JLG 400CRT Parts Manual

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Page 1

Illustrated Parts Manual

Models 330CRT 400CRT

P/N

3121112

October 16, 2013

Page 2

Page 3

REVISION LOG

March 20, 2000 - Original Issue Of Manual (Edited to 0010562 Revision 3)

August 7, 2000 - Revised Manual (Revised to B/M 0010562 Revision 8)

December 18, 2000 - Revised Manual (Revised to B/M 0010562 Revision 14)

March 31, 2002 - Revised Manual (Revised to B/M 0010562 Revision 22)

August 1, 2002 - Revised Manual (Revised to B/M 0010562 Revision 22)

April 15, 2003 - Revised Manual (Revised to B/M 0010562 Revision 25)

August 1, 2003 - Revised Manual (Revised to B/M 0010562 Revision 25)

December 7, 2006 - Revised Manual

May 2, 2011 - Revised Manual

October 16, 2013 - Revised Manual

3121112 A

Page 4

REVISION LOG

B 3121112

Page 5

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1-2 OSCILLATING REAR AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4 FRONT DRIVE MOTOR ASSEMBLY - 330CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-5 FRONT DRIVE MOTOR ASSEMBLY - 400CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-6 REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626. . . . . . . . .1-12

1-7 REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT &

ALL 400CRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-8 DIESEL ENGINE INSTALLATION - KUBOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-9 GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

1-10 PISTON PUMP ASSEMBLY (PRODUCTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

1-11 PISTON PUMP ASSEMBLY (POST PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

1-12 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36

1-13 FRAME COVERS AND LADDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38

1-14 LEVELING JACKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42

1-15 GENERATOR INSTALLATION - 110V (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 RIGHT SIDE COMPARTMENT INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

2-3 FLOW DIVIDER VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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

2-5 FUEL COMPARTMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 - SCISSOR ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SCISSOR ARMS INSTALLATION - 330CRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 SCISSOR ARMS INSTALLATION - 400CRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM AND ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED

PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-3 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-4 DRIVE/STEER CONTROLLER ASSEMBLY (PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-5 DRIVE/STEER CONTROLLER J.R. MERRITT ASSEMBLY (POST PRODUCTION). . . . . . . . . 4-14

SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 LEVELING JACK CYLINDER ASSEMBLY (PRIOR TO S/N 104829) . . . . . . . . . . . . . . . . . . . . .5-4

5-3 LEVELING JACK CYLINDER ASSEMBLY (S/N 104829 TO PRESENT) . . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT CYLINDER COMPONENTS ASSEMBLY - 330CRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-5 LIFT CYLINDER COMPONENTS ASSEMBLY - 400CRT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

3121112 i

Page 6

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 HYDRAULIC DIAGRAM - 330CRT OSCILLATING AXLE MACHINES . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - 400CRT OSCILLATING AXLE MACHINES . . . . . . . . . . . . . . . . . . . . 6-6

6-3 HYDRAULIC DIAGRAM - LEVELING JACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-4 HYDRAULIC DIAGRAM - 110V GENERATOR (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 ELECTRICAL SCHEMATIC - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL SCHEMATIC - MACHINES WITH GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 ELECTRICAL SCHEMATIC - DUAL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 DECALS INSTALLATIONS - ANSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATIONS - ANSI EXPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

ii 3121112

Page 7

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

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

1-2 OSCILLATING REAR AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4 FRONT DRIVE MOTOR ASSEMBLY - 330CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-5 FRONT DRIVE MOTOR ASSEMBLY - 400CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-6 REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626 . . . . . . . . 1-12

1-7 REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT &

ALL 400CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-8 DIESEL ENGINE INSTALLATION - KUBOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-9 GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-10 PISTON PUMP ASSEMBLY (PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-11 PISTON PUMP ASSEMBLY (POST PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-12 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

1-13 FRAME COVERS AND LADDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-14 LEVELING JACKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1-15 GENERATOR INSTALLATION - 110V (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

E C T

I O N

3121112 1-1

Page 8

SECTION 1 FRAME

101

103

LOCATED IN FRAME

(SHOWN HERE

FOR CLARITY)

LOCAT ED IN FRAME

(SHOWN HERE

FOR CLARITY)

102

104

105

S E C T

I O N

FIGURE 1-1. FRAME AND STEERING INSTALLATION

1-2 3121112

Page 9

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME WELDMENT OPTIONS: Ref.

2360525 330/400CRT - 4WD with Oscillating Rear Axle 1

0259337 STEERING INSTALLATION (2WS) Ref. E

1 0100011 Loctite #242 (Not Shown) A/R 2 0259336 Tie-Rod Assembly (See Items 101-105 for Breakdown) 1 3 0440228 Bearing 2 4 4740501 Bearing, Thrust 4 5 0641608 Bolt 3/8”-16NC x 1” 8 6 0642018 Bolt 5/8”-11NC x 2 1/4” 2 7 Not Used 8 0962257 Bushing 4

9 1683807 Steer Cylinder Assembly (See Section 5 for Breakdown) 1 10 3312005 Locknut 5/8”-11NC 2 11 Not Used 12 3422803 Kingpin 4 13 4130367 Spindle (Right Side) 1 14 4130372 Spindle (Left Side) 1 15 3431220 Pin, Clevis 2 16 3450406 Pin, Cotter 1/8” x 1 1/2” 2 17 4712200 Flatwasher 3/4” Narrow 2

S E

I O N

0259336 TIE-ROD ASSEMBLY Ref. C

101 3841146 End, Rod (Right Side) 1 102 3841432 Tie-Rod 1 103 3322002 Nut, Jam 5/8”- 18NF (Right Hand Thread) 1 104 3300409 Nut, Jam 5/8”- 18NF (Left Hand Thread) 1 105 3841469 End, Rod (Left Side) 1

3121112 1-3

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SECTION 1 FRAME

S E

I O N

FIGURE 1-2. OSCILLATING REAR AXLE INSTALLATION

1-4 3121112

Page 11

SECTION 1 FRAME

FIGURE 1-2. OSCILLATING REAR AXLE INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259649 OSCILLATING AXLE INSTALLATION Ref. F

1 0100011 Loctite #242 (Not Shown) A/R 2 0641416 Bolt 1/4”-20NC x 2” 4 3 0641610 Bolt 3/8”-16NC x 1 1/4” 6 4 0642012 Bolt 5/8”-11NC x 1 1/2” 1 5 0961950 Bushing 2 6 1683978 Oscillating Axle Cylinder Assembly (See Section 5 for

Breakdown) 7 3311405 Locknut 1/4”-20NC 4 8 3311605 Locknut 3/8”-16NC 6 9 3322201 Nut 3/4”-16NF 2

10 3422592 Pin, Axle Pivot 1 11 3422745 Pin, Cylinder (Top) 2 12 3422828 Pin, Cylinder (Bottom) 2 13 3538047 Shim 2 14 3572029 Cover, Axle 2 15 3760115 Ring, Retaining 4 16 3841143 Keeper, Pin 2 17 3841258 Keeper, Pin 1 18 3841367 End, Rod with Grease Fitting 2 19 0641407 Bolt 1/4”-20NC x 7/8” 4 20 4070878 Shim (.06) A/R 21 4070879 Shim (.12) A/R 22 4641143 Valve Assembly 1

7012693 Seal Kit - 4641143 Valve 1

7002840 Pin Removal Tool - 4641143 Valve 1 23 4711400 Flatwasher 1/4” Narrow 12 24 4711600 Flatwasher 3/8” 8 25 4740158 Thrustwasher 1 26 4846156 Axle Weldment 1 27 2080059 Fastener 1/4” 4 28 0100019 Loctite #271 (Not Shown) A/R

S E

I O N

3121112 1-5

Page 12

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. WHEEL DRIVE INSTALLATION

1-6 3121112

Page 13

SECTION 1 FRAME

FIGURE 1-3. WHEEL DRIVE INSTALLATION

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

WHEEL DRIVE INSTALLATION Ref. 0259460 330CRT Ref. C 0270679 400CRT Ref. A

1 0100011 Loctite #242 (Not Shown) A/R 2 0681812 Bolt 1/2”-13NC x 1 1/2” (Grade 8) 24 3 Drive Motor with Brake Assembly Options: (Rear) 2

3160254 330CRT - Prior to S/N 82626 (See Figure 1-6 for

Breakdown)

3160244 330CRT - S/N 82626 to Present (See Figure 1-7

for Breakdown)

3160244 400CRT (See Figure 1-7 for Breakdown)

4 Drive Motor Assembly Options: (Front) 2

3160255 330CRT (See Figure 1-4 for Breakdown) 3160245 400CRT (See Figure 1-5 for Breakdown)

5 4891800 Washer, Hardened 1/2” 24

TIRE AND WHEEL INSTALLATIONS OPTIONS: Ref. 0259652 Standard Foam Filled (30.4 x 10.4) Ref. D

Tire & Wheel Assembly Options: A/R 0270251 30.4 x 10.4 NHS (Right Side) (Foam Filled) 0270252 30.4 x 10.4 NHS (Left Side) (Foam Filled)

101 Not Used 102 4520238 Tire - 30.4 x 10.4 NHS A/R 103 4640113 Valve A/R 104 4860217 Rim A/R

I O N

3121112 1-7

Page 14

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. FRONT DRIVE MOTOR ASSEMBLY - 330CRT

1-8 3121112

Page 15

SECTION 1 FRAME

FIGURE 1-4. FRONT DRIVE MOTOR ASSEMBLY - 330CRT

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160255 DRIVE MOTOR ASSEMBLY Ref. B

1 to 9 Not Used

10 7023279 Cylinder Block Assembly 1 11 Not Serviced Block, Cylinder 1 12 7023276 Piston 1 13 Not Used 14 Not Used 15 7023278 Guide & Keeper Kit 1

16 to 24 Not Used

25 7023280 Cam Assembly 1 26 Not Serviced Cam 1 27 7027888 O-Ring (Note: Use Item 92 or 93) 2

28 to 39 Not Used

40 7023281 Valving Cover Assembly 1 41 Not Serviced Cover, Valving 1 42 7023282 Bolt 6

43 to 44 Not Used

45 See Note O-Ring (Note: Use Item 92 or 93) 1 46 Not Used 47 7023283 Distributor 1 48 Use Item 93 Seal Kit 1 49 Not Used 50 7023284 Plug 1 51 Not Used 52 7018411 Spring 4

53 to 58 Not Used

59 7023286 Pin, Split 1 60 7023285 Back Plate Assembly 1

61 to 65 Not Used

66 7018435 Bolt 8

67 to 69 Not Used

70 7023287 Support Assembly 1 71 Not Serviced Support, Bearing 1 72 See Note Seal (Note: Use Item 92 or 93) 1 73 7023288 Bearing 1 74 7023289 Bearing 1 75 7023302 Shim Set 1 76 7023290 Ring 1 77 7023291 Ring, Snap 1 78 See Note Seal (Note: Use Item 92 or 93) 1

79 to 89 Not Used

90 7023292 Shaft 1 91 7023303 Stud Set (1 Set of 5) 1

7018436 Nut, Wheel (1 Set of 5) 1

— — — — — — — — — — 92 7023300 Seal Kit - (Includes Items - 27,45,72 & 78) 1 93 7023301 Seal Kit - (Includes Items - 27,45,48,72 & 78) 1

S E

I O N

3121112 1-9

Page 16

SECTION 1 FRAME

S E

I O N

FIGURE 1-5. FRONT DRIVE MOTOR ASSEMBLY - 400CRT

1-10 3121112

Page 17

SECTION 1 FRAME

FIGURE 1-5. FRONT DRIVE MOTOR ASSEMBLY - 400CRT

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160245 DRIVE MOTOR ASSEMBLY - 400CRT Ref. D

1 Not Available Front Housing Assembly (See 101 to 108 for Breakdown) 1

2 Not Available Rotary Assembly 1 2A Not Available Rotary without Cam 1 2B Not Available Cam 1

3 Not Available Rear Housing Assembly (See 201 to 208 for Breakdown) 1

4 Use Item 251 Seal, Square 2

5 Not Available Screw, Cap 6

6 to 8 Not Used

9 7023806 Lugnut 5 10 7023807 Stud, Wheel 5

11 to 15 Not Used

16 7024008 Seal, Square 1 17 7024007 Plate, Rear Cover 1 18 7024009 Screw, Cap 8

FRONT HOUSING ASSEMBLY Ref. 101 7022586 Shaft 1 102 Use Item 251 Seal, Face 1 103 7022587 Bearing, Front 1 104 Not Available Casting, Front 1 105 Use Item 251 Seal, Shaft 1 106 7022588 Bearing, Rear 1 107 Not Available Washer 1 108 7022589 Ring, Split 1

S E

I O N

REAR HOUSING ASSEMBLY Ref. 201 Not Available Ring, Distributor 1 202 Not Available Spring 9 203 Use Item 251 Seal, Nylon 1 204 Use Item 251 Seal, Nylon 1 205 Use Item 251 Seal, Nylon 1 206 Not Available Housing, Rear 1 207 7022590 Pin, Stop 1 208 7022591 Plug (O-Ring Supplied with Plug) 1

209 to 250 Not Used

— — — — — — — — — —

251 7023801 Seal Kit (Includes Items - 4,102,105,203 -205) 1

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Page 18

SECTION 1 FRAME

S E

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FIGURE 1-6. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626

1-12 3121112

Page 19

SECTION 1 FRAME

FIGURE 1-6. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160254 DRIVE MOTOR ASSEMBLY Ref. C

1 to 9 Not Used

10 7023279 Cylinder Block Assembly 1 11 Not Serviced Block, Cylinder 1 12 7023276 Piston 1 13 Not Used 14 Not Used 15 7023278 Guide & Keeper Kit 1

16 to 24 Not Used

25 7023280 Cam Assembly 1 26 Not Serviced Cam 1 27 7027888 O-Ring 2

28 to 39 Not Used

40 7023281 Valving Cover Assembly 1 41 Not Serviced Cover, Valving 1 42 7023282 Bolt 6

43 to 44 Not Used

45 See Note O-Ring (Note: Use Item 151 or 152) 1 46 Not Used 47 7023283 Distributor 1 48 Use Item 152 Seal Kit 1 49 Not Used 50 7023284 Plug 1 51 Not Used 52 7018411 Spring 4

53 to 58 Not Used

59 7023286 Pin, Split 1

60 to 69 Not Used

70 7023287 Support Assembly 1 71 Not Serviced Support, Bearing 1 72 See Note Seal (Note: Use Item 151 or 152) 1 73 7023288 Bearing 1 74 7023289 Bearing 1 75 7023302 Shim Set 1 76 7023290 Ring 1 77 7023291 Ring, Snap 1 78 See Note Seal (Note: Use Item 151 or 152) 1

79 to 89 Not Used

90 7023292 Shaft 1 91 7023303 Stud Set (1 Set of 5) 1

7018436 Nut, Wheel (1 Set of 5) 1

92 to 99 Not Used

100 7023293 Disc Brake Assembly 1 101 Not Serviced Body, Brake 1 102 7023294 Bolt 8

103 to 105 Not Used

106 See Note O-Ring (Note: Use Item 151 or 152) 1

S E

I O N

3121112 1-13

Page 20

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

107 7023295 Piston, Brake 1 108 7023296 Washer, Spring 1 109 7023297 Ring, Snap 1 110 7023298 Shaft 1 111 Use Item 152 Seal 1 112 7018408 Bolt 1 113 See Note Gasket (Note: Use Item 151 or 152) 1

114 to 115 Not Used

116 7023305 Shim 1

117 to 134 Not Used

135 7023304 Brake Disc Kit (Includes Shim Kit) 1

7026191 Brake Shim Kit 1

136 to 140 Not Used

141 Use Item 152 Protector 1 142 Use Item 152 Plug, Dust 1 143 Use Item 152 O-Ring 1

144 to 150 Not Used

— — — — — — — — — — 151 7023300 Seal Kit - (Includes Items - 27,45,72,78,106 & 113) 1 152 7023301 Seal Kit - (Includes Items - 27,45,48,72,78,106,111,113,141,

142 & 143)

1-14 3121112

Page 21

SECTION 1 FRAME

FIGURE 1-6. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626 (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3121112 1-15

Page 22

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT & ALL 400CRT

1-16 3121112

Page 23

SECTION 1 FRAME

FIGURE 1-7. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT & ALL 400CRT

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3160244 DRIVE MOTOR ASSEMBLY Ref. D

1 7024963 Front Housing Assembly (See Items 101 to 108 for

Breakdown)

2 7023866 Rotary Assembly 1 2A Not Available Rotary without Cam 1 2B Not Available Cam 1

3 7024964 Rear Housing Assembly (See Items 201 to 208 for

Breakdown) 4 Use Item 331 Seal, Square 2 5 Not Available Screw, Cap 6 6 Not Used 7 7024965 Brake Assembly (See Items 301 to 327 for Breakdown) 1 8 Use Item 331 Seal, Square 1 9 7023806 Lugnut 5

10 7023807 Stud, Wheel 5

FRONT HOUSING ASSEMBLY Ref.

101 7022586 Shaft 1 102 Use Item 331 Seal, Face 1 103 7022587 Bearing, Front 1 104 Not Available Casting, Front 1 105 Use Item 331 Seal, Shaft 1 106 7022588 Bearing, Rear 1 107 Not Available Washer 1 108 7022589 Ring, Split 1

S E

I O N

REAR HOUSING ASSEMBLY Ref. 201 Not Available Ring, Distributor 1 202 Not Available Spring 9 203 Use Item 331 Seal, Nylon 1 204 Use Item 331 Seal, Nylon 1 205 Use Item 331 Seal, Nylon 1 206 Not Available Housing, Rear 1 207 7022590 Pin, Stop 1 208 7022591 Plug (O-Ring Supplied with Plug) 1

BRAKE ASSEMBLY Ref. 301 Not Available Housing, Brake 1 302 7022592 Shaft 1 303 7022593 Shim 1 304 7022594 Shim 1 305 7022595 Disc, Outer Brake 15 306 7022596 Disc, Inner Brake 13

307 to 313 Not Used

314 7022597 Bushing 1 315 Not Available Washer 8

3121112 1-17

Page 24

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT & ALL 400CRT (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

316 Not Available Screw, Cap 8 317 Not Used 318 Use Item 331 Ring, Square 1 319 7022598 Piston, Brake 1 320 Not Used 321 Use Item 331 Seal, Outer 1 322 7022599 Washer, Bellville 1 323 Use Item 331 Gasket 1 324 Not Available Cover, End 1 325 Use Item 331 O-Ring 1 326 Not Available Screw, Cap 12 327 7023800 Plug 1

328 to 330 Not Used

— — — — — — — — — —

331 7022585 Seal Kit - (Includes Items 4,8,102,105,203-

205,318,321,323 & 325)

1-18 3121112

Page 25

SECTION 1 FRAME

FIGURE 1-7. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT & ALL 400CRT (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3121112 1-19

Page 26

SECTION 1 FRAME

113

117

125

129

127

106

118

128

122

123

120

131

124

122

123

120

131

124

321

107119233131926

138

141

137

139

142

143

10414

04A

613013010812613

134

322

FRONT

REAR

109

112

316

314

315

310

FUEL

FILTER

INJECTOR

FUEL RAIL

114

320

132

110

115

132

111

306

301

313

309

308

319

329

332

328

325

334

324

326

333

331

304

S E

I O N

FIGURE 1-8. DIESEL ENGINE INSTALLATION - KUBOTA

1-20 3121112

Page 27

SECTION 1 FRAME

FIGURE 1-8. DIESEL ENGINE INSTALLATION - KUBOTA

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259851 DIESEL ENGINE ASSEMBLY Ref. D

1 Not Used 2 0641404 Bolt 1/4”-20NC x 1/2” 2 3 0641410 Bolt 1/4”-20NC x 1 1/4” 2 4 0641508 Bolt 5/16”-18NC x 1” 2 5 0641608 Bolt 3/8”-16NC x 1” 2 6 0641812 Bolt 1/2”-13NC x 1 1/2” 4 7 0641814 Bolt 1/2”-13NC x 1 3/4” 2 8 0700808 Bolt, Metric M8 x 16mm 2

9 0760812 Bolt, Metric M8 x 25mm 8 10 0902613 Bracket, Air Cleaner 1 11 0902624 Bracket, Radiator Seal 1 12 1320016 Clamp 4 13 Not Used 14 1320274 Clamp, Exhaust 1 15 2000169 Engine, Kubota Diesel 1 16 2720456 Hose, Air Intake 1 17 2720457 Hose, Air Intake 1 18 3290801 Nut, Metric M8 4 19 3311405 Locknut 1/4”-20NC 4 20 3311505 Locknut 5/16”-18NC 2 21 3311805 Locknut 1/2”-13NC 6 22 3460314 Pipe, Exhaust 1 23 3460316 Pipe, Exhaust 1 24 Not Used 25 3740049 Relay 2 26 4240143 Strap, Exhaust 1 27 4711400 Flatwasher 1/4” Narrow 4 28 4711800 Flatwasher 1/2” Narrow 12 29 4751600 Flatwasher 3/8” 2 30 4761600 Lockwasher 3/8” 6 31 4846036 Engine Tray Weldment 1 32 4846221 Reserve Tank Mounting Weldment 1 33 0840026 Boot, Terminal 1

S E

I O N

0259381 DIESEL ENGINE INSTALLATION Ref. J

101 0100011 Loctite #242 (Not Shown) A/R 102 0100020 Sealant, Pipe (Not Shown) A/R 103 Not Used 104 0400002 Hold-Down, Battery 1

2910479 Clip Repair Kit 1 105 0400003 Battery 1 106 0641418 Bolt 1/4”-20NC x 2 1/4” 4 107 0641632 Bolt 3/8”-16NC x 4” 2 108 0641672 Bolt 3/8”-16NC x 9” 2 109 1670945 Cover, Engine - Front 1

3121112 1-21

Page 28

SECTION 1 FRAME

S E

I O N

FIGURE 1-8. DIESEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

110 2221046 Fitting, 90° 1 111 2221047 Fitting, 90° 1 112 2540036 Grommet 1 113 2560163 Handle 1 114 Hose, Fuel Line Options:

2720339 Production

2720058 Post Production 115 2720271 Hose, Low Pressure 116 3300029 Wingnut 3/8”-16NC 2 117 3300374 Nut, Post Binding 1 118 3311405 Locknut 1/4”-20NC 4 119 3311605 Locknut 3/8”-16NC 2 120 3322202 Nut, Jam 3/4”-16NF 4 121 Not Used 122 3760348 Ring, Retaining 4 123 3841233 Rod, Roller Mount 4 124 3860059 Roller, Extension 4 125 3900184 Screw, Button Head #10-24NC x 5/8” 1 126 3980003 Seat, Battery 1 127 4160189 Spring, Extension 1 128 4711400 Flatwasher 1/4” Narrow 8 129 4740493 Washer, Nylon Insert 2 130 4751600 Flatwasher 3/8” 4 131 4752200 Flatwasher 3/4” 4 132 1320022 Clamp 6 133 1060823 Cable, Battery (Positive) 1 134 1060824 Cable, Battery (Negative) 1

135 to 136 Not Used

137 0641812 Bolt 1/2”-13NC x 1 1/2” 2 138 Piston Pump Assembly Options: 1

3600300 Production (See Figure 1-10 for Breakdown) 1

3600414 Post Production (See Figure 1-11 for Breakdown) 1 139 4711800 Flatwasher 1/2” Narrow 2 140 0840025 Boot, Cable 1 141 3600313 Gear Pump Assembly 1

7022389 Seal Kit - 3600313 Front Pump

Use 70002861 Seal Kit - 3600313 Rear Pump (was p/n 7022388) 142 0641608 Bolt 3-8”-16NC x 1” 2 143 4711600 Flatwasher 3/8” (Narrow) 2

144 to 299 Not Used

9ft/2.75m

2000169 ENGINE COMPONENTS Ref. A

301 7017923 Filter, Oil 1 302 7023177 Solenoid, Fuel Shutdown (Not Shown) 1

7023134 Gasket (Not Shown) 1 303 7023137 Plug, Glow (Not Shown) 3 304 7023199 Filter Cover Assembly 1

304A 7023138 Element, Fuel Filter 1

1-22 3121112

Page 29

SECTION 1 FRAME

FIGURE 1-8. DIESEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

305 7017995 Gasket, Fuel Pump (Not Shown) 1 306 7023169 Alternator 1

7023142 Brush 2

7023143 Spring, Brush 2 307 7023141 V-Belt (Not Shown) 1 308 7023144 Starter 1

7023186 Relay, Starter 1

7023187 Connector, Starter Relay 1 309 7017901 Switch, Oil 1 310 7023170 Thermostat 1 311 7017924 Pump, Water (Not Shown) 1 312 7017967 Cap, Radiator (Not Shown) 1 313 7017968 Hose, Radiator (Bottom) 1 314 7017969 Hose, Radiator (Top) 1 315 7017938 Element, Air Cleaner 1 316 7017942 Cap, Air Cleaner 1 317 Not Used 318 7023173 Sensor, Speed (Not Shown) 1 319 7023196 Coupling, Pump 1 320 7023124 Gasket, Exhaust 2 321 7023172 Muffler 1 322 7023126 Tank, Reservoir 1 323 7017908 Plug, Drain Oil Pan (Not Shown) 1

7017904 Gasket, Drain Plug (Not Shown) 1 324 7023133 Cap, Oil Filler 1 325 7023160 Dipstick 1 326 7023166 Nozzle Holder Assembly 3

7023167 Gasket (1 per holder) 3

7023168 Seal, Heat (1 per holder) 3 327 7026205 Pump, Fuel (Electric) (Not Shown) 1 328 7026211 Thermoswitch 1 329 7017963 Pipe, Water 1 330 7017964 Hose, Water (Not Shown - Located from Water Pipe to Bot-

tom of Water Pump) 331 7023149 Gasket, Intake Manifold 1 332 7023148 Gasket, Exhaust Manifold 1 333 7026202 Band, Air Cleaner 1

7026203 Cushion 1 334 7026207 Radiator Assembly 1 335 7023164 Pump, Injection (Not Shown) 1 336 7023188 Harness, Engine (Not Shown) 1 337 70001140 Gear, Ring (Flywheel) (Not Shown) 1 338 70001865 Fan, Cooling (Not Shown) 1

S E

I O N

3121112 1-23

Page 30

SECTION 1 FRAME

FUEL

SUPPLY

FUEL

PUMP

LP TANK

115

156

125

116

158

159

306

319

302A

302

320

321

314

315

323

324

309

308

301

303

328

304

326

316

24 17

313

26 14

149

151

150

154

142

401

155 153

141

103

126

139

108

135

19 402

325

124

109

305

162329

109

121

124

107

129

322

318

122

111

105 137 128

134 127 138

123

136

130

131

132

133

140

110

100

139 129 106

330

104

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA

I O N

1-24 3121112

Page 31

SECTION 1 FRAME

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259850 GAS DUAL FUEL ENGINE ASSEMBLY Ref. H

1 0641410 Bolt 1/4”-20NC x 1 1/4” 2 2 0641508 Bolt 5/16”-18NC x 1” 1 3 0641812 Bolt 1/2”-13NC x 1 1/2” 4 4 0641814 Bolt 1/2”-13NC x 1 3/4” 2 5 0760812 Bolt, Metric M8 x 25mm 8 6 0902614 Bracket, Air Cleaner 1 7 0902639 Bracket, Reserve Tank 1 8 0902623 Bracket, Radiator Seal 1

9 1320016 Clamp 4 10 1320274 Clamp, Exhaust 1 11 2000170 Engine, Kubota WG-750 Gas Dual Fuel 1 12 2720458 Hose, Air Intake 1 13 2720459 Hose, Air Intake 1 14 3290801 Nut, Metric M8 4 15 3311405 Locknut 1/4”-20NC 2 16 3311505 Locknut 5/16”-18NC 1 17 3311805 Locknut 1/2”-13NC 6 18 3460314 Pipe, Exhaust 1 19 3460315 Pipe, Exhaust 1 20 Not Used 21 4240143 Strap, Exhaust 1 22 4711400 Flatwasher 1/4” Narrow 4 23 4711500 Flatwasher 5/16” 2 24 4711800 Flatwasher 1/2” Narrow 12 25 4740495 Washer, Special 1 26 4761600 Lockwasher 3/8” 4 27 Not Used 28 4846036 Engine Tray Weldment 1 29 1320265 Clamp, Loop 1 30 0840026 Boot, Terminal (Not Shown - Located at Positive Post of

Alternator) 31 2120077 Filter-Lock, LP Gas 1 32 Not Used

S E

I O N

0259380 GAS DUAL FUEL ENGINE INSTALLATION Ref. J

100 4400275 Tank, LP 1 101 0100020 Sealant, Pipe (Not Shown) A/R 102 Not Used 103 0400002 Hold-Down, Battery 1

2910479 Clip Repair Kit 1 104 0400003 Battery 1 105 0641418 Bolt 1/4”-20NC x 2 1/4” 4 106 0641612 Bolt 3/8”-16NC x 1 1/2” 4 107 0641632 Bolt 3/8”-16NC x 4” 2 108 0641672 Bolt 3/8”-16NC x 9” 2

3121112 1-25

Page 32

SECTION 1 FRAME

S E

I O N

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

109 1320022 Clamp 4 110 1320220 Clamp Kit - LP 1 111 1670944 Cover, Engine - Front 1

112 to 114 Not Used

115 2180387 Fitting, LP 1 116 2180389 Fitting, Relief Valve 1 117 2200222 Fitting, Pipe Plug (Not Shown - Located on Fuel Tank) 1

118 to 120 Not Used

121 2221046 Fitting, 90° 1 122 2540036 Grommet 1 123 2560163 Handle 1 124 2720339 Hose, Fuel Line 125 2720463 Hose, LP 1 126 3300029 Wingnut 3/8”-16NC 2 127 3300374 Nut, Post Binding 1 128 3311405 Locknut 1/4”-20NC 6 129 3311605 Locknut 3/8”-16NC 6 130 3322202 Nut, Jam 3/4”-16NF 4 131 3760348 Ring, Retaining 4 132 3841233 Rod, Roller Mount 4 133 3860059 Roller, Extension 4 134 3900184 Screw, Button Head #10-24NC x 5/8” 1 135 3980003 Seat, Battery 1 136 4160189 Spring, Extension 1 137 4711400 Flatwasher 1/4” Narrow 12 138 Not Used 139 4751600 Flatwasher 3/8” 12 140 4752200 Flatwasher 3/4” 4 141 1060823 Cable, Battery (Positive) 1 142 1060824 Cable, Battery (Negative) 1

143 to 147 Not Used

148 0100011 Loctite #242 (Not Shown) A/R 149 0641812 Bolt 1/2”-13NC x 1 1/2” 2 150 Piston Pump Assembly Options: 1

3600300 Production (See Figure 1-10 for Breakdown) 1

3600414 Post Production (See Figure 1-11 for Breakdown) 1 151 4711800 Flatwasher 1/2” Narrow 2 152 Not Used 153 0641608 Bolt 3/8”-16NC x 1” 2 154 3600313 Gear Pump Assembly 1

7022389 Seal Kit - 3600313 Front Pump 1

Use 70002861 Seal Kit - 3600313 Rear Pump (was p/n 7022388) 1 155 4711600 Flatwasher 3/8” (Narrow) 2 156 2220399 Fitting 1 157 0641406 Bolt 1/4”-20NC x 3/4” 2 158 2220290 Fitting, Tee 1 159 2220773 Fitting, 90° 1

160 to 299 Not Used

9ft/2.75m

1-26 3121112

Page 33

SECTION 1 FRAME

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2000170 ENGINE COMPONENTS Ref.

301 7017901 Switch, Oil 1 302 7023174 Air Cleaner Assembly 1

302A 7023153 Element, Breather 1

303 7017980 Filter, Oil 1 304 7017985 Flywheel 1 305 7017992 Filter, Fuel 1

7022169 Shutoff, Fuel Filter (Not Shown) 1 306 7017998 Vaporizer 1 307 7023105 Coil, Ignition (Not Shown) 1 308 7023169 Alternator 1 309 7023107 V-Belt 1 310 7023108 Regulator (Not Shown) 1 311 7023109 Connector, Electrical (Not Shown) 1 312 7023110 Connector, Electrical (Not Shown) 1 313 7023111 Starter 1 314 7023113 Thermostat 1 315 7023115 Pump, Water 1 316 7023124 Gasket, Muffler 2 317 7017981 Dipstick (Not Shown) 1 318 7017942 Cover, Air Cleaner 1 319 7017978 Tube, Breather 1 320 7023104 Air Distributor 1 321 7023120 Fan 1 322 7023126 Tank, Overflow 1 323 7023128 Radiator 1 324 7023125 Shroud, Fan 1 325 7023127 Muffler 1 326 7023175 Coupling, Pump 1 327 7023190 Pump, Fuel (Not Shown) 1 328 Carburetor Assembly Options: 1

7023197 With Automatic Choke

7023176 Without Automatic Choke

Not Available Valve, LP Lockout Solenoid (Not Sold Separately) 1

7023184 Choke Assembly 1

7023191 Coupling, Bronze 1

7023193 Base, Choke 1

7023192 Bushing (Fits Between Choke and Carb) 1

7023194 Washer (Fits Between Choke and Carb) 1

7023195 Rod, Choke 1

7026209 Bracket, Choke Support 1

7023198 Horn, Air 1 329 7023173 Sensor, Speed (Not Shown) 1 330 70001439 Bracket, Adjusting 1

S E

I O N

3121112 1-27

Page 34

SECTION 1 FRAME

S E

I O N

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0270199 SPARK ARRESTOR INSTALLATION (DUAL FUEL) Ref. A

401 3220083 Muffler, Spark Arrestor 1 402 3460325 Pipe, Exhaust 1

1-28 3121112

Page 35

SECTION 1 FRAME

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3121112 1-29

Page 36

SECTION 1 FRAME

S E

I O N

FIGURE 1-10. PISTON PUMP ASSEMBLY (PRODUCTION)

1-30 3121112

Page 37

SECTION 1 FRAME

FIGURE 1-10. PISTON PUMP ASSEMBLY (PRODUCTION)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3600300 PISTON PUMP ASSEMBLY Ref. D

1 Not Available Rotary Group Assembly (Includes Items 101-116) 1 2 Not Available Shaft Assembly 1

7023887 Shaft 1 2A 7023888 Bearing, Roller 1 2B 7023889 Ring, Retaining 1

3 Not Available Housing Assembly (Includes Items 201-211) 1 4 Not Available Stroking Piston Assembly (Includes Items 301-309) 1 5 Not Available Port Block Assembly (Includes Items 401-410) 1 6 7023877 Control Valve Assembly (Includes Items 501-520) 1 7 Not Available Thru Drive Assembly (Includes Items 601-621) 1 8 7023878 Ring, Retaining 2

9 7024070 Seal, Shaft 1 10 Use Item 625 O-Ring 1 11 Not Used 12 Not Available Orifice (1.0) 2 13 Not Used 14 Not Serviced Plug, O-Ring 3

14A Use Item 625 O-Ring 3

15 Not Serviced Plug, O-Ring 3

15A Use Item 625 O-Ring 3

16 Not Used 1 17 7023879 Pin, Lens 1 18 Not Used 19 Not Used 20 7022380 Relief Valve Assembly 2

20A Use Item 625 Ring, Back-Up 2 20B Use Item 625 O-Ring 2

21 Not Used 22 Not Used 23 7023881 Charge Pressure Relief Valve Kit 1

23A Use Item 625 O-Ring 1

24 Use Item 625 Nut, Jam 1

25 to 28 Not Used

29 Not Serviced Plug, O-Ring 1

29A Use Item 625 O-Ring 2

30 to 31 Not Used

32 Not Available Cover, Stroking Piston 1

33 to 35 Not Used

36 7023882 Capscrew M6 x 12 4

S E

I O N

ROTARY GROUP ASSEMBLY Ref.

101 Not Available Barrel 1 102 Not Available Plate, Lens 1 103 Not Available Piston 9 104 Not Available Plate, Retaining 1

3121112 1-31

Page 38

SECTION 1 FRAME

S E

I O N

FIGURE 1-10. PISTON PUMP ASSEMBLY (PRODUCTION) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

105 Not Available Coupling, Ball 1 106 7023883 Spring 1 107 Not Available Pin, Pressure 3 108 7023884 Ring, Retaining 1 109 Not Available Disk 1 110 7023885 Cradle Bearing Set 1 111 7023834 Wire 1 112 Not Available Lever 1 113 Not Available Pin 1 114 Not Available Wire 1 115 Not Available Plate, Swash 1 116 7023886 Race, Bearing 1pr

HOUSING ASSEMBLY 1Ref.

201 Not Available Housing 1 202 Not Available Rollpin 2 203 Not Available Plug, O-Ring 3

203A Use Item 625 O-Ring 3

204 Not Used 205 7023890 Bushing 2 206 Use Item 625 Glyd-Ring 2 207 Not Available Plug, O-Ring 1

207A Use Item 625 O-Ring 1

208 Not Used 209 Not Available Pin 1 210 Use Item 625 Plug 1 211 Not Available Plug, Breakoff 1

STROKING PISTON ASSEMBLY Ref.

301 7023891 Bolt, Centering 1 302 Not Available Piston, Center 1 303 7023892 Collar, Spring 1 304 7023893 Spacer 1 305 7023894 Collar, Spring 1 306 7023895 Ring, Retaining 1 307 7023896 Ring 1 308 Use Item 625 O-Ring 1 309 7023897 Spring 1

PORT BLOCK ASSEMBLY

401 Not Available Block, Port 1 402 Use Item 625 Plug 1 403 7023898 Capscrew M12 x 70 4 404 Not Used 405 Use Item 625 O-Ring 1 406 Not Used

1-32 3121112

Page 39

SECTION 1 FRAME

FIGURE 1-10. PISTON PUMP ASSEMBLY (PRODUCTION) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

407 7023899 Bearing, Roller 1 408 Not Available Pin, Dowel 2 409 Not Used 410 Not Available Plug, O-Ring 2

410A Use Item 625 O-Ring 2

CONTROL VALVE ASSEMBLY Ref.

501 Use Item 625 Nut, Seal 1 502 Not Available Eccentric 1 503 7024000 Capscrew M6 x 45 1 504 7024001 Capscrew M6 x 70 4 505 Use Item 625 Gasket 1 506 7023854 Solenoid 2 507 7023855 Connector, Electrical (Gray) 1 508 Not Available Capscrew M4 x 50 8 509 Use Item 625 O-Ring 2 510 7023856 Connector, Electrical (Black) 1 511 Not Available Pin, Dowel 2 512 Use Item 625 Gasket 1 513 Not Available Pin 1 514 7024002 Lever, Feedback 1 515 7024003 Lever 2 516 7023859 Spring 1 517 Not Available Cover 1 518 Use Item 625 O-Ring 1 519 Not Available Block 1 520 Not Available Piston 1

S E

I O N

THRU DRIVE ASSEMBLY Ref.

601 Not Available Plate 1 602 7024004 Coupling, Shaft 1

603 to 606 Not Used

607 Use Item 625 O-Ring 2 608 Not Available Gear 1 609 Use Item 625 O-Ring 1 610 Not Available Capscrew M10 x 20 4

611 to 612 Not Used

613 Use Item 625 O-Ring 1

614 to 619 Not Used

620 7024005 Plate, Wear 1 621 Not Available Pin

622 to 624 Not Used

— — — — — — — — — —

625 7024006 Seal Kit (Includes Items 9,10,14A,15A,20A,20B,23A,

24,29A,203A,206,207A,210,308,402,405,410A,501, 505,509,512,518,607,609 & 613

3121112 1-33

Page 40

SECTION 1 FRAME

A-A

DETAIL

OF ITEM 5

DETAIL OF ITEM 2

DETAIL OF ITEM 1

503

514

516

501

504

512

502

513

511

505

506

510

507

515

403

420

413

407

409

410

401

421

114

136

131

117

132

112

138

137

126

119

113

118

217

216

213

218

201

231

230

DETAIL OF

ITEM 3

307

311

344

305

308

301

312

326

302

DETAIL OF ITEM 4

407

402

S E

I O N

FIGURE 1-11. PISTON PUMP ASSEMBLY (POST PRODUCTION)

1-34 3121112

Page 41

SECTION 1 FRAME

FIGURE 1-11. PISTON PUMP ASSEMBLY (POST PRODUCTION)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3600414 PISTON PUMP ASSEMBLY Ref. B

1 7024064 Rotary Group (See Items 101-138 for Breakdown) 1 2 7024065 Control Assembly (See Items 201-231 for Breakdown) 1 3 Not Available Valve Plate Assembly (See Items 301-344 for Breakdown) 1 4 Not Available Internal Pump Assembly (See Items 401-421 for Breakdown) 1 5 7024068 Module Assembly (See Items 501-516 for Breakdown) 1

6 to 9 Not Used

10 Not Available Housing 1

11 to 12 Not Used

13 80934596 Joint, Pin (Not Shown) 1 14 Not Available Pin, Dowel (Not Shown) 1

15 to 19 Not Used

20 Not Available Screw, Locking (Not Shown) 1 21 Not Used 22 Not Available Screw, Locking (Not Shown) 3 23 Not Available Screw, Locking (Not Shown) 1 24 Not Available Screw, Locking (Not Shown) 1

25 to 26 Not Used

27 Not Available Pin, Breakoff (Not Shown) 1 28 7018936 Orifice (Not Shown) 2

29 to 30 Not Used

31 7028877 Pin, Clamping (Not Shown) 2

32 to 40 Not Used

41 7024069 O-Ring (Not Shown) 1

42 to 48 Not Used

49 Not Available Plug (Not Shown) 1

S E

I O N

7024064 ROTARY GROUP Ref.

101 to 111 Not Used

112 Not Available Cradle (Purchase Assembly p/n 7024064) 1 113 Not Available Ring, Slide (Purchase Assembly p/n 7024064) 1 114 7023887 Driveshaft 1

115 to 116 Not Used

117 Not Available Wire (Purchase Assembly p/n 7024064) 1 118 Not Available Joint, Pin (Purchase Assembly p/n 7024064) 1 119 Not Available Wire (Purchase Assembly p/n 7024064) 1

120 to 125 Not Used

126 Not Available Liner, Bearing (Purchase Assembly p/n 7024064) 1 Pr

127 to 130 Not Used

131 7023888 Bearing, Roller 1 132 7023885 Cradle Bearing Assembly (Purchase Assembly p/n 7024064) 1 Set

133 to 135 Not Used

136 Not Available Ring, Retaining (Purchase Assembly p/n 7024064) 1 137 70001968 Ring, Retaining (Purchase Assembly p/n 7024064) 2 138 7024070 Seal, Shaft Ring 1

3121112 1-35

Page 42

SECTION 1 FRAME

S E

I O N

FIGURE 1-11. PISTON PUMP ASSEMBLY (POST PRODUCTION) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

7024065 CONTROL ASSEMBLY Ref.

201 Not Available Piston, Positioning - Complete (Purchase Assembly p/n

7024065) (Includes Items 213 & 218)

202 to 212 Not Used

213 7024071 O-Ring, Outer Seal 1

214 to 215 Not Used

216 Not Available Capscrew, Socket Head (Purchase Assembly p/n 7024065) 4 217 Not Available Nut, Hex (Purchase Assembly p/n 7024065) 1 218 7024072 O-Ring, Stem 1

219 to 229 Not Used

230 Not Available Ring, Guide (Purchase Assembly p/n 7024065) 2 231 Not Available Ring, Glide (Purchase Assembly p/n 7024065) 2

3Not AvailableVALVE PLATE ASSEMBLY Ref.

301 7024073 Cartridge, Relief Valve

Note: Sold as an Assembly Except O-Ring & Back-up Ring.

7024075 O-Ring (1 Per Assembly) 2 7024076 Ring, Back-up (1 Per Assembly) 2

302 7023881 Cartridge, Relief Valve

Note: Sold as an Assembly Except O-Ring.

7024077 O-Ring 1

303 to 304 Not Used

305 70003339 Plate, Port 1 306 Not Used 307 Not Available Capscrew 4 308 Not Available Pin, Dowel 2

309 to 310 Not Used

311 70003340 Pin, Breakoff 1 312 Not Available Screw, Locking 1

313 to 325 Not Used

326 7024908 O-Ring 1

327 to 334 Not Used

335 Not Available Screw, Locking (Not Shown) 2

336 to 343 Not Used

344 Not Available Bearing, Roller 1

Not Available INTERNAL PUMP ASSEMBLY Ref.

401 Not Available Plate, Sandwich 1 402 7024004 Coupling, Shaft 1 403 Not Available Seal, Ring 1

404 to 406 Not Used

407 Not Available Seal 2 408 Not Used 409 7024082 O-Ring 1 410 Not Available Capscrew 4

1-36 3121112

Page 43

SECTION 1 FRAME

FIGURE 1-11. PISTON PUMP ASSEMBLY (POST PRODUCTION) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

411 to 412 Not Used

413 7024081 O-Ring 1

414 to 419 Not Used

420 7024005 Plate, Wear 1 421 Not Available Pin, Dowel 1

7024068 MODULE ASSEMBLY Ref.

501 7024084 Module, Control (Valve Block) Less Coils

Note: No Internal Replacement Parts Available. Sold as an Assembly Only.

502 7024083 Coil, Solenoid 2 503 Not Available Adapter, Valve Block to Coil (Purchase Assembly p/n

7024068) 504 7024085 Gasket 1 505 Not Available Cover (Purchase Assembly p/n 7024068) 1 506 Not Available Spring, Draw (Purchase Assembly p/n 7024068) 1 507 7024086 Gasket 1

508 to 509 Not Used

510 80934644 Capscrew (Purchase Assembly p/n 7024068) 4 511 Not Available Capscrew (Purchase Assembly p/n 7024068) 1 512 Not Available Capscrew (Purchase Assembly p/n 7024068) 8 513 7024087 O-Ring 1 514 7024088 O-Ring 2 515 7024089 Cup, Spring 2 516 Not Available Pin, Dowel (Purchase Assembly p/n 7024068) 2

— — — — — — — — — —

Not Available Seal Kit - Complete 1

S E

I O N

3121112 1-37

Page 44

SECTION 1 FRAME

S E

I O N

FIGURE 1-12. FRAME MOUNTED COMPONENTS INSTALLATION

1-38 3121112

Page 45

SECTION 1 FRAME

FIGURE 1-12. FRAME MOUNTED COMPONENTS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

ALARM INSTALLATIONS (OPTIONAL) Ref. 0259591 Descent Ref. D 0259592 Motion Ref. D

1 Not Used 2 0641508 Bolt 5/16”-18NC x 1” 2 3 Not Used 4 3311505 Locknut 5/16”-18NC 2

5 to 6 Not Used

7 4711500 Flatwasher 5/16” Narrow 2 8 4922425 Harness, Alarm (Not Shown - See Section 7 for

Breakdown)

9 Not Used

0259593 BEACON LIGHT INSTALLATION (OPTIONAL) Ref. B

101 to 102 Not Used

103 2820018 Tube, Heat Shrink (Not Shown) A/R 104 2920146 Beacon Light Assembly 1

7016319 Tube, Flash 1 7016372 Lens, Replacement Amber 1

105 3941004 Screw, Self-Tapping #10-24NC x 1/2” 2

106 to 110 Not Used

111 4922426 Harness, Beacon (Not Shown - See Section 7 for Breakdown) 1

S E

I O N

3121112 1-39

Page 46

SECTION 1 FRAME

S E

I O N

FIGURE 1-13. FRAME COVERS AND LADDERS INSTALLATION

1-40 3121112

Page 47

SECTION 1 FRAME

FIGURE 1-13. FRAME COVERS AND LADDERS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259562 ENGINE COVER INSTALLATION Ref. C

1 0100019 Loctite #271 (Not Shown) A/R 2 0641405 Bolt 1/4”-20NC x 5/8” 6 3 1670943 Cover, Engine 1 4 4711400 Flatwasher 1/4” (Narrow) 6

FRAME COVERS INSTALLATION OPTIONS: Ref. 0259947 Fixed Rear Axle Machines (Prior to S/N 71310) Ref. B 0259948 Oscillating & Fixed Rear Axle Machines (S/N 71310 to

Present)

101 0100011 Loctite #242 (Not Shown) A/R 102 0641406 Bolt 1/4”-20NC x 3/4” A/R 103 Bolt Options: A/R

0641506 Bolt 5/16”-18NC x 3/4” (Fixed Rear Axle - Prior to

S/N 71310)

0641405 Bolt 1/4”-20NC x 5/8” (Oscillating/Fixed Rear Axle -

S/N 71310 to Present)

0641407 Bolt 1/4”-20NC x 7/8” (Oscillating/Fixed Rear Axle - Use

on Axle Covers) (S/N 71310 to Present)

104 Cover, Axle Options: 2

1670933 Fixed Rear Axle (Prior to S/N 71310) 3572029 Oscillating/Fixed Rear Axle (S/N 71310 to Present)

105 1670934 Cover, Frame - Front 1 106 Cover, Frame - Center Options: 1

1670935 Fixed Rear Axle (Prior to S/N 71310) 1670937 Oscillating/Fixed Rear Axle (Not Shown - Items 106 &

107 are 1 piece) (S/N 71310 to Present)

107 Cover, Frame - Rear Options: 1

1670936 Fixed Rear Axle (Prior to S/N 71310) 1670937 Oscillating/Fixed Rear Axle (Not Shown - Items 106 &

107 are 1 piece) (S/N 71310 to Present) 108 2080052 Fastener 1/4”-20NC A/R 109 Nut Options: A/R

0641506 Nut 5/16”-18NC (Fixed Rear Axle) (Prior to S/N 71310) 10 0641405 Nut 1/4”-20NC (Oscillating/Fixed Rear Axle) (S/N 71310

to Present) 110 4751400 Flatwasher 1/4” 8 111 4751500 Flatwasher 5/16” A/R 112 4060803 Flex-Trim

Ref. C

4.5in/11cm

S E

I O N

3121112 1-41

Page 48

SECTION 1 FRAME

S E

I O N

FIGURE 1-13. FRAME COVERS AND LADDERS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LADDER INSTALLATIONS Ref. 0259576 330CRT Ref. D 0259577 400CRT Ref. D 0270514 330/400CRT with Leveling Jacks Ref. A

201 0641828 Bolt 1/2”-13NC x 3 1/2” 4 202 3311805 Locknut 1/2”-13NC 4 203 3520071 Cap-Plug 2 204 4751800 Flatwasher 1/2” 8 205 Ladder Weldment Options: 1

4846159 330/400CRT without Leveling Jacks 4846282 330/400CRT with Leveling Jacks

1-42 3121112

Page 49

SECTION 1 FRAME

FIGURE 1-13. FRAME COVERS AND LADDERS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3121112 1-43

Page 50

SECTION 1 FRAME

S E

I O N

FIGURE 1-14. LEVELING JACKS INSTALLATION

1-44 3121112

Page 51

SECTION 1 FRAME

FIGURE 1-14. LEVELING JACKS INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259611 LEVELING JACKS INSTALLATION Ref. E

1 0100011 Loctite, #242 (Not Shown) A/R 2 0100019 Loctite, #271 (Not Shown) A/R 3 0641406 Bolt 1/4”-20NC x 3/4” 4 4 0641528 Bolt 5/16”-18NC x 3 1/2” 4 5 0641608 Bolt 3/8”-16NC x 1” 16 6 0641830 Bolt 1/2”-13NC x 3 3/4” 16 7 0682016 Bolt 5/8”-11NC x 2” 12 8 1670971 Cover, Valve 2 9 Jack Cylinder Assembly Options (See Section 5 for

Breakdown):

Use 1684217 Prior to S/N 104829 (p/n was 1683966)

1684217 S/N 104829 to Present 10 2080052 Fastener, Insert 4 11 Not Used 12 3272001 Nut 5/8”-11NC 12 13 3310805 Locknut #8-32NC 16 14 3311505 Locknut 5/16”-18NC 4 15 3440420 Pin, Roll 8 16 3841326 Rod 4 17 3930820 Bolt #8-32NC x 1 1/4” 16 18 4061003 Cover 4 19 4160116 Spring 4 20 4420052 Tape, Safety 21 4641150 Leveling Jack Control Valve Assembly (See 101-104 for

Breakdown) 22 4740415 Washer 4 23 4750800 Flatwasher #8 (Wide) 16 24 4751400 Flatwasher 1/4” (Wide) 4 25 4751500 Flatwasher 5/16” (Wide) 4 26 4751600 Flatwasher 3/8” (Wide) 16 27 4711800 Flatwasher 1/2” (Wide) 16 28 4846224 Weldment, Leveling Jack (Front) 1 29 4846225 Weldment, Leveling Jack (Rear) 1 30 4892000 Flatwasher 5/8” (Hardened) 28 31 4922454 Harness (See Section 7 for Breakdown) 2 32 4922455 Harness (See Section 7 for Breakdown) 2 33 4922456 Harness (Not Shown - See Section 7 for Breakdown) 1 34 0182005 Angle, Hold-down 2 35 0641609 Bolt 3/8”-16NC x 1 1/8” 2 36 3311605 Locknut 3/8”-16NC 2 37 3572782 Plate, Hose Support 1

8.3ft/2.5m

S E

I O N

3121112 1-45

Page 52

SECTION 1 FRAME

S E

I O N

FIGURE 1-14. LEVELING JACKS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4641150 LEVELING JACK CONTROL VALVE ASSEMBLY Ref. B

101 0561407 Valve, Jack Control 1 102 2220883 Plug 2 103 4641151 Cartridge, Relief Valve 2

7021653 Seal Kit - 4641151 Valve (1 Per Cartridge) 2

104 4641152 Valve, 4-Way 2

7012903 Seal Kit - 4641152 Valve (1 Per Cartridge) 2 7012943 Coil (2 Per Cartridge) 4

1-46 3121112

Page 53

SECTION 1 FRAME

FIGURE 1-14. LEVELING JACKS INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3121112 1-47

Page 54

SECTION 1 FRAME

S E

I O N

FIGURE 1-15. GENERATOR INSTALLATION - 110V (OPTIONAL)

1-48 3121112

Page 55

SECTION 1 FRAME

FIGURE 1-15. GENERATOR INSTALLATION - 110V (OPTIONAL)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259696 GENERATOR INSTALLATION - 110V Ref. A

Note: Mounting Hardware Supplied with Generator Assembly

1 1060882 Cable, AC (See Section 7 for Breakdown) 1 2 2460036 110V Generator Assembly (Hydraulic) 1

2A 7023232 Generator Only 1

7023233 Brush Assembly 1

2B 7023235 Motor Assembly Only 1

2C 7010635 Cartridge 1

2900708 Seal Kit - 7010635 Cartridge 1

7012943 Coil 1 2D 7023234 Cartridge 1 2E 7023247 Receptacle (Not Shown) 1

3 Not Used 4 3311401 Nut 1/4-20NC 1 5 3740049 Relay, Skirted 1 6 4060803 Shield, Flex Trim 1ft/.3m 7 4761400 Lockwasher 1/4” 1 8 4922452 Harness, Generator (See Section 7 for Breakdown) 1

Ref.

S E

I O N

3121112 1-49

Page 56

SECTION 1 FRAME

S E

I O N

FIGURE 1-15. GENERATOR INSTALLATION - 110V (OPTIONAL) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-50 3121112

Page 57

SECTION 2 GROUND COMPONENTS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

2-1 RIGHT SIDE COMPARTMENT INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

2-3 FLOW DIVIDER VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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

2-5 FUEL COMPARTMENT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

S E C T

I O N

G R O U N D

C O

P O N

E N

3121112 2-1

Page 58

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. RIGHT SIDE COMPARTMENT INSTALLATIONS

U N D

C O

P O N

E N

2-2 3121112

Page 59

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. RIGHT SIDE COMPARTMENT INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259559 HYDRAULIC COMPONENTS INSTALLATION Ref. K

Note: Replacement Decals must be Purchased Separately - See Section 8.

1 0100011 Loctite #242 (Not Shown) A/R 2 0641407 Bolt 1/4”-20NC x 7/8” A/R 3 0641506 Bolt 5/16”-18NC x 3/4” 5

4 to 5 Not Used

6 0651404 Bolt 1/4”-48NF x 1/2” 2 7Not Used 8 1380136 Clip, Gripper 2

9 1670926 Cover, Hydraulic Tray 1 10 2080052 Fastener 1/4”-20NC 8 11 Pressure Filter Assembly Options: 1

2120146 With Electrical Clog Indicator 1 2120209 With Manual Clog Indicator 1

Note: All machines equipped with 2120146 filter from the factory. However, if the filter was replaced after leaving the factory, it may have been replaced with a 2120209 filter. Check clog indicator to determine which filter is on the machine.

7023206 O-Ring 1

11A Element, Filter Options: 1

2120150 Element, Filter - p/n 2120146 1 2120210 Element, Filter - p/n 2120209 1

11B Indicator, Clog Options: 1

7016312 Electrical Indicator - p/n 2120146 1 7020020 Manual Indicator - p/n 2120209 1

12 to 13 Not Used

14 2940126 Latch 1 15 Not Used 16 3820019 Rivet 2 17 4400426 Hydraulic Tank Assembly 1 L

17A 7014802 Gauge, Sight 1 17B 7014811 Cap, Breather 1 17C 7014816 Screen 1

7020256 Neck 17D 7020253 Strainer 1 17E 7014813 Plug, Magnetic 1

7014812 Magnet 1

18 Not Used 19 4641157 Main Control Valve Assembly (See Figure 2-2 for

Breakdown)

20 4641147 Flow Divider Assembly (See Figure 2-3 for Break-

down) 21 4711400 Flatwasher 1/4” Narrow A/R 22 4711500 Flatwasher 5/16” Narrow 11 23 3311405 Locknut 1/4”-20NC A/R 24 3572229 Plate, Splash 1

Ref.

S E

I O N

G R O U N D

C O

P O N

E N

3121112 2-3

Page 60

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. RIGHT SIDE COMPARTMENT INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

25 3310805 Locknut #8-32NC 4 26 3311505 Locknut 5/16”-18NC 1 27 3900289 Screw, Phillips Head #8-32NC 4 28 3900208 Screw 3/8”-16NC x 1” 1 29 Not Used 30 4750800 Flatwasher #8 4 31 4060808 Flex-Trim 6ft/1.8m 32 3572362 Plate, Cover 1 33 4761500 Lockwasher 5/16” 1 34 0641524 Bolt 5/16”-18NC x 3” 4 35 4568114 Tube, Spacer 4 36 0641405 Bolt 1/4”-20NC x 5/8” 4 37 1780317 Door 1 38 2600147 Hinge, Door 1 39 0641410 Bolt 1/4”-20NC x 1 1/4” 8

U N D

C O

P O N

E N

ELECTRICAL COMPONENTS INSTALLATIONS Ref. 0259580 Dual Fuel Gas Machines Ref. D 0259583 Diesel Machines Ref. D 0259582 Dual Fuel Gas Machines with Leveling Jacks Ref. B 0259581 Diesel Machines with Leveling Jacks Ref. C

101 0140001 Horn 1 102 Ground Control Box Assembly Options (See Figure

2-4 for Breakdown): 0259645 Dual Fuel Gas Machines (Production) 0259864 Dual Fuel Gas Machines (Post Production) 0259829 Diesel Machines (Production) 0270423 Diesel Machines (Post Production) 0259864 Dual Fuel Gas Machines with Leveling Jacks 0270423 Diesel Machines with Leveling Jacks

103 0641404 Bolt 1/4”-20NC x 1/2” A/R 104 0641406 Bolt 1/4”-20NC x 3/4” 4 105 0641506 Bolt 5/16”-18NC x 3/4” 1 106 0902590 Bracket, Ground Control Box 2 107 3311405 Locknut 1/4”-20NC A/R 108 3311505 Locknut 5/16”-18NC 1 109 4751500 Flatwasher 5/16” 2 110 4761400 Lockwasher 1/4” 4 111 Harness, Engine & Valve Options (Not Shown - See

Section 7 for Breakdown): 4922343 Machines without Leveling Jacks 4922441 Machines with Leveling Jacks

112 4711400 Flatwasher 1/4” (Narrow) 1

2-4 3121112

Page 61

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. RIGHT SIDE COMPARTMENT INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

G R O U N D

C O

P O N

E N

3121112 2-5

Page 62

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

U N D

C O

P O N

E N

2-6 3121112

Page 63

SECTION 2 GROUND COMPONENTS

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4641157 MAIN CONTROL VALVE ASSEMBLY Ref. D

1 Not Serviced Manifold 1 2 7017410 Cartridge Less Coil (Dump) 1

7012967 Seal Kit - 7017410 Cartridge 1 7012944 Coil 1

3 7017418 Cartridge, Relief (Lift Up) 1

7012998 Seal Kit - 7017418 Cartridge 1

4 7017418 Cartridge, Relief (Main) 1

7012998 Seal Kit - 7017418 Cartridge 1

5A 7021649 Cartridge, Relief (Steer Right) 2

7021651 Seal Kit - 7021649 Cartridge (1 Per Cartridge) 2

5B 7021650 Cartridge, Relief (Steer Left) 2

7021651 Seal Kit - 7021650 Cartridge (1 Per Cartridge) 2

6 7022527 Orifice 1/16”/2.0mm (Not Shown - Located on Back of

Valve at Port L)

7 7012941 Cartridge Less Coil (Brake Release) 1

7010543 Seal Kit - 7012941 Cartridge 1 7012944 Coil 1

8 7018901 Valve Assembly 1

7022531 Seal Kit 1

9 7022529 Valve Assembly (Lift) 1

7012773 Seal Kit 1 9A 7021375 Nut 1 9B 7021376 Coil 1 10 7022530 Valve Assembly (Steer) 1

7012773 Seal Kit 2

10A 7021375 Nut 2 10B 7021376 Coil 2

11 7018903 Tube Assembly 1

7018904 Fitting, Straight 1 12 7021646 Cartridge, Check 1

7012998 Seal Kit - 7021646 Cartridge 1 13 7021629 Cartridge, Needle Valve 1

7012953 Seal Kit - 7021629 Cartridge 1 14 7023208 Valve Assembly (Manual Descent) 1

7023209 Seal Kit - 7023208 Cartridge 1

14A 7023210 Handle 1

15 7010542 Cartridge 1

7010543 Seal Kit - 7010542 Cartridge 1 16 7018942 Capscrew, Socket Head #10-24NC x 2” 12

I O N

G R O U N D

C O

P O N

E N

3121112 2-7

Page 64

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-3. FLOW DIVIDER VALVE ASSEMBLY

U N D

C O

P O N

E N

2-8 3121112

Page 65

SECTION 2 GROUND COMPONENTS

FIGURE 2-3. FLOW DIVIDER VALVE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4641147 FLOW DIVIDER VALVE ASSEMBLY Ref. C

1 Not Serviced Block 1 2Not Used 3 7023810 Cartridge (Reverse) 1

7011344 Seal Kit - 7023810 Cartridge 1

4 7012975 Cartridge 6

7012967 Seal Kit - 7012975 Cartridge 6 5 7022524 Orifice (.5mm) 3 6Not Used 7 7022528 Valve Assembly 3

7012773 Seal Kit - Valve Assembly 3

7A 7021376 Coil 3

8Not Used 9 7018942 Capscrew, Socket Head #10-24NC x 2” 12

10 7023809 Cartridge (Forward) 2

7011344 Seal Kit - 7023809 Cartridge 2

I O N

G R O U N D

C O

P O N

E N

3121112 2-9

Page 66

E C

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY

I O N

U N D

C O

P O N

E N

2-10 3121112

Page 67

SECTION 2 GROUND COMPONENTS

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

GROUND CONTROL BOX ASSEMBLY OPTIONS: Ref. 0259829 Diesel Machines Ref. K 0270423 Diesel Machines Ref. K 0259645 Dual Fuel Gas Machines (Production) Ref. L 0259864 Dual Fuel Gas Machines (Post Production) Ref. K 0270423 Diesel Machines with Leveling Jacks Ref. K 0259864 Dual Fuel Gas Machines with Leveling Jacks Ref. K

1 Circuit Board Options: 1

0610140 Machines without Leveling Jacks (Production) 0610134 Machines without Leveling Jacks (Post Production) 0610134 Machines with Leveling Jacks

2 0861315 Box Assembly 1

2A Not Available Latch 1

3 Decal Options: 1

1704462 Prior to S/N 112399 1705729 S/N 112399 to Present

4 2420172 Gauge, Hourmeter 1 5 2920026 Holder, Bulb 4 6 2920029 Bulb, Light 4 7 3900281 Screw, Socket Head 8 8 3910606 Screw #6-32NC x 3/8 3

9 3910616 Screw #6-32NC x 1” 4 10 3910804 Screw #8 x 1/4” 3 11 4070987 Shim (.015) 3 12 4070991 Shim (.125) 1 13 4360070 Breaker, Circuit - 15Amp 1 14 4360328 Switch, Toggle 1 15 4360387 Switch, Push Button 2 16 4360469 Switch, Key 1

16A 2860030 Key, Replacement (Set of 2) 1

17 4360475 Switch, Mushroom 1

7020175 Ring, Sealing 1

17A 7020176 Block, Contact 1

18 4360481 Block, Switch - Dual Axis 1 19 4750600 Flatwasher #6 3 20 4760600 Lockwasher #6 4 21 4761000 Lockwasher #10 8 22 Harness, Ground Control Box (Not Shown - See

Section 7 for Breakdown) 4922378 Diesel Machines 4922336 Gas/Dual Fuel Machines

23 4922339 Harness, Tilt (Not Shown - See Section 7 for Break-

down)

24 3520026 Plug (Dual Fuel Machines Only) 1 25 3520193 Plug (S/N 112399 to Present Only) 1 26 Not Used 27 3520030 Plug, Hole (Post Production) 1

S E

I O N

G R O U N D

C O

P O N

E N

3121112 2-11

Page 68

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. FUEL COMPARTMENT INSTALLATION

U N D

C O

P O N

E N

2-12 3121112

Page 69

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. FUEL COMPARTMENT INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259560 FUEL TANK INSTALLATION Ref. F

1 0100011 Loctite #242 (Not Shown) A/R 2 0641407 Bolt 1/4”-20NC x 7/8” 4 3 1670931 Cover, Fuel Tank 1 4 2080052 Fastener 1/4”-20NC 4 5 2420191 Gauge/Sender, Fuel Level 1 6 3900128 Screw, Round Head 5 7 4400427 Fuel Tank Assembly 1

See Item 102 Cap, Tank 1 8 4420037 Tape, Padded 52in/1.3m 9 4751000 Flatwasher #10 5

10 4751400 Flatwasher 1/4” 4 11 Not Used 12 3960525 Gasket, Fuel Gauge 1 13 3311601 Nut 3/8”-16NC 2 14 4240139 Strap, Tank Mounting 1 15 4711600 Flatwasher 3/8” (Narrow) 2

FUEL TANK CAP OPTIONS: Ref. 4400427 Standard Tank Cap Ref. D 0259613 Optional Locking Tank Cap Ref. B

101 0100020 Sealant, Pipe (Not Shown - Locking Cap only) A/R 102 Cap Options: 1

7020257 Standard Cap 1120485 Locking Cap

I O N

G R O U N D

C O

P O N

E N

3121112 2-13

Page 70

S E C

I O N

SECTION 2 GROUND COMPONENTS

FIGURE 2-5. FUEL COMPARTMENT INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

U N D

C O

P O N

E N

2-14 3121112

Page 71

SECTION 3 SCISSOR ARMS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

3-1 SCISSOR ARMS INSTALLATION - 330CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 SCISSOR ARMS INSTALLATION - 400CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

S E

I O N

S O R

A R

3121112 3-1

Page 72

S E C

I O N

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - 330CRT

S S

A R

3-2 3121112

Page 73

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - 330CRT

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259105 SCISSOR ARMS INSTALLATION - 330CRT Ref. K

1 Not Used 2 0100011 Loctite #242 (Not Shown) A/R 3 0200654 Arm Weldment (Bottom Inboard) 1 4 0200655 Arm Weldment (Lower Mid Inboard) 1 5 0200656 Arm Weldment (Upper Mid Inboard) 1 6 0200657 Arm Weldment (Top Inboard) 1 7 0200658 Arm Weldment (Bottom Left Side Outboard) 1 8 0200659 Arm Weldment (Lower Mid Left Side Outboard) 1

9 0200660 Arm Weldment (Upper Mid Left Side Outboard) 1 10 0200661 Arm Weldment (Top Outboard) 1 11 0200667 Arm Weldment (Bottom Right Side Outboard) 1 12 0200668 Arm Weldment (Lower Mid Right Side Outboard) 1 13 0200669 Arm Weldment (Upper Mid Right Side Outboard) 1 14 0362840 Bar, Cable Carrier 1 15 0362841 Bar, Cable Carrier 1 16 0440234 Bushing A/R 17 0440236 Bushing A/R 18 0641418 Bolt 1/4”-20NC x 2 1/4” 2 19 Not Used 20 0641510 Bolt 5/16”-18NC x 1 1/4” A/R 21 0641608 Bolt 3/8”-16NC x 1” 1 22 0641610 Bolt 3/8”-16NC x 1 1/4” 2 23 0681520 Bolt 5/16”-18NC x 2 1/2” (Grade 8) 2 24 0681622 Bolt 3/8”-16NC x 2 3/4” (Grade 8) 2 25 0681624 Bolt 3/8”-16NC x 3” (Grade 8) 20 26 Not Used 27 0902540 Bracket, Limit Switch 1 28 4740480 Washer, Plastic Insert 4 29 Harness, Limit Switch Options: (See Section 7 for Break-

down)

Use 4922630 Prior to S/N 101118 (Was p/n 1060868)

4922630 S/N 101118 to Present 30 Not Used 31 1100110 Cam, Activator 1 32 3450304 Pin, Cotter 4 33 1683858 Lift Cylinder Assembly (See Section 5 for Breakdown) 1 34 3311805 Locknut #8-32NC 2 35 3300151 Nut, Acorn 1/4”-20NC 2 36 3311505 Locknut 5/16”-18NC A/R 37 3311605 Locknut 3/8”-16NC 25 38 Not Used 39 3340856 Pad, Slide 2 40 3340866 Pad, Arm A/R 41 3422369 Pin, Plunger 1 42 3422821 Pin, Pivot 2 43 3422822 Pin, Pivot 2

S E

I O N

S O R

A R

3121112 3-3

Page 74

S E C

I O N

S C

S S

A R

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - 330CRT (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

44 3422778 Pin, Pivot 2 45 3422825 Pin, Pivot 16 46 3422826 Pin, Pivot 4 47 Not Used 48 3760420 Ring, Retaining 20 49 3841143 Keeper, Pin 2 50 3930820 Screw, Socket Head #8-32NC x 1 1/4” 2 51 3951603 Setscrew, Socket Head 3/8”-16NC x 3/8” 2

52 to 55 Not Used

56 4711500 Flatwasher 5/16” Narrow A/R 57 4740332 Washer, Special 20 58 4750800 Flatwasher #8 2 59 4751600 Flatwasher 3/8” 1 60 4845986 Slider Weldment (Bottom) 2 61 4846020 Prop, Safety 1 62 4922321 Harness, Lift Down (Not Shown - See Section 7 for

Breakdown) 63 3760387 Ring, Retaining 4 64 Not Used 65 0641408 Bolt 1/4”-20NC x 1” 2 66 1670965 Cover, Limit Switch 1 67 3311405 Locknut 1/4”-20NC 2 68 4751500 Flatwasher 5/16” 4 69 Not Used 70 3020022 Grease, Lithium (Not Shown) A/R 71 Not Used 72 1320110 Clamp 1

73 to 74 Not Used

75 4711600 Flatwasher 3/8” 1

— — — — — — — — — —

2901930 Arm Kit - (Includes Items - 3 thru 13,16,17,20,36,40 & 56) 1

3-4 3121112

Page 75

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - 330CRT (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

S O R

A R

3121112 3-5

Page 76

S E C

I O N

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - 400CRT

S S

A R

3-6 3121112

Page 77

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - 400CRT

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259561 SCISSOR ARMS INSTALLATION - 400CRT Ref. J

1 Not Used 2 0100011 Loctite #242 (Not Shown) A/R 3 0200683 Arm Weldment (Bottom Inboard) 1 4 0200684 Arm Weldment (Lower Mid Inboard) 1 5 0200685 Arm Weldment (Center Mid Inboard) 1 6 0200686 Arm Weldment (Upper Mid Inboard) 1 7 0200687 Arm Weldment (Top Inboard) 1 8 0200688 Arm Weldment (Bottom Right Side Outboard) 1

9 0200689 Arm Weldment (Bottom Left Side Outboard) 1 10 0200690 Arm Weldment (Lower Mid Right Side Outboard) 1 11 0200691 Arm Weldment (Lower Mid Left Side Outboard) 1 12 0200692 Arm Weldment (Center Mid Right Side Outboard) 1 13 0200693 Arm Weldment (Center Mid Left Side Outboard) 1 14 0200694 Arm Weldment (Upper Mid Right Side Outboard) 1 15 0200695 Arm Weldment (Upper Mid Left Side Outboard) 1 16 0200696 Arm Weldment (Top Outboard) 1 17 Not Used 18 0362841 Bar, Cable Carrier 1 19 0440234 Bushing A/R 20 0440236 Bushing A/R 21 0641418 Bolt 1/4”-20NC x 2 1/4” 2 22 Not Used 23 0641608 Bolt 3/8”-16NC x 1” 2 24 0641610 Bolt 3/8”-16NC x 1 1/4” 2 25 0681520 Bolt 5/16”-18NC x 2 1/2” (Grade 8) 2 26 0681622 Bolt 3/8”-16NC x 2 3/4” (Grade 8) 4 27 0681624 Bolt 3/8”-16NC x 3” (Grade 8) 26 28 Not Used 29 0902540 Bracket, Limit Switch 2 30 0940090 Bumper, Arm Spacer A/R 31 4740480 Washer, Plastic Insert 4 32 Harness, Limit Switch Options: (Right Side) (Not Shown -See

Section 7 for Breakdown)

Use 4922630 Prior to S/N 101118 (Was p/n 1060868)

4922630 S/N 101118 to Present 33 1100110 Cam, Activator 2 34 3450304 Pin, Cotter 4 35 1683891 Lift Cylinder Assembly - Lower (See Section 5 for

Breakdown)

36 1683892 Lift Cylinder Assembly - Upper (See Section 5 for

Breakdown) 37 3311805 Locknut #8-32NC 4 38 3300151 Nut, Acorn 1/4”-20NC 2 39 3311505 Locknut 5/16”-18NC 2 40 3311605 Locknut 3/8”-16NC 34 41 3311401 Nut 1/4”-20NC A/R 42 Not Used

S E

I O N

S O R

A R

3121112 3-7

Page 78

S E C

I O N

S C

S S

A R

SECTION 3 SCISSOR ARMS

FIGURE 3-2. SCISSOR ARMS INSTALLATION - 400CRT (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

43 3340856 Pad, Slide 2 44 3422369 Pin, Plunger 1 45 3422778 Pin, Pivot 4 46 3422821 Pin, Pivot 2 47 3422822 Pin, Pivot 2 48 3422825 Pin, Pivot 24 49 3422826 Pin, Pivot 2 50 3760420 Ring, Retaining 26 51 3841143 Keeper, Pin 2 52 3930820 Screw, Socket Head #8-32NC x 1 1/4” 4 53 3951603 Setscrew, Socket Head 3/8”-16NC x 3/8” 4

54 to 56 Not Used

57 4711400 Flatwasher 1/4” Narrow 8 58 4711500 Flatwasher 5/16” Narrow A/R 59 4740332 Washer, Special 26 60 4750800 Flatwasher #8 4 61 4751600 Flatwasher 3/8” 2 62 4845986 Slider Weldment (Bottom) 2 63 4846020 Prop, Safety 1 64 4922345 Harness, Lift Down (Not Shown - See Section 7 for

Breakdown) 65 3760387 Ring, Retaining 4 66 Not Used 67 0641408 Bolt 1/4”-20NC x 1” 4 68 1670965 Cover, Limit Switch 2 69 3311405 Locknut 1/4”-20NC 4 70 Not Used 71 4751500 Flatwasher 5/16” (Wide) 4 72 Not Used 73 3020022 Lube, Lithium Grease (Not Shown) A/R 74 Harness, Limit Switch Option: (Left Side) (Not Shown - See

Section 7 for Breakdown)

Use 4922630 Prior to S/N 101118 (Was p/n 1060869)

4922630 S/N 101118 to Present 75 Not Used 76 1320110 Clamp 1

77 to 79 Not Used

80 4711600 Flatwasher 3/8” 1

— — — — — — — — — —

2901931 Arm Kit - (Includes Items - 3 thru 16,19,20,30,41 & 58) 1

3-8 3121112

Page 79

SECTION 4 PLATFORM

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

4-1 PLATFORM AND ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED

PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-4 DRIVE/STEER CONTROLLER ASSEMBLY (PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 DRIVE/STEER CONTROLLER J.R. MERRITT ASSEMBLY (POST PRODUCTION) . . . . . . . . 4-14

S E

I O N

P L A T

F O R

3121112 4-1

Page 80

S E C

I O N

SECTION 4 PLATFORM

FIGURE 4-1.PLATFORM AND ACCESSORIES INSTALLATION

T F

4-2 3121112

Page 81

SECTION 4 PLATFORM

FIGURE 4-1. PLATFORM AND ACCESSORIES INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

PLATFORM INSTALLATION OPTIONS: Ref.

0259563 Platform without D-Rings Ref. B 0259564 Platform with D-Rings Ref. C

Note: Replacement Decals must be Purchased Separately - See Section 8.

Ref.

1 Platform Weldment Options: 1

3510723 Platform without D-Rings

3510734 Platform with D-Rings 2 4845987 Slider Weldment 2 3 3340856 Block, Slide Pad 2 4 3422823 Pin, Pivot 2 5 3422824 Pin, Slider 2 6 3841143 Keeper, Pin 4 7 0440234 Bearing 4 8 0100011 Loctite #242 (Not Shown) A/R 9 0630476 Screw, Button Head A/R

10 0641608 Bolt 3/8”-16NC x 1” 2 11 0641610 Bolt 3/8”-16NC x 1” 2 12 3311605 Locknut 3/8”-16NC 2 13 3760321 D-Ring, Swivel (Platforms with D-Rings Only) 2 14 Not Used 15 4711500 Flatwasher 5/16” A/R 16 1703175 Decal - Lanyard (Platforms with D-Rings Only) 2

S E

I O N

P L A T

F O R

3121112 4-3

Page 82

130

115

142

141

138

137

144

145

146

143

149

127

108

120

121

129

155

133

123

135

109

133

125

135

110

113

128

150

151

107

111

118

126

131

101

106

102

153

135

104

136

105

128

135

124

122

116

127

140

722

162129132824132527301

SECTION 4 PLATFORM

FIGURE 4-2. FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED PLATFORM)

E C

I O N

T F

4-4 3121112

Page 83

SECTION 4 PLATFORM

FIGURE 4-2. FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED PLATFORM)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FOLDDOWN HANDRAILS INSTALLATIONS OPTIONS: Ref.

0259566 Chain Gate Ref. F 0259568 Self-Closing Welded Gate Ref. H

Note: Replacement Decals must be Purchased Separately - See Section 8.

1 4846123 Side Rail Weldment 2 2 4846125 Rear Rail Weldment (Right Side) 1 3 4846124 Rear Rail Weldment (Left Side) 1 4 4846122 Gate Weldment (Self-Closing Gate Only) 1 5 2600253 Hinge (Self-Closing Gate Only) 2 6 2080069 Fastener #10-32NF (Self-Closing Gate Only) 12 7 3900267 Screw, Socket Head (Self-Closing Gate Only) 12 8 2940074 Latch (Self-Closing Gate Only) 1

9 3571829 Plate, Latch 1 10 4845829 Retainer, Rail (Chain Gate Only) 18 11 0901870 Bracket 2 12 3421565 Pin, Snap A/R 13 3760170 Ring, Split A/R 14 1260136 Chain (Chain Gate Only) 2ft/61cm 15 0641516 Bolt 5/16”-18NC x 2” 3 16 3300356 Nut, Acorn 5/16”-18NC 10 17 3300432 Nut, Acorn #10-24NC (Self-Closing Gate Only) 4 18 3311505 Locknut 5/16”-18NC 3 19 3911008 Screw #10-24NC x 1/2” (Self-Closing Gate Only) 4 20 2820097 Tubing, Mesh 2ft/.6m 21 3911532 Screw 5/16”-18NC x 2” A/R 22 4751000 Flatwasher #10 (Self-Closing Gate Only) 12 23 4751500 Flatwasher 5/16” 6 24 2540020 Grommet 1 25 3422219 Pin, Snap 2 26 0100011 Loctite #242 (Not Shown) A/R 27 3300151 Nut, Acorn 1/4”-20NC A/R 28 1060808 Lanyard A/R 29 3911536 Screw 5/16”-18NC x 2 1/4” 1 30 3911428 Screw 1/4”-20NC x 1 3/4” 2 31 Use 1001101076 Snap-Hook (Includes Item 39) (Chain Gate Only)

(was p/n 2940064) 32 3340612 Pad (Chain Gate Only) A/R 33 3422369 Pin, Plunger (Chain Gate Only) 2 34 3641310 Rail Weldment (Chain Gate Only) 1 35 3911424 Screw 1/4”-20NC x 1 1/2” (Chain Gate Only) 2 36 3911432 Screw 1/4”-20NC x 2” (Chain Gate Only) 4 37 4711400 Flatwasher 1/4” Narrow (Chain Gate Only) A/R 38 1320061 Clamp, Hose (Not Shown) 1 39 3010088 Link (Chain Gate Only) 2

Ref.

S E

I O N

P L A T

F O R

3121112 4-5

Page 84

SECTION 4 PLATFORM

FIGURE 4-2. FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED PLATFORM) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259565 PLATFORM EXTENSION INSTALLATION Ref. H

Note: Replacement Decals must be Purchased Separately - See Section 8.

Ref.

S E C

I O N

T F

101 4846117 Extension Weldment 1 102 3537619 Mounting Weldment - Roller 4 103 3841233 Rod, Roller 4 104 3760348 Ring, Retaining 4 105 3860059 Roller, Extension 4 106 3322202 Nut, Jam 3/4” 4 107 4846121 Side Rail Weldment (Left Side) 1 108 4846120 Front Rail Weldment 1 109 3537609 Plate, Pivot 2 110 4846191 Handle Weldment (Right Side) 1 111 4846181 Handle Weldment (Left Side) 1 112 Not Used 113 2560088 Handle 2 114 Not Used 115 0901870 Bracket 2 116 Angle, Extension Stop Options: 2

0181684 Prior to S/N 106729

0182035 S/N 106729 to Present 117 3020022 Grease, Lithium (Not Shown) A/R 118 3520072 Cap-Plug 4 119 Not Used 120 3571862 Plate, Placard 121 3820020 Rivet 7 122 Bolt Options: 4

0641407 Prior to S/N 106729 (Bolt 1/4”-20NC x 7/8”)

0681508 S/N 106729 to Present (Bolt 5/16-18NC x 1”) 123 0641516 Bolt 5/16”-18NC x 2” 4 124 0641510 Bolt 5/16”-18NC x 1 1/4” 16 125 0641676 Bolt 3/8”-16NC x 9 1/2” 2 126 3300356 Nut, Acorn 5/16”-18NC 6 127 Nut Options: A/R

3311405 Prior to S/N 106729 (Locknut 1/4”-20NC) 6

3311405 S/N 106729 to Present (Locknut 1/4”-20NC) 2

3271505 S/N 106729 to Present (Nut 5/16-18NC x 1”) 4 128 3311505 Locknut 5/16”-18NC 20 129 3311605 Locknut 3/8”-16NC 2 130 3911428 Screw 1/4”-20NC x 1 3/4” 2 131 3911532 Screw 5/16”-18NC x 2” 6 132 Not Used 133 4711600 Flatwasher 3/8” Narrow 4 134 Not Used 135 4711500 Flatwasher 5/16” Narrow 26 136 4752200 Flatwasher 3/4” 4

4-6 3121112

Page 85

SECTION 4 PLATFORM

FIGURE 4-2. FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED PLATFORM) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

137 3422219 Pin, Snap 2 138 3300151 Nut, Acorn 1/4”-20NC 2 139 0100011 Loctite #242 (Not Shown) A/R 140 3421565 Pin, Snap 2 141 1060808 Lanyard 4 142 3760170 Ring, Split 4 143 0641406 Bolt 1/4”-20NC x 3/4” 2 144 0700619 Bolt, 6mm 2 145 2940127 Latch, Rubber 2 146 3290601 Nut, 6mm 2

147 to 148 Not Used

149 4751400 Flatwasher 1/4” 2 150 4846256 Side Rail Weldment (Right Side) 1 151 4420055 Tape 152 0940090 Bumper 2 153 3311401 Nut 1/4”-20NC 2 154 0100048 Grease (Not Shown) A/R 155 3300420 Acorn Nut 3/8”-16NC (Nylon) 2

10in/25cm

S E

I O N

P L A T

F O R

3121112 4-7

Page 86

S E C

I O N

SECTION 4 PLATFORM

FIGURE 4-3.PLATFORM CONSOLE BOX ASSEMBLY

T F

4-8 3121112

Page 87

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

CONSOLE BOX ASSEMBLY OPTIONS: Ref.

0270198 Diesel Machines Ref. J 0270451 Diesel Machines with Leveling Jacks Ref. E 0270537 Diesel Machines with Generator Ref. E 0270539 Diesel Machines with Leveling Jacks & Generator Ref. E 0270128 Gas Dual Fuel Machines Ref. I 0270450 Gas Dual Fuel Machines with Leveling Jacks Ref. E 0270536 Gas Dual Fuel Machines with Generator Ref. E 0270538 Gas Dual Fuel Machines with Leveling Jacks &

Generator

1 0140011 Alarm 1 2 0181847 Angle, Latch 1 3 0610135 Board, P/C Display 1 4 0641404 Bolt 1/4”-20NC x 1/2” 4 5 0861357 Box, Console 1 6 0902499 Bracket, D-Ring 1 7 Drive/Steer Controller Assembly Options: 1

1600308 Production (See Figure 4-4 for Breakdown) 1 1600403 Post Production (See Figure 4-5 for Breakdown) 1

8 Decal - Display Board Options: 1

1704624 Production 1705947 Post Production 1706130 Machines With Generator Only (Post Production)

9 Decal - Toggle Switch Function Options: 1

1704589 Glow Plug (Diesel Machines)

1704588 Fuel Select (Gas Dual Fuel Machines) 10 2560141 Thumbscrew 1 11 Nameplate Options: 1

3252695 Machines without Generator (Prior to S/N 112399)

3252746 Machines with Generator (Prior to S/N 112399)

1705711 Machines without Generator

(S/N 112399 to Present)

1705948 Machines without Generator

(Post Production Replacement)

1705712 Machines with Generator

(S/N 112399 to Present)

1705976 Machines with Generator

(Post Production Replacement) 12 3310601 Nut #6-32NC 4 13 Component Options: 4

3520080 Machines without Leveling Jacks or Generator

(Plug)

4360387 Machines with Leveling Jacks & Generator (Toggle

Switch)

4360387 Machines with Leveling Jacks Only (Toggle Switch) 3520080 Machines with Generator Only (Plug)

14 Not Used

Ref. E

S E

I O N

P L A T

F O R

3121112 4-9

Page 88

S E C

I O N

T F

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

15 3900178 Screw, Plastite #10-32NC x 1/2” 4 16 3900265 Screw, Self-Tapping #8-18 x 3/4” 10 17 4060802 Guard, Switch 2 18 4360387 Switch, Push Button 4 19 4360475 Switch, Emergency Stop 1

7020175 Ring, Sealing 1

19A 7020176 Block, Contact 1

20 Toggle Switch Options: A/R

4360482 Machines without Leveling Jacks or Generator 1 4360331 Machines with Leveling Jacks & Generator 1 4360482 Machines with Leveling Jacks Only 1

4360331 Machines with Generator Only 1 21 4420008 Tape, Insulation 38in/1m 22 4460470 Nut, Terminal 1 23 4460471 Lockwasher, Terminal 1 24 4460480 Connector, Terminal 1 25 4740120 Washer, Nylon 12 26 4760600 Lockwasher #6 4 27 4791400 Starwasher 1/4” 4 28 4845938 Bracket, Box Mounting 1 29 4846249 Lid, Box 1 30 Platform Console Box Harness Options:

(Not Shown - See Section 7 for Breakdown)

4922391 DIesel/Gas Dual Fuel without Leveling Jacks &

Generator 4922437 DIesel/Gas Dual Fuel with Leveling Jacks Only 1 4922447 DIesel/Gas Dual Fuel with Generator Only 1 4922446 DIesel/Gas Dual Fuel with Leveling Jacks &

Generator

31 Switch, Toggle Options: 1

4360483 Diesel Machines 4360482 Gas Dual Fuel Machines

32 3340895 Pad, Spacer (Production Only) 1 33 Components Options (S/N 112399 to Present Only) A/R

3520193 Plug (S/N 112399 to Present Only) 1 2920026 Lamp, Indicator 1 2920029 Bulb, Light 1

34 1704574 Decal - Outrigger Select (Machines with Leveling

Jacks Only)

4-10 3121112

Page 89

SECTION 4 PLATFORM

FIGURE 4-3. PLATFORM CONSOLE BOX ASSEMBLY (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

P L A T

F O R

3121112 4-11

Page 90

2E2C2A2F2D2A2B1C1B

3D33A

E C

I O N

SECTION 4 PLATFORM

FIGURE 4-4. DRIVE/STEER CONTROLLER ASSEMBLY (PRODUCTION)

T F

4-12 3121112

Page 91

SECTION 4 PLATFORM

FIGURE 4-4. DRIVE/STEER CONTROLLER ASSEMBLY (PRODUCTION)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1600308 CONTROLLER ASSEMBLY Ref. D

7020527 Mechanical Assembly 1

1 7020503 Handle/Housing Assembly 1 1A 7020520 Housing 1 1B 7020504 Plate, Mounting 1

1C 7020502 Gasket 1 1D 7020528 Screw #10-32NF x 3/8” 2

2 7020529 Grip Assembly 1

2A 7020501 Push Button 1

7020530 Push Button W/Wires 1

7020500 Micro Switch 1 2B Use 7020541 Grip - Right Half (was p/n 7020531) 1 2C Use 7020541 Grip - Left Half (was p/n 7020532) 1 2D 7003791 Actuator, Switch 1 2E 7011997 Trigger 1 2F 7003790 Cap, Rubber 1

3 7020533 Electrical Assembly 1

7020535 Resistor 2 3A 7020509 Plate, Mounting - Potentiometer 1 3B 7020534 Potentiometer 1 3C 7011940 Gear, Pinion 1 3D 7020511 Setscrew #6-32 x 1/8” 1

4460265 Plug, Male - 9 Pin (Not Shown) 1

4460268 Socket, Female (Not Shown) 8

4460266 Connector, Receptacle - 9 Pin (Not Shown - Part of

Console Harness)

4460267 Pin, Male (Not Shown - Part of Console Harness) 8

S E

I O N

P L A T

F O R

3121112 4-13

Page 92

5 6

2 3

E C

I O N

SECTION 4 PLATFORM

FIGURE 4-5. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY

(POST PRODUCTION)

T F

4-14 3121112

Page 93

SECTION 4 PLATFORM

FIGURE 4-5. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY (POST PRODUCTION)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1600403 CONTROLLER ASSEMBLY Ref. E

Note: If your machine was equipped with a 1600403 J.R. Merritt controller in ordering a replacement controller you must order a 1600403 J.R. Merritt controller. You can not replace the 1600403 J.R. Merritt controller with the 1600308 P/Q controller.

1 70000081 Potentiometer 1 2 7027367 Switch, Push Button 1 3 7027765 Lever, Enabler 1 4 7027766 Ring, Retaining 1 5 70000082 Microswitch 1 6 70000083 Coupler, Microswitch 1 7 70000084 Cap, Rubber 1 8 70000085 Boot, Rubber 1

9 4460265 Plug, Male - 9 Pin 1 10 4460226 Socket, Female 8 11 70000685 Washer, Plastic (Not Shown) A/R 12 70000684 Screw, Handle (Not Shown) A/R 13 Not Available Nut, Handle (Not Shown) A/R 14 70000683 Washer, Neoprene (Not Shown) A/R 15 70000686 Screw, Handle (Not Shown) A/R 16 4460266 Connector, Receptacle - 9 Pin (Not Shown - Part of

Console Harness)

17 4460267 Pin, Male (Not Shown - Part of Console Harness) 8

I O N

P L A T

F O R

3121112 4-15

Page 94

S E C

I O N

SECTION 4 PLATFORM

FIGURE 4-5. DRIVE/STEER J.R. MERRITT CONTROLLER ASSEMBLY (POST PRODUCTION) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

T F

4-16 3121112

Page 95

SECTION 5 CYLINDERS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LEVELING JACK CYLINDER ASSEMBLY (PRIOR TO S/N 104829). . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVELING JACK CYLINDER ASSEMBLY (S/N 104829 TO PRESENT). . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT CYLINDER COMPONENTS ASSEMBLY - 330CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 LIFT CYLINDER COMPONENTS ASSEMBLY - 400CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

S E

I O N

Y L

I N D

3121112 5-1

Page 96

111513

1414121617

E C

I O N

SECTION 5 CYLINDERS

FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

C Y

I N

D E R

5-2 3121112

Page 97

SECTION 5 CYLINDERS

FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1683978 AXLE LOCKOUT CYLINDER ASSEMBLY Ref. C

1 0100011 Loctite #242 (Not Shown) A/R 2 0100038 Primer, Locking (Not Shown) A/R 3 Use Item 51 Ring, Wear 1 4 Use Item 51 T-Seal 1 5 Use Item 51 Ring, Wear 2 6 Use Item 51 O-Ring 1 7 Use Item 51 Ring, Back-Up 1 8 Use Item 51 Seal, Wiper 1

9 Use Item 51 Seal, Rod 1 10 Not Used 11 0962474 Bushing (Was p/n 0961890) 2 12 1683076 Head 1 13 1683572 Barrel Weldment 1 14 1683574 Rod/Piston 1 15 2220885 Plug, O-Ring 1 16 3760367 Ring, Washer 1 17 3931516 Capscrew, Socket Head 5/16”-18NC x1” 8 18 4640858 Valve, Bleeder 2 19 4641163 Valve, Counter Balance 2

2900770 Seal Kit - 4641163 Valve 2

20 to 50 Not Used

— — — — — — —

51 2901548 Seal Kit (Includes Items 3 to 9) 1

S E

I O N

Y L

3121112 5-3

N D

Page 98

S E C

I O N

SECTION 5 CYLINDERS

FIGURE 5-2. LEVELING JACK CYLINDERS ASSEMBLY (PRIOR TO S/N 104829)

C Y

I N

D E R

5-4 3121112

Page 99

SECTION 5 CYLINDERS

FIGURE 5-2. LEVELING JACK CYLINDERS ASSEMBLY (PRIOR TO S/N 104829)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1683966 LEVELING JACK CYLINDER ASSEMBLY Ref. G

1 0100011 Loctite #242 (Not Shown) A/R 2 0100035 Loctite #222 (Not Shown) A/R 3 0100038 Primer #7471 (Not Shown) A/R 4 0320015 Ball, Trailer 1 5 Bolt Options: 6

0681506 Bolt 5/16”-18NC x 3/4” (Prior to S/N 90659)

0681606 Bolt 3/8”-16NC x 3/4” (S/N 90659 to S/N 104829) 6 1120108 Cap 1 7 1681283 Head 1 8 1682723 Rod 1 9 1683967 Barrel 1

10 2220883 Plug 2 11 Not Used 12 3300281 Nut 1 13 Pad, Jack Options: 1

Use 2902023 Prior to S/N 90659 (was p/n 3340650)

Use 2902023 S/N 90659 to S/N 104829 (was p/n 3340904) 14 3480092 Piston 1 15 3536708 Plate 1 16 Ring, Retainer Options: 1

3760261 Prior to S/N 90659

3760453 (S/N 90659 to S/N 104829) 17 3900170 Screw, Locking 1 18 Use Item 51 Ring, Wear 1 19 Use Item 51 Guidelock 2 20 Use Item 51 O-Ring 1 21 Use Item 51 O-Ring 1 22 Use Item 51 Seal, Wiper 1 23 Use Item 51 Polyseal 2 24 Use Item 51 Hydrolock 1 25 4565647 Tube, Spacer 1 26 4640495 Valve, Counter Balance 1 27 4641156 Valve, Check 1

28 to 50 Not Used

— — — — — — — — — — 51 2901941 Seal Kit (Includes Items 18-24) 1 52 2902023 Jack Pad Kit (Includes Items 5, 13 & 16) 1

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SECTION 5 CYLINDERS

282822

292913

232321

27951

FIGURE 5-3. LEVELING JACK CYLINDER ASSEMBLY(S/N 104829 TO PRESENT)

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5-6 3121112

JLG 400CRT Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION

FIGURE 1-2. OSCILLATING REAR AXLE INSTALLATION

FIGURE 1-3. WHEEL DRIVE INSTALLATION

FIGURE 1-4. FRONT DRIVE MOTOR ASSEMBLY - 330CRT

FIGURE 1-5. FRONT DRIVE MOTOR ASSEMBLY - 400CRT

FIGURE 1-6. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT PRIOR TO S/N 82626

FIGURE 1-7. REAR DRIVE MOTOR WITH BRAKE ASSEMBLY - 330CRT S/N 82626 TO PRESENT & ALL 400CRT

FIGURE 1-8. DIESEL ENGINE INSTALLATION - KUBOTA

FIGURE 1-9. GAS DUAL FUEL ENGINE INSTALLATION - KUBOTA

FIGURE 1-10. PISTON PUMP ASSEMBLY (PRODUCTION)

FIGURE 1-11. PISTON PUMP ASSEMBLY (POST PRODUCTION)

FIGURE 1-12. FRAME MOUNTED COMPONENTS INSTALLATION

FIGURE 1-13. FRAME COVERS AND LADDERS INSTALLATION

FIGURE 1-14. LEVELING JACKS INSTALLATION

FIGURE 1-15. GENERATOR INSTALLATION - 110V (OPTIONAL)

SECTION 2 GROUND COMPONENTS

FIGURE 2-1. RIGHT SIDE COMPARTMENT INSTALLATIONS

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

FIGURE 2-3. FLOW DIVIDER VALVE ASSEMBLY

FIGURE 2-4. GROUND CONTROL BOX ASSEMBLY

FIGURE 2-5. FUEL COMPARTMENT INSTALLATION

SECTION 3 SCISSOR ARMS

FIGURE 3-1. SCISSOR ARMS INSTALLATION - 330CRT

FIGURE 3-2. SCISSOR ARMS INSTALLATION - 400CRT

SECTION 4 PLATFORM

FIGURE 4-1.PLATFORM AND ACCESSORIES INSTALLATION

FIGURE 4-2. FOLDDOWN HANDRAILS & EXTENSION INSTALLATION (MANUALLY OPERATED PLATFORM)

FIGURE 4-3.PLATFORM CONSOLE BOX ASSEMBLY

FIGURE 4-4. DRIVE/STEER CONTROLLER ASSEMBLY (PRODUCTION)

SECTION 5 CYLINDERS

FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 5-2. LEVELING JACK CYLINDERS ASSEMBLY (PRIOR TO S/N 104829)

FIGURE 5-3. LEVELING JACK CYLINDER ASSEMBLY(S/N 104829 TO PRESENT)