JLG 740AJ Parts Manual
Illustrated Parts Manual
Model
740AJ
With ADE or UGM
CONTROL MODULE
PRIOR TO
SN 0300185827
P/N
3121161
April 30, 2014
REVISION LOG
MODULE ON MACHINES
“WITHOUT UGM”
(UNIVERSAL
GROUND MODULE)
MODULE ON MACHINES
“WITH UGM”
(UNIVERSAL
GROUND MODULE)
GROUND MODULE MODULE IDENTIFICATION
February 10, 2006 - Original Issue Of Manual (Manual edited to 0010594 Revision 19)
May 31, 2006 - Revised Manual (Manual edited to 0010594 Revision 21)
September 25, 2006 - Revised Manual (Manual edited to 0010594 Revision 22)
April 17, 2007 - Revised Manual (Manual edited to 0010594 Revision 24)
July 30, 2007 - Revised Manual (Manual edited to 0010594 Revision 24)
December 7, 2007 - Revised Manual (Manual edited to 0010594 Revision 25)
March 15, 2008 - Revised Manual (Manual edited to 0010594 Revision 25)
November 28, 2008 - Revised Manual (Manual edited to 0010594 Revision 29)
May 15, 2009 - Revised Manual (Manual edited to 0010594 Revision 37)
October 15, 2009 - Revised Manual (Manual edited to 0010594 Revision 38)
April 15, 2010 - Revised Manual (Manual edited to 0010594 Revision 42)
December 30, 2010 - Revised Manual (Manual edited to 0010594 Revision 45)
April 27, 2011 - Revised Manual (Manual edited to 0010594 Revision 45)
July 29, 2011 - Revised Manual (Manual edited to 0010594 Revision 48)
October 21, 2011 - Revised Manual (Manual edited to 0010594 Revision 49)
January 10, 2012 - Revised Manual (Manual edited to 0010594 Revision B)
May 31, 2012 - Revised Manual (Manual edited to 0010594 Revision C)
July 31, 2012 - Revised Manual (Manual edited to 0010594 Revision C)
December 14, 2012 - Revised Manual (Manual edited to 0010594 Revision C)
March 26, 2013 - Revised Manual (Manual edited to 0010594 Revision D)
June 20, 2013 - Revised Manual (Manual edited to 0010594 Revision I)
September 16, 2013 - Revised Manual (Manual edited to 0010594 Revision J)
December 30, 2013 - Revised Manual (Manual edited to 0010594 Revision J)
April 30, 2014 - Revised Manual (Manual edited to 0010594 Revision O)
3121161 740AJ A
REVISION LOG
B 740AJ 3121161
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 AXLE AND STEERING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 TIRE AND WHEEL INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3 DRIVE HUB ASSEMBLY (PRIOR TO SN 0300138447) . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-4 DRIVE HUB ASSEMBLY (SN 0300138447 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . 1-16
1-5 DRIVE MOTOR ASSEMBLY (PRIOR TO SN 0300138447) . . . . . . . . . . . . . . . . . . . . . . 1-20
1-6 DRIVE MOTOR ASSEMBLY (SN 0300138447 TO PRESENT) . . . . . . . . . . . . . . . . . . . 1-22
1-7 DRIVE VALVES & SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-8 TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 CONTROL VALVES & HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 ACCESSORY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4 AUXILIARY PUMP ASSEMBLY (SN 0300109067 TO PRESENT) . . . . . . . . . . . . . . . . . 2-12
2-5 TURNTABLE BEARING AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . 2-16
2-6 SWING MOTOR/HUB ASSEMBLY (PRIOR TO SN 0300134353) . . . . . . . . . . . . . . . . . 2-18
2-7 SWING MOTOR/HUB ASSEMBLY (SN 0300134353 TO PRESENT) . . . . . . . . . . . . . . 2-24
2-8 DEUTZ ENGINE INSTALLATION (PRIOR TO SN 0300077500) . . . . . . . . . . . . . . . . . . 2-28
2-9 DEUTZ ENGINE INSTALLATION (SN 0300077500 TO PRESENT) . . . . . . . . . . . . . . . 2-34
2-10 FORD ENGINE INSTALLATION (PRIOR TO SN 0300077500) . . . . . . . . . . . . . . . . . . . 2-46
2-11 FORD ENGINE INSTALLATION (SN 0300077500 TO PRESENT) . . . . . . . . . . . . . . . . 2-52
2-12 DUAL FUEL INSTALLATION (GAS MACHINES OPTIONS) . . . . . . . . . . . . . . . . . . . . . 2-60
2-13 GM ENGINE INSTALLATION (PRIOR TO SN 0300140592) . . . . . . . . . . . . . . . . . . . . . 2-64
2-14 GM ENGINE INSTALLATION (SN 0300140592 TO PRESENT) . . . . . . . . . . . . . . . . . . 2-70
2-15 PISTON PUMP ASSEMBLY (SAUER DANFOSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
2-16 PISTON PUMP ASSEMBLY (EATON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
2-17 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
2-18 ROTARY COUPLING INSTALLATION (PRIOR TO SN 0300138447) . . . . . . . . . . . . . . 2-88
2-19 ROTARY COUPLING INSTALLATION (SN 0300138447 TO PRESENT) . . . . . . . . . . . 2-90
2-20 GROUND CONTROL BOX ASSEMBLY (PRIOR TO SN 0300139070) . . . . . . . . . . . . . 2-92
2-21 GROUND CONTROL BOX ASSEMBLY (SN 0300139070 TO PRESENT) . . . . . . . . . . 2-96
2-22 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . 2-100
2-23 HOODS INSTALLATION (PRIOR TO SN 0300089982). . . . . . . . . . . . . . . . . . . . . . . . . 2-104
2-24 HOODS INSTALLATION (ABS) (SN 0300089982 TO PRESENT). . . . . . . . . . . . . . . . . 2-108
2-25 HOODS INSTALLATION (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
2-26 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
2-27 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (ANSI & CSA SPEC
ONLY) (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2-28 2500W GENERATOR INSTALLATION - FORD MACHINES (ANSI & CSA SPEC
ONLY) (OPTIONAL) (PRIOR TO SN 0300077500). . . . . . . . . . . . . . . . . . . . . . . . . . 2-126
2-29 2500W GENERATOR INSTALLATION - FORD MACHINES (ANSI & CSA SPEC
ONLY) (OPTIONAL) (SN 0300077500 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 2-130
2-30 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL). . . . . . . . . . . . . 2-134
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 BOOM AND CYLINDERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 MAIN BOOM ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 ROTATOR ASSEMBLY (PRIOR TO SN 0300130881) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4 ROTATOR ASSEMBLY (SN 0300130881 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED). . . . . . . . . . . . . . . 3-16
3121161 740AJ i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 PLATFORM COMPONENTS INSTALLATION (PRIOR TO SN 0300130881) . . . . . . . . . 4-2
4-2 PLATFORM COMPONENTS INSTALLATION (SN 0300130881 TO PRESENT) . . . . . . 4-6
4-3 PLATFORM CONSOLE ASSEMBLY (PRIOR TO SN 0300138447) . . . . . . . . . . . . . . . . 4-10
4-4 PLATFORM CONSOLE ASSEMBLY (SN 0300138447 TO PRESENT) . . . . . . . . . . . . . 4-14
4-5 CONTROLLER ASSEMBLY (SWING & LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-7 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (PRIOR TO SN 0300137666) . . 4-26
4-8 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) (SN 0300137666 TO
PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 UPRIGHT LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 LIFT CYLINDER ASSEMBLY - JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5 MASTER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6 SLAVE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 STEER CYLINDER ASSEMBLY (PRIOR TO SN 0300142664). . . . . . . . . . . . . . . . . . . . 5-14
5-8 STEER CYLINDER ASSEMBLY (SN 0300142664 TO PRESENT) . . . . . . . . . . . . . . . . . 5-16
5-9 TELESCOPE CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-1 DRIVE HYDRAULIC DIAGRAM (PRIOR TO SN 0300137975) . . . . . . . . . . . . . . . . . . . . 6-2
6-2 DRIVE HYDRAULIC DIAGRAM (SN 0300137975 TO PRESENT) . . . . . . . . . . . . . . . . . 6-6
6-3 STANDARD HYDRAULIC DIAGRAM (WITH FENNER & HALDEX BRAND
AUXILIARY PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-4 STANDARD HYDRAULIC DIAGRAM (WITH BUCHER BRAND AUXILIARY PUMP) . . . 6-14
6-5 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-1 ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 HARNESS COMPONENTS INSTALLATION WITHOUT UGM . . . . . . . . . . . . . . . . . . . 7-4
7-3 HARNESS COMPONENTS INSTALLATION WITH UGM . . . . . . . . . . . . . . . . . . . . . . . 7-20
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 DECAL INSTALLATION (ANSI SPEC) (PRIOR TO SN 0300089982). . . . . . . . . . . . . . . 8-2
8-2 DECAL INSTALLATION (ANSI & CSA SPEC) (SN 0300089982 TO PRESENT) . . . . . . 8-6
8-3 DECAL INSTALLATION (COUNTRY SPEC) (PRIOR TO SN 0300089982) . . . . . . . . . . 8-10
8-4 DECAL INSTALLATION (COUNTRY SPEC) (SN 0300089982 TO PRESENT) . . . . . . . 8-14
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . .9-1
SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
ii 740AJ 3121161
SECTION 1
FRAME
3121161 740AJ 1-1
SECTION 1 FRAME
106
6
7
6
110
106
114
11
17
104
102
118
401
105
117
112
12
13
16
115
116
19
122
212
212
206
206
220
220
214
214
215
318
214
211
203
201
317
309
304
301
301
203
201
204
305
315
315
305
320
324
307
223
204
223
317
304
214
211
310
216
317
317
311
311
306
306
325
325
302
202
205
205
307
219
224
312
304
301
329
322
326
321
314
313
316
330
330
331
304
301
317
317
303
327
328
217
217
321
321
301
203
201
317
214
308
208
222
323
323
208
308
107
111
120
121
4
1
5
1
101
2
1
8
9
14
15
10
119
304
304
301
301
203
203
201
201
221
332
332
FIGURE 1-1. AXLE AND STEERING INSTALLATION
1-2 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0258286 Ref FIXED AXLE INSTALLATION WITHOUT TOW PACKAGE C
1 0100011 AR Compound, Locking
2 0681608 4 Bolt 3/8in-16NC x 1in (Grade 8)
3Not Used
4 0641820 2 Bolt 1/2in-13NC x 2-1/2in
5 0642212 1 Bolt 3/4in-10NC x 1-1/2in
6 0962102 2 Bushing, Garmax
7 3422703 1 Pin, Axle Pivot
8 3538047 2 Shim, Wear
9 3539877 2 Plate, Stop
10 3539878 2 Plate, Stop
11 3841287 1 Keeper, Pin
12 4070878 AR Shim 1/16in
13 4070879 AR Shim 1/8in
14 4070944 AR Shim 1/16in
15 4070945 AR Shim 1/4in
16 4711600 4 Flatwasher 3/8in Narrow
17 4740472 1 Washer, Special
18 Not Used
19 4845658 1 Axle Weldment
0271654 Ref FIXED AXLE INSTALLATION WITH TOW PACKAGE B
101 0100011 AR Compound, Locking
102 0100019 AR Compound, Locking
103 Not Used
104 0642212 1 Bolt 3/4in-10NC x 1-1/2in
105 0681608 4 Bolt 3/8in-16NC x1in (Grade 8)
106 0962102 2 Bushing, Composite
107 0641820 2 Bolt 1/2in-13NC x 2-1/2in
108 to 109 Not Used
110 3422703 1 Pin, Main Pivot
111 3539877 2 Plate, Stop
112 3538047 2 Shim, Axle Wear
113 Not Used
114 3841287 1 Shaft, Keeper 3/8in Dia x 6in
115 4070878 2 Shim, Axle Wear
116 4070879 2 Shim, Axle Wear
117 4711600 4 Flatwasher 3/8in Narrow
118 4740472 1 Washer, Special
119 3539878 2 Plate, Stop
120 4070944 AR Shim 1/16in
121 4070945 AR Shim 1/4in
122 4846413 1 Axle Weldment
3121161 740AJ 1-3
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
Ref STEERING INSTALLATION WITHOUT TOW
0258909 Ref Prior to SN 0300138447 C
1001100156 Ref SN 0300138447 to SN 0300185827 D
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.
201 0100011 AR Compound, Locking
202 0362726 1 Tie-Rod
203 0641608 6 Bolt 3/8in-16NC x 1in
204 AR Bolt Options:
0641608 8 Prior to SN 0300138447 (3/8in-16NC x 1in)
0641810 16 SN 0300138447 to SN 0300185827 (1/2in-13NC x 1-1/4in)
205 4 Bearing Options:
0962224 Bearing, Composite (Prior to SN 0300138447)
0962448 Bearing, Composite (SN 0300138447 to SN 0300149294)
1001112651 Bearing, Aluminum Bronze (SN 0300149294 to SN
0300185827)
206 0962152 2 Bearing, Garmax
207 Not Used
208 2 Steer Cylinder Assembly Options (See CYLINDER SECTION
for Breakdown):
1683740 Prior to SN 0300142664
1001097243 SN 0300142664 to SN 0300185827
209 to 210 Not Used
211 3422701 2 Pin, Steer, Spindle Attach
212 3422702 2 Pin, Tie-Rod
213 Not Used
214 3841143 6 Shaft, Keeper 3/8inx 3in
215 1 Spindle Weldment (Right Side) Options:
4130357 Prior to SN 0300138447
4130389 SN 0300138447 to SN 0300185827
216 1 Spindle Weldment (Left Side) Options:
4130358 Prior to SN 0300138447
4130390 SN 0300138447 to SN 0300185827
217 4740111 4 Washer, Special
218 Not Used
219 4740463 2 Washer, Thrust
220 4740473 2 Washer, Special
221 1001103810 AR Washer, Thrust (.187in)
222 4740256 AR Washer, Thrust
223 4 Kingpin Options:
3422753 Prior to SN 0300138447
3422972 SN 0300138447 to SN 0300185827
1-4 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
224 3422754 2 Pin, Attach
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.
301 0100011 AR Compound, Locking
302 0362726 1 Tie-Rod
303 0641508 1 Bolt 5/16in-18NC x 1in
304 0641608 7 Bolt 3/8in-16NC x 1in
305 0641810 16 Bolt 1/2in-13NC x 1-1/4in
306 0962152 2 Bushing
307 4 Bushing Options:
0962448 Prior to SN 0300149294
1001112651 SN 0300149294 to SN 0300185827
308 2 Steer Cylinder Assembly Options (See CYLINDER SECTION
for Breakdown):
1683740 Prior to SN 0300142664
1001097243 SN 0300142664 to SN 0300185827
309 3422587 1 Pin
310 3422701 1 Pin
311 3422702 2 Pin
312 3422754 2 Pin
313 3422813 1 Pin
314 3422848 1 Pin
315 3422972 4 Kingpin
316 3573001 1 Link
317 3841143 8 Keeper, Pin
318 4130388 1 Spindle (Front Right)
319 4130389 1 Spindle (Left Rear) (Not Shown)
320 4130390 1 Spindle (Left Front and Right Rear)
321 4740111 6 Thrustwasher
322 4740155 AR Thrustwasher
323 4740256 4 Thrustwasher
324 4740463 2 Thrustwasher
325 4740473 2 Flatwasher
326 1 Bar, Pivot Options:
4846414 Prior to SN 0300136124
4846935 SN 0300136124 to SN 0300185827
327 3340966 2 Pad, Stop
328 4071059 AR Shim
329 0741609 4 Screw, Countersunk 3/8in-16NC x 1-1/8in
330 0962292 2 Bushing
3121161 740AJ 1-5
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
331 0962348 1 Bushing
332 3020029 AR Lube, Bearing
401 Ref FRAME WELDMENT
2360570 Ref Prior to SN 0300138447
2360686 Ref SN 0300138447 to SN 0300185827
1-6 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121161 740AJ 1-7
SECTION 1 FRAME
104
101
113
114
106
108
PRIOR TO
SN 0300137975
SN 0300137975
TO PRESENT
6
8
9
13
4
3
5
14
7
201
202
203
109
201
202
203
301
303
302
301
303
302
FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS
1-8 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0270211 Ref WHEEL DRIVE INSTALLATION (PRIOR TO SN 0300138447) D
1 to 2 Not Used
3 0682016 32 Bolt 5/8in-11NC x 2in (Grade 8)
4 4 Drive Brake Assembly Options:
Use 0920119 Prior to SN 0300133482 (was p/n 0920117)
0920119 SN 0300133482 to SN 0300185827
7018612 1 Repair Kit (Includes Case Seal, Piston Inner & Outer O-Rings
& Back-up Rings, Stator Disc, Rotor Disc, Return Plate,
Springs, Oil Seal, Bearing, 2 Retaining Rings & 2 Mounting
Face Gaskets) (1 Per Assembly)
7000731 2 Gasket, Mounting Face (2 Per Assembly)
7007990 1 O-Ring, Mounting (1 Per Assembly) (0920119 Brake)
Ref Note: No Other Parts Available.
5 2780228 4 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for
Breakdown)
6 3160204 4 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for
Breakdown)
7 3300007 40 Nut, Wheel
8 3311801 8 Nut 1/2in-13 NC
9 4300097 8 Stud
10 to 12 Not Used
13 4891800 8 Flatwasher, 1/2in
14 4892000 32 Flatwasher, 5/8in
0274232 Ref WHEEL DRIVE INSTALLATION (SN 0300138447 TO PRESENT) D
101 0100011 AR Compound, Locking
102 Not Used
103 3311801 8 Nut 1/2in-13 NC
104 0682016 32 Bolt 5/8in-11NC x 2in (Grade 8)
105 Not Used
106 2780272 2 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for
Breakdown)
107 Not Used
108 3160348 4 Drive Motor Assembly (See DRIVE MOTOR ASSEMBLY for
Breakdown)
109 3300007 40 Nut, Wheel
110 to 112 Not Used
113 4891800 8 Flatwasher, 1/2in Hardened
114 4892000 32 Flatwasher, 5/8in Hardened
3121161 740AJ 1-9
SECTION 1 FRAME
FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
0270888 Ref TIRE AND WHEEL INSTALLATION C
0271090 2 18-625 Foam-Filled Left Side
0271091 2 18-625 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,
201 4520253 1 Tire, Replacement
202 Not Required 1 Valve, Air
203 4860225 1 Rim, Wheel
0256196 Ref WHEEL COVER INSTALLATION (OPTIONAL) 2/A
301 1670776 4 Cover, Wheel
302 0641550 20 Bolt 5/16in - 18NC x 6-1/4in
303 0100011 AR Compound, Locking
1-10 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-2. TIRE AND WHEEL INSTALLATIONS (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121161 740AJ 1-11
SECTION 1 FRAME
191A1B
1C1D1N
1G1F1E1H2
11
7
7
21
8
9
10
6A
6
161615
15
2WD
15
15
12
13
14
3B
3F
3C
3D
3C
3B
3A
3
3E
3G
5
1
4
5
6B
6H
6G
20
20
6F
6E
6D
6C
17
1
1J1J25
FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300138447)
1-12 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300138447)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
2780228 Ref DRIVE HUB ASSEMBLY (4WD) E
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
1K Not Used
1L Not Used
1M Not Used
1N 7000265 10 Stud, Wheel
2 7017034 1 Gear, Ring
3 See Note 1 Carrier Assembly (Note: Not Available - Purchase Individual
Components.)
3A 7017036 1 Carrier
3B 7001901 6 Thrustwasher, Tanged
3C 7001902 96 Bearing, Needle
3D 7001903 3 Spacer, Thrust
3E 7017040 3 Shaft, Planet
3F 7017037 3 Gear, Cluster
3G 7001906 3 Rollpin
4 7017035 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 7017042 1 Cap
6C 7000220 4 Bolt 1/4in-20NC x 3/4in
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 Thrustwasher
8 7000283 1 O-Ring
9 7000284 1 Ring, Retaining
10 7017027 1 Ring, Retaining
11 7017044 1 Shaft, Input
12 7017045 1 Spacer, Input
13 7017043 1 Gear, Sun
14 7017046 1 Spacer, Input
15 7000287 4 Thrustwasher
3121161 740AJ 1-13
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300138447) (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
16 7000288 2 Thrustwasher
17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)
18 Not Used
19 7000290 1 Coupling
20 7017047 2 Pin, Dowel
21 Not Required Thrustwasher
22 to 24 Not Used
25 7017068 1 Seal Kit (Includes Items 1B, 1I, 5, 6F, 6G, 15 &16)
1-14 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300138447) (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3121161 740AJ 1-15
SECTION 1 FRAME
105
31
111
110
112
121
102
119
122
123
104
103
103
101
109
107
108
28
29
114
113
116
115
118
117
120
27191A1B1C
1D
1N1G1F1E1H
26
2
6A
16
16
15
15
15
15
35
126A
126B
127
128
125
12
13
3B
3F
3C
3D
3C
3B
3
3A
3E
3G
5
1
4
5
6B
6H
6G
20
20
6F
6E
6D
6C
17
1
106
106
1J
1J
11
7
7
21
8
9
10
FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300138447 TO PRESENT)
1-16 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300138447 TO PRESENT)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
2780272 Ref DRIVE HUB/BRAKE ASSEMBLY B
2780227 Ref Hub Assembly A
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
1K Not Used
1L Not Used
1M Not Used
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 Thrustwasher, 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 1/4in-20NC x 3/4in
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 Thrustwasher
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
14 Not Used
3121161 740AJ 1-17
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300138447 TO PRESENT) (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
15 7000287 4 Thrustwasher
16 7000288 2 Thrustwasher
17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8)
18 Not Used
19 7000290 1 Coupling
20 7017047 2 Pin, Dowel
21 7017050 1 Thrustwasher
22 to 25 Not Used
26 7024182 1 Brake Assembly (Includes Items 101-123)
27 7024763 2 O-Ring
28 7024717 2 Stud 1/2in-13NC x 4-5/8in
29 7024718 2 Nut 1/2in-13NC
30 Not Used
31 7000731 1 Gasket
32 to 34 Not Used
35 7017068 1 Seal Kit - Hub (Includes Items 1B,1I, 5, 6F, 6G, 15 & 16)
7024182 Ref BRAKE ASSEMBLY
101 7024189 1 Shaft
102 Use 7024182 1 Housing (Note: Not Available - Purchase Complete Assy.)
103 Use 7024193 2 Plate, Friction
104 Use 7024193 1 Plate, Pressure
105 7000731 1 Gasket
106 Use 7024193 2 Plate, Outer
107 See Note 1 Gasket (Note: Use Item 125, 127 or 128.)
108 7024191 1 Cylinder
109 7024192 1 Piston
110 Use 7024197 1 Bearing, Ball
111 Use 7024197 1 Ring, Retaining
112 Use 7024197 1 Seal, Shaft
113 See Note 6 Capscrew (Note: Not Available for Purchase.)
114 See Note 6 Lockwasher (Note: Not Available for Purchase.)
115 Use 7024194 1 O-Ring
116 Use 7024194 1 Ring, Back-up
117 Use 7024194 1 O-Ring
118 Use 7024194 1 Ring, Back-up
119 7024190 2 Pin, Dowel
120 See Note 1 Plug (Note: Not Available - Purchase Locally.)
121 See Note 2 Plug (Note: Not Available - Purchase Locally.)
122 Use 7024195 10 Spring Kit (Natural)
123 Use 7024196 2 Spring Kit (Blue)
124 Not Used
125 7024194 1 Seal Kit - Brake (Includes Items 105, 107 & 115-118)
126 Spring Kit - Brake Options:
126A 7024195 1 Includes 12 Natural Colored Springs Item 122 (was p/n
7024195)
Note: Spring Kit no Longer Available, Purchase Kit p/n
7024196.
126B 7024196 1 Includes 12 Natural & 2 Blue Colored Springs Items 122 & 123
1-18 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300138447 TO PRESENT) (CONTINUED)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
127 7024193 1 Friction Disc Kit - Brake (Includes Items 103, 104, 106 & 107)
128 7024197 1 Bearing Kit - Brake (Includes Items 107 & 110-112)
3121161 740AJ 1-19
SECTION 1 FRAME
23
22
21
20
30
31
19
18
1716151413121110987
6
5
4
3
2
24
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (PRIOR TO SN 0300138447)
1-20 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-5. DRIVE MOTOR ASSEMBLY (PRIOR TO SN 0300138447)
ITEM # PART NUMBER QTY. DESCRIPTION REV.
3160204 Ref DRIVE MOTOR ASSEMBLY A
1 7012701 1 Shaft - 13 Teeth
2 Use 2900788 1 Seal, Shaft
3 7012702 2 Bearing, Cradle
4 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.)
5 7012703 1 Rod, Piston
6 7012704 1 Piston, Stroking
7 Use 2900788 1 O-Ring
8 7012705 1 Nut, Adapter
9 7012706 1 Bearing, Roller
10 7012707 4 Bolt, Socket Head M12 x 65
11 7012708 1 Block, Port
12 7012709 1 Shim
13 7012710 1 Pin, Dowel M6 x 18
14 Use 2900788 1 O-Ring
15 7012711 1 Nut, Cap M10 x 1
16 7012712 1 Screw, Adjusting
17 Use 2900788 2 O-Ring
18 7012713 1 Nut, Jam M10 x 1
19 Use 7012716 1 Rotary Group Assembly
20 See Note 1 Plug (Note: Not Available - Purchase Locally.)
21 Use 7012716 1 Plate, Swash
22 7012714 1 Bearing, Roller
23 7012715 1 V-Ring
24 7012700 1 Control Plate Assembly
25 to 29 Not Used
30 2900788 1 Seal Kit (Includes Items 2,7,14,17 and O-Rings under Item 24)
31 7012716 1 Rotary Group Kit (Includes Items 19 and 21)
3121161 740AJ 1-21
SECTION 1 FRAME
3
41340193830343332
313231
18
1
1
4
11
129107A1316151714
7
8
6
2
5
5
22
20
21
23
24
25
26
28
27
37
36
35
39
29
50
FIGURE 1-6. DRIVE MOTOR ASSEMBLY (SN 0300138447 TO PRESENT)
1-22 740AJ 3121161
SECTION 1 FRAME
FIGURE 1-6. DRIVE MOTOR ASSEMBLY (SN 0300138447 TO PRESENT)
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 1 Swashplate
5 See Note 2 Pin (Note: Not Available for Purchase)
6 Use 7022328 1 Gasket
7 7023907 1 Cylinder Block Kit (Includes Items 7A & 9-17)
7A Use 7023907 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 Use 7022328 1 O-Ring
25 2220883 1 Plug (Includes Item 26)
26 Use 7022328 1 O-Ring
27 2220888 2 Plug (Includes Item 28)
28 Use 7022328 2 O-Ring
29 7022372 1 Seat, Spring
30 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.)
31 2220883 2 Plug (Items Item 32)
32 Use 7022328 2 O-Ring
33 2220886 1 Plug (Items Item 34)
34 Use 7022328 1 O-Ring
35 Use 7022328 1 O-Ring
36 Use 7022328 1 Ring, Seal
37 7024854 1 Piston, Servo (Includes Items 35 & 36)
38 7007437 1 Bearing
39 7022326 1 Spring
40 Use 7022328 1 Seal, Lip
41 7022371 1 Washer, Support
42 to 49 Not Used
50 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)
3121161 740AJ 1-23
SECTION 1 FRAME
OR
VALVE ROTATED FOR CLARITY
111
102
112
112
110
111C
111A
111B
111C
111D
111E
111B
203
202
201
202
201
205
205
204
11
12
1
2
2
1
12
10B
10A
10
10C
111F
111F
111G
FIGURE 1-7. DRIVE VALVES & SHIELDS INSTALLATIONS
1-24 740AJ 3121161
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