JLG 601S Parts Manual

Illustrated Parts Manual

Models

601S

P/N

3120867

September 26, 2012

REVISION LOG

August 6, 1999 - Original Issue Of Manual

April 26, 2001 - Revised (Manual edited to 0010550 Revision 30)

(Manual edited to 0010576 Revision 3 With Engine Power Boom Control System)

January 22, 2002 - Revised (Manual edited to 0010576 Revision 11)

May 9, 2002 - Revised (Manual edited to 0010576 Revision 13)

February 27, 2003 - Revised (Manual edited to 0010576 Revision 19)

June 18, 2003 - Revised (Manual edited to 0010576 Revision 22)

September 16, 2003 - Revised (Manual edited to 0010576 Revision 23)

May 28, 2004 - Revised (Manual edited to 0010576 Revision 25)

January 10, 2005 - Revised (Manual edited to 0010576 Revision 25)

August 15, 2005 - Revised (Manual edited to 0010576 Revision 28)

(Manual edited to 0010630 Revision 6 With New Frame)

October 30, 2006 - Revised (Manual edited to 0010630 Revision 9)

April 30, 2007 - Revised (Manual edited to 0010630 Revision 10)

October 15, 2007 - Revised (Manual edited to 0010630 Revision 10)

May 1, 2008 - Revised (Manual edited to 0010630 Revision 10)

November 11, 2009 - Revised (Manual edited to 0010630 Revision 10)

September 26, 2012 - Revised

ADE SYSTEM IDENTIFICATION

Most 601S machines from S/N 62137 incorporate the ADE System, but no clean S/N break exist. A machine that incorporates ADE System can be outwardly identified by the analyzer connection at the base of the platform control box as shown by the arrow.

3120867 601S A

REVISION LOG

B 601S 3120867

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 4WD FRONT AXLE AND STEERING INSTALLATIONS (PRIOR TO S/N 85132). . . . 1-2

1-2 4WD FRONT AXLE AND STEERING INSTALLATIONS (S/N 85132 TO PRESENT) . 1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATIONS (PRIOR TO S/N 85132) . . . . . . . . . . . . 1-10

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS (S/N 85132 TO PRESENT) . . . . . . . . . 1-14

1-5 DRIVE HUB ASSEMBLY (PRIOR TO S/N 65218) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 DRIVE HUB ASSEMBLY (S/N 65218 TO S/N 85132) . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-7 DRIVE HUB ASSEMBLY (S/N 85132 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-8 DRIVE BRAKE ASSEMBLY (PRIOR TO S/N 85132). . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1-9 DRIVE MOTOR ASSEMBLY (PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1-10 DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY) (S/N 85132 TO S/N 98765) . . . . 1-30

1-11 DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (S/N 98765 TO PRESENT) . . . . 1-32

1-12 FRAME SHIELD INSTALLATION (PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . . . . . . 1-34

1-13 DRIVE VALVES & SHIELDS INSTALLATION (FRAME MOUNTED)

(S/N 85132 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

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

2-1 CONTROL VALVES INSTALLATIONS (PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . . 2-2

2-2 CONTROL VALVES INSTALLATIONS (S/N 85132 TO PRESENT) . . . . . . . . . . . . . . 2-6

2-3 MAIN CONTROL VALVE ASSEMBLY (PRIOR TO S/N 85132). . . . . . . . . . . . . . . . . . 2-10

2-4 MAIN CONTROL VALVE ASSEMBLY (S/N 85132 TO PRESENT) . . . . . . . . . . . . . . . 2-14

2-5 SWING DRIVE, TURNTABLE BEARING & LOCK INSTALLATIONS . . . . . . . . . . . . . 2-18

2-6 SWING HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-7 SWING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-8 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-9 DEUTZ ENGINE INSTALLATIONS (PRIOR TO S/N 78257) . . . . . . . . . . . . . . . . . . . . 2-28

2-10 DEUTZ ENGINE INSTALLATIONS (S/N 78257 TO PRESENT) . . . . . . . . . . . . . . . . . 2-36

2-11 GENERATOR INSTALLATION (DEUTZ ENGINE MODEL - 601S WITH A

“ENHANCED HOSTILE ENVIRONMENT PACKAGE”). . . . . . . . . . . . . . . . . . . . . . 2-44

2-12 PISTON PUMP ASSEMBLY (WITHOUT HYDRAULIC WELDER)

(PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2-13 PISTON PUMP ASSEMBLY (WITHOUT HYDRAULIC WELDER)

(S/N 85132 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

2-14 PISTON PUMP ASSEMBLY (WITH HYDRAULIC WELDER) . . . . . . . . . . . . . . . . . . . 2-58

2-15 GEAR PUMP ASSEMBLY (WITHOUT HYDRAULIC WELDER) . . . . . . . . . . . . . . 2-62

2-16 GEAR PUMP ASSEMBLY (WITH HYDRAULIC WELDER) . . . . . . . . . . . . . . . . . . . . . 2-64

2-17 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-18 ROTARY COUPLING INSTALLATION (PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . . 2-70

2-19 ROTARY COUPLING INSTALLATION (S/N 85132 TO PRESENT) . . . . . . . . . . . . . . 2-72

2-20 GROUND CONTROL BOX ASSEMBLY (PRIOR TO S/N 62137) . . . . . . . . . . . . . . . . 2-76

2-21 GROUND CONTROL BOX ASSEMBLY (ADE SYSTEM)

(S/N 62137 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

2-22 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . 2-84

2-23 HOODS INSTALLATION - MODEL 601S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

2-24 HOODS INSTALLATION - MODEL 601S WITH A “ENHANCED HOSTILE

ENVIRONMENT PACKAGE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

3120867 601S i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

3-1 BOOM AND CYLINDER INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-3 ROTATOR ASSEMBLY (FRONT ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-4 ROTATOR ASSEMBLY (SIDE ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 POWER TRACK INSTALLATION - MODEL 601S . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-6 POWER TRACK INSTALLATION - MODEL 601S WITH A “ENHANCED HOSTILE

ENVIRONMENT PACKAGE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-7 BOOM WIPERS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

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

4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY PLATFORM) . . . . . .4-2

4-2 PLATFORM COMPONENTS INSTALLATION - SIDE ENTRY PLATFORM . . . . . . . .4-6

4-3 PLATFORM CONSOLE ASSEMBLIES (PRIOR TO S/N 62137) . . . . . . . . . . . . . . . . .4-10

4-4 PLATFORM CONSOLE ASSEMBILES - WITH ADE SYSTEM

(S/N 62137 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-5 CONTROLLER ASSEMBLY (SWING & LIFT) (PRIOR TO S/N 62137) . . . . . . . . . . . .4-22

4-6 CONTROLLER ASSEMBLY (SWING & LIFT) (WITHOUT ADE SYSTEM)

(S/N 62137 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-7 CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N 62137) . . . . . . . . . .4-28

4-8 CONTROLLER ASSEMBLY (DRIVE & STEER) (WITH ADE SYSTEM)

(S/N 62137 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

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

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY (PRIOR TO S/N 85132). . . . . . . . . . . . . . .5-2

5-2 AXLE LOCKOUT CYLINDER ASSEMBLY (S/N 85132 TO PRESENT) . . . . . . . . . . . .5-4

5-3 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4 LIFT (BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-5 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6 STEER CYLINDER ASSEMBLY (PRIOR TO S/N 85132)

(ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 STEER CYLINDER ASSEMBLY (S/N 85132 TO PRESENT)

(ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-8 STEER CYLINDER ASSEMBLY (SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . .5-16

5-9 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-10 CYLINDER BELLOWS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

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

6-1 HYDRAULIC DIAGRAM - DRIVE & STEER (PRIOR TO S/N 85132). . . . . . . . . . . . . .6-2

6-2 HYDRAULIC DIAGRAM - DRIVE & STEER (S/N 85132 TO PRESENT) . . . . . . . . . . .6-6

6-3 HYDRAULIC DIAGRAM - OSCILLATING AXLE (PRIOR TO S/N 85132) . . . . . . . . . .6-8

6-4 HYDRAULIC DIAGRAM - OSCILLATING AXLE (S/N 85132 TO PRESENT). . . . . . . .6-10

6-5 HYDRAULIC DIAGRAM - W/HYDRAULIC WELDER (OPTIONAL) . . . . . . . . . . . . . . .6-12

6-6 HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 85132) . . . . . . . . . . . . . . . . .6-16

6-7 HYDRAULIC DIAGRAM - STANDARD (S/N 85132 TO PRESENT). . . . . . . . . . . . . . .6-20

6-8 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

ii 601S 3120867

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

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

7-2 ELECTRICAL SCHEMATIC - DEUTZ ENGINE MACHINES

(PRIOR TO S/N 62137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 ELECTRICAL SCHEMATIC - DEUTZ/FORD EFI ENGINE MACHINES

(ADE SYSTEM) (W/INTERNAL TILT) (S/N 62137 TO S/N 99060) . . . . . . . . . . . . 7-6

7-4 ELECTRICAL SCHEMATIC - DEUTZ EMR2 (S/N 85132 TO S/N 99060) . . . . . . . . . . 7-12

7-5 ELECTRICAL SCHEMATIC - DEUTZ TIER 2 (S/N 99060 TO PRESENT) . . . . . . . . . 7-18

7-6 HARNESS COMPONENTS INSTALLATION (PRIOR TO S/N 62137) . . . . . . . . . . . . 7-24

7-7 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)

(S/N 62137 TO S/N 85132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-8 HARNESS COMPONENTS INSTALLATION (DEUTZ EMR2)

(S/N 85132 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

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

8-1 DECAL INSTALLATION - STANDARD (PRIOR TO S/N 87744) . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION - STANDARD (S/N 87744 TO PRESENT) . . . . . . . . . . . . . . 8-6

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

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

10-1 SPECIAL OPTIONS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 SKY WELDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

3120867 601S iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 601S 3120867

SECTION 1

FRAME

3120867 601S 1-1

SECTION 1 FRAME

FIGURE 1-1. 4WD FRONT AXLE AND STEERING INSTALLATIONS (PRIOR TO S/N 85132)

1-2 601S 3120867

SECTION 1 FRAME

FIGURE 1-1. 4WD FRONT AXLE AND STEERING INSTALLATIONS (PRIOR TO S/N 85132)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME WELDMENT OPTIONS: 2360462 1 Frame Weldment (4WD) - Model 601S 2360504 1 Frame Weldment (4WD) - Model 601S with “Enhanced Hostile

Environment Package”

Ref. OSCILLATING AXLE INSTALLATION OPTIONS: 0257896 Ref. MODEL 601S 8 0258994 Ref. MODEL 601S With a “Enhanced Hostile Environment Pack-

age”

1 4845651 1 Axle Weldment 2 1683280 2 Lockout Cylinder Assembly (See Section 5 for Breakdown) 3 3422592 1 Pin, Axle Pivot 4 3422426 4 Pin, Cylinder 5 3841143 4 Keeper, Pin 6 0641608 4 Bolt 3/8”-16NC x 1” 7 0100011 A/R Loctite #242 8 3841258 1 Keeper

9 0642012 1 Bolt 5/8”-11NC x 1 1/2” 10 4740158 1 Thrustwasher 11 4640871 1 Valve, Cam

7012693 1 Seal Kit - 4640871 Valve 12 0641414 4 Bolt 1/4”-20NC x 1 3/4” 13 4711400 A/R Flatwasher 1/4” Narrow 14 Not Used 15 3538047 2 Plate, Axle Wear 16 4070878 A/R Shim (.06) 17 4070879 A/R Shim (.12) 18 0641608 4 Bolt 3/8”-16NC x 1” 19 4711600 4 Flatwasher 3/8” Narrow 20 1 Cam Options:

1100086 Model 601S

1100111 Model 601S with “Enhanced Hostile Environment Package” 21 0641814 2 Bolt 1/2”-13NC x 1 3/4” 22 4751800 A/R Flatwasher 1/2” 23 Not Used 24 0961950 2 Bushing, Garmax

0259414 Ref. FIXED AXLE INSTALLATION 1/B

51 4845651 1 Axle Weldment 52 3539877 2 Plate, Stop 53 3422592 1 Pin, Axle Pivot 54 4070944 A/R Shim 55 4070945 A/R Shim 56 0641826 2 Bolt 1/2”-13NC x 3 1/4” 57 0100011 A/R Loctite #242 58 3841258 1 Keeper

3120867 601S 1-3

SECTION 1 FRAME

FIGURE 1-1. 4WD FRONT AXLE AND STEERING INSTALLATIONS (PRIOR TO S/N 85132)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

59 0642012 1 Bolt 5/8”-11NC x 1 1/2” 60 4740158 1 Thrustwasher 61 0961950 2 Bushing, Garmax 62 3538047 2 Plate, Axle Wear 63 4070878 A/R Shim (.06) 64 4070879 A/R Shim (.12) 65 0641608 4 Bolt 3/8”-16NC x 1” 66 4711600 4 Flatwasher 3/8” Narrow 67 3571593 2 Plate, Stop

0257902 STEERING INSTALLATIONS

101 4130362 1 Spindle Weldment (RH) 102 4130365 1 Spindle Weldment (LH) 103 1683616 2 Steer Cylinder Assembly (See Section 5 for Breakdown) 104 3422802 4 Kingpin 105 3841285 1 Tie-Rod 106 3422426 1 Pin, Steer Cylinder 107 3422429 1 Pin, Steer Cylinder 108 0440161 4 Thrustwasher 109 3422430 2 Pin, Attach 110 3841143 4 Pin, Keeper 111 0641608 3 Bolt 3/8”-16NC x 1” 112 0100011 A/R Loctite #242 113 0641610 1 Bolt 3/8”-16NC x 1 1/4” 114 3311605 1 Locknut 3/8”-16NC 115 0641608 8 Bolt 3/8”-16NC x 1” 116 1670752 4 Cover, King Pin (Prior to S/N 43441) 117 0962005 2 Bushing 118 0962272 4 Bearing, Garmax 119 0100063 A/R Loctite RC-609

Ref. DRIVE VALVE INSTALLATION - 4WD OPTIONS: 0257907 Ref. Prior to S/N 56791 4 0270126 Ref. S/N 56791 to S/N 65218 1 0271684 Ref. S/N 65218 to Present 3

201 4641052 1 Valve, Flow Divider

7020049 1 Cartridge 7020051 1 Seal Kit 7020050 1 Plug, Orifice

202 0641522 4 Bolt 5/16”-18NC x 2 5/8” 203 3311505 4 Locknut 5/16”-18NC 204 4751500 10 Flatwasher 5/16” 205 0641520 2 Bolt 5/16”-18NC x 2 1/2” 206 Not Used 207 0100011 A/R Loctite #242

1-4 601S 3120867

SECTION 1 FRAME

FIGURE 1-1. 4WD FRONT AXLE AND STEERING INSTALLATIONS (PRIOR TO S/N 85132)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

208 4641051 2 Valve, Flow Divider 4WD

7020047 1 Cartridge (1 Per Valve) 7020051 1 Seal Kit

7020048 1 Plug, Orifice 209 4060808 A/R Flex Trim 210 4060807

1.6ft/.49m

Flex Trim (Prior to S/N 67821)

3120867 601S 1-5

SECTION 1 FRAME

111

103

108

101

105

110

109

106

218

206

216

202

212

210

204

213

209

215

206

219

201

202 212

208

217

224

207

112

212

202

214

211

205

217

215

107

102

101

104

FIGURE 1-2. 4WD FRONT AXLE AND STEERING INSTALLATIONS (S/N 85132 TO PRESENT)

1-6 601S 3120867

SECTION 1 FRAME

FIGURE 1-2. 4WD FRONT AXLE AND STEERING INSTALLATIONS (S/N 85132 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME WELDMENT OPTIONS: 2360699 1 Frame Weldment (4WD) - Model 601S 2360706 1 Frame Weldment (4WD) - Model 601S with “Enhanced Hostile

Environment Package”

0273081 Ref. AXLE INSTALLATIONS - OSCILLATING F

1 0100011 A/R Loctite #242 2 0641814 8 Bolt 1/2”-13NC x 1 3/4” 3 0642012 1 Bolt 5/8”-11NC x 1 1/2” 4 0961950 2 Bearing 5 2 Lockout Cylinder Assembly Options (See Section 5 for

Breakdown): 1684280 Prior to S/N 89729 1684465 S/N 89729 to Present

6 3422592 1 Pin, Pivot 7 3841258 1 Keeper, Pin 8 4740158 1 Thrustwasher

9 4846814 1 Axle Weldment 10 4891800 8 Flatwasher 1/2” Hardened 11 Not Used 12 0100038 A/R Primer #7471

0273226 Ref. AXLE INSTALLATIONS - FIXED A

101 0100011 A/R Loctite #242 102 0642012 1 Bolt 5/8”-11NC x 1 1/2” 103 0961950 2 Bearing 104 3422592 1 Pin, Pivot 105 3539877 2 Plate, Stop 106 3539878 2 Plate, Stop 107 3841258 1 Keeper, Pin 108 3931840 2 Screw 1/2”-13NC x 2 1/2” 109 4070944 4 Shim (.06) 110 4070945 4 Shim (.25) 111 4740158 1 Thrustwasher 112 4846814 1 Axle Weldment

0273080 STEERING INSTALLATIONS E

201 0100011 A/R Loctite #242 202 0641608 6 Bolt 3/8”-16NC x 1” 203 Not Used 204 0642012 2 Bolt 5/8”-11NC x 1 1/2” 205 0961977 2 Bushing 206 0962131 4 Bearing

3120867 601S 1-7

SECTION 1 FRAME

FIGURE 1-2. 4WD FRONT AXLE AND STEERING INSTALLATIONS (S/N 85132 TO PRESENT)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

207 2 Steer Cylinder Assembly Options (See Section 5 for

Breakdown):

1683208 Original Equipment

1001097242 Service Replacement 208 3422326 2 Pin, Steer Cylinder 209 3422900 2 Kingpin 210 3422902 2 Pin, Steer Cylinder 211 3422903 2 Pin, Tie-Rod 212 3841143 6 Shaft, Keeper 213 3841258 2 Shaft, Keeper 214 3841510 1 Tie-Rod 215 4130394 1 Spindle - Left Side 216 4130395 1 Spindle - Right Side 217 4740111 6 Thrustwasher 218 4740256 2 Thrustwasher 219 4740263 2 Thrustwasher

1-8 601S 3120867

SECTION 1 FRAME

FIGURE 1-2. 4WD FRONT AXLE AND STEERING INSTALLATIONS (S/N 85132 TO PRESENT)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120867 601S 1-9

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (PRIOR TO S/N 85132)

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SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (PRIOR TO S/N 85132)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE INSTALLATION (4WD) OPTIONS: 0257907 Ref. Prior to S/N 56791 4/C 0270126 Ref. S/N 56791 to S/N 65218 1/A 0271684 Ref. S/N 65218 to S/N 85132 2/B

1 4 Drive Hub Assembly Options:

2780213 Prior to S/N 65218 (See Figure 1-5 for Breakdown) 2780252 S/N 65218 to S/N 85132 (See Figure 1-6 for Breakdown)

2 2 Drive Brake Assembly Options (See Figure 1-8 for Breakdown):

0920112 Prior to S/N 56791 0920117 S/N 56791 to S/N 85132

3 3160204 4 Drive Motor Assembly (See Figure 1-9 for Breakdown)

Ref. Note: Adjustment required when replacing complete motor.

(See Service Manual for Adjustments)

4 0682016 32 Bolt 1/2”-11NC x 2” (Grade 8) 5 4712000 32 Flatwasher 5/8” 6 4300092 4 Stud (2 Per Wheel) (Prior to S/N 56791)

4300097 4 Stud (2 Per Wheel) (S/N 56791 to S/N 85132)

6A 0641811 4 Bolt 5/8”-13NC x 3/4” (2 Per Wheel)

7 3311801 4 Nut 1/2”-13NC (2 Per Wheel) 8 0100011 A/R Loctite #242 9 3300106 32 Nut, Wheel

10 4891800 8 Flatwasher 1/2”

Ref. TIRE AND WHEEL INSTALLATIONS 0255420 Ref. 14-17.5 Pneumatic (Prior to S/N 65351)

0271612 Ref. 14-17.5 Pneumatic (S/N 65351 to S/N 85132) 1 0255421 Ref. 14-17.5 Foam-Filled (Prior to S/N 65351)

0271613 Ref. 14-17.5 Foam-Filled (S/N 65351 to S/N 85132) 1

0255514 2 14-17.5 Pneumatic Left Side (Prior to S/N 65351) 0271608 2 14-17.5 Pneumatic Left Side (S/N 65351 to S/N 85132) 0255513 2 14-17.5 Pneumatic Right Side (Prior to S/N 65351) 0271609 2 14-17.5 Pneumatic Right Side (S/N 65351 to S/N 85132) 0255606 2 14-17.5 Foam-Filled Left Side (Prior to S/N 65351) 0271610 2 14-17.5 Foam-Filled Left Side (S/N 65351 to S/N 85132) 0255605 2 14-17.5 Foam-Filled Right Side (Prior to S/N 65351) 0271611 2 14-17.5 Foam-Filled Right Side (S/N 65351 to S/N 85132)

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.

101 1 Tire 14-17.5 Options:

4520171 Prior to S/N 65351 4520259 S/N 65351 to S/N 85132

102 4860158 1 Rim, Wheel 103 4640113 1 Valve, Air

⎯

3120867 601S 1-11

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (PRIOR TO S/N 85132) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

104 1702740 1 Decal - 95 PSI

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SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (PRIOR TO S/N 85132) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120867 601S 1-13

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (S/N 85132 TO PRESENT)

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SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (S/N 85132 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0273048 Ref. WHEEL DRIVE INSTALLATION (4WD) J

1 0100011 A/R Loctite #242 2Not Used 3 0681810 8 Bolt 1/2”-13NC x 1 1/4” (Grade 8) 4 0682016 24 Bolt 5/8”-11NC x 2” (Grade 8) 5 2780269 4 Drive Hub Assembly (See Figure 1-7 for Breakdown) 6 Use 3160350 4 Drive Motor Assembly (Prior to S/N 98765 p/n was 3160300 - See

Figure 1-10 for Breakdown) (S/N 98765 to Present p/n 3160350 -

See Figure 1-11 for Breakdown) 7 3300106 36 Nut, Wheel 8Not Used 9 4 Hardware Options:

3790045 O-Ring (Prior to S/N 102229) 3960526 Gasket (S/N 102229 to Present)

10 to 11 Not Used

12 4891800 8 Flatwasher 1/2” 13 4740393 24 Flatwasher 5/8” Hardened

Ref. TIRE AND WHEEL INSTALLATIONS 4520328 Ref. IN355/55D625 Pneumatic 1 4520346 Ref. IN355/55D625 Foam-Filled 1

4520289 2 IN355/55D625 Pneumatic Left Side 4520290 2 IN355/55D625 Pneumatic Right Side 4520344 2 IN355/55D625 Foam-Filled Left Side 4520345 2 IN355/55D625 Foam-Filled Right Side

Ref. Note: Assemblies may require ballast/foam filling to

101 4520288 1 Tire 14-17.5 Options: 102 4860287 1 Rim, Wheel 103 4640113 1 Valve, Air 104 1702740 1 Decal - 95 PSI

3120867 601S 1-15

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (PRIOR TO S/N 65218)

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SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY (PRIOR TO S/N 65218)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780213 Ref. DRIVE HUB ASSEMBLY B

1 7014700 1 Coupling - 13 Teeth 2 7014701 1 Shaft, Input - 13 Teeth 3 7014702 1 Spindle 4 7014728 1 Seal, Boot 5 7014703 1 Seal, Oil 6 7014704 1 Cone, Bearing 7 7014705 1 Cup, Bearing 8 7014727 8 Bolt, Wheel

9 7014706 1 Hub 10 7014707 1 Cup, Bearing 11 7014708 1 Cone, Bearing 12 7001711 1 Thrustwasher 13 7014709 1 Ring, Retaining Kit 14 7014711 2 Ring, Retaining 15 7014712 2 Thrustwasher 16 7014710 1 Spring 17 7014713 1 Gear, Ring 18 7014714 1 Secondary Carrier Assembly 19 7014715 1 Primary Carrier Assembly 20 7014716 1 Gear, Sun - 15 Teeth 21 7014722 1 Thrustwasher 22 7014717 1 Plunger, Disengage 23 7014718 1 O -Ring

24 7014719 1 Cover, Hub 25 7014721 12 Bolt

26 7014720 12 Flatwasher 27 7014725 1 Plug, Magnetic 28 7014726 1 Plug, Pipe 29 7014723 1 Cover, Disengage 30 7014724 2 Bolt

— — — — — — — — — — 100 7014729 1 Bearing and Seal Kit (includes Items 5, 6,7,10,11 & 13) 200 7014730 1 Seal Kit (includes Items 5 & 13)

3120867 601S 1-17

SECTION 1 FRAME

100

18 4624 30 41 22

46 2033 47 43 44 4135

26 27

17 34

FIGURE 1-6. DRIVE HUB ASSEMBLY (S/N 65218 TO S/N 85132)

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SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (S/N 65218 TO S/N 85132)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780252 Ref. DRIVE HUB ASSEMBLY B

1 7017029 1 Rod, Disengage 2 7017093 1 Cover, Disengage 3 7000290 1 Coupling 4 7000272 1 Cup, Bearing 5 7000273 1 Cone, Bearing 6 7000274 1 Cup, Bearing 7 7000275 1 Cone, Bearing 8 7000236 1 Seal, Lip

9 7000239 1 Thrustwasher 10 7000282 1 Thrustwasher 11 7000283 1 Spring 12 7024157 1 Shaft, Input 13 7024158 1 Gear, Sun 14 7024159 1 Gear, Sun 15 7024160 3 Shaft, Planet 16 7024161 1 Carrier 17 7024162 3 Shaft, Planet 18 7024163 1 Carrier (Make Version) 19 7024164 3 Gear, Planet (Make Version) 20 7024165 3 Gear, Planet (Make Version) 21 7024166 1 Spindle (Make Version) 22 7024167 1 Gear, Ring 23 7024168 1 Cover, Plate 24 7024169 1 Housing 25 7024170 57 Bearing, Needle 26 7024171 3 Thrustwasher 27 7024172 108 Bearing, Needle 28 Not Used 29 7024173 1 Ring, Retaining - Ext 30 7000240 1 Ring, Retaining - Ext 31 7000284 1 Ring, Retaining - Int 32 7000285 1 Ring, Retaining - Ext 33 7001906 3 Pin, Roll 34 7024174 3 Pin, Roll 35 7024175 3 Pin, Spring 36 7017047 2 Pin, Dowel (Not Shown) 37 7000216 2 Bolt 1/4”-20NC x 1/2” 38 7024176 20 Bolt 3/8”-16NC x 5 1/2” (Grade 8) 39 Not Used 40 7000213 1 O -Ring 41 7024177 2 O -Ring 42 7017094 2 Plug, Pipe 43 7024178 6 Thrustwasher 44 7024179 6 Thrustwasher 45 7024180 1 Spacer, Thrust 46 7024181 1 Thrustwasher 47 7007640 8 Stud, Wheel

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SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY (S/N 65218 TO S/N 85132) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

— — — — — — — — — —

100 7024745 1 Seal Kit - 2780252 Drive Hub

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FIGURE 1-6. DRIVE HUB ASSEMBLY (S/N 65218 TO S/N 85132) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120867 601S 1-21

SECTION 1 FRAME

3B3F3C3B191120

176A6E6D6B6C6G15166F1B1C1H1D18

1G1G8C

8A8F8H8K8J

217200A

200B

100A

100B

GENUINE PARTS

FIGURE 1-7. DRIVE HUB ASSEMBLY (S/N 85132 TO PRESENT)

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