JLG 3969 Parts Manual

Illustrated Parts Manual

Model 3369electric 3969electric

3120769

May 31, 2013

REVISION LOG

March 22, 1999 - Original Issue Of Manual (Was part of complete Manual #3120597)

(Model 3369 Manual edited to 0010498 Revision 22)

(Model 3969 Manual edited to 0010487 Revision 24)

June 29, 1999 Updated Pages - Cover, Effectivity Page & 2-19

November 10, 1999 Updated Pages - Cover, Effectivity Page & 1-4

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 Manual

November 1, 2010 - Revised Manual

May 31, 2013 - Revised Manual

3120769 A

REVISION LOG

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-7 BATTERY CHARGER ASSEMBLY - 22VAC/50Hz (SERVICE REPLACEMENT) . . . . . . .1-22

1-8 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

SECTION 2 - GROUND COMPONENTS

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

2-2 CONTROL VALVE ASSEMBLY (PRIOR TO SEPTEMBER 1994) . . . . . . . . . . . . . . . . . .2-6

2-3 CONTROL VALVE ASSEMBLY (SEPTEMBER 1994 TO PRESENT). . . . . . . . . . . . . . . .2-8

2-4 PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5 GROUND CONTROL BOX ASSEMBLY (PRIOR TO OCTOBER 1994) . . . . . . . . . . . . . .2-12

2-6 GROUND CONTROL BOX ASSEMBLY (OCTOBER 1994 TO PRESENT) . . . . . . . . . . .2-14

2-7 COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

SECTION 3 - SCISSOR ARMS

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

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

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) . . . . . . . . . . . . . . . . . . . . . . .4-18

4-6 CONTROLLER ASSEMBLY - PQ (S/N 71506 TO PRESENT) . . . . . . . . . . . . . . . . . . . . .4-20

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 ELECTRICAL SCHEMATIC - PLATFORM (PRIOR TO S/N 71506) . . . . . . . . . . . . . . . . .7-4

7-3 ELECTRICAL SCHEMATIC - PLATFORM (S/N 71506 TO PRESENT) . . . . . . . . . . . . . .7-5

7-4 ELECTRICAL DIAGRAM - STANDARD (PRIOR TO S/N 71506) . . . . . . . . . . . . . . . . . . .7-6

7-5 ELECTRICAL DIAGRAM - STANDARD (S/N 71506 TO PRESENT) . . . . . . . . . . . . . . . .7-7

7-6 MAIN ELECTRICAL CONNECTOR AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

3120769 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO. SECTION 8 - DECALS

8-1 DECALS INSTALLATION (PRIOR TO S/N 69694). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION (S/N 69694 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK

SECTION 10 - SPECIAL OPTIONS

ii 3120769

SECTION 1 FRAME

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-7 BATTERY CHARGER ASSEMBLY - 220VAC/50Hz (SERVICE REPLACEMENT). . . . . . . . . . . 1-22

1-8 FRAME MOUNTED COMPONENTS INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

E C T

I O N

3120769 1-1

SECTION 1 FRAME

S E C T

I O N

FIGURE 1-1.FRAME AND STEERING INSTALLATION

1-2 3120769

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME AND STEERING INSTALLATION Ref.

Frame Weldment Options: 1 2360370 3369/3969electric (Prior to S/N 71506) 2360534 3369electric (S/N 71506 to Present)

STEERING AND SPINDLES INSTALLATION OPTIONS:

0252243 Steering and Spindles - Standard Ref. 8 0255552 Steering and Spindles - CSA Ref. 5

1 Use

1001139010

2 Spindle Options:

4130286 Standard 2 4130327 CSA 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)

1683695 Steer Cylinder Assembly (See Section 5 for Breakdown)

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 Not Used 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

Hub Assembly (Includes Items 101-107) (was p/n 2780186) 2

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

(S/N 47596 to Present)

S E

I O N

3120769 1-3

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

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) 2 106 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

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

1001139010)

— — — — — — — — — —

Hub) (Hub Assemblies 2780186 & 1001139010)

4130286 SPINDLE WELDMENT - STANDARD Ref. A 4130327 SPINDLE WELDMENT - CSA Ref.

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

—

1-4 3120769

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120769 1-5

SECTION 1 FRAME

S E

I O N

FIGURE 1-2.TIRE AND WHEEL DRIVE INSTALLATION

1-6 3120769

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

WHEEL DRIVE INSTALLATION OPTIONS: Ref. 0254491 Standard (Prior to S/N 71506) Ref. 10 0255203 Standard (S/N 71506 to Present) Ref. 8 0256908 UL Ref.

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

I O N

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

3120769 1-7

SECTION 1 FRAME

S E

I O N

FIGURE 1-3.DRIVE HUB ASSEMBLY

1-8 3120769

SECTION 1 FRAME

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

S E

I O N

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

3120769 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-4.DRIVE BRAKE ASSEMBLY

1-10 3120769

SECTION 1 FRAME

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

S E

I O N

3120769 1-11

SECTION 1 FRAME

S E

I O N

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

1-12 3120769

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE CONTACTOR INSTALLATION OPTIONS: Ref. 0254491 Standard (Prior to S/N 71506) Ref. 10 0255203 Standard (S/N 71506 to Present) Ref. 8 0256908 UL Ref.

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” 9 14 4711400 Flatwasher 1/4” A/R 15 Not Used 16 1060540 Cable Assembly 1 17 0641416 Bolt 1/4”-20NC x 2” 4 18 3311405 Locknut 1/4”-20NC A/R

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

2400045 UL 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

15in./38cm

S E

O N

3120769 1-13

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

46 2560126 Handle, Pull 1

47 to 48 Not Used

49 4420008 Tape, Seal 7ft./2m 50 4360371

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

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 7013307 Board, PC 1

7013314 Kit 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

Blue and Orange Versions)

Sensor, Level - 2

1-14 3120769

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BATTERY CHARGER INSTALLATION OPTIONS: Ref. 0254496 Charger - 110VAC/60HZ - USA/CSA (Non UL) Ref. 4 0255536 Charger - 110VAC/60HZ - USA/CSA (UL) Ref.

0254497 Charger - 220VAC/50HZ - Latin America (Non UL) Ref. B 0255627 Charger - 220VAC/50HZ - Latin America (UL) Ref.

0257478 Charger - 220VAC/60HZ - USA/CSA/Latin America/Brazil

(Non UL)

0254498 Charger - 100VAC 50/60HZ - Japanese Spec. Ref. B

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 1701695 Decal 1 210 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

0400102 USA/CSA (Non UL) (Prior to S/N 60218) 0400162 USA/CSA (Non UL) (S/N 60218 to Present) 0400124 USA/CSA (UL) 0400103 Latin America (Non UL) 0400137 Latin America (UL) 0400158 USA/CSA/Latin American/Brazil (Non UL) 0400105 Japanese Spec.

Ref. 1

—

S E

I O N

BATTERY BOX INSTALLATION OPTIONS: Ref. 0255087 Standard Ref. 7 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)

3120769 1-15

SECTION 1 FRAME

S E

I O N

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

311 1060405 Cable Assembly 2 312 1060561 Cable, Battery (Prior to August 1995) 6

1060092 Cable, Battery (August 1995 to Present) 6 313 0100048 Silicone 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

0254482 DRIVE CUTOUT LIMIT SWITCH INSTALLATION Ref. 3

401 Cam Options: 1

Use 1100101 Cam (Prior to S/N 49916) (was p/n 1100085)

1100101 Cam (S/N 49916 to Present) 402 Not Used 403 4360300 Switch, Limit 1 404 4460049 Stain Relief 1 405 0902033 Bracket, Mounting 1 406 0641408 Bolt 1/4”-20NC x 1” 4 407 4751400 Flatwasher 1/4” 4 408 3311405 Locknut 1/4”-20NC 4 409 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)

1-16 3120769

SECTION 1 FRAME

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

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

410 Flatwasher Options: 4

4750800 Flatwasher #8 (Prior to S/N 49916) 4750800 Flatwasher #10 (S/N 49916 to Present)

411 Lockwasher Options: 4

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

412 Nut Options: 4

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

3310801 Nut #10-32 (S/N 49916 to Present) 413 1320237 Clamp (S/N 49916 to Present) 1 414 4761400 Lockwasher (S/N 49916 to Present) 2 415 4711400 Flatwasher (S/N 49916 to Present) 2 416 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

S E

I O N

0255047 HORN INSTALLATION OPTIONAL: 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 (Prior to S/N 71506) 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

3120769 1-17

7ft./21m

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SECTION 1 FRAME

S E

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FIGURE 1-6.BATTERY CHARGER ASSEMBLY

1-18 3120769

SECTION 1 FRAME

FIGURE 1-6. BATTERY CHARGER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

BATTERY CHARGER ASSEMBLY Ref. A 0400102 Standard 110VAC/60HZ (Prior to S/N 60218) Ref. A 0400162 Standard 110VAC/60HZ (S/N 60218 to Present) Ref. A 0400124 UL 110VAC/60HZ (PRODUCTION) Ref.

0400124 UL 110VAC/60HZ (SERVICE REPLACEMENT) Ref.

0400103 Non-UL 220VAC/50HZ Ref.

0400137 UL 220VAC/50HZ Ref.

0400158 Non-UL 220VAC/60HZ (USA/CSA/LATIN AMERICA/

BRAZIL)

0400105 100VAC 50HZ/60HZ (JAPANESE SPEC) Ref.

Note: 0400124 Service Replacement Chargers Use a Relay. 0400124 Production Chargers Use a Triac.

1 7011573 Ammeter 1 2 Board, Circuit Options: 1

Use 7011662 Prior to January 1995 (Was p/n 7011588) (0400102/

0400162/0400124 Production/0400103/0400137/ 0400105 Chargers)

7011662 January 1995 to Present (0400102/0400162/0400124

Production/0400103/0400137/0400105 Chargers)

7022961 0400124 Service Replacement Charger

Use 7011679 All 0400158 Chargers (Was p/n 7018538)

3 Condenser Options: 1

7018500 0400102/0400124 Production/0400158/0400105

Chargers 7020624 0400124 Service Replacement/0400162 Chargers 7011623 0400103 Chargers 7011574 0400137 Chargers

4 7011590 Connector, DC 1 5 Cord, AC Options: 1

7011591 0400102/0400162/0400105 Chargers 7011643 0400124 Production Chargers 7022962 0400124 Service Replacement Chargers 7011544 0400103 Chargers 7011572 0400137 Chargers 7011677 0400158 Chargers

6 Diode Options: 2

7011576 0400102/0400124 Production/0400103/0400137/

0400105 Chargers 7011668 0400162/0400124 Service Replacement/0400158 Char-

gers

7 Fuse, DC Options: 1

7011593 0400102/0400162/0400124 Production/0400103/

0400137/0400105 Chargers 7020691 0400124 Service Replacement Chargers 7018570 0400158 Chargers

Ref.

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3120769 1-19

SECTION 1 FRAME

S E

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FIGURE 1-6. BATTERY CHARGER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

8 Holder, Fuse - DC Options: 1

7011594 0400102/0400162/0400124 Production/0400103/

0400137/0400105 Chargers

7018571 0400124 Service Replacement/0400158 Chargers

9 Connector, Strain Relief Options: A/R

7011528 0400102/0400124 Production/0400105 Chargers 3 7011646 0400124 Service Replacement/0400162 Chargers 2 7011646 0400103 Chargers (AC Cord) 2 7011528 0400103 Chargers (DC Cord) 1 7011528 0400137 Chargers 1 7011646 0400158 Chargers 1 7020659 0400124 Service Replacement Chargers (DC Cord) 1

10 Triac Options: 1

7011517 0400102/0400124 Production/0400103/0400137/

0400105 Chargers

7018572 0400162/0400158 Chargers

Not Required 0400124 Service Replacement Chargers

11 Transformer, Control Options: 1

7011518 0400102/0400162/0400124 Production/0400124

Service Replacement/0400105 Chargers

7011551 0400103/0400137/0400158 Chargers

12 Transformer, Main Options: 1

Use 7011595 0400102 Chargers (Was p/n 7011622)

7018574 0400162 Chargers 7011595 0400124 Production/0400105 Chargers 7022963 0400124 Service Replacement Chargers 7011598 0400103/0400137 Chargers 7018573 0400158 Chargers

13 Varistor Options: 1

7011596 0400102/0400105/0400124 Service Replacement Char-

gers

7011584 0400162/0400124 Production/0400124 Service

Replacement/0400103/0400137/0400158 Chargers

14 Fuse, AC Options: 1

7011597 0400102/0400105 Chargers 7011645 0400162/0400124 Production/0400124 Service Replace-

ment Chargers 7011508 0400103/0400137 Chargers 7018569 0400158 Chargers

15 7011507 Holder, Fuse - AC 1 16 Not Available Handle 2 17 7011621 Connector, Enable Switch 1 18 Heatsink Options: 1

7011610 0400102/0400103/0400137 Chargers 7018539 0400124 Service Replacement/0400162/0400158 Char-

gers 7011611 0400124 Production Chargers 7011628 0400105 Chargers

19 7011511 Strap, Condenser 1 20 7018506 Relay (0400124 Service Replacement Charger Only) 1

1-20 3120769

SECTION 1 FRAME

FIGURE 1-6. BATTERY CHARGER ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

21 7020687 Harness, Relay (0400124 Service Replacement Charger

Only - Not Shown)

S E

I O N

3120769 1-21

SECTION 1 FRAME

S E

I O N

FIGURE 1-7.BATTERY CHARGER ASSEMBLY - 220VAC/50HZ (SERVICE

REPLACEMENT)

1-22 3120769

SECTION 1 FRAME

FIGURE 1-7. BATTERY CHARGER ASSEMBLY - 220VAC/50HZ (SERVICE REPLACEMENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0400198 BATTERY CHARGER ASSEMBLY (SERVICE REPLACE-

MENT 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.

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3120769 1-23

SECTION 1 FRAME

S E

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FIGURE 1-8.FRAME MOUNTED COMPONENTS INSTALLATION

1-24 3120769

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