Page 1
Illustrated Parts Manual
Models
E45A/AJ
E40AJP
E40AJPnarrow
M45A/AJ
M40AJP
M40AJPnarrow
P/N
3120885
August 31, 2011
Page 2
Page 3
REVISION LOG
June 30, 1999 - Original Issue Of Manual
September 30, 1999 - Revised Manual (Revised to B/M 0010554 Revision 5)
November 1, 1999 - Updated Page 2-15
June 1, 2000 - Revised Manual (E45 & M45 Revised to B/M 0010554 Revision 15)
Added E40 & M40 Models. (E40 & M40 Edited to B/M 0010571 Revision 1)
August 15, 2000 - Revised Manual (Revised to B/M 0010554 Revision 19)
January 27, 2004 - Revised Manual
January 31, 2008 - Revised Manual
August 31, 2011 - Revised Manual
3120885 A
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REVISION LOG
B 3120885
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TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME
1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-4 HYDRAULIC COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-5 BRAKE/STEER VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1-6 BATTERIES AND CHARGER INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
1-7 BATTERY CHARGER ASSEMBLY (PRIOR TO S/N 49542). . . . . . . . . . . . . . . . . . . . . . .1-22
1-8 BATTERY CHARGER ASSEMBLY (S/N 49542 TO PRESENT) . . . . . . . . . . . . . . . . . . . .1-24
1-9 ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) . . . . . . . . . . . . . .1-26
1-10 MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY) . . . . . . . . . . . . . . . . . . . . .1-30
1-11 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
SECTION 2 - TURNTABLE
2-1 VALVES AND HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-3 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-4 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-5 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2-6 TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION
(M45 & M40 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-7 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2-8 HOODS AND BEACON LIGHT INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
SECTION 3 - BOOM
3-1 BOOMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 MAIN BOOM ASSEMBLY (E45A & M45A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-3 MAIN BOOM ASSEMBLY (E45AJ & M45AJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-4 MAIN BOOM ASSEMBLY (E40AJP & M40AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-5 SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (PRIOR TO S/N49945). . . . . .3-12
3-6 SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N49945 TO PRESENT) . . .3-14
3-7 SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP) . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-8 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-9 CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONS . . . . . . . . . . . . . . . . . . . .3-24
SECTION 4 - PLATFORM
4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2 PLATFORM PADDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-4 CONTROLLER ASSEMBLY (SWING AND LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-5 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
SECTION 5 - CYLINDER
5-1 JIB CYLINDER ASSEMBLY (AJ & AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 PLATFORM LEVEL CYLINDER ASSEMBLY (E45A & M45A) . . . . . . . . . . . . . . . . . . . . .5-4
5-3 PLATFORM LEVEL CYLINDER ASSEMBLY (AJ & AJP) . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4 LIFT CYLINDER ASSEMBLY - LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-5 LIFT CYLINDER ASSEMBLY - MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-6 LIFT CYLINDER ASSEMBLY - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-7 MASTER CYLINDER ASSEMBLY (A MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
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TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
5-8 MASTER CYLINDER ASSEMBLY (AJ & AJP MODELS) . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-9 ROTATOR CYLINDER ASSEMBLY (E45 & M45 ONLY) (PRIOR TO
S/N 49945 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-10 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5-11 TELESCOPE CYLINDER ASSEMBLY (E45 & M45) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-12 TELESCOPE CYLINDER ASSEMBLY (E40 & M40) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
SECTION 6 - HYDRAULIC
6-1 STANDARD HYDRAULIC DIAGRAM (E45A & M45A) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 STANDARD HYDRAULIC DIAGRAM (E45AJ & M45AJ) . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-3 STANDARD HYDRAULIC DIAGRAM (E40AJP & M40AJP) . . . . . . . . . . . . . . . . . . . . . . 6-10
6-4 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
SECTION 7 - ELECTRICAL
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-2 ELECTRICAL SCHEMATIC (E45 & M45 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7-3 ELECTRICAL SCHEMATIC (E40 & M40 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-4 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
SECTION 8 - DECALS
8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK
SECTION 10 - SPECIAL OPTIONS
SECTION INDEX
ii 3120885
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SECTION 1 FRAME
S
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 HYDRAULIC COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 BRAKE/STEER VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-6 BATTERIES AND CHARGER INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-7 BATTERY CHARGER ASSEMBLY (Prior to S/N 49542) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-8 BATTERY CHARGER ASSEMBLY (S/N 49542 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-9 ELECTRICAL COMPONENTS INSTALLATION (Frame Mounted). . . . . . . . . . . . . . . . . . . . . . . 1-26
1-10 MOTOR/GENERATOR INSTALLATION (M45A/AJ Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1-11 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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SECTION 1 FRAME
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FIGURE 1-1. STEER INSTALLATION
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SECTION 1 FRAME
FIGURE 1-1. STEER INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
STEER INSTALLATION OPTIONS: Ref.
0257817 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP Ref. 4/B
0270010 E40AJPnarrow & M40AJPnarrow Ref. 1/A
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1 Hub/Spindle Assembly Options: (Left Side) (See
Items 101-115 for Breakdown)
2780242 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
2780250 E40AJPnarrow & M40AJPnarrow
2 Hub/Spindle Assembly Options: (Right Side) (See
Items 101-115 for Breakdown)
2780241 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
2780251 E40AJPnarrow & M40AJPnarrow
3 3300426 Lugnut 5/8”-18NF 18
4 3422692 Kingpin 2
5 Steering Link Options: 2
3010119 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
3010121 E40AJPnarrow & M40AJPnarrow
6 1683591 Steer Cylinder Assembly (See Section 5 for
Breakdown)
7 3841367 End, Rod 2
8 0440162 Washer, Thrust 2
9Not Used
10 3312008 Nut, Serrated 5/8”-11NC 4
11 0641606 Bolt 3/8”-16NC x 3/4” 4
12 3450810 Pin, Cotter 1/4” x 2 1/2” 2
13 3323003 Nut, Castle 1 1/4”-12NF 2
14 3900109 Screw, Socket Head Shoulder 3/4”-16NF x 1 3/4” 4
15 3322202 Nut, Jam 3/4”-16NF 2
16 0681810 Bolt 1/2”-13NC x 1 1/4” (Grade 8) 4
17 0100011 Loctite #242 (Not Shown) A/R
18 4891800 Washer, Hardened 1/2” 4
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HUB/SPINDLE ASSEMBLY OPTIONS:
2780242 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
(Left Side)
2780250 E40AJPnarrow & M40AJPnarrow (Left Side) Ref. B
2780241 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
(Right Side)
2780251 E40AJPnarrow & M40AJPnarrow (Right Side) Ref. B
101 Spindle Options: A/R
4130350 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
(Left Side)
7023216 E40AJPnarrow & M40AJPnarrow (Left Side)
4130351 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
(Right Side)
7023217 E40AJPnarrow & M40AJPnarrow (Right Side)
102 0962140 Bushing (1 per Assembly) 2
103 0961951 Bushing (2 per Assembly) 4
104 7020035 Hub Assy (1 per Assembly) 2
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Ref. B
Ref. B
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FIGURE 1-1. STEER INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
105 7020036 Cup, Bearing - Inner (1 per Assembly) 2
106 7020038 Cup, Bearing - Outer (1 per Assembly) 2
107 7020041 Stud (9 per Assembly) 18
108 7020037 Cone, Bearing - Inner (1 per Assembly) 2
109 7020039 Cone, Bearing - Outer (1 per Assembly) 2
110 7020040 Seal, Lip (1 per Assembly) 2
111 7020137 Dust Cap (1 per Assembly) 2
112 3300426 Lugnut 5/8”-18NF (9 per Assembly) 18
113 7020055 Washer, Tanged (1 per Assembly) 2
114 7020054 Nut, Castle (1 per Assembly) 2
115 7020140 Pin, Cotter (1 per Assembly) 2
201 FRAME WELDMENTS 1
2360505 E45A, M45A, E40AJP & M40AJP
2360510 E45AJ & M45AJ
2360531 E40AJPnarrow & M40AJPnarrow
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FIGURE 1-1. STEER INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 1 FRAME
7
6
101
201
202
203
104
103
102
5
11
4
88
3
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1
1
5A
2
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FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION
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SECTION 1 FRAME
FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
WHEEL DRIVE INSTALLATION OPTIONS: Ref.
0259069 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP Ref. 6/G
0270103 E40AJPnarrow & M40AJPnarrow Ref. 4
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1 0100019 Loctite #271 A/R
2 0641609 Bolt 3/8”-16NC x 1 1/8” 8
3 0641826 Bolt 1/2”-13NC x3 1/4” 4
4 0682010 Bolt 5/8”-11NC x 1 1/4” (Grade 8) 12
5 0920113 Drive Brake Assembly 2
7011757 Repair Kit - Complete for 0920113 Brake (1 per
Assembly)
2900768 Bearing Kit for 0920113 Brake (1 per Assembly) 2
7007900 Seal, Oil for 0920113 Brake (1 per Assembly) 2
7007977 Ring, Retaining for 0920113 Brake (1 per Assem-
bly)
7011716 Ring, Retaining for 0920113 Brake (1 per Assem-
bly)
5A 7000731 Gasket (1 Per Assembly) 2
6 3300426 Lugnut 18
7 2780236 Drive Hub Assembly (See Figure 1-3 for Breakdown) 2
8 3160239 Drive Motor Assembly 2
7020138 Brush Kit for 3160239 (1 per Assembly) 2
7020150 Holder for 3160239 (1 per Assembly) 2
9 3990105 Sensor, Speed 2
10 4711600 Flatwasher 3/8” Narrow 8
11 4892000 Washer, Hardened 5/8” 12
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TIRE AND WHEEL INSTALLATIONS
0258995 IN240/55-17.5 Pneumatic Ref. 1
0270416 IN240/55-17.5 Pneumatic (Non-Marking) Ref. 1
0258996 IN240/55-17.5 Foam-Filled Ref. 1
0270418 IN240/55-17.5 Foam-Filled (Non-Marking) Ref. 1
0259679 LT215/8R16 Pneumatic Ref. 1
0270037 26” x 7” x 20” Solid (Non-Marking) Ref. A
0270028 Solid (Non-Marking) Ref. 1/B
Tire Assembly Options: A/R
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.
E45A, M45A, E45AJ, M45AJ:
0258688 OTR IN240/55-17.5 Pneumatic 4 1/A
0270415 OTR IN240/55-17.5 Pneumatic (Non-Marking) 4 1/A
0258997 OTR IN240/55-17.5 Foam-Filled 4 1/A
0270417 OTR IN240/55-17.5 Foam-Filled (Non-Marking) 4 1/A
0258037 Goodyear LT215/8R16 Pneumatic 4 1/A
4520232 Monarch 26” x 7” x 20” Solid (Non-Marking)
(Sold as Assembly Only)
4A
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FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
E40AJP & M40AJP:
0258997 OTR IN240/55-17.5 Foam-Filled 4 1/A
0270417 OTR IN240/55-17.5 Foam-Filled (Non-Marking) 4 1/A
E40AJPnarrow & M40AJPnarrow:
4520231 Trelleborg 22” x 6” x 17.75” (M40AJPnarrow &
E40APJnarrow Front Tire) (Solid) Non-Marking
(Sold as Assembly Only)
4520208 Trelleborg 25” x 7” x 12” (M40AJPnarrow &
E40APJnarrow Rear Tire) (Solid) Non-Marking
(Sold as Assembly Only)
101 Tire Options: 1
4520209 IN240/55-17.5
4520247 IN240/55-17.5 Non-Marking
4520206 LT215/8R16
102 Rim, Wheel Options: 1
4860191 Use with IN240/55-17.5 Tires
4860181 Use with LT215/8R16 Tires
Not Available Other Tire/Wheel Assemblies (Purchase
Complete Assembly)
103 4640392 Valve, Air 1
104 Decal - Tire Air Pressure Options: 1
1702740 90PSI
1702701 95PSI
2B
2E
0259302 WHEEL COVER INSTALLATION (IN240/55-17.5 TIRES
ONLY)
201 1670887 Cover, Wheel 4
202 0641542 Bolt 5/16”-18NC x 5 1/4” 12
203 4711500 Flatwasher 5/16” Narrow 12
204 0100011 Loctite #242 (Not Shown) A/R
Ref. 1/A
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FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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FIGURE 1-3. DRIVE HUB ASSEMBLY
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FIGURE 1-3. DRIVE HUB ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
2780236 DRIVE HUB ASSEMBLY Ref. C
1 7021323 Gear, Planet 4
2 7021324 Gear, Planet 3
3 7021325 Gear, Sun 1
4 Kits 2 & 5 Nut, Shaft 1
5 7021326 Bolt, Planet 3
6 7021327 Ring, Support 1
7 7021328 Carrier, Planet 1
8 Kit 1 Cover 1
9Not Used
10 Kit 2 Bearing, Roller 3
11 Kit 2 Bearing, Roller 4
12 Kit 2 Bearing, Roller 2
13 Not Used
14 Kit 2 Ring, Retaining 3
15 Kit 2 Ring, Retaining 4
16 7021341 Ring, Retaining 1
17 Kit 2 Disk, Support 3
18 Not Used
19 Kit 3 O-Ring 1
20 Kit 3 Seal, Ring 1
21 Kits 3 & 5 Plug 3
22 Kit 3 Seal, Ring 3
23 7021342 Bolt 3
24 Kit 2 Ball 2
25 Kits 2 & 5 Expander 2
26 to 28 Not Used
29 Kit 2 Washer, Housing 1
30 7021335 Gear, Ring 1
31 to 32 Not Used
33 Kits 1 & 3 O-Ring 1
34 Kit 1 Ring, Retaining 1
35 to 42 Not Used
43 7021336 Shaft, Sun Gear 1
44 7021337 Shaft, Input 1
45 to 48 Not Used
49 Kit 2 Washer, Thrust 1
50 Not Used
51 Kit 1 Cover 1
52 Kit 1 Disk 1
53 Kit 1 Bolt 2
54 Kits 1, 3 & 4 O-Ring 1
55 Kit 4 Spring, Pressure 1
56 Kit 4 Rod, Shaft 1
57 to 58 Not Used
59 Kit 4 Disk, Rotor 1
60 7021339 Spindle 1
61 Not Used
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FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
62 7021340 Coupler 1
63 to 65 Not Used
66 Kit 4 Ring, Retaining 1
67 to 80 Not Used
81 Kit 2 Bearing, Ball 1
82 Kit 2 Ring, Retaining 2
83 Kit 2 Ring, Retaining 1
84 to 87 Not Used
88 7021344 Stud, Wheel 9
— — — — — — — — — —
7021329 Kit 1 - Cover Kit (Includes Items 8, 33, 34, 51, 52, 53 &
54)
7021330 Kit 2 - Bearing Kit (Includes Items 4, 10, 11, 12, 14, 15,
17, 24, 25, 29, 49, 81, 82 & 83)
7021333 Kit 3 - Seal Kit (Includes Items 19-22, 33 & 54) 1
7021338 Kit 4 - Mechanical Disconnect Kit (Includes Items 54-
56, 59 & 66)
2910601 Kit 5 - Shaft Nut Kit (Includes Items 4, 21 & 25) 1
1
1
1
1-12 3120885
Page 19
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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1
F
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3120885 1-13
Page 20
SECTION 1 FRAME
7
S
E
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T
I
O
N
1
F
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A
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E
FIGURE 1-4. HYDRAULIC COMPONENTS INSTALLATION
1-14 3120885
Page 21
SECTION 1 FRAME
FIGURE 1-4. HYDRAULIC COMPONENTS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0257816 HYDRAULIC MOTOR/PUMP/TANK INSTALLATION Ref. 4/C
1 3600289 Motor/Pump Assembly 1
1A 7021318 Motor Assembly 1
7021368 Brush Kit 1
1B 7021319 Pump Assembly 1
Not Available Seal Kit 1
1C 7021367 Coupling 1
2 4400416 Hydraulic Tank Assembly 1
2A 7021320 Cap 1
3 3571160 Plate, Mounting 1
4 4711400 Flatwasher 1/4” Narrow 4
5 3311405 Locknut 1/4”-20NC 4
6 0741506 Screw, Flathead Countersink 5/16”-18NC x 3/4” 4
7 4751500 Flatwasher 5/16” 4
8 3311505 Locknut 5/16”-18NC 4
9 3311605 Locknut 3/8”-16NC 2
10 4751600 Flatwasher 3/8” 2
11 4761400 Lockwasher 1/4” 4
12 4761600 Lockwasher 3/8” 2
S
E
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T
I
O
N
1
F
R
A
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E
VALVES INSTALLATIONS
0258034 E45A & M45A Ref. 4/C
0259399 E45AJ & M45AJ Ref. 3/B
0259951 E40AJP, M40AJP, E40AJPnarrow & M40AJPnarrow Ref. 3/A
101 to 107 Not Used
108 0641608 Bolt 3/8”-16NC x 1” 2
109 4711600 Flatwasher 3/8” 2
110 4761600 Lockwasher 3/8” 2
111 to 113 Not Used
114 Brake/Steer Control Valve Assembly Options: 1
Use 4641149 Prior to S/N 47551 (was p/n 4641071)
Use 4641149 S/N47551 to S/N50960 (was p/n 464113)
4641149 S/N50960 to Present (See Figure 1-5 for
Breakdown)
115 to 119 Not Used
120 Harness Assembly - Brake/Steer Control Valve
Options: (Not Shown -See Section 7 for Breakdown)
4922069 Prior to S/N 47551
4922328 S/N47551 to Present
1
3120885 1-15
Page 22
SECTION 1 FRAME
S
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N
1
F
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FIGURE 1-5. BRAKE/STEER VALVE ASSEMBLY
1-16 3120885
Page 23
SECTION 1 FRAME
FIGURE 1-5. BRAKE/STEER VALVE ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4641149 BRAKE/STEER VALVE ASSEMBLIES Ref. A
1 7017450 Cartridge, Proportional without Coil (Flow Control) 1
7012518 Seal Kit- 7017450 Cartridge 1
7021618 Coil 1
2 7021659 Cartridge, Relief (Main) 1
7012972 Seal Kit - 7021659 Cartridge 1
3 7017433 Cartridge (Steer) 1
7017402 Seal Kit - 7017433 Cartridge 1
7021609 Coil 2
4 7012941 Cartridge without Coil (Brake Release) 1
7010543 Seal Kit - 7017455 Cartridge 1
7021609 Coil 1
5 7017412 Cartridge, Check 1
7012967 Seal Kit - 7017412 Cartridge 1
6 7010542 Cartridge, Shuttle 1
7010543 Seal Kit - 7010542 Cartridge 1
7 7017428 Cartridge, Relief (Steer) 1
7012998 Seal Kit - 7012912 Cartridge 1
8 7022532 Switch, Pressure 1
9 7021616 Cartridge, Filter 1
10 7024832 Plug 1
S
E
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O
N
1
F
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3120885 1-17
Page 24
SECTION 1 FRAME
S
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I
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N
1
F
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A
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E
FIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS
1-18 3120885
Page 25
SECTION 1 FRAME
FIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
BATTERIES INSTALLATION Ref.
0258689 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP Ref. 2/C
0259763 E40AJPnarrow & M40AJPnarrow Ref. B
S
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1 Battery Box Weldment Options: A/R
4845846 All Models Except AJPn 2
4846106 AJPnarrow (Left Side) 1
4846107 AJPnarrow (Right Side) 1
2Not Used
3 Battery Hold Down Options: 2
4567679 All Models Except AJPnarrow
0182010 AJPnarrow
4 4711500 Flatwasher 5/16” Narrow 4
5 0641514 Bolt 5/16”-18NC x 1 3/4” 4
6 3000003 Liner, Battery Box 2
7 Battery Options: 6
0400055 Wet
7016177 Dry
8 Cable, Battery (Left) A/R
1060760 All Models Except AJPnarrow 1
Not Required AJPnarrow 0
9 1060092 Cable, Battery 6
10 0100048 Adhesive, Silicone A/R
11 0100051 Grease, Terminal A/R
12 0840031 Boot, Terminal (“d” shape) 8
13 0840032 Boot, Terminal (“b” shape) 8
14 0641808 Bolt 1/2”-13NC x 1” 4
15 Not Used
16 4711800 Flatwasher 1/2” Narrow 8
17 Cable, Battery (Right) A/R
1060761 All Models Except AJPnarrow 1
Not Required AJPnarrow 0
18 1320172 Clamp, Cable 2
19 Cable, Battery (Battery to Battery) A/R
Not Required All Models Except AJPnarrow 0
1060811 AJPnarrow 1
20 Cable, Battery (Battery to Clamp) A/R
Not Required All Models Except AJPnarrow 0
1060809 AJPnarrow 1
21 3311405 Locknut 1/4”-20NC 2
22 3931430 Capscrew, Socket Head 1/4”-20NC x 1 7/8” 2
23 4711400 Flatwasher 1/4” Narrow 2
O
N
1
F
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3120885 1-19
Page 26
SECTION 1 FRAME
S
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N
1
F
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A
M
E
FIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
BATTERY CHARGER INSTALLATIONS
0259258 CE Spec (110V/220V - 50Hz) (Prior to S/N49542) Ref. 2
0259826 CE Spec (110V/220V - 50Hz) (S/N49542 to Present) Ref. 2
0259693 Australian Spec (250V - 50Hz) Ref. 1
101 Battery Charger Assembly Options: (See Figure 1-7
& 1-8 for Breakdown)
0400192 CE Spec (110V/220V - 50Hz) (Prior to S/N49542)
0400197 CE Spec (110V/220V - Auto Seeking Volts & Hz)
(S/N49542 to Present)
0400195 Australian Spec (250V - Auto Seeking Hz)
102 0641408 Bolt 1/4”-20NC x 1” 4
103 4711400 Flatwasher 1/4” Narrow 6
104 3311405 Locknut 1/4”-20NC 5
105 4761400 Lockwasher 1/4” 2
106 0641404 Bolt 1/4”-20NC x 1/2” 1
107 Not Used
108 Plate, Panel Options: 1
See Note Prior to S/N49542 (Note: Panel and Ammeter
Supplied with Charger)
3571834 S/N49542 to Present (Uses LED Lights)
109 to 112 Not Used
113 1320136 Clamp, Insulated 1
114 to 115 Not Used
1
1-20 3120885
Page 27
SECTION 1 FRAME
FIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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1
F
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3120885 1-21
Page 28
SECTION 1 FRAME
NOTE:
CHARGER COVER
REMOVED FOR
CLARITY.
17
8
1
19
AC
AC BRN
A
7
4
1
B
9
6
3
2
1
C
D
B
A
SCR
WHT
DC FUSE OR
CIRCUIT BREAKER
SCREW CONNECTION
W/VARFLEX
.001
OHM
SHUNT
AMMETER
DC POS.
RED
GRNGRN
YEL
BLK
ORG
ORG
YEL
WHITE
BLUE
5
6
8
8
4
3
7
7
7
WHT
WHT
WHT
GRN
NOTE:VARISTOR LEADS MUST BE
COVEREDWITH VARFLEX.
WHT
WHT
BLK
BLK
RED
WHT
9
9
1
171615
CIRCUIT
BOARD
HARNESS
11
13
13
12
12
12
14
14
10
AMP
CONNECTOR
BLACK
DC NEG
SOLDER CONNECTION
WHT
SCR
CIRCUIT
BREAKER
HEATSINK
HEATSINK
TX
PRI
CIRCUIT
BREAKER
VARISTOR
RELAY
WHT/
ORG
AC BLU
YLW
240V 120V
15
2
7
3
4 8 BLU
AC
DC
DC
AC1
AC
RELAY
CIRCUIT
CONTROL
TRANSFORMER
BLU
WHT
WHT
WHT
GROUND
SCREW
YLW/GRN
4
12
11
18
6
19
2
9
9
13
14
20
22
21
16
3
5
7
15
S
FIGURE 1-7. BATTERY CHARGER ASSEMBLY (PRIOR TO S/N 49542)
E
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1
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1-22 3120885
Page 29
SECTION 1 FRAME
FIGURE 1-7. BATTERY CHARGER ASSEMBLY (PRIOR TO S/N 49542)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
Note: Refer to battery charger serial number nameplate for build date. Example: BA515 (Spec) 9631
(Date Code). First and second digits in the date
code indicate year. Third and fourth digits indicate
the week of manufacture.
S
E
C
T
I
O
BATTERY CHARGER ASSEMBLIES
0400192 CE Spec (110/220V - 50 Hz) Ref. A
1 7011573 Ammeter 1
2 7018597 Breaker, Circuit 2
3 7020607 PC Board 1
4 7011621 Connector, Enable Switch 1
5 7020640 Controller PC Board 1
6 7020667 DC Cord Assembly 1
7 7020668 Harness 1
8 7011590 Plug, DC 1
9 7020669 Cord, AC 1
10 Not Used
11 7018570 Fuse, DC - 80 Amp 1
12 7018571 Holder, Fuse - AC 1
13 7020649 Rectifier Assembly 2
14 7020650 Rectifier, SCR 2
15 7018506 Relay (White) 1
16 7020654 Relay (Clear Cover) 1
17 7020651 Shunt Assembly 1
18 7011528 Relief, Strain 1
19 7020659 Relief, Strain 2
20 7020670 Transformer, Main 1
21 7020633 Varistor Assembly 1
22 7011596 Varistor 2
N
1
F
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3120885 1-23
Page 30
SECTION 1 FRAME
AUSTRALI AN
WI RI NG DI AGRAM
CE WIRI NG
DIA GRAM
BLK
BLK
AC BLK
OR BRN
AC GRN OR
YLW/GRN
AC WHT/O RG
OR BLUE
INTERLOCK
CONNECTOR
2
1
C
D
B
A
SCR
CAP CAP
WHT
DC FUSE OR
CIRCUIT BREAKER
SCREW
CONNECTION
W/VARFLEX
.001
OHM
SHUNT
DC POS.
RED
GRN
YEL
BLK
ORG
ORG
YEL
WHITE
BLUE
5
6
8
8
7
7
7
WHT
GRN
NOTE: VARISTOR LEADS MUST BE
COVERED WITH VARFLEX.
WHT
WHT
BLK
WHT
9
13
12
14
9
1
171615
CIRCUIT
BOARD
HARNESS
11
3
13
2
4 3 2 1
BLK
TO 4POS CONN
OF MAIN BOARD
RED
1
2
3
4
1
2
3
4
WHT GRN
GRN WHT
RED BLK
J-2
CONNECTOR
12
12
4
14
10
BLACK
DC NEG
SOLDER CONNECTION
WHT
SCR
HEATSINK
HEATSINK
TX
PRI
CIRCUIT
BREAKER
VARI ST OR
RELAY
N.C.
N.O.
COM
GROUND
SCREW
NOTE:
CHARGER COVER
REMOVED FOR
CLARI TY.
15
19
5
211
17
18
3
7
6
10
12
13
16
14
8
4
20
21
AC
AC BRN
A
7
4
1
B
9
6
3
2
1
C
D
B
A
DC FUSE OR
CIRCUIT BREAKER
SCREW CONNECTION
W/VARFLEX
.001
OHM
SHUNT
DC POS.
RED
GRN
YEL
BLK
ORG
ORG
YEL
WHITE
BLUE
BLUE
BLUE
5
6
8
8
4
3
7
7
7
WHT
WHT
WHT
GRN
NOTE: VARISTOR LEADS MUST BE
COVERED WITH VARFLEX.
WHT
WHT
BLK
BLK
BLK
RED
RED
WHT
9
9
1
171615
CIRCUIT
BOARD
HARNESS
11
13
13
12
12
12
14
14
10
BLACK
DC NEG
SOLDER CONNECTION
CIRCUIT
BREAKER
TX
PRI
CIRCUIT
BREAKER
RELAY
WHT/
ORG
AC BLU
AC
DC
DC
AC1
AC
RELAY
CIRCUIT
REMOTE
LIGHT BOARD
WHT
WHT
GROUND
SCREW
YLW/GRN
BLK
BLK
TO 4POS CONN
OF MAIN BOARD
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
WHT
WHT
GRN
GRN
RED
RED
VARISTOR
SCR
CAP CAP
WHT
WHT
SCR
HEATSINK
HEATSINK
BLK
BLK
INTERLOCK
CONNECTOR
RELAY
N.C.
N.O.
COM
4 3 2 1
RED
GRN
WHT
BLK
J-2
CONNECTOR
9
S
E
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T
I
O
N
1
F
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A
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E
FIGURE 1-8. BATTERY CHARGER ASSEMBLY (S/N 49542 TO PRESENT)
1-24 3120885
Page 31
SECTION 1 FRAME
FIGURE 1-8. BATTERY CHARGER ASSEMBLY (S/N 49542 TO PRESENT)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
Note: Refer to battery charger serial number nameplate for build date. Example: BA515 (Spec) 9631
(Date Code). First and second digits in the date
code indicate year. Third and fourth digits indicate
the week of manufacture.
BATTERY CHARGER ASSEMBLIES
0400197 CE Spec (110/220V - Auto Seeking Volts & Hz)
(S/N 49542 to Present)
0400195 Australian Spec (250V - Auto Seeking Hz) Ref. A
1Not Used
2 Breaker, Circuit Options: A/R
7020653 Charger p/n 0400197 2
7018525 Charger p/n 0400195 1
3 7011621 Connector, Enable Switch 1
4 Circuit, Control Options: 1
7022902 Charger p/n 0400197
7020685 Charger p/n 0400195
5 7020644 DC Cord Assembly 1
6 7020690 Fuse Assembly 1
7 7020691 Fuse, DC - 50Amp 1
8 7020697 Harness 1
9 7020693 Harness 1
10 7018571 Holder, Fuse 1
11 7020648 Plug, AC Inlet 1
12 7020649 Rectifier Assembly 2
13 7020650 Rectifier, SCR 40-Amp 1
14 Relay (Black) Options: 1
7018564 Charger p/n 0400197
7018563 Charger p/n 0400195
15 7020651 Shunt Assembly 1
16 Transformer, Main Options: 1
7022905 Charger p/n 0400197
7020699 Charger p/n 0400195
17 7018537 Varistor Assembly 1
18 7020663 Varistor 1
19 7018577 Capacitor Assembly 2
20 Control, AC1-48V Options: A/R
7022903 Charger p/n 0400197 1
Not Required Charger p/n 0400195 0
21 Relay, 24VDC-30A (Clear) Options: A/R
7020654 Charger p/n 0400197 1
Not Required Charger p/n 0400195 0
Ref. A
S
E
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N
1
F
R
A
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E
3120885 1-25
Page 32
SECTION 1 FRAME
S
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I
O
N
1
F
R
A
M
E
FIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)
1-26 3120885
Page 33
SECTION 1 FRAME
FIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
CONTACTOR INSTALLATION OPTIONS: Ref.
0259069 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP Ref. 6/G
0270103 E40AJPnarrow & M40AJPnarrow Ref. 4/B
S
E
C
T
I
1 0100019 Loctite #242 (Not Shown) A/R
2 to 11 Not Used
12 4240084 Strap, Static 1
13 0641508 Bolt 5/16”-18NC x 1” 1
14 3311505 Locknut 5/16”-15NC 1
15 4751500 Flatwasher 5/16” 10
16 Not Used
17 4300135 Stud, Stand-Off 4
18 1600293 Module (Positrac/Tilt)
(Note: Calibration required when replaced)
19 0641406 Bolt 1/4”-20NC x 3/4” 6
20 4761400 Lockwasher 1/4” 6
21 3311501 Locknut 5/16”-18NC 8
22 3910636 Screw #6-32NC x 2 1/4” 4
23 3310601 Nut #10-24NC 4
24 1600294 Contactor Plate Assembly (See Items 101-103 for
Breakdown)
25 1600292 Module, Power 1
26 3931430 Capscrew, Socket Head 1/4”-20NC x 2” A/R
27 4711400 Flatwasher 1/4” A/R
28 3311405 Locknut 1/4”-20NC A/R
29 4750600 Flatwasher #6 4
30 1060717 Cable, Electrical (Motor B S1 to Motor A S2) 1
31 1060718 Cable, Electrical (Motor B A1 to Contactor Plate
MB1)
32 1060719 Cable, Electrical (Motor A A2 to Contactor Plate
MA2)
33 1060720 Cable, Electrical (Motor B A2 to Contactor Plate SB1) 1
34 1060721 Cable, Electrical (Power Module A to Contactor
Plate)
35 1060722 Cable, Electrical (Power Module B+ to Contactor
Plate)
36 1060723 Cable, Electrical (Motor B S2 to Contactor Plate
MB2)
37 1060724 Cable, Electrical (Motor A A1 to Contactor Plate
MA1)
38 1060725 Cable, Electrical (Motor A S1 to Contactor Plate
SA1)
39 Cable, Electrical Options: (Contactor Plate to
Batteries)
1060726 E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP
1060810 E40AJPnarrow & M40AJPnarrow
40 1060727 Cable, Electrical (Module to Hydraulic Pump Motor –) 1
41 1060728 Cable, Electrical (Contactor Plate to Hydraulic Pump
Motor +)
42 2540019 Grommet 4
43 2540021 Grommet 1
O
N
1
F
1
R
A
M
E
1
1
1
1
1
1
1
1
1
1
3120885 1-27
Page 34
SECTION 1 FRAME
S
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1
F
R
A
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E
FIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
44 4760600 Lockwasher #6 4
45 4922103 Cable, Electrical (Contactor/Module to Charger) 1
4460444 Connector, DC 1
46 2540020 Grommet 3
47 Clamp, Cable Options (Not Shown - Located on Item
39):
Not Required E45A, M45A, E45AJ, M45AJ, E40AJP & M40AJP 0
1320172 E40AJPnarrow & M40AJPnarrow 1
1600294 CONTACTOR PLATE ASSEMBLY Ref. B
7022003 Harness, Contactor (See Section 7 for Breakdown) 1
7022004 Harness, Posi-Track Contactor (See Section 7 for
Breakdown)
7022005 Harness, Shunt (See Section 7 for Breakdown) 1
101 7022002 Contactor 1
102 7022001 Contactor 1
103 7022000 Contactor 1
A/R
1
1-28 3120885
Page 35
SECTION 1 FRAME
FIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
E
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1
F
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3120885 1-29
Page 36
SECTION 1 FRAME
BATTERY LOCATED
ON FRAME SIDE
(SHOWN HERE
FOR CLARITY)
1
101
102
103
104
119
156
105
111
113
114
115
118
117
116
137
131
132
133
134
135
136
112
153
12
14
18
19
29
129
19
17
15
50
51
16
13
2
20
63
INSULATION
SHOWN HERE
FOR CLARITY
65
64
(OPPOSITE SIDE)
2
0
45
59
5
9
46
46
66
67
4
6
68
60
535455
4
8
48
49
44
165
62
61
62
2
25
28
20
4
6
6
8
7
138
(LOCATED
UNDER
AIR COWL)
110
162
163
161
1
1LOCA
T
E
A
T AXL
E
176
177
181
182
183
175
174
S
E
C
T
I
O
N
1
F
R
A
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E
FIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY)
1-30 3120885
Page 37
SECTION 1 FRAME
FIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
MOTOR/GENERATOR INSTALLATION (YANMAR
DIESEL)
0257824 M45A, M45AJ & M40AJP Ref. 11
0270344 M40AJPnarrow Ref. 1/A
1 0257858 Motor/Generator Assembly (See Items 101 to 183 for
Breakdown)
2 3311505 Locknut 5/16”-18NC 8
3 Not Used N/R
4 3200404 Mount, Insolation 3
5 Not Used N/R
6 4751600 Flatwasher 3/8” 6
7 3311605 Locknut 3/8”-16NC 3
8 0641618 Bolt 3/8”-16NC x 2 1/4” 3
9 to 10 Not Used N/R
11 2820117 Foam, Sound (Steer Axle) (S/N 46103 to Present) 1
12 1060755 Cable, Battery (Includes Terminal Boot)
(+ Generator)
13 1060754 Cable, Battery (Includes Terminal Boot)
(– Generator)
14 Battery Options: 1
Use 0400201 Prior to S/N53986 (was p/n 0400186)
0400201 S/N53986 to Present
15 Starter Battery Tray Options: 1
4845642 M45A, M40AJP & M45AJ
Not Required M40AJPnarrow (Welded-In Part of Battery Tray)
16 Battery Hold Down Options: 1
Use 4220179 Prior to S/N53986 (was p/n 4567693)
4220179 S/N53986 to Present
17 Battery Seat Options: 1
Use 3980035 Prior to S/N53986 (was p/n 3000012)
3980035 S/N53986 to Present
18 0641518 Bolt 5/16”-18NC x 1 5/8” 2
19 4711500 Flatwasher 5/16” Narrow 6
20 0641505 Bolt 5/16”-18NC x 5/8” 8
21 to 24 Not Used
25 2120042 Filter, In-Line Fuel 1
26 to 27 Not Used
28 2720339 Hose 12ft/3.7m
29 1320022 Clamp, Hose 7
30 to 32 Not Used
33 4240033 Strap, Tie 8
34 to 43 Not Used
44 4567845 Tube, Exhaust 1
45 3571401 Plate 1
46 3960389 Seal 5ft/1.5m
47 0100011 Loctite #242 (Not Shown) A/R
48 4751500 Flatwasher 5/16” 6
49 2820107 Insulation 1
Ref.
1
1
1
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3120885 1-31
Page 38
SECTION 1 FRAME
S
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1
F
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FIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
50 1060731 Cable, Battery (Includes Terminal Boot) (– Battery to
Ground)
51 1060730 Cable, Battery (Includes Terminal Boot) (+ Battery to
Starter)
52 Not Used
53 0461406 Bolt 1/4”-20NC x 3/4” 4
54 4711400 Flatwasher 1/4” Narrow 8
55 3311405 Locknut 1/4”-20NC 4
56 Not Used
57 Not Used
58 Not Used
59 4060803 Flex-Trim 16in/4.9m
60 3960417 Seal 28in/
61 4100025 Sleeve, Fiberglass 26in/
62 4920385 Wire, Safety 7in/18cm
63 2820112 Insulation 2
64 2820116 Insulation (Right Side) 1
65 2820116 Insulation (Left Side) 1
66 2720455 Hose 1
67 1320012 Clamp 2
68 0259481 Plenum Box Assembly 1
69 3960418 Seal 3ft/.9m
70 4922319 Harness, Generator (Not Shown - See Section 7 for
Breakdown)
71 4460267 Socket, Female (Not Shown - See Section 7 for Call-
Out)
1
1
71cm
66cm
1
1
0257858 MOTOR/GENERATOR ASSEMBLY Ref. E
101 7018126 Motor, Yanmar 1
102 Use 7023485 Alternator (was p/n 7020203) 1
103 Not Available Filter, Oil with Element 1
7020215 Element, Oil 1
104 7020167 Solenoid, Throttle 1
105 7020166 Swivel, In-line 1
106 to 109 Not Used
110 7018125 Handle, Regulator 1
111 Use 70000323 Relay, Bosch (was p/n 7020207) 2
112 3571412 Plate, Mounting, Oil Filter 1
113 7018127 Switch, Pressure 1
114 7020164 Fitting, Adapter 1
115 7020163 Adapter, Oil Drain 1
116 7020162 Bolt, Banjo 1
117 Not Serviced Washer, Rubber 1
118 7020204 Drain Line Assembly 1
119 7020161 Bracket 1
120 to 128 Not Used
129 3570581 Baseplate 1
1-32 3120885
Page 39
SECTION 1 FRAME
FIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
130 Not Used
131 7020160 Flange, Air Intake 1
132 7020159 Flange, Air Intake 1
133 7020165 Heater, Air 1
134 7018123 Gasket, Air Cleaner 2
135 7018122 Gasket, Air Adapter 2
136 7018124 Cover, Air Filter 1
137 7020158 Probe, Temperature 1
138 7020157 Bracket, Magnetic Pick-Up 1
139 to152 Not Used
153 Use 70000324 Sensor, Hall Effect Zero Speed (was p/n 7020206) 1
154 to 155 Not Used
156 Use 70000322 Relay, Sealed 14VDC/40Amp (was p/n 7023274) 1
157 to 160 Not Used
161 Use 7018125 Lever (was p/n 7020197) 1
162 7020198 Spring 1
163 7020199 Dipstick 1
164 7020200 Regulator, Voltage (Not Shown - Located Below
Starter)
165 7020201 Muffler 1
166 7020202 Starter (Not Shown - Located Below Muffler) 1
7018137 Stopper Set, Pinion
7018138 Pinion Assy
167 7020217 Element, Air Cleaner (Washable) 1
168 7018142 Pump, Fuel (Not Shown) 1
169 7018134 Flywheel w/Gear (Not Shown) 1
170 7018135 Valve, Assembly Fuel Injection (Not Shown) 1
171 7018136 Pipe, Fuel Injection (Not Shown) 1
172 7018139 Rectifier (Not Shown) 1
173 7018140 Gasket Set (Not Shown) 1
174 7018128 Gasket, Cylinder Head 1
175 7018129 O-Ring, Cylinder Head 1
176 7018132 Gasket, Valve Cover 1
177 7018133 Bolt M6 x 55mm 2
178 7020156 Printed Circuit Board (Not Shown) 1
179 7023349 Fuse 15Amp (Not Shown) 1
180 7023350 Fuse 20Amp (Not Shown) 1
181 Use 70001144 Filter, Head (was p/n 7023489) 1
182 7026669 Spring, Governor 1
183 7026670 Spring, Return 1
1
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3120885 1-33
Page 40
SECTION 1 FRAME
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FIGURE 1-11. FRAME COVERS INSTALLATION
1-34 3120885
Page 41
SECTION 1 FRAME
FIGURE 1-11. FRAME COVERS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
FRAME COVERS INSTALLATIONS
0258974 E45A, E45AJ & E40AJP Ref. 4
0258035 M45A, M45AJ & M40AJP Ref. 7
0270100 M40AJPnarrow Ref. 1
0270101 E40AJPnarrow Ref. 2
1 3570572 Cover, Charger 1
2 3900174 Screw, Special 7
3 3760308 Retainer 7
4 1380138 Cup, Receptacle 1
5 Axle Cover Options: 1
4844603 E45A, E45AJ, E40AJP, M45A, M45AJ & M40AJP
4846223 M40AJPnarrow & E40AJPnarrow
6 0940036 Bumper 2
7 3960447 Seal 93in/2.4m
8 3960433 Seal 39in/1m
9 3300371 Wingnut 4
10 3520026 Plug, Hole 2
11 3570573 Cover, Pump 1
12 Cover Options: 1
12A 3571094 E45A, E45AJ, E40AJP & E40AJPnarrow
12B 1670880 M45A, M45AJ, M40AJP & M40AJPnarrow
13 Latch Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
2940115 M45A, M45AJ, M40AJP & M40AJPnarrow 2
14 0721006 Screw, Machine #10-24NC x 3/4” A/R
15 Flatwasher Options: A/R
4750800 E45A, E45AJ, 8
4751000 M45A, M45AJ, M40AJP, E40AJP,M40AJPnarrow &
E40AJPnarrow
16 3311005 Locknut #10-24NC 12
17 0630440 Eyebolt A/R
18 0100011 Loctite #242 (Not Shown) A/R
19 2940095 Latch 4
20 0721004 Screw, Machine #10-24NC x 1/2” 16
21 2700093 Hook 2
22 0641406 Bolt 1/4”-20NC x 3/4” A/R
23 4751400 Flatwasher 1/4” A/R
24 3311405 Locknut 1/4”-20NC 4
25 Battery Cover Options: 2
1670879 E45A, E45AJ, E40AJP, M45A, M45AJ & M40AJP
1670951 M40AJPnarrow & E40AJPnarrow
26 Flex-Trim Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
4060804 M45A, M45AJ, M40AJP & M40AJPnarrow 6ft/1.8m
27 Flex-Trim Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
2820105 M45A, M45AJ, M40AJP & M40AJPnarrow 1
12
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3120885 1-35
Page 42
SECTION 1 FRAME
S
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1
F
R
A
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E
FIGURE 1-11. FRAME COVERS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
28 Flex-Trim Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
2820106 M45A, M45AJ, M40AJP & M40AJPnarrow 1
29 0902543 Strip, Mounting 2
30 Seal Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
3960389 M45A, M45AJ, M40AJP & M40AJPnarrow 2.5ft/7.6m
31 Seal Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
3960417 M45A, M45AJ, M40AJP & M40AJPnarrow 10ft/3m
32 Insulation Options: A/R
Not Required E45A, E45AJ, E40AJP & E40AJPnarrow 0
2820110 M45A, M45AJ, M40AJP & M40AJPnarrow 1
33 3520082 Plug 1
1-36 3120885
Page 43
SECTION 2 TURNTABLE
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
2-1 VALVES AND HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-5 SWING BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-6 TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION (M45 & M40 Only) . . . . . 2-16
2-7 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-8 HOODS AND BEACON LIGHT INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
S
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3120885 2-1
Page 44
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2
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SECTION 2 TURNTABLE
FIGURE 2-1. VALVES AND HORN INSTALLATIONS
N
T
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2-2 3120885
Page 45
SECTION 2 TURNTABLE
FIGURE 2-1. VALVES AND HORN INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
VALVE AND HORN INSTALLATIONS
0258034 E45A & M45A Ref. 4/C
0259399 E45AJ & M45AJ Ref. 3/B
0259951 E40AJP, M40AJP, E40AJPnarrow & M40AJPnarrow Ref. 3/A
1 4641070 Main Control Valve Assembly Options (See Figure 2-
2 for Breakdown):
2 4641029 Releveling Valve Assembly 1
2A 7017466 Cartridge 1
2900708 Seal Kit - Cartridge 1
2B 7012959 Knob 1
2C 7012981 Cartridge 1
7012998 Seal Kit - Cartridge 1
3Not Used
4 0140028 Horn 1
5 2560122 Handle 1
6 2560123 Grip, Handle 1
7 1380136 Clip 1
8 0641608 Bolt 3/8”-16NC x 1” 4
9 4711400 Flatwasher 3/8” Narrow 2
10 4761400 Lockwasher 3/8” 4
11 0641508 Bolt 5/16”-18NC x 1” 1
12 4711500 Flatwasher 5/16” Narrow 2
13 3311505 Locknut 5/16”-18NC 1
14 Not Used
15 4300106 Stud 1
16 3311405 Locknut 1/4”-20NC A/R
17 4711400 Flatwasher 1/4” Narrow A/R
18 0641408 Bolt 1/4”-20NC x 1” A/R
19 0641413 Bolt 1/4”-20NC x 1 5/8” A/R
20 Not Used
21 Jib Valve Assembly Options: A/R
Not Required E45A & M45A 0
4641102 E45AJ & M45AJ 1
4641119 E40AJP, M40AJP, E40AJPnarrow &
M40AJPnarrow
21A 7017452 Cartridge without Coils 1
7017402 Seal Kit- 701452 Cartridge 1
7021609 Coil 2
21B Cartridge Options: 1
7017460 E45AJ & M45AJ
Use 7017460 E40AJP, M40AJP, E40AJPnarrow &
M40AJPnarrow (was p/n 7021623)
7017461 Seal Kit- 7017460 & 7021623 Cartridges 1
22 0100011 Loctite #242 (Not Shown) A/R
1
1
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2
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3120885 2-3
Page 46
S
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2
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SECTION 2 TURNTABLE
FIGURE 2-1. VALVES AND HORN INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
ALARM INSTALLATIONS
0259064 Motion Alarm Ref. 1
101 0140031 Alarm, Motion (Remove ground strap before
installation)
3311405 Locknut 1/4”-20NC 2
4711400 Flatwasher 1/4” Narrow 4
0641408 Bolt 1/4”-20NC 2
4460685 Terminal, Stud Mounted Tab 2
1
N
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L
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2-4 3120885
Page 47
SECTION 2 TURNTABLE
FIGURE 2-1. VALVES AND HORN INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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2
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3120885 2-5
Page 48
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2
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SECTION 2 TURNTABLE
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY
N
T
A
B
L
E
2-6 3120885
Page 49
SECTION 2 TURNTABLE
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4641070 MAIN CONTROL VALVE ASSEMBLY Ref. F
1 7017450 Cartridge without Coil (Flow Regulator) 1
7012518 Seal Kit- 7017450 Cartridge 1
7021618 Coil 1
2 7017410 Cartridge without Coil (Bypass Unloading) 1
7012967 Seal Kit- 7017410 Cartridge 1
7021609 Coil 2
3 7021603 Cartridge without Coil (Lower Lift) 1
7012903 Seal Kit - 7021603 Cartridge 1
7021610 Coil 2
4 7021603 Cartridge without Coil (Upper Lift) 1
7012903 Seal Kit - 7021603 Cartridge 1
7021610 Coil 2
5 7017433 Cartridge without Coil (Swing) 1
7017402 Seal Kit - 7017433 Cartridge 1
7021609 Coil 1
6 7021604 Cartridge without Coil (Swing Restrictor) 1
7012953 Seal Kit - 7021604 Cartridge 1
7021609 Coil 1
7 7017479 Cartridge without Coil (Telescope Out) 1
7012518 Seal Kit - 7017479 Cartridge 1
7021610 Coil 1
8 7017479 Cartridge without Coil (Telescope In) 1
7012518 Seal Kit - 7017479 Cartridge 1
7021610 Coil 1
9 7017452 Cartridge without Coil (Platform Level) 1
7017402 Seal Kit - 7017452 Cartridge 1
7021609 Coil 2
10 7017452 Cartridge without Coil (Rotator) 1
7017402 Seal Kit- 7017452 Cartridge 1
7021609 Coil 2
11 7017423 Cartridge, (Lower Lift Down) 1
7012998 Seal Kit- 7017423 Cartridge 1
12 7021606 Cartridge, (Upper Lift Down) 1
7012998 Seal Kit - 7021606 Cartridge 1
13 7021607 Cartridge (Telescope) 1
7012998 Seal Kit- 7021607 Cartridge 1
14 7017421 Cartridge (Platform Level Backward Piston End) 1
7012998 Seal Kit - 7017421 Cartridge 1
15 7017422 Cartridge (Platform Level Forward Rod End) 1
7012998 Seal Kit - 7017422 Cartridge 1
16 7010542 Cartridge (Telescope) 1
7010543 Seal Kit - 7010542 Cartridge 1
17 7012914 Cartridge (Platform Level Piston Side) 1
7012918 Seal Kit - 7012914 Cartridge 1
18 7012914 Cartridge (Platform Level Rod Side) 1
7012918 Seal Kit - 7012914 Cartridge 1
S
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2
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N
T
A
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3120885 2-7
Page 50
S
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2
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SECTION 2 TURNTABLE
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
19 7012947 Cartridge, (Emergency Descent) 1
7012518 Seal Kit - 7012947 Cartridge 1
7012949 Knob 1
20 7012694 Pump, Manual 1
Use 7017496 Seal Kit - 7012694 Cartridge (was p/n 2900708) 1
21 Not Available Plug, Orifice (.031”) 1
22 7021624 Disc, Orifice (.028”) 1
23 Not Available Cartridge, Plug 1
N
T
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L
E
2-8 3120885
Page 51
SECTION 2 TURNTABLE
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
E
C
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I
O
N
2
T
U
R
N
T
A
B
L
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3120885 2-9
Page 52
S
6
7
2
8
5
9
4
10
7
101
1
3
E
C
T
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O
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2
T
SECTION 2 TURNTABLE
FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION
U
R
N
T
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B
L
E
2-10 3120885
Page 53
SECTION 2 TURNTABLE
FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0258653 TURNTABLE BEARING AND SWING INSTALLATION Ref. 1/A
1 0440203 Turntable Bearing and Rotation Box Assembly (See
Figure 2-5 for Breakdown)
2 0100019 Loctite A/R
3 3160233 Swing Motor Assembly (See Figure 2-4 for Breakdown) 1
4 0681814 Bolt 1/2”-13NC x 1 3/4” (Grade 8) 2
5 4740171 Washer, Hardened 2
6 0682026 Bolt 5/8”-11NC x 3 1/4” (Grade 8) 18
7 4740393 Washer, Hardened 42
8 3020036 Lube A/R
9 3020029 Grease, Bearing A/R
10 0682028 Bolt 5/8”-11NC x 3 1/2” (Grade 8) 24
1
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2
101 TURNTABLE WELDMENTS 1
4620118 E45A & M45A
4620124 E45AJ, M45AJ, E40AJP, E40AJPnarrow, M40AJP &
M40AJPnarrow
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3120885 2-11
Page 54
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2
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SECTION 2 TURNTABLE
FIGURE 2-4. SWING MOTOR ASSEMBLY
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2-12 3120885
Page 55
SECTION 2 TURNTABLE
FIGURE 2-4. SWING MOTOR ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
3160233 SWING MOTOR ASSEMBLY Ref.
1 Not Serviced Screw, Metric M6 x 20mm 6
2 Not Serviced Ring, Dust 1
3 Not Serviced Flange, Spigot 1
4 Kit Seal, Shaft 1
5 Kit O-Ring 1
6 7020128 Race, Bearing 1
7 7020129 Bearing, Needle 1
8 7020126 Key, Woodruff 1
9 Not Available Shaft, Output 1
10 7020130 Shaft 1
11 Kit O-Ring 3
12 Not Serviced Plate, Distributor 1
13 7020131 Gear Set 1
14 Not Serviced Cover, End 1
15 Not Serviced Washer 6
16 Not Serviced Screw, Metric M8 x 35mm 6
17 Not Serviced Nameplate 1
18 Not Serviced Housing
19 Not Serviced Plug, Drain 7/16”-20NF
— — — — — — — — — —
7020127 Seal Kit (Includes Items 4, 5 & 11) 1
S
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2
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N
T
A
B
L
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3120885 2-13
Page 56
S
1
3
1
18
2
7
10
10
11
13
3
17
16
154686
5
12
9
14
107
107
108
108
109
114
110
111
112
112
101
104
109
106
102
105
103
113
117
116
115
E
C
T
I
SECTION 2 TURNTABLE
FIGURE 2-5. SWING BEARING ASSEMBLY
O
N
2
T
U
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B
L
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2-14 3120885
Page 57
SECTION 2 TURNTABLE
FIGURE 2-5. SWING BEARING ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
Note: Visually identify the brand before ordering
replacement parts.
Ref.
S
E
0440339 SWING BEARING ASSEMBLY (PERFECTION GEAR)
(SERVICE REPLACEMENT)
1 7026042 Bearing, Cup 2
7026043 Bearing, Cone 2
2 7027356 Adapter, Motor 1
3 7027361 Seal 2
4 7027354 Cap, End 1
5 0641510 Bolt 5/16”-18NC x 1 1/4” 2
6 0641812 Bolt 1/2”-13NC x 1 1/2” 2
7 70000865 Plug 1
8 7027360 Seal 1
9 7027359 Straight Fitting, Grease 2
2160003 Fitting, Grease - 45° 2
10 7027358 90° Fitting, Grease 2
11 Not Available Housing 1
12 4891500 Flatwasher 5/16” (Hardened) 2
13 7027363 Gear, Worm 1
14 70000868 Ring, Bearing 1
15 7027352 Gasket (.010 - Brown) A/R
16 7027351 Gasket (.0075 - Clear) A/R
17 7027350 Gasket (.005 - Blue) A/R
18 7027353 Gasket (.020 - Yellow) 1
0440203 SWING BEARING ASSEMBLY (KAYDON) (ORIGINAL
EQUIPMENT)
101 7012597 Swing Rotation Box Assembly 1
102 7023484 Cap, End 1
103 Not Available Bolt 1/2”-13NC x 1 1/2” Grade 8 2
104 Not Available Gear, Worm 1
105 7012654 Seal, Outer - Capped End (1.75 O.D.) 1
106 7016682 Shims Kit (Includes Qty 3 each of .005, .0075 &
.010 Shims)
107 70001677 Cup, Bearing 2
108 90206369 Cone, Bearing 2
109 7016676 Seal, Outer - Capped End (2.063 O.D.) 1
110 Not Available Ring, Retaining 1
111 7012655 Seal, Outer - Motor End 1
112 2160001 Fitting, Grease - 90° 2
113 Not Available Lockwasher 1/2” 2
114 Component Options: 1
Not Available Plug, Pipe
2160001 Fitting, Grease - 45°
115 7012596 Bearing, Turntable 1
116 2160003 Fitting, Grease - 45° 2
117 Not Available Capscrew, Socket Head 5/16”-18NC 4
Not Available Washer 5/16” (Not Shown) 4
Ref. C
Ref. G
C
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2
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B
L
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1
3120885 2-15
Page 58
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2
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SECTION 2 TURNTABLE
FIGURE 2-6. TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION (M45 & M40 ONLY)
N
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L
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2-16 3120885
Page 59
SECTION 2 TURNTABLE
FIGURE 2-6. TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION (M45 & M40 ONLY)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
TANK AND MOTOR/GENERATOR COMPONENTS
INSTALLATION (TURNTABLE MOUNTED)
0257824 M45A, M40AJP & M45AJ Ref. 11
0270344 M40AJPnarrow Ref. 1
1 7020156 Module, Control 1
2 7020155 Harness, Wiring (Not Shown - See Section 7 for
Breakdown)
3 to 20 Not Used
21 2180536 Fitting, Barbed 1
22 4400417 Tank, Gas 1
22A 7016314 Cap (Standard) 1
1120487 Lockable Cap (Blue) (Optional) 1
23 4751600 Flatwasher 3/8” 2
24 0641616 Bolt 3/8”-16NC x 2” 2
25 Not Used
26 2720271 Hose 10ft/3m
27 2220315 Fitting, Barbed 2
28 2720339 Hose 12ft/3.7m
29 1320022 Clamp, Hose 7
30 0100020 Sealant (Not Shown) A/R
31 4100026 Sleeve, Hose 3ft/1m
32 2220459 Fitting 90° 3
33 4240033 Strap, Tie 10
34 to 51 Not Used
52 3571157 Plate 1
53 0641406 Bolt 1/4”-20NC x 3/4” 4
54 4711400 Flatwasher 1/4” Narrow 16
55 3311405 Locknut 1/4”-20NC 8
56 0641412 Bolt 1/4”-20NC x 1 1/2” 4
57 1320041 Clamp 1
58 0641408 Bolt 1/4”-20NC x 1” 1
Ref.
1
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I
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N
2
T
U
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N
T
A
B
L
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3120885 2-17
Page 60
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I
O
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2
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SECTION 2 TURNTABLE
FIGURE 2-7. GROUND CONTROL BOX ASSEMBLY
N
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A
B
L
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2-18 3120885
Page 61
SECTION 2 TURNTABLE
FIGURE 2-7. GROUND CONTROL BOX ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
GROUND CONTROL BOX ASSEMBLY Ref.
0861263 E45 & M45 Models Ref. 2/B
0861352 E40 & M40 Models Ref. 2/B
S
E
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1 0861152 Box Weldment 1
2 0641605 Bolt 3/8”-16NC x 5/8” 4
3 4761600 Lockwasher 3/8” 4
4 4751600 Flatwasher 3/8” 4
5 0902406 Bracket, Module Mounting 1
6 Nameplate Options: 1
3252632 E45 & M45 Models
3252669 E40 & M40 Models
7 4740120 Washer, Nylon 12
8 3300365 Nut, Retainer 6
9 0630464 Screw 6
10 3960438 Seal
11 4460007 Strip, Terminal - 6 Position 1
3990106 Limiter, Inrush 1
12 Module 1
0610129 E45 & M45 Models
0610139 E40 & M40 Models
13 0750808 Screw #8 x 1” 6
14 4460264 Buss, Terminal 3
15 3300188 Nut, Tinnerman 6
16 4460425 Connector, Strain Relief 1
17 4360476 Block, Contact 1
18 4460495 Connector, Receptacle 1
19 4460497 Nut, Conduit 1
20 4460496 Lockwasher 1
21 2420106 Gauge, Hourmeter/Battery Capacity 1
22 4740397 Spacer 6
23 4360328 Switch, Toggle 6
24 4060906 Guard, Switch 6
25 4360475 Switch, Emergency Stop 1
7020175 Mushroom Head 1
7020176 Block, Contact 1
26 4360470 Keyswitch 1
26A 2860030 Key, Replacement A/R
27 4360070 Breaker, Circuit - 15Amp 2
28 3300396 Nut, Special 2
29 Not Used
30 3911012 Screw #10-24NC x 3/4” 2
31 3311005 Locknut #10-24NC 2
32 1060584 Cable, Lanyard 1
33 3311011 Nut, Push #10 1
34 Not Used
35 3520028 Plug, Hole 1/2” 2
36 3520054 Plug, Hole 7/16” 1
37 4070987 Shim, Nylon 5
50in/1.26m
T
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N
2
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U
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N
T
A
B
L
E
3120885 2-19
Page 62
S
SECTION 2 TURNTABLE
FIGURE 2-7. GROUND CONTROL BOX ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
38 3910804 Screw #8-32NC x 1/4” 6
E
C
T
I
O
N
2
T
U
R
N
T
A
B
L
MOTOR CONTROLS INSTALLATION (M45 & M40
ONLY)
0257824 M45 Models Ref. 11
0270344 M40 Models Ref. 1
101 2920151 Led (Red) 1
4460248 Terminal, Button Splice 2
102 4360274 Switch, Push Button 1
4460259 Terminal, Posi-Lock 2
4460260 Terminal, Housing 2
4933101 JIB SWITCH INSTALLATION (AJ & AJP ONLY) Ref. 1/A
201 4360328 Switch, Toggle 1
3790012 O-Ring 1
4060906 Shield, Switch 1
Ref.
E
2-20 3120885
Page 63
SECTION 2 TURNTABLE
FIGURE 2-7. GROUND CONTROL BOX ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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T
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O
N
2
T
U
R
N
T
A
B
L
E
3120885 2-21
Page 64
S
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I
O
N
2
T
U
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SECTION 2 TURNTABLE
FIGURE 2-8. HOODS AND BEACON LIGHT INSTALLATIONS
N
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2-22 3120885
Page 65
SECTION 2 TURNTABLE
FIGURE 2-8. HOODS AND BEACON LIGHT INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
HOODS INSTALLATION
0258953 M45 & M40 Models Ref. 2/B
0253709 E45 & E40 Models Ref. 7/G
Note: Replacement Decals Must be Ordered Separately - See Section 8.
Ref.
S
E
C
T
1 Hood, LH Options: 1
Use 2680473 Prior to S/N 48133 (Was p/n 2680410)
2680473 S/N 48133 to Present
2 Hood Options: 1
Use 2680474 M45 & M40 Models (Prior to S/N 48133) (Was p/n
2680453)
2680474 M45 & M40 Models (S/N 48133 to Present)
Use 2680475 E45 & E40 Models (Prior to S/N 48133) (Was p/n
2680411)
2680475 E45 & E40 Models (S/N 48133 to Present)
3 2940071 Latch 2
4 3430840 Pin, Clevis 2
5 0253687 Hinge, Swing 2
6 3420156 Pin, Hair Cotter 4
7 4751800 Flatwasher 1/2” A/R
8 0940049 Bumper (Prior to S/N 48133 Only) 2
9 3311501 Nut 5/16”-18NC A/R
10 0630468 Bolt 5/16”-18NC x 1” 3
11 4751500 Flatwasher 5/16” 5
12 4060803 Shield, Flex Trim A/R
13 0901923 Bracket, Hood Mounting 2
14 0901921 Bracket, Hood Mounting 1
15 3960453 Seal, Door 5ft/1.5m
16 3311601 Nut 3/8”-16NC A/R
17 4751600 Flatwasher 3/8” A/R
18 1320043 Clamp, Insulated Cable 3/8” 1
19 0641510 Bolt 5/16”-18NC x 1 1/4” A/R
20 4751400 Flatwasher 1/4” 1
21 3311401 Nut 1/4”-20NC 1
22 0100011 Loctite #242 (Not Shown) A/R
I
O
N
2
T
U
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N
T
A
B
L
E
0259305 STROBE LIGHT INSTALLATION (OPTIONAL) Ref. 1
101 4060865 Guard, Light 1
102 2920146 Light, Strobe (Amber) 1
7016319 Bulb, Light 1
7016372 Amber Lens 1
103 0630491 Bolt, Special 1
104 3537903 Plate, Mounting 1
105 0741606 Screw, Flathead 3/8”-16NC x 3/4” 1
106 0721008 Bolt #10-24NC x 1” 2
107 3311005 Locknut #10-24NC 2
108 4751000 Flatwasher #10 4
3120885 2-23
Page 66
S
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SECTION 2 TURNTABLE
FIGURE 2-8. HOODS AND BEACON LIGHT INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
109 4220162 Spacer 1
110 0100011 Loctite #242 A/R
111 4240032 Tie-Strap 1
112 4460234 Clamp 1
113 2820036 Loom (Not Shown)
16in/41cm
I
O
N
2
T
U
R
N
T
A
B
L
E
0253984 STORAGE COMPARTMENT INSTALLATION (PRIOR
TO S/N 48133 ONLY)
201 4761600 Lockwasher 3/8" 4
202 0641605 Bolt 3/8"-16NC x 5/8" 4
203 3536691 Box, Storage 1
204 2940042 Latch 1
205 3960438 Seal
206 4844404 Door Front Weldment 1
207 4740120 Washer, Nylon 6
208 0630464 Screw, Button Head #10-24NC x 1/2" 6
209 3300365 Retainer, Nut #10-24NC 6
210 0100011 Loctite #242 A/R
211 4751600 Flatwasher 3/8” 4
Ref. B
50 in./1.3m
2-24 3120885
Page 67
SECTION 3 BOOM
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
3-1 BOOMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 MAIN BOOM ASSEMBLY (E45A & M45A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 MAIN BOOM ASSEMBLY (E45AJ & M45AJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4 MAIN BOOM ASSEMBLY (E40AJP & M40AJP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-5 SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (Prior to S/N 49945) . . . . . . . . . . . . . 3-12
3-6 SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N 49945 to Present) . . . . . . . . . . . 3-14
3-7 SUPPORT/ROTATOR AND JIB ASSEMBLY (AJ & AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-8 ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-9 CABLE/CLAMPS AND LIMIT SWITCHES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
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3120885 3-1
Page 68
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3
B
SECTION 3 BOOM
FIGURE 3-1. BOOMS INSTALLATION
O
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3-2 3120885
Page 69
SECTION 3 BOOM
FIGURE 3-1. BOOMS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
BOOMS INSTALLATIONS
0258691 E45A & M45A Ref. 2
0259366 E45AJ & M45AJ Ref. 3/C
0259939 E40AJP & M40AJP Ref. 2/B
S
1 Boom Assembly -Tower Options: 2
0800852 E45 & M45
0801227 E40 & M40
1A Teflon Bushing Options: (4 per Assembly) A/R
0961726 E45 & M45
0961950 E40 & M40
2 Level Link Options: 2
4844541 E45 & M45
4846209 E40 & M40
2A Teflon Bushing Options: (4 per Assembly) A/R
0961726 E45 & M45
0961950 E40 & M40
3 4844427 Upright Weldment (Lower) 1
4 Upright Weldment (Upper) Options: 1
4844304 E45A & M45A
4846026 E45AJ, M45AJ, E40AJP & M40AJP
5 Boom Assembly - Main Options : 1
0801169 E45A & M45A (See Figure 3-2 for Breakdown)
0801197 E45AJ & M45AJ (See Figure 3-3 for Breakdown)
0801225 E40AJP & M40AJP (See Figure 3-4 for
Breakdown)
6 Hose Guard Plate Options: 1
3537045 E45 & M45
3536491 E40 & M40
7 Lift Cylinder Assembly - Lower Options (See Section
5 for Breakdown):
1683711 E45A & M45A
1683826 E45AJ & M45AJ
1683939 E40AJP & M40AJP
8 Lift Cylinder Assembly - Mid Options (See Section 5
for Breakdown):
1683713 E45A & M45A
1683825 E45AJ & M45AJ
1683942 E40AJP & M40AJP
9 Lift Cylinder Assembly - Upper Options (See Section
5 for Breakdown):
1683708 E45A & M45A
1683813 E45AJ & M45AJ
1683945 E40AJP & M40AJP
10 Master Cylinder Assembly Options (See Section 5 for
Breakdown):
1683325 E45A & M45A
1683773 E45AJ & M45AJ
1683923 E40AJP & M40AJP
1
1
1
1
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3
B
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3120885 3-3
Page 70
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SECTION 3 BOOM
FIGURE 3-1. BOOMS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
11 Pin Options: 3
3422175 E45 & M45
3422481 E40 & M40
12 Pin Options: 2
3422176 E45 & M45
3422845 E40 & M40
13 Pin Options: 9
3422177 E45 & M45
3422480 E40 & M40
14 Pin Options: 1
3422178 E45 & M45
3422844 E40 & M40
15 Pin Options: 1
3422179 E45A & M45A
3422806 E45AJ, M45AJ, E40AJP & M40AJP
16 Pin Options: 1
3422180 E45A & M45A
3422582 E45AJ, M45AJ, E40AJP & M40AJP
17 4844467 Boom Rest Weldment 1
18 0561076 Block, Boom Rest 1
19 3841203 Keeper, Pin - 1/2” A/R
20 3841143 Keeper, Pin - 3/8” A/R
21 3780184 O-Ring - 2” (E45, M45, E45AJ & M45AJ Only) 30
22 3780181 O-Ring - 1” (E45 & M45 Only) 4
23 3020022 Grease A/R
24 0641506 Bolt 5/16”-18NC x 3/4” 4
25 3311505 Locknut 5/16”-18NC 4
26 0641608 Bolt 3/8”-16NC x 1” 5
27 0641610 Bolt 3/8”-16NC x 1 1/4” 4
28 4751600 Flatwasher 5/16” 8
29 Not Used
30 3311605 Locknut 3/8”-16NC 3
31 0641812 Bolt 1/2”-13NC x 1 1/2” 6
32 0940048 Bumper 1
33 0641806 Bolt 1/2”-13NC x 3/4” 2
34 3422669 Pin 1
35 3311805 Locknut 1/2”-13NC 3
36 to 39 Not Used
40 Tube 1
4566356 E45 & M45
4566427 E40 & M40
41 Not Used
42 4751500 Flatwasher 5/16” 4
43 Not Used
44 0100011 Loctite #242 A/R
45 0641810 Bolt 1/2”-13NC x 1 1/4” 12
46 4846091 Rest, Boom (S/N 46063 to Present Only) 1
3-4 3120885
Page 71
SECTION 3 BOOM
FIGURE 3-1. BOOMS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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3
B
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3120885 3-5
Page 72
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3
B
SECTION 3 BOOM
FIGURE 3-2. MAIN BOOM ASSEMBLY (E45A & M45A)
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3-6 3120885
Page 73
SECTION 3 BOOM
FIGURE 3-2. MAIN BOOM ASSEMBLY (E45A & M45A)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0801169 MAIN BOOM ASSEMBLY Ref. 1/A
1 0800854 Base Weldment 1
1A 0961726 Bearing 2
2 0801154 Fly Weldment 1
3 1683704 Telescope Cylinder Assembly (See Section5 for
Breakdown)
4 3422185 Pin 1
5 1180302 Powertrack Assembly 1
6 4844579 Holder, Wear Pad 1
7 3340663 Pad, Wear (Base Front Top & Sides/Fly Rear Sides &
Bottom)
8 3340820 Pad, Wear (Fly Rear Top) 2
9 3340682 Pad, Wear (Base Front Bottom) 1
10 1760160 Disc 8
11 0630487 Bolt, Special 6
12 3311602 Nut, Jam 3/8”-16NC 8
13 0641818 Bolt 1/2”-13NC x 2 1/4” 4
14 4761800 Lockwasher 1/2” 4
15 3760115 Ring, Snap 2
16 0641405 Bolt 1/4”-20NC x 5/8” 2
17 0641404 Bolt 1/4”-20NC x 1/2” 2
18 4761400 Lockwasher 1/4” 7
19 0641606 Bolt 3/8”-16NC x 3/4” 7
20 4761600 Lockwasher 3/8” 7
21 0100011 Loctite #242 A/R
22 1670678 Cover, Boom 1
23 1670698 Cover, Boom 1
24 4751400 Flatwasher 1/4” 7
25 3311401 Nut 1/4”-20NC 3
26 1220038 Holder, Wear Pad (Base Front Left Sides) 1
27 1220039 Holder, Wear Pad (Base Front Right Side) 1
28 1220040 Holder, Wear Pad (Base Front Top) 1
29 0630399 Bolt, Special 2
30 0100009 Silicone A/R
31 4740413 Washer, Spacer 5
32 4751600 Flatwasher 3/8” 5
33 0641608 Bolt 3/8”-16NC x 1” 5
34 3520034 Plug, Hole 4
35 0961951 Bearing, Garmax 2
1
8
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3
B
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3120885 3-7
Page 74
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3
B
SECTION 3 BOOM
FIGURE 3-3. MAIN BOOM ASSEMBLY (E45AJ & M45AJ)
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3-8 3120885
Page 75
SECTION 3 BOOM
FIGURE 3-3. MAIN BOOM ASSEMBLY (E45AJ & M45AJ)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0801197 MAIN BOOM ASSEMBLY Ref. 2/B
1 0801198 Base Weldment 1
1A 0961726 Bearing 2
2 0801192 Fly Weldment 1
3 1683798 Telescope Cylinder Assembly (See Section 5 for
Breakdown)
4 1180352 Powertrack Assembly 1
7006139 1ft. Repair Section A/R
7006151 Feet, Mounting A/R
7006152 Pin Kit (Includes 1 Link Pin, 4 Different Size Washers
& 1 Retaining Ring)
5 4846033 Pushtube Weldment 1
6 3340756 Pad, Wear (Base Front Top & Sides/Fly Rear Sides) 8
7 3340837 Pad, Wear (Base Bottom/Fly Rear Top & Bottom) 5
8 4070897 Shim 18 Gauge 10
9 4070898 Shim 16 Gauge 8
10 4070982 Shim 11 Gauge 2
11 3422804 Pin 1
12 3760115 Ring, Snap 2
13 0641606 Bolt 3/8”-16NC x 3/4” 22
14 0641607 Bolt 3/8”-16NC x 7/8” 4
15 0641605 Bolt 3/8”-16NC x 5/8” 8
16 0641608 Bolt 3/8”-16NC x 1” 24
17 0641818 Bolt 1/2”-13NC x 2 1/4” 4
18 4761800 Lockwasher 1/2” 4
19 1670678 Cover, Boom 1
20 4761600 Lockwasher 3/8” 3
21 3311401 Nut 1/4”-20NC 3
22 4711600 Flatwasher 3/8” 12
23 3311605 Locknut 3/8”-16NC 4
24 0100011 Loctite #242 (Not Shown) A/R
25 0961948 Bearing, Garmax 4
1
A/R
S
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B
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3120885 3-9
Page 76
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SECTION 3 BOOM
FIGURE 3-4. MAIN BOOM ASSEMBLY (E40AJP & M40AJP)
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3-10 3120885
Page 77
SECTION 3 BOOM
FIGURE 3-4. MAIN BOOM ASSEMBLY (E40AJP & M40AJP)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0801225 MAIN BOOM ASSEMBLY Ref. 2/B
1 0801224 Base Weldment 1
2 0801226 Weldment, Fly Boom 1
3 1683911 Cylinder, Telescope (See Section 5 for Breakdown) 1
4 1180353 Carrier, Power Track 1
7006139 1ft. Repair Section A/R
7006151 Feet, Mounting A/R
7006152 Pin Kit (Includes 1 Link Pin, 4 Different Size Washers
& 1 Retaining Ring)
5 4846180 Weldment, Push Tube 1
6 3340878 Pad, Wear 10
7 3340884 Pad, Wear 4
8 4070864 Shim 18 Gauge 12
9 4070863 Shim 11 Gauge 8
10 3340886 Pad, Wear 2
11 3422804 Pin 1
12 3760115 Ring, Retaining 2
13 0641606 Bolt 3/8”-16NC x 3/4” 30
14 0961948 Bearing 2
15 0641605 Bolt 3/8”-16NC x 5/8” 8
16 0641608 Bolt 3/8”-16NC x 1” 22
17 0641818 Bolt 1/2”-13NC x 2 1/4” 4
18 4761800 Lockwasher 1/2” 4
19 1670959 Cover 1
20 4761400 Lockwasher 1/4” 3
21 3311401 Nut 1/4”-20NC 3
22 4711600 Flatwasher 3/8” 12
23 3311605 Locknut 3/8”-16NC 4
24 0100011 Loctite #242 (Not Shown) A/R
25 0961950 Bearing 2
26 3520082 Plug (Not Shown) 2
27 4070997 Shim 16 Gauge 2
28 4070998 Shim 18 Gauge 2
A/R
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3120885 3-11
Page 78
S
12
16
16
18
25
23
26
27
21
20
22
4
30
3
0
17
36
1
7191
9
10
9
18
8
2
12
28
28
9
7
10
5
9
18
FLY BOOM
SECTION REF.
MOUNTS TO
BOTTOM OF
PLATFORM
10
9
18
6
29
29
29
29
11
3
31
34
32
35
3
5
35B
35A
1
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3
B
SECTION 3 BOOM
FIGURE 3-5. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (PRIOR TO S/N49945)
O
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3-12 3120885
Page 79
SECTION 3 BOOM
FIGURE 3-5. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (PRIOR TO S/N49945)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0258383 PLATFORM ROTATOR AND SUPPORT INSTALLATION Ref. 6/C
1 4845770 Support Weldment 1
2 4845769 Pivot Weldment 1
3 1683285 Platform Level Cylinder Assembly (See Section 5 for
Breakdown)
4 1682930 Platform Rotator Cylinder Assembly (See Section 5 for
Breakdown)
5 3422709 Pin, Pivot 1
6 3422180 Pin, Pivot 1
7 3422181 Pin, Pivot 1
8 3422748 Pin, Pivot 1
9 3841143 Pin, Keeper 4
10 0641608 Bolt 3/8”-16NC x 1 1/4” 3
11 4740007 Washer, Thrust 1
12 0641607 Bolt 3/8”-16NC x 7/8” 7
13 to 15 Not Used
16 4751600 Flatwasher 3/8” 6
17 4751800 Flatwasher 1/2” 2
18 3311605 Locknut 3/8"-16NC 9
19 3430816 Pin, Clevis 1/2" x 2" 2
20 0460106 Bellows 1
21 1320014 Clamp, Hose 1
22 1320031 Clamp, Hose 1
23 4060855 Shield 1
24 Not Used
25 0641516 Bolt 5/16”-18NC x 2” 2
26 4751500 Flatwasher 5/16" 4
27 3311505 Locknut 5/16"-18NC 2
28 0100011 Loctite #242 A/R
29 3780181 O-Ring 4
30 3450405 Pin, Cotter 2
31 0641422 Bolt 1/4”-20NC x 2 3/4” 2
32 3311405 Locknut 1/4”-20Nc 2
33 Not Used
34 4751400 Flatwasher 1/4" 2
35 4641080 Valve Assembly - Counterbalance 1
7017498 Piston, Pilot 1
35A 7012981 Cartridge, Relief 2
7012953 Seal Kit - 7012981 Cartridge (1 per Assembly) 2
35B 7012955 Cartridge, Check 2
7012967 Seal Kit - 7012955 Cartridge (1 per Assembly) 2
36 0961947 Bushing (Platform Pivot) 2
1
1
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3120885 3-13
Page 80
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SECTION 3 BOOM
FIGURE 3-6. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N49945 TO PRESENT)
O
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3-14 3120885
Page 81
SECTION 3 BOOM
FIGURE 3-6. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N49945 TO PRESENT)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0259754 PLATFORM ROTATOR AND SUPPORT INSTALLATION Ref. 1
1 4846050 Weldment, Support 1
2 0060052 Rotator, Helac (See Figure 3-8 for Breakdown) 1
3 1683285 Cylinder Assembly (See Section 5 for Breakdown) 1
4 3422709 Shaft, Pin 1
5 3422180 Shaft, Pin 1
6 3422181 Shaft, Pin 1
7 3841143 Keeper 3
8 0641608 Bolt 3/8”-16NC x 1” 8
9 0641607 Bolt 3/8”-16NC x 7/8” 1
10 4751600 Flatwasher 3/8” 12
11 3311605 Locknut 3/8”-16NC 8
12 0100011 Loctite #242 (Not Shown) A/R
13 3780181 O-Ring (1”) 4
14 0641610 Bolt 3/8”-16NC x 1 1/4” 6
15 0641407 Bolt 1/4”-20NC x 7/8” 2
16 4740362 Washer, Fender 4
17 3311405 Nut 1/4”-20NC 2
S
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3120885 3-15
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SECTION 3 BOOM
FIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP)
O
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3-16 3120885
Page 83
SECTION 3 BOOM
FIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
JIB ASSEMBLIES
0259440 E45AJ & M45AJ Ref. C
0259441 E40AJP & M40AJP Ref. C
1 0060044 Rotator Assembly (See Figure 3-8 for Breakdown) 1
2 Rotator Assembly Options (See Figure 3-8 for
Breakdown):
Not Required E45AJ & M45AJ
0060046 E40AJP & M40AJP
3 0641407 Bolt 1/4”-20NC x 7/8” 2
4 0641608 Bolt 3/8”-16NC x 1” 6
5 0641610 Bolt 3/8”-16NC x 1 1/4” 6
6 0641616 Bolt 3/8”-16NC x 2” 4
7 0641618 Bolt 3/8”-16NC x 2 1/4” 2
8 0641810 Bolt 1/2”-13NC x 1 1/4” A/R
9 0961947 Bushing, Garmax 2
10 0961951 Bushing, Garmax 2
11 1320259 Clamp, Block 2
12 1683779 Jib Cylinder Assembly (See Section 5 for
Breakdown)
13 3311405 Locknut 1/4”-20NC 2
14 3311501 Nut 5/16”-18NC 8
15 3311605 Locknut 3/8”-16NC 12
16 3422791 Pin 2
17 3422794 Pin 2
18 3571406 Plate, Jib Cover 1
19 4711600 Flatwasher 3/8” Narrow A/R
20 4711800 Flatwasher 1/2” Narrow A/R
21 4740362 Flatwasher 1/4” 4
22 4751600 Flatwasher 3/8” 12
23 4845926 Link (Upper) 1
24 4845927 Link (Lower) 2
25 4846050 Support Weldment 1
26 Pivot Options: 1
26A 4845925 E45AJ & M45AJ
26B 4846073 E40AJP & M40AJP
27 0100011 Loctite #242 (Not Shown) A/R
A/R
1
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SUPPORT & ROTATOR ASSEMBLY Ref.
0259366 E45AJ & M45AJ Ref. 3
0259939 E40AJP & M40AJP Ref. 2
101 to 118 Not Used
119 3841203 Keeper, Pin 1
120 3841143 Keeper, Pin 2
121 Not Used
122 Pin Options: 1
3422793 E45AJ & M45AJ
3422814 E40AJP & M40AJP
3120885 3-17
Page 84
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SECTION 3 BOOM
FIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
123 3020022 Grease A/R
124 to 126 Not Used
127 0641610 Bolt 3/8”-16NC x 1 1/4” 1
128 Not Used
129 Platform Level Cylinder Assembly Options (See
Section 5 for Breakdown):
1683760 E45AJ & M45AJ
1683924 E40AJP & M40AJP
130 to 133 Not Used
134 3422669 Pin 1
135 3311805 Locknut 1/2”-13NC 1
136 0641607 Bolt 3/8”-16NC x 7/8” 1
137 3422792 Pin 1
138 Jib Assembly Options (Includes Items 1-27): 1
0259440 E45AJ & M45AJ
0259441 E40AJP & M40AJP
139 0641810 Bolt 1/2”-13NC x 1 1/4” 1
140 to 143 Not Used
144 0100011 Loctite #242 (Not Shown) A/R
1
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3-18 3120885
Page 85
SECTION 3 BOOM
FIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120885 3-19
Page 86
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1
25
32
3234342527
24
44242
32022
41526
GENUINE PARTS
51
52
2
1B
1A
7
7
53
53
53
53
41A
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SECTION 3 BOOM
FIGURE 3-8. ROTATOR ASSEMBLY
O
N
3
B
O
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3-20 3120885
Page 87
SECTION 3 BOOM
FIGURE 3-8. ROTATOR ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
ROTATOR ASSEMBLIES Ref.
0060044 E45AJ & M45AJ Ref. D
0060052 E45A & M45A (S/N49945 to Present Only) Ref. F
0060046 E40AJP & M40AJP Ref. C
Note: There are 2 different versions each of Rotators p/n 0060044 & 0060052. No s/n break exists.
Order parts by the Helac Control #.
S
E
C
1 Not Serviced Case/Bracket Weldment (Purchase Complete
Assembly)
1A 0962257 Bushing, Garmax (0060044 Rotator Only) 2
1B 0961947 Bushing, Garmax (0060044 Rotator Only) 2
2 Shaft Options: 1
7017120 0060052 Rotators with Helac Control #26409
7017196 0060052 Rotators with Helac Control #26966
7017120 0060044 Rotators with Helac Control #25928
7017196 0060044 Rotators with Helac Control #26962
7017130 0060046 Rotator
3 Piston Sleeve Options: 1
7017121 0060052 Rotators with Helac Control #26409
7027900 0060052 Rotators with Helac Control #26966
7017121 0060044 Rotators with Helac Control #25928
7027900 0060044 Rotators with Helac Control #26962
7017131 0060046 Rotator
4 Cap, End Options: 1
7017153 0060052 Rotators with Helac Control #26409
7027901 0060052 Rotators with Helac Control #26966
Not Available 0060044 Rotators with Helac Control #25928
7027901 0060044 Rotators with Helac Control #26962
Not Available 0060046 Rotator
5 Not Available Capscrew 1/4”-20NC (Grade 8) 3
6Not Used
7 Bolt & Nut Assembly Options: 1
7017126 0060044 & 0060052 Rotators
7017135 0060046 Rotator
8 to 19 Not Used
20 See Note Seal, Rod (Note: Use Items 100A-102B) 1
21 Not Used
22 See Note Seal, Piston (Note: Use Items 100A-102B) 1
23 Not Used
24 See Note Seal, Cap (Note: Use Items 100A-102B) 1
25 See Note Packing, Bearing (Note: Use Items 100A-102B) 2
26 See Note Seal (Note: Use Items 100A-102B) 2
27 See Note Ring, Back-Up Cap (Note: Use Items 100A-102B) 1
28 to 31 Not Used
32 Use Item 51 Bearing, Shaft 2
33 Not Used
34 Use Item 51 Washer, Thrust 2
35 to 40 Not Used
1
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3120885 3-21
Page 88
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SECTION 3 BOOM
FIGURE 3-8. ROTATOR ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
41 Counterbalance Valve Assembly Options: 1
Use 7017172 Helac p/n 24327 Stamped beside Mounting
Screws (was p/n 7017125)
7017172 Helac p/n 26553 or 26554 Stamped beside Mount-
ing Screws
41A Valve, Cartridge Options: A/R
7011323 Valve, Cartridge for Helac p/n 24327 Valve 2
2900770 Seal Kit - 7011323 Cartridge (1 Per Assem-
bly)
7017192 Valve, Cartridge Helac p/n 26553 (No Seal Kit
Available)
42 Not Available Bushing, Shaft 2
43 to 50 Not Used
— — — — — — — — — —
51 Bearing Kit Options (Includes Items 32 - 34): 1
7017122 0060044 & 0060052 Rotators
7017134 0060046 Rotator
52 Seal Kit Options (Includes Items 20,22,24,25,26 &
27):
0060044 & 0060052 Rotators Options:
7017127 Standard
70000341 Low Temperature
0060046 Rotator Options:
7017165 Standard (was p/n 7017133)
Not Available Low Temperature
53 Hardware Kit Options: 1
7017123 0060044 & 0060052 Rotators
7017132 0060046 Rotator
2
2
1
3-22 3120885
Page 89
SECTION 3 BOOM
FIGURE 3-8. ROTATOR ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120885 3-23
Page 90
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SECTION 3 BOOM
FIGURE 3-9. CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONS
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3-24 3120885
Page 91
SECTION 3 BOOM
FIGURE 3-9. CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
CABLES AND CLAMPS INSTALLATION
0257735 E45A & M45A Ref. 4/D
0259367 E45AJ & M45AJ Ref. 1/B
0259970 E40AJP & M40AJP Ref. 2/A
S
1 Harness Assembly - Upper Boom Options: (See
Section 7 for Breakdown)
4922178 E45 & M45
4922364 E40 & M40
2 Harness Assembly - Lower Boom Options: (See
Section 7 for Breakdown)
4922179 E45 & M45
4922363 E40 & M40
3 4460754 Connector 1
4 1320260 Block, Hose Clamp 2
5 0561317 Block, Hose Clamp 1
6 4460753 Connector 1
7 Shield Options: 1
3536999 E45A & M45A
3571462 E45AJ, M45AJ, E40AJP & M40AJP
8 Cover, Clamp Options: 1
1320195 E45A & M45A
Not Required E45AJ & M45AJ
9 Clamp Options: 1
1320199 E45A & M45A
Not Required E45AJ & M45AJ
10 4751500 Flatwasher 5/16" 5
11 4751400 Flatwasher 1/4" 12
12 3311401 Nut 1/4"-20NC 6
13 0641514 Bolt 5/16"-18NC x 1 3/4" 3
14 0100011 Loctite #242 (Not Shown) A/R
15 4060805 Trim 3.6ft/1.1m
16 4060808 Trim 1/2" 8ft/2.4m
17 4240099 Tie-Strap 26
18 0641520 Bolt 5/16"-18NC x 2 1/2" A/R
19 Not Used
20 3311505 Locknut 5/16"-18NC 2
21 4566243 Roller 1
22 0641560 Bolt 5/16"-18NC x 7 1/2" 1
23 4300140 Stud, Weld 5/16"-18NC x 3 5/8" 2
24 Hose Clamp Block Options: 1
0561359 E45A & M45A (Prior to S/N 56080)
0561384 E45A & M45A (S/N 56080 to Present)
0561359 E45AJ & M45AJ
0561384 E40 & M40
25 1670697 Cover, Hose 1
26 0630467 Capscrew, Button 5/16"-18NC x 1/2" 4
27 3300151 Nut, Acorn 1/4" - 20NC 6
28 1320040 Clamp, Cable 1
1
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3120885 3-25
Page 92
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SECTION 3 BOOM
FIGURE 3-9. CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONS (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
29 0641410 Bolt 1/4"-20NC x 1 1/4" 1
30 3311405 Locknut 1/4"-20NC 1
31 Hose Clamp Block Options: 1
0561360 E45 & M45
0561385 E40 & M40
32 Hose Clamp Block Options: 1
0561361 E45 & M45
0561386 E40 & M40
33 0100019 Loctite #271 (Not Shown) A/R
34 Clamp Options: A/R
1320095 E45A,M45A,E45AJ & M45AJ (S/N 45407 to
S/N 49945)
Not Required E45A & M45A (S/N 49945 to Present) 0
1320095 E45AJ & M45AJ (S/N 49945 to Present) 1
Not Required E40AJP & M40AJP 0
35 Sleeve Options: A/R
Not Required E45A,M45A,E45AJ & M45AJ (Prior to S/N 49945) 0
4100065 E45A & M45A (S/N 49945 to Present) 1
Not Required E45AJ & M45AJ (S/N 49945 to Present) 0
Not Required E40AJP & M40AJP 0
1
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LIMIT SWITCHES INSTALLATION Ref.
0254875 E45 & M45 Ref. 4
0253704 E40 & M40 Ref. 5
101 4360321 Switch, Limit 2
102 4460428 Connector, Strain Relief 2
103 3311005 Locknut #10-24NC 4
104 Not Used
105 3900246 Screw, Filister Head #10-24NC x 1 3/4” 2
106 3900104 Screw, Filister Head #10-24NC x 2 1/4” 2
107 1060341 Cable, Electrical - 16/2 A/R
108 1670832 Cover, Switch Lower (S/N 33795 to Present Only) 1
109 1670833 Cover, Switch Upper (S/N 33795 to Present Only) 1
3-26 3120885
Page 93
SECTION 4 PLATFORM
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 PLATFORM PADDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4 CONTROLLER ASSEMBLY (SWING AND LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-5 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
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3120885 4-1
Page 94
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301
6
302
304
305
303
129
130
132
146
201
4
9
9
3
1
10
7
150
151
152
152
153
11
12
13
E
C
SECTION 4 PLATFORM
FIGURE 4-1.PLATFORM COMPONENTS INSTALLATION
T
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4
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4-2 3120885
Page 95
SECTION 4 PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PLATFORM INSTALLATIONS WITH LIFT GATE
3510696 4ft/1.22m Width Ref. B
3510695 5ft/1.52m Width (Without Stop) Ref. B
0270408 5ft/1.52m Width (With Stop) Ref. A
Note: Replacement Decals Must be Ordered Separately - See Section 8.
Ref.
S
1 0641418 Bolt 1/4”-20NC x 2 1/4” (Grade 8) 2
2Not Used
3 0961845 Bushing 2
4 3300151 Nut Acorn 1/4”-20NC 2
5Not Used
6 Not Serviced Platform Options (Purchase Complete Platform): 1
3510696 4ft/1.22m Width
3510695 5ft/1.52m Width (Without Stops)
0270408 5ft/1.52m Width (With Stops)
7 4420055 Tape 4in/10cm
8Not Used
9 4740411 Washer, Nylon 4
10 4845288 Slide Bar Weldment 1
11 0641609 Bolt 3/8”-16NC x 1 1/8” A/R
12 3311605 Locknut 3/8”-16NC A/R
13 4846276 Stop 1
— — — — — — — — — —
7016652 Huck Fastener Kit (Replaces Huck Fasteners with
Bolts)
0861176 PEDESTAL PANEL & FOOTSWITCH INSTALLATION Ref. 7/F
101 to 128 Not Used
129 4360031 Footswitch 1
7000625 Block, Contact 2
3252347 Nameplate (Note: See Section 8 for Other
Languages)
130 0641408 Bolt 1/4”-20NC x 1” 3
131 3311401 Nut 1/4”-20NC 3
132 4751400 Flatwasher 1/4” 3
133 to 145 Not Used
146 4460071 Connector, Strain Relief 1
147 to 149 Not Used
150 3380434 Panel, Pedestal 1
151 0641407 Bolt 1/4”-20NC x 7/8” 2
152 4740362 Washer, Fender 4
153 3311405 Locknut 1/4”-20NC 2
13
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1
TRAY INSTALLATIONS (OPTIONAL)
201 1580012 Tray, Storage (Center) 1
202 1580013 Tray, Storage (Rail Mounted - Not Shown) 1
3120885 4-3
Page 96
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SECTION 4 PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0259338 WORKLIGHTS INSTALLATION (OPTIONAL) Ref. 1/A
301 3536089 Plate, Mounting 2
302 0641414 Bolt 1/4”-20NC x 1 3/4” 4
303 3311405 Locknut 1/4”-20NC 4
304 4711400 Flatwasher 1/4” Narrow 8
305 2920095 Worklight 2
7016356 Bulb, Replacement (1 Per Assembly) 2
306 4240099 Tie-Strap (Not Shown) 10
307 2820035 Loom, Vinyl (Not Shown) 9
308 Not Used
309 4460428 Connector, Strain Relief (Not Shown - Located at
Console Box)
1
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4-4 3120885
Page 97
SECTION 4 PLATFORM
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
S
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3120885 4-5
Page 98
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SECTION 4 PLATFORM
FIGURE 4-2.PLATFORM PADDING INSTALLATION
P
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4-6 3120885
Page 99
SECTION 4 PLATFORM
FIGURE 4-2. PLATFORM PADDING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0270338 PLATFORM PADDING INSTALLATION Ref. A
1 0641508 Bolt 5/16”-18NC x 1” 4
2 0641516 Bolt 5/16”-18NC x 2” 2
3 0940038 Padding 24ft/7.3m
4 3311501 Nut 5/16”-18NC 6
5 3941405 Screw, Self Tapping 1/4”-20NC x 5/8” 2
6 4240099 Tie, Wire A/R
7 4711400 Flatwasher 1/4” 2
8 4751500 Flatwasher 5/16” (Wide) 6
9 4761500 Lockwasher 5/16” 6
10 4844917 Rail, Bumper 1
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3120885 4-7
Page 100
S
12
13
13
13
15
14
8
20
301(M45 & M40)
8 (E45 & E40)
101
10
9
7
42
7
42
6
16
7
42
8 (A Models)
201(AJ & AJP Models)
41
42
18
8
39
3
3
43
24
23
27
26
26
25
25
54A
54B
1
45
49
17
33
34
35
2
21
4
47
48
11
5
38
38
37
8 2628
27
25
PRIOR TO
S/N 46103
S/N 46103
TO PRESENT
1A
1B
1C
19
101
22
101
101
101
101
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4
P
SECTION 4 PLATFORM
FIGURE 4-3.PLATFORM CONSOLE ASSEMBLY
L
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F
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4-8 3120885
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