JLG 3969 Parts Manual

5 (1)

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

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

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

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

S E C T I O N

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1-1

	SECTION 1 FRAME
S	FIGURE 1-1.FRAME AND STEERING INSTALLATION
E
C
T
I
O
N
1
F
R
A
M
E

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	Hub Assembly (Includes Items 101-107) (was p/n 2780186)	2
	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)	1
		(Prior to S/N 47596) (was p/n 1682527)
	1683695	Steer Cylinder Assembly (See Section 5 for Breakdown)	1
		(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	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

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1-3

S E C T I O N

R A M E

SECTION 1 FRAME

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	Cap, Dust (1 Per Hub) (was p/n 7012524)	2
	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 -
		1001139010)
	3300407	Nut, Wheel 1/2in x 20NF (Hub Assembly -
		1001139010)
		— — — — — — — — — —
	2900804	Bearing & Seal Kit (Includes Qty 1 Items 101-105) (1 Per	2
		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			S
FIGURE 1-1. FRAME AND STEERING INSTALLATION (CONTINUED)					S
					E
FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.	C
FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.
					T
					T
					I
					O
					N
					1
					F
					R
					A
					M
					E

3120769

1-5

	SECTION 1 FRAME
S	FIGURE 1-2.TIRE AND WHEEL DRIVE INSTALLATION
E
C
T
I
O
N
1
F
R
A
M
E

1-6

3120769

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

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.	4
1	2780204	Drive Hub Assembly (See Figure 1-3 for Breakdown)	2
2	0920090	Drive Brake Assembly (See Figure 1-4 for Break-	2
		down)
3	3160186	Drive Motor Assembly	2
	2900811	Repair Kit (Includes All Bearings, Brushes, Springs	2
		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
		TIRE AND WHEEL INSTALLATION OPTIONS:
101	0252430	Tire And Wheel Assembly (Foam-Filled) (Sold as an	4
		Assembly)
	4520151	Tire And Wheel Assembly (Non-Marking Optional)	4
		(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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1-7

	SECTION 1 FRAME
S	FIGURE 1-3.DRIVE HUB ASSEMBLY
E
C
T
I
O
N
1
F
R
A
M
E

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

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1-9

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

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

15Not Used

16Not Used

17Not Used

18Not 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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1-11

	SECTION 1 FRAME
S	FIGURE 1-5.ELECTRICAL COMPONENTS INSTALLATIONS (FRAME MOUNTED)
E
C
T
I
O
N
1
F
R
A
M
E

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.	2
1 to 11	Not Used
12	0254549	Contactor Plate Assembly (Includes Items 101-111 and	1
		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)	15in./38cm
	4060807	Flex-Trim (S/N 56587 to Present)	15in./38cm
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	1
43	4751400	Flatwasher 1/4”	1
44	3300353	Nut, Tinnerman	1
45	Not Used

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1-13

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SECTION 1 FRAME

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	Sensor, Level - 4.5°	1
	7012608	Fuse - 1.5 Amp (Black Version Only - Not Required on	1
		Blue and Orange Versions)
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	Sensor, Level - 2°	1
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

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	Ref.	1
		(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.
		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)

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S E C T I O N

R A M E

SECTION 1 FRAME

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.	A
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
	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	7ft./21m

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1-17

	SECTION 1 FRAME
S	FIGURE 1-6.BATTERY CHARGER ASSEMBLY
E
C
T
I
O
N
1
F
R
A
M
E

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/		Ref.	—
		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

S E C T I O N

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1-19

S E C T I O N

R A M E

SECTION 1 FRAME

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			S
FIGURE 1-6. BATTERY CHARGER ASSEMBLY (CONTINUED)					S
					E
FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.	C
FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.
					T
21	7020687	Harness, Relay (0400124 Service Replacement Charger	1
		Only - Not Shown)
					I
					O
					N
					1
					F
					R
					A
					M
					E

3120769

1-21

	SECTION 1 FRAME
S	FIGURE 1-7.BATTERY CHARGER ASSEMBLY - 220VAC/50HZ (SERVICE
E	REPLACEMENT)
C
T
I
O
N
1
F
R
A
M
E

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-	Ref.	—
		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

S E C T I O N

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1-23

	SECTION 1 FRAME
S	FIGURE 1-8.FRAME MOUNTED COMPONENTS INSTALLATION
E
C
T
I
O
N
1
F
R
A
M
E

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3120769

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