Breakdown)

(Prior to S/N 47596) (was p/n 1682527)

1683695 Steer Cylinder Assembly (See Section 5 for Breakdown)

(S/N 47596 to Present)
12 3340644 Pad, Wear 1
13 0641510 Bolt 5/8”-18NC x 1 1/4” 2
14 3311505 Locknut 5/8”-18NC 4
15 4751500 Flatwasher 5/16” 8
16 3020022 Grease A/R
17 4070809 Shim A/R
18 3780182 O-Ring 4
19 0630016 Bolt, Wheel (5 Per Hub) 10
20 0641608 Bolt 3/8”-16NC x 1” (S/N 80825 to Present) 2
21 4740453 Flatwasher 3/8” (S/N 80825 to Present) 2
22 0182002 Angle (S/N 80825 to Present) 1
23 0182000 Angle (S/N 80825 to Present) 1
24 0641514 Bolt 5/16”-18NC x 1 3/4” (S/N 80825 to Present) 2
25 0100019 Loctite (Not Shown) (S/N 80825 to Present) A/R
26 4711600 Flatwasher 3/8” (Narrow) (S/N 82838 to Present) 2

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HUB ASSEMBLIES Ref.

2780186 Original Equipment Ref. C

1001139010 Service Replacement Ref. A

Note: Original Equipment components may have been
replaced with Service Replacement components,
Identify hub by bolts or studs before ordering parts.

101 Kit Cup, Bearing - Inner (1 Per Hub) 2
102 Kit Cone, Bearing - Inner (1 Per Hub) 2
103 Kit Cup, Bearing - Outer (1 Per Hub) 2
104 Kit Cone, Bearing - Outer (1 Per Hub) 2
105 Kit Seal (1 Per Hub) 2

3120882 1-3

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FIGURE 1-1. FRAME AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

106 Use

1001102354

107 Hardware Options (5 Per Spindle): 10

0630016 Bolt, Wheel 1/2in x 20NF(Hub Assembly - 2780186)
7016360 Stud, Wheel 1/2in x 20NF (Hub Assembly -

3300407 Nut, Wheel 1/2in x 20NF (Hub Assembly -

2900804 Bearing & Seal Kit (Includes Qty 1 Items 101-105) (1 Per

4130286 SPINDLE WELDMENT - STANDARD Ref. A

201 0961621 Bushing, Bronze (2 Per Spindle) 2
202 Not Used
203 7012542 Washer (1 Per Spindle) 2

Cap, Dust (1 Per Hub) (was p/n 7012524) 2

1001139010)

1001139010)

— — — — — — — — — —

2

Hub) (Hub Assemblies 2780186 & 1001139010)

1-4 3120882

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

1-6 3120882

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

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FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0255203 WHEEL DRIVE INSTALLATION Ref. 8

1 2780204 Drive Hub Assembly (See Figure 1-3 for Breakdown) 2
2 0920090 Drive Brake Assembly (See Figure 1-4 for Break-

down)

3 3160186 Drive Motor Assembly 2

2900811 Repair Kit (Includes All Bearings, Brushes, Springs

and Wavy Washer (1 Per Motor)
7012546 Field Coil Kit (1 Per Motor) 2
7019609 Head Band Assembly (1 Per Motor) 2

4 3321805 Locknut 1/2”-20NF 18
5 4711800 Flatwasher 1/2” Narrow 22
6 0641811 Bolt 1/2”-13NC x 1 3/8” 4
7 0641608 Bolt 3/8”-16NC x 1” 8
8 4711600 Flatwasher 3/8” Narrow 8

9 4761600 Lockwasher 3/16” 8
10 0630016 Bolt, Wheel 10
11 3990053 Sensor, Tach Drive 2

7012609 Boot 2
12 4761800 Lockwasher 1/2” 4
13 3790240 O-Ring 2

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TIRE AND WHEEL INSTALLATION OPTIONS:

101 0252430 Tire And Wheel Assembly (Foam-Filled) (Sold as an

Assembly)

4520151 Tire And Wheel Assembly (Non-Marking Optional)

(Sold as an Assembly)

0252754 HUBCAP INSTALLATION (OPTIONAL) Ref. B

201 1670633 Hubcap (Prior to S/N 27282) 4

1670806 Hubcap (S/N 27282 to Present) 4
202 0630455 J-Bolt 5/16”-18NC 8
203 4761500 Lockwasher 5/16” 8
204 3300356 Nut, Acorn 5/16”-18NC 8
205 3311501 Nut 5/16”-18NC 8

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FIGURE 1-3. DRIVE HUB ASSEMBLY

1-8 3120882

SECTION 1 FRAME

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FIGURE 1-3. DRIVE HUB ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780204 DRIVE HUB ASSEMBLY Ref. B

Hub-Shaft Assembly 1
1 7010487 Spindle 1
2KitSeal, Lip 1
3 7000255 Cup, Bearing (Outer) 1
4 7000256 Cone, Bearing (Outer) 1
5 7000257 Cup, Bearing (Inner) 1
6 7000258 Cone, Bearing (Inner) 1
7 7000259 Housing 1
8 Kit Washer, Thrust 1
9 Kit Ring, Retaining 1

10 7000242 Plug, Pipe - 1/4”NPTF 2
11 7000241 Stud, Wheel 1/2”-20NF 9
12 7001952 Plug, Pipe - 3/4”NPTF 1
13 7000246 Gear, Internal 1

Carrier Assembly 1

14 7001931 Carrier 1
15 7001985 Washer, Tanged Thrust 6
16 7001909 Bearing, Needle 96
17 7000263 Spacer, Thrust 3
18 7001911 Shaft, Planet 3
19 7001987 Gear, Cluster 3
20 7010474 Rollpin 3
21 7001988 Gear, Ring 1
22 Kit O-Ring 2
23 7000209 Cover, Input 1
24 7010488 Gear, Sun 1
25 7000269 Spacer, Input 1
26 7000270 Washer, Thrust 1
27 7000253 Washer, Thrust 2
28 7000217 Bolt, Hex 8
29 7000214 Bolt, Shoulder 4
30 7000242 Plug, Pipe - 1/4”NPTF 1

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2900034 Seal Kit (Includes Items 2,8,9, and 22) 1

3120882 1-9

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FIGURE 1-4. DRIVE BRAKE ASSEMBLY

1-10 3120882

SECTION 1 FRAME

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FIGURE 1-4. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920090 DRIVE BRAKE ASSEMBLY Ref. A

1 7012552 Magnet and Coil Assembly 1
2 7012582 Armature 1
3 7012554 Shaft 1
4 Not Available Plate, Mounting 1
5 Kit Plate, Friction (Solid) 3
6 Not Used
7 Kit Plate, Outer 2
8 7012692 Spacer 3

9 7014116 Bolt, Metric Socket Head 3
10 Kit Spring, Compression 8
11 7026609 Bearing, Ball 1
12 7014129 Ring, Retainer (External) 1
13 7014130 Ring, Retainer (Internal) 1
14 7012689 Manual Release Assembly 3
15 Not Used
16 Not Used
17 Not Used
18 Not Used
19 3790240 O-Ring 1
20 7012691 Shim A/R
21 7012580 Connector, Electrical 1
22 3790225 O-Ring (January 1995 to Present) 1
23 7014128 Seal (S/N 73241 to Present) 1

— — — — — — — — — —

7012583 Repair Kit (Includes Items 5,7,10,11, and 22 1

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FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED)

1-12 3120882

SECTION 1 FRAME

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FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0255203 DRIVE CONTACTOR INSTALLATION Ref. 8

1 to 11 Not Used

12 0254549 Contactor Plate Assembly (Includes Items 101-111 and other

diodes,coils, fuse and wiring) (Purchase fuses locally)
13 0641408 Bolt 1/4”-20NC x 1” 11
14 4711400 Flatwasher 1/4” 20
15 4761400 Lockwasher 1/4” 7
16 1060540 Cable Assembly 1
17 0641416 Bolt 1/4”-20NC x 2” 4
18 3311405 Locknut 1/4”-20NC 13

19 to 20 Not Used

21 1060549 Cable - 105”/267cm 1
22 1060429 Cable - 39”/99cm 1
23 1060430 Cable - 36”/91.5cm 1
24 1060550 Cable - 108”/274cm 1
25 1060551 Cable - 90”/228cm 1
26 1060552 Cable - 90”/228cm 1
27 1060553 Cable - 90”/228cm 1
28 1060554 Cable - 108”/274cm 1
29 1060555 Cable - 18”/46cm 1
30 Not Used
31 2540023 Grommet 2
32 4060805 Flex-Trim (Prior to S/N 56587)

4060807 Flex-Trim (S/N 56587 to Present)

33 Plate, Mounting Options: 1

3537950 Prior to S/N 75352

3572196 S/N 75352 to Present
34 1320216 Clamp, Cable (Prior to S/N 75352) 1
35 Not Used
36 Screw Options: A/R

0721006 Screw #10-24NC x 3/4” (Prior to S/N 75352) 7

0721008 Screw #10-24NC x 1” (S/N 75352 to Present) 4
37 4751000 Flatwasher #10 13
38 3311005 Locknut #10-24NC 6
39 2400044 Fuseblock 1
40 Fuse Options: 1

2400045 Standard (Prior to S/N 28687)

2400053 Standard (S/N 28687 to Present)
41 0741010 Screw, Countersunk #10-24NC x 1 1/8” 2
42 4060873 Cover, Controller
43 4751400 Flatwasher 1/4” 1
44 3300353 Nut, Tinnerman 1
45 Not Used
46 2560126 Handle, Pull 1

47 to 48 Not Used

49 4420008 Tape, Seal 7ft./2m

1

15in./38cm

15in./38cm

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FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

50 4360371

7012608 Fuse - 1.5 Amp (Black Version Only - Not Required on Blue

51 1702310 Decal - Cable Rounting 1
52 Not Used
53 0100048 Sealant, Silicone RTV (Not Shown) A/R
54 0641406 Bolt 1/4”-20NC x 3/4” 4
55 4360349

56 1320270 Clamp, Cable (S/N 75352 to Present) 2
57 1320061 Clamp, Cable (S/N 75352 to Present) 2

0254549 CONTACTOR PLATE ASSEMBLY Ref.

101 7013310-ES Control Module Assembly 1
102 7013301 Contactor (Changeover) 1

7013316 Tip Repair Kit - 7013301 Contactor 1

103 7013306 Contactor (Main) 1

7013317 Tip Repair Kit - 7013306 Contactor 1

103A 7013332 Micro Switches Kit - 7013306 Contactor 1

104 7013303 Contactor (By-Pass) 1

7013318 Tip Repair Kit - 7013303 Contactor 1

105 7013302 Contactor (Forward/Reverse) 1

7013319 Tip Repair Kit - 7013302 Contactor 1
106 7013312 Fuse, Buss - 200 Amp 1
107 7013336 Bar, Buss 1
108 Not Serviced Plate, Mounting 1
109 7013314 Board, PC 1

2400005 Fuse - 20 Amp 1

7013322 Fuse - 7 Amp 1
110 Not Serviced Decal 1
111 7013313 Harness (Module to Contactors) (Not Shown) 1

7013325 Connector, Electrical - 16 Pin (At PC Board) 1

7013326 Connector, Electrical - 17 Pin (At Control Module) 1

7013330 Connector, Electrical - 6 Pin (At Contactors) 5

7013327 Connector, Electrical - 15 Pin (To JLG Harness) 1

7013328 Connector, Electrical - 4 Pin (To JLG Harness) 1

7013320 Pin (Use with 7013325 & 7013326 Connectors) A/R

7013329 Socket (Use with 7013327 & 7013328 Connectors) A/R

7013331 Pin (Use with 7013330 Connector) A/R
112 7013315 Resistor/Bracket Assembly 1
113 70003552 Cable, Electrical (8.5in/21.5cm) 3
114 70003553 Cable, Electrical (10in/25.4cm) 1

Sensor, Level - 4.5°

and Orange Versions)

Sensor, Level - 2

°

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SECTION 1 FRAME

FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BATTERY CHARGER INSTALLATION OPTIONS: Ref.
0254497 Charger - 220VAC/50HZ - (Non UL) Ref. B
0255627 Charger - 220VAC/50HZ - (UL) Ref.

0255877 Charger - 110VAC/120VAC 50HZ - (Australian Spec) Ref.

0255204 Charger - 100VAC 50/60HZ - (UK Spec) Ref. 2

201 Not Used
202 0641406 Bolt 1/4”-20NC x 3/4” 3
203 4711400 Flatwasher 1/4” Narrow 5
204 3311405 Locknut 1/4”-20NC 1
205 4761400 Lockwasher 1/4” 4
206 0641408 Bolt 1/4”-20NC x 1” 2
207 3300181 Nut, Retainer 1/4”-20NC 2
208 3537637 Cover - Front 1
209 Not Used
210 4060871 Cover - Top 1
211 3900022 Screw, Self-Tapping 1/4”-20NC x 3/4” 2

212 to 250 Not Used

251 Battery Charger Options: (See Figure 1-6 for Breakdown) 1

0400103 220VAC/50HZ (Non UL)
0400137 220VAC/50HZ (UL)
0400130 Australian Spec.
0400111 UK Spec. (Prior to S/N 43921)
0400182 UK Spec. (S/N 43921 to Present)

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BATTERY BOX INSTALLATION OPTIONS: Ref.
0255087 Standard Ref. 8
0254276 HI-Output (Prior to S/N 75765 Ref. H
0258444 HI-Output (S/N 75765 to Present) Ref. 5

301 4844424 Battery Box Weldment 2
302 1670696 Cover, Battery Box 2
303 Cover, Insulator Options: 2

Not Required Standard

2820063 HI-Output

304 0100065 Adhesive (Prior to S/N 36134) A/R
305 2940073 Latch 2
306 4565640 Tube 2
307 4711500 Flatwasher 5/16” 8
308 0641512 Bolt 5/16”-18NC x 1 1/2” 4
309 3000003 Liner, Tray 2
310 Battery Options: 8

0400069 Battery - 6V225 (Wet)
0400112 Battery - 6V225 (Dry)
0400055 HI-Output Battery - 6V370 (Wet)
0400107 HI-Output Battery - 6V370 (Dry)

311 1060405 Cable Assembly 2

3120882 1-15

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FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

312 1060561 Cable, Battery (Prior to August 1995) 6

1060092 Cable, Battery (August 1995 to Present) 6
313 0100048 Silicon Compound A/R
314 0100051 Grease, Terminal A/R
315 1060492 Lanyard 4
316 0641405 Bolt 1/4”-20NC x 5/8” 8
317 3311405 Locknut 1/4”-20NC 8
318 0840031 Boot, Terminal - “d” shape 10
319 0840032 Boot, Terminal - “b” shape 6
320 Gromment Options: 2

Not Required Standard

2540016 HI-Output
321 Ring Options: 2

Not Required Standard

3760170 HI-Output
322 Cable, Lanyard Options: 2

Not Required Standard

1060491 HI-Output
323 Handle, Pull Options: 2

Not Required Standard

1320172 HI-Output
324 3421799 Pin, Quick Release 4
325 0641612 Bolt 3/8”-16NC x 1 1/2” 4
326 4751600 Flatwasher 3/8” 8
327 3311605 Locknut 3/8”-16NC 4
328 Cover, Insulator Options: 4

Not Required Standard

1320172 HI-Output
329 3300429 Nut 5/16”-18NC Stainless 16
330 4740474 Lockwasher 5/16” Stainless 16
331 0630526 Bolt 5/16”-18NC x 1 1/4” Stainless 16

0255213 DRIVE CUTOUT LIMIT SWITCH INSTALLATION Ref. 4

401 Cam Options: 1

1100085 Cam (Prior to S/N 49916)

1100101 Cam (S/N 49916 to Present)
402 4360300 Switch, Limit 1
403 0902033 Bracket, Mounting 1
404 0641408 Bolt 1/4”-20NC x 1” 4
405 4751400 Flatwasher 1/4” 4
406 3311405 Locknut 1/4”-20NC 4
407 4460049 Strain Relief 2
408 Bolt Options: 4

3910832 Bolt #8-32 x 2” (Prior to S/N 49916)

3911032 Bolt #10-32 x 2” (S/N 49916 to Present)
409 Flatwasher Options: 4

4750800 Flatwasher #8 (Prior to S/N 49916)

4751000 Flatwasher #10 (S/N 49916 to Present)

1-16 3120882

SECTION 1 FRAME

FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

410 Lockwasher Options: 4

4760800 Lockwasher #8 (Prior to S/N 49916)
4761000 Lockwasher #10 (S/N 49916 to Present)

411 Nut Options: 4

3310801 Nut #8-32 (Prior to S/N 49916)
3311001 Nut #10-32 (S/N 49916 to Present)

412 to 416 Not Used

417 1320237 Clamp (S/N 49916 to Present) 1
418 4761400 Lockwasher (S/N 49916 to Present) 2
419 4711400 Flatwasher (Narrow) (S/N 49916 to Present) 2
420 0100019 Loctite #271 (S/N 49916 to Present) A/R

0254827 BEACON LIGHT INSTALLATION (OPTIONAL) Ref.

501 4060865 Shield, Cage 1

2920119 Light, Beacon (Prior to S/N 23604) 1
7016319 Bulb, Flash Bulb 1
7016320 Lens, Amber 1
2920146 Light, Beacon (S/N 23604 to Present) 1
7016319 Bulb, Flash Bulb 1
7016372 Lens, Amber 1
0721006 Screw, Machine #10-24NC x 3/4” 2
4751000 Flatwasher #10 4
3311005 Locknut #10-24NC 2
1060341 Cable, Electrical - 16/2

121in/3m

A

S
E

C

T

I
O
N

1

F

R

A

M

E

0255047 HORN INSTALLATION Ref. 3

601 0140028 Horn 1

0641508 Bolt 5/16”-18NC x 1” (Prior to S/N 71522) 1
3311501 Nut 5/16”-18NC (Prior to S/N 71522) 1
4761500 Lockwasher 5/16” (Prior to S/N 71522) 1
1060341 Cable, Electrical - 16/2 8ft/2.4m
0840026 Boot, Terminal 2

ALARMS INSTALLATIONS Ref.

0255046 Descent Ref.

0255044 Motion Ref. A
0255045 Travel Ref. B

701 0140031 Alarm (Remove ground strap before installation) 1

0641408 Bolt 1/4”-20NC x 1” 2
3311401 Locknut 1/4”-20NC 2
4761400 Lockwasher 1/4” 2
4711400 Flatwasher 1/4” 4
1060341 Cable, Electrical - 16/2

7ft./21m

—

3120882 1-17

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0252529 OVERLOAD BY-PASS LIMIT SWITCH INSTALLATION

(FRENCH SPEC ONLY)

801 4360277 Switch, Limit 1

4360236 Head, Switch 1
4360237 Roller 1

Connector, Strain Relief Options: 1
4460052 Prior to S/N 84815
4460428 S/N 84815 to Present

Screw Options: 2
3900163 Screw #10-24NC x 1 1/2” (Prior to S/N 84815)
3901032 Bolt #10-24NC x 2” (S/N 84815 to Present)
3311005 Locknut #10-24NC (S/N 84815 to Present) 2

Ref. 6

1-18 3120882

SECTION 1 FRAME

FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
E

C

T

I
O
N

1

F

R

A

M

E

3120882 1-19

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-6. BATTERY CHARGER ASSEMBLY

1-20 3120882

SECTION 1 FRAME

.

FIGURE 1-6. BATTERY CHARGER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BATTERY CHARGER ASSEMBLY Ref.

0400130 110V Single Voltage (Australian Spec) Ref.

0400103 Non-UL 220VAC/50HZ (Euro Spec Except UK Spec) Ref.

0400137 UL 220VAC/50HZ (Euro Spec Except UK Spec) Ref.

0400111 110/220 Dual Voltage (UK Spec Prior to S/N 43921 See

Notes)

Note: Dual Voltage Battery Chargers with date codes
prior to January 1995 should be replaced as a unit.
Consult JLG Industries (Europe) for Replacement.

Note: See Figure 1-8 for service parts for Battery Char­ger 0400198 (Service Replacement for 0400103 &
0400137 Chargers)

Note: For Dual Voltage Chargers Built S/N 43921 to
Present See Figure 1-7.

Date Code Note: Battery Charger Serial Number Name­plate located on right side of Charger. First line is the
Charger Spec and Date Code. Example: BA515 (Spec)
AP (Date Code). First Letter in the Date Code Indicates
Month (A - January/B - February/C - March/ etc. with
exception of Letter “I” which is not used). Second
Letter Indicates Year (N - 1992/O - 1993/P - 1994/
S - 1995 etc.)

Ref.

—
—
—
—

S
E

C

T

I
O
N

1

F

R

A

M

E

1 7011573 Ammeter 1
2 Board, Circuit Options: 1

Use 7011679 0400130 Chargers (Was p/n 7011662 Prior to January

1995)

7011679 0400130 Chargers (January 1995 to Present)

Use 7011662 0400103/0400137 Chargers (Was p/n 7011588 Prior

to January 1995)

7011662 0400103/0400137 Chargers (January 1995 to

Present)

7011647 0400111 Chargers

3 Condenser Options: 1

7018500 0400130 Chargers
7011623 0400103/0400111 Chargers

7011574 0400137 Chargers
4 7011590 Connector, DC 1
5 Cord, AC Options: 1

7011672 0400130 Chargers

7011669 Socket for 0400130 Chargers

7011544 0400103/0400111 Chargers

7011572 0400137 Chargers

7011674 0400111 Chargers
6 Diode Options: 2

7011668 0400130 Chargers

7011576 0400103/0400137/0400111 Chargers
7 7011593 Fuse, DC - 45 Amp 1
8 7011594 Holder, Fuse - DC 1

3120882 1-21

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-6. BATTERY CHARGER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

9 7011646 Strain Relief (AC Cord) 2

7011528 Strain Relief (DC Cord) 1

10 Triac Options: A/R

7011517 0400103/0400137/0400130 Chargers 1

Not Required 0400111 Chargers 0
11 7011551 Transformer, Control 1
12 Transformer, Main Options: 1

7011669 0400130 Chargers
7011598 0400103/0400137 Chargers

7011648 0400111 Chargers
13 7011584 Varistor 1
14 Fuse, AC Options: 1

7011645 0400130 Chargers

7011508 0400103/0400137/0400111 Chargers
15 7011507 Holder, Fuse - AC 1
16 Not Available Handle 2
17 7011621 Connector, Enable Switch 1
18 Heatsink Options: 1

7011610 0400103/0400137/0400130 Chargers

Not Available 0400111 Chargers
19 7011511 Strap, Condenser 1
20 Automatic Switching Card Options: A/R

Not Required 0400103/0400137/0400130 Chargers 0

Use 7018504 0400111 Chargers Prior to Date Code BT (Was P/N

7011644)

7018530 0400111 Chargers Date Code BT (February 1996) to

Present

21 Relay Options: A/R

Not Required 0400103/0400137/0400130 Chargers 0

7011649 0400111 Chargers 1

1

1

1-22 3120882

SECTION 1 FRAME

FIGURE 1-6. BATTERY CHARGER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
E

C

T

I
O
N

1

F

R

A

M

E

3120882 1-23

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-7. BATTERY CHARGER ASSEMBLY - UK ONLY (110/220 DUAL VOLT­AGE) (S/N 43921 TO PRESENT)

1-24 3120882

SECTION 1 FRAME

.

FIGURE 1-7. BATTERY CHARGER ASSEMBLY - UK ONLY (110/220 DUAL VOLTAGE) (S/N 43921 TO
PRESENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0400182 BATTERY CHARGER ASSEMBLY - UK ONLY (110/220

DUAL VOLTAGE) (S/N 43921 TO PRESENT)

1 7011573 Ammeter 1
2 7018566 Case, Remote Ammeter 1
3 7018597 Breaker, Circuit 2
4 7020607 Board, Circuit 1
5 7011621 Connector 1
6 7020618 Control, Circuit 1
7 7020608 Cord, AC 1
8 7020609 Cord, DC 1

9 7020610 Fuse Assembly - DC 1
10 7018570 Fuse, DC - 80 Amp 1
11 7020611 Harness (Not Shown) 1
12 7018571 Holder, Fuse - DC 1
13 7020612 Insulator, Relay 1
14 7011590 Connector, DC 1
15 7020613 Recifier Assembly 2
16 7020614 Recifier (1 Per Assembly) 1
17 7011649 Relay 1
18 Not Used
19 7020605 Shunt Assembly 1
20 7011528 Strain Relief (DC Cord) 2
21 7020616 Transformer 1
22 Not Used
23 7018537 Varistor 1

Ref.

—

S
E

C

T

I
O
N

1

F

R

A

M

E

3120882 1-25

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-8. BATTERY CHARGER ASSEMBLY - EURO SPEC (SERVICE
REPLACEMENT)

1-26 3120882

SECTION 1 FRAME

.

FIGURE 1-8. BATTERY CHARGER ASSEMBLY - EURO SPEC (SERVICE REPLACEMENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0400198 BATTERY CHARGER ASSEMBLY - EURO SPEC (SERVICE

REPLACEMENT FOR 0400103 & 0400137 BATTERY CHAR­GERS)

1 Use 7011573 Ammeter (was p/n 7022915) 1
2 7022904 Cover Assembly, Case 1
3 7018525 Breaker, Circuit 1
4 7022938 Board, Circuit (was p/n 7022934) 1
5 7011621 Connector 1
6 7022914 Cord, AC 1
7 7022916 Cord, DC 1
8 7018577 Capacitor Assembly (Not Shown) 2

9 7011593 Fuse, DC - 45 Amp 1
10 7020658 Harness (Not Shown) 1
11 7011594 Holder, Fuse - DC 1
12 7011590 Connector, DC 1
13 7020649 Recifier Assembly 2
14 7020650 Recifier (1 Per Assembly) 1
15 7018563 Relay 1
16 7020674 Shunt Assembly 1
17 7011529 Strain Relief 1

7020659 Strain Relief 1
18 Use 7022939 Transformer (was p/n 7022917) 1
19 7020633 Varistor Assembly 1

Ref.

—

S
E

C

T

I
O
N

1

F

R

A

M

E

3120882 1-27

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-9. FRAME MOUNTED COMPONENTS INSTALLATION

1-28 3120882

SECTION 1 FRAME

.

FIGURE 1-9. FRAME MOUNTED COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0253995 AXLE COVER INSTALLATION Ref. 3

1 3538294 Cover 1
2 3900174 Thumbscrew 4
3 3760308 Retainer 4
4 1380138 Clip, Receptacle 4
5 3960447 Seal
6 2560003 Handle 1
7 3820020 Rivet 4
8 4751000 Flatwasher #10 4
9 3538157 Plate, Drain (Prior to S/N 70891) 2

10 0791004 Screw #10 x 1/2” (Prior to S/N 70891) 8

LADDER INSTALLATION OPTIONS: Ref.
0254459 Model 3369 (Prior to S/N 33424) Ref. A
0257335 Model 3369 (S/N 33424 to Present) Ref. 4
0254461 Model 3969 (Prior to S/N 33811) Ref. A
0257334 Model 3969 (S/N 33811 to Present) Ref. 4

11.5ft./3.5m

S
E

C

T

I
O
N

1

F

R

A

M

E

101 Not Used
102 0641610 Bolt 3/8”-16NC x 1 1/4” (Prior to S/N 56271) 2

0641612 Bolt 3/8”-16NC x 1 1/4” (S/N 56271 to Present) 4
103 4751600 Flatwasher 3/8” 8
104 4761600 Lockwasher 3/8” (Prior to S/N 55724) 4
105 3311601 Nut 3/8”-16NC (Prior to S/N 55724) 4

3311605 Nut 3/8”-16NC (S/N 55724 to Present)) 4
106 4300034 Stud (Welded on Parts) (Prior to February 1995) 2
107 3520071 Cap 4

108 to 150 Not Used

151 Ladder Options: 1

4844636 Model 3369 (Prior to S/N 33424)

4845492 Model 3369 (S/N 33424 to S/N 54195)

4845916 Model 3369 (S/N 54195 to Present)

4844638 Model 3969 (Prior to S/N 33811)

4845491 Model 3969 (S/N 33811 to S/N 54195)

4845917 Model 3969 (S/N 54195 to Present)

0255065 ANTI-STATIC STRAP INSTALLATION Ref. 2

201 4240084 Strap, Anti-Static 1
202 0641508 Bolt 5/16”-18NC x 1” 1
203 3311501 Nut 5/16”-18NC 1
204 4761500 Lockwasher 5/16” 1
205 4751500 Flatwasher 5/16” 2
206 3538157 Plate, Drain (S/N 70891 to Present) 2
207 0791004 Screw #10 x 1/2” (S/N 70891 to Present) 8

3120882 1-29

SECTION 1 FRAME

S
E

C

T

I
O
N

1

F

R

A

M

E

FIGURE 1-9. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-30 3120882

SECTION 2 GROUND COMPONENTS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

2-1 HYDRAULIC COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

S
E

C

T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

E
N

T

S

3120882 2-1

S
E
C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. HYDRAULIC COMPONENTS INSTALLATION

U
N
D

C
O

M

P
O
N

E
N

T

S

2-2 3120882

SECTION 2 GROUND COMPONENTS

..

FIGURE 2-1. HYDRAULIC COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254492 HYDRAULIC TANK AND FILTER INSTALLATION Ref. 4

1 4400358 Tray, Hydraulic 1
2 3520077 Plug, Fill 1
3 1340052 Breather 1
4 3538236 Plate, Support 1
5 0641408 Bolt 1/4”-20NC x 1” 4
6 4751400 Flatwasher 1/4” 16
7 4761400 Lockwasher 1/4” 13
8 2820064 Insulator, Rubber 4

9 0641405 Bolt 1/4”-20NC x 5/8” 13
10 0902034 Bracket, Mounting 1
11 2120105 Filter Assembly 1

2120072 Element, Filter 1
12 0641404 Bolt 1/4”-20NC x 1/4” (Prior to S/N 39555) 9
13 4566413 Tube, Return 1
14 2220347 Fitting, Straight 1
15 1320033 Clamp, Hose 1
16 Cover, Hose Options: 1

4060866 Prior to S/N 71522

4060983 S/N 71522 to Present
17 3311405 Locknut 1/4”-20NC 4
18 0100020 Sealant (Not Shown) A/R
19 2200053 Plug, Drain (Prior to S/N 50189) 1

2200233 Plug, Drain (S/N 50189 to Present) 1
20 4060867 Cover, Rear 1
21 3300377 Stand-off 4
22 0641406 Bolt 1/4”-20NC x 3/4” (S/N 71522 to Present) 2
23 0100011 Loctite #242 (Not Shown) (S/N 71522 to Present) A/R
24 3300353 Nut, Tinnerman (S/N 71522 to Present) 2

S
E
C
T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

0255270 HYDRAULIC MOTOR AND VALVE ASSEMBLY (PRIOR TO

JULY 1994)

0255843 HYDRAULIC MOTOR AND VALVE ASSEMBLY (JULY 1994

TO PRESENT)

0258797 HYDRAULIC MOTOR AND VALVE ASSEMBLY - CE (WITH

ELECTRIC BRAKE RELEASE) (S/N 53019 TO PRESENT)

0258796 HYDRAULIC MOTOR AND VALVE ASSEMBLY - AUSTRA-

LIAN SPEC (S/N 53019 TO PRESENT)

101 3538736 Plate, Mounting 1
102 3300377 Stand-off 4
103 3311405 Locknut 1/4”-20NC 14
104 4751400 Flatwasher 1/4” 29
105 4761400 Lockwasher 1/4” 4
106 0641406 Bolt 1/4”-20NC x 3/4” 10
107 0181747 Angle 4
108 0641408 Bolt 1/4”-20NC x 1” 4
109 4640915 Control Valve (See Figure 2-2 for Breakdown) 1

3120882 2-3

Ref. 5

Ref. 4

Ref. 2

Ref. 2

E
N

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. HYDRAULIC COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

110 0641507 5/16”-18NC 10
111 4761500 Lockwasher 5/16” 4
112 4751500 Flatwasher 5/16” 18
113 3311505 Locknut 5/16”-18NC 6
114 3160194 Motor Assembly 1

7023231 Endhead, Drive 1
7023479 Armature 1
2900811 Repair Kit - 3160194 Motor (Includes Bearing, Brushes,

Springs and Wavy Washer)
115 3600220 Pump Assembly (See Figure 2-3 for Breakdown) 1
116 0641608 Bolt 3/8”-16NC x 1” 2
117 4761600 Lockwasher 3/8” 2
118 4640859 Pump Assembly - Manual Descent (See Items 201-203 for

Breakdown)
119 0641424 Bolt 1/4”-20NC x 3” 2
120 2560123 Grip 1
121 2560122 Handle (Prior to S/N 45740) 1

2560155 Handle (S/N 45740 to Present) 1
122 1380136 Clip, Grip 2
123 3820019 Rivet 2
124 0902038 Bracket, Mounting 1
125 Ground Control Box Assembly Options: (See Figure 2-4 for

Breakdown)
0860969 Prior to July 1995
0861014 July 1995 to Present
0861248 CE With Electric Brake Release (S/N 53019 to Present)
0861247 Australian Spec (S/N 53019 to Present)

126 3537692 Plate, Shield 1
127 Cover, Hose Options: 1

4060866 Prior to S/N 71522
4060983 S/N 71522 to Present

128 4711600 Flatwasher 3/8” 2
129 0840027 Boot, Terminal (September 1995 to Present) 2
130 Angle, Valve Mounting Options: 1

Not Required Prior to October 1994

0181791 October 1994 to Present

131 0100011 Loctite #242 (Not Shown) (S/N 71522 to Present) A/R
132 3300353 Nut, Tinnerman (S/N 71522 to Present) 2

1

1

1

4640859 PUMP ASSEMBLY - MANUAL DESCENT Ref.

201 7012952 Pump Cartridge Assembly 1

2900708 Seal Kit 1

202 7012954 Release Cartridge Assembly 1

7012953 Seal Kit - 7012954 Valve 1
7012961 Knob 1

203 7012955 Check Cartridge Assembly 1

7012540 Seal Kit - 7012955 Valve 1

2-4 3120882

—

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. HYDRAULIC COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0257177 PUMP ASSEMBLY - MANUAL DESCENT Ref. 1

251 4641007 Valve, Check 5psi 1

S
E

C

T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

E
N

3120882 2-5

S
E
C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-2. CONTROL VALVE ASSEMBLY

U
N
D

C
O

M

P
O
N

E
N

T

S

2-6 3120882

SECTION 2 GROUND COMPONENTS

.

FIGURE 2-2. CONTROL VALVE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4640915 CONTROL VALVE ASSEMBLY Ref. F

1 7011323 Cartridge, Valve (Counterbalance) 1

2900770 Seal Kit 1

2 7012962 Cartridge, Valve (Steer and Lift Down Relief) 2

2900708 Seal Kit 2

3 Cartridge, Relief Options: (Lift Up and Main) 1

See Note Prior to February 1996 (Note: Use 7017400 in place of

original part number 7012963)
7017400 February 1996 to Present
2900708 Seal Kit - 7012963 and 7017400 Cartridges 1

4 Not Serviced Block 1
5 4640865 Valve Assembly - Steer (Prior to S/N 56599) 1

7012725 Seal Kit 1
7012752 Coil 2
4641088 Valve Assembly - Steer (S/N 56599 to Present) 1
7012773 Seal Kit 1
7021321 Coil 2

6 4640864 Valve Assembly - Lift (Prior to S/N 56599) 1

7012725 Seal Kit 1
7012752 Coil 2
4641087 Valve Assembly - Lift (S/N 56599 to Present) 1
7012773 Seal Kit 1
7021321 Coil 2

7 7010542 Cartridge, Shuttle 1

7010543 Seal Kit 1

8 4460499 Plug (Supplied with Harness) 4

0253647 PRESSURE CHECK INSTALLATION (NOT SHOWN) Ref.

—

S
E

C

T

I
O
N

2

G
R
O
U
N
D

C
O

M

P

O

2220466

2751394 Hose 2
2220414 Fitting, Straight 2
2220428 Fitting, Quick Disconnect 2
2220429 Cap, Quick Disconnect 2

3120882 2-7

Fitting, 90

°

2

N

E

N

S
E
C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-3. PUMP ASSEMBLY

U
N
D

C
O

M

P
O
N

E
N

T

S

2-8 3120882

SECTION 2 GROUND COMPONENTS

.

FIGURE 2-3. PUMP ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3600220 PUMP ASSEMBLY Ref.

1 7010102 Bearing 2
2 Not Serviced Housing 1
3 7010100 Flange, Front 1
4 7010103 Cover 1
5 7010101 Gear, Drive 1
6 7007499 Gear, Idle 1
7 Kit Ring, Anti-Extrusion 2
8 Kit Seal, Pressure 2

9 Not Serviced Bolt 4
10 7010104 Ring, Snap 1
11 Not Serviced Pin, Dowel 4
12 Kit Seal, Outer 2
13 7007298 Seal, Shaft 1

— — — — — — — — — —

7007489 Seal Kit - 3600220 Pump (Includes Items 7,8,12 and 13) 1

—

S
E

C

T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

E
N

3120882 2-9

S
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C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY

U
N
D

C
O

M

P
O
N

E
N

T

S

2-10 3120882

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0860969 GROUND CONTROL BOX ASSEMBLY (PRIOR TO JULY

1995)

0861014 GROUND CONTROL BOX ASSEMBLY (JULY 1995 TO

PRESENT)

0861248 GROUND CONTROL BOX ASSEMBLY (CE WITH ELECTRIC

BRAKE RELEASE) (S/N 53019 TO PRESENT)

0861247 GROUND CONTROL BOX ASSEMBLY (AUSTRALIAN WITH

ELECTRIC BRAKE RELEASE) (S/N 53019 TO PRESENT)

1 Box Options: 1

0860970 Prior to S/N 53019
0861246 S/N 53019 to S/N 66901
0861312 S/N 66901 to S/N 72148

0861342 S/N 72148 to Present
2 3300177 Nut, Tinnerman 4
3 0750806 Screw, Self-Tap #8 x 3/4” 4
4 4740120 Washer, Nylon 4
5 0860971 Lid, Box 1
6 4420037 Strip, Rubber
7 4460052 Connector, Strain Relief 3
8 0960239 Bushing 3
9 3300047 Locknut, Conduit 3

10 4460071 Connector, Strain Relief 1
11 0960238 Bushing 2
12 3300048 Locknut, Conduit 2
13 Nameplate Options: 1

3252330 Prior to S/N 66901

3252651 S/N 66901 to S/N 72148

3252666 S/N 72148 to Present

14 Switch, Key Options: A/R

4360347 Switch, Key (Prior to S/N 66901) 1

7012587 Keys, Replacement 1 Set

4360474 Switch, Key (S/N 66901 to Present) 1

2860030 Keys, Replacement 1 Set

15 4360314 Switch, Toggle 1
16 3790012 O-Ring 1
17 2420106 Gauge, Hourmeter 1
18 Not Used
19 4750600 Flatwasher #6 2
20 4760600 Lockwasher #6 2
21 3310601 Nut #6-32NC 2
22 3740087 Relay (Std Qty 2/With Options Qty 3 or 4) A/R
23 4120027 Socket (Std Qty 2/With Options Qty 3 or 4) A/R
24 3910606 Screw #6-32NC x 3/8” 2
25 3640865 Strip, Terminal (Prior to S/N 53228) 1

3641308 Strip, Terminal (S/N 53228 to Present) 1

26 4460299 Stop, Terminal 2
27 4460298 Block, Terminal 35
28 4460301 Strip, Terminal Marking 1

Ref. B

Ref.

Ref.

Ref.

52in/1.3m

6

5

5

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E

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T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

E
N

3120882 2-11

S
E
C
T

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N

2

G

R

O

U
N
D

C
O

M

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

29 4460300 Barrier, Terminal 2
30 Not Used
31 4921700 Harness - Ground Control Box to Control Module 1
32 4921666 Harness - Ground Control Box to Valves 1
33 4460310 Bar, Buss 1
34 4460300 Barrier, Terminal 1
35 4460308 Bar, Buss 1
36 Not Used
37 4360274 Switch, Push Button (Prior to S/N 72148) 1
38 3740063 Clip, Relay (Std Qty 2/With Options Qty 3 or 4) A/R
39 4460305 Screw, Terminal 8
40 4460306 Washer, Terminal 8
41 4460307 Sleeve, Terminal 8
42 4460051 Connector, Strain Relief A/R
43 4360282 EMS, Contact Block (S/N 72148 to Present) 1
44 4740066 Washer, Thrust (S/N 72148 to Present) 1
45 4360475 Switch, E-Stop (S/N 72148 to Present) 1

7020175 Cap/E-Stop With Seal 1
7020176 Contact Block W/Mount 1

46 4922133 Harness - Brake Disconnect MTB (Machines Equipped With

Electric Brake Release Only)

47 4922065 Harness - Brake Disconnect Switch (Machines Equipped With

Electric Brake Release Only)

48 3990001 Diode 3.5 Amp (CE Machines Equipped With Electric Brake

Release Only) (Not Shown)

49 2820026 Loom (CE Machines Equipped With Electric Brake Release

Only) (Not Shown)

1

1

1

08ft/.02m

.

P
O
N

E
N

T

S

0255253 KEY ATTACH LANYARD (OPTIONAL) Ref. A

101 1060380 Cable, Lanyard 1
102 3760170 Ring 1

2-12 3120882

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY (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

3120882 2-13

S
E
C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. COVERS INSTALLATION

U
N
D

C
O

M

P
O
N

E
N

T

S

2-14 3120882

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. COVERS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254494 COVERS INSTALLATION Ref. 4

1 4060868 Cover (Left Side) 1
2 4060869 Cover (Right Side) 1
3 2560124 Handle, Pull 4
4 Not Used
5 3340747 Pad, Slide 4
6 Not Used
7 0641410 Bolt 1/4”-20NC x 1 1/4” 16
8 4751400 Flatwasher 1/4” (Wide) 32

9 3311405 Locknut 1/4”-20NC 16
10 Not Used
11 Not Used
12 0181742 Angle, Slide Mount 4
13 2940080 Latch 2
14 3911008 Screw, Round Head #10-24NC x 1/2” 6
15 4761000 Lockwasher #10 6
16 1320136 Clamp 2
17 3760170 Ring 4
18 1060379 Lanyard 2
19 2940065 Latch 2
20 3860090 Roller, Stop (S/N 71522 to Present) 4

S
E

C

T

I
O
N

2

G
R
O
U
N
D

C
O

M

P
O
N

E
N

3120882 2-15

S
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C
T

I
O
N

2

G

R

O

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. COVERS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

U
N
D

C
O

M

P
O
N

E
N

T

S

2-16 3120882

SECTION 3 SCISSOR ARMS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

3-1 SCISSOR ARMS INSTALLATION - 3369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 SCISSOR ARMS INSTALLATION - 3969 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 ARM GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

S
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N

3

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O
R

A
R

M

S

3120882 3-1

S
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N

3

S

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - MODEL 3369

C

I

S

S
O
R

A
R

M

S

3-2 3120882

SECTION 3 SCISSOR ARMS

.

FIGURE 3-1. SCISSOR ARMS INSTALLATION - MODEL 3369

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254239 SCISSOR ARMS INSTALLATION - STANDARD Ref. 11

1 0200495 Arm Weldment (Lower Inboard) 1
2 0200496 Arm Weldment (2nd Inboard) 1
3 0200497 Arm Weldment (3rd Inboard)
4 0200521 Arm Weldment (Top Inboard) 1
5 0200523 Arm Weldment (4nd Inboard) 1
6 0200500 Arm Weldment (Lower and Top Outboard) 2
7 0200501 Arm Weldment (2nd Outboard Left Side) 1
8 0200502 Arm Weldment (2nd Outboard Right Side) 1

9 3422199 Pin, Pivot 1
10 3422200 Pin, Pivot 1
11 3422201 Pin, Cylinder Attach 4
12 3422202 Pin, Pivot 9
13 4640381 Holding Valve Assembly 2

7000644 Coil (Hydraforce Version) A/R
7004334 Coil (Modular Controls Version) A/R
2900756 Seal Kit (Hydraforce Version) A/R

2900503 Seal Kit (Modular Controls Version) A/R
14 3422204 Pin, Pivot 4
15 3340669 Pad, Sliding (Bolt On) 4
16 3340675 Pad, Sliding (Pivoting) 4
17 1682935 Lift Cylinder Assembly (See Section 5 for Breakdown) 2
18 0200503 Arm Weldment (3rd Outboard Right Side) 1
19 0200504 Arm Weldment (3rd Outboard Left Side) 1
20 3538343 Prop, Safety 2

4844380 Prop, Safety (S/N’s 11657, 12289 and 12651 Only) 2
21 Not Used
22 0200522 Arm Weldment (4th Outboard Left Side) 1
23 4751600 Flatwasher 3/8” 32
24 0961756 Bushing, Spacer (S/N’s 11657, 12289 and 12651 Only) (Not

Shown - Located at Item 20)
25 1440227 Collar 28
26 0641528 Bolt 5/16”-18NC x 3 1/2” 28
27 3311505 Locknut 5/16”-18NC 47
28 0630471 Bolt, Special 4
29 0641624 Bolt 3/8”-16NC x 3” 16
30 3311605 Locknut 3/8”-16NC 18
31 3422275 Pin, Pivot 2
32 3841203 Pin, Keeper 4
33 3311805 Locknut 1/2”-13NC 4
34 0232139 Lock, Prop (Right Side) (S/N’s 11657, 12289 and 12651 Only)

(Not Shown - Located at Item 20)
35 0232140 Lock, Prop (Left Side) (S/N’s 11657, 12289 and 12651 Only)

(Not Shown - Located at Item 20)
36 0200524 Arm Weldment (4th Outboard Right Side) 1
37 2940081 Latch 2
38 0641405 Bolt 1/4”-20NC x 5/8” 8
39 4751400 Flatwasher 1/4” 8

S
E

C

T

I
O
N

3

S

C

I

S

S
O
R

A
R

2

M

S

1

1

3120882 3-3

S
E

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O
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3

S

C

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - MODEL 3369 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

40 4761400 Lockwasher 1/4” 8
41 3422416 Pin, Pivot 1
42 Not Used
43 3422202 Pin, Pivot 1
44 0641526 Bolt 5/16”-18NC x 3 1/4” 19
45 0902156 Bracket 2
46 0961664 Bushing, Gar-Max 26
47 1320061 Clamp, Cable (Not Shown) (Prior to S/N 68667) 8
48 4300038 Stud (Welded on Part) (Not Shown) (Prior to S/N 68667) 8
49 4761500 Lockwasher 5/16” (Not Shown) (Prior to S/N 68667) 8
50 3311501 Nut 5/16”-18NC (Not Shown) (Prior to S/N 68667) 8
51 4070964 Shim (S/N 37453 to Present) 2
52 4740229 Shims, Washer (S/N 37453 to Present) 2
53 0200697 Arm Weldment (Top Outboard) 1

2901327 Sizzor Arms Kit (Includes Items 1-8, 18, 19, 20, 22, 36 and

53)

0252588 ARM PADS INSTALLATION Ref. 3

13

I

S

S
O
R

A
R

M

S

101 3340645 Pad (Prior to S/N 47469) 32

3340841 Pad (S/N 47469 to S/N 53856) 32
3340848 Pad (S/N 53856 to Present) 32

0257362 PLATFORM CONTROL BOX CABLE ROUTING INSTALLA-

TION (NOT SHOWN) (S/N 31253 TO S/N 68667)

151 4240033 Strap, Tie 8

1320061 Clamp 11
0641508 Bolt 5/16”-18NC x 1” 10
4751500 Flatwasher 5/16” 20
3311505 Locknut 5/16”-18NC 10

0259832 PLATFORM CONTROL BOX CABLE ROUTING INSTALLA-

TION (NOT SHOWN) (S/N 68667 TO PRESENT)

151 1320061 Clamp 7

0641408 Bolt 1/4”-20NC x 1” 7
4751400 Flatwasher 1/4” 14
3311405 Locknut 1/4”-20NC 7
4240033 Strap, Tie 8

Ref. 1

Ref. 1

3-4 3120882

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - MODEL 3369 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
E

C

T

I
O
N

3

S

C

I

S

S
O
R

A
R

M

S

3120882 3-5

S
E

C

T

I
O
N

3

S

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - MODEL 3969

C

I

S

S
O
R

A
R

M

S

3-6 3120882

SECTION 3 SCISSOR ARMS

.

FIGURE 3-2. SCISSOR ARMS INSTALLATION - MODEL 3969

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0253761 SCISSOR ARMS INSTALLATION - STANDARD Ref. 12

1 0200495 Arm Weldment (Lower Inboard) 1
2 0200496 Arm Weldment (2nd Inboard) 1
3 0200497 Arm Weldment (3rd Inboard)
4 0200498 Arm Weldment (5th Inboard) 1
5 0200499 Arm Weldment (Top Inboard) 1
6 0200500 Arm Weldment (Lower and Top Outboard) 2
7 0200501 Arm Weldment (2nd and 5th Outboard Left Side) 2
8 0200502 Arm Weldment (2nd and 5th Outboard Right Side) 2

9 3422199 Pin, Pivot 1
10 3422200 Pin, Pivot 1
11 3422201 Pin, Cylinder Attach 4
12 3422202 Pin, Pivot 10
13 4640381 Holding Valve Assembly 2

7000644 Coil (Hydraforce Version) A/R
7004334 Coil (Modular Controls Version) A/R
2900756 Seal Kit (Hydraforce Version) A/R

2900503 Seal Kit (Modular Controls Version) A/R
14 3422204 Pin, Pivot 4
15 3340669 Pad, Sliding (Bolt On) 4
16 3340675 Pad, Sliding (Pivoting) 4
17 1682935 Lift Cylinder Assembly (See Section 5 for Breakdown) 2
18 0200503 Arm Weldment (3rd Outboard Right Side) 1
19 0200504 Arm Weldment (3rd Outboard Left Side) 1
20 3538343 Prop, Safety 2

4844380 Prop, Safety (S/N’s 11657, 12289 and 12651 Only) 2
21 0200523 Arm Weldment (4th Inboard) 1
22 0200522 Arm Weldment (4th Outboard Left Side) 1
23 4751600 Flatwasher 3/8” 32
24 0961756 Bushing, Spacer (S/N’s 11657, 12289 and 12651 Only) (Not

Shown - Located at Item 20)
25 1440227 Collar 34
26 0641528 Bolt 5/16”-18NC x 3 1/2” 56
27 3311505 Locknut 5/16”-18NC 56
28 0630471 Bolt, Special 4
29 0641624 Bolt 3/8”-16NC x 3” 16
30 3311605 Locknut 3/8”-16NC 18
31 3422275 Pin, Pivot 2
32 3841203 Pin, Keeper 4
33 3311805 Locknut 1/2”-13NC 4
34 0232139 Lock, Prop (Right Side) (S/N’s 11657, 12289 and 12651 Only)

(Not Shown - Located at Item 20)
35 0232140 Lock, Prop (Left Side) (S/N’s 11657, 12289 and 12651 Only)

(Not Shown - Located at Item 20)
36 0200524 Arm Weldment (4th Outboard Right Side) 1
37 2940081 Latch 2
38 0641405 Bolt 1/4”-20NC x 5/8” 8
39 4751400 Flatwasher 1/4” 8

S
E

C

T

I
O
N

3

S

C

I

S

S
O
R

A
R

2

M

S

1

1

3120882 3-7

S
E

C

T

I
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3

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - MODEL 3969 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

40 4761400 Lockwasher 1/4” 8
41 3422416 Pin, Pivot 1
42 Not Used
43 3422202 Pin, Pivot 3
44 Not Used
45 0641526 Bolt 5/16”-18NC x 3 1/4” 19
46 0902156 Bracket 2
47 0961664 Bushing, Gar-Max 26
48 1320061 Clamp, Cable (Not Shown) (Prior to S/N 68667) 8
49 4300038 Stud (Welded on Part) (Not Shown) (Prior to S/N 68667) 8
50 4761500 Lockwasher 5/16” (Not Shown) (Prior to S/N 68667) 8
51 3311501 Nut 5/16”-18NC (Not Shown) (Prior to S/N 68667) 8
52 4070964 Shim (S/N 37453 to Present) 2
53 4740229 Shims, Washer (S/N 37453 to Present) 2

2901326 Sizzor Arms Kit (Includes Items 1-8, 18, 19-22 and 36) 1

S

C

I

S

S
O
R

A
R

M

S

0254475 ARM PADS INSTALLATION Ref. 3

101 3340645 Pad (Prior to S/N 47469) 40

3340841 Pad (S/N 47469 to S/N 53856) 40
3340848 Pad (S/N 53856 to Present) 40

0257363 PLATFORM CONTROL BOX CABLE ROUTING INSTALLA-

TION (NOT SHOWN) (PRIOR TO S/N 68667)

151 4240033 Strap, Tie 8

1320061 Clamp 13
0641508 Bolt 5/16”-18NC x 1” 12
4751500 Flatwasher 5/16” 24
3311505 Locknut 5/16”-18NC 12

0259833 PLATFORM CONTROL BOX CABLE ROUTING INSTALLA-

TION (NOT SHOWN) (S/N 68667 TO PRESENT)

151 1320061 Clamp 8

0641408 Bolt 1/4”-20NC x 1” 8
4751400 Flatwasher 1/4” 16
3311405 Locknut 1/4”-20NC 8

Ref. 1

Ref.

3-8 3120882

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - MODEL 3969 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
E

C

T

I
O
N

3

S

C

I

S

S
O
R

A
R

M

S

3120882 3-9

S
E

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N

3

S

SECTION 3 SCISSOR ARMS

FIGURE 3-3. ARM GUARD INSTALLATION

C

I

S

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A
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M

S

3-10 3120882

SECTION 3 SCISSOR ARMS

.

FIGURE 3-3. ARM GUARD INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254374 ARM GUARD INSTALLATION Ref. 7

1 4844624 Weldment, Arm Guard End Rail 2
2 4844625 Weldment, Arm Guard Side 1
3 3430416 Pin Clevis 1/4” x 2” 4
4 3580228 Sheave, Cable 4
5 4844856 Weldment, Tube 2
6 4160122 Spring 2
7 1060578 Cable 4
8 0181737 Angle 4

9 4751500 Flatwasher 5/16” 24
10 4761500 Lockwasher 5/16” (Prior to S/N 80825) 16
11 3311505 Locknut 5/16”-18NC 16
12 1320217 Clip, Wire 4
13 4060862 Netting, Arm Guard 2
14 4240023 Strap, Tie 104
15 0641508 Bolt 5/16”-18NC x 1” 4
16 4300038 Stud 5/16”-18NC x 1” (Welded Part) (Prior to February 1995) 8
17 4060861 Netting, Arm Guard 2
18 4060864 Netting, Arm Guard 1
19 4060860 Guard, Accordian 2
20 0641516 Bolt 5/16”-18NC x 2” 4
21 4844692 Weldment, Arm Guard Side 1
22 4060863 Netting, Arm Guard 1
23 3450203 Cotter Pin 4
24 4420055 Tape
25 4562083 Tube, Spacer 8
26 Pad Options: 4

3340645 Pad (Prior to S/N 47115)

3340841 Pad (S/N 47115 to Present)
27 Not Used
28 0641510 Bolt 5/16”-18NC x 1 1/4” 8

8in/20.3cm

S
E

C

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I
O
N

3

S

C

I

S

S
O
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A
R

M

S

2901867 Kit, Netting (Includes Items 13, 17, 18 & 22) 1 1

3120882 3-11

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3

S

SECTION 3 SCISSOR ARMS

FIGURE 3-3. ARM GUARD INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

C

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3-12 3120882

SECTION 4 PLATFORM

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 MANUAL PLATFORM EXTENSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-3 PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506) . . . . . . . . . . . . . . . . . . . . . . 4-12

4-4 PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT) . . . . . . . . . . . . . . . . . . . 4-16

4-5 CONTROLLER ASSEMBLY - PQ (PRIOR TO S/N 71506). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-6 CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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4

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M

3120882 4-1

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4

SECTION 4 PLATFORM

FIGURE 4-1.PLATFORM COMPONENTS INSTALLATION

P
L
A
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F
O
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M

4-2 3120882

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3510410 PLATFORM WELDMENT 1

HANDRAIL INSTALLATION OPTIONS: Ref.

0253940 Handrails Without Extension Ref. 8
0253939 Handrails With Extension Ref. 12
0257361 Handrails With Swing Gate (S/N 33811 to Present) Ref. 4

1 3640857 Rail Weldment - Side 2
2 Rail Weldment - Rear Options: 1

3640859 Rail Weldment - Rear

4845494 Rail Weldment With Swing Gate - Rear
3 0901870 Bracket 2
4 Not Required
5 Not Required
6 Not Required
7 0641420 Bolt 1/4”-20NC x 2 1/2” A/R
8 4711400 Flatwasher 1/4” Narrow A/R
9 4420055 Tape 1ft./31cm

10 3311405 Locknut 1/4”-20NC A/R
11 Rail Weldment 1

3640860 Rail Weldment - With Out Extension

3640860 Rail Weldment - With Extension

Not Required Rail Weldment - With Swing Gate
12 0641416 Bolt 1/4”-20NC x 2” 2
13 3422219 Spring Pin A/R
14 1060379 Cable, Lanyard A/R
15 0961845 Bushing 6
16 0641406 Bolt 1/4”-20NC x 3/4” A/R
17 Kick Plate Options: 1

3536936 Kick Plate - With Out Extension
Not Required Kick Plate - With Extension
Not Required Kick Plate - With Swing Gate

18 3520072 Plug, Cap A/R
19 Rail Weldment - Front Options: 1

3640858 Rail Weldment With Out Extension
Not Required Rail Weldment With Extension
Not Required Rail Weldment With Swing Gate

20 3252234 Decal (Prior to S/N 56271) 1
21 Not Used
22 Plate, Kick Options: 1

3536987 Plate, Kick - With Drop Gate
Not Required Plate, Kick - With Swing Gate

23 4160028 Spring (Machines With Swing Gate Option Only) 1
24 4751500 Flatwasher 5/16” 4
25 Not Used
26 0641420 Bolt 1/4”-20NC x 2 1/2” 12

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4

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3120882 4-3

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4

P
L

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

27 Ring Options: A/R

3760170 Ring - With Out Extension
Not Required Ring - Machine With Extension
Not Required Ring - Machine With Swing Gate

28 Hinge Options: 1

2600201 Hinge - With Out Extension
Not Required Hinge - With Extension
Not Required Hinge - With Swing Gate

29 4740411 Washer, Nylon 20
30 3300375 Nut, Binding 2
31 3900184 Screw, Special 2
32 Not Required
33 Not Required
34 2940074 Latch (Machines With Swing Gate Option Only) 1
35 3911014 Screw #10-24NC x 7/8” (Machines With Swing Gate

Option Only)

36 3311005 Locknut #10-24NC (Machines With Swing Gate

Option Only)

37 4751000 Flatwasher #10 (Machines With Swing Gate Option

Only)

38 0100011 Loctite #242 (Not Shown) A/R

4

4

4

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0254828 WORKLIGHTS INSTALLATION - 3369 (OPTIONAL) Ref. B
0254829 WORKLIGHTS INSTALLATION - 3969 (OPTIONAL) Ref. 2

101 2920095 Worklight 2

1060341 Cable, Electrical - 16-2 A/R
0901930 Bracket 2
0641416 Bolt 1/4”-20NC x 2” 2
3311405 Locknut 1/4”-20NC 2
4240033 Strap, Tie 14

0255032 BEACON LIGHT INSTALLATION - 3369 (OPTIONAL) Ref. A
0255034 BEACON LIGHT INSTALLATION - 3969 (OPTIONAL) Ref. A

201 4060865 Shield, Cage 1

2920119 Light, Beacon (Prior to S/N 23604) 1
7016319 Bulb, Flash Bulb 1
7016320 Lens, Amber 1
2920146 Light, Beacon (S/N 23604 to Present) 1
7016319 Bulb, Flash Bulb 1
7016372 Lens, Amber 1
0721006 Screw, Machine #10-24NC x 3/4” 2
4751000 Flatwasher #10 4
3311005 Locknut #10-24NC 2
1060341 Cable, Electrical 16/2 A/R

4-4 3120882

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254825 110 VOLT RECEPTACLE INSTALLATION - MODEL

3369 (OPTIONAL)

0254826 110 VOLT RECEPTACLE INSTALLATION - MODEL

3969 (OPTIONAL)

0255786 220 VOLT RECEPTACLE INSTALLATION - MODEL

3369 (OPTIONAL)

0255787 220 VOLT RECEPTACLE INSTALLATION - MODEL

3969 (OPTIONAL)

301 Supply Locally Box, Mounting 1
302 Supply Locally Receptacle 1
303 Supply Locally Shield, Cover 1
304 3538051 Plate, Mounting 1
305 0641406 Bolt 1/4”-20NC x 3/4” 2
306 4751400 Flatwasher 1/4” 4
307 3311405 Locknut 1/4”-20NC 2
308 1320061 Clamp A/R
309 4240033 Strap, Tie 10
310 1060308 Cable, Electrical - 12-3 Options: (Prior to S/N 45013) A/R

1060461 Cable, Electrical - 12-3 Options: (S/N 45013 to Present) A/R

Model 3369 (Prior to S/N 45013)
Model 3369 (S/N 45013 to Present)
Model 3969 (Prior to S/N 45013)

Model 3969 (S/N 45013 to Present)
311 Supply Locally Plug, Connector 1
312 1700598 Decal - Ground (Prior to S/N 50044) 2
313 1700599 Decal - Neutral (Prior to S/N 50044) 2
314 Supply Locally Connector, Strain Relief 1
315 Supply Locally Bushing 1
316 4060805 Shield, Flex Trim (S/N 50044 to Present)
317 4761500 Lockwasher 5/16” (S/N 50044 to Present) 4
318 3311501 Nut 5/16”-18NC (S/N 50044 to Present) 4

Ref. 5

Ref. 4

Ref. 2

Ref. 2

80ft./24.4m

60ft./18.3m

90ft./27.4m

65ft./19.8m

10in./25.4cm

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0255213 LIMIT SWITCH INSTALLATION Ref. 4

401 Not Used
402 4360300 Switch, Limit 1

403 - 406 Not Used

407 4460049 Connector, Strain Relief 1
408 3910832 Screw, Machine #8-32NC x 2” (Prior to S/N 49916) 4

3910832 Screw, Machine #10-24NC x 2” (S/N 49916 to Present) 4

409 4750800 Flatwasher #8 (Prior to S/N 49916) 4

4751000 Flatwasher #10 (S/N 49916 to Present) 4

410 4760800 Lockwasher #8 (Prior to S/N 49916) 4

4761000 Lockwasher #10 (S/N 49916 to Present) 4

411 3310801 Nut #8-32NC (Prior to S/N 49916) 4

3311001 Nut #10-24NC (S/N 49916 to Present) 4

412 3440413 Rollpin 1

3120882 4-5

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

413 0902106 Bracket 1
414 4751600 Flatwasher 3/8” 2
415 1100092 Cam 1
416 3951512 Setscrew 5/16”-18NC x 1 1/4” 2

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4

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0257371 D-RING INSTALLATION (OPTIONAL) Ref. 1

501 3760321 D-Ring, Swivel Ring 4
502 0630476 Button Head Screw 5/16”-18NC x 3/4” 16
503 4761500 Lockwasher 5/16” 16
504 1703175 Decal - Anchorage Point 4
505 3510583 Deck Weldment 1

0258828 AC CABLE INSTALLATION - 3369 (AUSTRALIAN

SPEC.) (S/N 50044 TO PRESENT)

0258829 AC CABLE INSTALLATION - 3969 (AUSTRALIAN

SPEC.) (S/N 50044 TO PRESENT)

551 - 554 Not Used

555 1320061 Clamp 6
556 4240033 Strap, Tie 10
557 1060461 Cable, Electrical - 12/3 Options:

3369

3969
558 3311501 Nut 5/16”-18NC 4
559 4761500 Lockwasher 5/16” 4
560 4060805 Trim, Loom (Not Shown)

Ref. 1

Ref. 1

65ft/19.8m

70ft/21.3m

1ft/0.30m

M

4-6 3120882

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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3120882 4-7

S
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4

SECTION 4 PLATFORM

FIGURE 4-2. MANUAL PLATFORM EXTENSION INSTALLATION

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4-8 3120882

SECTION 4 PLATFORM

FIGURE 4-2. MANUAL PLATFORM EXTENSION INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254476 MANUAL PLATFORM EXTENSION INSTALLATION Ref. 8

1 3510446 Extension Weldment 1
2 Kick Plate - Front Options: 1

3537610 Prior to S/N 69983

3571800 S/N 69983 to Present
3 3537619 Plate, Support (Roller) 4
4 3841233 Rod, Support (Roller) 4
5 3312202 Nut, Jam 3/4”-10NC 4

3322202 Nut, Jam 3/4”-16NF 4
6 3760348 Ring, Retainer 4
7 4752200 Flatwasher 3/4” 4
8 3860059 Roller 4
9 3536639 Plate 2

10 Not Used
11 0641607 Bolt 3/8”-16NC x 7/8” 4
12 4761600 Lockwasher 3/8” 4
13 0641510 Bolt 5/16”-18NC x 1 1/4” 16
14 4711500 Flatwasher 5/16” 16
15 3311505 Locknut 5/16”-18NC (Prior to S/N 69983) 16
16 Not Used
17 3340653 Pad, Slide 2
18 4070829 Shim 4
19 0641420 Bolt 1/4”-20NC x 2 1/2” 10
20 4751400 Flatwasher 1/4” 70
21 3311405 Locknut 1/4”-20NC 50
22 3520072 Plug, Cap 8
23 0641416 Bolt 1/4”-20NC x 2” 18
24 3422219 Spring Pin 4
25 1060379 Cable, Lanyard 4
26 Not Used
27 0641406 Bolt 1/4”-20NC x 3/4” 4
28 0961845 Bushing 2
29 4420055 Tape 3in./8cm
30 3640916 Rail Weldment (Right Side) 1
31 3640917 Rail Weldment (Left Side) 1
32 3640918 Rail Weldment (Front) 1
33 3537609 Plate, Pivot 2
34 4844683 Handle Weldment (Right Side) 1
35 4844684 Handle Weldment (Left Side) 1
36 2560088 Grip 2
37 3537615 Plate, Latch 2
38 3760170 Ring 2
39 2600201 Hinge 1
40 Not Used
41 4740411 Washer, Nylon 16
42 1380132 Clip, Grip 2

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4

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3120882 4-9

S
E

C

SECTION 4 PLATFORM

FIGURE 4-2. MANUAL PLATFORM EXTENSION INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

43 3941004 Screw, Self-Tapping #10 x 1/2” 2
44 3911440 Screw 1/4”-20NC x 2 1/2” 4
45 0641676 Bolt 3/8”-16NC x 9 1/2” 2
46 3311605 Locknut 3/8”-16NC 2
47 4711600 Flatwasher 3/8” Narrow 4
48 0940049 Bumper 2
49 3300151 Nut, Acorn 1/4”-20NC (Prior to S/N 69983) 2
50 0641405 Bolt 1/4”-20NC x 5/8” (S/N 69983 to Present) 2

T

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4

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0255254 PLATFORM EXTENSION LIMIT SWITCH INSTALLA-

TION (FRENCH AND ITALIAN SPEC) (PRIOR TO S/
N29596)

101 4460052 Connector, Strain Relief 1
102 4360277 Switch, Limit 1
103 4360236 Head, Switch Actuator 1
104 4360278 Roller and Arm Assembly 1
105 3900168 Screw, Special 2
106 4920140 Lockwire A/R
107 1100093 Cam, Limit Switch 1
108 4751400 Flatwasher 1/4” 4
109 4761400 Lockwasher 1/4” 4
110 3311401 Nut 1/4”-20NC 4
111 4300084 Stud, Weld (Welded Part) 4
112 4460298 Block, Terminal 1
113 1060341 Cable, Electrical 16/2

Ref. B

90ft./27.4m

4-10 3120882

SECTION 4 PLATFORM

FIGURE 4-2. MANUAL PLATFORM EXTENSION INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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4

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3120882 4-11

S
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4

SECTION 4 PLATFORM

FIGURE 4-3.PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506)

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4-12 3120882

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0254546 CONSOLE BOX ASSEMBLY (PRIOR TO S/N 29596) Ref. 9
0257162 CONSOLE BOX ASSEMBLY (S/N 29596 TO PRESENT) Ref. 5

1 0860784 Box, Console 1
2 Nameplate Options: 1

3252326 Nameplate (Prior to S/N 29596)

3252522 Nameplate (S/N 29596 to Present)
3 4420008 Tape, Insulation 32in./.8m
4 Bracket, Hanger Options: 1

0901859 Bracket, Hanger (Prior to S/N 29596)

0902498 Bracket, Hanger (S/N 29596 to Present)
5 0641404 Bolt 1/4”-20NC x 1/2” 4
6 4791400 Starwasher 1/4” 4
7 1060380 Lanyard - 10”/25.4cm 1
8 3760170 Ring 1
9 3421453 Pin, Snapper 1

10 4460463 Receptacle, Terminal 1
11 4460470 Nut, Panel 1
12 4460471 Lockwasher 1
13 4360339 Switch, Push Button 1

7012593 Boot, Green 1

14 4360267 Switch, Contact - N.O. 1
15 3520026 Plug 1
16 3900177 Screw 6
17 4740120 Washer, Nylon 2
18 Switch, Push/Pull (Emergency Stop) Options: 1

4360317 Switch (Prior to S/N 29596)

7012566 Lens 1

7012517 Bulb 1

4360289 Switch (S/N 29596 to Present)

7012611 Push-Pull Mushroom Head 1

7012612 Boot 1

19 4740066 Washer, Brass (June 1995 to Present) 2
20 4360328 Switch, Toggle 1
21 3790012 O-Ring 1
22 1600180 Controller, PQ 1
23 3900178 Screw #10-24NC x 3/4” 2
24 4360274 Switch, Push Button (Prior to S/N 47782) 1
25 Not Used
26 4460578 Connector (Red) (Prior to S/N 50044) 2
27 2920125 Light, Indicator (Red) (Prior to S/N 50044) 1
28 0100009 Sealant, Silicone A/R
29 0140030 Alarm, Sonalert (Red) (Prior to S/N 50044) 1
30 Potentiometer, Speed Control Options: 1

4360370 Prior to S/N 29596

4360445 S/N 29596 to Present

31 3300352 Nut, Special (Prior to S/N 29596) 2

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3120882 4-13

S
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SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

32 Knob, Speed Control Options: 1

2560121 Prior to S/N 29596

2560136 S/N 29596 to Present
33 Not Used
34 1701827 Decal - Legend 1
35 4740066 Washer, Thrust (Prior to S/N 29596) 2
36 4360282 Switch 1
37 4360112 Breaker, Circuit - 5 Amp 1
38 0610112 Card, Circuit 1
39 4770600 Lockwasher #6 2
40 3310601 Nut #6-32 2

O
N

4

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0255064 OPTIONAL TILT INDICATOR INSTALLATION Ref. 2

101 2920125 Light, Indicator (Red) 1
102 4460578 Terminal 2
103 0140030 Alarm, Sonalert 1
104 0840026 Boot, Cable (S/N 50044 to Present) 2

OVERLOAD PROTECTION INSTALLATION (FRENCH
SPEC. ONLY) (NOT SHOWN)

0255653 Prior to S/N 29596 Ref. C
0255241 S/N 29596 to S/N 71506 Ref. —

1060341 Cable, Electrical 18/2 25ft/7.6m
4921636 Wire 2ft/.61m
4921501 Wire 2ft/.61m
3990010 Diode 6Amp 5
2820026 Tubing, Vinyl A/R
4460115 Terminal 4
4460035 Terminal, Splice 3

Ref

4-14 3120882

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY (PRIOR TO S/N 71506) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
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4

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F
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3120882 4-15

S
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I
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4

SECTION 4 PLATFORM

FIGURE 4-4.PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT)

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4-16 3120882

SECTION 4 PLATFORM

FIGURE 4-4. PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259863 CONSOLE BOX ASSEMBLY Ref. C

1 0100009 Sealant (Not Shown) A/R
2 0140030 Alarm, Sonalert 1
3 0610136 Circuit Card, W/Hardware 1
4 0641404 Bolt 1/4”-20NC x 1/2” 4
5 Box, Console Options: 1

0860784 Prior to S/N 83228

0861376 S/N 83228 to Present
6 1060380 Lanyard - 10”/25.4cm 1
7 1600301 Controller, PQ 1
8 1701827 Decal - Symbol Legend 1
9 1704260 Decal - EMS 1

10 2560136 Knob, Speed Control 1
11 2920125 Light, Indicator - Red 1
12 3252662 Nameplate 1
13 3310601 Nut #6-32NC 2
14 3421453 Pin, Snapper 1
15 Not Used
16 3760170 Ring 1
17 3900178 Screw #10-24NC x 3/4” 4
18 3900265 Screw #8-18NC x 3/4” 6
19 4060802 Guard, Switch 1
20 4360112 Breaker, Circuit - 5 Amp 1
21 4360267 Switch, Contact - N.O. 1
22 4360282 EMS, Contact Block 1
23 4360328 Switch, Toggle 1
24 4360339 Switch, Push Button 1

7012593 Boot, Green 1

25 4360387 Switch, Push Button 1
26 4360445 Potentiometer, Speed Control 1
27 4360475 Switch, Push/Pull (Emergency Stop) 1

7020175 Push-Pull Mushroom Head W/Seal 1

7020176 Contact Block W/Mount 1

28 Plug, Male Options: 1

4460463 23 Pin Plug (Prior to S/N 77820)

4460503 31 Pin Plug (S/N 77820 to Present)

29 4460470 Nut, Panel 1
30 4460471 Lockwasher 1
31 4740066 Washer, Brass 2
32 4740120 Washer, Nylon 4
33 4760600 Lockers #6 2
34 4761400 Lockwasher 1/4” 4
35 4845755 Bracket, Hanger 1
36 3790012 O-Ring 1

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3120882 4-17

SECTION 4 PLATFORM

FIGURE 4-4. PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258663 OPTIONAL HORN BUTTON INSTALLATION Ref. 1

101 4360274 Switch, Push Button 1

S
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I
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N

4

P
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A
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F

O

OVERLOAD PROTECTION INSTALLATION (FRENCH
SPEC. ONLY) (NOT SHOWN)

0255241 S/N 71506 to S/N 75625 Ref. —
0270412 S/N 75625 to Present Ref. 2

1060341 Cable, Electrical 18/2 25ft/7.6m
4921636 Wire 2ft/.61m
4921501 Wire 2ft/.61m
3990010 Diode 6Amp 5
2820026 Tubing, Vinyl A/R
4460115 Terminal 4
4460035 Terminal, Splice 3
3740087 Relay 1
4120027 Socket, Relay 1
3740063 Spring, Relay 1

Ref

R

M

4-18 3120882

SECTION 4 PLATFORM

FIGURE 4-4. PLATFORM CONSOLE BOX ASSEMBLY (S/N 71506 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
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4

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F
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M

3120882 4-19

S
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I
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4

SECTION 4 PLATFORM

FIGURE 4-5.CONTROLLER ASSEMBLY - PQ (PRIOR TO S/N 71506)

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4-20 3120882

SECTION 4 PLATFORM

FIGURE 4-5. CONTROLLER ASSEMBLY - PQ (PRIOR TO S/N 71506)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1600180 CONTROLLER ASSEMBLY - PQ Ref. B

1 7003790 Boot, Rocker Switch 1
2 7003791 Actuator, Switch 1
3 7003789 Switch Assembly 1
4 7011976 Handle Half Assembly (2 Per) 1
5 7011971 Screw #6-32NC x 5/8” 2

7011970 Nut #6-32NC 2
6 7011972 Lockwasher #6 2
7 7011934 Spring, Compression 1
8 7011984 Knob, Lower Slide-Lock 1
9 7011985 Ring, Snap 1

10 7011986 Slide-Lock (Internal) 1
11 7011989 Screw #10-32NC x 1/2” 2
12 7011936 Gasket 1
13 7003772 Boot 1
14 7003774 Gasket, Lower 1
15 7011932 Stem Assembly 1
16 7011987 Spring 1
17 7011988 Gear, Sector 1
18 7011945 Electrical, Assembly 1
19 7003780 Electrical Pot Assembly 1
20 7003751 Pot With Out Wires 1
21 7011940 Gear, Pinion 1
22 7011983 Screw, Set 1
23 4460266 Connector 1

4460226 Pin, Male A/R

24 7020536 Screw #6-32NC x 1” 1

7011970 Nut #6-32NC 2

S
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4

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3120882 4-21

S
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4

SECTION 4 PLATFORM

FIGURE 4-6.CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT)

P
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4-22 3120882

SECTION 4 PLATFORM

FIGURE 4-6. CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1600301 CONTROLLER ASSEMBLY - PQ Ref. A

1 7020503 Handle/Housing Assembly 1
2 7020520 Boot 1
3 7020504 Plate, Mounting 1
4 7020502 Gasket 1
5 7011991 Grip Assembly 1
6 7011992 Switch Assembly 1
7 7020501 Switch, Pushbutton 1
8 Use 7020514 Grip - Right Side (was p/n 7011993 & p/n 7020531) 1

9 Use 7020514 Grip - Left Side (was p/n 7011994 & p/n 7020532) 1
10 7003791 Actuator, Switch 1
11 7011997 Trigger 1
12 7003790 Boot, Rocker Switch 1
13 7020526 Electrical, Assembly 1
14 7003780 Electrical Pot Assembly 1
15 7020509 Plate, Mounting - Potentiometer 1
16 7003751 Pot With Out Wires 1
17 7011940 Gear, Pinion 1
18 7020511 Screw, Set 1

S
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4

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3120882 4-23

S
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4

SECTION 4 PLATFORM

FIGURE 4-6. CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

P
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4-24 3120882

SECTION 5 CYLINDER

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

5-1 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

S
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5

C

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I
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D

E

R

3120882 5-1

S
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I
O
N

SECTION 5 CYLINDER

FIGURE 5-1.LIFT CYLINDER ASSEMBLY

5

C

Y
L

I
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D

E

R

5-2 3120882

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1682935 LIFT CYLINDER ASSEMBLY Ref 3

1 1682936 Barrel Assembly 1

0961826 Bushing 2

2 1682938 Rod Assembly 1

0961826 Bushing 2
3 1120336 Retainer 1
4 1681843 Head 1
5 3480102 Piston 1
6 3300281 Nut 1
7 4566171 Spacer 1
8Not Used
9Not Used

10 Not Used
11 Not Used
12 Not Used
13 3900170 Set Screw 1
14 Not Used
15 Kit Wiper, Rod 1
16 Kit Seal, Rod 1
17 Kit T-Seal 1
18 Kit Ring, Wear 1
19 Kit O-Ring 1
20 Kit Ring, Lock 2
21 Kit Seal, Piston 2
22 0100011 Loctite #242 A/R
23 0100038 Primer, Locking A/R
24 0100035 Loctite #222 A/R
25 Not Used
26 4640903 Valve, Thermal Relief 1

S
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I
O
N

5

C

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I
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D

E

2901102 Seal Kit - 1682935 Cylinder (Includes Items 15-21) 1

OVERLOAD PROTECTION INSTALLATION (FRENCH
SPEC. ONLY)

0255653 Prior to S/N 29596 Ref. C
0255241 S/N 29596 to S/N 75625 Ref. —
0270412 S/N 75625 to Present Ref. 2

101 2220879 Fitting, 90° 1
102 2220440 Fitting, Straight 1
103 1692617 Switch, Pressure 1

4460428 Connector, Strain Relief 1
1060341 Cable, Electrical 18/2 25ft/7.6m

104 2220273 Reducer 1

3120882 5-3

Ref

R

S
E

C

T

I
O
N

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

SCISSORS ARMS INSTALLATION COMPONENTS Ref.

201to 212 Not Used

213 4640381 Cartridge, Holding Valve 1

7000644 Coil (Hydraforce Version) 1
7004334 Coil (Modular Controls Version) 1
2900756 Seal Kit (Hydraforce Version) 1
2900503 Seal Kit (Modular Controls Version) 1

5

C

Y
L

I
N
D

E

R

5-4 3120882

SECTION 5 CYLINDER

FIGURE 5-1. LIFT CYLINDER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S
E

C

T

I
O
N

5

C

Y
L

I
N
D

E

R

3120882 5-5

S
E

C

T

I
O
N

SECTION 5 CYLINDER

FIGURE 5-2.STEER CYLINDER ASSEMBLY

5

C

Y
L

I
N
D

E

R

5-6 3120882

SECTION 5 CYLINDER

FIGURE 5-2. STEER CYLINDER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

STEER CYLINDER ASSEMBLIES Ref

1682527 Prior to S/N 47596 Ref C
1683695 S/N 47596 to Present Ref 2

Note: When replacing complete cylinder
assembly p/n 1682527 use p/n 1683695 cylinder
assembly as Service Replacement.

Note: Original Equipment may have been
replaced with Service Replacement components
part. Identify the p/n stamped on cylinder before
ordering parts.

Ref.

Ref.

S
E

1 Barrel Weldment Options: 1

1682528 Prior to S/N 47596

1683694 S/N 47596 to Present
2 1682530 Rod 1
3 3480153 Piston 1
4 1682364 Head 2
5 1120387 Retainer 2
6 4565275 Spacer 2
7 3760141 Ring, Retaining 2
8 Kit Seal, Wiper 2
9 Kit Seal, Rod 2

10 Kit O-Ring 2
11 Kit Ring, Wear 2
12 Kit T-Seal 1
13 Kit O-Ring 1
14 Follower, Cam Options: 1

3860054 Prior to S/N 47596

3860080 S/N 47596 to Present

15 Nut 1/2”-20NF Options: 1

3321801 Prior to S/N 47596

3321802 S/N 47596 to Present

16 0100035 Loctite #222 A/R
17 Not Used
18 2220472

19 2220515 Fitting, Cap 2
20 2180699 Fitting, Modified 1
21 2180394 Orifice 1

Fitting 90

°

1

C

T

I
O
N

5

C

Y
L

I
N
D

E

R

2901178 Seal Kit (Includes Items 8-13) 1

3120882 5-7

S
E

C

T

I
O
N

SECTION 5 CYLINDER

FIGURE 5-2. STEER CYLINDER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

5

C

Y
L

I
N
D

E

R

5-8 3120882

SECTION 6 HYDRAULIC

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

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

S
E

C

T

I
O
N

6

H

Y
D
R

A
U

L

I

C

3120882 6-1

S
E

C

T

I

SECTION 6 HYDRAULIC

FIGURE 6-1.HYDRAULIC DIAGRAM

O
N

6

H

Y
D
R

A
U

L

I

C

6-2 3120882

SECTION 6 HYDRAULIC

FIGURE 6-1. HYDRAULIC DIAGRAM

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2792080 HYDRAULIC DIAGRAMS Ref. 4

1 2220415 Fitting, Straight 4
2 2220371 Fitting, Straight 2
3 2220373 Fitting, Straight 6
4 2220466 Fitting, 90° 3
5 2220235 Fitting, Plug 3
6 2220470 Fitting, 90° 1
7 2220451 Fitting, Straight 1
8 2220490 Fitting, Tee 2

9 2220504 Fitting, Tee 1
10 2220374 Fitting, Straight 1
11 4566419 Tube 1
12 4566414 Tube 1
13 Not Used
14 2210008 Fitting, 90° 1
15 2220582 Fitting, Straight 2
16 0100020 Sealant (Not Shown) A/R
17 1320033 Clamp 4
18 2220347 Fitting, Straight 1
19 2220497 Fitting, Straight 2

2901277 HYDRAULIC HOSE KITS Ref. B

S
E

C

T

I
O
N

6

101 2750968 Hose 1
102 2752392 Hose 1
103 Hose Options: 2

2750895 Prior to S/N 61791

2751906 S/N 61791 to Present
104 2750998 Hose 2
105 2752460 Hose 2
106 2751160 Hose 2
107 2752438 Hose 1
108 2751407 Hose 1
109 2751418 Hose 1
110 2752448 Hose 1
111 2720298 Hose, Suction - 3/4” 18”/46cm

H

Y
D
R

A
U

L

I

C

3120882 6-3

S
E

C

T

I

SECTION 6 HYDRAULIC

FIGURE 6-1. HYDRAULIC DIAGRAM (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

O
N

6

H

Y
D
R

A
U

L

I

C

6-4 3120882