JLG T500J Parts Manual

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Page 1

Illustrated Parts Manual

Models

T350

T500J

3121199

December 30, 2013

Page 2

Page 3

REVISION LOG

December 15, 2004 - Original Issue Of Manual (Edited to B/M 0010612 Revision 3)

March 15, 2005 - Revised Manual (Edited to B/M 0010612 Revision 5)

August 31, 2005 - Revised Manual (Edited to B/M 0010612 Revision 8)

February 15, 2006 - Revised Manual (Edited to B/M 0010612 Revision 14)

July 18, 2006 - Revised Manual (Edited to B/M 0010612 Revision 16)

November 13, 2006 - Revised Manual (Edited to B/M 0010612 Revision 19)

January 31, 2007 - Revised Manual (Edited to B/M 0010612 Revision 20)

June 1, 2007 - Revised Manual (Edited to B/M 0010612 Revision 22)

January 15, 2008 - Revised Manual (Edited to B/M 0010612 Revision 26)

July 31, 2008 - Revised Manual (Edited to B/M 0010612 Revision 27)

March 1, 2009 - Revised Manual (Edited to B/M 0010612 Revision 28)

July 2, 2010 - Revised Manual (Edited to B/M 0010612 Revision 31)

January 15, 2011 - Revised Manual (Edited to B/M 0010612 Revision 32)

May 5, 2011 - Revised Manual (Edited to B/M 0010612 Revision 32)

August 1, 2011 - Revised Manual (Edited to B/M 0010612 Revision 33)

November 4, 2011 - Revised Manual (Edited to B/M 0010612 Revision 34)

March 23, 2012 - Revised Manual (Edited to B/M 0010612 Revision 34)

July 6, 2012 - Revised Manual (Edited to B/M 0010612 Revision B)

October 3, 2012 - Revised Manual (Edited to B/M 0010612 Revision B)

February 8, 2013 - Revised Manual (Edited to B/M 0010612 Revision C)

June 1, 2013 - Revised Manual (Edited to B/M 0010612 Revision E)

September 1, 2013 - Revised Manual (Edited to B/M 0010612 Revision F)

December 30, 2013 - Revised Manual (Edited to B/M 0010612 Revision F)

3121199 T350 & T500J A

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REVISION LOG

B T350 & T500J 3121199

Page 5

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

1-1 TONGUE JACK INSTALLATIONS (WITH POLY JACK TIRES) . . . . . . . . . . . . . . . . . . . 1-2

1-2 TONGUE JACK INSTALLATIONS (WITH PNEUMATIC JACK TIRES) . . . . . . . . . . . . . 1-4

1-3 AXLE AND TONGUE INSTALLATION WITH ELECTRIC BRAKES

(ANSI, ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPECS) . . . . . . . . . . . . 1-6

1-4 AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES) . . . . . . . . . . . . . . 1-10

1-5 AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 50MM

BALL (ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPEC Machines) . . . . . 1-16

1-6 AXLE AND TONGUE INSTALLATION WITH MECHANICAL BRAKES

(CE SPEC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 HYDRAULIC BRAKE COUPLER WITH 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099) . . . . . . . 1-24

1-8 HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099) . . . . . . . 1-26

1-9 HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (SN 0030002099 TO PRESENT) . . . . 1-28

1-10 HYDRAULIC BRAKE COUPLER WITH 50MM BALL ASSEMBLY (CE SPEC

MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

1-11 PARKING BRAKE CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES

ONLY) AND TRANSPORT LOCK ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-12 ELECTRIC BRAKE & AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1-13 HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES) . . . . . . 1-38

1-14 MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES) . . . . . . . . . . . . . . . . . . . . 1-44

1-15 CHASSIS DRIVE INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1-16 DRIVE ENABLE VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY) . . . . . . . . . 1-54

1-17 DRIVE DIRECTIONAL VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY) . . . . 1-56

1-18 DRIVE MOTOR ASSEMBLY (USED WITH DRIVE OPTION ONLY). . . . . . . . . . . . . . . . 1-58

1-19 CONTROL MODULES AND VALVES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

1-20 CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES) . . . . . . . . . . . . . 1-64

1-21 CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES) . . . . . . . . . . . . . . . . . . 1-68

1-22 HONDA ENGINE INSTALLATION (GAS POWERED MACHINES) . . . . . . . . . . . . . . . . 1-72

1-23 BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES)

(PRIOR TO SN 0030001804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78

1-24 BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES)

(SN 0030001804 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80

1-25 MAC BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINES) . . . . . . 1-82

1-26 DELTA-Q & PRO CHARGING BATTERY CHARGER ASSEMBLIES (ELECTRIC

POWERED MACHINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84

1-27 TAILLIGHTS & MARKERS INSTALLATION (ANSI & ANSI EXPORT SPECS) . . . . . . . . 1-86

1-28 TAILLIGHTS & MARKERS INSTALLATION (AUSTRALIAN, CE & SOUTH

AFRICAN SPECS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88

1-29 SPARE TIRE & WHEEL CHOCKS INSTALLATIONS (OPTIONAL) . . . . . . . . . . . . . . . . 1-92

1-30 FENDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96

1-31 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100

1-32 OUTRIGGERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102

1-33 SIDE GUARDS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106

3121199 T350 & T500J i

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

2-1 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS. . . . . . . . . . . . . . . . . . . 2-2

2-2 TURNTABLE BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 SWING DRIVE MOTOR ASSEMBLY (WHITE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 SWING DRIVE MOTOR ASSEMBLY (PARKER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 GROUND CONTROL BOX ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . 2-12

2-6 TURNTABLE MOUNTED COMPONENTS (STROBE LIGHT, ALARM &

ACCESSORY TRAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7 2500W GENERATOR INSTALLATION (OPTIONAL) (PRIOR TO SN 0030004340) . . . . 2-18

2-8 3000W GENERATOR INSTALLATION (OPTIONAL) (SN 0030004340 TO PRESENT) . 2-22

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

3-1 BOOM ASSEMBLY AND INSTALLATION (T350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 MAIN BOOM ASSEMBLY (T350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-3 BOOM ASSEMBLY AND INSTALLATION (T500J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-4 MAIN BOOM ASSEMBLY (T500J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-5 MATERIAL HOOK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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

4-1 PLATFORM & ROTATOR INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM ROTATOR ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 CONSOLE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

5-1 BRAKE RELEASE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 DRIVE ENGAGE CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 JIB CYLINDER ASSEMBLY (T500J ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLY (T350) . . . . . . . . . . . . . . . . . . . . 5-8

5-5 PLATFORM LEVEL (SLAVE) CYLINDER ASSEMBLY (T500J) . . . . . . . . . . . . . . . . . . . 5-10

5-6 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 MASTER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-8 OUTRIGGER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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

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

6-1 HYDRAULIC DIAGRAM - BOOM & CHASSIS (T350 ALL SPECS) . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - BOOM & CHASSIS (T500J). . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 HYDRAULIC DIAGRAM - DRIVE AND SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

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

7-1 ELECTRICAL COMPONENTS INSTALLATION - ELECTRIC POWERED

MACHINES (PRIOR TO SN 00300001804). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL COMPONENTS INSTALLATION - ELECTRIC POWERED

MACHINES (SN 00300001804 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-3 ELECTRICAL COMPONENTS INSTALLATION - ENGINE POWERED MACHINES . . . 7-22

ii T350 & T500J 3121199

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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

8-1 DECAL INSTALLATION (ANSI SPEC PRIOR TO SN 0030000281) . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION (ANSI SPEC SN 0030000281 TO PRESENT). . . . . . . . . . . . . 8-6

8-3 DECAL INSTALLATION (COUNTRY SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-4 DECAL INSTALLATION (AUSTRALIAN & CE SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

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

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

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

3121199 T350 & T500J iii

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TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv T350 & T500J 3121199

Page 9

SECTION 1

FRAME

3121199 T350 & T500J 1-1

Page 10

SECTION 1 FRAME

FIGURE 1-1. TONGUE JACK INSTALLATIONS (WITH POLY JACK TIRES)

1-2 T350 & T500J 3121199

Page 11

SECTION 1 FRAME

FIGURE 1-1. TONGUE JACK INSTALLATIONS (WITH POLY JACK TIRES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref JACK INSTALLATION (WITH POLY JACK TIRES) 0274306 Ref T350 (All Specs) C 0274308 Ref T500J with Ball Hitch (All Specs Except CE Spec) B 0274486 Ref T500J with Ball Hitch (CE & South Africa Spec) B 0274453 Ref T500J with Combination Hitch (ANSI & ANSI Export Specs) C

1 4 Bolt Options:

0641632 3/8in-16NC x 4in 0641630 3/8in-16NC x 3-3/4in 0641638 3/8in-16NC x 4-3/4in

2 Use 2840026 1 Jack Assembly (No Service Parts Available Due to the Variety of

Jacks Used by either JLG or Supplier. Replace Complete

Assembly) (was p/n 2840020) 3 3311605 4 Locknut 3/8in-16NC 4 4751600 8 Flatwasher 3/8in Regular 5 AR Mounting Options:

5A 3575757 1 Plate 5B 7027727 2 Strap, Mounting

3121199 T350 & T500J 1-3

Page 12

SECTION 1 FRAME

27B7D57A

FIGURE 1-2. TONGUE JACK INSTALLATIONS (WITH PNEUMATIC JACK TIRES)

1-4 T350 & T500J 3121199

Page 13

SECTION 1 FRAME

FIGURE 1-2. TONGUE JACK INSTALLATIONS (WITH PNEUMATIC JACK TIRES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref JACK INSTALLATIONS (WITH PNEUMATIC JACK TIRES) 0274305 Ref T350 (ANSI &ANSI Export Specs) B 0274485 Ref T350 (Australian & CE Specs) B 0274307 Ref T500J with Ball Hitch (ANSI & ANSI Export Specs) B 0274452 Ref T500J with Combination Hitch (ANSI & ANSI Export Specs) B 0274486 Ref T500J (Australian & CE Specs) B

1 4 Bolt Options:

0641632 3/8in-16NC x 4in 0641630 3/8in-16NC x 3-3/4in 0641638 3/8in-16NC x 4-3/4in

2 0641826 1 Bolt 1/2in-13NC x 3-1/4in 3 2840026 1 Jack Assembly (No Service Parts Available Due to the Variety of

Jacks Supplied under the Same P/N. Replace Complete Assembly)

Ref Note: Replacement Jack is supplied with poly wheels.

Pneumatic wheels can not be used with replacement jack.

4 3311605 4 Locknut 3/8in-16NC 5 3311805 1 Locknut 1/2in-13NC 6 AR Plate, Mounting Options:

6A 3575757 1 T350

Not Required 0 T500J ANSI &ANSI Export Specs with Ball Hitch

3575757 1 T500J ANSI &ANSI Export Specs with Combination Hitch

Not Required 0 T500J Australian & CE Specs with Ball Hitch

6B 7027727 2 Strap, Mounting

7 4341002 1 Tire and Support Assembly 7A 4340992 1 Support 7B See Note 2 Tire, Pneumatic

(Note: Not Available - Purchase p/n 4341002)

7C See Note 1 Bolt, Axle 3/4in

(Note: Not Available - Purchase p/n 4341002)

7D See Note 1 Locknut 3/4in (Note: Not Available - Purchase p/n 4341002)

8 4711600 4 Bolt 5/8in-11NC x 2-1/2in

3121199 T350 & T500J 1-5

Page 14

16C

101

20114141414

313636

203530

16A

16B

19918

102327

1929281737

104

103

101

104

102

1024140

2in Ball

50mm Ball

BRAKE

LEVER

SECTION 1 FRAME

FIGURE 1-3. AXLE AND TONGUE INSTALLATION WITH ELECTRIC BRAKES

(ANSI, ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPECS)

1-6 T350 & T500J 3121199

Page 15

SECTION 1 FRAME

FIGURE 1-3. AXLE AND TONGUE INSTALLATION WITH ELECTRIC BRAKES (ANSI, ANSI

EXPORT, AUSTRALIAN & SOUTH AFRICAN SPECS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref ELECTRIC BRAKE AND TONGUE INSTALLATION 0273648 Ref T350 with 2in Ball (ANSI & ANSI Export Specs) H 0273654 Ref T500J with 2in Ball (ANSI & ANSI Export Specs) G 0274767 Ref T500J with 50mm Ball (ANSI Export & Australian Specs) C 0275626 Ref T500J with 50mm Ball (South Africa Specs) C

1 2 Chain, Safety with Hook Options:

70212 2in Ball (ANSI & ANSI Export Specs)

Not Required 50mm Ball (ANSI Export, Australian & South Africa Specs) 2 0641422 4 Bolt 1/4in-20NC x 2-3/4in 3 0641412 AR Bolt 1/4in-20NC x 1-1/2in 4Not Used 5 AR Bolt Options:

0641832 2 Bolt 1/2in-13NC x 4in (2in Ball - ANSI & ANSI Export Specs) 0711234 4 Bolt (Metric) 12mm x 170mm (50mm Ball - ANSI Export,

Australian & South Africa Specs)

6 2 Bolt Options:

0642240 Bolt 3/4in-10NC x 5in (2in Ball - ANSI & ANSI Export Specs) 0642246 Bolt 3/4in-10NC x 5-3/4in (50mm Ball - ANSI Export, Austra-

lian & South Africa Specs)

7 1 Coupler Assembly - Electric Brake Options (No Repair Parts

Available): 1660273 2in Ball (ANSI & ANSI Export Specs) 1660297 50mm Ball (ANSI Export, Australian & South Africa Specs)

8Not Used

9 3311405 6 Locknut 1/4in-20NC 10 3311505 2 Locknut 5/16in-18NC 11 2 Bolt Options:

0641430 Bolt 1/4in-20NC x 3-3/4in (2in Ball - ANSI & ANSI Export

Specs)

0641440 Bolt 1/4in-20NC x 5in (50mm Ball - ANSI Export, Australian &

South Africa Specs) 12 Not Used 13 3312205 2 Locknut 3/4in-10NC 14 1 Parking Brake Cable Assembly Options (See PARKING BRAKE

CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES ONLY) AND TRANSPORT LOCK ASSEMBLIES for

Breakdown): 3890043 T350 3890044 T500J

15 4191706 1 Screw, Rolling Thread 6mm x 12mm

16 4360570 1 Breakaway Switch Kit 16A 71820 1 Switch, Replacement Breakaway 16B 71820-1 1 Replacement Switch Pin & Cable 16C See Note 1 Charger, Replacement Battery (Note: Not Available -

Purchase Complete Kit p/n 4360570)

17 1 Tongue Options:

Use 4569512 T350 Prior to SN 0030002199 (was p/n 4568985)

4569512 T350 SN 0030002199 to Present

3121199 T350 & T500J 1-7

Page 16

SECTION 1 FRAME

FIGURE 1-3. AXLE AND TONGUE INSTALLATION WITH ELECTRIC BRAKES (ANSI, ANSI

EXPORT, AUSTRALIAN & SOUTH AFRICAN SPECS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

17 (cont’d) 4568986 T500J (2in Ball - ANSI & ANSI Export Specs)

4569445 T500J (50mm Ball - ANSI Export, Australian)

4569470 T500J (50mm Ball - South Africa Spec) 18 0641514 2 Bolt 5/16in-18NC x 1-3/4in 19 4751400 15 Flatwasher 1/4in Regular 20 AR Bolt Options:

0641836 2 Bolt 1/2in-13NC x 4-1/2in (2in Ball - ANSI & ANSI Export

Specs)

Not Required 0 50mm Ball - ANSI Export, Australian & South Africa Specs 21 4752200 4 Flatwasher 3/4in Regular 22 Not Used 23 8580420 AR Wellnut 24 AR Bolt Options:

0641838 2 Bolt 1/2in-13NC x 4-3/4in (T500J Only) (2in Ball - ANSI &

ANSI Export Specs)

Not Required 0 50mm Ball - ANSI Export, Australian & South Africa Specs 25 0903108 1 Bracket, Parking Brake 26 1320060 AR Clamp 27 1320061 1 Clamp 28 1560016 1 Conduit 29 1560017 2 Conduit 30 AR Nut Options:

3311805 3 Locknut 1/2in-13NC (2in Ball - ANSI & ANSI Export Specs) 3331211 4 Nut M12 x 1.75 (50mm Ball - ANSI Export, Australian & South

Africa Specs) 31 3450304 4 Pin, Cotter 32 4240032 AR Tiestrap 4in/10cm (Not Shown) 33 4240033 AR Tiestrap 7in/18cm (Not Shown) 34 4711400 1 Flatwasher 1/4in Thin 35 AR Flatwasher Options:

4711800 4 Flatwasher 1/2in Thin (2in Ball - ANSI & ANSI Export Specs)

Not Required 0 50mm Ball - ANSI Export, Australian & South Africa Specs 36 4751500 4 Flatwasher 5/16in Regular 37 AR Adapter, Tongue Options:

Not Required 0 T350

Use 0080291 1 T500J (All Specs except South Africa Spec)

(Prior to SN 0030002199 - was p/n 0080265)

0080291 1 T500J (All Specs except South Africa Spec)

(SN 0030002199 to Present)

Not Required 0 T500J (South Africa Spec) 38 1 Trailer Plug Harness Options (Not Shown - See ELECTRICAL

SECTION for Breakdown): 4923203 2in Ball - ANSI & ANSI Export Specs 4923318 50mm Ball - ANSI Export, Australian & South Africa Specs

39 3430506 2 Pin, Clevis 40 4711500 2 Flatwasher 5/16inThin 41 3450302 2 Pin, Cotter 42 4569438 4 Spacer (50mm Ball - ANSI Export, Australian & South Africa

Specs Only)

1-8 T350 & T500J 3121199

Page 17

SECTION 1 FRAME

FIGURE 1-3. AXLE AND TONGUE INSTALLATION WITH ELECTRIC BRAKES (ANSI, ANSI

EXPORT, AUSTRALIAN & SOUTH AFRICAN SPECS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

43 4891800 8 Flatwasher 1/2in Hardened (50mm Ball - ANSI Export,

Australian & South Africa Specs Only)

Ref ELECTRIC BRAKE AND AXLE INSTALLATION 0273699 Ref T350 B 0273700 Ref T500J B

101 1 Axle Assembly with Electric Brakes Options (See

ELECTRICAL BRAKE & AXLE ASSEMBLY for Breakdown): 0280158 T350 0280159 T500J

102 0642012 4 Bolt 5/8in-11NC x 1-1/2in 103 3312005 4 Locknut 5/8in-11NC 104 4892000 8 Flatwasher 5/8in Hardened

Ref TIRE AND WHEEL INSTALLATION

Ref T350 0273610 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275210 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present C 0275210 Ref Australian & South Africa Specs C

Ref T500J 0273611 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275211 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present B 0275211 Ref Australian & South Africa Specs B

201 AR Tire and Wheel Assembly

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only) (was p/n 4520323 & 4520613)

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs -

SN 0030002529 to SN 0030003105 & Australian & South Africa Specs - Prior to SN 0030003105) (Serviced as an Assembly Only) (was p/n 4520613)

1001109586 2 T350 (215-75-R14) (ANSI & ANSI Export Specs -

SN 0030003105 to Present & Australian & South Africa

Specs - SN 0030003105 to Present) 70002204 2 Tire, Replacement (215-75-R14) 70002205 2 Wheel, Replacement (14 x 6)

Use 4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only)

(was p/n 4520322)

4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs -

SN 0030002529 to Present & Australian & South Africa

Specs - All) (Serviced as an Assembly Only)

3121199 T350 & T500J 1-9

Page 18

SECTION 1 FRAME

101

146A33

6A6A282115

281791813

231793225

263429

201

101

42A

42B

103

39 40

BRAKE

LEVER

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES)

1-10 T350 & T500J 3121199

Page 19

SECTION 1 FRAME

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HYDRAULIC BRAKE AND TONGUE INSTALLATIONS 0273647 Ref T350 Prior to SN 0030002099 with 2in Ball I 0273649 Ref T350 Prior to SN 0030002099 with Combination 2in Ball E 0275907 Ref T350 SN 0030002099 to Present D 0273653 Ref T500J Prior to SN 0030002099 with 2in Ball H 0273655 Ref T500J Prior to SN 0030002099 with Combination 2in Ball F 0275908 Ref T500J SN 0030002099 to Present C

1 70212 2 Chain, Safety with Hook 2 0641406 AR Bolt 1/4in-20NC x 3/4in 3 0641412 AR Bolt 1/4in-20NC x 1-1/2in 4Not Used 5 2 Bolt Options:

0642240 Prior to SN 0030002099 with 2 inch Ball 0642244 Prior to SN 0030002099 with Combination 2 inch Ball 0642244 SN 0030002099 to Present

6 1 Coupler Assembly - Hydraulic Brake Options:

6A 1660265 Prior to SN 0030002099 with 2in Ball (See HYDRAULIC

BRAKE COUPLER WITH 2 INCH BALL ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES) for Breakdown)

6B 1660279 Prior to SN 0030002099 with 2in Ball Combination (See

HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES) for Breakdown)

6C 1660278 Prior to SN 0030002099 with 2in Ball Combination

See Note 1 Latch Repair Kit - 1660278 Coupler (Note: Not Available -

Purchase p/n 1660278)

6D With 2in Ball Combination (See HYDRAULIC BRAKE

COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES for Breakdown)

Use 1001116350 SN 0030002099 to SN 0030003343 (was p/n 1660307)

1001116350 SN 0030003343 to Present 7Not Used 8 2902349 1 Brake Line Kit (Includes qty 2 of these items: 12in Steel Lines

with Fittings, 18in Hoses, Mounting Angles and Clamps. Also, Includes qty 1 Tee Fitting with Mounting Bracket)

8A 7027890 2 Replacement Hose Only

9 3311405 AR Locknut 1/4in-20NC

10 3311505 2 Locknut 5/16in-18NC 11 AR Bolt Options:

0641430 1/4in-20NC x 3-3/4in

0641440 1/4in-20NC x 5in 12 3312205 2 Locknut 3/4in-10NC 13 1 Parking Brake Cable Assembly Options (See PARKING BRAKE

CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES ONLY) AND TRANSPORT LOCK ASSEMBLIES for

Breakdown): 3890041 T350 3890042 T500J

3121199 T350 & T500J 1-11

Page 20

SECTION 1 FRAME

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

14 1 Tongue Options:

4569512 T350 (was p/n 4568985) 4568986 T500J

15 1 Brake Line Options:

4569096 T350

4569097 T500J 16 Not Used 17 4751400 AR Flatwasher 1/4in Regular 18 0641514 2 Bolt 5/16in-18NC x 1-3/4in 19 4752200 4 Flatwasher 3/4in Regular 20 8580420 AR Wellnut 21 1 Bolt Options:

0641836 Prior to SN 0030002099 with 2 inch Ball

0641838 Prior to SN 0030002099 with Combination 2 inch Ball

0641838 SN 0030002099 to Present 22 0641838 2 Bolt 1/2in-13NC x 4-3/4in (T500J Only) 23 0903108 1 Bracket, Parking Brake 24 1320060 AR Clamp 25 1320061 1 Clamp (T500J Only - Not Shown) 26 1560016 1 Conduit 27 1560017 AR Conduit 28 3311805 AR Locknut 1/2in-13NC 29 3450304 4 Pin, Cotter 30 3820017 2 Rivet 31 4240032 AR Tiestrap 4in/10cm (Not Shown)

4240033 AR Tiestrap 7in/18cm (Not Shown) 32 4711400 AR Flatwasher 1/4in Thin 33 4711800 AR Flatwasher 1/2in Thin 34 4751500 2 Flatwasher 5/16in Regular 35 AR Adapter, Tongue Options:

Not Required 0 T350

0080291 1 T500J (was p/n 0080265) 36 Not Used 37 2300006 AR Fluid, Brake - DOT3 (Not Shown) 38 AR Bolt Options:

Not Required 0 Prior to SN 0030002099 with 2 inch Ball (Supplied with

Coupler Item 6A) 0641832 3 Bolt 1/2in-13NC x 4in 0641836 3 Bolt 1/2in-13NC x 4-1/2in

39 AR Bolt 5/8in-11NC x 4-1/4in

Not Required 0 Prior to SN 0030002099 with 2 inch Ball

0642034 2 Prior to SN 0030002099 with Combination 2 inch Ball

Not Required 0 SN 0030002099 to Present (Supplied with Coupler Item 6D)

40 AR Locknut 5/8in-11NC

Not Required 0 Prior to SN 0030002099 with 2 inch Ball

3312005 2 Prior to SN 0030002099 with Combination 2 inch Ball

Not Required 0 SN 0030002099 to Present (Supplied with Coupler Item 6D)

41 0721005 1 Screw, Machine #10-24NC x 5/8in (With 2 inch Ball Only)

4751000 2 Flatwasher #10 Regular (With 2 inch Ball Only)

1-12 T350 & T500J 3121199

Page 21

SECTION 1 FRAME

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3311005 1 Locknut #10-24NC (With 2 inch Ball Only)

42 1 Lanyard Options (Not Used SN 0030002099 to

SN 0030002199): 42A 1060380 10in/25.4cm Length 42B 1060799 11-1/2in/29cm Length

43 3420592 1 Hairpin (Not Used SN 0030002099 to SN 0030002199) 44 3760170 1 Ring, Split (Prior to SN 0030002099 Only with Combination 2

inch Ball)

Ref HYDRAULIC BRAKE AND AXLE INSTALLATION

0273608 Ref T350 All Machines Except SNs 0030000121-0030000140,

0030000142,0030000143 & 0030000153

9984242 Ref T350 SNs 0030000121-0030000140, 0030000142,0030000143 &

0030000153 Only

0273609 Ref T500J B

101 1 Axle Assembly with Hydraulic Brakes Options (See HYDRAULIC

BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES

for Breakdown):

0280154 T350 Except SNs 0030000121-0030000140, 0030000142,

0030000143 & 0030000153

Use 0280154 T350 SNs 0030000121-0030000140, 0030000142,

0030000143 & 0030000153 Only (was p/n 9984240)

0280155 T500J 102 0642012 4 Bolt 5/8in-11NC x 1-1/2in 103 3312005 4 Locknut 5/8in-11NC 104 4892000 8 Flatwasher 5/8in Hardened 105 9984241 8 Spacer (Not Shown) (T350 SNs 0030000121-0030000140,

0030000142,0030000143 & 0030000153 Only)

Ref TIRE AND WHEEL INSTALLATION

Ref T350 0273610 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275210 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present C 0275210 Ref Australian Specs C

Ref T500J 0273611 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275211 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present B 0275211 Ref Australian Specs B

201 AR Tire and Wheel Assembly

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only) (was p/n 4520323 & 4520613)

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs -

SN 0030002529 to SN 0030003105 & Australian Specs Prior to SN 0030003105) (Serviced as an Assembly Only) (was p/n 4520613)

1001109586 2 T350 (215-75-R14) (ANSI & ANSI Export Specs -

SN 0030003105 to Present & Australian Specs SN 0030003105 to Present)

3121199 T350 & T500J 1-13

Page 22

SECTION 1 FRAME

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

70002204 2 Tire, Replacement (215-75-R14) 70002205 2 Wheel, Replacement (14 x 6)

Use 4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only) (was p/n

4520322)

4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs -

SN 0030002529 to Present & Australian Specs - All) (Serviced as an Assembly Only)

1-14 T350 & T500J 3121199

Page 23

SECTION 1 FRAME

FIGURE 1-4. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 2IN

BALL (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-15

Page 24

SECTION 1 FRAME

103

201

101

21A

BRAKE

LEVER

3128433731424223211232

23631

104740

3715474011345941

1918162645

174526

432722

1330382914

FIGURE 1-5. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 50MM

BALL (ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPEC MACHINES)

1-16 T350 & T500J 3121199

Page 25

SECTION 1 FRAME

FIGURE 1-5. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 50MM

BALL (ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HYDRAULIC BRAKE AND TONGUE INSTALLATIONS 0274766 Ref T350 with 50mm Ball (ANSI Export & Australian Specs) E 0275629 Ref T350 with 50mm Ball (South Africa Specs) E 0274772 Ref T500J with 50mm Ball (ANSI Export Specs)

(Note: Information Not Available at Time of Printing)

1 AR Adapter, Tongue Options:

0080282 1 T350 (ANSI Export & Australian Spec) 0080286 1 T350 (South Africa Spec)

See Note 0 T500J (Note: Not Available for Purchase) 2 0641406 5 Bolt 1/4in-20NC x 3/4in 3 0641412 2 Bolt 1/4in-20NC x 1-1/2in 4 0641416 1 Bolt 1/4in-20NC x 2in 5 0641430 2 Bolt 1/4in-20NC x 3-3/4in 6 0641514 2 Bolt 5/16in-18NC x 1-3/4in 7 0642240 2 Bolt 3/4in-10NC x 5in 8 0711227 4 Bolt (Metric) 12 x 100mm 9 0711229 2 Bolt (Metric) 12 x 120mm

10 0903108 1 Bracket, Parking Brake 11 1320060 2 Clamp 12 1320061 1 Clamp 13 1321676 2 Clamp 14 1560016 1 Conduit 15 1560017 1 Conduit 16 1660298 1 Coupler, 50mm Ball (Note: No Service Parts Breakdown at

Time of Printing)

17 1684524 1 Cylinder, Master Brake Assembly (Note: No Service Parts

Breakdown at Time of Printing)

18 2221272 1 Fitting 19 2221273 1 Fitting 20 2300006 AR Fluid, Brake - DOT3 (Not Shown) 21 2902349 1 Brake Line Kit (Includes qty 2 of these items: 12in Steel Lines

with Fittings, 18in Hoses, Mounting Angles and Clamps. Also, Includes qty 1 Tee Fitting with Mounting Bracket)

21A 7027890 2 Replacement Hose Only

22 2980130 1 Lever, Pivot 23 3311405 7 Locknut 1/4in-20NC 24 3311505 2 Locknut 5/16in-18NC 25 3312205 2 Locknut 3/4in-10NC 26 3331211 6 Nut M12 x 1.75 27 3371910 1 Pin, Roll 28 3450304 4 Pin, Cotter 29 3460557 1 Pipe, Brake Line Assembly 30 3820017 4 Rivet, Pop 31 1 Parking Brake Cable Assembly Options (See PARKING BRAKE

CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC MACHINES ONLY) AND TRANSPORT LOCK ASSEMBLIES for Breakdown):

3890041 T350

3121199 T350 & T500J 1-17

Page 26

SECTION 1 FRAME

FIGURE 1-5. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 50MM

BALL (ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

31 (cont’d) 3890042 T500J

32 4071122 1 Shim, Spacer 33 4240032 AR Tiestrap 4in/10cm (Not Shown) 34 4240033 AR Tiestrap 7in/18cm (Not Shown) 35 4460121 6 Terminal, Wire Cap (Not Shown) 36 4569096 1 Tube, Hydraulic Brake 37 1 Tongue Options:

4569447 T350

See Note T500J (Note: Not Available for Purchase) 38 4569450 2 Tube, Spacer 39 4641496 1 Valve, 10lb. Residual Pressure 40 4711400 3 Flatwasher 1/4in Thin 41 4740571 2 Flatwasher, Copper 42 4751400 16 Flatwasher 1/4in Regular 43 4751500 4 Flatwasher 5/16in Regular 44 4752200 4 Flatwasher 3/4in Regular 45 4812100 10 Flatwasher 12mm 46 1 Trailer Plug Harness Options (Not Shown - See ELECTRICAL

SECTION for Breakdown): 4923268 Prior to SN 0030002169 4923317 SN 0030002169 to Present

47 8580420 3 Wellnut

Ref HYDRAULIC BRAKE AND AXLE INSTALLATION 0273608 Ref T350 B 0273609 Ref T500J B

101 1 Axle Assembly with Hydraulic Brakes Options (See HYDRAULIC

BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES

for Breakdown): 0280154 T350 0280155 T500J

102 0642012 4 Bolt 5/8in-11NC x 1-1/2in 103 3312005 4 Locknut 5/8in-11NC 104 4892000 8 Flatwasher 5/8in Hardened

1-18 T350 & T500J 3121199

Page 27

SECTION 1 FRAME

FIGURE 1-5. AXLE AND TONGUE INSTALLATION WITH HYDRAULIC BRAKES - WITH 50MM

BALL (ANSI EXPORT, AUSTRALIAN & SOUTH AFRICAN SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TIRE AND WHEEL INSTALLATION

Ref T350 0273610 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275210 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present C 0275210 Ref Australian & South Africa Specs C

Ref T500J 0273611 Ref ANSI & ANSI Export Specs - Prior to SN 0030002529 B 0275211 Ref ANSI & ANSI Export Specs - SN 0030002529 to Present B 0275211 Ref Australian & South Africa Specs B

201 AR Tire and Wheel Assembly

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only) (was p/n 4520323 & 4520613)

Use 1001109586 2 T350 (205-75-R14) (ANSI & ANSI Export Specs -

SN 0030002529 to SN 0030003105 & Australian & South Africa Specs - Prior to SN 0030003105) (Serviced as an Assembly Only) (was p/n 4520613)

1001109586 2 T350 (215-75-R14) (ANSI & ANSI Export Specs -

SN 0030003105 to Present & Australian & South Africa

Specs - SN 0030003105 to Present) 70002204 2 Tire, Replacement (215-75-R14) 70002205 2 Wheel, Replacement (14 x 6)

Use 4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs - Prior to

SN 0030002529) (Serviced as an Assembly Only) (was p/n

4520322)

4520614 2 T500J (225-75-R15) (ANSI & ANSI Export Specs -

SN 0030002529 to Present & Australian & South Africa

Specs - All) (Serviced as an Assembly Only)

3121199 T350 & T500J 1-19

Page 28

101

262124261310210

201

T-500J

T500JMIDDLESUPPOR

T-350

350

T50

0JF

SUPPORT

USE EXISTING

BOLT

05201104101

334

SECTION 1 FRAME

FIGURE 1-6. AXLE AND TONGUE INSTALLATION WITH MECHANICAL BRAKES

(CE SPEC MACHINES)

1-20 T350 & T500J 3121199

Page 29

SECTION 1 FRAME

FIGURE 1-6. AXLE AND TONGUE INSTALLATION WITH MECHANICAL BRAKES (CE SPEC

MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HYDRAULIC BRAKE AND TONGUE INSTALLATIONS 0273651 Ref T350 with 50mm Ball (Machines without Drive Option) D 0275379 Ref T350 with 50mm Ball (Machines with Drive Option) C 0273657 Ref T500J with 50mm Ball (Machines without Drive Option) D 0273658 Ref T500J with 50mm Ball (Machines with Drive Option) B

1 AR Adapter, Hitch

0080266 1 T350

Not Required T500J 2 0641412 AR Bolt 1/4in-20NC x 1-1/2in 3 0641608 AR Bolt 3/8in-16NC x 1in 4 2 Bolt Options:

0711225 T350 (Bolt 12mm x 85mm)

0711631 T500J (Bolt 16mm x 140mm) 5 0711227 2 Bolt 12mm x 100mm (T350 Only) 6 2 Bolt Options:

0642240 T350 (Bolt 3/4in-10NC x 5in)

0642244 T500J (Bolt 3/4in-10NC x 5-1/2in) 7 0903215 1 Bracket, Brake Rod Support (Without Drive Option Only) 8 1320061 AR Clamp 9 1560016 AR Conduit Options:

2 T350 4 T500J

10 1 Coupler Assembly - Hydraulic Brake Options (See HYDRAULIC

BRAKE COUPLER WITH 50MM BALL ASSEMBLY (CE SPEC

MACHINES) for Breakdown): 1660282 T350 1660283 T500J

11 4 Nut Options:

3290801 T350 (Nut M8) 3291001 T500J (Nut M10)

12 3291001 3 Nut M10 13 3311405 AR Locknut 1/4in-20NC 14 3311605 2 Locknut 3/8in-16NC 15 AR Nut M12

3331205 4 T350 (Nut M12) 3291605 2 T500J (Nut M16)

16 3312205 2 Locknut 3/4in-10NC 17 3575853 1 Plate, Equalizer (Parking Brake) (Without Drive Option Only) 18 3575869 1 Plate, Support (Parking Brake) 19 1 Rod Options (Without Drive Option Only):

3841696 T350 3841697 T500J

20 4240032 AR Tie-Strap 4in/10cm (Not Shown) 21 4341040 1 Support, Brake Rod 22 1 Tube, Tongue Options:

4569182 T350 4569220 T500J

3121199 T350 & T500J 1-21

Page 30

SECTION 1 FRAME

FIGURE 1-6. AXLE AND TONGUE INSTALLATION WITH MECHANICAL BRAKES (CE SPEC

MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

23 4711400 AR Flatwasher 1/4in Thin 24 AR Flatwasher Options:

4711600 8 T350 (3/8in Thin) 4751600 4 T500J (3/8in Regular)

25 AR Flatwasher Options:

4812100 8 T350 (Flatwasher M12)

4812300 4 T500J (Flatwasher M16) 26 4751400 AR Flatwasher 1/4in Regular 27 4751600 2 Flatwasher 3/8in Regular 28 4752200 4 Flatwasher 3/4in Regular 29 4 Flatwasher Options:

4811900 T350 (M8)

4812000 T500J (M10) 30 4812000 3 Flatwasher M10 31 1 Harness Options (Not Shown - See ELECTRICAL SECTION for

Breakdown):

T350 Options:

4923268 Prior to SN 0030005642

1001155254 SN 0030005642 to Present

4923269 T500J 32 8580420 AR Wellnut 33 AR Stop, Hitch Options:

4220259 T350

4220260 T500J 34 2 Nut Options

3311605 T350 (Locknut 3/8in-16NC)

3311608 T500J (Serrated Flange Nut 3/8in-16NC) 35 0100011 AR Compound, Locking

36 to 39 Not Used

40 0641538 1 Bolt 5/16in-18NC x 4-3/4in (T500J Only) 41 Not Used 42 3311505 1 Locknut 5/16in-18NC (T500J Only) 43 4751500 2 Flatwasher 5/16in Regular (T500J Only) 44 0903216 1 Bracket, Support (T500J Only)

Ref BRAKE AND AXLE INSTALLATION 0273652 Ref T350 D 0273656 Ref T500J C

101 1 Axle Assembly with Brakes Options (See MECHANICAL

BRAKE ASSEMBLY (CE SPEC MACHINES) for Breakdown): 0280186 T350 0280187 T500J

102 0642012 4 Bolt 5/8in-11NC x 1-1/2in 103 Not Used 104 3312005 4 Locknut 5/8in-11NC 105 4892000 8 Flatwasher 5/8in Hardened

1-22 T350 & T500J 3121199

Page 31

SECTION 1 FRAME

FIGURE 1-6. AXLE AND TONGUE INSTALLATION WITH MECHANICAL BRAKES (CE SPEC

MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274351 Ref T350 D 0274352 Ref T500J (225-75-R16 Radial) C

201 2 Tire & Wheel Assembly Options (Serviced as an Assembly

Only): 4520377 2 185R14C Tire & Wheel (T350) 4520378 2 225R16C Tire & Wheel (T500J)

2 Decal - Tire Pressure Options (Not Shown Located on Frame

Below VIN Plate): 1706705 Decal - 4.5 Bar (T350) 1706706 Decal - 5.7 Bar (T500J)

3121199 T350 & T500J 1-23

Page 32

SECTION 1 FRAME

282

5152535455565

FIGURE 1-7. HYDRAULIC BRAKE COUPLER WITH 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099)

1-24 T350 & T500J 3121199

Page 33

SECTION 1 FRAME

FIGURE 1-7. HYDRAULIC BRAKE COUPLER WITH 2 INCH BALL ASSEMBLY (ANSI & ANSI

EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1660265 Ref HYDRAULIC BRAKE COUPLER WITH 2 INCH BALL ASSEMBLY B

1 to 2 Not Used

3 See Note 1 Push-Rod (Note: Use Item 55 or 56) 4 Use 7027680 1 Shock Absorber 5 Use 7027683 1 Handle, Release 6 Use 7027687 1 Master Cylinder 7 See Note 1 Gasket (Note: Use Item 55 or 56) 8 7027686 1 Boot

9 See Note 1 Stop (Note: Use Item 54, 55 or 56) 10 Not Used 11 See Note 1 Locknut (Note: Use Item 54, 55 or 56) 12 Not Used 13 Use 7027683 1 Spring 14 See Note 5 Bolt (Note: Use Item 54, 55 or 56) 15 7027681 1 Cap 16 See Note 1 Lanyard (Note: Use Item 55 or 56) 17 See Note 1 S-Hook (Note: Use Item 55 or 56) 18 Use 7027683 1 Bolt 19 Not Used 20 Use 7027682 1 Bolt 21 Use 7027682 1 Flatwasher 22 Use 7027683 1 Link 23 See Note 1 Flatwasher (Note: Not Available for Purchase) 24 See Note 3 Locknut (Note: Use Item 51, 52, 53, 54, 55 or 56) 25 Use 7027682 1 Block 26 Use 7027682 1 Bushing 27 Use 7027682 1 Flatwasher 28 Use 7027680 2 Flatwasher 29 Use 7027680 2 Flatwasher 30 Use 7027683 1 Bracket 31 70000233 1 Fitting, Elbow

32 to 33 Not Used

34 See Note 1 Piston (Note: Use Item 55 or 56) 35 See Note 1 Housing (Note: Purchase Complete Assembly p/n 1660265) 36 See Note 1 Hitch (Note: Purchase Complete Assembly p/n 1660265)

37 to 50 Not Used

— — — — — — — — — —

51 7027680 1 Kit 1 - Shock Absorber Kit (Includes Qty 1 of Item 4 & Qty 2 of

Items 24, 28 & 29)

52 7027682 1 Kit 2 - Hardware Kit (Includes Qty 1 of Items 20, 21, 25, 26, 27 &

Qty 2 of Item 24)

53 7027683 1 Kit 3 - Release Handle Kit (Includes Qty 1 of Items 5, 13, 18, 22,

30 & Qty 3 of Item 24) 54 7027684 1 Kit 4 - Stop and Spring Kit (Includes Qty 1 of Items 9, 11, 14 & 24) 55 7027685 1 Kit 5 - Push Rod Kit (Includes Qty 1 of 3, 7, 8, 9, 11, 16, 17, 34 &

Qty 2 of Item 24 & Qty 5 of Item 14) 56 7027687 1 Kit 6 - Master Cylinder & Push Rod Kit (Includes Qty 1 of Items 3,

6-9, 11, 16, 17, 34 & Qty 2 of Item 24 & Qty 5 of Item 14) 57 7027689 1 Kit 7 - Solenoid Kit (Includes Solenoid, Cylinder & Gasket)

3121199 T350 & T500J 1-25

Page 34

SECTION 1 FRAME

171415

21202299

101

102

103

FIGURE 1-8. HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099)

1-26 T350 & T500J 3121199

Page 35

SECTION 1 FRAME

FIGURE 1-8. HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (PRIOR TO SN 0030002099)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1660279 Ref HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH

BALL ASSEMBLY

1 to 3 Not Used

4 7026352 1 Pin 5Not Used 6 7026353 1 Shock, Damper 7 7026354 1 Case, Outer 8 4761500 2 Lockwasher 5/16in

9 See Note 2 Pin, Cotter (Note: Not Available - Purchase Locally) 10 19613 1 Cable with Hooks 11 See Note 2 Hook (Note: Not Available Purchase p/n 19613) 12 Use 7026361 1 Plate, Emergency Lever Spring 13 0641505 2 Bolt 5/16in-18NC x 5/8in 14 0641416 4 Bolt 1/4in-20NCx 2in 15 4761400 4 Lockwasher 1/4in 16 Use 7026361 1 Lever, Emergency 17 19616 1 Cap, Master Cylinder (Includes Diaphragm & O-Ring) 18 See Note 1 Push Rod & Piston Assembly (Master Cylinder) (Note: Not

Available - Purchase Repair Kit p/n 7026362)

19 3311401 4 Nut 1/4in-20NC 20 7026370 1 Gasket (Master Cylinder) 21 Use 19615 1 Reservoir (Master Cylinder) 22 7026355 1 Fitting with Orifice 23 7026356 1 Guide, Emergency Lever 24 7026374 1 Boot 25 7026357 1 Pin 26 7026358 1 Slider, Upper 27 7026359 1 Slider, Lower 28 7026360 2 Spacer, Side

29 to 54 Not Used

55 7027718 1 Slider, Channel Centered 56 7026373 1 Decal - Towable/Not Towable

57 to 100 Not Used

— — — — — — — — — —

101 7026361 1 Kit 1 - Emergency Lever Replacement Kit (Includes Items 11,12 &

16)

102 7026362 1 Kit 2 - Master Cylinder Repair Kit (Includes Items 20, 24 and Parts

to Rebuilt #18)

103 19615 1 Kit 3 - Master Cylinder Replacement Kit (Includes Items 14, 15,

19, 20 and 21)

3121199 T350 & T500J 1-27

Page 36

SECTION 1 FRAME

123

107

104

109

105

103

101

119119

117

124

127

111

110

106

116

118

102

114

108

113

125

121

SN 0030002099 TO

SN 0030003343

TO PRESENT

112

120

115

129

128

126

122

201

FIGURE 1-9. HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (SN 0030002099 TO PRESENT)

1-28 T350 & T500J 3121199

Page 37

SECTION 1 FRAME

FIGURE 1-9. HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH BALL ASSEMBLY

(ANSI & ANSI EXPORT SPEC MACHINES) (SN 0030002099 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HYDRAULIC BRAKE COUPLER WITH COMBINATION 2 INCH

BALL ASSEMBLIES

1 1660307 Ref SN 0030002099 TO SN 0030003343: C

70001047 1 Rebuild Kit, Breakaway (Includes Roller, Push Rod & Top Slide) 70001048 1 Cap, Master Cylinder

1001116350 Ref SN 0030003343 TO PRESENT B

101 4761400 4 Lockwasher 1/4in 102 3311401 4 Nut 1/4in-20NC 103 0641416 4 Bolt 1/4in-20NCx 2in 104 7026372 1 Guide, Emergency Lever 105 19616 1 Cap, Master Cylinder (Includes Diaphragm & O-Ring) 106 19613 1 Cable with Hooks 107 70002632 2 Lockwasher 5/16in 108 7026355 1 Fitting with Orifice 109 70002633 1 Plate, Emergency Lever Spring 110 70002634 1 Lever, Emergency 111 0641505 2 Bolt 5/16in-18NC x 5/8in 112 70002635 1 Push Rod (Master Cylinder) 113 7026367 1 Pin 114 7026370 1 Gasket (Master Cylinder) 115 19611 1 Reservoir (Master Cylinder) 116 7026358 1 Slider, Upper 117 7026359 1 Slider, Lower 118 7026360 2 Spacer, Side 119 70002636 1 Slider, Channel Centered 120 70002637 1 Ring Lock, Cotter 121 70002638 1 Ring Lock, Cotter 122 70002639 1 Cover (Master Cylinder) 123 70002631 1 Case, Outer 124 70002640 1 Lever, Lock Out 125 70002641 1 Pin 126 7026353 1 Shock, Damper 127 70002628 4 Locknut 5/8in-11NC 128 70002629 4 Bolt 5/8in-11NC x 1-1/2in 129 70002630 1 2in Coupler

— — — — — — — — — —

201 70002722 1 Actuator Replacement Kit (Includes Items 116,117 & 118)

3121199 T350 & T500J 1-29

Page 38

SECTION 1 FRAME

FIGURE 1-10. HYDRAULIC BRAKE COUPLER WITH 50MM BALL ASSEMBLY (CE SPEC

MACHINES)

1-30 T350 & T500J 3121199

Page 39

SECTION 1 FRAME

FIGURE 1-10. HYDRAULIC BRAKE COUPLER WITH 50MM BALL ASSEMBLY (CE SPEC

MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref COUPLER ASSEMBLY - HYDRAULIC BRAKE 1660282 Ref T350 D 1660283 Ref T500J B

1 1 Spring, Gas Options:

70000029 T350

70000037 T500J 2 70000030 1 Boot 3 70000031 1 Cable, Breakaway 4 70000032 1 Brake Lever Assembly 5 1 Brake Cylinder Assembly Options:

70000033 T350

70000038 T500J 6 1 Tube, Draw Option (Includes Item 7):

70000034 T350

70000039 T500J 7 70000035 1 Stop-Ring 8 1 Coupling Head Options:

70000036 T350

70000040 T500J

3121199 T350 & T500J 1-31

Page 40

SECTION 1 FRAME

3A3C3C1106

101

104

108

107

105

102

103

NOTE: REFER TO HYDRAULIC BRAKE ASSEMBLY FOR CABLE THAT ENTERS BRAKE DRUM.

FIGURE 1-11. PARKING BRAKE CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC

MACHINES ONLY) AND TRANSPORT LOCK ASSEMBLIES

1-32 T350 & T500J 3121199

Page 41

SECTION 1 FRAME

FIGURE 1-11. PARKING BRAKE CABLE (ANSI, ANSI EXPORT & AUSTRALIAN SPEC

MACHINES ONLY) AND TRANSPORT LOCK ASSEMBLIES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref PARKING BRAKE CABLE ASSEMBLIES (ANSI & ANSI EXPORT

SPEC MACHINES ONLY)

Ref Note: For CE Spec Components, See Axle & Tongue

Installation or Hydraulic Brake Assembly.

3890043 Ref T350 with Electric Brakes B 3890041 Ref T350 with Hydraulic Brakes B 3890044 Ref T500J with Electric Brakes C 3890042 Ref T500J with Hydraulic Brakes C

1 2980123 1 Handle Assembly (No Serviceable Parts Available) 2 1 Brake Cable Assembly - Tongue Options:

3890045 T350 3890046 T500J

3 1 Brake Cable Assembly - Splitter to Wheels Options:

3890049 T350 with Electric Brakes B 3890047 T350 with Hydraulic Brakes B 3890050 T500J with Electric Brakes B 3890048 T500J with Hydraulic Brakes B

3A See Note 1 Splitter/ Equalizer (Note: Purchase Complete Brake

Cable Assembly)

3B See Note 2 Cable, Brake (Note: Purchase Complete Brake Cable

Assembly)

3C See Note 2 Pin (Note: Purchase Complete Brake Cable Assembly

or Source Locally)

Ref Note: See Axle & Tongue Installation for Additional

Hardware.

Ref TRANSPORT LOCK ASSEMBLY 0273627 Ref T350 E 0274395 Ref T500J B

101 4 Bolt Options:

0641640 Bolt 3/8in-16NC x 5in (T350) 0641646 Bolt 3/8in-16NC x 5-3/4in (T500J)

102 0681506 6 Bolt 5/16in-18NC x 3/4in 103 2940159 1 Latch, Manual Clamp 104 3311605 4 Locknut 3/8in-16NC 105 3271505 6 Locknut 5/16in-18NC 106 3575420 1 Plate, Transport Lock 107 1 Plate, Mounting Options:

3575719 T350 3575783 T500J

108 4751600 8 Flatwasher 3/8in Regular

3121199 T350 & T500J 1-33

Page 42

207

208

101

102

103

124

110

104

113

105

109

128

129

107

108

206

210

211

213

221

202

204

212

209

206

229

222

206

224

228

226

227

SECTION 1 FRAME

FIGURE 1-12. ELECTRIC BRAKE & AXLE ASSEMBLY

1-34 T350 & T500J 3121199

Page 43

SECTION 1 FRAME

FIGURE 1-12. ELECTRIC BRAKE & AXLE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref AXLE ASSEMBLY 0280158 Ref T350 C 0280159 Ref T500J B

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

1 See Note 1 Axle (Not Shown) (Note: Not Available - Purchase Complete

Axle Assembly)

22Drum Assembly (Includes Item 101-129)

70001003 T350

See Note T500J (Note: Not Available - Purchase individual parts)

3 Electric Brake Assembly (Includes Item 201-229)

7027665 1 T350 Left Side 7027666 1 T350 Right Side 7027675 1 T500J Left Side 7027676 1 T500J Right Side

Ref DRUM ASSEMBLY

101 2 Seal Options (1 Per Assembly):

7027647 1 T350 7027654 1 T500J

102 2 Cone, Inner Options (1 Per Assembly):

7027648 1 T350 7026384 1 T500J

103 2 Cup, Inner Options (1 Per Assembly):

7027649 1 T350 7026385 1 T500J

104 2 Cup, Outer Options (1 Per Assembly):

7027650 1 T350 7027655 1 T500J

105 2 Cone, Outer Options (1 Per Assembly):

7027651 1 T350 7027656 1 T500J

106 Not Used 107 80317 2 Pin, Cotter (1 Per Assembly) 108 2 Cap Options (1Per Assembly):

7027652 1 T350 7027511 1 T500J

109 See Note 2 Washer, Spindle (1 Per Assembly) (Note: Not Available for

Purchase)

110 AR Stud, Wheel Options:

Ref Note: Please verify the length of your original stud before

ordering.

7026390 AR 2in Stud

70003756 AR 2-58in Stud

10 T350 (5 Per Assembly) 12 T500J (6 Per Assembly)

111 to 112 Not Used

3121199 T350 & T500J 1-35

Page 44

SECTION 1 FRAME

FIGURE 1-12. ELECTRIC BRAKE & AXLE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

113 7026313 AR Lugnut

10 T350 (5 Per Assembly) 12 T500J (6 Per Assembly)

Ref Note: See SPECIAL OPTIONS SECTION for Security Wheel

Locks.

114 to 123 Not Used

124 2 Hub and Drum Options (1 Per Assembly):

7027653 1 T350 7027657 1 T500J

125 to 127 Not Used

128 7027692 2 Nut, Spindle (1 Per Assembly) 129 7027693 2 Retainer, Nut Spindle (1 Per Assembly)

Ref ELECTRIC BRAKE ASSEMBLIES 7027665 1 T350 Left Side 7027666 1 T350 Right Side 7027675 1 T500J Left Side 7027676 1 T500J Right Side

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

201 Not Used 202 1 Lever, Actuating Options:

7027667 T350 Left Side 7027668 T350 Right Side 7026391 T500J Left Side 7026392 T500J Right Side

203 Not Used 204 7026393 2 Clip, Wire 205 Not Used 206 1 Brake Shoe Assembly Options (Includes 1 Primary & 1 Second-

ary Brake Shoe with Lining, 2 Pins, 2 Springs and 2 Cups):

7027669 T350

70132 T500J 207 7026395 1 Adjuster Assembly 208 7026396 1 Spring, Adjuster 209 1 Magnet Assembly (Includes 1 each of Magnet, Spring & Clip)

7027671 T350

7027677 T500J 210 See Note 1 Plug, Adjuster Slot (Note: Not Available - Purchase Locally) 211 See Note 1 Grommet (Note: Not Available - Purchase Locally) 212 See Note 4 Bolt, Mounting (Note: Not Available - Purchase Locally) 213 See Note 4 Nut

214 to 220 Not Used

221 See Note 1 Plate, Backing (Note: Not Available - Purchase Complete

Assy)

222 1 Actuating Cam & Pin Options:

7027672 Left Side

7027673 Right Side

223 Not Used

1-36 T350 & T500J 3121199

Page 45

SECTION 1 FRAME

FIGURE 1-12. ELECTRIC BRAKE & AXLE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

224 See Note 1 Anchor Post & Nut (Note: Not Available - Purchase Complete

Assy)

225 Not Used 226 See Note 1 Washer, Anchor (Note: Not Available - Purchase Locally) 227 See Note 1 Locknut (Note: Not Available - Purchase Locally) 228 7027678 1 Lever, Parking Brake 229 2 Spring, Retractor Options:

7027674 T350 7027679 T500J

3121199 T350 & T500J 1-37

Page 46

SECTION 1 FRAME

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

1-38 T350 & T500J 3121199

Page 47

SECTION 1 FRAME

3121199 T350 & T500J 1-39

Page 48

SECTION 1 FRAME

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref HYDRAULIC BRAKE ASSEMBLY

0280154 Ref T350 Except SNs 0030000121-0030000140, 0030000142,

0030000143 & 0030000153

9984240 Ref T350 SNs 0030000121-0030000140, 0030000142,0030000143 &

0030000153 Only

0280155 Ref T500J C

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

1See Note1Axle (Not Shown) (Note: Not Available - Purchase Complete

Assembly)

2See Note2Drum Assembly (Includes Item 101-129) (Note: Not Available -

Purchase Individual Parts)

32Hydraulic Brake Assembly

7027640 1 T350 Left Side (Includes Item 201-218)

7027641 1 T350 Right Side (Includes Item 201-218)

70001005 1 T500J Left Side (Includes Item 301-322) 70001006 1 T500J Right Side (Includes Item 301-322)

42Cable, Parking Brake Options:

70000015 2 T350 70000016 2 T500

Ref DRUM ASSEMBLY

101 2 Seal Options (1 Per Assembly):

7027647 1 T350

7027654 1 T500J 102 2 Cone, Inner Options (1 Per Assembly):

7027648 1 T350

7026384 1 T500J 103 2 Cup, Inner Options (1 Per Assembly):

7027649 1 T350

7026385 1 T500J 104 2 Cup, Outer Options (1 Per Assembly):

7027650 1 T350

7027655 1 T500J 105 2 Cone, Outer Options (1 Per Assembly):

7027651 1 T350

7027656 1 T500J 106 Not Used 107 80317 2 Pin, Cotter (1 Per Assembly) 108 2 Cap Options (1Per Assembly):

7027652 1 T350

7027511 1 T500J 109 70000131 1 Washer, Spindle (1 Per Assembly) 110 AR Stud, Wheel Options:

Ref Note: Please verify the length of your original stud before

ordering.

7026390 AR 2in Stud

70003756 AR 2-58in Stud

1-40 T350 & T500J 3121199

Page 49

SECTION 1 FRAME

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

110 (cont’d) 10 T350 (5 Per Assembly)

12 T500J (6 Per Assembly)

111 to 112 Not Used

113 7026313 AR Lugnut

10 T350 (5 Per Assembly) 12 T500J (6 Per Assembly)

Ref Note: See SPECIAL OPTIONS SECTION for Security Wheel

Locks.

114 to 123 Not Used

124 2 Hub and Drum Options (1 Per Assembly):

7027653 1 T350 7027657 1 T500J

125 to 127 Not Used

128 7027692 2 Nut, Spindle (1 Per Assembly) 129 7027693 2 Retainer, Nut Spindle (1 Per Assembly)

Ref HYDRAULIC BRAKE ASSEMBLIES 7027640 1 T350 Left Side 7027641 1 T350 Right Side

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

201 See Note 1 Plate, Backing (Note: Not Available - Purchase Complete

Assy)

202 1 Cylinder, Uni-Servo Wheel Options:

70145 Left Side

70144 Right Side 203 7026399 1 Pin, Push 204 See Note 1 Screw & Washer (Note: Not Available - Purchase Locally) 205 See Note 1 Washer, Anchor (Note: Not Available - Purchase Locally) 206 7026394 2 Spring, Retractor 207 7027642 1 Brake Shoe Assembly (Includes 1 Primary & 1 Secondary Brake

Shoe with Lining, 2 Pins, 2 Springs and 2 Cups)

208 7026395 1 Adjuster Assembly 209 7026396 1 Spring, Adjuster 210 See Note 1 Plug, Adjuster Slot (Note: Not Available - Purchase Locally) 211 See Note 4 Bolt, Mounting (Note: Not Available - Purchase Locally) 212 See Note 4 Nut (Note: Not Available - Purchase Locally) 213 Not Used 214 1 Lever, Parking Brake Actuating Options:

7027643 Left Side

7027644 Right Side 215 7027645 1 Strut 216 7027646 1 Spring, Strut

217 70001658 1 Washer 218 70001659 1 Retainer

3121199 T350 & T500J 1-41

Page 50

SECTION 1 FRAME

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

70001005 1 T500J Left Side 70001006 1 T500J Right Side

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

301 See Note 1 Plate, Backing (Note: Not Available - Purchase Complete

Assy)

302 1 Cylinder, Uni-Servo Wheel Options:

70145 Left Side

70144 Right Side 303 7026399 1 Pin, Push 304 See Note 1 Screw & Washer (Note: Not Available - Purchase Locally) 305 7027500 1 Link, Travel 306 7027501 1 Spring, Retractor 307 7027502 1 Spring, Lever Return 308 1 Brake Shoe Assembly Options (Includes 1 Primary & 1 Second-

ary Brake Shoe with Lining, 2 Pins, 2 Springs and 2 Cups):

7027503 Left Side

7027504 Right Side 309 7027505 1 Adjuster Assembly 310 7027506 1 Spring, Adjuster 311 See Note 1 Plug, Adjuster Slot (Note: Not Available - Purchase Locally) 312 See Note 4 Bolt, Mounting (Note: Not Available - Purchase Locally) 313 See Note 4 Nut (Note: Not Available - Purchase Locally) 314 See Note 1 Locknut (Note: Not Available - Purchase Locally) 315 See Note 1 Bolt (Note: Not Available - Purchase Locally) 316 See Note 1 Washer (Note: Not Available - Purchase Locally) 317 7027508 1 Spring, Primary Shoe Return 318 70001659 1 Retainer 319 1 Lever, Parking Brake Actuating Options:

7027662 Left Side

7027663 Right Side 320 70001007 1 Strut

321 7027507 1 Lever, Shoe 322 70001658 1 Washer

1-42 T350 & T500J 3121199

Page 51

SECTION 1 FRAME

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-43

Page 52

SECTION 1 FRAME

106

113

101

102

103

114

115

123

120

121

119

117

118

134

133

136

135

132

129

124

130

206

213

210

215

205

201

202

203

214

216

223

220

221

219

218

217

222

224

229

224

230

232

234

233

236

235

FIGURE 1-14. MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES)

1-44 T350 & T500J 3121199

Page 53

SECTION 1 FRAME

FIGURE 1-14. MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref AXLE ASSEMBLY 0280186 Ref T350 D 0280187 Ref T500J C

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

1 See Note 1 Axle (Not Shown) (Note: Not Available - Purchase Complete

Assembly)

2ARMechanical Brake Assembly Options: 2A 7027885 1 T350 Right Side (Includes Item 101-136) 2A 0277886 1 T350 Left Side (Includes Item 101-136) 2B 7027883 1 T500J Right Side (Includes Item 201-236) 2B 7027884 1 T500J Left Side (Includes Item 201-236)

Ref MECHANICAL BRAKE ASSEMBLY (T350)

7027885 1 T350 Right Side 7027886 1 T350 Left Side

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

101 7027801 5 Screw, Spherical Flanged 102 7027802 5 Screw, Conical Flanged 103 7027821 1 Hub/Drum Assembly

104 to 105 Not Used

106 7027803 1 Cap, Dust

107 to 112 Not Used

113 7027804 1 Nut, Flanged 114 7027805 1 Bearing 115 7027806 2 Circle Clip 116 Not Used 117 7027807 1 Shoe, Brake (Smaller of the 2 Shoes) 118 7027808 1 Shoe, Brake (Larger of the 2 Shoes) 119 7027809 1 Spring, Tension (Top) 120 7027810 1 Spring, Tension (Bottom) 121 7027811 1 Spring, Compression (Center) 122 Not Used 123 7027812 1 Spreader, Compression Spring 124 7027813 2 Key, Adjusting

125 to 128 Not Used

129 7027814 1 Bolt, Adjusting 130 7027815 1 Bolt 131 Not Used 132 7027816 2 Plug, Adjustment Hole 133 7027817 1 Shield, Protective 134 7027818 1 Drawbar Eye 135 7027819 1 Sleeve, Protective 136 7027820 1 Cable, Brake

3121199 T350 & T500J 1-45

Page 54

SECTION 1 FRAME

FIGURE 1-14. MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref MECHANICAL BRAKE ASSEMBLY (T350)

7027883 1 T500J Right Side 7027884 1 T500J Left Side

Ref Note: Front/Rear & Left/Right are determined by facing the

Tow Vehicle.

201 7027822 6 Nut, Flanged 202 7027823 6 Lockwasher 203 7027826 1 Hub/Drum Assembly 204 Not Used 205 7027824 1 Pin, Cotter 206 7027825 1 Cap, Dust

207 to 209 Not Used

210 7027827 1 Washer

211 to 212 Not Used

213 7027828 1 Nut, Castle 214 7027829 1 Bearing (Inner) 215 7027830 1 Bearing (Outer) 216 7027831 1 Washer 217 Use 70003038 1 Shoe, Brake (Larger of the 2 Shoes) (was p/n 7027832) 218 Use 70003038 1 Shoe, Brake (Smaller of the 2 Shoes) (was p/n 7027833) 219 7027834 1 Spring, Tension (Bottom) 220 7027835 1 Spring, Tension (Top) 221 7027836 1 Spring, Compression (Center) 222 7027837 1 Clip, Spring 223 7027838 1 Spreader, Compression Spring 224 7027839 2 Key, Adjusting

225 to 228 Not Used

229 7027840 1 Bolt, Adjusting 230 7027841 1 Bolt 231 Not Used 232 7027842 2 Plug, Adjustment Hole 233 7027843 1 Shield, Protective 234 7027844 1 Drawbar Eye 235 7027845 1 Sleeve, Protective 236 7027846 1 Cable, Brake

1-46 T350 & T500J 3121199

Page 55

SECTION 1 FRAME

FIGURE 1-14. MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-47

Page 56

SECTION 1 FRAME

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL)

1-48 T350 & T500J 3121199

Page 57

SECTION 1 FRAME

3121199 T350 & T500J 1-49

Page 58

SECTION 1 FRAME

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref CHASSIS DRIVE INSTALLATION (OPTIONAL) 0274679 Ref T350 (ANSI, ANSI Export, Australian & South Africa Specs) F 0275380 Ref T350 (CE Specs) C 0274754 Ref T500J (ANSI, ANSI Export, Australian & South Africa Specs) F 0275203 Ref T500J (CE Specs) C

1 0100011 AR Compound, Locking 2 1 Drive Assembly Options (See Items 101-111 for Breakdown):

0274806 T350 (All Specs Except CE Specs) 0275391 T350 (CE Specs) 0274803 T500J

3 Use 0630613 AR Bolt, Carriage M10 x 25mm (Prior to SN 0030002018 -

p/n was 0630588) 4 0641406 AR Bolt 1/4in-20NC x 3/4in 5 4 Bolt 1/4in-20NC Options:

0641408 1in Length 0641412 1-1/2in Length

0641420 2-1/2in Length 6 0641410 2 Bolt 1/4in-20NC x 1-1/4in 7 0641416 2 Bolt 1/4in-20NC x 2in 8 0641506 3 Bolt 5/16in-18NC x 3/4in 9 AR Bolt 5/16in-18NC Options:

0641526 3-1/4in Length

0641536 4-1/4in Length

0641538 4-3/4in Length

0641540 5in Length

10 0641607 2 Bolt 3/8in-16NC x 7/8in 11 0641608 6 Bolt 3/8in-16NC x 1in 12 0903284 1 Bracket, Switch Mounting 13 0903298 1 Bracket, Valve Mounting 14 0903299 1 Bracket, Drive Valve Mounting 15 1600392 1 Module, Drive Propulsion 16 1 Brake Release Cylinder Assembly (See CYLINDER SECTION

for Breakdown)

Use 1684507 All Specs Except CE Specs (Prior to SN 0030001444) (was

p/n 1684466) 1684507 All Specs Except CE Specs (SN 0030001444 to Present) 1684507 CE Specs

17 1 Drive Engage Cylinder Assembly Options (See CYLINDER

SECTION for Breakdown): 1684467 T350 1684468 T500J

18 1706701 1 Decal - Drive Set 19 AR Locknut Options:

3291007 Locknut M10 (Prior to SN 0030002018) 3291001 Locknut M10 x 1.5 (SN 0030002018 to Present)

20 3311405 AR Locknut 1/4in-20NC 21 3311501 3 Nut 5/16in-18NC 22 3311505 4 Locknut 5/16in-18NC 23 3311605 10 Locknut 3/8in-16NC

1-50 T350 & T500J 3121199

Page 59

SECTION 1 FRAME

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

24 3380624 1 Cover 25 3422351 2 Pin, Steer 26 3450304 3 Pin, Cotter 3/32in x 1in (All Specs Except CE Specs Only) 27 1 Plate, Equalizer

3576092 All Specs Except CE Specs

3575853 CE Specs 28 3576136 2 Plate, Strap 29 3841143 2 Keeper, Pin 30 4000008 2 Sensor, Proximity 31 4300115 1 Stud 32 4341097 1 Support, Cylinder Slide 33 4341116 1 Support, Cylinder Slide 34 4520338 2 Disc, Friction Drive 35 4641418 1 Valve Assembly - Flow Divider 36 4641419 1 Valve Assembly - Drive Enable (See DRIVE ENABLE VALVE

ASSEMBLY (USED WITH DRIVE OPTION ONLY) for Breakdown)

37 4641420 1 Valve Assembly - Drive Directional (See DRIVE DIRECTIONAL

VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY) for Breakdown)

38 4640866 1 Valve Assembly - Manual Pull

7017466 1 Cartridge

2900708 1 Seal Kit - 7017466 Cartridge

7012959 1 Knob 39 4711400 AR Flatwasher 1/4in Thin 40 4711500 AR Flatwasher 5/16in Thin 41 4711600 12 Flatwasher 3/8in Thin 42 4751500 3 Flatwasher 5/16in Regular (All Specs Except CE Specs Only) 43 AR Flatwasher Options:

4812000 Flatwasher 10mm (Prior to SN 0030002018)

4891700 Flatwasher 7/16in Hardened (SN 0030002018 to Present) 44 4923340 1 Harness, Drive & Set (Not Shown - See ELECTRICAL

SECTION for Breakdown)

45 4 Bolt 3/8in-16NC

0641634 T350 (4-1/2in Length)

0641640 T500J (5in Length) 46 0641812 4 Bolt 1/2in-13NC x 1-1/2in 47 0642230 1 Bolt 3/4in-10NC x 3-3/4in 48 0721006 1 Screw #10-24NC x 3/4in 49 1060584 1 Cable, Lanyard 50 3311005 1 Locknut #10-24NC 51 3311805 4 Locknut 1/2in-13NC 52 3312205 1 Locknut 3/4in-10NC 53 3421565 1 Snap-Pin 54 3423249 1 Pin, Drive Motor Pivot 55 3520071 1 Cap-Plug 56 3760170 1 Ring, Split 57 1 Mount, Wheel Drive Pivot Options:

4341148 T350

4341150 T500J

3121199 T350 & T500J 1-51

Page 60

SECTION 1 FRAME

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

58 1 Mount, Wheel Drive Options:

4341149 T350

4341151 T500J 59 4520591 1 Wheel, Drive 60 4711800 8 Flatwasher 1/2in Thin 61 4712200 2 Flatwasher 3/4in Thin 62 4751000 2 Flatwasher #10 Regular 63 4751600 8 Flatwasher 3/8in Regular 64 0903356 1 Bracket, Mounting

65 to 69 Not Used

70 3291001 7 Nut M10 (CE Specs Only) 71 1 Brake Rod/Cable Options:

See Note T350 & T500J All Specs Except CE Specs (Note: See Axle &

Tongue Installation)

3841740 T350 CE Specs

3841730 T500J CE Specs

72 to 81 Not Used

82 09033311 1 Bracket, Cable (T500J CE Spec Only) 83 2 Spacer, Brake Cylinder Pad Options:

Not Required T350 & T500J All Specs Except CE Specs

4220304 T350 CE Specs

4220296 T500J CE Specs 84 1 Spacer, Switch Mounting Options:

Not Required T350 & T500J All Specs Except CE Specs

4220305 T350 CE Specs

4220297 T500J CE Specs

Ref DRIVE ASSEMBLY 0274806 Ref T350 (ANSI, ANSI Export, Australian & South Africa Specs) D 0275391 Ref T350 (CE Specs) A 0274803 Ref T500J D

101 0100011 AR Compound, Locking 102 0440321 4 Bearing, Flanged 103 0641607 2 Bolt 3/8in-16NC x 7/8in 104 2 Drive Motor Assembly Options (See DRIVE MOTOR

ASSEMBLY (USED WITH DRIVE OPTION ONLY) for

Breakdown): 3160319 Prior to SN 0030001055 3160327 SN 0030001055 to Present

105 3311805 8 Locknut 1/2in-13NC 106 3422709 2 Pin, Slider 107 3841143 2 Keeper, Pin 108 3931840 8 Capscrew 1/2in-13NC x 2-1/2in 109 4130417 2 Spindle, Drive/Set 110 1 Mount, Motor

4341092 T350 All Specs Except CE Specs 4341267 T350 CE Specs 4341113 T500J

111 4711800 8 Flatwasher 1/2in Thin

1-52 T350 & T500J 3121199

Page 61

SECTION 1 FRAME

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-53

Page 62

SECTION 1 FRAME

456

FIGURE 1-16. DRIVE ENABLE VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

1-54 T350 & T500J 3121199

Page 63

SECTION 1 FRAME

FIGURE 1-16. DRIVE ENABLE VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641419 Ref DRIVE ENABLE VALVE ASSEMBLY B

1 4641129 1 Cartridge, Check Valve

7012998 1 Seal Kit - 4641129 Cartridge

2 Use 2915194 1 Element, Filter (Includes p/n 70000065 O-Ring)

(was p/n 7027634) See Note 1 Adapter (Note: Not Available - Purchase p/n 2915194) See Note 1 Retainer (Note: Not Available - Purchase p/n 2915194) See Note 1 Plug (Note: Not Available - Purchase p/n 2915194)

3 7024893 1 Cartridge, Pressure Relief Valve

7021653 1 Seal Kit - 7024893 Cartridge

4 7024894 1 Cartridge, Relief Valve

7012998 1 Seal Kit - 7024894 Cartridge

5 7017418 1 Cartridge, Relief Valve

7012998 1 Seal Kit - 7017418 Cartridge

6 8036580 1 Cartridge, Solenoid Cartridge

7012903 1 Seal Kit - 8036580 Cartridge 7024883 1 Coil

3121199 T350 & T500J 1-55

Page 64

SECTION 1 FRAME

433

FIGURE 1-17. DRIVE DIRECTIONAL VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

1-56 T350 & T500J 3121199

Page 65

SECTION 1 FRAME

FIGURE 1-17. DRIVE DIRECTIONAL VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641420 Ref DRIVE DIRECTIONAL VALVE ASSEMBLY B

1 70002815 4 Cartridge, Counterbalance Valve

Not Required 4 Seal Kit - Cartridge

2 7024898 2 Cartridge, Valve

7012518 2 Seal Kit - 7024898 Cartridge

3 7010542 3 Cartridge, Load Sensing Valve

7010543 3 Seal Kit - 7010542 Cartridge

4 7024899 2 Cartridge, Solenoid Cartridge

7017402 2 Seal Kit - Cartridge 7024885 4 Coil

5 See Note 2 Orifice (.40) (Not Shown) (Note: Not Available for Purchase)

3121199 T350 & T500J 1-57

Page 66

SECTION 1 FRAME

12A

12F

12C

12E

12D

FIGURE 1-18. DRIVE MOTOR ASSEMBLY (USED WITH DRIVE OPTION ONLY)

1-58 T350 & T500J 3121199

Page 67

SECTION 1 FRAME

FIGURE 1-18. DRIVE MOTOR ASSEMBLY (USED WITH DRIVE OPTION ONLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref DRIVE MOTOR ASSEMBLY 3160319 Ref Prior to SN 0030001055 3160327 Ref SN 0030001055 to Present

1 7 Bolt Options:

7023329 3160319 Motor Prior to SN 0030001055

70000287 3160327 Motor SN 0030001055 to Present 2 7023328 1 Cover 3 Use 7023412 1 Seal, Commutator 4 Use 7023412 5 Ring, Seal 5 7023315 1 Commutator (Includes Item 6) 6 7023315 1 Ring, Commutator (Includes Item 5) 7 70000277 1 Manifold 8 1 Rotor Set Options:

70000278 3160319 Motor Prior to SN 0030001055

70000288 3160327 Motor SN 0030001055 to Present 9 7023311 1 Plate, Wear

10 1 Link, Drive Options:

70000279 3160319 Motor Prior to SN 0030001055

See Note 3160327 Motor SN 0030001055 to Present (Note: Not

Available - Purchase Complete Drive Motor p/n 3160327)

11 7023308 1 Bearing, Thrust

12 70000281 1 Shaft 12A 70000282 1 Key, Shaft 12B Not Used 12C 70000283 1 Washer, Shaft 12D 70000284 1 Bolt, Shaft 12E 70000285 1 Lockwasher, Shaft 12F 70000286 1 Ring, Shaft Retaining

13 7023405 1 Bearing, Inner

14 7023406 2 Thrustwasher

15 7023407 1 Bearing, Thrust

16 Use 7023412 1 Seal

17 Use 7023412 1 Washer, Backup

18 70000280 1 Housing

19 7023408 1 Bearing, Outer

20 Use 7023412 Seal, Dirt & Water

21 to 25 Not Used

25 Use 7023412 1 Washer, Backup

— — — — — — — — — —

26 7023412 1 Seal Kit (Includes Items 3, 4 16, 17 & 25)

3121199 T350 & T500J 1-59

Page 68

SECTION 1 FRAME

10101314

11B

11D

THIS VIEW

SHOWN FOR

CLARITY

225B

226

225A

226

224

225B

225

225C

226C

223

109

106

108

103

104

107

110

117

231

232

234

233

157556

11A

11C

121

105A 115

101

123

110

122

119

120

105B

FIGURE 1-19. CONTROL MODULES AND VALVES INSTALLATION

1-60 T350 & T500J 3121199

Page 69

SECTION 1 FRAME

FIGURE 1-19. CONTROL MODULES AND VALVES INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref CONTROL VALVE INSTALLATION 0273616 Ref T350 Electric Powered E 0273618 Ref T350 Gas Powered E 0273617 Ref T500J Electric Powered E 0273619 Ref T500J Gas Powered E

1 0100011 AR Compound, Locking 2 1 Bolt Options:

0700610 Bolt 6mm x 20mm (T350) 0700812 Bolt 8mm x 25mm (T500J)

3 0760810 3 Bolt 8mm x 20mm 4 1320263 1 Clamp 5 1380136 2 Clip, Gripper 6 2560122 1 Handle 7 2560123 1 Grip, Handle 8 1 Locknut Options:

3290605 Locknut 6mm x 20mm (T350) 3290805 Locknut 8mm x 25mm (T500J)

9Not Used 10 3820017 2 Rivet 5/32in 11 1 Control Valve Assembly Options:

11A 4641342 T350 Electric Powered (See CONTROL VALVE ASSEMBLY

(ELECTRICAL POWERED MACHINES) for Breakdown)

11B 4641344 T350 Gas Powered (See CONTROL VALVE ASSEMBLY

(GAS POWERED MACHINES) for Breakdown)

11C 4641343 T500J Electric Powered (See CONTROL VALVE ASSEMBLY

(ELECTRICAL POWERED MACHINES) for Breakdown)

11D 4641345 T500J Gas Powered (See CONTROL VALVE ASSEMBLY

(GAS POWERED MACHINES) for Breakdown) 12 Not Used 13 2 Flatwasher Options:

4811900 Flatwasher 8mm (T350)

4711400 Flatwasher 1/4in Thin (T500J) 14 4811900 3 Flatwasher 8mm 15 0100081 AR Loctite #454

Ref CONTROL MODULE INSTALLATIONS

0273793 Ref Electric Machines without Drive Option

(Prior to SN 0030001804)

0275776 Ref Electric Machines without Drive Option

(SN 0030001804 to Present)

9984274 Ref Electric Machines with Drive Option D

0273794 Ref Gas Machines F

101 3311405 4 Locknut 1/4in-20NC (Prior to SN 0030001397) 102 Not Used 103 0700510 1 Bolt 5mm x 20mm 104 1600370 1 Module, Ground Control (Note: Control System must be

recalibrated when Module is replaced)

3121199 T350 & T500J 1-61

Page 70

SECTION 1 FRAME

FIGURE 1-19. CONTROL MODULES AND VALVES INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

105 AR Controller, Sevcon Options:

105A 1600371 1 Electric Powered Machines without Drive

(Prior to SN 0030001804)

1600412 1 Electric Powered Machines without Drive

(SN 0030001804 to Present) 105B 1600412 1 Electric Powered Machines with Drive 105C Not Required 0 Gas Powered Machines

106 3290507 1 Locknut 5mm 107 3290605 5 Locknut 6mm 108 3740145 1 Relay 109 4811600 2 Flatwasher 5mm 110 4811700 10 Flatwasher 6mm 111 1 Harness, Frame (Not Shown - See ELECTRICAL SECTION for

Breakdown) 4922975 Electric Powered Machines (Prior to SN 0030001804) 4923427 Electric Powered Machines (SN 0030001804 to Present) 4923130 Gas Powered Machines

112 4923041 1 Harness, Jack and Valve (Not Shown - See ELECTRICAL

SECTION for Breakdown)

113 1 Harness, Frame to Boom Options (Not Shown - See

ELECTRICAL SECTION for Breakdown): 4923103 Prior to SN 0030001804 4923427 SN 0030001804 to Present

114 4923109 1 Harness, Main Valve (Not Shown - See ELECTRICAL SECTION

for Breakdown)

115 0100083 AR Grease, Heat Transfer (Prior to SN 0030001397) 116 Not Used 117 4031714 5 Capscrew 6mm x 50mm 118 4460905 5 Plug, Connector (Not Shown) 119 0100011 AR Compound, Locking 120 0760608 4 Capscrew 6mm x 16mm (Electric Machines Only) (Prior to

SN 0030001397)

121 3575884 1 Plate, Mounting (Electric Machines Only) (Prior to

SN 0030001397)

122 4 Capscrew Options (Electric Machines Only):

4031708 Capscrew 6mm x 20mm (Prior to SN 0030001397) 3931416 Capscrew 1/4in-20NC x 1in (SN 0030001397 to

SN 0030001804)

4191709 Capscrew 6mm x 25mm (SN 0030001804 to Present)

123 4711400 4 Flatwasher 1/4in Thin

Ref OUTRIGGER VALVE INSTALLATION 0273712 Ref T350 ANSI, ANSI Export & South Africa Specs G 0274375 Ref T350 Australian & CE Specs B 0273715 Ref T500J ANSI & ANSI Export & South Africa Specs I 0274321 Ref T500J Australian & CE Specs D

201 to 222 Not Used

223 0700827 2 Bolt 8mm x 100mm 224 3290805 2 Locknut 8mm 225 4641380 1 Outrigger Valve Assembly B

1-62 T350 & T500J 3121199

Page 71

SECTION 1 FRAME

FIGURE 1-19. CONTROL MODULES AND VALVES INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

225A 2220885 4 Plug 225B 2110406 6 Fitting, Straight 225C 2110606 2 Fitting, Straight

226 4811900 4 Flatwasher 8mm

227 to 230 Not Used

231 0641516 4 Bolt 5/16in-18NC x 2in 232 1320159 4 Clamp 233 3311505 4 Locknut 5/16in-18NC 234 4751500 4 Flatwasher 5/16in Regular

Ref FRAME WELDMENT 2360718 Ref T350 2360717 Ref T500J All Specs Except CE Specs 2360716 Ref T500J CE Specs without Drive Option 2360773 Ref T500J CE Specs with Drive Option

3121199 T350 & T500J 1-63

Page 72

SECTION 1 FRAME

111

112

103712

30A

109

1011338613

30B30243110

1A1417

109

113

101

113

101

12937

16A

109

102

FIGURE 1-20. CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES)

1-64 T350 & T500J 3121199

Page 73

SECTION 1 FRAME

FIGURE 1-20. CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref CONTROL VALVE ASSEMBLY 4641325

See Note

4641326

See Note

1 7027617 1 Motor Assembly

See Note 1 Brush Kit (Note: Not Available - Purchase Complete Motor

1A 7027618 1 Coupling

2 7027619 1 Pump

See Note 1 Seal Kit - Pump

3 See Note 1 Block, Valve

4 7027620 1 Cartridge, Relief Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Relief Valve Car-

4A 7027621 1 Cartridge, Relief Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Relief Valve Car-

5 7027622 1 Cartridge, Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Cartridge Valve

6 7027623 7 Cartridge, Valve

See Note 7 Seal Kit (Note: Not Available - Purchase Cartridge Valve

7 7027624 2 Cartridge, Solenoid Less Coil (Swing & Leveling Jacks)

70002227 2 Nut, Coil 70000100 2 Seal Kit

8 7027625 1 Cartridge, Solenoid Less Coil (Level)

70002227 1 Nut, Coil 70000100 1 Seal Kit

9 7027626 1 Cartridge, Solenoid Less Coil (Tele)

70002228 1 Nut, Coil 70000100 1 Seal Kit

10 7024500 1 Cartridge, Solenoid Less Coil (Lift Up)

70002230 1 Nut, Coil

7024505 1 Seal Kit

11 7027627 1 Cartridge, Solenoid Less Coil (Manual Descent)

70002229 1 Nut, Coil

7024505 1 Seal Kit

12 7027628 9 Coil 13 7027629 3 Cartridge, Valve

7024505 3 Seal Kit

14 7027630 1 Cartridge, Manual Pump Valve (Manual Descent)

See Note 1 Seal Kit (Note: Not Available - Purchase Manual Pump

Ref T350 Electric Powered Machines

Note: When replacing complete unit order p/n 4641342 instead of p/n 4641325.

Ref T500J Electric Powered Machines

Note: When replacing complete unit order p/n 4641343 instead of p/n 4641326.

Assembly p/n 7027617)

(Note: Not Available - Purchase Pump p/n 7027619)

(Note: Not Available - Purchase Complete Valve Assembly)

tridge p/n 7027620)

tridge p/n 7027621)

p/n 7027622)

p/n 7027623)

Valve Cartridge p/n 7027630)

3121199 T350 & T500J 1-65

Page 74

SECTION 1 FRAME

FIGURE 1-20. CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

15 1 Tank Options:

7027631 T350 7027639 T500J

16 7027632 1 Filter, Hydraulic (Suction)

16A 7027633 1 Tube, Suction

17 See Note 2 Capscrew 8mm x 90mm (Note: Not Available for Purchase) 18 See Note 1 Ring, Seal (Note: Not Available for Purchase)

19 to 23 Not Used

24 Use 2915194 1 Element, Filter (Includes p/n 70000065 O-Ring)

(was p/n 7027634)

See Note 1 Adapter

(Note: Not Available - Purchase Filter Element p/n 2915194)

70002282 1 Fitting, Plug 70003615 1 Retainer, Filter Element Contamination

25 7027635 1 O-Ring

26 to 29 Not Used

30 7027690 1 Valve Block Assembly (Jib) (T500J Only)

30A 7024500 1 Cartridge, Solenoid Less Coil

70002230 1 Nut, Coil

7024505 1 Seal Kit 7027628 1 Coil

30B See Note 1 Cartridge, Valve (Note: Not Available - Purchase Complete

Valve Block Assembly p/n 7027690)

See Note 1 Seal Kit (Note: Not Available - Purchase Complete Valve

Block Assembly p/n 7027690)

31 to 36 Not Used

37 70000894 4 Nut

70000895 4 Stud

38 7027636 2 Orifice

39 to 94 Not Used

95 7027638 1 Breather 96 70000378 1 Dipstick

Ref VALVE AND FITTINGS SUBASSEMBLY 4641342 Ref T350 Electric Powered Machines E 4641343 Ref T500J Electric Powered Machines E

101 2110404 AR Fitting, Straight

4T350

6 T500J 102 2110604 1 Fitting, Straight 103 2130404 1 Fitting, Elbow

104 to 108 Not Used

109 2221086 3 Fitting, Test Port 110 1 Valve Assembly Less Fittings (Includes Items 1-95)

4641325 T350

4641326 T500J 111 2130606 1 Fitting, Elbow 112 2170206 1 Fitting, Long Elbow

1-66 T350 & T500J 3121199

Page 75

SECTION 1 FRAME

FIGURE 1-20. CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES)

(CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

113 2110606 3 Fitting, Straight

3121199 T350 & T500J 1-67

Page 76

SECTION 1 FRAME

111127129253011330A

109

1011338624

109

113

101

113

111

31C

31A

114

1114963730B

109

102

31B

FIGURE 1-21. CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES)

1-68 T350 & T500J 3121199

Page 77

SECTION 1 FRAME

FIGURE 1-21. CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref CONTROL VALVE ASSEMBLY

4641327

See Note

4641328

See Note

1 to 2 Not Used

3 See Note 1 Block, Valve

4 7027620 1 Cartridge, Relief Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Relief Valve Car-

4A 7027621 1 Cartridge, Relief Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Relief Valve Car-

5 7027622 1 Cartridge, Valve

See Note 1 Seal Kit (Note: Not Available - Purchase Cartridge Valve

6 7027623 7 Cartridge, Valve

See Note 7 Seal Kit (Note: Not Available - Purchase Cartridge Valve

7 7027624 2 Cartridge, Solenoid Less Coil (Swing & Leveling Jacks)

70002227 2 Nut, Coil 70000100 2 Seal Kit

8 7027625 1 Cartridge, Solenoid Less Coil (Level)

70002227 1 Nut, Coil 70000100 1 Seal Kit

9 7027626 1 Cartridge, Solenoid Less Coil (Tele)

70002228 1 Nut, Coil 70000100 1 Seal Kit

10 7024500 1 Cartridge, Solenoid Less Coil (Lift Up)

70002230 1 Nut, Coil

7024505 1 Seal Kit

11 7027627 1 Cartridge, Solenoid Less Coil (Manual Descent)

70002229 1 Nut, Coil

7024505 1 Seal Kit 12 7027628 9 Coil 13 7027629 3 Cartridge, Valve

7024505 3 Seal Kit 14 7027630 1 Cartridge, Manual Pump Valve (Manual Descent)

See Note 1 Seal Kit (Note: Not Available - Purchase Manual Pump

15 1 Tank Options:

7027631 T350

7027639 T500J

16 to 23 Not Used

Ref T350 Gas Powered Machines

Note: When replacing complete unit order p/n 4641344 instead of p/n 4641327.

Ref T500J Gas Powered Machines

Note: When replacing complete unit order p/n 4641345 instead of p/n 4641325.

(Note: Not Available - Purchase Complete Valve Assembly)

tridge p/n 7027620)

tridge p/n 7027621)

p/n 7027622)

p/n 7027623)

Valve Cartridge p/n 7027630)

3121199 T350 & T500J 1-69

Page 78

SECTION 1 FRAME

FIGURE 1-21. CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

24 Use 2915194 1 Element, Filter (Includes p/n 70000065 O-Ring)

(was p/n 7027634)

See Note 1 Adapter (Note: Not Available - Purchase Filter Element p/n

2915194)

70003615 1 Retainer, Filter Element Contamination

25 7027635 1 O-Ring

26 to 29 Not Used

30 7027690 1 Valve Block Assembly (Jib) (T500J Only)

30A 7024500 1 Cartridge, Solenoid Less Coil

70002230 1 Nut, Coil

7024505 1 Seal Kit 7027628 1 Coil

30B See Note 1 Cartridge, Valve (Note: Not Available - Purchase Complete

Valve Block Assembly p/n 7027690)

See Note 1 Seal Kit (Note: Not Available - Purchase Complete Valve

Block Assembly p/n 7027690)

31 7027691 1 Valve Block Assembly (Proportional)

31A 70000025 1 Cartridge, Solenoid Less Coil

7026623 1 Seal Kit

70000026 1 Coil

31B 70000028 1 Cartridge, Valve (Check)

See Note 1 Seal Kit (Note: Not Available - Purchase Cartridge Valve

p/n 70000028)

31C 70000027 1 Compensator

32 to 36 Not Used

37 70000894 4 Nut

70000895 4 Stud

38 7027636 2 Orifice

39 to 94 Not Used

95 7027638 1 Breather 96 70000378 1 Dipstick

Ref VALVE AND FITTINGS SUBASSEMBLY 4641344 Ref T350 Gas Powered Machines F 4641345 Ref T500J Gas Powered Machines F

101 2110404 AR Fitting, Straight

4T350

6 T500J 102 2110604 1 Fitting, Straight 103 2130404 1 Fitting, Elbow

104 to 108 Not Used

109 2221086 3 Fitting, Test Port 110 1 Valve Assembly Less Fittings (Includes Items 1-95)

4641327 T350

4641328 T500J 111 2130606 2 Fitting, Elbow 112 2170206 1 Fitting, Long Elbow 113 2110606 3 Fitting, Straight 114 2111610 1 Fitting, Straight

1-70 T350 & T500J 3121199

Page 79

SECTION 1 FRAME

FIGURE 1-21. CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-71

Page 80

SECTION 1 FRAME

111

107

106

107

107 106

108

109

107

102

104

105

211

210

110

201

202623

107

217

206

222217

103

106

103

107

203

4 11 22

283112221

5 11 22

199D218

13113

220

2051427511

214

219

221

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES)

1-72 T350 & T500J 3121199

Page 81

SECTION 1 FRAME

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0273763 Ref HONDA ENGINE ASSEMBLY F

1 0100011 AR Compound, Locking 2 0641406 2 Bolt 1/4in-20NC x 3/4in 3 0641407 6 Bolt 1/4in-20NC x 7/8in 4 0641410 2 Bolt 1/4in-20NC x 1-1/4in 5 0641416 2 Bolt 1/4in-20NC x 2in (Prior to SN 0030001968, SN 0030001975 & SN

0030002002 to SN 0030002006) 6 0641614 4 Bolt 3/8in-16NC x 1-3/4in 7 1321130 2 Clamp (Prior to SN 0030001968, SN 0030001975 &

SN 0030002002 to SN 0030002006) 8 1 Engine, Honda GX270 Options:

Use

1001136471 1001127719 Engine SN 0030004208 to Present

9 2902333 1 Pump Coupling Kit

9A 7027326 1 Housing & Bolt Kit 9B 0641608 6 Bolt 3/8in-16NC x 1in 9C 4751600 6 Flatwasher 3/8in Regular 9D 70001008 1 Cover 9E 7027327 1 Coupling 9F 7027328 1 Neoprene with Metal Ring 10 3020015 1.16qt Oil, Motor (Not Shown) 11 3311405 12 Locknut 1/4in-20NC 12 3311605 4 Locknut 3/8in-16NC 13 3321401 2 Nut 1/4in-28NF 14 3450202 1 Pin, Cotter 15 3575070 1 Plate, Motor Mounting 16 3600403 1 Gear Pump Assembly (No Serviceable Parts - Replace Complete Part) 17 3740080 2 Relay 18 3740144 1 Actuator, Solenoid (Choke) 19 2 Cable, Throttle Options:

Use 2915213 Prior to SN 0030001968, SN 0030001975 & SN 0030002002 to SN

3890065 SN 0030001969 to SN 0030001974, SN 0030001976 to

20 4100097 2 Spacer 21 4751000 1 Flatwasher #10 Regular 22 AR Flatwasher Options:

4751400 22 Flatwasher 1/4in Regular (Prior to SN 0030001968,

4711400 26 Flatwasher 1/4in Thin (SN 0030001969 to SN 0030001974,

23 4751600 8 Flatwasher 3/8in Regular 24 Not Used 25 2820179 1 Shield, Heat (Top) 26 3900184 2 Screw #10-24NC x 5/8in 27 4791400 4 Starwasher 1/4in (Prior to SN 0030001968, SN 0030001975 &

28 3740112 1 Relay

Engine Prior to SN 0030004208 (was p/n 2000230) (1001136471 Kit includes p/n 1001127719 Engine & 1001128929 Harness)

0030002006 (was p/n 3890051)

SN 0030002001 & SN 0030002007 to Present

SN 0030001975 & SN 0030002002 to SN 0030002006)

SN 0030001976 to SN 0030002001 & SN 0030002007 to Present)

SN 0030002002 to SN 0030002006)

3121199 T350 & T500J 1-73

Page 82

SECTION 1 FRAME

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

29 3740148 1 Actuator, Solenoid (Throttle) 30 0903597 2 Bracket, Cable Mount (SN 0030001969 to SN 0030001974,

SN 0030001976 to SN 0030002001 & SN 0030002007 to Present)

Ref HONDA ENGINE INSTALLATION 0274336 Ref T350 F 0273939 Ref T500J I

101 Not Used 102 0400201 1 Battery 103 0641610 3 Bolt 3/8’-16NC x 1-1/4in 104 0641660 2 Bolt 3/8in-16NC x 7-1/2in 105 0902659 1 Bracket, Battery Hold-Down 106 3311605 5 Locknut 3/8in-16NC 107 4751600 10 Flatwasher 3/8in Regular 108 4923153 1 Cable, Battery Ground 109 4923154 1 Cable, Battery Power 110 1706260 1 Decal - Fuel 111 3575775 1 Spacer 112 1 Harness, Engine Options (Not Shown - See ELECTRICAL SECTION

for Breakdown):

4923132 Harness Prior to SN 0030004208 (Original Equipment) (Note: If

item 8 Kit has been installed use p/n 1001128929)

1001128929 Harness SN 0030004208 to Present

Ref HONDA ENGINE COMPONENTS

Ref Note: Original Equipment engine p/n 200030 may have been

replaced with Service Replacement engine p/n 1001136471. Identify engine before ordering parts.

2000230 Ref Engine Prior to SN 0030004208 (Original Equipment) D

1001136471 Ref Engine Prior to SN 0030004208 (Service Replacement Kit) (Kit

includes a 1001127719 Engine)

1001127719 Ref Engine SN 0030004208 to Present A

201 70001453 1 Filter Assembly, Inner Air

7027372 1 Filter Assembly, Outer Air

202 1 Carburetor, Replacement Options (See Service & Maintenance Man-

ual for Instructions when Replacing Complete Assembly):

7027376 Carburetor (2000230 Engine)

70003493 Carburetor (1001127719 Engine)

7027373 1 Gasket Set - Carburetor 7027374 1 Valve Set - Carburetor

1 Float Set - Carburetor Options:

7027375 Float (2000230 Engine)

70003549 Float (1001127719 Engine)

1 Gasket, Carburetor to Insulator Options:

7027377 Gasket (2000230 Engine)

70003495 Gasket (1001127719 Engine)

1 Gasket, Insulator to Block Options:

7027378 Gasket (2000230 Engine)

1-74 T350 & T500J 3121199

Page 83

SECTION 1 FRAME

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

202 cont’d 70003496 Gasket (1001127719 Engine)

70003494 1 Spacer, Carburetor (1001127719 Engine Only)

7027379 1 Cup, Fuel Strainer

1 Remote Choke Assembly Options:

7027380 Choke (2000230 Engine)

See Note Choke (1001127719 Engine) (Note: Not Available - Purchase

Complete Carburetor p/n 70003493)

7027381 1 Rod, Governor 7027382 1 Spring, Governor 7027383 1 Spring, Throttle Return (Long)

1 Control, Throttle (Mechanical) 7027384 Control (2000230 Engine) 7023519 Control (1001127719 Engine) 7027385 1 Spring, Return (Short) (Part of Throttle Control)

203 7027386 1 Regulator, Voltage (2000230 Engine) 204 7027387 1 Unit, Oil Alert (Not Shown) (2000230 Engine) 205 1 Plug, Oil Fill Options:

7027388 Plug (2000230 Engine)

70003488 Plug (1001127719 Engine)

206 1 Dipstick Options:

7027389 Dipstick (2000230 Engine)

70003489 Dipstick (1001127719 Engine)

207 1 Switch, Oil Pressure Options (Not Shown):

7027390 1 Switch, Oil Pressure (2000230 Engine)

70003487 1 Switch, Oil Pressure (1001127719 Engine)

208 1 Plug, Spark Options (Not Shown):

7027391 Denso Brand

70002770 NGK Brand

209 1 Flywheel Options (Not Shown):

7027393 Flywheel (2000230 Engine)

70003512 Flywheel (1001127719 Engine)

7027392 1 Key, Flywheel (Not Shown):

1 Fan, Cooling Options (Not Shown):

See Note Fan (2000230 Engine)

(Note: Not Available - Purchase Flywheel p/n 7027393)

70003511 Fan (1001127719 Engine)

210 1 Cap, Fuel Options:

7027394 Cap (2000230 Engine)

70003508 Cap (1001127719 Engine) 70003506 Gasket, Fuel Cap (Part of 70003508 Cap

1 Strainer/Filter, Fuel Cap 7027395 Strainer (2000230 Engine)

70003509 Strainer (1001127719 Engine)

211 1 Tank, Fuel Options:

70000944 Tank (2000230 Engine) 70003510 Tank (1001127719 Engine) 70003505 1 Fitting, Fuel Tank Outlet (1001127719 Engine) 70003507 1 O-Ring (Used at Fuel Tank Outlet) (1001127719 Engine)

3121199 T350 & T500J 1-75

Page 84

SECTION 1 FRAME

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

212 1 Coil, Charging Options (Not Shown):

7027396 Coil (2000230 Engine)

Use 7027396 Coil (1001127719 Engine) (was p/n 70003515)

7027397 1 Ignition Less Charging Coil (2000230 Engine) (Not Shown)

70003516 1 Coil, Ignition (1001127719 Engine) (Not Shown)

1 Suppressor, Noise Option (Not Shown):

7027398 Suppressor (2000230 Engine) 70003514 Suppressor (1001127719 Engine) 70003517 1 Wiring Harness (1001127719 Engine) (Not Shown)

213 1 Decal - Caution (Not Shown - Located Near Exhaust Outlet)

7027399 Decal (2000230 Engine) 70003531 Decal (1001127719 Engine)

7027600 1 Decal - Oil Level Mark (2000230 Engine Only) (Not Shown) 70003529 1 Decal - Choke (1001127719 Engine Only) (Not Shown) 70003530 1 Decal - Throttle Indication (1001127719 Engine Only) (Not Shown) 70003532 1 Decal - Operator Caution (1001127719 Engine Only) (Not Shown)

214 1 Muffler Options:

7027601 Muffler (2000230 Engine) 70003500 Muffler (1001127719 Engine)

1 Gasket, Exhaust Pipe to Block Options:

7027602 Gasket (2000230 Engine) 70003503 Gasket (1001127719 Engine)

7027603 1 Gasket, Exhaust Pipe to Muffler 70003504 1 Arrester, Spark (1001127719 Engine Only)

215 1 Pull Start Assembly Options (Includes Case Cover, Pulley, Recoil, Pull

Cord, Starter Ratchet, Ratchet Springs and Spring Retainer) (Not Shown):

7027604 Pull Start (2000230 Engine) 70003490 Pull Start (1001127719 Engine) 70003492 1 Rope, Recoil (1001127719 Engine Only)

216 1 Starter, Electrical Options (Not Shown):

7027605 Starter (2000230 Engine) 70003518 Starter (1001127719 Engine)

7027606 1 Contactor Assembly

217 See Note 1 Key, Shaft (Note: Not Available for Purchase) 218 1 Cover, Air Cleaner/Carburetor Options:

70001964 Cover (2000230 Engine)

See Note Cover (1001127719 Engine)

(Note: Not Available for Purchase)

1 Element, Air Cleaner Options: 70001453 Element (2000230 Engine) 70001453 Element (1001127719 Engine) (Includes Element, Outside Band Fil-

ter and Grommet)

7027372 Filter, Outer Band (1001127719 Engine Only) (Part of p/n

70001453)

1 Gasket, Air Cleaner to Carburetor Options:

See Note Gasket (2000230 Engine)

(Note: Not Available for Purchase)

70003497 Gasket (1001127719 Engine)

1-76 T350 & T500J 3121199

Page 85

SECTION 1 FRAME

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

219 1 Nut, Air Cleaner Options:

See Note Nut (2000230 Engine) (Note: Not Available for Purchase) 70003498 Nut, Housing/Cover (1001127719 Engine) 70003499 Nut, Filter (1001127719 Engine)

220 1 Shield, Muffler Cover Options:

70002738 Shield (2000230 Engine) 70003501 Shield (1001127719 Engine)

221 70003502 1 Cap, Muffler Cover 222 70003521 1 Key Switch (1001127719 Engine) (Not Shown)

70003522 1 Fuse 5A (1001127719 Engine) (Not Shown) 70003550 1 Key (1001127719 Engine) (Not Shown) 70003520 1 Rectifier (1001127719 Engine) (Not Shown)

3121199 T350 & T500J 1-77

Page 86

SECTION 1 FRAME

FIGURE 1-23. BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES)

(PRIOR TO SN 0030001804)

1-78 T350 & T500J 3121199

Page 87

SECTION 1 FRAME

FIGURE 1-23. BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES) (PRIOR TO SN

0030001804)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref BATTERIES INSTALLATION 0273662 Ref T350 without Drive Option J 9984274 Ref T350 with Drive Option E 0273947 Ref T500J without Drive Option K 9984274 Ref T500J with Drive Option E

1 0100011 AR Compound, Locking 2 0100048 AR Grease, Dielectric 3 0100051 AR Grease, Battery Terminal 4 0400215 4 Battery - 6V/220Amp 5Not Used 6 0641412 2 Bolt 1/4in-20NC x 1-1/2in 7Not Used 8 3311402 2 Nut, Jam 1/4in-20NC

9Not Used 10 4240177 4 Strap, Tie-Down (was p/n 4240169 &p/n 4240174) 11 4420038 80in/2m Tape, Rubber 12 4711400 2 Flatwasher 1/4in Thin 13 1 Battery Cables Kit (Not Shown - See ELECTRICAL SECTION

for Breakdown) 4923020 Without Drive Option 4923428 With Drive Option

14 1701644 1 Decal - Battery Charger (Not Shown - DECAL SECTION For

Location)

15 1702155 1 Decal - Battery Disconnect (Prior to SN 0030001498)

Ref CONTACTOR INSTALLATION 0275442 Ref Without Drive Option B 0275536 Ref With Drive Option B

101 0275439 1 Contactor Assembly A

101A 2400087 1 Fuse - 300 Amp

2400088 1 Fuseholder

101B 3576773 1 Bar, Clamping 101C 0903560 1 Bracket, Contactor Mount 101D 3740150 1 Relay 101E 4923545 1 Cable, Electrical (Fuse to Battery B+) (Not Shown - See

ELECTRICAL SECTION for Breakdown)

101F 4923570 1 Cable, Electrical

102 4220306 1 Pad, Battery 103 1702155 1 Decal, Battery Disconnect 104 3576777 1 Plate, Tie 105 0641416 1 Bolt 1/4in-20NC x 2in 106 4923544 1 Cable, Battery (Not Shown - See ELECTRICAL SECTION for

Breakdown) 107 0100048 AR Grease, Dielectric (Not Shown) 108 3300506 2 Nut, Acorn 5/16in-24 109 2820247 AR Heatshrink (Not Shown)

3121199 T350 & T500J 1-79

Page 88

SECTION 1 FRAME

104

113

109

PRIOR TO

SN 0030003105

PRIOR TO

SN 0030003105

TO PRESENT

106

105

102 107 112

101

110

BATTERY

201412137

114

103 108 111

FIGURE 1-24. BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES)

(SN 0030001804 TO PRESENT)

1-80 T350 & T500J 3121199

Page 89

SECTION 1 FRAME

FIGURE 1-24. BATTERIES INSTALLATION (ELECTRIC POWERED MACHINES) (SN

0030001804 TO PRESENT)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref BATTERIES INSTALLATION 0275709 Ref T350/T500J without Drive Option (Prior to SN 0030001896) B 0275718 Ref T350/T500J with Drive Option E

1 0100048 AR Grease, Dielectric 2 0100051 AR Grease, Battery Terminal 3Not Used 4 0400215 4 Battery - 6V/220Amp 5 1701644 1 Decal - Battery Charger (Not Shown - DECAL SECTION For

Location) 6 1702155 1 Decal - Battery Disconnect 7 3300506 2 Nut, Acorn 5/16in-24 8 4220306 1 Pad, Battery (Prior to SN 0030003105 Only) 9 4240177 4 Strap, Tie-Down (Prior to SN 0030003105 Only)

10 4420038 80in/2m Tape, Rubber 11 1 Battery Cables Kit (Not Shown - See ELECTRICAL SECTION

for Breakdown)

4923020 Without Drive Option

4923428 With Drive Option 12 0630541 8 Bolt, Battery Hold-Down (SN 0030003105 to Present Only) 13 3311608 8 Nut, Serrated 3/8in-16NC (SN 0030003105 to Present Only) 14 0100011 AR Compound, Locking

15 to 19 Not Used

20 1001104509 4 Plate, Hold-Down (SN 0030003105 to Present Only)

0275439 Ref CONTACTOR INSTALLATION B

101 0630468 2 Screw 5/16in-18NC x 1in 102 0641407 2 Bolt 1/4in-20NC x 7/8in 103 0721004 2 Screw, Machine #10-24NC x 1/2in 104 0903560 1 Bracket, Contactor Mount 105 2400087 1 Fuse - 300 Amp 106 2400088 1 Fuseholder 107 3311405 2 Locknut 1/4in-20NC 108 3311005 2 Locknut #10-24NC 109 3576773 1 Bar, Clamping 110 3740150 1 Relay 111 4711000 2 Flatwasher #10 Thin 112 4711400 2 Flatwasher 1/4in Thin 113 4923545 1 Cable, Electrical (Fuse to Battery B+) (See ELECTRICAL

SECTION for Breakdown)

114 4923570 1 Cable, Electrical

3121199 T350 & T500J 1-81

Page 90

SECTION 1 FRAME

FIGURE 1-25. MAC BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINES)

1-82 T350 & T500J 3121199

Page 91

SECTION 1 FRAME

FIGURE 1-25. MAC BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0400164 Ref MAC BATTERY ASSEMBLY C

1 7020620 1 Transformer 2 7018553 1 Card, Circuit 3 7018554 1 Shunt Assembly 4 7018505 1 Relay, Interlock 5 7018555 2 SCR Rectifier 6 7011596 1 Varistor 7 7011638 1 AC Cord Assembly 8 7018556 1 Connector, Strain Relief - Elbow 9 7018567 1 DC Harness Assembly

9A 4460424 1 Connector, Male - 2 Position

4460267 2 Pin, Male 9B 7011528 1 Connector, Strain Relief 10 7018514 1 Breaker, Circuit - AC 11 7011509 1 Breaker, Circuit - DC

0274340 Ref BATTERY CHARGER INSTALLATION A

101 0100011 AR Compound, Locking 102 0400164 1 Battery Charger Assembly (Includes Items 1-11) 103 0641406 4 Bolt 1/4in-20NC x 3/4in 104 4751400 4 Flatwasher 1/4in Regular

3121199 T350 & T500J 1-83

Page 92

245

101

SECTION 1 FRAME

FIGURE 1-26. DELTA-Q & PRO CHARGING BATTERY CHARGER ASSEMBLIES (ELECTRIC

POWERED MACHINES)

1-84 T350 & T500J 3121199

Page 93

SECTION 1 FRAME

FIGURE 1-26. DELTA-Q & PRO CHARGING BATTERY CHARGER ASSEMBLIES (ELECTRIC

POWERED MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref BATTERY CHARGER INSTALLATION

0274380 Ref ANSI & CSA Specs without Optional Generator B

1001131393 Ref ANSI & CSA Specs with Optional Generator A

0274380 Ref ANSI Export Specs B

0274731 Ref CE, Australian & South Africa Specs B

1 1 Battery Charger Assembly Options (No Serviceable Parts

Available): 1A 0400236 Charger - All Specs Except ANSI Spec (Delta-Q) 1A 0400236 Charger - ANSI Spec without Optional Generator (Delta-Q) 1B 1001134313 Charger - ANSI Spec with Optional Generator (Pro-Charging

Systems) (was p/n 1001133506) 2 0641406 4 Bolt 1/4in-20NC x 3/4in 3 1 AC Extension Cord

1060688 ANSI & ANSI Export Specs (With Standard 110V ANSI Plug) 1060689 CE, Australian & South Africa Specs (With Locally Supplied

Plug) 4 3311405 4 Locknut 1/4in-20NC 5 4711400 8 Flatwasher 1/4in Thin

101 Use 2915230 1 BATTERY CHARGER REPROGRAM CONTROLLER (WAS P/N

1600466)

3121199 T350 & T500J 1-85

Page 94

91112

4 8

1453

SECTION 1 FRAME

FIGURE 1-27. TAILLIGHTS & MARKERS INSTALLATION (ANSI & ANSI EXPORT SPECS)

1-86 T350 & T500J 3121199

Page 95

SECTION 1 FRAME

FIGURE 1-27. TAILLIGHTS & MARKERS INSTALLATION (ANSI & ANSI EXPORT SPECS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TAILLIGHTS AND MARKERS INSTALLATION 0273665 Ref T350 E 0273934 Ref T500J E

1 71101 1 Bracket, License Plate 2 71906 1 Taillight Assembly with License Plate Light (Road Side)

7026341 1 Bulb, Stop/Turn/Taillight 7026342 1 Bulb, Side Marker Light 7026343 1 Lens, Red Taillight 7026340 1 Lens, Red Side Marker

3 71907 1 Taillight Assembly without License Plate Light (Curb Side)

7026341 1 Bulb, Stop/Turn/Taillight 7026342 1 Bulb, Side Marker Light 7026343 1 Lens, Red Taillight 7026340 1 Lens, Red Side Marker

4 0761012 4 Screw 10mm x 25mm 5 0903107 2 Bracket, Taillight 6 2920113 1 Taillight, Boom 7 2920179 2 Side Marker Light/Reflector Assembly

7027717 2 Bulb (1 Per Assembly)

8 3291005 4 Locknut 10mm

9 3311005 6 Locknut #10-24NC 10 0721006 4 Screw #10-24NC x 3/4in 11 3911040 2 Screw #10-24NC x 2-1/2in 12 3960461 1 Seal, Gasket 13 4751000 6 Flatwasher #10 Regular 14 4812000 8 Flatwasher 10mm 15 1 Harness, Lights (Not Shown - See ELECTRICAL SECTION for

Breakdown): 4923148 T350 4923149 T500J

3121199 T350 & T500J 1-87

Page 96

SECTION 1 FRAME

109

102

115

110

111

114

104

112

113

103

114

111

110

115

101

107

110

510

106

110

115

101

105

FIGURE 1-28. TAILLIGHTS & MARKERS INSTALLATION (AUSTRALIAN, CE & SOUTH

AFRICAN SPECS)

1-88 T350 & T500J 3121199

Page 97

SECTION 1 FRAME

FIGURE 1-28. TAILLIGHTS & MARKERS INSTALLATION (AUSTRALIAN, CE & SOUTH

AFRICAN SPECS)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TAILLIGHTS AND MARKERS INSTALLATION 0274739 Ref T350 Australian & South Africa Spec A 0273666 Ref T350 CE Spec A 0274740 Ref T500J Australian & South Africa Spec A 0274430 Ref T500J CE Spec A

1 1 Rear Light Bracket Assembly Options (See Items 101-115 for

Breakdown): 0274741 Australian & South Africa Spec 0274538 CE Spec

2 0274539 2 Side Marker Light Assembly

2920182 2 Lamp Only (1 Per Assembly)

70000095 2 Bulb (1 Per Assembly) 3 0641406 4 Bolt 1/4in-20NC x 3/4in 4 0641407 2 Bolt 1/4in-20NC x 7/8in 5 0641608 4 Bolt 3/8in-16NC x 1in 6 3311005 4 Locknut #10-24NC (T500J Only) 7 3311405 6 Locknut 1/4in-20NC 8 3311605 4 Locknut 3/8in-16NC 9 AR Reflector (White) Options:

Not Required 0 T350

3700014 2 T500J 10 3911010 2 Screw #10-24NC x 5/8in (T500J Only) 11 4711400 8 Flatwasher 1/4in Thin 12 4751000 2 Flatwasher #10 Regular (T500J Only) 13 4751600 6 Flatwasher 3/8in Regular 14 AR Light Assembly, Rear Options:

0274638 1 T350 Australian & South Africa Spec

Not Required 0 T350 CE Spec

0274638 1 T500J Australian & South Africa Spec

0274638 1 T500J CE Spec

2920189 1 Lamp Only (1 Per Assembly)

70000098 1 Bulb (1 Per Assembly)

Ref REAR LIGHT BRACKET ASSEMBLY 0274741 Ref Australian & South Africa Spec B 0274538 Ref CE Spec A

101 0700408 8 Bolt 4mm x 16mm 102 0700410 4 Bolt 4mm x 20mm 103 0721006 4 Screw, Machine #10-24NC x 3/4in 104 0903177 2 Plate, Reflector Mounting 105 0940136 1 Bar, Light 106 2920180 2 Taillight

70000092 2 Bulb (Double Contact) (1 Per Assembly) 70000093 2 Bulb (Single Contact) (1 Per Assembly)

3121199 T350 & T500J 1-89

Page 98

SECTION 1 FRAME

FIGURE 1-28. TAILLIGHTS & MARKERS INSTALLATION (AUSTRALIAN, CE & SOUTH

AFRICAN SPECS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

107 1 Foglight, Rear Options:

Not Required 0 Australian & South Africa Spec

2920181 1 CE Spec

70000093 1 Bulb

108 2920183 1 License Plate Light

70000096 1 Bulb (1 Per Assembly)

109 2920184 2 Side Marker Light

70000097 2 Bulb (1 Per Assembly) 110 3290405 12 Locknut 4mm 111 3311005 8 Locknut #10-24NC 112 3700012 2 Reflector, Red Triangle 113 3911010 4 Screw #10-24NC x 5/8in 114 4751000 12 Flatwasher #10 Regular 115 4811400 16 Flatwasher 4mm

1-90 T350 & T500J 3121199

Page 99

SECTION 1 FRAME

FIGURE 1-28. TAILLIGHTS & MARKERS INSTALLATION (AUSTRALIAN, CE & SOUTH

AFRICAN SPECS) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121199 T350 & T500J 1-91

Page 100

SECTION 1 FRAME

107

104

109

106

205

208

209

212

207

211

201

210

204

206

203

202

101

103

102

108

105

11912

CE SPEC

ONLY

131413

FIGURE 1-29. SPARE TIRE & WHEEL CHOCKS INSTALLATIONS (OPTIONAL)

1-92 T350 & T500J 3121199

JLG T500J Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. TONGUE JACK INSTALLATIONS (WITH POLY JACK TIRES)

FIGURE 1-2. TONGUE JACK INSTALLATIONS (WITH PNEUMATIC JACK TIRES)

FIGURE 1-12. ELECTRIC BRAKE & AXLE ASSEMBLY

FIGURE 1-13. HYDRAULIC BRAKE ASSEMBLY (ANSI & ANSI EXPORT SPEC MACHINES)

FIGURE 1-14. MECHANICAL BRAKE ASSEMBLY (CE SPEC MACHINES)

FIGURE 1-15. CHASSIS DRIVE INSTALLATION (OPTIONAL)

FIGURE 1-16. DRIVE ENABLE VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

FIGURE 1-17. DRIVE DIRECTIONAL VALVE ASSEMBLY (USED WITH DRIVE OPTION ONLY)

FIGURE 1-18. DRIVE MOTOR ASSEMBLY (USED WITH DRIVE OPTION ONLY)

FIGURE 1-19. CONTROL MODULES AND VALVES INSTALLATION

FIGURE 1-20. CONTROL VALVE ASSEMBLY (ELECTRIC POWERED MACHINES)

FIGURE 1-21. CONTROL VALVE ASSEMBLY (GAS POWERED MACHINES)

FIGURE 1-22. HONDA ENGINE INSTALLATION (GAS POWERED MACHINES)

FIGURE 1-25. MAC BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINES)

FIGURE 1-27. TAILLIGHTS & MARKERS INSTALLATION (ANSI & ANSI EXPORT SPECS)

FIGURE 1-29. SPARE TIRE & WHEEL CHOCKS INSTALLATIONS (OPTIONAL)