JLG 450AJ Parts Manual

Illustrated Parts Manual

Models

450A

450AJ

P/N

3120750

January 28, 2011

REVISION LOG

May 1998 - Original Issue Of Manual

November 18, 1998 - Revised (Edited to Top B/M Revision 7)

February 5, 1999 - Revised (Edited to Top B/M Revision 9)

August 15, 1999 - Revised (Edited to Top B/M Revision 14)

February 16, 2000 - Revised (Edited to Top B/M Revision 18)

February 7, 2001 - Revised (Edited to Top B/M Revision 23)

February 14, 2003 - Revised (Edited to Top B/M Revision 25)

December 16, 2004 - Revised (Edited to Top B/M Revision 25)

June 20, 2007 - Revised (Edited to Top B/M Revision 26)

Jauuary 28, 2011 - Revised Manual

3120750 A

REVISION LOG

B 3120750

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR . . . . . . . . . . . . . .1-2

1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR . . . . . . . . . . . . . . . . . . .1-6

1-3 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-6 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

1-7 DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

1-8 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

1-9 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

1-10 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

1-11 TOW BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38

1-12 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

2-3 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5 SWING BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-6 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-7 GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . .2-22

2-8 FORD ENGINE INSTALLATION (WITH CARBURETOR) (PRIOR TO S/N 46089). . . . . .2-26

2-9 FORD ENGINE INSTALLATION (WITH EFI) (S/N 46089 TO PRESENT) . . . . . . . . . . . .2-34

2-10 DUAL FUEL INSTALLATIONS (FORD MACHINE OPTION) (PRIOR TO S/N 46089) . . .2-42 2-11 DUAL FUEL INSTALLATIONS (FORD MACHINE OPTION) (S/N 46089 TO PRESENT) 2-44

2-12 GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . .2-46

2-13 ISUZU ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

2-14 GENERATOR INSTALLATION - ISUZU MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . .2-56

2-15 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

2-16 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

2-17 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-18 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . .2-70

2-19 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 TOWER/MID BOOMS AND CYLINDERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 MAIN BOOM AND CYLINDERS INSTALLATION - 450A . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3 MAIN BOOM AND CYLINDERS INSTALLATION - 450AJ . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-4 MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 BOOM COVERS, CABLES AND CLAMPS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . .3-18

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

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

4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 CONTROLLER ASSEMBLY (LIFT AND SWING) (PRIOR TO S/N39857) . . . . . . . . . . . .4-12

4-4 CONTROLLER ASSEMBLY (LIFT & SWING) (S/N39857 TO PRESENT) . . . . . . . . . . . .4-14

4-5 CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) . . . . . . . . . . . . .4-18

4-6 CONTROLLER ASSEMBLY (DRIVE & STEER) (S/N39857 TO PRESENT) . . . . . . . . . .4-22

4-7 CONTROLLER ASSEMBLY (SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

4-8 SOFT TOUCH SYSTEM INSTALLATION (S/N 49601 TO PRESENT) . . . . . . . . . . . . . .4-28

3120750 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

5-2 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LIFT CYLINDER ASSEMBLY - JIB (450AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-4 LIFT CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-5 LIFT CYLINDER ASSEMBLY - MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-6 LIFT CYLINDER ASSEMBLY - TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-7 ROTATOR CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-9 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

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

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 TOW BAR HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-5 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-6 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-7 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

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

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

7-2 ELECTRICAL SCHEMATIC - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 ELECTRICAL SCHEMATIC - FORD ENGINE MACHINES WITH CARBURETOR. . . . . . 7-8

7-4 ELECTRICAL SCHEMATIC - FORD ENGINE MACHINES WITH EFI . . . . . . . . . . . . . . . 7-12

7-5 ELECTRICAL SCHEMATIC - ISUZU ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-6 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

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

8-1 DECALS INSTALLATION (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION (COUNTRY SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

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

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

ii 3120750

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 AXLE AND STEERING INSTALLATION - 2WD WITH OUT TOW BAR . . . . . . . . . . . . . . . . . . . 1-2

1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) . 1-6

1-3 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 DRIVE HUB ASSEMBLY (S/N 39594 to PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1-9 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-10 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1-11 TOW BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-12 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

E C T

I O N

3120750 1-1

SECTION 1 FRAME

S E C T

I O N

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR

1-2 3120750

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258026 FIXED AXLE INSTALLATION Ref. C

1 0100011 Loctite #242 (Not Shown) A/R 2 0362763 Bar, Stop 4 3 0362764 Bar, Stop 2 4 0641606 Bolt 3/8”-16NC x 3/4” 6 5 0641626 Bolt 3/8”-16NC x 3 1/4” 2 6 0642012 Bolt 5/8”-11NC x 1 1/2” 1 7 0961950 Bushing, Garmax 2 8 Pin, Axle Pivot Options: 1

Use 3422592 Prior to S/N 56275 (Was p/n 3422431)

3422592 S/N 56275 to Present

9 3570901 Plate, Stop 2 10 3841258 Keeper, Pin 1 11 4060951 Shield, Frame 1 12 4070972 Shim 3/16” A/R 13 4070973 Shim 1/8” A/R 14 4070974 Shim 1/16” A/R 15 4740158 Thrustwasher 1 16 4751600 Flatwasher 3/8” 8 17 Not Used 18 4845643 Axle Weldment 1

18A 0561300 Steer Cylinder Mounting Block Assembly 2

S E

I O N

0258024 OSCILLATING AXLE INSTALLATION Ref. G

101 0100011 Loctite #242 (Not Shown) A/R 102 0641414 Bolt 1/4”-20NC x 1 3/4” 4 103 0641606 Bolt 3/8”-16NC x 3/4” 6 104 0641812 Bolt 1/2”-13NC x 1 1/2” 2 105 0642012 Bolt 5/8”-11NC x 1 1/2” 1 106 0682248 Bolt 3/4”-10NC x 6” 2 107 0961950 Bushing, Garmax 2 108 1100107 Cam, Lockout 1 109 Lockout Cylinder Assembly Options (See Section 5 for Break-

down): 1683575 Prior to S/N 63921 1684139 S/N 63921 to Present

110 3272201 Nut 3/4”-10NC 2 111 3322201 Nut 3/4”-16NF 2 112 Pin, Axle Pivot Options: 1

Use 3422592 Prior to S/N 56275 (Was p/n 3422431)

3422592 S/N 56275 to Present

113 3841258 Keeper, Pin 1 114 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1

3120750 1-3

SECTION 1 FRAME

S E

I O N

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

115 Hardware Options: 2

3900109 Screw, Shoulder (Prior to S/N 63921)

3422936 Pin (S/N 63921 to Present) 116 4060951 Shield, Frame 1 117 4567462 Tube, Mounting 2 118 4640871 Lockout Valve Assembly 1

7012693 Seal Kit - 4640871 Valve 1

7002840 Anit-Rotation Pin Removal Tool 1 119 4711400 Flatwasher 1/4” Narrow 4 120 4740158 Thrustwasher 1 121 4751800 Flatwasher 1/2” 4 122 4751600 Flatwasher 3/8” 6 123 4845643 Axle Weldment 1

123A 0561300 Steer Cylinder Mounting Block Assembly 2

124 4892200 Flatwasher 3/4” 4 125 Not Used 126 0100019 Loctite #271 (Not Shown) A/R 127 0641607 Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) 2 128 3841520 Keeper 3/8” (S/N 63921 to Present) 2

0258022 STEERING INSTALLATION Ref. B

201 0100011 Loctite #242 (Not Shown) A/R 202 0440162 Thrustwasher 2 203 0641606 Bolt 3/8”-16NC x 3/4” 4 204 0681828 Bolt 1/2”-13NC x 3 1/2” 4 205 1683614 Steer Cylinder Assembly (See Section 5 for Breakdown) 1 206 2780230 Hub/Spindle Assembly (See 301 to 313 for Breakdown) 2 207 3312008 Nut 5/8”-11NC 4 208 3322201 Nut 3/4”-16NF 2 209 3323003 Nut 1 1/4”-12NF 2 210 3422692 Kingpin 2 211 3450812 Pin, Cotter 1/4” x 3” 2 212 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1 213 3841377 Tie-Rod 2 214 3900109 Screw, Shoulder 4 215 4060950 Shield, Frame 1 216 4713000 Flatwasher 1 1/4” 2 217 4751800 Flatwasher 1/2” 4 218 4740086 Washer, Thrust 2

1-4 3120750

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780230 HUB ASSEMBLY Ref. A

301 7020033 Cap, Dust (1 per Assembly) 2

— — — — — — — — — — — 302 7020034 Spindle Assembly (1 per Assembly) 2 303 0961951 Bushing, Garmax (2 per Assembly) 4 304 0962140 Bearing, Garmax (1 per Assembly) 2 305 7020035 Hub (1 per Assembly) (Includes 306 & 307) 2 306 7020036 Cup, Bearing - Inner(1 per Assembly) 2 307 7020038 Cup, Bearing - Outer (1 per Assembly) 2 308 7020037 Cone, Bearing - Inner (1 per Assembly) 2 309 7020039 Cone, Bearing - Outer (1 per Assembly) 2 310 7020040 Seal (1 per Assembly) 2 311 7020041 Stud, Wheel (9 per Assembly) 18 312 Not Used 313 7020042 Lugnut (9 per Assembly) 18 314 7020054 Nut, Castle (1 Per Assembly) 2 315 3450608 Pin, Cotter (1 Per Assembly) 2 316 7020055 Washer, Spindle (1 Per Assembly) 2

S E

I O N

401 FRAME WELDMENT OPTIONS Ref.

2360460 Frame Weldment - Standard 1 2360536 Frame Weldment - With Semi Track 1

3120750 1-5

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR

1-6 3120750

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0259967 OSCILLATING AXLE INSTALLATION Ref. C

1 0100011 Loctite #242 (Not Shown) A/R 2 0641414 Bolt 1/4”-20NC x 1 3/4” 4 3 0641606 Bolt 3/8”-16NC x 3/4” 10 4 0641812 Bolt 1/2”-13NC x 1 1/2” 2 5 0642012 Bolt 5/8”-11NC x 1 1/2” 1 6 0682248 Bolt 3/4”-10NC x 6” 2 7 0961950 Bushing, Garmax 2 8 1100107 Cam, Lockout 1 9 Lockout Cylinder Assembly Options (See Section 5 for Break-

down): 1683575 Prior to S/N 63921 1684139 S/N 63921 to Present

10 Not Used 11 3272201 Nut 3/4”-10NC 2 12 3322201 Nut 3/4”-16NF 2 13 3422592 Pin, Axle Pivot 1 14 3841258 Keeper, Pin 1 15 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1

16 Hardware Options: 2

3900109 Screw, Shoulder (Prior to S/N 63921) 3422936 Pin (S/N 63921 to Present)

17 4060951 Shield, Frame 1 18 4567462 Tube, Mounting 2 19 4640871 Lockout Valve Assembly 1

7012693 Seal Kit - 4640871 Valve 1 7002840 Anit-Rotation Pin Removal Tool 1

20 4711400 Flatwasher 1/4” Narrow 4 21 4740158 Thrustwasher 1 22 4751600 Flatwasher 3/8” 6 23 4751800 Flatwasher 1/2” 4 24 4846167 Axle Weldment 1

24A 0561300 Steer Cylinder Mounting Block Assembly 2

25 4892200 Flatwasher 3/4” 4 26 0641607 Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) 2 27 3841520 Keeper 3/8” (S/N 63921 to Present) 2

S E

I O N

0259966 STEERING INSTALLATION Ref. B

101 0100011 Loctite #242 (Not Shown) A/R 102 0440162 Thrustwasher 2 103 0630544 Bolt 1”-8NC x 6” 1 104 0641508 Bolt 5/16”-18NC x 1” 1 105 0641606 Bolt 3/8”-16NC x 3/4” 4 106 0681828 Bolt 1/2”-13NC x 3 1/2” 4 107 0682648 Bolt 1”-8NC x 6” 1

3120750 1-7

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

108 1683614 Steer Cylinder Assembly (See Section 5 for Breakdown) 1 109 2160002 Fitting, STR Grease 1 110 2780230 Hub/Spindle Assembly (See 201 to 213 for Breakdown) 2 111 3272605 Locknut 1”-8NC 2 112 3312008 Nut 5/8”-11NC 4 113 3322201 Nut 3/4”-16NF 4 114 3323003 Nut 1 1/4”-12NF 2 115 3422692 Kingpin 2 116 3422848 Pin, Hitch 1 117 3450812 Pin, Cotter 1/4” x 3” 2 118 3571975 Plate, Tow Bar Pivot 1 119 3841143 Keeper 1 120 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1 121 3841377 Tie-Rod 2 122 3900109 Screw, Shoulder 6 123 4712600 Flatwasher 1” 4 124 4713000 Flatwasher 1 1/4” 2 125 4740086 Washer, Thrust 2 126 4740155 Washer, Thrust 2 127 4740491 Washer, Thrust 2 128 4751800 Flatwasher 1/2” 4 129 4846162 Weldment, Link 1 130 2160001 Fitting, Grease 2

2780230 HUB ASSEMBLY Ref. A

201 7020033 Cap, Dust (1 per Assembly) 2

— — — — — — — — — — — 202 7020034 Spindle Assembly (1 per Assembly) 2 203 0961951 Bushing, Garmax (2 per Assembly) 4 204 0962140 Bearing, Garmax (1 per Assembly) 2 205 7020035 Hub (1 per Assembly) (Includes 306 & 307) 2 206 7020036 Cup, Bearing - Inner(1 per Assembly) 2 207 7020038 Cup, Bearing - Outer (1 per Assembly) 2 208 7020037 Cone, Bearing - Inner (1 per Assembly) 2 209 7020039 Cone, Bearing - Outer (1 per Assembly) 2 210 7020040 Seal (1 per Assembly) 2 211 7020041 Stud, Wheel (9 per Assembly) 18 212 Not Used 213 7020042 Lugnut (9 per Assembly) 18 214 7020054 Nut, Castle (1 Per Assembly) 2 215 3450608 Pin, Cotter (1 Per Assembly) 2 216 7020055 Washer, Spindle (1 Per Assembly) 2

301 FRAME WELDMENT OPTIONS Ref.

2360460 Frame Weldment - Standard 1 2360536 Frame Weldment - With Semi Track 1

1-8 3120750

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120750 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD

1-10 3120750

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD

S E

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0258027 FIXED AXLE INSTALLATION Ref. C

1 0100011 Loctite #242 (Not Shown) A/R 2 0362763 Bar, Stop 2 3 0641606 Bolt 3/8”-16NC x 3/4” 6 4 0641620 Bolt 3/8”-16NC x 2 1/4” 2 5 0642012 Bolt 5/8”-11NC x 1 1/2” 1 6 0961950 Bushing, Garmax 2 7 Pin, Axle Pivot Options: 1

Use 3422592 Prior to S/N 56275 (Was p/n 3422431)

3422592 S/N 56275 to Present 8 3570901 Plate, Stop 2 9 3841258 Keeper, Pin 1

10 4060951 Shield, Frame 1 11 4070973 Shim 1/8” A/R 12 4070974 Shim 1/16” A/R 13 4740158 Thrustwasher 1 14 4751600 Flatwasher 3/8” 8 15 Not Used 16 4845700 Axle Weldment 1

16A 0561300 Steer Cylinder Mounting Block Assembly 2

I O N

0258025 OSCILLATING AXLE INSTALLATION Ref. F

Breakdown): 1683575 Prior to S/N 63921 1684139 S/N 63921 to Present

110 3272201 Nut 3/4”-10NC 2 111 3322201 Nut 3/4”-16NF 2 112 Pin, Axle Pivot Options: 1

Use 3422592 Prior to S/N 56275 (Was p/n 3422431)

3422592 S/N 56275 to Present

113 3841258 Keeper, Pin 1 114 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1

115 Hardware Options: 2

3900109 Screw, Shoulder (Prior to S/N 63921) 3422936 Pin (S/N 63921 to Present)

116 4060951 Shield, Frame 1

3120750 1-11

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

117 4567462 Tube, Mounting 2 118 4640871 Lockout Valve Assembly 1

7012693 Seal Kit - 4640871 Valve 1

7002840 Anit-Rotation Pin Removal Tool 1 119 4711400 Flatwasher 1/4” Narrow 4 120 4740158 Thrustwasher 1 121 4751800 Flatwasher 1/2” 4 122 4751600 Flatwasher 3/8” 6 123 4845700 Axle Weldment 1

123A 0561300 Steer Cylinder Mounting Block Assembly 2

124 4892200 Flatwasher 3/4” 4 125 Not Used 126 0100019 Loctite #271 (Not Shown) A/R 127 0641607 Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) 2 128 3841520 Keeper 3/8” (S/N 63921 to Present) 2

0258023 STEERING INSTALLATION Ref. B

201 0100011 Loctite #242 (Not Shown) A/R 202 0440161 Thrustwasher 4 203 0641606 Bolt 3/8”-16NC x 3/4” 8 204 0681828 Bolt 1/2”-13NC x 3 1/2” 4 205 0961951 Bushing, Garmax 4 206 0962140 Bearing, Garmax 2 207 1683614 Steer Cylinder Assembly (See Section 5 for Break-

down) 208 3312008 Nut 5/8”-11NC 4 209 3322201 Nut 3/4”-16NF 2 210 3422716 Kingpin 4 211 3841367 Rod-End with Grease Fitting 2

7020180 Grease Fitting 1 212 3900109 Screw, Shoulder 4 213 4060950 Shield, Frame 1 214 4130363 Spindle (Left Side) 1 215 4130364 Spindle (Right Side) 1 216 4751800 Flatwasher 1/2” 4 217 4845711 Tie-Rod 2 218 4740086 Thrustwasher 4

301 FRAME WELDMENT OPTIONS Ref.

2360460 Frame Weldment - Standard 1

2360536 Frame Weldment - With Semi Track 1

1-12 3120750

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

3120750 1-13

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

1-14 3120750

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

WHEEL DRIVE INSTALLATION (2WD) Ref. 0258020 Prior to S/N 56958 Ref. E 0270207 S/N 56958 to Present Ref. B

1 0100011 Loctite #242 (Not Shown) A/R 2 Not Used 3 0682014 Bolt 5/8”-11NC x 1 3/4” 12 4 Drive Brake Assembly (See Figure 1-5 for Breakdown) 2

0920112 Prior to S/N 56958 0920117 S/N 56958 to Present

5 Drive Hub Assembly Options: 2

Note: Do NOT Mix Hub Assemblies on Machine!

2780224 Prior to S/N 39594 (See Figure 1-6 for Breakdown) 2780235 S/N 39594 to Present (See Figure 1-7 for Breakdown)

6 3160158 Drive Motor Assembly (See Figure 1-8 For Breakdown) 2 7 3300106 Lugnut 18 8 Not Used

9 3311801 Nut 1/2”-13NC 4 10 4300120 Stud 4 11 0641836 Bolt 1/2”-13NC x 3” 4 12 Not Used 13 4891800 Flatwasher 1/2” 4 14 4892000 Flatwasher 5/8” 12 15 0641606 Bolt 3/8”-16NC x 3/4” 4 16 4060970 Shield (S/N38566 to Present Only) 1 17 4751600 Flatwasher 3/8” 4

S E

I O N

WHEEL DRIVE INSTALLATION (4WD) Ref. 0258021 Prior to S/N 56958 Ref. F 0270208 S/N 56958 to Present Ref. C

101 0100011 Loctite #242 (Not Shown) A/R 102 Not Used 103 Not Used 104 0641810 Bolt 1/2”-13NC x 1 1/4” 4 105 0642014 Bolt 5/8”-11NC x 1 3/4” 24 106 Drive Brake Assembly (Rear Only) (See Figure 1-5 for

Breakdown) 0920112 Prior to S/N 56958 0920117 S/N 56958 to Present

107 Drive Hub Assembly Options: 4

Note: Do NOT Mix Hub Assemblies on Machine!

2780224 Prior to S/N 39594 (See Figure 1-6 for Breakdown) 2780235 S/N 39594 to Present (See Figure 1-7 for Breakdown)

108 3160158 Drive Motor Assembly - Rear (See Figure 1-8 For

Breakdown)

109 Use

1001096417

110 3300106 Lugnut 36

Drive Motor Assembly-Front (See Figure 1-9 For

Breakdown) (was p/n 3160227)

3120750 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

111 Not Used 112 3311801 Nut 1/2”-13NC 4 113 4300120 Stud 4 114 0641836 Bolt 1/2”-13NC x 3” 4

115 to 116 Not Used

117 4711800 Flatwasher 1/2” Narrow 4 118 Not Used 119 4751600 Flatwasher 3/8” 4 120 4891800 Flatwasher 1/2” 4 121 4892000 Flatwasher 5/8” 24

122 to 123 Not Used

124 0641606 Bolt 3/8”-16NC x 3/4” 4 125 Not Used 126 4060970 Shield (S/N38566 to Present Only) 1

127 to 128 Not Used

129 3960526 Gasket, Brake (Not Shown - Located Between Drive Motor

& Hub on Front of Machine)

TIRE AND WHEEL INSTALLATIONS

0258028 12 x 16.5 Pneumatic Ref. A 0258030 12 x 16.5 Foam-Filled Ref. A 0259642 12 x 21.5 Pneumatic Ref. A 0259643 12 x 21.5 Foam-Filled Ref. A 0258029 33/1550 x 16.5 Pneumatic Ref. A 0258031 33/1550 x 16.5 Foam-Filled Ref. A 0258831 33/16LL x 16.1 Pneumatic (Requires special counter-

weighting)

0259129 33/16LL x 16.1 Foam-Filled (Requires special counter-

weighting)

Ref. A

0257740 12 x 16.5 Pneumatic Right Side 2 C 0257746 12 x 16.5 Pneumatic Left Side 2 C 0259637 12 x 21.5 Pneumatic Right Side 2 A 0259635 12 x 21.5 Pneumatic Left Side 2 A 0258009 12 x 16.5 Foam-Filled Right Side 2 C 0258010 12 x 16.5 Foam-Filled Left Side 2 C 0259638 12 x 21.5 Foam-Filled Right Side 2 A 0259636 12 x 21.5 Foam-Filled Left Side 2 A 0257755 33/1550 x 16.5 Pneumatic Right Side 2 C 0257756 33/1550 x 16.5 Pneumatic Left Side 2 C 0258011 33/1550 x 16.5 Foam-Filled Right Side 2 C 0258012 33/1550 x 16.5 Foam-Filled Left Side 2 C 0258830 33/16LL x 16.1 Pneumatic (Requires special counter-

weighting)

0259128 33/16LL x 16.1 Foam-Filled (Requires special counter-

weighting)

1-16 3120750

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly,

201 Decal Options (Pneumatic Only): 1

1702740 Decal - 90PSI 1 1703067 Decal - 40PSI 1

202 Tire Options: 1

Use 4520216 12 x 16.5 NHS (Prior to S/N 43177) (was p/n 4520202

Galaxy brand tire) 4520216 12 x 16.5 NHS (OTR Brand) (S/N 43177 to Present) 4520223 12 x 21.5 NHS (OTR Brand)

Use 4520217 33/1550 x 16.5 NHS (Prior to S/N 43177) (was p/n

4520203 Galaxy brand tire) 4520217 33/1550 x 16.5 NHS (OTR Brand) (S/N 43177 to

Present) 4520212 33/16LL x 16.1

203 4640113 Valve, Air (Pneumatic Only) 1 204 Rim, Wheel 1

4860203 21.5 x 8.5 (Use with 12 x 21.5 Tires) 4860178 16.5 x 9.75 (Use with 12 x 16.5 Tires) 4860179 16.5 x 12 (Use with 33/1550 x 16.5 Tires) 4860193 16.1 x 14 (Use with 33/16LL x 16.1 Tires)

S E

I O N

3120750 1-17

SECTION 1 FRAME

161718

192221

242325

101

S E

I O N

FIGURE 1-5. DRIVE BRAKE ASSEMBLY

1-18 3120750

SECTION 1 FRAME

FIGURE 1-5. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920112 DRIVE BRAKE ASSEMBLY (PRIOR TO S/N 56958) Ref. D

1 7003451 Housing 1 2 7003452 Gasket 1 3 7003094 Pin, Torque 2 4 7003049 Bearing, Ball 1 5 7003453 Ring, Retaining 1 6 7003050 Seal 1 7 7003454 Retainer, Spring 1 8 7000798 Spring, Compression (Small) 10

9 7000782 Spring, Compression (Large) 10 10 7003455 Shaft 1 11 7003456 Disc, Primary 1 12 7003457 Disc, Rotating 2 13 Not Used 14 7003459 Disc, Stationary 2 15 7003460 Piston 1 16 7000722 Ring, Back-Up 1 17 7000723 O-Ring 1 18 7000724 Ring, Back-Up 1 19 7000725 O-Ring 1 20 Not Used 21 7003461 Plate, Power 1 22 7000728 Plug, Protective 1 23 7003462 Flatwasher 1/2” 4 24 7003463 Bolt 1/2”-13NC 4 25 7000731 Gasket 2

— — — — — — — — — — —

Not Available Seal Kit - 0920112 Brake 1

S E

I O N

0920117 DRIVE BRAKE ASSEMBLY (NOT SHOWN) (S/N 56958 TO

PRESENT)

101 7000731 Gasket (Located between Hub/Brake & Brake/Motor) 2

7018612 Kit, Repair - 0920117 Brake 1 7018613 Screw, Washer Head Cap (Securing Pressure Plate to Cover

Plate)

Note: No Other Serviceable Parts Available. Ref.

3120750 1-19

Ref. B

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594)

1-20 3120750

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780224 DRIVE HUB ASSEMBLY Ref. A

1 Not Available Spindle/Housing Assembly 1 1A 7017004 Spindle 1 1B 7017010 Seal 1

1C 7017006 Cone, Bearing 1 1D 7017007 Cup, Bearing 2 1E 7017008 Cone, Bearing 1 1F Not Used 1G 7017005 Housing 1 1H 7017009 Washer, Thrust 1

1J 7017021 Ring, Retaining 1

1K Not Used

1L Not Used

1M Not Used 1N 7007640 Stud, Wheel 9

2 7017018 Gear, Ring 1

3 Not Available Carrier Assembly 1

3A 7017015 Carrier 1 3B 7017019 Bearing, Needle 96 3C 7000263 Spacer, Thrust 3 3D 7017014 Flatwasher, Tanged 6 3E 7017013 Shaft, Planet 3 3F 7017016 Gear, Cluster 3 3G 7010474 Rollpin 3

4 7017017 Gear, Internal 1

5 7017011 O-Ring 1

6 7000213 O-Ring 1

7 7017024 Shaft, Input 1

8 7000211 Cap, Disengage 1

9 0641404 Bolt 1/2”-20NC x 1/2” 2 10 7017029 Rod, Disengage 1 11 7000253 Washer, Thrust 2 12 7017012 Gear, Sun 1 13 7017020 Washer, Thrust 1 14 7017022 Screw, Socket Head Countersunk 3/8”-16NC 3 15 7017026 Spring 1 16 7010421 Washer, Thrust 1 17 7007620 Ring, Retaining 1 18 7017027 Ring, Retaining 1 19 7017025 Coupling 1 20 7017023 Plug, Pipe 2 21 Not Available Plate, ID (Not Shown) 1 22 7000281 Screw, Drive (Not Shown - Installs Item 21) 4 23 7017028 Ring, Retaining 1

S E

I O N

3120750 1-21

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT)

1-22 3120750

SECTION 1 FRAME

FIGURE 1-7. DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780235 DRIVE HUB ASSEMBLY Ref. B

1 Not Available Spindle/Housing Assembly 1 1A 7017059 Spindle 1 1B 7001998 Seal 1

1C/1D 7010429 Cone & Cup, Bearing (Includes 1C & 1D) 1

1E 7000257 Cone, Bearing 1 1F 7000258 Cup, Bearing 1 1G 7007601 Housing 1 1H 7000232 Washer, Thrust 1

1I 7000229 Ring, Retaining 1

1J Not Available Plug, Pipe 1

1K/1L/1M Not Used

1N 7007640 Stud, Wheel 9

2 7000246 Gear, Ring 1

3 Not Available Carrier Assembly 1 3A 7001931 Carrier 1 3B 7001985 Flatwasher, Tanged 6 3C 7001909 Bearing, Needle 96 3D 7000263 Spacer, Thrust 3 3E 7001911 Shaft, Planet 3 3F 7007643 Gear, Cluster 3 3G 7010474 Rollpin 3

4 7000203 Gear, Internal 1

5 7000230 O-Ring 1 5A 7000230 O-Ring (Black) (Prior to S/N 61323) 1

7017070 O-Ring (White) (S/N 61323 to Present) 1 6 Not Available Cover Assembly (Includes Items 101 - 109) 1 7 Not Available Input Shaft Assembly 1

7A 7000250 Shaft, Input 1 7B 7000261 Ring, Retaining 1 7C 7000262 Spring 1 7D 7000263 Spacer, Thrust 2

8 7000201 Gear, Sun 1 9 7000252 Spacer, Thrust 1

10 Not Used 11 Spacer, Thrust Options: A/R

7000253 Prior to S/N 61323 2

7017096 S/N 61323 to Present 1

12 Bolt (Grade 8) Options: 12

7000217 Prior to S/N 61323

7017067 S/N 61323 to Present

13 Hardware Options: 4

7000214 Bolt, Shoulder (Grade 8) (Prior to S/N 61323)

7017080 Dowel Pin (S/N 61323 to Present)

14 7017060 Coupling 1 15 Not Used 16 7007603 Flatwasher 12

7017063 Seal Kit 1

S E

I O N

3120750 1-23

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

COVER ASSEMBLIES Ref. See Kit Options PRIOR TO S/N 61323 Ref. See Kit Options S/N 61323 TO PRESENT Ref.

101 Cover Options: 1

See Kit Options Prior to S/N 61323

7017091 S/N 61323 to Present

102 Cap Options: 1

7000227 Prior to S/N 61323

Not Required S/N 61323 to Present

103 Bolt Options: A/R

7000220 Bolt 1/4”-20NC x 3/4” (Prior to S/N 61323) 4 7000216 Bolt 1/4”-20NC x 1/2” (S/N 61323 to Present) 2

104 Cap, Disengage Options: 1

7000211 Prior to S/N 61323 7017093 S/N 61323 to Present

105 Rod, Disengage Options: 1

7017062 Prior to S/N 61323 7017092 S/N 61323 to Present

106 O-Ring Options: 1

7000213 Prior to S/N 61323 7017095 S/N 61323 to Present

107 O-Ring Options: 1

7000215 Prior to S/N 61323

Not Required S/N 61323 to Present

108 Plug, Pipe A/R

7017048 Prior to S/N 61323 1 7017094 S/N 61323 to Present 2

109 Not Serviced Plate, Identification 1

COVER KIT OPTIONS:

No Longer

Available

7017099 Aluminum Cover Replacement for Cast Cover (Includes

7017090 Aluminum Cover (Includes Items 5A & 101) (S/N 61323 to

1-24 3120750

Cast Cover (Prior to S/N 61323) 1

Items 5, 5A, 11, 12, 13, 101, & 103-109) (Prior to S/N

61323) 1

Present)

+ 236 hidden pages