JLG 740AJ Parts Manual

Illustrated Parts Manual

Model

740AJ

With ADE or UGM

CONTROL MODULE

SN 0300185828

to Present

P/N

3121652

April 30, 2014

REVISION LOG

April 30, 2014 - Original Issue Of Manual (Manual edited to 1001156800 Revision J)

3121652 740AJ A

REVISION LOG

B 740AJ 3121652

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE . . . . . . . . . . . . . . 1-2

1-2 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . . . 1-4

1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-5 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-6 FRAME VALVES & SHIELDS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-7 TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

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

2-1 CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . 2-2

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

2-3 ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 AUXILIARY PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 TURNTABLE BEARING AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . 2-14

2-6 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7 DEUTZ D2011 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-8 DEUTZ TD2.9L4 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-9 GM ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-10 HYDROSTATIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-11 VARIABLE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

2-12 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

2-13 LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) . . . . . . . . . . . . . . . . . . . 2-58

2-14 ROTARY COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2-15 GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-16 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . 2-66

2-17 HOODS INSTALLATION (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

2-18 HOODS INSTALLATION (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

2-19 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

2-20 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES . . 2-80

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

3-1 BOOM AND CYLINDERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4 VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED). . . . . . . . . . . . . . . 3-12

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

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

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

4-3 CONTROLLER ASSEMBLY - SWING & LIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 CONTROLLER ASSEMBLY - DRIVE & STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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

5-1 LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LIFT CYLINDER ASSEMBLY - JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

3121652 740AJ i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

5-6 MASTER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 STEER CYLINDER ASSEMBLY WITHOUT TOW PACKAGE . . . . . . . . . . . . . . . . . . . . . 5-14

5-8 STEER CYLINDER ASSEMBLY WITH TOW PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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

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

6-1 DRIVE HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

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

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

7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

8-1 DECAL INSTALLATION (ANSI & CSA SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (AUSTRALIAN & CE SPEC). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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

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

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

ii 740AJ 3121652

SECTION 1

FRAME

3121652 740AJ 1-1

SECTION 1 FRAME

201 203

201 202

214 204

201 203

216

213

209

205

206

207

208 210 218

211

217

215

212

215

1 3

1 4

1 2

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

1-2 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001151037 Ref FIXED AXLE INSTALLATION C

1 0100011 AR Compound, Locking 2 0641818 2 Bolt 1/2-13 x 2-1/4 3 0642212 1 Bolt 3/4-10 x 1-1/2 4 0681608 4 Bolt 3/8-16 x 1 Grade 8 5 0962102 2 Bushing, Garmax 6 3020039 AR Lubricant 7 3538047 2 Shim, Wear 8 3539877 2 Plate, Stop

9 3841287 1 Keeper, Pin 10 4070878 AR Shim 1/16 11 4070879 AR Shim 1/8 12 4070944 AR Shim 1/16 13 4070945 AR Shim 1/4 14 4711600 4 Washer 3/8 15 4740472 1 Washer, Special 16 1001152719 1 Axle 17 1001156710 1 Pin

1001151035 Ref STEERING INSTALLATIONS (4WS) D

201 0100011 AR Compound, Locking 202 0641607 8 Bolt 3/8-16 x 7/8 203 0641810 32 Bolt 1/2-13 x 1-1/4 204 3020029 AR Lubricant 205 3422417 4 Pin 206 3422790 4 Pin 207 3841520 8 Keeper, Pin 208 4740256 AR Washer, Thrust 209 4740473 4 Washer, Special 210 1001103810 AR Washer, Thrust 211 1001165657 8 Bearing 212 1001150372 4 Spindle 213 1001150539 4 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 214 1001161355 8 Kingpin 215 1001150937 8 Plate 216 1001151980 2 Tie-Rod 217 1001161399 4 Washer, Thrust 218 4740463 AR Washer, Thrust

3121652 740AJ 1-3

SECTION 1 FRAME

517121516

118

117

109

104

101

105

115

105

120

124

107

117

104

110

117

111

106

125

102

107

112

104

101 129

122

126

121

114

113

116

130

131

104

101

117

103

127

128

121

101

117

108

123

108

112021119

104

101

132

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

1-4 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271654 Ref FIXED AXLE INSTALLATION WITH TOW PACKAGE B

1 0100011 AR Compound, Locking 2 0100019 AR Compound, Locking 4 0642212 1 Bolt 3/4-10 x 1-1/2 5 0681608 4 Bolt 3/8-16 x1 (Grade 8) 6 0962102 2 Bushing, Composite

7 0641820 2 Bolt 1/2-13 x 2-1/2 10 3422703 1 Pin, Main Pivot 11 3539877 2 Plate, Stop 12 3538047 2 Shim, Axle Wear 14 3841287 1 Shaft, Keeper 15 4070878 2 Shim, Axle Wear 16 4070879 2 Shim, Axle Wear 17 4711600 4 Washer 3/8 18 4740472 1 Washer, Special 19 3539878 2 Plate, Stop 20 4070944 AR Shim 1/16 21 4070945 AR Shim 1/4 22 4846413 1 Axle Weldment

0272319 Ref STEERING INSTALLATION WITH TOW E

1001137261 Ref KING PIN KIT A

Ref Note: Before ordering king pin kit, verify that machines is equipped

with the original components (king pin with 4 bolt holes) or service kit components (king pin with 8 bolt holes).- If the king pin hole in the axle measurement exceeds 2.252in OD or is elongated, use King Pin Kit p/n 1001137261.

Ref Note: Front Axle Shown. Rear Steer Typical. Double Qty Listed for

Complete Machine.

101 0100011 AR Compound, Locking 102 0362726 1 Tie-Rod 103 0641508 1 Bolt 5/16-18 x 1 104 0641608 7 Bolt 3/8-16 x 1 105 0641810 16 Bolt 1/2-13 x 1-1/4 106 0962152 2 Bushing 107 1001112651 4 Bushing 108 1001097243 2 Steer Cylinder Assembly (See CYLINDER SECTION for

Breakdown): 109 3422587 1 Pin 110 3422701 1 Pin 111 3422702 2 Pin 112 3422754 2 Pin 113 3422813 1 Pin 114 3422848 1 Pin 115 3422972 4 Kingpin 116 3573001 1 Link 117 3841143 8 Keeper, Pin 118 4130388 1 Spindle (Front Right)

3121652 740AJ 1-5

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

119 4130389 1 Spindle (Left Rear) (Not Shown) 120 4130390 1 Spindle (Left Front and Right Rear) 121 4740111 6 Washer, Thrust 122 4740155 AR Washer, Thrust 123 4740256 4 Washer, Thrust 124 4740463 2 Washer, Thrust 125 4740473 2 Washer 126 4846935 1 Bar, Pivot 127 3340966 2 Pad, Stop 128 4071059 AR Shim 129 0741609 4 Screw 3/8-16 x 1-1/8 130 0962292 2 Bushing 131 0962348 1 Bushing 132 3020029 AR Lube, Bearing

1-6 740AJ 3121652

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121652 740AJ 1-7

SECTION 1 FRAME

303

302

304

1331

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

1-8 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157094 Ref WHEEL DRIVE INSTALLATION (4WD/4WS) A

1 0100011 AR Compound, Locking 3 3311801 8 Nut 1/2-13 4 0682016 32 Bolt 5/8-11 x 2 Grade 8 5 2300016 AR Fluid, Hydraulic (Not Shown) 6 2780272 4 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for

Breakdown) 7 3020008 AR Lubricant (Not Shown) 8 3160348 4 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for

Breakdown) 9 3300007 40 Nut, Wheel

13 4891800 8 Washer, 1/2 14 4892000 32 Washer 5/8

0270888 Ref TIRE AND WHEEL INSTALLATION -18-625 NHS Foam-Filled C 0271090 2 Tire & Wheel Assembly - 18-625 NHS Foam-Filled Left Side 0271091 2 Tire & Wheel Assembly - 18-625 NHS Foam-Filled Right Side

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. 302 4520253 1 Tire 303 4640113 1 Valve, Air 304 4860225 1 Rim, Wheel

3121652 740AJ 1-9

SECTION 1 FRAME

10531111

110

112

121

102

119

122

123

104

103

101

109

107

108

114 113

116

115

118

117

120

1A1B1C

1N1G1F1E1H

151515

133B3F3C3D3C3B

106

200A

200B

201D

201C

201B

201A

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

1-10 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780272 Ref DRIVE HUB/BRAKE ASSEMBLY B

2780227 Ref Hub Assembly B

1 See Note 1 Spindle/Housing Assembly (Note: Not Available - Purchase

Individual Components.)

1A 7010464 1 Spindle

1B 7000236 1 Seal 1C 7000273 1 Cone, Bearing 1D 7000272 1 Cup, Bearing 1E 7000275 1 Cone, Bearing 1F 7000274 1 Cup, Bearing 1G 7017033 1 Housing 1H 7000239 1 Washer, Thrust

1I 7000240 1 Ring, Retaining

1J 7001928 1 Plug, Pipe 1N 7000265 10 Stud, Wheel

2 7024782 1 Gear, Ring 3 See Note 1 Carrier Assembly (Note: Not Available - Purchase Individual

Components.) 3A 7024147 1 Carrier 3B 7001901 6 Washer, Thrust, Tanged 3C 7001902 96 Bearing, Needle 3D 7001903 3 Spacer, Thrust 3E 7024146 3 Shaft, Planet 3F 7024148 3 Gear, Cluster 3G 7001906 3 Rollpin

4 7024151 1 Gear, Internal 5 7000224 1 O-Ring 6 See Note 1 Cover Assembly (Note: Not Available - Purchase Individual

Components.) 6A 7024155 1 Cover 6B 7024783 1 Cap 6C 7000220 4 Bolt 1/4-20 x 3/4 6D 7000231 1 Cap, Disengage 6E 7000235 1 Rod, Disengage 6F 7000213 1 O-Ring 6G 7000238 1 O-Ring 6H 7017048 1 Plug, Pipe

7 7000282 2 Washer, Thrust 8 7000283 1 O-Ring

9 7000284 1 Ring, Retaining 10 7000285 1 Ring, Retaining 11 7024781 1 Shaft, Input 12 7024154 1 Spacer, Input 13 7024149 1 Gear, Sun 15 7000287 4 Washer, Thrust 16 7000288 2 Washer, Thrust 17 7000289 12 Bolt 3/8-16 x 2-1/2 Grade 8 19 7000290 1 Coupling

3121652 740AJ 1-11

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

20 7017047 2 Pin, Dowel 21 7017050 1 Washer, Thrust 26 7024182 1 Brake Assembly (Includes Items 101-123) 27 7024763 2 O-Ring 28 7024717 2 Stud 1/2-13 x 4-5/8 29 7024718 2 Nut 1/2-13 31 7000731 1 Gasket

7024182 Ref BRAKE ASSEMBLY

101 7024189 1 Shaft 102 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.) 103 See Note 2 Plate, Friction (Note: Use p/n 7024193) 104 See Note 1 Plate, Pressure (Note: Use p/n 7024193) 105 7000731 1 Gasket 106 See Note 2 Plate, Outer (Note: Use p/n 7024193) 107 See Note 1 Gasket (Note: Use Items 200B, 201C or 201D) 108 7024191 1 Cylinder 109 7024192 1 Piston 110 See Note 1 Bearing, Ball (Note: Use p/n 7024197) 111 See Note 1 Ring, Retaining (Note: Use p/n 7024197) 112 See Note 1 Seal, Shaft (Note: Use p/n 7024197) 113 See Note 6 Capscrew (Note: Not Available for Purchase.) 114 See Note 6 Washer, Lock (Note: Not Available for Purchase.) 115 See Note 1 O-Ring (Note: Use p/n 7024194) 116 See Note 1 Ring, Back-up (Note: Use p/n 7024194) 117 See Note 1 O-Ring (Note: Use p/n 7024194) 118 See Note 1 Ring, Back-up (Note: Use p/n 7024194) 119 7024190 2 Pin, Dowel 120 See Note 1 Plug (Note: Not Available for Purchase.) 121 See Note 2 Plug (Note: Not Available for Purchase.) 122 See Note 10 Spring Kit (Natural) (Note: Use p/n 7024196) 123 See Note 2 Spring Kit (Blue) (Note: Use p/n 7024196)

Ref KIT OPTIONS:

200A 7017068 1 Seal Kit - Hub (Includes Items 1B,1I, 5, 6F, 6G, 15 & 16) 200B 7024194 1 Seal Kit - 7024182 Brake (Includes Items 105, 107 & 215-218) 201A 7024195 NLA Spring Kit - 7024182 Brake (Includes 12 Natural Colored Springs)

(Note: Use p/n 7024196)

201B

201C 7024193

201D 7024197 1 Bearing Kit - 7024182 Brake (Includes Items 107 & 110-112)

7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural & 2 Blue Colored

Springs)

Friction Disc Kit - 7024182 Brake (Includes Items 103, 104, 106 &

107)

1-12 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121652 740AJ 1-13

SECTION 1 FRAME

41340193830343332

313231

129107A1316151714

100

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

1-14 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3160348 Ref DRIVE MOTOR ASSEMBLY B

1 7022302 2 Bearing, Journal

2 7007446 1 Pin

3 7007438 2 Ring, Retaining

4 7022305 Swashplate

5 See Note 2 Pin (Note: Not Available for Purchase.)

6 See Note 1 Gasket (Note: Use p/n 7022328)

7 7023907 1 Cylinder Block Kit (Includes Items 7A & 9-17)

7A See Note 1 Block, Cylinder (Note: Not Available - Purchase Complete

Cylinder Block Kit.) 8 7023908 1 Plate, Valve 9 7021277 1 Guide, Slipper Retainer

10 7021275 3 Pin, Slipper Hold Down 11 See Note 9 Piston Assembly (Note: Not Available - Purchase Complete

Assy.) 12 7022310 1 Retainer, Slipper 13 7021276 1 Retainer, Hold Down Pin 14 7022311 1 Ring, Retaining 15 7022312 1 Spring 16 7024868 1 Washer 17 7022314 1 Retainer, Spring 18 7023910 1 Shaft 19 7007439 1 Ring, Retaining 20 70000797 1 Cap, End - Axial 21 7022368 5 Screw 22 7021249 1 Bearing, Needle 23 2220886 1 Plug (Includes Item 24) 24 See Note 1 O-Ring (Note: Use p/n 7022328 or 2220886) 25 2220883 1 Plug (Includes Item 26) 26 See Note 1 O-Ring (Note: Use p/n 7022328 or 2220883) 27 2220888 2 Plug (Includes Item 28) 28 See Note 2 O-Ring (Note: Use p/n 7022328 or 2220888) 29 7022372 1 Seat, Spring 30 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.) 31 2220883 2 Plug (Items Item 32) 32 See Note 2 O-Ring (Note: Use p/n 7022328 or 2220883) 33 2220886 1 Plug (Items Item 34) 34 See Note 1 O-Ring (Note: Use p/n 7022328 or 2220886) 35 See Note 1 O-Ring (Note: Use p/n 7022328) 36 See Note 1 Ring, Seal (Note: Use p/n 7022328) 37 7024854 1 Piston, Servo (Includes Items 35 & 36): 38 7007437 1 Bearing 39 7022326 1 Spring 40 See Note 1 Seal, Lip (Note: Use p/n 7022328) 41 7022371 1 Washer, Support

100 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)

3121652 740AJ 1-15

SECTION 1 FRAME

VALVE ROTATED FOR CLARITY

11C

11A

11B

11C

11D

11E

11B

11F

11G

101

102

103

105

FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS

1-16 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-6. FRAME VALVES & SHIELDS INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001157094 Ref DRIVE VALVES INSTALLATION - 4WD/4WS A

2 0641560 3 Bolt 5/16-18 x 7-1/2 10 3311505 3 Nut 5/16-18 11 4641303 1 Flow Divider Valve Assembly

11A 7023933 1 Cartridge, Flow Divider 11A 7021625 1 Seal Kit - 7023933 Cartridge 11B 7022397 6 Cartridge, Check

11B 7022399 6 Seal Kit - 7022397 Cartridge 11C 7021639 2 Cartridge, Check Valves 11C 2900756 2 Seal Kit - 7022398 Cartridge 11D 7024881 1 Piston, Pilot 11E 7023917 2 Cartridge, Flow Divider 11E 7021625 2 Seal Kit - 7023917 Cartridge 11F 70003935 2 Orifice 11G 70003936 1 Orifice

12 4711500 6 Washer 5/16

1001158204 Ref FRAME SHIELDS INSTALLATION (4WS) C

101 0100011 AR Compound, Locking

102 0641606 2 Bolt, 3/8-16 x 3/4

103 4751600 2 Washer 3/8

104 1001158187 1 Cover

105 4280296 27in/

68cm

Tr i m

3121652 740AJ 1-17

SECTION 1 FRAME

104

105

101

103

113

106 107

110

112

111

109

1081317

6711

1 8

102

1 3

FIGURE 1-7. TOW PACKAGE INSTALLATION

1-18 740AJ 3121652

SECTION 1 FRAME

FIGURE 1-7. TOW PACKAGE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TOW BAR INSTALLATIONS

0272373 Ref ANSI, CSA & Australian Specs B

1001166807 Ref CE Specs A

1 0100011 AR Compound, Locking 2 0232121 1 Tow Bar Assembly (See Items 101-113 for Breakdown) 3 0641504 2 Bolt 5/16-18 x 1/2 4 1260017 2 Chain 5 1704578 2 Decal - Crushing (ANSI, CSA & Australian Specs) 5 1706960 2 Decal - Crushing (CE Spec) 6 1705090 1 Decal - Towing Instructions (ANSI, CSA & Australian Specs

Only)

7 3250872 1 Nameplate - Steer/Tow Select Valve (ANSI, CSA & Australian

Specs Only) 8 3311401 2 Nut 1/4-20 9 3420292 2 Pin

11 3820001 4 Rivet (ANSI, CSA & Australian Specs Only) 12 4420051 AR Tape, Safety 13 4640261 1 Valve, Select 14 4711500 2 Washer 5/16 15 4751400 2 Washer 1/4 16 4846507 1 Bracket (Right Front) 17 4846508 1 Bracket (Right Rear) 18 1706957 Decal - Tow Bar & Steer Select (CE Spec Only)

0232121 Ref TOW BAR ASSEMBLY 7/G

101 0362910 1 Pintle, Draw Eye 102 See Note 1 Tow Bar (Note: Use p/n 0232121) 103 0642038 5 Bolt 5/8-11 x 4-3/4 104 3312001 5 Nut 5/8-11 105 4762000 5 Washer, Lock 5/8 106 4070450 AR Shim 107 4070561 AR Shim 108 4740036 1 Washer, Special 109 3420447 1 Pin, Towing 110 3420372 1 Pin, Cotter 111 1260135 1 Chain 112 3760170 2 Ring, Split 113 4070560 2 Shim

3121652 740AJ 1-19

SECTION 1 FRAME

FIGURE 1-7. TOW PACKAGE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-20 740AJ 3121652

SECTION 2

TURNTABLE

3121652 740AJ 2-1

SECTION 2 TURNTABLE

ENGINE SIDE

OF TURNTABLE

102 101

103 101

1 4

2 11 18

104

107

106

105

106

1 5

10812

12A

12B

FIGURE 2-1. CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS

2-2 740AJ 3121652

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001156797 Ref VALVES INSTALLATION B

1 0100011 AR Compound, Locking 2 0641416 2 Bolt 1/4-20 x 2i 3 0641418 2 Bolt 1/4-20 x 2-1/4 4 0641606 8 Bolt 3/8-16 x 3/4 5 0641614 3 Bolt 3/8-16 x 1-3/4 6 0651406 3 Bolt 1/4-28 x 3/4 7 3841340 Loop, Hose 8 2120167 1 Return Filter Assembly 8 2120168 1 Element, Filter 8 7020021 1 Indicator, Clogged 9 2120209 1 Pressure Filter Assembly 9 2120210 1 Element, Filter 9 70000934 1 O-Ring, Filter Bowl

9 7020020 1 Indicator, Clog 10 2220893 1 Fitting, Adapter 11 3311405 2 Nut 1/4-20 12 4640866 1 Valve Assembly (Level)

12A 7017466 1 Cartridge 12A 2900708 1 Seal Kit - Cartridge (Use p/n 7017496) 12B 7012959 1 Knob

13 4640921 1 Valve Assembly - Jib (See ACCESSORY VALVE ASSEMBLY for

Breakdown)

14 4640922 1 Valve Assembly (See ACCESSORY VALVE ASSEMBLY for

Breakdown)

16 4641317 1 Valve Assembly (Brake & 2 Speed)

7012944 2 Coil 7012941 2 Cartridge without Coil 7010543 2 Seal Kit - 7012941 Cartridge (1 Per Cartridge)

17 4641453 1 Main Control Valve Assembly (See MAIN CONTROL VALVE

ASSEMBLY for Breakdown) 18 4711400 9 Washer 1/4 19 4711600 3 Washer 3/8 20 4921927 1 Harness Assembly (Jib Control) (Not Shown - See

ELECTRICAL SECTION for Breakdown) 21 4921928 1 Harness Assembly (4WS) (Not Shown - See ELECTRICAL

SECTION for Breakdown) 22 1001110425 2 Spacer

1001142005 Ref AUXILIARY PUMP INSTALLATION WITH BRACKET C 1001156137 Ref AUXILIARY PUMP INSTALLATION WITHOUT BRACKET A

101 0100011 AR Compound, Locking 102 0641607 4 Bolt 3/8-16 x 7/8 (Pump without Bracket) 102 0811612 4 Bolt 3/8-16 x 1-1/2 Grade 8 (Pump with Bracket) 103 0641610 4 Bolt 3/8-16 x 1-1/4 (Pump without Bracket Only) 104 4711600 4 Washer 3/8 (Pump without Bracket Only) 105 4751600 4 Washer 3/8 (Pump without Bracket Only)

3121652 740AJ 2-3

SECTION 2 TURNTABLE

FIGURE 2-1. CONTROL VALVES & AUXILIARY PUMP INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

106 1001137460 1 Pump, Auxiliary (See AUXILIARY PUMP ASSEMBLY for

Breakdown)

107 1001141783 1 Bracket, Pump Mounting

2-4 740AJ 3121652

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