JLG 500RTS Parts Manual

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Illustrated Parts Manual

Models 400RTS 500RTS

P/N

3120830

September 30, 2013

REVISION LOG

June 1, 1993 - Original Issue Of Manual

January 1996 - Revised

December 1997 - Revised

November 11, 1999 - Updated Page 7-3, 7-5, 7-14 & 7-15

July 18, 2000 - Revised

July 11, 2003 - Revised (Manual edited to 0010488 Revision 36 - 400RTS)

(Manual edited to 0010458 Revision 59 - 500RTS)

February 4, 2004 - Revised (Manual edited to 0010458 Revision 62 - 500RTS)

June 14, 2004 - Revised (Manual edited to 0010458 Revision 63 - 500RTS)

June 30, 2007 - Revised (Manual edited to 0010458 Revision 69 - 500RTS)

March 1, 2011 - Revised

September 30, 2013 - Revised

3120830 400RTS 500RTS A

REVISION LOG

B 400RTS 500RTS 3120830

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

1-2 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE HUB ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 DRIVE HUB/BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-7 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-8 FRAME MOUNTED OPTIONS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1-9 TOW PACKAGE INSTALLATION - BALL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-10 TOW PACKAGE INSTALLATION - PINTLE HOOK (OPTIONAL). . . . . . . . . . . . . . . . . . 1-40

SECTION 2 - GROUND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES AND TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516). . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3 CONTROL VALVE ASSEMBLY (S/N 107516 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . 2-12

2-4 ENGINE INSTALLATION - FORD VSG-411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-5 DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION . . . 2-20

2-6 110 VOLT GENERATOR INSTALLATION (FORD VSG-411) (OPTIONAL). . . . . . . . . . . 2-24

2-7 ENGINE INSTALLATION - FORD LSG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-8 ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 . . . . . . . . . . . . . . . . . . . . . . . 2-32

2-9 DUAL FUEL COMPONENTS INSTALLATION - FORD LSG-423/LRG-423 DIS/

LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-10 GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425 . . . . . . . . . . . . . . . 2-42

2-11 ENGINE INSTALLATION - DEUTZ F3L1011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-12 110 VOLT GENERATOR INSTALLATION - DEUTZ (OPTIONAL). . . . . . . . . . . . . . . . . . 2-54

2-13 PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2-14 PUMP ASSEMBLY - BARNES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-15 GROUND CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

2-16 HOODS AND BEACON LIGHT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

SECTION 3 - SCISSORS ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SIZZORS ARMS INSTALLATION - 400RTS (PRIOR TO S/N 41058) . . . . . . . . . . . . . . 3-2

3-2 SIZZORS ARMS INSTALLATION - 400RTS (S/N 41058 TO PRESENT). . . . . . . . . . . . 3-6

3-3 SIZZORS ARMS INSTALLATION - 500RTS (PRIOR TO S/N 27997) . . . . . . . . . . . . . . 3-10

3-4 SIZZORS ARMS INSTALLATION - 500RTS (S/N 27997 TO PRESENT). . . . . . . . . . . . 3-14

3-5 SIZZORS ARMS GUARD INSTALLATION - 500RTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-6 SIZZORS ARMS GUARD INSTALLATION - 400RTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

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

4-1 FIXED PLATFORM (STANDARD), HANDRAILS AND OPTIONAL COMPONENTS

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM EXTENSION INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-3 PLATFORM EXTENSION INSTALLATION - MEGADECK (OPTIONAL) . . . . . . . . . . . . . 4-12

4-4 POWER DECK EXTENSION AND PLATFORM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 4-16

4-5 PLATFORM CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-6 DRIVE/LIFT CONTROLLER ASSEMBLY (PRIOR TO S/N 57701) . . . . . . . . . . . . . . . . . 4-26

4-7 DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT). . . . . . . . . . . . . . . 4-28

3120830 400RTS 500RTS i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY (OSCILLATING CYLINDER) (OPTIONAL) . . 5-2 5-2 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION)

(PRIOR TO S/N 104832) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION)

(S/N 104832 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 PLATFORM EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-6 STEER CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO JUNE 1993) . . . . . . . . 5-14

5-7 STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT) . . . . . 5-16

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

6-1 HYDRAULIC DIAGRAM - AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - OSCILLATING AXLE (OPTIONAL). . . . . . . . . . . . . . . . . . . . . 6-4

6-3 HYDRAULIC DIAGRAM - PLATFORM EXTENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 HYDRAULIC DIAGRAM - STANDARD 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5 HYDRAULIC DIAGRAM - STANDARD 4WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-6 HYDRAULIC DIAGRAM - STANDARD 4WD/4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-7 HYDRAULIC DIAGRAM - STANDARD 2WD/4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-8 HYDRAULIC DIAGRAM - TOW PACKAGE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-9 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

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

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

7-2 WIRING DIAGRAM - 0610114 CIRCUIT CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-3 WIRING DIAGRAM - DUAL FUEL (FORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-4 WIRING DIAGRAM - 110 VOLT GENERATOR (FORD) . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-5 WIRING DIAGRAM - 110 VOLT GENERATOR (DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-6 WIRING DIAGRAM - STANDARD 500RTS (FORD LRG-425 GAS MACHINES) . . . . . . 7-12

7-7 WIRING DIAGRAM - STANDARD 500RTS (DEUTZ DIESEL MACHINES). . . . . . . . . . . 7-14

7-8 WIRING DIAGRAM - AUSTRALIAN SPEC 500RTS (DEUTZ DIESEL MACHINES) . . . . 7-16

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

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

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

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

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii 400RTS 500RTS 3120830

SECTION 1

FRAME

3120830 400RTS 500RTS 1-1

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS

1-2 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME, STEERING AND AXLE INSTALLATIONS

Ref. FRAME WELDMENT - 2WS OPTIONS: 2360364 Ref. FRAME WELDMENT (PRIOR TO S/N 46528) 8 2360491 Ref. FRAME WELDMENT (S/N 46528 TO PRESENT) 2

1 0961739 2 Bushing, Bronze (Sizzor Arm Pivot)

Ref. FRAME WELDMENT - 4WS OPTIONS: 2360358 Ref. FRAME WELDMENT (PRIOR TO S/N 46528) 9 2360492 Ref. FRAME WELDMENT (S/N 46528 TO PRESENT) 2

51 0961739 2 Bushing, Bronze (Sizzor Arm Pivot) 52 0961029 4 Bushing, Bronze (Kingpin Pivot)

0252790 Ref. STEERING INSTALLATION - 2WD FRONT (STANDARD

PARTS)

101 4130287 1 Spindle Weldment (R.H.)

0960523 2 Bushing, Bronze (Kingpin)

102 4130288 1 Spindle Weldment (L.H.)

0960523 2 Bushing, Bronze (Kingpin)

103 1 Steer Cylinder Assembly (See Section 5 for Breakdown)

Options:

Use 1682967 Standard (Prior to June 1993) (was p/n 1682681)

1682967 Standard (June 1993 to Present)

104 1660204 1 Rod-End (Left Side) 105 3322602 1 Nut, Jam 1" - 12NF Right Hand Threads (Left Side) 106 1660205 1 Rod-End (Right Side) 107 3300228 1 Nut, Jam 1"-12" NF Left Hand Threads (Right Side) 108 2160002 2 Fitting, Grease 109 0642622 2 Bolt 1" - 8NC x 2 3/4" 110 4712600 2 Flatwasher 1" Narrow 111 Not Used 112 3421243 2 Kingpin 113 0440183 2 Bearing, Thrust 114 3323403 2 Nut, Slotted 1 1/2"-12NF 115 3451012 2 Pin, Cotter 5/16" x 3" 116 2780177 2 Hub, Wheel 117 3960353 2 Seal, Oil 118 0440174 4 Cup, Bearing 119 0440175 4 Cone, Bearing 120 3322603 2 Nut, Slotted 1" -12NF 121 4740034 2 Washer, Hardened 122 3450610 2 Pin, Cotter 3/16" x 2 1/2" 123 1120311 2 Cap, Hub 124 0721004 6 Screw, Machine #10-24NC x 1/2" 125 4761000 6 Lockwasher #10 126 3300012 18 Nut, Wheel

3120830 400RTS 500RTS 1-3

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

127 0630137 18 Stud, Wheel

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0100019 A/R Loctite #271 0100011 A/R Loctite #242

0253078 Ref. STEERING INSTALLATION - 4WD FRONT (STANDARD

PARTS WITH 2WS) 0253059 Ref. STEERING INSTALLATION - 2WD REAR (STANDARD PARTS

WHEN EQUIPPED WITH OPTIONAL

REAR STEER)

201 4130279 1 Spindle Weldment (Right Side - Front/Left Side - Rear) 202 4130280 1 Spindle Weldment (Left Side - Front/Right Side - Rear) 203 1 Steer Cylinder Assembly (See Section 5 for Breakdown)

Options: 1682681 Standard (Prior to June 1993) 1682967 Standard (June 1993 to Present)

204 1660204 1 Rod-End 205 3322602 1 Nut, Jam 1"-12NF 206 1660205 1 Rod-End 207 3300228 1 Nut, Jam 1"-12NF Left Hand Thread 208 2160003 4 Fitting, Grease - 45° 209 0642622 2 Bolt 1"-8NC x 2 3/4" 210 4712600 A/R Flatwasher 1" Narrow 211 Not Used 212 3421190 4 Kingpin 213 0440161 4 Bearing, Thrust

214 to 216 Not Used

217 0641608 8 Bolt 3/8"-16NC x 1" 218 4751600 8 Flatwasher 3/8" 219 1380124 8 Clip, Retainer (Prior to S/N 69836) 220 4920096 4 ft./1.2m Wire, Safety (4 Pieces 1 ft./30 cm Long) (Prior to S/N 69836)

— — — — — — — — — — 0100019 A/R Loctite #271 0100011 A/R Loctite #242

0252532 Ref. STEERING INSTALLATION - 4WD FRONT AND REAR (STAN-

DARD PARTS WHEN EQUIPPED WITH OPTIONAL REAR

STEER)

301 4130279 1 Spindle Weldment (Right Side - Front/Left Side-Rear) 302 4130280 2 Spindle Weldment (Left Side - Front/Right Side - Rear) 303 2 Steer Cylinder Assembly (See Section 5 for Breakdown)

Options: 1682681 Prior to June 1993 1682967 June 1993 to Present

304 1660204 2 Rod-End 305 3322602 2 Nut, Jam 1"-12NF 306 1660205 2 Rod-End 307 3300228 2 Nut, Jam 1"-12NF Left Hand Thread

1-4 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

308 2160003 8 Fitting, Grease - 45° 309 0642622 4 Bolt 1"-8NC x 2 3/4" 310 4712600 A/R Flatwasher 1" Narrow 311 Not Used 312 3421190 8 Kingpin 313 0440161 8 Bearing, Thrust

314 to 316 Not Used

317 0641608 16 Bolt 3/8"-16NC x 1" 318 4751600 16 Flatwasher 3/8" 319 1380124 16 Clip, Retainer (Prior to S/N 69836) 320 4920096 8 ft./2.4m Wire, Safety (8 Pieces 1 ft./30cm long) (Prior to S/N 69836)

— — — — — — — — — —

0100019 A/R Loctite #271

Ref. FIXED AXLE INSTALLATIONS (STANDARD PARTS) 0253171 Ref. FIXED AXLE INSTALLATION - 2WD 4 0253172 Ref. FIXED AXLE INSTALLATION - 4WD 4

401 1 Axle Weldment - 2WD Options:

4844129 Prior to October 1994 4844868 October 1994 to Present 0961029 4 Bushing, Bronze (Kingpin Pivot)

1 Axle Weldment - 4WD Options: 4844059 Prior to October 1994 4844867 October 1994 to Present 0961029 4 Bushing, Bronze (Kingpin Pivot)

402 0560901 2 Block, Stop 403 0641610 1 Bolt 3/8"-16NC x 1 1/4" 404 4740185 2 Flatwasher 405 Not Used 406 1 Pin Weldment Options:

4842621 Prior to October 1994 3422401 October 1994 to Present

407 Not Used 408 3780183 2 O-Ring (October 1994 to Present) 409 4640812 1 Valve, Relief (October 1994 to Present - Not Shown) 410 3820030 6 Rivet, Pop 3/16" (Prior to S/N 77909) 411 3311605 8 Nut 3/8"-16NC (September 1995 to Present) 412 0641612 4 Bolt 3/8" x 1 1/2"-16NC (September 1995 to Present) 413 0641614 4 Bolt 3/8" x 1 3/4"-16NC (September 1995 to Present) 414 4751600 16 Flatwasher (September 1995 to Present) 415 0902214 1 Bracket, L.H. (September 1995 to Present) 416 0902215 1 Bracket, R.H. (September 1995 to Present) 417 3440616 4 Pin, Roll 3/16" x 1" (September 1995 to Present) 418 4280298 2 Strip, Wear (Prior to S/N 77909)

3120830 400RTS 500RTS 1-5

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. OSCILLATING AXLE INSTALLATION - OPTION (STANDARD

PARTS WHEN EQUIPPED)

0253381 Ref. OSCILLATING AXLE INSTALLATION - 2WD 11 0253380 Ref. OSCILLATING AXLE INSTALLATION - 4WD 10

501 1 Axle Weldment - 2WD Options:

4844129 Prior to October 1994 4844868 October 1994 to Present 0961029 4 Bushing, Bronze (Prior to October 1994)

1 Axle Weldment - 4WD Options: 4844059 Prior to October 1994 4844867 October 1994 to Present 0961029 4 Bushing, Bronze (Prior to October 1994)

502 1682427 2 Axle Lockout Cylinder Assembly (See Section 5 for

Breakdown) 503 0641608 2 Bolt 3/8"-16NC x 1" 504 4751600 18 Flatwasher 3/8" 505 4761600 4 Lockwasher 3/8" 506 1 Pin, Axle Pivot Options:

4842621 Prior to October 1994

3422401 October 1994 to Present 507 2160002 3 Fitting, Grease 508 3422137 2 Pin, Attach (Bottom) 509 0641510 2 Bolt 5/16"-18NC x 1 1/4" 510 3311505 2 Locknut 5/16"-18NC 511 4751500 2 Flatwasher 5/16" 512 3421335 2 Pin, Attach (Top) 513 4740308 4 Flatwasher, Special 514 0641608 4 Bolt 3/8-16NC x 1" 515 4640668 1 Lockout Valve Assembly 516 Not Used 517 3311605 2 Nut 3/8"-16NC 518 Not Used 519 3841143 2 Pin, Keeper 520 3534805 1 Plate, Mounting 521 4640273 2 Bleeder (October 1994 to Present) 522 4740185 2 Washer (October 1994 to Present) 523 Not Used 524 3780183 2 O-Ring (October 1994 to Present - Not Shown) 525 4640812 1 Valve, Relief (October 1994 to Present) 526 3820030 6 Rivet, Pop 3/16" (Prior to S/N 77909) 527 3311605 8 Nut 3/8"-16NC (September 1995 to Present) 528 0641612 4 Bolt 3/8" - 16NC x 1 1/2" (September 1995 to Present)

529 0641614 4 Bolt 3/8" - 16NC x 1 3/4" (September 1995 to Present) 530 4280298 2 Strip, Wear (Prior to S/N 77909) 531 0902214 1 Bracket, L.H. (September 1995 to Present) 532 0902215 1 Bracket, R.H. (September 1995 to Present) 533 3440616 4 Pin, Roll (September 1995 to Present) 534 0641406 2 Bolt 1/4”-20NC x 3/4”

1-6 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

535 4761400 2 Lockwasher 1/4” 536 3911014 4 Screw #10-24NC x 5/8” 537 4761000 4 Lockwasher #10 538 3311001 4 Nut #10 539 4751600 2 Flatwasher 3/8” 540 4751000 4 Flatwasher #10 541 0641610 4 Bolt 3/8"- 16NC x 1 1/4"

— — — — — — — — — —

0100019 A/R Loctite #271

3120830 400RTS 500RTS 1-7

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

1-8 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. TIRE AND WHEEL DRIVE INSTALLATIONS

0252484 Ref. WHEEL DRIVE INSTALLATION - 2WD/2WS 3

1 2780169 2 Drive Hub Assembly (See Figure 1-6 for Breakdown) 2 3300012 18 Nut, Wheel 3 0642014 12 Bolt 5/8"-11NC x 1 3/4" 4 4762000 12 Lockwasher 5/8" 5 0920084 2 Drive Brake Assembly (See Figure 1-5 for Breakdown) (Prior to

S/N 36645)

0920110 2 Drive Brake Assembly (See Figure 1-5 for Breakdown) (S/N

36645 to Present) 6 3160158 2 Drive Motor Assembly (See Figure 1-4 for Breakdown) 7 3311801 4 Nut 1/2"-13NC 8 4761800 4 Lockwasher 1/2" 9 4300092 4 Stud 1/2"-13NC x 5 1/2"

10 4711800 4 Flatwasher 1/2" Narrow

— — — — — — — — — — —

0100011 A/R Loctite #242

0251661 Ref. WHEEL DRIVE INSTALLATION - 2WD/4WS B

101 2780195 2 Drive Hub/Brake Assembly (See Figure 1-7 for Breakdown) 102 3160158 2 Drive Motor Assembly (See Figure 1-4 for Breakdown) 103 0642014 12 Bolt 5/8"-11NC x 1 3/4" 104 4762000 12 Lockwasher 5/8" 105 0641810 4 Bolt 1/2"-13NC x 1 1/4" 106 4761800 4 Lockwasher 1/2" 107 3300012 18 Nut, Wheel

0253545 Ref. WHEEL DRIVE INSTALLATION - 4WD/2WS FRONT AND

REAR (2MPH)

0255103 Ref. WHEEL DRIVE INSTALLATION - 4WD/2WS FRONT

AND REAR (4MPH)

201 2 Drive Hub/Brake Assembly (See Figure 1-7 for Breakdown)

Options:

2780191 2 MPH

2780193 4 MPH 202 3160158 4 Drive Motor Assembly (See Figure 1-4 for Breakdown) 203 0642014 24 Bolt 5/8"-11NC x 1 7/8" 204 4762000 24 Lockwasher 5/8" 205 0641810 4 Bolt 1/2"-13NC x 1 1/4" 206 4761800 8 Lockwasher 1/2" 207 3300012 36 Nut, Wheel 208 2 Drive Hub Assembly (See Figure 1-6 for Breakdown) Options:

2780167 2 MPH

2780175 4 MPH 209 4300092 4 Stud 1/2"-13NC x 5 1/2"

3120830 400RTS 500RTS 1-9

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

210 0920084 2 Drive Brake Assembly (See Figure 1-5 for Breakdown) (Prior to

S/N 36645)

0920110 2 Drive Brake Assembly (See Figure 1-5 for Breakdown) (S/N

36645 to Present) 211 3311801 4 Nut 1/2"-13NC 212 4711800 4 Flatwasher 1/2"

— — — — — — — — — —

0100011 A/R Loctite #242

0251660 Ref. WHEEL DRIVE INSTALLATION - 4WD/4WS FRONT

FRONT AND REAR (2MPH)

301 2780191 4 Drive Hub/Brake Assembly (See Figure 1-7 for Breakdown) 302 3160158 4 Drive Motor Assembly (See Figure 1-4 for Breakdown) 303 0642014 24 Bolt 5/8" - 11NC x 1 3/4" 304 4762000 24 Lockwasher 5/8" 305 0641810 8 Bolt 1/2"-13NC x 1 1/4" 306 4761800 8 Lockwasher 1/2" 307 3300012 36 Nut, Wheel

0253089 Ref. TIRE AND WHEEL INSTALLATION - OPTIONAL FOAM FILLED

12 x 16.5

Ref. TIRE AND WHEEL INSTALLATION - OPTIONAL FOAM FILLED

OPTIONS:

0255660 Ref. FOAM FILLED 31 x 15.50 x 15 - OTR TRITAN (Prior to S/N

115825)

0272826 Ref. FOAM FILLED 31 x 15.50 x 15 - OTR NHS (S/N 115825 to

Present)

Ref. 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.

—

401 2 Tire and Wheel Assembly - Left Side Options: —

0253088 12 x 16.5

Use 0273414 31 x 15.50 x 15 - OTR Tritan (was p/n 0255661)

0273414 31 x 15.50 x 15 - OTR NHS

2 Tire and Wheel Assembly - Right Side Options: —

0253087 12 x 16.5

Use 0273415 31 x 15.50 x 15 - OTR Tritan (was p/n 0255662)

0273415 31 x 15.50 x 15 - OTR NHS

402 to 404 Not Used

1-10 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 1-11

SECTION 1 FRAME

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

1-12 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE MOTOR ASSEMBLY

3160158 Ref. DRIVE MOTOR ASSEMBLY (STANDARD PARTS)

1 Use Item 51 1 Ring, Retaining 2 Use Item 51 1 Seal, Shaft 3 7004906 1 Washer 4 Use Item 51 2 Ring, Retaining 5 7004907 2 Race, Thrust 6 7004908 1 Bearing, Thrust 7 7007874 1 Shaft, Splined 8 7004910 1 Bearing

9 7007875 1 Housing Assembly (Includes Item 8) 10 7007876 1 Insert, Camplate 11 7004917 1 Bearing 12 Use Item 51 1 O-Ring 13 7007878 1 Back Plate Assembly (Includes Item 11) 14 7007879 6 Bolt 15 7007880 1 Rotating Kit Assembly (Sold As An Assembly Only)

— — — — — — — — — —

51 2900714 1 Seal Kit (Includes Items 1,2,4 and 12)

3120830 400RTS 500RTS 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

1-14 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE BRAKE ASSEMBLIES

0920084 Ref. MICO - (ORIGINAL EQUIPMENT) (MACHINES BUILT PRIOR

TO S/N 36645)

0920110 Ref. MICO - (SERVICE REPLACEMENT) (MACHINES BUILT S/N

36645 TO PRESENT)

Ref. Note: Original Equipment Brake may have been replaced with

Service Replacement Brake. Identify the brake by the serial number plate before ordering parts.

1 See Note 1 Seal, Oil (Note: Use Item 101 & 102)

2 Use Item 102 1 Bearing

3 7007977 1 Ring, Retaining

4 7011712 1 Shaft

5 6 Spring Options:

7007979 Spring (Inner) - Prior to S/N 36645 (Use with p/n 0920084) 7007970 Spring (Red) - S/N 36645 to Present (Use with p/n 0920110)

6 A/R Spring Options:

7007980 6 Spring (Outer) - Prior to S/N 36645 (Use with p/n 0920084) 7018602 3 Spring (Blue) - S/N 36645 to Present (Use with p/n 0920110)

7 1 Housing Options:

7011713 Prior to S/N 36645 (Use with p/n 0920084) 7018605 S/N 36645 to Present (Use with p/n 0920110)

8 4 Bolt, Washer Head Options:

7007985 Prior to S/N 36645 (Use with p/n 0920084) 7018607 S/N 36645 to Present (Use with p/n 0920110)

9 1 Guide, Spring Options:

7011717 Prior to S/N 36645 (Use with p/n 0920084) 7018606 S/N 36645 to Present (Use with p/n 0920110)

10 1 Piston Options:

7007923 Prior to S/N 36645 (Use with p/n 0920084)

7018603 S/N 36645 to Present (Use with p/n 0920110) 11 See Note 1 Seal, Case (Note: Use Item 101,102, 103A & 103B) 12 Use Item 103B 1 Plate, Return

7011715 2 Separator Assembly

7011714 4 Pin

7007983 2 Separator 13 7007986 1 Cover 14 7007914 1 Screw, Bleeder 15 7011716 1 Ring, Retainer 16 Not Used 17 7007987 2 Pin, Dowel 18 Use Item 101 1 Ring, Back-up 19 Use Item 101 1 O-Ring 20 Use Item 101 1 Ring, Back-up 21 Use Item 101 1 O-Ring 22 See Note 2 Rotor (Note: Use Item 103A & 103B) 23 See Note 2 Stator (Note: Use Item 103A & 103B) 24 Not Used 25 7007924 1 Plug, Pipe 26 Not Used

—

3120830 400RTS 500RTS 1-15

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

27 Not Used 28 See Note 2 O-Ring (Note: Use Item 101,102, 103A & 103B) 29 7007933 2 Gasket

— — — — — — — — — —

101 2900766 1 Seal Kit (Includes Items 1,11,18,19,20,21,28 and 29) 102 2900768 1 Bearing Kit (Includes Items 1,2,11,28 and 29) 103 1 Lining Kit Options:

103A 2900767 Lining Kit (Includes Items 58, 11, 22,23, 28 and 29) (Prior to

S/N 36645 (Use with p/n 0920084)

103B 7018608 Lining Kit (Includes Items 58, 11, 12, 22,23, 28 and 29) (S/N

36645 to Present (Use with p/n 0920110)

1-16 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 1-17

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLIES

1-18 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLIES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE HUB ASSEMBLIES

2780169 Ref. DRIVE HUB ASSEMBLY -2WD/2WS GAS/DIESEL

(2MPH)

2780167 Ref. DRIVE HUB ASSEMBLY - 4WD/2WS REAR DRIVE

ONLY (2MPH)

1 1 Hub-Spindle Sub Assembly (See Items 101-111 for Breakdown) 2 7000246 1 Gear, Internal 3 7000247 1 Carrier Assembly (See Items 201-207 for Breakdown) 4 7000248 1 Gear, Ring 5 7000230 2 O-Ring 6 7001989 1 Cover Assembly (Includes Items 301-308) 7 1 Input Shaft Assembly (See Items 401-404 for Breakdown)

Options: 7000250 Input Shaft Assembly (2WD Machines) 7007650 Input Shaft Assembly (4WD Machines)

8 1 Gear, Input Options:

7000251 Gear, Input (2WD) 7007652 Gear, Input (4WD)

9 1 Spacer, Thrust Options:

7000252 Spacer, Thrust (2WD Machines) 7007653 Spacer, Thrust (4WD Machines)

10 1 Spacer, Thrust Options:

Not Required Spacer, Thrust (2WD Machines)

7007654 Spacer, Thrust (4WD Machines)

11 7000253 2 Washer, Thrust 12 7000217 12 Bolt 13 7000214 4 Bolt, Shoulder 14 7000206 1 Coupling 15 Not Used 16 7007603 16 Flatwasher

Ref. HUB - SPINDLE SUB-ASSEMBLY

101 7001997 1 Spindle 102 7001998 1 Seal 103 Use Item 502 1 Cone, Bearing 104 Use Item 502 1 Cup, Bearing 105 7007697 9 Bolt, Wheel 106 7000242 2 Plug, Pipe 107 7007601 1 Hub 108 7000257 1 Cup, Bearing 109 7000258 1 Cone, Bearing 110 7000232 1 Spacer 111 7000229 1 Ring, Retaining

3120830 400RTS 500RTS 1-19

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

7000247 Ref. CARRIER ASSEMBLY

201 7001931 1 Carrier 202 7001911 3 Shaft 203 7001913 3 Pin, Roll 204 7001985 6 Washer, Thrust 205 7001909 96 Roller, Needle 206 7000263 3 Spacer 207 7001912 3 Gear, Cluster (2MPH)

Ref. COVER ASSEMBLY See Kit Options Ref. Cast Cover (Original Equipment) See Kit Options Ref. Aluminum Cover (Service Replacement)

301 1 Cover Options:

Use 70001111 Cast Cover (Original Equipment)

(was p/n 7000226)

Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017091)

302 1 O-Ring Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017070)

303 1 Cap, Cover

Use 70001111 Cast Cover (Original Equipment)

Not Required Aluminum Cover (Service Replacement)

304 1 O-Ring Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017095)

305 1 Rod, Disconnect Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017092)

306 1 Cap, Disconnect

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017093)

307 A/R Bolt Options:

Use 70001111 4 Cast Cover (Original Equipment)

(was p/n 7000220)

Use 70001349 2 Aluminum Cover (Service Replacement)

(was p/n 7000216)

308 A/R Plug, Pipe Options:

Use 70001111 1 Cast Cover (Original Equipment)

(was p/n 7000243)

Use 70001349 2 Aluminum Cover (Service Replacement)

(was p/n 7017094)

— — — — — — — — — — —

1-20 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1 Cover Kit Options:

Ref. Note: Kit Replaces Items 5, 11 (Spacer), 12, 13 (Dowel

Pins) & 301-308.

Use 70001111 Cast Cover (Original Equipment)

(was p/n 7001989 & p/n 7017099)

Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017090)

7000250 Ref. INPUT SHAFT ASSEMBLY (2WD MACHINES) 7007650 Ref. INPUT SHAFT ASSEMBLY (4WD MACHINES)

401 7000260 1 Shaft (2WD Machines)

7007651 1 Shaft (4WD Machines) 402 7000263 2 Spacer 403 7000262 1 Spring 404 7000261 1 Ring, Retaining

— — — — — — — — — —

501 1 Seal Kit Options:

501A 7017063 1 Seal Kit (Includes Items 5, 11, 102, 111, 302 and 304) 501B 2900034 1 Seal Kit (Includes Items 5, 102 110 and 111)

502 7010429 1 Bearing Kit (Includes Items 103 and 104) 503 2900137 Disconnect and Seal Kit (Includes Items 5, 102, 110, 110 and

302 - 307

3120830 400RTS 500RTS 1-21

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES

1-22 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE HUB/BRAKE ASSEMBLY OPTIONS: 2780195 Ref. 2WD/4WS GAS/DIESEL MACHINES (2MPH) — 2780191 Ref. 4WD GAS/DIESEL MACHINES (2MPH) — 2780193 Ref. 4WD/2WS GAS/DIESEL MACHINES (4MPH) —

1 See Note 1 Hub/Spindle/Brake Assembly (Note: Not sold as a complete

assembly) (See Items 101-113 for Breakdown) 2 7007691 1 Gear, Internal 3 1 Carrier Assembly Options (See Items 201-207 for Breakdown):

Not Available 2WD/4WS Machines

7000247 4WD with 2MPH Machines

See Note 4WD with 4MPH Machines (Note: Purchase 7000247 & install

(3) 7007643 Cluster Gears to make this carrier assembly) 4 7000248 1 Gear, Internal 5 See Note 2 O-Ring (Note: Use Items 351 & 352) 6 1 Cover Assembly

(See Items 301-308 for Breakdown)

7 1 In put Shaft Assembly Options

(See Items 401-404 for Breakdown): 7007650 4WD Machines 7000250 2WD/4WS Machines

8 1 Gear, Input Options:

7007652 4WD Machines 7000251 2WD/4WS Machines

9 1 Spacer, Input Options:

7007653 4WD Machines 7000252 2WD/4WS Machines

10 1 Spacer, Input Options:

7007654 4WD Machines

Not Required 2WD/4WS Machines

11 7000253 2 Washer, Thrust

7017096 1 Spacer (S/N 92158 to Present Only)

12 12 Bolt Options:

7000217 Prior to S/N 92158 7017067 S/N 92158 to Present

13 4 Hardware Options:

7000214 Bolt Used Prior to S/N 92158 7017080 Dowel Pin Used S/N 92158 to Present

14 to 15 Not Used

16 7007603 16 Flatwasher 17 7007692 1 Gasket 18 Not Used 19 7010470 1 Coupling 20 Not Used 21 7010459 1 Ring, Retainer 22 7001922 1 Washer, Thrust

3120830 400RTS 500RTS 1-23

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. HUB/SPINDLE/BRAKE SUB-ASSEMBLY

101 1 Brake Assembly Options:

7010473 2WD/4WS Machines and 4WD Machines with I.D. Plate

(Stamped July 1992 or Later (See Items 601-604 for Breakdown)

7010469 4WD Machines with I.D. Plate Stamped Prior to July 1992

(See Items 501-514 for Breakdown) 102 Use Item 701 1 Seal, Lip 103 7007683 1 Cup, Bearing 104 7007684 1 Cone, Bearing 105 7007685 1 Cup, Bearing 106 7007686 1 Cone, Bearing 107 7007687 1 Housing 108 7007688 1 Flatwasher, Tanged 109 7007689 1 Flatwasher, Tanged 110 7007690 1 Nut, Bearing 111 7000242 2 Plug, Pipe 1/4" NPT 112 7000241 9 Stud, Wheel 113 7007617 2 Plug, Pipe 3/8" NPT (Magnetic)

7000247 Ref. CARRIER ASSEMBLY - 4WD(2MPH) MACHINES

NPN Ref. CARRIER ASSEMBLY - 4WD(4MPH) MACHINES NPN Ref. CARRIER ASSEMBLY - 2WD/4WS MACHINES

201 7001931 1 Carrier 202 7001985 6 Washer, Thrust - Tanged 203 7001909 96 Bearing, Needle 204 7000263 3 Spacer, Thrust 205 7001911 3 Shaft, Planet 206 3 Gear, Cluster Options:

7001912 4WD with 2MPH Hub and 2WD/4WS 7007643 4WD with 4MPH Hub

207 3 Rollpin Options:

7001913 4WD Machines 7010474 2WD/4WS Machines

Ref. COVER ASSEMBLY See Kit Options Ref. Cast Cover (Original Equipment) See Kit Options Ref. Aluminum Cover (Service Replacement)

301 1 Cover Options:

Use 70001111 Cast Cover (Original Equipment)

(was p/n 7000226)

Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017091)

302 1 O-Ring Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017070)

1-24 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

303 1 Cap, Cover

Use 70001111 Cast Cover (Original Equipment)

Not Required Aluminum Cover (Service Replacement)

304 1 O-Ring Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017095)

305 1 Rod, Disconnect Options:

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017092)

306 1 Cap, Disconnect

Use 70001111 Cast Cover (Original Equipment) Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017093)

307 A/R Bolt Options:

Use 70001111 4 Cast Cover (Original Equipment)

(was p/n 7000220)

Use 70001349 2 Aluminum Cover (Service Replacement)

(was p/n 7000216)

308 A/R Plug, Pipe Options:

Use 70001111 1 Cast Cover (Original Equipment)

(was p/n 7000243)

Use 70001349 2 Aluminum Cover (Service Replacement)

(was p/n 7017094)

309 to 350 Not Used

— — — — — — — — — — —

1 Cover Kit Options:

Ref. Note: Kit Replaces Items 5, 11 (Spacer), 12, 13 (Dowel

Pins) & 301-308.

351 Use 70001111 Cast Cover (Original Equipment)

(was p/n 7001989 & p/n 7017099)

352 Use 70001349 Aluminum Cover (Service Replacement)

(was p/n 7017090)

7007650 Ref. INPUT SHAFT ASSEMBLY - 4WD MACHINES 7000250 Ref. INPUT SHAFT ASSEMBLY - 2WD/4WS MACHINES

401 1 Shaft Options:

7007651 4WD Machines

7000260 2WD/4WS Machines 402 7000261 1 Ring, Retaining 403 7000262 1 Spring 404 7000263 2 Spacer, Thrust

7010469 Ref. BRAKE ASSEMBLY - 4WD MACHINES WITH I.D. PLATE

STAMPED JUNE 1992 OR EARLIER

501 7014100 1 Spindle 502 7014101 1 Spacer 503 7014102 7 Disc, Stationary

3120830 400RTS 500RTS 1-25

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

504 7014103 6 Disc, Rotating 505 Use Item 702 1 Ring, Back-up 506 Use Item 702 1 O-Ring 507 Use Item 702 1 Ring, Back-up Ring 508 Use Item 702 1 O-Ring 509 7014108 1 Piston 510 7014109 6 Spring

7014110 2 Spring 511 Use Item 702 1 O-Ring 512 7014112 1 Cover 513 Not Available 8 Bolt, Socket Head 3/8"-16NC x 1 1/4" 514 7014113 1 Expander

7010473 Ref. BRAKE ASSEMBLY - 2WD/4WS MACHINES AND 4WD

MACHINES WITH I.D. PLATE STAMPED JULY 1992 OR LATER

601 7010475 1 Brake Lining Kit 602 7010476 1 Brake O-Ring Kit 603 7010477 1 Brake Spring Repair Kit 604 7010478 1 Brake Piston Repair Kit

— — — — — — — — — —

Ref Kit Options:

701 Use 70001940 1 Seal Kit - Hub (Includes Items 5,17,102,306 and 307)

(was p/n 2900754)

702 2900816 1 Brake O-Ring Kit (Includes Items 505-508 and 511)

1-26 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 1-27

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION

1-28 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME MOUNTED COMPONENTS INSTALLATION

0253517 Ref. LIMIT SWITCH INSTALLATION - 500RTS (Prior to S/N 111178) 5 0272935 Ref. LIMIT SWITCH INSTALLATION - 500RTS (S/N 111178 to S/N

112737)

0272969 Ref. LIMIT SWITCH INSTALLATION - 500RTS (S/N 112737 to Pres-

ent)

0254058 Ref. LIMIT SWITCH INSTALLATION - 400RTS WITH STANDARD

TIRES (Prior to S/N 111178)

0254059 Ref. LIMIT SWITCH INSTALLATION - 400RTS WITH 31 x 15.5-15

(Prior to S/N 111178)

0272936 Ref. LIMIT SWITCH INSTALLATION - 400RTS WITH 31 x 15.5-15 (S/

N 111178 to Present)

1 1 Bracket, Mounting Options:

500RTS Options: 0901902 Prior to S/N 111178 4846822 S/N 111178 to Present

Not Required 400RTS With Standard Tires

400RTS With 31 x 15.5-15 Tires Options: 0901966 Prior to S/N 111178 4846822 S/N 111178 to Present

2 4360300 A/R Switch, Limit 3 4460049 A/R Connector, Strain Relief 4 2 Washer Options:

4751500 Flatwasher 5/16" (Prior to S/N 111178) 4891600 Washer, Hardened 3/8" (S/N 111178 to Present)

Not Required 400RTS With Standard Tires

5 2 Lockwasher Options:

4761500 Lockwasher 5/16" (Prior to S/N 111178)

Not Required 400RTS With Standard Tires

6 2 Nut Options:

3311501 Nut 5/16"-18NC

Not Required 400RTS With Standard Tires 7 3440413 A/R Rollpin 1/8" x 13/16" (Prior to S/N 112737) 8 1100083 1 Cam (Hi-Drive Cutout) (Prior to S/N 112737) 9 4300038 2 Stud (Welded Part)

10 3911032 A/R Bolt, Socket Head #10-24NC x 2" 11 4751000 A/R Flatwasher #10 12 4761000 A/R Lockwasher #10 (Prior to S/N 111178) 13 3311005 A/R Locknut #10-24NC 14 0901917 1 Bracket (Prior to S/N 112737) 15 4751600 A/R Flatwasher 3/8" 16 3951503 2 Setscrew 5/16"-18NC x 3/4" (Prior to S/N 112737) 17 1100137 1 Cam, Limit Switch (S/N 111178 to Present) 18 0100011 A/R Loctite #242 (Not Shown) (S/N 111178 to Present) 19 0641626 2 Bolt 3/8 - 16NC x 3 1/4” (S/N 111178 to Present) 20 3574274 1 Plate, Clamp (S/N 111178 to Present) 21 1060965 1 Cable - 16/2 (92ft/28.1m) (Not Shown) (S/N 1075516 to Pres-

ent)

3120830 400RTS 500RTS 1-29

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

22 1060966 1 Cable - 16/2 (85ft/25.9m) (Not Shown) (S/N 1075516 to S/N

109670)

0253237 Ref. LADDER INSTALLATION - 500RTS WITHOUT DUAL

EXTENDABLE PLATFORMS

0253238 Ref. LADDER INSTALLATION - 500RTS WITH DUAL

EXTENDABLE PLATFORMS

0271332 Ref. LADDER INSTALLATION - 500RTS WITH MEGADECK PLAT-

FORMS (S/N 95337 TO PRESENT)

0253933 Ref. LADDER INSTALLATION - 400RTS WITHOUT DUAL

EXTENDABLE PLATFORMS (PRIOR TO S/N 70978)

0253934 Ref. LADDER INSTALLATION - 400RTS WITH DUAL

EXTENDABLE PLATFORMS (PRIOR TO S/N 70978)

0254302 Ref. LADDER INSTALLATION - 400RTS WITHOUT DUAL

EXTENDABLE PLATFORMS

101 2 Ladder Weldment - Side Options:

4844249 500RTS 4846407 500RTS - With Megadeck Platform 4844490 400RTS

102 1 Ladder Weldment - Rear

4844250 500RTS Without Dual Extendable Platform

(Prior to S/N 65789)

4846051 500RTS Without Dual Extendable Platform

(S/N 65789 to Present) Not Required 500RTS With Dual Extendable Platform Not Required 500RTS - With Megadeck Platform

4844491 400RTS Without Dual Extendable Platform

(Prior to S/N 65789)

4846055 400RTS Without Dual Extendable Platform

(S/N 65789 to Present) Not Required 400RTS With Dual Extendable Platform

103 0362171 1 Bar 104 0181678 1 Angle, Mounting 105 0181679 1 Angle, Mounting 106 0641612 A/R Bolt 3/8"-16NC x 1 1/2" 107 4751600 A/R Flatwasher 3/8" 108 4761600 A/R Lockwasher 3/8

Not Required 500RTS - With Megadeck Platform

109 A/R Nut Options:

3311601 Nut 3/8"-16NC (With Dual Extendable Platform) 3311605 Locknut 3/8-16NC (Without Dual Extendable Platform/Mega-

deck Platform)

110 0641524 3 Bolt 5/16"-18NC x 3" 111 4751500 8 Flatwasher 5/16" 112 4761500 4 Lockwasher 5/16"

Not Required 500RTS - With Megadeck Platform

113 4 Nut Options:

3311501 Nut 5/16”-18NC (With Dual Extendable Platform) 3311505 Locknut 5/16”-18NC (Without Dual Extendable Platform/

Megadeck Platform)

1-30 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

114 0641510 1 Bolt 5/16"-18NC x 1 1/4"

115 to 116 Not Used

117 3520071 A/R Cap

0253446 Ref. OPTIONAL TRAVEL ALARM INSTALLATION (STANDARD

PARTS WHEN EQUIPPED) (PRIOR TO S/N 71538)

0253727 Ref. OPTIONAL DESCENT ALARM INSTALLATION

(STANDARD PARTS WHEN EQUIPPED) (PRIOR TO S/N 112737)

0273055 Ref. OPTIONAL DESCENT ALARM INSTALLATION

(STANDARD PARTS WHEN EQUIPPED) (S/N 112737 TO PRESENT)

0253728 Ref. OPTIONAL MOTION ALARM INSTALLATION (STANDARD

PARTS WHEN EQUIPPED) (PRIOR TO S/N 112737)

0273056 Ref. OPTIONAL MOTION ALARM INSTALLATION (STANDARD

PARTS WHEN EQUIPPED) (S/N 112737 TO PRESENT)

See Note Ref. CE Spec (Note: For CE Spec Machines with Overload Refer to

JLG Supplement p/n 3124288 for Components.)

201 0140032 1 Alarm (Prior to S/N 112737) 202 4300038 2 Stud (Welded on Part) (Prior to S/N 112737) 203 4761500 2 Lockwasher 5/16" (Prior to S/N 112737) 204 3311501 2 Nut 5/16"-18NC (Prior to S/N 112737) 205 4751500 2 Flatwasher 5/16" (Prior to S/N 112737)

— — — — — — — — — — 3990010 A/R Diode - 6 Amp (Not Shown - Located at Ground Control) 3740049 1 Relay (Not Shown - Located at Ground Control) 1540002 1 Capacitor (Not Shown - Located at Ground Control) (S/N

112737 to Present)

0273057 Ref. OPTIONAL HORN INSTALLATION (STANDARD PARTS WHEN

EQUIPPED)

251 0140044 1 Alarm 252 4300032 2 Stud (Welded on Part) 253 4761400 2 Lockwasher 1/4" 254 3311401 2 Nut 1/4"-20NC 255 4751400 2 Flatwasher 1/4"

— — — — — — — — — — 4460539 1 Terminal, Male - 3 Position 4460465 2 Socket, Female 4460466 1 Terminal, Sealing Plug

0253448/0253449 Ref. AXLE COVERS INSTALLATION (2WS) (STANDARD PARTS) —

301 2 Plate, Cover Options:

4844186 Gas Machines 3536092 Diesel Machines

302 0641510 8 Bolt 5/16"-18NC x 1 1/4" 303 4751500 16 Flatwasher 5/16" 304 4761500 8 Lockwasher 5/16" 305 3311501 8 Nut 5/16"-18NC

3120830 400RTS 500RTS 1-31

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0253453 Ref. CIRCULAR LEVEL INSTALLATION —

401 2420038 1 Level, Circular 402 3910610 3 Screw #6-32NC x 5/8" 403 4770600 3 Starwasher #6

1-32 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 1-33

SECTION 1 FRAME

FIGURE 1-8. FRAME MOUNTED OPTIONS INSTALLATION

1-34 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-8. FRAME MOUNTED OPTIONS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0253678 Ref. LEVELING JACKS INSTALLATION (OPTIONAL ON

400RTS/STANDARD ON 500RTS) (PRIOR TO S/N 107516) 0271314 Ref. LEVELING JACKS INSTALLATION (500RTS) (S/N 107516 TO

PRESENT)

1 4844346 2 Jack Cylinder Weldment 2 4 Jack Cylinder Assembly Options (See Section 5 for Breakdown):

Use 1684216 Prior to S/N 104832 (was p/n 1682720)

1684216 S/N 104832 to S/N 107516

Use 1684217 S/N 107516 to Present (was p/n 1683966)

3 16 Bolt Options:

0641828 Bolt 1/2-13NC x 3 1/2 (Prior to S/N 103576) 0641830 Bolt 1/2-13NC x 3 3/4 (S/N 103576 to Present)

4Not Used 5 4761800 16 Lockwasher 1/2" 6 0642014 16 Bolt 5/8"-11NC x 1 3/4" 7 4712000 32 Flatwasher 5/8" Narrow 8 4762000 16 Lockwasher 5/8" (Prior to S/N 64796)

9 3312005 16 Nut 5/8"-11NC 10 4420052 8.5 ft. Tape, Safety 11 8 Switch, Limit Options:

Use 4360548 Prior to S/N 109670 (was p/n 4360321)

4360548 S/N 109670 to Present

12 3911020 16 Screw, Machine #10-24NC x 1 1/4" (Prior to S/N 27385)

3930820 16 Screw #8-32 x 1 1/4" (S/N 27385 to Present)

13 3311005 16 Lock Nut #10-24NC (Prior to S/N 27385)

3310805 16 Lock Nut #8-32 (S/N 27385 to Present)

14 4751000 16 Flatwasher #10 (Prior to S/N 27385)

4750800 16 Flatwasher #8 (S/N 27385 to Present)

15 8 Connector, Strain Relief Options:

4460428 Prior to S/N 109670 4460968 S/N 109670 to Present

16 3841208 4 Rod (Prior to S/N 26251)

3841326 4 Rod (S/N 26251 to Present) 17 4160116 4 Spring 18 4740415 4 Washer, Special 19 3440420 8 Rollpin 20 4060848 4 Cover 21 0641406 16 Bolt 1/4"-20NC x 3/4" 22 4751400 16 Flatwasher 1/4" 23 4761400 16 Lockwasher 1/4" 24 1703814 4 Decal - Tie Down 25 3520082 8 Plug, Cap (Not Shown) 26 4460234 4 Pad, Adhesive (Not Shown) 27 1060971 1 Cable, 16/2 (18ft/5.5m)(Not Shown) (S/N 79847 to Present) 28 1060968 1 Cable, 16/2 (16ft/4.9m)(Not Shown) (S/N 79847 to Present) 29 1060969 2 Cable, 16/2 (10ft/3.0m)(Not Shown) (S/N 79847 to Present) 30 1060970 1 Cable, 16/2 (23ft/7.0m)(Not Shown) (S/N 79847 to Present)

3120830 400RTS 500RTS 1-35

SECTION 1 FRAME

FIGURE 1-8. FRAME MOUNTED OPTIONS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0253821 Ref. HEADLIGHTS AND TAILLIGHTS INSTALLATION

(OPTIONAL)

101 2920110 2 Headlight 102 0901927 2 Bracket - Headlight 103 4300032 4 Stud (Welded on Part) 104 4761400 4 Lockwasher 1/4" 105 4751400 4 Flatwasher 1/4" 106 3311401 4 Nut 1/4"-20NC 107 2920113 2 Taillight 108 Not Used 109 0901928 2 Bracket - Taillight 110 0642012 2 Bolt 5/8"-11NC x 1 1/2" 111 4752000 2 Flatwasher 5/8" 112 4762000 2 Lockwasher 5/8" 113 3312001 2 Nut 5/8"-20NC 114 3911040 4 Screw, Machine #10-24NC x 2 1/2" 115 4771000 4 Starwasher #10 116 4751000 4 Flatwasher #10 117 3311001 4 Nut #10-24NC 118 4360329 1 Switch, Toggle (Not Shown - Located at Platform Console Box) 119 3790012 1 O-Ring (Not Shown - Located at Platform Console Box)

120 to 124 Not Used

125 1060341 30 ft./9m Cable, Electrical - 16/2 126 Not Used 127 3740049 1 Relay, Bosch (Not Shown - Located at Ground Control)

128 to 133 Not Used

134 4460051 1 Relief, Strain (Not Shown - Located at Ground Control) (S/N

106887 to Present)

135 3300048 1 Locknut (Not Shown - Located at Ground Control) (S/N 106887 to

Present)

136 0960238 1 Bushing (Not Shown - Located at Ground Control) (S/N 106887 to

Present)

1-36 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-8. FRAME MOUNTED OPTIONS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 1-37

SECTION 1 FRAME

FIGURE 1-9. TOW PACKAGE INSTALLATION - BALL (OPTIONAL)

1-38 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-9. TOW PACKAGE INSTALLATION - BALL (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0253079 Ref. TOW BAR INSTALLATION E

1 0362080 1 Bar 2 3536156 1 Plate, Hitch Attach 3 4712600 4 Flatwasher 1" 4 2620037 1 Hitch, Tow 5 1660114 2 Coupling, Tie-Rod 6 3323002 2 Nut, Jam 1 1/4"-12NF 7 3841184 1 Tie-Rod 8 0642624 1 Bolt 1"-8NC x 3"

9 0642636 1 Bolt 1"-8NC x 4 1/2" 10 3422091 1 Pin 11 3841143 1 Keeper, Pin 12 2160002 1 Fitting, Grease 13 0900479 1 Bracket, Valve Mounting 14 4640261 1 Valve 15 0641507 2 Bolt 5/16"-18NC x 7/8" 16 4751500 3 Flatwasher 5/16" 17 4761500 3 Lockwasher 5/16" 18 3250872 1 Nameplate - Steer/Tow 19 3820001 4 Rivet 20 3420292 2 Pin, Quick Release 21 1260017 2 Chain 22 3536157 2 Plate 23 3537973 2 Plate 24 0362126 1 Tow Bar Assembly

3420352 1 Pin, Tow

3420158 1 Hairpin 25 0641508 1 Bolt 5/16"-18NC x 1" 26 Not Used 27 3420372 1 Hairpin, Cotter

3120830 400RTS 500RTS 1-39

SECTION 1 FRAME

FIGURE 1-10. TOW PACKAGE INSTALLATION - PINTLE HOOK (OPTIONAL)

1-40 400RTS 500RTS 3120830

SECTION 1 FRAME

FIGURE 1-10. TOW PACKAGE INSTALLATION - PINTLE HOOK (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271499 Ref. TOW BAR INSTALLATION 1

9 0642636 1 Bolt 1"-8NC x 4 1/2" 10 3422091 1 Pin 11 3841143 1 Keeper, Pin 12 2160002 1 Fitting, Grease 13 0900479 1 Bracket, Valve Mounting 14 4640261 1 Valve 15 0641507 2 Bolt 5/16"-18NC x 7/8" 16 4751500 3 Flatwasher 5/16" 17 4761500 3 Lockwasher 5/16" 18 3250872 1 Nameplate - Steer/Tow 19 3820001 4 Rivet 20 0641508 1 Bolt 5/16”-18NC x 1” 21 Not Used 22 0363019 1 Tow Bar Assembly (See Items 101-111 for breakdown) 23 0902733 1 Bracket 24 0902734 1 Bracket 25 0642018 4 Bolt 5/8"-11NC x 2 1/4" 26 3312005 4 Locknut 5/8”-11NC 27 4752000 8 Flatwasher 5/8 28 3340841 1 Pad

0363019 Ref. TOW BAR ASSEMBLY B

101 0360406 1 Bar, Draw 102 0642040 5 Bolt 5/8”-11NC x 5” 103 3312005 5 Locknut 5/8”-11NC 104 3420352 1 Pin, Towing 105 3420372 1 Pin, Cotter 106 3760170 1 Ring, Split 107 4070450 2 Shim 108 4070560 2 Shim 109 4070561 2 Shim 110 4752000 10 Flatwasher 5/8 111 4846439 1 Tow Bar Weldment

3120830 400RTS 500RTS 1-41

SECTION 1 FRAME

FIGURE 1-10. TOW PACKAGE INSTALLATION - PINTLE HOOK (OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-42 400RTS 500RTS 3120830

SECTION 2

GROUND CONTROLS

3120830 400RTS 500RTS 2-1

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION

2-2 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONTROL VALVES AND TANKS INSTALLATION

0253424 Ref. CONTROL VALVES AND TANKS INSTALLATION - 2WD/2WS

WITH LEVELING JACKS (PRIOR TO S/N 107516)

0271668 Ref. CONTROL VALVES AND TANKS INSTALLATION - 2WD/2WS

WITH LEVELING JACKS (S/N 107516 TO PRESENT)

0253423 Ref. CONTROL VALVES AND TANKS INSTALLATION - 2WD/ 4WS

WITH LEVELING JACKS (PRIOR TO S/N 107516)

0271669 Ref. CONTROL VALVES AND TANKS INSTALLATION - 2WD/ 4WS

WITH LEVELING JACKS (S/N 107516 TO PRESENT)

0253422 Ref. CONTROL VALVES AND TANKS INSTALLATION - 4WD/2WD

WITH LEVELING JACKS (PRIOR TO S/N 107516)

0271670 Ref. CONTROL VALVES AND TANKS INSTALLATION - 4WD/2WD

WITH LEVELING JACKS (S/N 107516 TO PRESENT)

0253421 Ref. CONTROL VALVES AND TANKS INSTALLATION - 4WD/4WS

WITH LEVELING JACKS (PRIOR TO S/N 107516)

0271671 Ref. CONTROL VALVES AND TANKS INSTALLATION - 4WD/4WS

WITH LEVELING JACKS (S/N 107516 TO PRESENT)

1 4640123 1 Solenoid Valve Assembly (Prior to April 1993)

7004368 1 Coil (Hydraforce Version) 7000558 1 Coil (FPS Version) 7012518 1 Seal Kit (Hydraforce Version) 7006075 1 Seal Kit (FPS Version)

Ref. Note: Solenoid Valve 4640123 not required on 4WD/2WS

Machines Built May 1993 to Present.

2 0641420 1 Bolt 1/4"-20NC x 2 1/2" (Prior to April 1993)

3 4751400 2 Flatwasher 1/4"

4 3311405 2 Locknut 1/4"-20NC

5 1320202 A/R Clamp, Hose (Prior to S/N 35422)

6 A/R Valve, Flow Divider Options:

2WD/2WS - 2WD/4WS:

6A 4640629 1 Valve, Flow Divider (Machines built prior to July 1993)

2900745 1 Seal Kit 4640443 1 Valve, Flow Divider (Machines built July 1993 to Present) 2900745 1 Seal Kit - 4640443 Valve

4WD/4WS

6B 4640260 2 Valve, Flow Divider

7009739 1 Seal Kit (Vickers/Modular Controls) 7007321 1 Cartridge (Fluid Controls)

Use 7007321 1 Seal Kit (Fluid Controls) (was p/n 7007323) (Note: No

Longer Available for Purchase)

4WD/2WS:

6C 4640260 2 Valve, Flow Divider (Machines built prior to May 1993)

7009739 1 Seal Kit (Vickers/Modular Controls) 7007321 1 Cartridge (Fluid Controls)

Use 7007321 1 Seal Kit (Fluid Controls) (was p/n 7007323) (Note: No

Longer Available for Purchase)

4640841 1 Valve, Flow Divider (Machines built May 1993 to Present) 7007321 1 Cartridge - 4640841 Valve

7 4751500 A/R Flatwasher 5/16"

3120830 400RTS 500RTS 2-3

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

8 3311505 A/R Locknut 5/16"-18NC

9 4751600 8 Flatwasher 3/8" 10 0901971 1 Bracket, Valve Mounting (Prior to S/N 63888) 11 1 Control Valve Assembly Options (See Figure 2-2 for Break-

down): (Prior to S/N 107516) 4640840 400RTS 4640786 500RTS 4641190 1 Control Valve Assembly (See Figure 2-3 for Breakdown) (S/N

107516 to Present)

12 3100071 1 Manifold 13 0641506 6 Bolt 5/16"-18NC x 3/4" 14 4761500 6 Lockwasher 5/16" (Prior to S/N 69708) 15 2120109 1 Filter Assembly

2120110 1 Element

16 0641508 4 Bolt 5/16"-18NC x 1" (Prior to S/N 63888) 17 0641608 A/R Bolt 3/8"-16NC x 1" 18 4400273 1 Tank, Fuel (Prior to S/N 34451)

4400402 1 Tank, Fuel (S/N 34451 to S/N 79765) 4400430 1 Tank, Fuel (S/N 79765 to Present) 7020257 1 Cap, Vented Kelch

19 1120362 1 Cap, Fuel Tank (Prior to S/N 34451) 20 2200222 3 Plug, Pipe 1/4" NPT 21 1 Hydraulic Tank Assembly Options:

4400347 Prior to S/N 112737 (See Items 101-113 for Breakdown) 4400461 S/N 112737 to Present (See Items 151-161 for Breakdown)

22 1 Breather Options:

1340021 Prior to S/N 63179 1340062 S/N 63179 to Present

23 Not Used 24 4761600 8 Lockwasher 3/8" 25 0641511 A/R Bolt 5/16"-18NC x 1 3/8" Options:

2WS (Prior to S/N 74638) 4WS

26 1320187 A/R Clamp, 5/8" Twin Hole Options:

2WS

4WS 27 1320188 6 Bolt, Stacking (Prior to S/N 74638) 28 1320189 6 Lockwasher, Stacking (Prior to S/N 74638) 29 1320190 A/R Plate, Clamp Cover

2WS (Prior to S/N 74638)

4WS 30 0641514 A/R Bolt 5/16"-18NC x 1 3/4" 31 1320192 A/R Clamp, 7/8" Twin Hole

62WD

84WD 32 1320193 A/R Bolt, Stacking 33 1320194 A/R Lockwasher, Stacking 34 1320195 A/R Plate, Cover

42WS

54WS

2-4 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

35 A/R Clamp Options:

Not Required 2WD-2WS

1320198 2WD-4WS - Clamp 5/8" Twin Hole (Prior to S/N 74638) 1320197 4WD-2WS/4WD-4WS - Clamp 7/8" x 5/8" (Prior to S/N

103576)

36 A/R Clamp Options:

Not Required 0 2WD-2WS/4WD-2WS

1320200 1 2WD-4WS/4WD-4WS - Clamp 1 1/4" Twin Hole (Prior to S/N

74638)

37 A/R Hardware Options:

Not Required 0 2WD-2WS

1320199 1 4WD-2WS/4WD-4WS - Clamp 3/4" x 1/2"(Prior to S/N 74638)

0641530 1 2WD-4WS - Bolt 5/16"-18NC x 3 3/4" (Prior to S/N 74638) 38 Not Used 39 3600130 1 Hand Pump Assembly

7012592 1 Seal Kit - 3600130 Pump 40 0641406 2 Bolt 1/4"-20NC x 3/4" 41 1 Control Valve Assembly Options (Machines with 4WS Only)

(See Figure 2-2 for Breakdown):

Use 4641090 Prior to S/N 54922 (was p/n 4640788)

4641090 S/N 54922 to S/N 107516 42 3010099 A/R Link Options:

2WD-2WS/2WD-4WS (Prior to S/N 63888)

4WD-2WS/4WD-4WS 43 0100010 A/R Loctite #242 44 2200009 1 Fitting, Cap (S/N 74638 to S/N 103576) 45 4060807

6.75ft/2.1m

Shield, Flex Trim (Not Shown) (S/N 101987 to Present)

4400347 Ref. HYDRAULIC TANK ASSEMBLY (PRIOR TO S/N 112737) 3

101 4400348 1 Tank 102 3536523 1 Plate, Cover 103 3960435 1 Gasket 104 4751400 12 Flatwasher 1/4" 105 4761400 12 Lockwasher 1/4" 106 3311401 12 Nut 1/4"-20NC 107 2120120 1 Filter, Suction 108 Not Used 109 3520022 1 Plug, Magnetic 110 2200009 1 Cap, Pipe 111 Not Used 112 2420115 2 Gauge, Sight 113 2220340 1 Fitting

— — — — — — — — — —

0100020 A/R Sealant, Pipe

3120830 400RTS 500RTS 2-5

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4400461 Ref. HYDRAULIC TANK ASSEMBLY (S/N 112737 TO PRESENT) E

151 4400461 1 Tank 152 7026122 1 Plate, Cover 153 7024440 1 Gasket 154 7024441 1 Gauge, Fluid Level 155 7024443 1 Neck, Filler 156 2120120 1 Strainer 157 7024444 1 Fill Cap, Vented 158 7024445 1 Strainer 159 7024446 1 Plug, Magnetic 160 3311401 6 Nut 1/4"-20NC 161 4751400 6 Flatwasher 1/4"

Ref. TILT INDICATOR INSTALLATIONS (STANDARD PARTS) 0254055 Ref. 500RTS 5 0254063 Ref. 400RTS —

201 1 Sensor Options:

Use 4360354 Sensor, Tilt - 3° (500RTS - Prior to S/N 74959) (was 2°

Sensor p/n 4360349) 4360354 Sensor, Tilt -3° (500RTS) (S/N 74959 to Present) 4360348 Sensor, Tilt - 5° (400RTS)

202 0641406 2 Bolt 1/4"-20NC x 3/4" 203 4751400 A/R Flatwasher 1/4" 204 3311405 A/R Locknut 1/4"-20NC

Ref. OPTIONAL AUXILIARY PUMP INSTALLATIONS: (MACHINES

WITH PLATFORM EXTENSIONS ONLY)

0254196 Ref. MACHINES WITH PLATFORM EXTENSIONS (400RTS) 10 0254197 Ref. MACHINES WITH PLATFORM EXTENSIONS (DUAL EXT.)

(400RTS)

0253614 Ref. MACHINES WITH PLATFORM EXTENSIONS (500RTS) 14 0253615 Ref. MACHINES WITH PLATFORM EXTENSIONS (DUAL EXT.)

(500RTS)

0271196 Ref. MACHINES WITH PLATFORM EXTENSIONS (MEGADECK

EXT.)

0273062 Ref. MACHINES WITH PLATFORM EXTENSIONS (POWER DECK

EXT.)

301 3600050 1 Auxiliary Pump Assembly (Machines Built Prior to July 1993)

7004249 1 Coupling 7004248 1 Motor 7010923 1 Pump

2-6 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

301 (cont’d) 3600208 1 Auxiliary Pump Assembly (Machines Built July 1993 to Pres-

ent) 7013710 1 Motor 7013753 Brush Kit 7013711 1 Coupling 7016746 1 Adapter, Motor to Pump 7013712 1 Pump 3600468 1 Auxiliary Pump Assembly (Service Replacement) 7011003 1 Motor 7011016 1 Coupling 7012576 1 Adapter, Motor to Pump

70001108 1 Pump Kit (includes Coupling)

Ref. Note: Original Equipment pump may have been replaced

with Service Replacement Valve. Identify the name plate on pump before ordering parts.

302 4761600 2 Lockwasher 3/8" 303 0641608 2 Bolt 3/8"-16NC x 1" 304 3740067 1 Relay 305 0641406 2 Bolt 1/4"-20NC x 3/4" 306 4751400 2 Flatwasher 1/4" 307 3311405 2 Locknut 1/4"-20NC 308 1060221 1 Cable, Battery

1061003 1 Cable, Battery (Power Deck Only)

309 1060401 1 Cable, Battery

1061004 1 Cable, Battery (Power Deck Only)

310 0840025 2 Boot, Cable

Not Required 0 Boot, Cable (Power Deck Only)

311 0840026 2 Boot, Cable

Not Required 0 Boot, Cable (Power Deck Only)

Ref. FUEL CAP INSTALLATIONS

Ref. Prior To S/N 34451 Installation: 401 1120362 1 Cap, Fuel 402 Not Required

Ref. S/N 34451 To Present Installations:

0257412 Ref. Standard Cap Installation 2 401 1120486 1 Cap, Fuel 402 2200108 1 Plug

0257413 Ref. Protectoseal Cap Installation (Prior to S/N 80990) 1 401 1120485 1 Cap, Protectoseal (Not Shown) 402 2420183 1 Gauge, Fuel (Not Shown)

0270492 Ref. Protectoseal Cap Installation (S/N 80990 to Present) 1 401 1120485 1 Cap, Protectoseal (Not Shown) 402 Not Used

3120830 400RTS 500RTS 2-7

SECTION 2 GROUND CONTROLS

FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516)

2-8 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONTROL VALVE ASSEMBLIES

4640786 Ref. CONTROL VALVE ASSEMBLY (WITH LEVELING JACKS

OPTIONS) (STANDARD PARTS)

1Not Used 2 4641094 1 Valve Assembly (Lift)

7021322 1 Solenoid

7012725 1 Seal Kit

7012754 1 Repair Kit, Push Button End Cap (Includes Rubber

Boot, Metal End Cap, O-Ring, and Metal Retainer) 3Not Used 4 4641090 1 Valve Assembly (Front Steer)

7012730 2 Solenoid 7012725 1 Seal Kit 7012754 2 Repair Kit, Push Button End Cap (Includes Rubber Boot,

Metal End Cap, O-Ring, and Metal Retainer)

5 to 8 Not Used

9 7012941 1 Cartridge (Less Coil) (Outrigger Dump)

7012944 1 Coil 7010543 1 Seal Kit

10 7012941 1 Cartridge (Less Coil) (Brake Valve)

7012944 1 Coil 7010543 1 Seal Kit

11 7012910 1 Cartridge (Less Coil) (Main Dump)

7012943 1 Coil 2900756 1 Seal Kit

12 7012940 1 Cartridge (Outrigger Dump)

7012942 1 Seal Kit

13 7012935 1 Cartridge (Rear Steer Shuttle Valve)

7012518 1 Seal Kit

14 7012935 1 Cartridge (Front Steer Shuttle Valve)

7012518 1 Seal Kit

15 7012935 1 Cartridge (Brake Shuttle Valve) (Hydraforce LS10-30)

7012518 1 Seal Kit (LS10-30 Valve) 7010542 1 Cartridge (Brake Shuttle Valve) (Hydraforce LS08-30)

7010543 1 Seal Kit (L508-30 Valve) 16 Not Used 17 7012939 1 Cartridge (Main Relief Pressure Setting)

2900708 1 Seal Kit 18 7012938 1 Cartridge (Rear Steer Pressure Setting)

2900708 1 Seal Kit 19 7012938 1 Cartridge (Front Steer Pressure Setting)

2900708 1 Seal Kit 20 7012937 1 Cartridge (Traversing Deck Pressure Setting)

2900708 1 Seal Kit 21 7012936 1 Cartridge (Lift Down Speed)

7017477 1 Seal Kit

3120830 400RTS 500RTS 2-9

SECTION 2 GROUND CONTROLS

FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. CONTROL VALVE OPTIONS —

51 4 Leveling Jack Valves Option:

7012591 Cover Assembly (Includes Seals and Hardware) (Without

Leveling Jacks) 4640789 Valve Assembly (With Leveling Jacks) (Prior to S/N 54922) 7012730 8 Solenoid (2 Per Assembly) 7012725 4 Seal Kit (1 Per Assembly) 7012736 4 Orifice - 1.2mm (P Port) (1 Per Assembly) 7012754 8 Repair Kit, Push Button End Cap (Includes: Rubber Boot,

Metal End Cap, O-Ring and Metal Retainer) 4641091 Valve Assembly (With Leveling Jacks) (S/N 54922 to Present) 7018991 8 Solenoid (2 Per Assembly) 7012773 4 Seal Kit (1 Per Assembly)

52 1 Platform Extension Valves Option:

7012591 Cover Assembly (Includes Seals and Hardware) (Without

Platform Extensions)

4640788 Valve Assembly (With Platform Extension) (Prior to S/N

54922) 7012730 2 Solenoid 7012725 1 Seal Kit 4641090 Valve Assembly (With Platform Extension) (S/N 54922 to

Present) 7018991 2 Solenoid 7012773 1 Seal Kit 3931032 4 Bolt, Socket Head #10-24NC x 2" (With Platform Extension) 7012754 2 Repair Kit, Push Button End Cap (Includes:

Rubber Boot, Metal End Cap, O-Ring and Metal Retainer)

Ref. Note: Original Equipment Valve may have been replaced with

Service Replacement Valve. Identify the name plate on valve before ordering parts.

53 1 Rear Steer Valve Option:

7012591 Cover Assembly (Includes Seals and Hardware) (Without

Rear Steer) 4640788 Valve Assembly (With Platform Extension) (Prior to S/N

54922) 7012730 2 Solenoid 7012725 1 Seal Kit 4641090 Valve Assembly (With Platform Extension) (S/N 54922 to

Present) 7018991 2 Solenoid 7012773 1 Seal Kit 3931032 4 Bolt, Socket #10-24NC x 2" (With Rear Steer) 7012754 2 Repair Kit, Push Button End Cap (Includes: Rubber Boot,

Metal End Cap, O-Ring and Metal Retainer)

Ref. Note: Original Equipment Valve may have been replaced with

Service Replacement Valve. Identify the name plate on valve before ordering parts.

2-10 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-11

SECTION 2 GROUND CONTROLS

FIGURE 2-3. CONTROL VALVE ASSEMBLY (S/N 107516 TO PRESENT)

2-12 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-3. CONTROL VALVE ASSEMBLY (S/N 107516 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641190 Ref. CONTROL VALVE ASSEMBLY B

1 7012936 1 Cartridge (Lift Down Speed)

7017477 1 Seal Kit

2 7010542 2 Cartridge (Brake Shuttle Valve) (Hydraforce LS08-30)

7010543 2 Seal Kit (L508-30 Valve)

3 7017420 1 Cartridge, Relief (Steer)

7012998 1 Seal Kit - 7017420 Cartridge

4 7023988 1 Cartridge, Relief (Deck)

7012998 1 Seal Kit - 7023988 Cartridge

5 7023989 1 Cartridge, Relief (Main)

7017496 1 Seal Kit - 7023989 Cartridge

6 7012941 1 Cartridge (Less Coil) (Brake Valve)

7012944 1 Coil 7010543 1 Seal Kit

7 7017433 2 Cartridge (Less Coil) (Steer Valve)

7012944 4 Coil 7017402 2 Seal Kit

8 7023990 1 Cartridge (Less Coil) (Lift Valve)

7023994 1 Coil 7012925 1 Seal Kit

9 7012910 1 Cartridge (Less Coil) (Main Dump)

7012943 1 Coil 2900708 1 Seal Kit

10 7017454 4 Cartridge (Less Coil)

7012943 9 Coil

7012903 4 Seal Kit 11 Not Serviced 1 Plug, Orifice 12 7017492 1 Plug, Orifice 13 Not Serviced 1 Plug, Orifice 14 7017493 4 Plug, Orifice

4641197 Ref. CONTROL VALVE (STEER) B

101 7012981 1 Cartridge

7012998 1 Seal Kit

102 7010542 1 Cartridge (Shuttle Valve) (Hydraforce LS08-30)

7010543 1 Seal Kit (L508-30 Valve)

103 7017433 1 Cartridge (Less Coil) (Steer Valve)

7012539 2 Coil

7017402 1 Seal Kit

3120830 400RTS 500RTS 2-13

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411

2-14 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ENGINE ASSEMBLIES 0253307 Ref. ENGINE ASSEMBLY - STANDARD GAS 8 0253309 Ref. ENGINE ASSEMBLY - DUAL FUEL 8

1 2000118 1 Engine 2 3600164 1 Pump Assembly - Sunstrand (See Figure 2-13 for Breakdown) 3 3600205 1 Pump Assembly - Barnes (See Figure 2-14 for Breakdown) 4 4843497 1 Bracket, Engine Mounting 5 3533445 1 Plate, Governor and Carburetor Mounting 6 Use 2902064 1 Controller, Governor (Was p/n 1600117) 7 2500005 1 Governor, Precision 8 0641410 4 Bolt 1/4"-20NC x 1 1/4"

9 4761400 9 Lockwasher 1/4" 10 3311401 9 Nut 1/4"-20NC 11 0901419 2 Bracket, Controller 12 4751400 5 Flatwasher 1/4" 13 0641408 1 Bolt 1/4"-20NC x 1" 14 3911012 4 Screw, Machine #10-24NC x 3/4" 15 3311001 4 Nut #10-24NC 16 4751000 6 Flatwasher #10 17 4761000 8 Lockwasher #10 18 0100009 A/R Adhesive 19 3533291 1 Plate, Engine 20 0701014 5 Bolt, Metric M10 x 30MM 21 4832000 5 Lockwasher, Metric M10 22 3200202 2 Mount, Engine - Rear 23 3200201 1 Mount, Engine - Front 24 4740273 2 Washer, Snubbing 25 4751700 4 Flatwasher 7/16" 26 0641726 2 Bolt 7/16" - 14NC x 3 1/4" 27 3311705 2 Locknut 7/16" - 14NC 28 4740274 1 Washer, Snubbing 29 0641826 1 Bolt 1/2"-13NC x 3 1/4" 30 4751800 1 Flatwasher 1/2" 31 3311805 2 Locknut 1/2"-13NC 32 0641608 8 Bolt 3/8"-16NC x 1" 33 4761600 8 Lockwasher 3/8" 34 3311601 8 Nut 3/8"-16NC 35 1060221 1 Cable, Battery (Engine to Ground) 36 0641812 3 Bolt 1/2"-13NC x 1 1/2" (S/N 37789 to Present) 37 4761800 2 Lockwasher 1/2"

38 to 39 Not Used

40 0901858 1 Bracket, Exhaust Support 41 1 Adapter, Carburetor

0080092 Adapter, Carburetor (Standard Gas)

Adapter, Carburetor (Dual Fuel) (See Figure 2-5 for Call-out)

42 3311405 1 Locknut 1/4"-20NC

3120830 400RTS 500RTS 2-15

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

43 1 Stud Options:

4300056 Stud (Standard Gas)

Stud (Dual Fuel) (See Figure 2-5 for Call-out) 44 3841049 1 Rod, Throttle 45 3321402 2 Nut, Jam 1/4"-28NF 46 1660157 2 Ball-joint 47 Not Used 48 2220273 1 Fitting, Reducer 49 2180360 1 Fitting, Tee 50 2420033 1 Sender, Oil Pressure 51 4360357 1 Switch, Pressure 52 2120135 1 Filter, Pressure

2120136 1 Element, Filter 53 1320014 2 Clamp, Hose 54 1 Adapter, Air Intake Options:

0080175 Adapter, Air Intake (Standard Gas)

Adapter, Air Intake (Dual Fuel) (See Figure 2-5 for Call-out)

55 1 Plug Options:

3520046 Plug (Standard Gas)

Not Required Plug (Dual Fuel) 56 2720341 1 Hose - Air Cleaner Outlet 57 1320058 1 Clamp, Hose 58 2180537 1 Fitting, Nipple 59 2200261 1 Fitting, Pipe Coupling 60 1 Bracket Options:

0901778 Bracket (Standard Gas)

1 Bracket (Dual Fuel) (Figure 2-5 for Call-out) 61 3790152 1 O-Ring 62 0641610 2 Bolt 3/8"-16NC x 1 1/4" 63 4740185 2 Washer, Hardened

64 to 66 Not Used

67 3911014 2 Screw, Machine #10-24NC x 7/8" 68 0641810 2 Bolt 1/2"-13NC x 1 1/4" (Prior to S/N 37789) 69 2720042 70 1320032 2 Clamp 71 4300090 2 Stud 72 3321501 2 Nut 5/16"-24NF 73 3536481 1 Plate, Engine Mounting 74 2420118 1 Sender, Temperature 75 0140001 1 Horn 76 2060019 1 Fan and Spacer Kit 77 Not Used 78 0721008 2 Screw, Machine #10-24NC x 1" 79 Not Used 80 4031709 1 Screw m6-1.25 x 25mm (S/N 31574 to Present) 81 3290607 1 Locknut m6-1.25 (S/N 31574 to Present) 82 0100019 A/R Loctite (Not Shown) (S/N 31574 to Present) 83 0100020 A/R Loctite (Not Shown) (S/N 31574 to Present)

18 in/46cm

Hose

2-16 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0253308/0253310 Ref. ENGINE INSTALLATION (STANDARD PARTS) 2/1

101 Not Used 102 4565830 1 Tube, Manifold 103 3220084 1 Muffler 104 1320019 1 U-Clamp 105 1 Bracket, Exhaust Hanger Options:

0901387 1 Prior to S/N 34962

0902382 1 S/N 34962 to Present 106 4565956 1 Tailpipe 107 1320058 3 Clamp, Hose 108 4844298 1 Tube, Air Intake 109 0080039 1 Elbow, Rubber 110 1340020 1 Air Cleaner Assembly

7004214 1 Element 111 0340002 2 Band, Air Cleaner Mounting 112 1120161 1 Cap, Air Inlet 113 0641406 4 Bolt 1/4"-20NC x 3/4" 114 4761400 4 Lockwasher 1/4" 115 3311401 4 Nut 1/4"-20NC 116 2220675 1 Fitting, 90° 117 4761600 9 Lockwasher 3/8" 118 3311601 9 Nut 3/8"-16NC 119 0641710 2 Bolt 7/16"-14NC x 1 1/4" 120 3533663 1 Plate, Radiator Mounting 121 0630403 2 Bolt, Carriage 7/16"-14NC x 1 1/2" 122 4751700 2 Flatwasher 7/16" 123 3311705 2 Locknut 7/16"-14NC 124 4761700 2 Lockwasher 7/16" 125 3311701 2 Nut 7/16"-14NC 126 3533664 1 Plate, Radiator Support 127 0630360 1 Bolt, Carriage 5/16"-18NC x 1 1/4" 128 4751500 5 Flatwasher 5/16" 129 3311501 5 Nut 5/16"-18NC 130 0641508 1 Bolt 5/16"-18NC x 1" 131 4761500 2 Lockwasher 5/16" 132 0641610 6 Bolt 3/8"-16NC x 1 1/4" 133 4751600 15 Flatwasher 3/8" 134 4060713 1 Shield 135 3536151 1 Guard, Exhaust 136 1320022 2 Clamp 137 2720058 6 ft./1.8m Hose, Fuel Line 138 0721004 3 Bolt #10-24NC x 1/2" 139 Not Used 140 0400003 1 Battery 141 3980003 1 Masonite 142 1060254 1 Cable, Battery (Battery + to Starter Solenoid) 143 3300029 2 Wingnut 3/8"-16NC 144 3536144 1 Cover, Battery

3120830 400RTS 500RTS 2-17

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

145 1060360 1 Cable, Battery (Battery Neg to Ground) 146 0630370 2 Rod, Tie-Down 147 0400002 1 Tie-Down, Battery

2910479 2 Clips, Tie Down 148 3620027 1 Radiator 149 Not Used 150 1320020 1 U-Clamp 1 1/2" 151 1320026 1 U-Clamp 1 3/4"

0252808 Ref. PUMP COUPLING INSTALLATION (STANDARD PARTS) —

201 1660207 1 Coupling, Pump 202 0080163 1 Adapter, Pump Mounting 203 0700808 6 Bolt, Metric 8mm 1.25 x 16mm 204 4831900 6 Lockwasher, Metric 8mm 205 0641610 8 Bolt 3/8"-16NC x 1 1/4" 206 4761600 8 Lockwasher 3/8"

— — — — — — — — — —

3020021 A/R Grease, Coupling

Note: Coupling Spine must be greased with lithium soap based grease prior to installation.

0250815 Ref. ENGINE HEATER INSTALLATION (OPTIONAL - NOT SHOWN) A

2580026 1 Heater, Engine Coolant (Located at Rear of Cylinder Head)

0701020 2 Bolt, Metric 10mm x 6mm

4564328 2 Spacer, Tube

Ref. SPARE COMPONENTS

301 7000892 1 Carburetor (Standard Gas)

1140009 1 Carburetor (LP Gas)

— — — — — — — — — —

Use 7019933 1 Carburetor Rebuild Kit (p/n was 7000878)

7023471 1 Assembly, Float (Not Shown)

70000163 1 Needle-Spring Load Fuel Valve

7012577 1 Fitting, Vacuum Line

7012578 1 Vacuum Line Assembly

7000884 1 Fuel Shut-Off

7024321 1 Gasket, Carburetor (Top)

7027607 1 Gasket, Carburetor (Bottom) 302 7012564 1 Wiring Harness

7014682 1 Tune-Up Kit (Includes Oil and Fuel Filters, Spark Plugs and

Wire Set) (“Push On” Spark Plug Wires) 7019998 1 Coil Pack (“Push On” Spark Plug Wires) 7023669 1 Plug Wire Set (“Push On” Spark Plug Wires) 7023668 1 Tune-Up Kit (Includes Oil and Fuel Filters, Spark Plugs and

Wire Set) (“Clip On” Spark Plug Wires) 7019939 1 Filter, Fuel (Not Shown) 7019949 1 Filter, Oil (Not Shown)

2-18 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

302 (cont’d) 7019987 1 Coil Pack (“Clip On” Spark Plug Wires)

7019989 1 Plug Wire Set (“Clip On” Spark Plug Wires) 7014682 1 Tune-Up Kit (Includes Oil and Fuel Filters, Spark Plugs and

Wire Set)

7014680 1 Spare Components Kit (Includes Carburetor, Fuel Pump, Water

Pump, Bosch Alternator, Starter and Ignition Control)

303 1 Alternator Options:

7000893 Bosch 7019670 Prestolite (was p/n 7012653) 7019934 1 Belt, Alternator

7019935 1 Pulley, Alternator 304 Use 7023670 1 Control, Ignition (was p/n 7019665) 305 3960423 1 Gasket, Thermostat (Not Shown)

7014687 1 Spare Components Kit (Includes Carburetor, Fuel Pump, Water

Pump, Prestolite Alternator, Starter and Ignition Control)

306 7019666 1 Pump, Fuel (Not Shown)

7019952 1 Separator, Fuel (Not Shown)

7025153 1 Gasket, Fuel Pump (Not Shown) 307 7019667 1 Cap, Oil Filler (Not Shown) 308 7019668 1 Starter 309 7019936 1 Pulley, Crankshaft (Not Shown) 310 7019937 1 Pulley, Water Pump (Not Shown)

7019938 1 Outlet, Water (Not Shown)

7019945 1 Hose, Bypass (Not Shown) 311 7019951 1 Pump, Water (Not Shown)

7019941 1 Hose, Radiator (Upper)

7019943 1 Hose, Radiator (Lower)

7019942 1 Hose, Water Pump/Intake Inlet 312 7019944 1 Block Assembly, 11-Stud Terminal (Not Shown) 313 7019946 1 Flange, Exhaust Pipe (Not Shown)

7019947 1 Gasket, Exhaust Pipe Flange (Not Shown) 314 7019948 1 Manifold, Exhaust Outlet (Not Shown) 315 7019950 1 Thermostat 316 7019987 1 Coil, Ignition (Not Shown) 317 7019954 1 Harness, Ignition Module Patch (Not Shown) 318 7019959 1 Dipstick (Not Shown)

0251945 Ref. ENGINE DISTRESS SWITCH INSTALLATION (OPTIONAL) B

401 to 403 Not Used

404 2420131 1 Sender, Oil Pressure

0253875 Ref. SPARK ARRESTOR INSTALLATION (OPTIONAL) —

501 3220083 1 Arrestor, Spark (Includes Mounting Hardware)

0253902 Ref. SPIN-ON FUEL FILTER INSTALLATION (OPTIONAL) A

601 2120138 1 Filter, Fuel 602 0901932 1 Bracket, Mounting

3120830 400RTS 500RTS 2-19

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

603 4300068 2 Stud (Welded on Part) 604 4751400 4 Flatwasher 1/4" 605 4761400 4 Lockwasher 1/4" 606 0641406 2 Bolt 1/4"-20NC x 3/4" 607 2220459 1 Fitting, 90° 608 2220315 2 Fitting 609 1320022 2 Clamp 610 2220273 1 Fitting, Reducer 611 0100020 A/R Sealant, Pipe 612 3311401 2 Nut 1/4"-20NC

2-20 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-21

SECTION 2 GROUND CONTROLS

FIGURE 2-5. DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION

2-22 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-5. DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0250790 Ref. DUAL FUEL INSTALLATION - VSG 411 FORD F

1 3720011 1 Regulator, LPG 2 2220364 2 Fitting, Adapter 3 2180535 2 Fitting, Barbed 4 2220648 1 Fitting, 90° 5 2120077 1 Filter-Lock 6 2220003 1 Fitting, Swivel 7 2220675 1 Fitting, 90° 8 2720112

9 2720042 10 2720118 1 Hose, LP (48 in./1.22m Length) 11 1320032 A/R Clamp 12 2180104 1 Fitting 13 2180360 1 Fitting, Tee 14 4360188 1 Switch, Vacuum 15 2180536 1 Fitting, Barbed 16 2180623 1 Fitting, Tee 17 0641405 2 Bolt 1/4"-20NC x 5/8" 18 4761400 2 Lockwasher 1/4" 19 2180387 1 Fitting, Tank Connector 20 Not Used 21 0901778 1 Bracket 22 Not Used 23 0080167 1 Adapter, Air Intake 24 0080092 1 Adapter, Carburetor 25 3840979 1 Rod 26 Not Used 27 1700818 1 Decal - Liquid LPG 28 Not Used 29 Not Used 30 1320023 2 Clamp, LP Tank 31 4640391 1 Valve, Gasoline 32 1320095 1 Clamp, Support 33 2220805 2 Fitting, Straight 34 1320022 2 Clamp 35 2220290 1 Fitting, Tee 35 2220290 1 Fitting, Tee 36 2180389 1 Fitting, Pressure Relief 37 4400040 2 Tank, LP (33.5 Lbs.)

4400275 2 Tank, LP (43.5 Lbs.)

24 in./.61m

28 in./.71m

Hose, LP Hose, Heater

0253447 Ref. LP TANK BRACKETS INSTALLATION —

101 4844185 2 Support, Tank Bracket 102 0641522 2 Bolt 5/16"-18NC x 2 3/4" 103 4761500 2 Lockwasher 5/16" 104 3311501 2 Nut 5/16"-18NC 105 0641610 8 Bolt 3/8"-16NC x 1 1/4"

3120830 400RTS 500RTS 2-23

SECTION 2 GROUND CONTROLS

FIGURE 2-5. DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

106 4751600 8 Flatwasher 3/8" 107 4761600 8 Lockwasher 3/8" 108 3311601 Nut 3/8"-16NC

2-24 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-5. DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-25

SECTION 2 GROUND CONTROLS

FIGURE 2-6. 110 VOLT GENERATOR INSTALLATION (FORD VSG-411) (OPTIONAL)

2-26 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-6. 110 VOLT GENERATOR INSTALLATION (FORD VSG-411) (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0250444 Ref. 110 VOLT GENERATOR INSTALLATION (FORD VSG-411)

(OPTIONAL) (PRIOR TO JULY 1994)

0255037 Ref. 110 VOLT GENERATOR INSTALLATION (FORD VSG-411)

(OPTIONAL) (JULY 1994 TO PRESENT)

1 3580134 1 Pulley

2 2460011 1 110 Volt Generator

7003657 1 Control Box Assembly

1 Note: Replacement 110V Control Box comes with 2 stan-

dard Receptacles p/n 4460190. Optional Industrial Twist Lock Receptacles p/n 44600027 must be ordered separately.

2420203 1 Voltmeter 4360542 1 Breaker, Circuit 2920162 1 Lamp 7020191 1 Switch, Toggle 3520028 1 Plug, Hole 7012558 1 Generator Assembly 7026199 1 Armature with Slip Rings 7020108 4 Brushes 7020109 4 Holders, Brush 7012513 4 Cap, Brush Holder 3580134 1 Pulley 7012514 1 Fan 7020193 1 Cord, Power 7020110 1 Bell End, Front 7020111 1 Bell End, Rear

7020190 2 Bearing 3 7027887 1 Keystock 4 0901650 1 Bracket, Generator Mounting 5 4340569 1 Support, Adjustable 6 0480057 1 V-Belt 7 1360037 1 Sender, Oil (July 1994 to Present) 8 4761600 4 Lockwasher 3/8" 9 3311601 2 Nut 3/8" - 16NC

10 0641511 1 Bolt 5/16"-18NC x 1 3/8" 11 4751500 2 Flatwasher 5/16" 12 4761500 2 Lockwasher 5/16" 13 0961247 1 Bushing 14 0641507 1 Bolt 5/16"-18NC x 7/8” 15 0901609 1 Bracket, Box Mounting 16 3911004 2 Screw, Machine #10-24NC x 1/2" 17 3311001 2 Nut #10-24NC 18 4761000 2 Lockwasher #10 19 Not Used 20 0681610 2 Bolt 3/8"-16NC x 1 1/4" (Grade 8) 21 4751600 2 Flatwasher 3/8" 22 2180749 1 Fitting, 45º (July 1994 to Present) 23 2180360 1 Fitting, Tee (July 1994 to Present)

3120830 400RTS 500RTS 2-27

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423

2-28 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0254965/0254963 Ref. ENGINE ASSEMBLY (STANDARD PARTS) C/C

1 2000125 1 Engine (Includes 301 thru 303) 2 3600164 1 Pump Assembly - Sunstrand (See Figure 2-13 for Breakdown) 3 3600205 1 Pump Assembly - Barnes (See Figure 2-14 for Breakdown) 4 2720232 1 Hose, Radiator (Bottom) 5 0641810 2 Bolt, 1/2"-13NC x 1 1/4" 6 4761800 2 Lockwasher 1/2" 7 1320012 4 Clamp, Hose 8 4761600 A/R Lockwasher 3/8" 9 2720254 1 Hose, Radiator (Top)

10 3737289 1 Plate, Engine Mounting 11 0711014 4 Bolt 10mm x 30mm 12 Not Used 13 0711020 2 Bolt 10mm x 60mm 14 4562637 2 Spacer 15 4740273 3 Washer, Snubbing 16 3200362 3 Mount, Engine 17 0641826 3 Bolt 1/2"-13NC x 3 1/4" 18 3311805 3 Nut, Lock 1/2" 19 4751800 3 Flatwasher 1/2" 20 4740185 2 Washer, Hardened 21 Not Used 22 2060025 1 Fan 23 0901401 1 Bracket, Terminal Strip 24 1700901 1 Decal, Terminal Cable 25 1670414 1 Cover, Terminal Strip 26 1320070 2 Clamp, Wire 27 3910812 2 Screw #8-32NC x 3/4" 28 4770800 2 Starwasher #8 29 3310801 2 Nut #8-32 30 0100020 A/R Loctite 31 2180360 1 Fitting, Tee 32 4360357 1 Switch, Oil Pressure 33 2220273 1 Fitting, Reducer 34 2420131 1 Sender, Oil Pressure 35 2420149 1 Sender, Water Temperature

36 to 37 Not Used

38 0080092 1 Adapter, Choke 39 Not Used 40 1060045 1 Cable 41 4751600 12 Flatwasher 3/8" 42 0641406 20 Bolt 1/4"-20NC x 3/4" 43 4751400 40 Flatwasher 1/4" 44 3311405 3 Locknut 1/4" 45 Not Used 46 0701010 7 Bolt 10mm x 20mm 47 4740116 7 Lockwasher 10mm 48 4564281 1 Tube, Dipstick

3120830 400RTS 500RTS 2-29

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

49 2420109 1 Gauge, Dipstick 50 3790152 1 O-Ring, Pump 51 4921714 1 Harness, Wiring (Not Shown) 52 Not Used 53 2720015 10 in. Hose 54 1320022 2 Clamp, Hose

55 to 61 Not Used

62 4844613 1 Exhaust Manifold

63 to 66 Not Used

67 1120432 1 Cap, Vacuum 68 Not Used 69 4360056 1 Stud, Carb 70 0901978 1 Bracket, Muffler Mounting 71 3220089 1 Muffler, Spark Arrestor 72 0340041 2 Clamp, Muffler 73 0641506 4 Bolt 5/6"-18NC x 3/4" 74 4751500 A/R Flatwasher 5/16" 75 3311505 6 Locknut 5/16" 76 3538178 1 Plate, Engine Tray 77 0641608 8 Bolt, 3/8"-16NC x 1" 78 3311601 6 Nut 3/8" 79 4340660 1 Support, Radiator 80 4300038 2 Stud 81 4751700 2 Flatwasher 7/16" 82 4761700 2 Lockwasher 7/16" 83 3311701 2 Nut 7/16" 84 0630375 2 Bolt, Carriage 7/6"-16NC x 1" 85 3940804 6 Screw, Self Tapping #8-32 x 1" 86 4750800 6 Flatwasher #8 87 2680336 1 Fan Shroud 88 1320019 1 Clamp, Muffler 89 0641610 8 Bolt 3/8"-16NC x 1 1/4" 90 3311605 8 Locknut 3/8"

91 to 95 Not Used

96 3620026 1 Radiator 97 1600098 1 Controller, Engine 98 0901419 1 Bracket

99 0641006 4 Bolt #10-24NC x 3/4 Lg. 100 4751000 4 Flatwasher #10 101 3311005 4 Locknut #10-24 102 0902092 1 Bracket 103 2120135 1 Filter, Charge 104 3740061 1 Relay, Start Lockout 105 3740059 1 Relay

106 to 107 Not Required

108 0902093 1 Bracket, Relay Mounting 109 0641510 2 Bolt 110 4761500 2 Lockwasher

111 to 112 Not Required

2-30 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0254964/0254966 Ref. ENGINE INSTALLATION 4/D

120 to 121 Not Used

122 2 Bracket, Exhaust Hanger Options:

0901387 Prior to S/N 34962

0902382 S/N 34962 to Present 123 1320011 3 Clamp, Muffler 124 0641508 2 Bolt 5/16"-18NC x 1" 125 4751500 8 Flatwasher 5/16" 126 3311505 6 Locknut 5/16" 127 3533664 1 Plate, Radiator Support 128 0630360 2 Bolt, Carriage 5/16"-18NC x 1 1/4" 129 4566520 1 Tube, Exhaust 130 3536151 1 Plate, Exhaust Guard 131 1320058 4 Clamp, Hose 132 4566541 1 Tube, Air Intake 133 0080039 1 Adapter, Elbow 134 1340020 1 Air Cleaner

7004214 1 Element 135 1120161 1 Bonnet 136 0340002 2 Band, Mounting 137 0641408 4 Bolt 1/4"-20NC x 1" 138 4751400 4 Flatwasher 1/4" 139 3311405 4 Locknut 1/4" 140 Not Used 141 4761600 3 Lockwasher 3/8" 142 3311601 3 Nut 3/8" 143 4751600 3 Flatwasher 3/8" 144 3536144 1 Cover, Battery 145 1060360 1 Cable, Battery 146 0630370 2 Tie Down 147 0400002 1 Battery Tie Down

2910479 2 Clips, Tie Down 148 3300029 2 Wingnut 3/8" 149 1060254 1 Cable, Battery 150 0400003 1 Battery 151 3980003 1 Masonite

152 to 154 Not Used

155 0140001 1 Horn 156 Not Required 157 0840025 4 Boot, Cable (Red) 158 Not Used 159 1060221 1 Cable Assembly, 12" 160 1060080 1 Cable Assembly, 30" 161 1060401 1 Cable Assembly, 56"

162 to 166 Not Required

3120830 400RTS 500RTS 2-31

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0238044 Ref. PRECISION GOVERNOR INSTALLATION A

201 0901373 1 Bracket, Governor 202 2500004 1 Governor 203 0641408 7 Bolt 1/4"-20NC x 1" 204 3311401 7 Nut 1/4"-20NC 205 4751400 7 Flatwasher 1/4" 206 4761400 7 Lockwasher 1/4" 207 3840898 1 Rod 208 3321401 2 Nut 1/4"-28NF 209 1660157 2 Coupling, Ball Joint

2000125 Ref. ENGINE SUB-ASSEMBLY —

301 2000088 1 Engine, Ford 423 302 1660212 1 Coupling, Hayes 303 4860155 1 Fly Wheel, Ford

Ref. ENGINE COMPONENTS

7000643 1 Carburetor (Standard Gas) with Built-In Choke 7000878 1 Rebuilt Kit 1140009 1 Carburetor - LP Gas 7000877 1 Fuel Shut-Off (With Wire) 7000884 1 Fuel Shut-Off (With Terminal Post) 7012577 1 Vacuum Line Fitting 7012578 1 Vacuum Line Tube Assembly 7000867 1 Engine Harness 7010633 1 Fuel Pump Assembly 7012595 4 Spark Plug 7014677 1 Major Components Kit (Includes 1 each of Standard Gas Car-

buretor, Water Pump, Fuel Pump, Starter and Standard Alternator)

7014678 1 Gasket, Electrical Kit (Includes Upper and Lower Gasket Kits, 1

each of Thermostat, ring Gear, Belt, Coil, Ignition Module, Voltage Regulator, Starter Solenoid and Hose)

7014679 1 Tune-up Kit (Includes 4 Spark Plugs and 1 each of Oil Filter,

Fuel Filter, Cap, Rotator and Ignition Wire Set)

2-32 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-33

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425

2-34 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ENGINE ASSEMBLY (STANDARD PARTS) OPTIONS:

0255207/0255208 Ref. LRG 423 DIS (PRIOR TO S/N 46528) 7/7 0258320/0258321 Ref. LRG 425 (S/N 46528 TO PRESENT) 6/6

1 2000126 1 Engine, Ford LRG 423 DIS (Prior to S/N 30660)

2000149 1 Engine, Ford LRG 423 DIS (S/N 30660 to S/N 46528)

2000156 1 Engine, Ford LRG 425 (S/N 46528 to S/N 60462)

2000165 1 Engine, Ford LRG 425 (S/N 60462 to Present)

2Not Used 3 3600164 1 Pump Assembly - Sunstrand (See Figure 2-13 for Breakdown)

(Prior to S/N 30660)

3600260 1 Pump Assembly - Sunstrand (See Figure 2-13 for Breakdown)

(S/N 30660 to Present) 4 3200377 1 Mount, Front Engine 5 4566605 1 Tube, Spacer 6 2500005 1 Governor, Precision 7 0902088 1 Bracket, Governor Mounting 8 3841255 1 Rod, Throttle 9 1660157 2 Ball Joint Coupling

10 0902089 1 Bracket, Terminal Mounting Strip 11 0902087 1 Bracket, Fuel Pump Mounting 12 2420149 1 Sender, Water Temperature 13 2420131 1 Sender, Oil Pressure 14 4360357 1 Switch, Oil Pressure 15 2220273 1 Fitting, Reducer 16 2220994 1 Fitting, 1/8" Pipe Cross 17 4300056 1 Stud, Carburetor 18 1 Oil Drain Valve Options:

4640750 Prior to S/N 23751

4640989 S/N 23751 to Present 19 2750532 2.5 ft. Hose, Low Pressure 20 1320032 A/R Clamp, Hose 21 1700901 1 Decal, Terminal Strip 22 1670414 1 Cover, Terminal Strip 23 2220315 1 Fitting, Straight Pipe Barb 24 2720058 1.5 ft. Fuel Line - 5/16" I.D. 25 2180536 1 Fitting, Straight Pipe Barb 26 2720271 2.5 ft. Vacuum Hose - 3/16" I.D. 27 0701022 2 Screw, M10 x 1.5 x 70 Lg. 28 0701014 2 Screw, M10 x 1.5 x 30 Lg. 29 4832000 4 Lockwasher - M10 30 0700810 3 Screw, M8 x 1.25 x 20 Lg. 31 4831900 3 Lockwasher - M8 32 0641812 2 Screw, 1/2"-13NC x 1 1/4" Lg. 33 4761800 2 Lockwasher, 1/2" 34 0641408 A/R Bolt, 1/4"-20NC x 1" Lg. 35 4761400 A/R Lockwasher, 1/4" 36 3311401 A/R Nut, 1/4"-20NC 37 0641406 2 Bolt, 1/4"-20NC x 3/4 Lg.

3120830 400RTS 500RTS 2-35

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

38 2 Screw Options:

3911024 Screw #10-24NC x 1 1/2" Lg. (Prior to S/N 32690) 3911026 Screw #10-24NC x 1 5/8" Lg. (S/N 32690 to S/N 46528) 3911014 Screw #10-24NC x 7/8" Lg. (S/N 46528 to Present)

39 2 Nut Options:

3311001 Nut #10-24NC (Prior to S/N 32690) 3311005 Locknut #10-24NC (S/N 32690 to Present)

40 2 Washer Options:

4761000 Lockwasher, #10 (Prior to S/N 32690)

4751000 Flatwasher, #10 (S/N 32690 to Present) 41 3321401 1 Nut, 1/4"-28NF 42 0701017 2 Screw, M10 x 1.5 x 45 Lg. (Prior to S/N 46528) 43 4564281 1 Tube, Dipstick 44 1 Gauge, Dipstick Options:

2420109 Gauge, Dipstick (Prior to S/N 48837)

2420189 Gauge, Dipstick (S/N 48837 to S/N 60462)

2420187 Gauge, Dipstick (S/N 60462 to Present) 45 3740080 3 Relay, Bosch 46 4100025 2 ft. Guard, Hose 47 0100020 A/R Loctite, #56747 48 1 Switch, Oil Pressure Options:

4360405 Prior to S/N 80259

4360037 S/N 80259 to Present 49 2220437 1 Fitting, Male Pipe 1/4" x 1/8" 50 0902361 1 Bracket, Terminal Strip 51 1320022 2 Clamp, Worm Gear (S/N 99226 to Present)

Ref. ENGINE INSTALLATION OPTIONS:

0255209/0255210 Ref. LRG 423 DIS (PRIOR TO S/N 46528) 5/8 0258319/0258322 Ref. LRG 425 (S/N 46528 TO PRESENT) 7/8

101 Not Required 102 1320012 4 Clamp, Hose Worm Gear 103 2060014 1 Fan, 16" Pusher 104 0080212 1 Adapter, Fan Spacer 105 0700822 4 Screw, M8 x 1.25 x 70 Lg. 106 4831900 4 Lockwasher - M8 107 3620026 1 Radiator 108 0181781 1 Bracket, Radiator Support 109 0630360 1 Bolt, 5/16"-18NC x 1 1/4" Lg. 110 4751500 4 Flatwasher, 5/16" 111 3311505 4 Locknut, 5/16"-18NC 112 2 Bolt Options:

0630375 Bolt, 7/16"-14NC x 1" Lg. (Prior to S/N 46528)

0630403 Bolt, 7/16"-14NC x 1 1/2" Lg. (S/N 46528 to Present)

113 4751700 2 Flatwasher, 3/16" 114 3311701 2 Nut, 7/16"-14NC 115 2680386 1 Fan Shroud

2-36 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

116 6 Flatwasher Options:

4750800 Flatwasher, #8 (Prior to S/N 46528) 4751000 Flatwasher, #10 (S/N 46528 to Present)

117 6 Screw Options:

3940804 Screw, #8-32NC x 1" Lg. Self-Tap (Prior to S/N 46528) 3941004 Screw, #10-24NC x 1/2" Lg. Self-Tap (S/N 46528 to Pres-

ent)

118 1 Engine Tray Options:

4844942 Engine Tray - LRG 423 DIS (Prior to S/N 46528)

4845757 Engine Tray - LRG 425 (S/N 46528 to Present) 119 3200362 3 Mount, Engine 120 4740274 3 Washer, Snubbing 121 0641826 3 Screw, 1/2"-13NC x 3 1/4" Lg. 122 4751800 6 Flatwasher, 1/2" 123 3311805 3 Locknut, 1/2"-13NC 124 0641608 8 Screw, 3/8"-16NC x 1" Lg. 125 4751600 28 Flatwasher, 3/8" 126 3311605 14 Locknut, 3/8"-16NC 127 1 Cable Options:

1060045 Cable (Prior to S/N 64796)

1060221 Cable (S/N 64796 to Present) 128 1600211 1 Controller 129 0901419 1 Bracket 130 0721006 4 Screw #10-24NC x 3/4" Lg. 131 4751000 4 Flatwasher, #10 132 3311005 6 Locknut, #10-24 133 0641407 A/R Screw, 1/4"-20NC x 7/8" Lg. 134 4751400 A/R Flatwasher, 1/4" 135 3311405 A/R Locknut, 1/4"-20NC 136 0902092 1 Bracket, Filter Mount 137 0140001 1 Horn (Prior to S/N 112737) 138 2120135 1 Filter, Charge Pressure

2120136 1 Element, Charge Filter 139 3600205 1 Pump, Gear (See Figure 2-14 for Breakdown) 140 0641610 8 Screw, 3/8"-16NC x 1 1/4" Lg. 141 4761600 2 Lockwasher, 3/8" 142 1340020 1 Air Cleaner

7004214 1 Element, Air Cleaner 143 0340002 2 Mounting Band 144 1120161 1 Bonnet, Air Inlet 145 0080039 2 Adapter, Elbow 146 1320058 6 Clamp, Hose - Worm Gear 147 4561815 1 Tube, Air Inlet (Standard Gas)

4567127 1 Tube, Air Inlet (Dual Fuel) 148 4566673 1 Tube, Air Intake 149 0080124 1 Adapter 150 0080092 1 Adapter, Choke 151 0701010 4 Screw M10 x 1.5 x 20 152 4832000 4 Lockwasher, M10 153 4844962 1 Exhaust Manifold

3120830 400RTS 500RTS 2-37

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

154 0340041 2 Clamp, 2" Muffler (Prior to September 1995)

1320019 2 Clamp, 2" Muffler (September 1995 to Present) 155 4566672 1 Tube, Exhaust 156 3220095 1 Muffler, Spark Arrest 157 0901387 1 Bracket (Prior to S/N 34962)

0902382 1 Bracket (S/N 34962 to Present) 158 1320011 1 Clamp, 2 1/2" Muffler

1320011 1 Clamp, 2 1/2" Muffler (Dual Fuel) (Prior to S/N 83238)

1320021 1 Clamp, 2 1/4" Muffler (Dual Fuel) (S/N 83238 to Present) 159 1060360 1 Cable 160 0630370 2 Rod, Tie Down 161 1 Tie Down, Battery Options:

0400002 Tie Down, Battery (Prior to S/N 46528)

2910479 Clips

0400174 Tie Down, Battery (S/N 46528 to Present) 162 3300029 2 Wing Nut, 3/8"-16NC 163 1 Plate, Battery Cover Options:

3536144 Ford LRG 423 DIS (Prior to S/N 46528)

1670841 Ford LRG 425 (S/N 46528 to Present) 164 1060254 1 Cable 165 1 Battery, 12 Volt Options:

0400003 Ford LRG 423 DIS (Prior to S/N 46528)

0400075 Ford LRG 425 (S/N 46528 to Present) 166 1 Masonite Options:

3980003 Ford LRG 423 DIS (Prior to S/N 46528)

3980007 Ford LRG 425 (S/N 46528 to Present) 167 3538735 1 Plate, Exhaust Cover 168 Not Used 169 4921746 1 Wiring Harness 170 3911012 4 Screw #10-24NC x 3/4" 171 1320022 6 Clamp, Worm Gear 172 2720015 10 ft. Hose 1/4" 173 2720160 2 ft. Hose, Low Pressure 1/2" 174 2 Vacuum Cap Options:

1120342 Vacuum Cap (Prior to S/N 64796)

1120432 Vacuum Cap (S/N 64796 to Present) 175 4740185 1 Flatwasher (S/N 46528 to Present) 176 1320180 5 Clamp, Worm Gear (S/N 46528 to Present) 177 4761700 2 Lockwasher 7/16” (S/N 46528 to Present) 178 Not Used 179 2220315 1 Fitting, Straight (S/N 46528 to Present) 180 0840046 1 Boot, Battery Pos. (S/N 103576 to Present) 181 0840047 1 Boot, Battery Neg. (S/N 103576 to Present)

— — — — — — — — — —

0100020 A/R Sealant, Pipe

2-38 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2000126/2000149

301 7012680 1 Alternator 302 Use 1660249 1 Coupling (13 Teeth) (Prior to S/N 30660) (was p/n 7012656)

Use 1660250 1 Coupling (15 Teeth) (S/N 30660 to S/N 46528) (was p/n

303 7012681 1 Module, Ignition 304 7012679 1 Starter (Not Shown)

7025145 1 Solenoid, Starter 305 Use 7021869 1 Filter, Oil (was p/n 7014501) 306 7012690 1 Carburetor

7019933 1 Carburetor Kit

7012683 1 Spring

7023471 1 Float Assy 307 7016600 1 Pump, Fuel

7012678 1 Pump, Fuel (Electric)

7000884 1 Solenoid, Fuel

7016601 1 Filter, Fuel 308 7016605 1 Choke, Automatic 309 Use 7019926 1 Hose, Radiator (Top) (was p/n 7016375) 310 Use 7019927 1 Hose, Radiator (Bottom) (was p/n 7016376) 311 Use 7022153 1 Pump, Water (Not Shown) (was p/n 7016638) 312 7019976 1 Flywheel

7022180 1 Ring Gear

7020120 1 Bell Housing 313 7022143 1 Gasket, Exhaust Manifold (Not Shown) 314 70002307 1 Gasket, Exhaust Pipe (Not Shown)

7025126 1 Gasket, Intake Manifold to Head (Not Shown)

7019924 1 Manifold, Exhaust (Not Shown) 315 7022150 1 Belt, Timing (Engine 2000126) 316 7019921 1 Belt, Alternator (Engine 2000126) 317 4360157 1 Switch, Water Temperature (Not Shown) 318 7012682 1 Harness, Engine (Not Shown) 319 7019925 1 PCV Valve (Not Shown) 320 7019929 1 Pulley, Idler (Not Shown) 321 7019930 1 Coil Pack (Not Shown)

7019931 1 Spark Plug Wires (Set) (Not Shown)

7019932 4 Spark Plug Wires (Not Shown) 322 7022178 1 Sensor, Crank Shaft (Not Shown) 323 2420109 1 Gauge, Oil Dipstick (Not Shown) (Engine 2000149)

4564281 1 Tube, Dipstick (Not Shown) (Engine 2000149)

Ref. ENGINE COMPONENTS

7016662)

2000156/2000165

401 7019977 1 Alternator

7019997 1 Regulator 402 Use 1660250 1 Coupling (15 Teeth) (S/N 46528 to S/N 60462) (was p/n

Use 1660249 1 Coupling (13 Teeth) (S/N 60462 to Present) (was p/n 7012656)

403 Use 7023687 1 Module, Ignition (was p/n 7019961)

Ref. ENGINE COMPONENTS

7016662)

3120830 400RTS 500RTS 2-39

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

404 7012679 1 Starter (Not Shown) 405 7021869 1 Filter, Oil 406 Use 7019988 1 Carburetor (Engine 2000156) (was p/n 7019974)

7019988 1 Carburetor (Engine 2000165) 7019933 1 Carburetor Kit 7027292 1 Float Assembly 7025122 1 Base, Carburetor 7024321 1 Gasket, Carburetor (Top) 7000646 1 Gasket, Carburetor (Bottom) 7000646 1 Gasket, Carburetor 7016605 1 Choke, Automatic

407 7016600 1 Pump, Fuel (Facet Brand)

7019983 1 Pump, Fuel (Airtex Brand) 7000884 1 Solenoid, Fuel

7016601 1 Filter, Fuel 408 Not Required 409 Use 7019926 1 Hose, Radiator (Top) (was p/n 7016375) 410 Use 7019927 1 Hose, Radiator (Bottom) (was p/n 7016376) 411 7022153 1 Pump, Water (Not Shown)

7019982 1 Tube, Water Pump Inlet (Not Shown)

7019985 1 Pulley, Water Pump (Not Shown)

7022156 1 Thermostat (Not Shown)

7025134 1 Gasket, Water Outlet Connection (Not Shown) 412 7019976 1 Flywheel

7022180 1 Ring Gear 413 7022143 1 Gasket, Exhaust Manifold (Not Shown) 414 70002307 1 Gasket, Exhaust Manifold to Pipe (Not Shown)

7019924 1 Manifold, Exhaust (Not Shown)

7025125 1 Gasket, Intake (Manifold to Cylinder Head) (Not Shown) 415 7019978 1 Tensioner, Belt (Not Shown) 416 7027402 1 Belt, Drive (was p/n 7019979) 417 Not Used 418 7019980 1 Harness, Engine Wiring (Not Shown)

419 to 420 Not Used

421 7019930 1 Coil Pack (Not Shown)

7022157 1 Spark Plug Wires (Set) (Not Shown) (Engine 2000156)

7019931 1 Spark Plug Wires (Set) (Not Shown) (Engine 2000165)

7019932 4 Spark Plug (Not Shown) (Engine 2000165) 422 7022178 1 Sensor, Crank Shaft (Not Shown) 423 7019981 1 Indicator, Oil Level (Not Shown)

0253875 Ref. SPARK ARRESTOR INSTALLATION (OPTIONAL) — 501 3220083 1 Spark Arrestor

0257154 Ref. ENGINE HEATER INSTALLATION (OPTIONAL NOT

SHOWN)

2580048 1 Block Heater Kit (Located Left Side of Intake)

A/1

2-40 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-41

SECTION 2 GROUND CONTROLS

FIGURE 2-9. DUAL FUEL COMPONENTS INSTALLATION - FORD LSG-423/LRG-423 DIS/

LRG-425

2-42 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-9. DUAL FUEL COMPONENTS INSTALLATION - FORD LSG-423/LRG-423 DIS/ LRG-

425

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DUAL FUEL COMPONENTS INSTALLATION (FORD LSG423,

LRG423 AND LRG 425 ENGINES)

1 4700005 1 Vaporizer/Regulator

7017515 1 Kit, Rebuilding 2 2120077 1 LPG Filter Lock 3 4360188 1 Vacuum Switch 4 2220675 3 Fitting, 90° Pipe Barb 5 2220251 1 Reducer 6 2200204 1 Pipe Plug 3/4" NPT 7 1320130 2 Clamp, 1" 8 0701010 1 Screw, M10 x 1.5 x 20

0700610 1 Screw, M6 x 1 x 20 9 4832000 1 Lockwasher M10

4831700 1 Lockwasher M6

10 0080124 1 Adaptor, Carburetor 11 1700712 4 Decal, Caution 12 1320022 6 Clamp 13 1120432 1 Cap, Vacuum 14 2720112 2 ft. Hose, Vapor 5/8" 15 2180389 1 Fitting, Relief 16 2720249 1 Hose, L.P. 62" Lg. 17 0902094 1 Bracket, L.P. Filter 18 2180388 1 Filter, Bulkhead 19 2180418 1 Fitting, 1/4" NPT to 3/8", 45° Flare 20 2720144 1 Hose, L.P. 21 2180387 1 Fitting, Tank Connector 22 1320023 2 Clamp, LP Tank 23 4400040 2 Tank, LP (33.5 Lbs.) (Prior to S/N 61097)

4400281 2 Tank, LP (33.5 Lbs.) (S/N 61097 to Present)

4400275 2 Tank, LP (43.5 Lbs.)

24 4640391 1 Lock, Fuel (Prior to June 1995) 25 2200222 1 Pipe Plug 1/4" NPT (S/N 36855 to Present) 26 2220290 1 Fitting, Tee (S/N 36855 to Present) 27 2220504 1 Fitting, 90° 1/4" NPT to 3/8", 45° Flare (S/N 26845 to Present)

0254963/0254964 Ref. DUAL FUEL COMPONENTS INSTALLATION - LSG-423 D/4 0255210/0255208 Ref. DUAL FUEL COMPONENTS INSTALLATION - LRG-423 8/E 0258322/0258321 Ref. DUAL FUEL COMPONENTS INSTALLATION - LRG-425 8/6

51 2220003 1 Fitting, Straight (Not Shown) (LSG-423)

2220082 1 Fitting, 90° (LRG-423/LRG-425) (Prior to S/N 99226)

2220504 1 Fitting, 90° (LRG-423/LRG-425) (S/N 99226 to Present)

52 2220082 1 Fitting, 90° (LSG-423)

Not Required 0 LRG-423/LRG-425

53 2180537 1 Fitting, Nipple (LSG-423)

2180104 1 Fitting, Nipple (LRG-423/LRG-425)

3120830 400RTS 500RTS 2-43

SECTION 2 GROUND CONTROLS

FIGURE 2-9. DUAL FUEL COMPONENTS INSTALLATION - FORD LSG-423/LRG-423 DIS/ LRG-

425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

54 Not Required 0 LSG-423

2180360 1 Fitting, Tee 1/8" NPT (LRG-423/LRG-425)

55 0641510 2 Bolt 5/16"-18NC x 1 1/4" (LSG-423)

0641416 2 Screw 1/4"-20NC x 2" Lg. (LRG-423/LRG-425)

56 4761500 2 Lockwasher 5/16" (LSG-423)

4761400 2 Lockwasher 1/4" (LRG-423/LRG-425)

57 3311501 2 Nut 5/16"-18NC (LSG-423)

3311401 2 Nut 1/4"-20NC (LRG-423/LRG-425)

58 2180250 1 Fitting, Adapter (LSG-423)

2220273 1 Fitting, Adapter (LRG-423/LRG-425)

59 3538436 1 Plate, Mounting (LSG-423)

Not Required 0 LRG-423/LRG-425

60 Not Required 0 LSG-423

0902089 1 Bracket, Mounting (LRG-423/LRG-425)

61 2180749 1 Fitting, 45° (LSG-423)

Not Required 0 LRG-423/LRG-425

62 2180504 1 Fitting, 45° (LSG-423)

Not Required 0 LRG-423/LRG-425

63 Not Required 0 LSG-423

0902361 1 Bracket, Terminal (S/N 33309 to Present)

0253447 Ref. LP TANK BRACKETS INSTALLATION (PRIOR TO S/N 32690) —

101 4844185 2 Support, Tank Bracket 102 0641522 2 Bolt 5/16"-18NC x 2 3/4" 103 4761500 2 Lockwasher 5/16" 104 3311501 2 Nut 5/16"-18NC 105 0641610 8 Bolt 3/8"-16NC x 1 1/4" 106 4751600 8 Flatwasher 3/8" 107 4761600 8 Lockwasher 3/8" 108 3311601 Nut 3/8"-16NC

0256909 Ref. LP TANK BRACKETS INSTALLATION (S/N 32690 TO PRES-

ENT)

151 0902360 1 Support, Tank Bracket (RH) (Prior to S/N 80673) 152 4844185 1 Support, Tank Bracket (LH) (Prior to S/N 80673)

4844185 2 Support, Tank Bracket (S/N 80673 to Present) 153 0641516 1 Bolt 5/16"-18NC x 2" (Prior to S/N 80673) 154 0641522 2 Bolt 5/16"-18NC x 2 3/4" 155 4751500 4 Flatwasher 5/16" 156 3311505 2 Locknut 5/16"-18NC 157 0641610 8 Bolt 3/8"-16NC x 1 1/4" 158 4751600 16 Flatwasher 3/8" 159 3311605 8 Locknut 3/8"-16NC 160 0100011 A/R Loctite 161 1320023 2 Clamp, LP Gas

2-44 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-9. DUAL FUEL COMPONENTS INSTALLATION - FORD LSG-423/LRG-423 DIS/ LRG-

425 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-45

SECTION 2 GROUND CONTROLS

FIGURE 2-10. GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425

2-46 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-10. GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0257152 Ref. GENERATOR INSTALLATION 3/B

1 3580250 1 Pulley, Crankshaft 2 1 Belt, Generator Options:

0480090 Ford LSG 423/LRG 423 (Prior to S/N 46528)

0480110 Ford LRG 425 (S/N 46528 to Present) 3 0902372 1 Bracket, Generator Mounting 4 2460011 1 110 Volt Generator

7003657 1 Control Box Assembly

1 Note: Replacement 110V Control Box comes with 2 stan-

dard Receptacles p/n 4460190. Optional Industrial Twist Lock Receptacles p/n 44600027 must be ordered separately.

2420203 1 Voltmeter

4360542 1 Breaker, Circuit

2920162 1 Lamp

7020191 1 Switch, Toggle

3520028 1 Plug, Hole

7012558 1 Generator Assembly

7026199 1 Armature with Slip Rings

7020108 4 Brushes

7020109 4 Holders, Brush

7012513 4 Cap, Brush Holder

3580134 1 Pulley

7012514 1 Fan

7020193 1 Cord, Power

7020110 1 Bell End, Front

7020111 1 Bell End, Rear

7020190 2 Bearing 5 7027887 1 Key, Woodruff (Prior to S/N 46528) 6 0200530 1 Arm, Adjusting 7 0641612 3 Bolt 3/8"-16NC x 1 1/2" 8 4751600 3 Flatwasher 3/8" 9 4761600 3 Lockwasher 3/8"

10 3311601 1 Nut 3/8"-16NC 11 3580239 1 Pulley, Idler 12 4740275 1 Washer 13 0100011 A/R Loctite 14 4564417 1 Tube, Spacer 15 0641512 1 Bolt 5/16"-18NC x 1 1/2" 16 4751500 3 Flatwasher 5/16" 17 4761500 3 Lockwasher 5/16" 18 4566650 1 Tube, Spacer 19 0701015 2 Bolt 10mm-1.5 x 35mm 20 4812000 2 Flatwasher 10mm 21 4832000 2 Lockwasher 10mm 22 3911008 2 Screw, Machine #10-24 x 1/2" 23 3311001 2 Nut #10-24 24 4761000 2 Lockwasher #10

3120830 400RTS 500RTS 2-47

SECTION 2 GROUND CONTROLS

FIGURE 2-10. GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425

ITEM # PART NUMBER QTY. DESCRIPTION REV.

25 0901609 1 Bracket, Box Mounting 26 2 Bolt Options:

0641507 2 Bolt 5/16-18NC x 7/8"

0641407 2 Bolt 1/4”-24NC x 7/8" 27 2180360 1 Fitting, Tee 28 4360037 1 Switch, Oil Pressure 29 4932735 1 Wiring, Diagram 30 4711400 2 Flatwasher 1/4” 31 3311405 2 Locknut 1/4”-20NC 32 0641608 1 Bolt 3/8”-16NC x 1”

2-48 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-10. GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120830 400RTS 500RTS 2-49

SECTION 2 GROUND CONTROLS

FIGURE 2-11. ENGINE INSTALLATION - DEUTZ F3L1011

2-50 400RTS 500RTS 3120830

SECTION 2 GROUND CONTROLS

FIGURE 2-11. ENGINE INSTALLATION - DEUTZ F3L1011

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. ENGINE INSTALLATIONS

0253370 Ref. DEUTZ F3L1011 (AUSTRALIAN SPEC) (PRIOR TO S/N

121830)

0273976 Ref. DEUTZ F3L2011 (AUSTRALIAN SPEC) (S/N 121830 TO PRES-

ENT)

0257247 Ref. DEUTZ F3L1011F (CE SPEC) (PRIOR TO S/N 121830) 11 0273977 Ref. DEUTZ F3L2011 (CE SPEC) (S/N 121830 TO PRESENT) 1

1 Engine Options:

2000107 1 Deutz F3L1011 (includes Items 101-110) (Prior to July 1995) 2000138 1 Deutz F3L1011F (includes Items 201-211) (July 1995 to S/N

121830)

2000242 1 Deutz F3L2011 (includes Items 251-271) (S/N 121830 to

Present)

2 1 Tray, Engine Mounting Options:

4844275 Prior to S/N 121830

4844275 S/N 121830 to Present 3Not Used 4 1 Pump Assembly - Sunstrand Options (See Figure 2-13 for

Breakdown): 3600164 1 Prior to S/N 30660 3600260 1 S/N 30660 to Present

5 0080174 4 Adapter, Engine Mounting 6 0080177 1 Adapter, Air Intake 7 0080172 1 Adapter, Throttle for F3L1011

4460302 1 Adapter, Throttle for F3L1011F/F3L2011

8 3450202 1 Pin, Cotter 1/16" x 1/2" 9 3951003 1 Setscrew #10-24NC x 3/8" for F3L1011

0902244 1 Bracket, Throttle for F3L1011F 0080249 1 Bracket, Throttle for F3L2011

10 4 Bolt Options:

CE Spec

0641844 Bolt 1/2"-13NC x 5 1/2"

Australian Spec 0641844 Bolt 1/2"-13NC x 5 1/2" (Prior to S/N 33431) 0701230 Bolt m12-1.75 x 130mm (S/N 33431 to S/N 72218) 0641840 Bolt 1/2"-13NC x 5" (Prior to S/N 72218)

11 4 Locknut Options:

CE Spec 3311805 Locknut 1/2"-13NC

Australian Spec 3311805 Locknut 1/2"-13NC (Prior to S/N 33431) 3311205 Locknut m12-1.75 (S/N 33431 to S/N 72218) 3311805 Locknut 1/2"-13NC (Prior to S/N 72218)

12 4751800 4 Flatwasher 1/2" 13 0641408 8 Bolt 1/4"-20NC x 1" 14 4761400 10 Lockwasher 1/4" 15 3311401 8 Nut 1/4"-20NC 16 0641512 3 Bolt 17 1060254 1 Cable, Battery

3120830 400RTS 500RTS 2-51

SECTION 2 GROUND CONTROLS

FIGURE 2-11. ENGINE INSTALLATION - DEUTZ F3L1011 (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

18 1060093 1 Cable, Battery 19 0140001 1 Horn (Prior to S/N 112737) 20 0641610 2 Bolt 3/8"-16NC x 1 1/4" 21 4751600 11 Flatwasher 3/8" 22 0060023 1 Actuator, Throttle

7008828 1 Cable, Throttle 23 0901838 1 Bracket, Air Cleaner Mounting 24 0701010 4 Bolt, Metric M10 x 20mm 25 4832000 4 Lockwasher 10m 26 4711600 1 Flatwasher 3/8" 27 3311501 3 Nut 5/16"-18NC 28 4761500 3 Lockwasher 5/16" 29 4751600 9 Lockwasher 3/8" 30 1 Battery Options:

0400003 Prior to S/N 48582

0400075 S/N 48582 to Present 31 1 Tie-Down, Battery Options:

0400002 Prior to S/N 48582

0400147 S/N 48582 to S/N 50806

0400174 S/N 50806 to Present 32 1 Seat, Battery Options:

3980003 Prior to S/N 48582

3980007 S/N 48582 to Present 33 0630370 2 Rod, Tie-Down 34 3300029 2 Wingnut 3/8"-16NC 35 1 Cable, Battery Options:

1060360 Australian Spec

1060646 CE Spec 36 4740185 2 Washer, Hardened 37 3311601 9 Nut 3/8"-16NC 38 0641612 6 Bolt 3/8"-16NC x 1 1/2" 39 4843513 1 Air Intake Weldment 40 2180730 1 Fitting, Adapter 41 2420110 1 Sender, Oil Pressure 42 3960407 1 Gasket 43 1340020 1 Air Cleaner Assembly

7004214 1 Element, Air Cleaner 44 0340002 2 Band, Mounting - Air Cleaner 45 1320180 8 Clamp, Hose 46 0080039 1 Elbow, Rubber 90° 47 0721008 2 Screw, Machine #10-24NC x 1" (Prior to S/N 30660)

0701015 2 Screw, Machine 10mm x 35mm (S/N 30660 to Present) 48 4761000 2 Lockwasher #10 (Prior to S/N 30660)

4761400 2 Lockwasher (S/N 30660 to Present) 49 0080046 2 Elbow, Rubber 90° 50 4751000 2 Flatwasher #10 (Prior to S/N 34060)

4751400 2 Flatwasher (S/N 34060 to Present) 51 2720379 52 2720342

3 in./7.6cm

4 in./10cm

Hose Hose, Air Intake

2-52 400RTS 500RTS 3120830

JLG 500RTS Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. FRAME, STEERING, AND AXLE INSTALLATIONS

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS

FIGURE 1-3. DRIVE MOTOR ASSEMBLY

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

FIGURE 1-5. DRIVE HUB ASSEMBLIES

FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES

FIGURE 1-7. FRAME MOUNTED COMPONENTS INSTALLATION

FIGURE 1-8. FRAME MOUNTED OPTIONS INSTALLATION

FIGURE 1-9. TOW PACKAGE INSTALLATION - BALL (OPTIONAL)

FIGURE 1-10. TOW PACKAGE INSTALLATION - PINTLE HOOK (OPTIONAL)

FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION

FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 107516)

FIGURE 2-3. CONTROL VALVE ASSEMBLY (S/N 107516 TO PRESENT)

FIGURE 2-4. ENGINE INSTALLATION - FORD VSG-411

FIGURE 2-5. DUAL FUEL COMPONENTS INSTALLATION - FORD VSG-411 ENGINE OPTION

FIGURE 2-6. 110 VOLT GENERATOR INSTALLATION (FORD VSG-411) (OPTIONAL)

FIGURE 2-7. ENGINE INSTALLATION - FORD LSG-423

FIGURE 2-8. ENGINE INSTALLATION - FORD LRG-423 DIS/LRG-425

FIGURE 2-10. GENERATOR INSTALLATION - FORD LSG-423/LRG-423/LRG-425

FIGURE 2-11. ENGINE INSTALLATION - DEUTZ F3L1011