JGL 45

Illustrated Parts Manual
Models
40ic
45ic
P/N
3120853
September 30 2011
REVISION LOG
August 1, 1996 - Original Issue of Manual

August 15, 1997 - Revised Manual
December 1, 2000 - Revised Manual (Edited to B/M 0010531 Revision 21 & B/M 0010530 Revision 22)
August 16, 2005 - Revised Manual
January 31, 2008 - Revised Manual
September 30, 2011 - Revised Manual
3120853 A
REVISION LOG
B 3120853
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.

SECTION 1 -FRAME..............................................................................................................1-1
1-1 FRAME AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 TIRE AND WHEEL DRIVE INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-4 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-5 DRIVE BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-6 VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED). . . .1-18
1-7 ACCESSORY VALVE ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
1-8 VANGUARD GAS ENGINE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1-9 DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES). . . . . . . . .1-30
1-10 YANMAR DIESEL ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
1-11 PISTON PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
1-12 GEAR PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
1-13 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
1-14 FRAME COVERS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44
SECTION 2 -TURNTABLE................................................................................................... 2-1

2-1 TURNTABLE MOUNTED COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-3 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS. . . . . . . . . . . . . . . . . . . .2-8
2-4 SWING MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-5 GROUND CONTROL COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-6 TURNTABLE AND HOODS INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
SECTION 3 -BOOM............................................................................................................. 3-1

3-1 BOOM AND LIMIT SWITCHES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 MAIN BOOM COMPONENTS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
SECTION 4 -PLATFORMS................................................................................................... 4-1

4-1 PLATFORM COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2 ROTATOR MOTOR/PUMP/TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3 PLATFORM CONSOLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-4 CONTROLLER ASSEMBLY - DRIVE/STEER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
SECTION 5 -CYLINDER...................................................................................................... 5-1

5-1 UPPER LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 MID LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-3 LOWER LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-4 MASTER CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-5 PLATFORM ROTATOR CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-6 SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-7 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-8 TELESCOPE CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-9 OPTIONAL CYLINDER BELLOWS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
SECTION 6 -HYDRAULICS.................................................................................................. 6-1

6-1 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-2 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-3 HYDRAULIC DIAGRAM - MANUAL ASCENT (DUTCH AND GERMAN SPEC). . . . . . . .6-10
3120853 i
TABLE OF CONTENTS (CONTINUED)
FIGURE NO. TITLE PAGE NO.

SECTION 7 -ELECTRICAL.................................................................................................. 7-1
7-1 ELECTRICAL DIAGRAMS AND DIAGRAM LIST.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 HARNESS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
SECTION 8 -DECALS ......................................................................................................... 8-1

8-1 DECALS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SECTION 9 -RECOMMENDED SERVICE PARTS STOCK ................................................ 9-1
SECTION 10 -SPECIAL OPTIONS.................................................................................... 10-1
ii 3120853
SECTION 1 FRAME
S
E
TABLE OF CONTENTS
C
FIGURE DESCRIPTION PAGE
T
I
O
1-1 FRAME AND STEERING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 TIRE AND WHEEL DRIVE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

N
1-3 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1
1-5 DRIVE BRAKE ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-6 VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED). . . . . . . . 1-18
F
1-7 ACCESSORY VALVE ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 R
1-8 VANGUARD GAS ENGINE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 A
1-9 DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES). . . . . . . . . . . . . 1-30 M
1-10 YANMAR DIESEL ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 E
1-11 PISTON PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1-12 GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1-13 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
1-14 FRAME COVERS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
3120853 1-1
S SECTION 1 FRAME
E FIGURE 1-1. FRAME AND STEERING INSTALLATIONS.
C
T
I
O
N
F
R
A
M
E
1-2 3120853
SECTION 1 FRAME S
E
FIGURE 1-1. FRAME AND STEERING INSTALLATIONS.
C
T
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
FRAME WELDMENT OPTIONS: 1
2360402 Model 40ic I
2360403 Model 45ic
O
0256855 STEERING AND SPINDLES INSTALLATION Ref. –/3 N
1 2780201 Hub Assembly (See Items 101-105 for Breakdown)
Spindle Weldment (See Items 201-202 for
2
1
2 4130319 2
Breakdown)
3
4
3421988
3450810
Kingpin
Pin, Cotter 1/4" x 2 1/3"
2
2
F
5 3313003 Nut, Slotted 1 1/4 -7NC 2 R
6 0440162 Washer, Thrust 2 A
7
8
0642016
3312005
Bolt 5/8"-11NC x 2"
Locknut 5/8"-11NC
2
2
M
9 3841146 End, Rod 2 E
10 3322002 Nut, Jam 5/8"-18NF 2
Steer Cylinder Assembly (See Section 5 for
11 Use 1683698 1
Breakdown) (Was P/N 1683487 Prior to S/N 37950)
12 3340644 Pad, Wear 1
13 3020022 Grease A/R
14 4070809 Shim A/R
15 4712400 Flatwasher 7/8" 2
16 3450506 Pin, Cotter 2
17 3780182 O-Ring 4
18 0641510 Bolt 5/16"-18NC x 1 1/4" 1
19 4751500 Flatwasher 5/16" 1
20 3311505 Locknut 5/16"-18NC 1
21 0630016 Bolt, Wheel 1/2"-20NF x 1" 12
22 4060808 Trim 2 Ft/.61m
23 1120457 Cap, Dust 2
2780201 HUB ASSEMBLY Ref. D
101 Kit Cup, Bearing - Inner (1 Per Hub) 2

102 Kit Cone, Bearing - Inner (1 Per Hub) 2
103 Kit Cup, Bearing - Outer (1 Per Hub) 2
104 Kit Cone, Bearing - Outer (1 Per Hub) 2
105 Kit Seal (1 Per Hub) 2
––––––––––
2900842 Bearing Kit (Includes Item 101-105) 2
SPINDLE ASSEMBLY Ref.
201 0961621 Bushing (2 Per Spindle) 4

202 3322403 Nut, Slotted 7/8"-14NF (1 Per Spindle) 2
3120853 1-3
S SECTION 1 FRAME
E
C FIGURE 1-1. FRAME AND STEERING INSTALLATIONS. (CONTINUED)
T
0253613 AXLE INSTALLATION Ref. D
I
O 301 4844324 Axle Weldment (Includes Item 301A) 1
N
301A 0961621 Bushing 2
302 0940048 Bumper 2
303 4070832 Shim 1/2"-13mm A/R
1 304
305
4070833
0641814
Shim 1/16"-1.6mm
Bolt 1/2"-13NC x 1 3/4"
A/R
4
306 3311805 Locknut 1/2"-13NC 4
F 307 0641608 Bolt 3/8"-16NC x 1" 1
R
308 3841143 Pin, Keeper 1
309 3422170 Pin, Axle 1
A 310 4740247 Washer, Thrust 2
M 311
312
3451210
3340450
Pin, Cotter 3/8" x 2 1/2"
Pad, Wear
1
2
E 313 4070834 Shim 1/4"-6.4mm A/R
314 4070835 Shim 1/16"-1.6mm A/R
315 0641610 Bolt 3/8"-16NC x 1 1/4"" 4
316 4751600 Flatwasher 3/8" 4
317 4070853 Shim 1/32"-.8mm A/R
–––––––––––
0100011 Loctite #242 (Not Shown) A/R
1-4 3120853
SECTION 1 FRAME S
FIGURE 1-1. FRAME AND STEERING INSTALLATIONS. (CONTINUED) E
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. C
T
I
O
N
F
R
A
M
E
3120853 1-5
S SECTION 1 FRAME
E FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.
C
T
I
O
N
F
R
A
M
E
1-6 3120853
SECTION 1 FRAME S
E
FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.
C
T
0255994 WHEEL DRIVE INSTALLATION Ref. A
I
1 2780219 Drive Hub Assembly (See Figure 1-3 For Breakdown) 2
O
N
Drive Motor Assembly (See Figure 1-4 for
2 3160158 2
Breakdown)
Drive Brake Assembly (See Figure 1-5 for
3 0920084 2
Breakdown)
4 3321801 Nut 1/2"-20NF 18 1
5 4711800 Flatwasher 1/2" Narrow 22
6
7
4300092
4761800
Stud 1/2"-13NC x 5 1/2"
Lockwasher 1/2"
4
4
F
8 3311801 Nut 1/2"-13NC 8 R
9 0100019 Loctite #271 (Not Shown) A/R
A
M
10 0630016 Bolt, Wheel 12
E
TIRE AND WHEEL INSTALLATIONS - MODEL 40IC Ref.
0256837 G78-15 X28 FOAM-FILLED TIRE WITH 6" WIDE RIM Ref. –
0256643 G78-15 X28 FOAM-FILLED TIRE WITH 8" WIDE RIM Ref. –
0256968 10 X 16.5 FOAM-FILLED TIRE Ref. –
0254874 SOLID - NON-MARKING TIRE Ref. –
Note: Assemblies may require ballast/foam fill-
ing to manufacturer’s specifications prior to
installing on a machine. Refer to Operation &
Safety or Service & Maintenance Manuals. Pur-
chase individual tire and/or rim only if able to
foam fill tire & wheel assembly, otherwise, pur-
chase complete assembly.
Tire and Wheel Assembly (G78-15 X28 Foam-Filled

100 0256836 4
with 6" Wide Rim) (Sold As An Assembly Only)
Tire and Wheel Assembly (G78-15 X28 Foam-Filled
0256642 4
with 8" Wide Rim) (Sold As An Assembly Only)
0256953 Tire and Wheel Assembly (10 X 16.5 Foam-Filled 2
Right Side) (Sold As An Assembly Only)
Left Side) (Sold As An Assembly Only)
3120853 1-7
S SECTION 1 FRAME
E FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS. (CONTINUED)
C FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
T TIRE AND WHEEL INSTALLATIONS - MODEL 45IC Ref.
I
0254866 LT215/85RI6 FOAM-FILLED TIRE Ref. –
0256968 10 X 16.5 FOAM-FILLED TIRE Ref. –
O 0254874 SOLID - NON-MARKING TIRE (OPTIONAL) Ref. –
N Note: Assemblies may require ballast/foam fill-

ing to manufacturer’s specifications prior to
installing on a machine. Refer to Operation &
1
Safety or Service & Maintenance Manuals. Pur-
chase individual tire and/or rim only if able to
foam fill tire & wheel assembly, otherwise, pur-
chase complete assembly.
F
R 0254865
Tire and Wheel Assembly (LT215/85RI6 Foam-Filled)
(Sold As An Assembly Only)
4
A 0256953 Tire and Wheel Assembly (10 X 16.5 Foam-Filled 2
M Right Side) (Sold As An Assembly Only)
E
Left Side) (Sold As An Assembly Only)
4520159 Tire and Wheel Assembly (Solid - Non-Marking) 4
(Sold As An Assembly Only)
HUBCAP INSTALLATION - 40IC (G78-15 X28 TIRES)

0256832 Ref. –
(OPTIONAL)
HUBCAP INSTALLATION - 45IC (LT215/85RI6 TIRES)
0254590 Ref. C
(OPTIONAL)
201 Hubcap Options: 4

1670808 Model 40ic
1670810 Model 45ic
202 J-Bolt 5/16"-18NC Options: 8
0630513 Model 40ic
0641510 Model 45ic
203 4761500 Lockwasher 5/16" 8
204 3300356 Nut, Acorn 5/16"-18NC ) (40ic Only) 8
205 3311501 Nut 5/16"-18NC (40ic Only) 8
1-8 3120853
SECTION 1 FRAME S
E
FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS. (CONTINUED)
C
T
I
O
N
F
R
A
M
E
3120853 1-9
S SECTION 1 FRAME
E FIGURE 1-3. DRIVE HUB ASSEMBLY.
C
T
I
O
N
F
R
A
M
E
1-10 3120853
SECTION 1 FRAME S
E
FIGURE 1-3. DRIVE HUB ASSEMBLY.
C
T
2780219 DRIVE HUB ASSEMBLY 1
I
1 7010486 Spindle 1
O
N
2 Kit Seal, Lip 1
3 7000255 Cup, Bearing (Outer) 1
4 7000256 Cone, Bearing (Outer) 1
5
6
7000257
7000258
Cup, Bearing (Inner)
Cone, Bearing (Inner)
1
1
1
7 7000259 Housing 1
8 7000232 Washer, Thrust 1 F
R
9 Kit Ring, Retaining 1
10 7000242 Plug, Pipe - 1/4" NPTF 2
11 7000241 Stud, Wheel 1/2"-20NF 9 A
12
13
7001952
7000246
Plug, Pipe 3/4" NPTF
Gear, Internal
1
1
M
–––––––––– E
Carrier Assembly 1
14 7001931 Carrier 1
15 7001985 Washer, Tanged Thrust 6
16 7010408 Bearing, Needle 96
17 7000263 Spacer, Thrust 3
18 7001911 Shaft, Planet 3
19 7007643 Gear, Cluster 3
20 7010474 Rollpin 3
21 7000203 Gear, Ring 1
22 Kit O-Ring 2
23 7000209 Cover, Input 1
24 7017001 Gear, Sun 1
25 Not Used
26 7007642 Washer, Thrust 1
27 Kit Washer, Thrust 2
28 7000217 Bolt, Hex 8
29 7000214 Bolt, Shoulder 4
30 7000242 Plug, Pipe 1/4" NPTF 1
––––––––––
2900661 Seal Kit (Includes Items 2,9,22 and 27) 1
3120853 1-11
S SECTION 1 FRAME
E FIGURE 1-4. DRIVE MOTOR ASSEMBLY.
C
T
I
O
N
F
R
A
M
E
1-12 3120853
SECTION 1 FRAME S
E
FIGURE 1-4. DRIVE MOTOR ASSEMBLY.
C
T
3160158 DRIVE MOTOR ASSEMBLY Ref. A
I
O
N
2 Kit Seal, Shaft 1
3 7004906 Washer 1
5
6
7004907
7004908
Race, Thrust
Bearing
2
1
1
7 7004974 Shaft, Drive 1
8 7004910 Bearing 1 F
R
9 7007875 Housing Assembly (Includes Item 8) 1
10 7007876 Camplate 1
11 7007880 Rotating Kit Assembly 1 A
12
13
7004917
Kit
Bearing
O-Ring
1
1
M
14 7007878 Backplate Assembly (Includes Item 12) 1 E
15 7007879 Bolt 6
––––––––––
2900714 Repair Kit Includes Items 1,2,4 and 13) 1
3120853 1-13
S SECTION 1 FRAME
E FIGURE 1-5. DRIVE BRAKE ASSEMBLY.
C
T
I
O
N
F
R
A
M
E
1-14 3120853
SECTION 1 FRAME S
FIGURE 1-5. DRIVE BRAKE ASSEMBLY. E
FIG & ITEM #
1
PART NUMBER
Kit Seal, Oil
DESCRIPTION QTY.
1
REV.
C
2 Kit Bearing 1 T
I
3 7007977 Ring, Retaining 1
4 Not Used
5
6
Not Used
Not Used
O
7 Not Used N
8 Not Used
9 Not Used
10
11
Not Used
Kit Seal, Case 1
1
12 Not Used
13
14
7007986
Not Used
Cover 1
F
15 7011716 Ring, Retainer 1 R
16
17
Not Used
7007987 Pin, Dowel 2 A
18 Kit Ring, Back-up 1 M
E
19 Kit O-Ring 1
20 Kit Ring, Back-up 1
21 Kit O-Ring 1
22 Kit Rotor 2
23 Kit Stator 2
24 Not Used
25 Not Used
26 Not Used
27 Not Used
28 Kit O-Ring 2
29 7007933 Gasket 2
––––––––––
2900766 Seal Kit (Includes Items 1,11,18,19,20,21,28 and 29) 1
2900768 Bearing Kit (Includes Items 1,2,11,28 and 29) 1
0920084 DRIVE BRAKE ASSEMBLY - MICO PRIOR TO S/N 33476 Ref. –

0920110 S/N 33476 TO PRESENT Ref. A
51 Shaft Options: 1
7011712 Prior to S/N 33476
7011720 S/N 33476 to Present
52 Spring (Inner) Options: 6
7007979 Prior to S/N 33476
7007970 S/N 33476 to Present
53 Spring (Outer) Options: 6
7007980 Prior to S/N 33476
7018602 S/N 33476 to Present
54 Housing Options: 1
7011713 Prior to S/N 33476
7018605 S/N 33476 to Present
55 Bolt, Washer Head Options: 4
7007985 Prior to S/N 33476
7018607 S/N 33476 to Present
56 Guide, Spring Options: 1
7011717 Prior to S/N 33476
7018606 S/N 33476 to Present
57 Piston Options: 1
7007923 Prior to S/N 33476
7018603 S/N 33476 to Present
3120853 1-15
S SECTION 1 FRAME
E
C FIGURE 1-5. DRIVE BRAKE ASSEMBLY. (CONTINUED)
T
58 Plate, Return 1
I Kit
O
7011715 Separator Assembly 2
7011714 Pin 4
N 59
7007983
7018609 Plug
Separator 2
1
7018608 Lining Kit (Includes Items 58,11,22,23,28 and 29) 1
1
F
R
A
M
E
1-16 3120853
SECTION 1 FRAME S
FIGURE 1-5. DRIVE BRAKE ASSEMBLY. (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120853 1-17
S SECTION 1 FRAME
E FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME
C MOUNTED).
T
I
O
N
F
R
A
M
E
1-18 3120853
SECTION 1 FRAME S
FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED). E
C
T
0255994 VALVES INSTALLATION Ref. A
I
1 to 10 Not Used
O
N
12 4640969 Accessory Valve Assembly (See Figure 1-7 for 1
Breakdown)
13
14
0641506
4751500
Bolt 5/16"-18NC x 3/4"
Flatwasher 5/16"
3
7
1
15 3600208 Auxiliary Pump Assembly 1
15A 7013710 Motor, Replacement 1 F
R
7013753 Brush Kit - 7013710 Motor 1
15B 7013711 Coupling 1
15C 7013712 Pump, Replacement 1 A
16
17
0641606
4751600
Bolt 3/8’-16NC x 3/4"
Flatwasher 3/8"
2
2
M
18 3539716 Plate, Valve Mounting 1 E
19 0641508 Bolt 5/16"-18NC x 1" 2
20 3311505 Locknut 5/16"-18NC 4
21 4640976 Flow Divider Valve Assembly 1
21A 7017404 Cartridge, Flow Divider Valve 1
7017405 Seal Kit - 7017404 Valve 1
21B 7017406 Plug, Check 1
7012993 Orifice 1
22 0641526 Bolt 5/16"-18NC x 3 1/4" 2
23 4566987 Spacer 2
24 2120146 Filter Assembly 1
24A 2120150 Element, Filter 1
24B 7016312 Switch 1
25 0641405 Bolt 1/4"-20NC x 5/8" 4
27 4640974 Brake Release Valve Assembly 1
Not Available Seal Kit - 4640974 Valve 1
28 4640005 Valve, Needle 1
29 2900062 Valve Mounting Kit 1
31 0641414 Bolt 1/4"-20NC x 1 3/4" 2
32 3311405 Locknut 1/4"-20NC 2
33 4060807 Flex-Trim 30in/76cm
34 1703030 Decal - Close (Tow Valve) 1
0256405 TILT INDICATOR INSTALLATION Ref. B
101 4360442 Switch, Tilt Indicator 1

102 0641406 Bolt 1/4"-20NC x 3/4" 2
103 3311405 Locknut 1/4"-20NC 2
3120853 1-19
S SECTION 1 FRAME
E
C FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED).
T
0256307 BATTERY AND CABLES INSTALLATION Ref. C
I
O 201 0400003 Battery 1
N
202 0400002 Hold-down, Battery 1
202 A 2910479 Hold-down, Clips (Not Shown) 4
203 3980003 Seat, Battery 1
1 204
205
0630505
3300371
Bolt, Tie-down
Wingnut 1/4"-20NC
2
2
206 1060623 Cable, Battery (Positive) 1
F 207 1060624 Cable, Battery (Negative) 1
R
208 1060620 Cable, Battery (Auxiliary Pump) 1
209 3300401 Nut, Brass 1
A 210 0641508 Bolt 5/16"-18NC x 1" 1
M 211
212
4791500
3311505
Starwasher 5/16"
Locknut 5/16"-18NC
2
1
E 213 4751400 Flatwasher 1/4" 4
214 4761400 Lockwasher 1/4" 2
215 3311401 Nut 1/4"-20NC 2
216 3740067 Relay, Continuous Duty 1
217 2540021 Grommet 2
218 3300220 Nut, Special 1
219 3321001 Nut #10-32NF 1
220 4761000 Lockwasher #10 1
1-20 3120853
SECTION 1 FRAME S
FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED). E
T
I
O
N
F
R
A
M
E
3120853 1-21
S SECTION 1 FRAME
E FIGURE 1-7. ACCESSORY VALVE ASSEMBLY.
C
T
I
O
N
F
R
A
M
E
1-22 3120853
SECTION 1 FRAME S
E
FIGURE 1-7. ACCESSORY VALVE ASSEMBLY.
C
T
4640969 ACCESSORY VALVE ASSEMBLY Ref. E
I
1 Not Serviced Block, Manifold 1
O
N
2 7017410 Cartridge, Solenoid Valve (Less Coil) 1
7012967 Seal Kit - 7017410 Valve 1
2A 7012944 Coil, Solenoid 1
3 7012969
7012540
Cartridge, Check Valve
Seal Kit - 7012969 Valve
1
1
1
4 7017419 Cartridge, Relief Valve 1
7012953 Seal Kit - 7017419 Valve 1 F
R
5 7012968 Cartridge, Pilot Valve 1
7012518 Seal Kit - 7012968 Valve 1
6 7010542 Cartridge, Shuttle Valve 2 A
7
7010543
7018902
Plug, Orifice - 1.5mm
2
2
M
8 7017429 Cartridge, Relief Valve 2 E
7012967 Seal Kit - 7017429 Valve 2
9 7012941 Cartridge, Solenoid Valve (Less Coil) 1
7012907 Seal Kit - 7012941 Valve 1
10 7012795 Control Valve Assembly 1
7012773 Seal Kit - 7012795 Valve 1
10B 7018912 Nut, Coil 2
11 7018913 Control Valve Assembly 1
7012773 Seal Kit - 7018913 Valve 1
11B 7018912 Nut, Coil 1
11C 7018916 Plug, Orifice - 2mm 1
12 7018905 Plug 1
3120853 1-23
S SECTION 1 FRAME
E FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
C
T
I
O
N
F
R
A
M
E
1-24 3120853
SECTION 1 FRAME S
E
FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
C
T
0255999 ENGINE ASSEMBLY AND INSTALLATION Ref. 12/N
I
1 4845223 Tray, Engine 1
O
N
2 4845238 Arm, Swing-Out 2
3 3422426 Pin 4
4 2000140 Engine - Vanguard DM700G 1
5 3600256 Piston Pump Assembly (See Figure 1-11 for
Breakdown)
1
1
6 3600199 Gear Pump Assembly (See Figure 1-12 for 1
Breakdown) 1 F
R
7 3539459 Plate, Mounting (Rear Right Side) 1
8 3539460 Plate, Mounting (Rear Left Side) 1
9 3539461 Plate, Mounting (Front) 1 A
10
11
3200381
1340057
Mount, Motor
Air Cleaner Assembly
3
1
M
11A 7015004 Element, Filter 1 E
11B 7015005 Cover Assembly 1
11C 7015006 Valve, Vacuator 1
11D 7015007 Latch 2
12 0340045 Band, Mounting 1
13 3539484 Plate, Mounting (Air Cleaner) 1
14 0641509 Bolt 5/16"-18NC x 1 1/8" 4
15 3311405 Locknut 1/4"-20NC 10
16 3620035 Radiator 1
7016606 Cap, Radiator 1
7019618 Draincock 1
17 2060027 Fan, Electric Cooling 1
7016617 Control, Thermostatic 1
18 1320026 Clamp, Exhaust 1
Pipe, Exhaust (Prior to S/N 33269) (Use 4567108 and
19 4845391 1
#109 as Replacement)
4567108 Pipe, Exhaust (S/N 33269 to Present) 1
20 3841143 Pin, Keeper 4
21 2540031 Grommet 2
22 0641406 Bolt 1/4"-20NC x 3/4" 6
23 3311505 Locknut 5/16"-18NC 12
24 0641608 Bolt 3/8"-16NC x 1" 6
25 3311605 Locknut 3/8"-16NC 6
26 0641820 Bolt 1/2"-13NC x 2 1/2" 3
27 3311805 Locknut 1/2"-18NC 3
28 0701014 Bolt, Metric M10-1.5 x 30mm 2
Actuator Assembly (Was p/n 0060037) (See Section 7
29 Use 2910000 1
for Breakdown)
30 3841315 Rod, Throttle 1
31 3220109 Muffler 1
32 0080223 Elbow, Air Intake 1
33 4740274 Washer, Snubbing 3
34 4751600 Flatwasher 3/8" 6
35 0760812 Bolt, Metric 8mm x 25mm 15
3120853 1-25
S SECTION 1 FRAME
E
C FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED)
T
36 4751500 Flatwasher 5/16" 33
I 37 0100011 Loctite #242 (Not Shown) A/R
O 38 0760605 Bolt 6mm x 10mm 8
N
39 0641508 Bolt 5/16"-18NC x 1" 4
40 2720015 Hose, Fuel Line (1/4") 92in/2.3m
41 1320022 Clamp, Hose 10
1 42
43
0641812
4751800
Bolt 1/2"-13NC x 1 1/2"
Flatwasher 1/2"
2
2
44 4891600 Washer, Hardened 2
F 45 1320031 Clamp, Hose 3
R
46 2720423 Hose, Air Intake (1 3/4") 3in/8cm
47 2750058 Hose (5/16") 1ft/30.5cm
A 48 Not Used
M 49
50
Not Used
Not Used
E 51 4751400 Flatwasher 1/4" 8
52 Not Used
53 Not Used
54 Not Used
55 1320014 Clamp, Hose 4
56 1660222 Coupling, Throttle 1
57 3321402 Nut, Jam 1/4"-28NF 1
58 Not Used
59 1660220 Swivel, Throttle 1
60 4740442 Washer, Belleville 1
61 3900217 Bolt, Socket Head Shoulder 1
62 0962031 Bushing, Flanged 1
63 Not Used
64 2220250 Fitting, Reducer 1
65 2220317 Fitting, 90° 1
66 Not Used
67 Radiator Mounting Plate Options: 1
3539477 Prior to S/N23060
4845432 S/N23060 to Present
68 0641505 Bolt 5/16"-18NC x 5/8" 2
69 0902270 Bracket, Mounting (Throttle Control) 1
70 0641408 Bolt 1/4"-20NC x 1" 4
71 Not Used
72 3539663 Plate, Mounting (Cooling Fan) 1
73 2200223 Fitting 2
74 0100020 Sealant, Pipe (Not Shown) A/R
76 1701542 Decal - Gas (Not Shown - Located on Hood) 1
77 4845338 Mount, Fuel Pump 1
78 1060221 Strap, Ground 1
79 3740080 Relay 4
80 Not Used
81 Not Used
82 4751000 Flatwasher #10 6
1-26 3120853
SECTION 1 FRAME S
E
FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED)
C
T
83 4921852 Harness, Engine 1
84 3539816 Plate, Mounting - Coolant Overflow Tank 1 I
85 4400395 Tank, Coolant Overflow 1
O
N
86 2221010 Fitting, Barbed 2
87 Not Used
88 3539929 Plate, Throttle Mounting 1
89 4160150
Spring (Used Prior to S/N23060 - Recommend #231 as
replacement)
1 1
90 2720428 Hose, Radiator (Top) 1
91
92
2720429
4711400
Hose, Radiator (Bottom)
Flatwasher 1/4" Narrow
1
13
F
93 0641405 Bolt 1/4"-20NC x 5/8" 6 R
94 0641404 Bolt 1/4"-20NC x 1/2" 4 A
95
96
0641405
4567086
Bolt 1/4"-20NC x 5/8"
Spacer, Throttle Tube
1
2
M
97 2180812 Fitting, Adaptor 1 E
98 4360405 Switch, Oil Pressure 1
99 4320002 Stud, Rubber Mounted 1
100 0641820 Bolt 1/2"-13NC x2 1/2" 2
101 4751800 Flatwasher 1/2" 2
102 0940070 Bumper, Rubber 2
103 0641516 Bolt 5/16"-18NC x 2" 1
104 4791500 Starwasher 5/16" 1
105 4060807 Flex-Trim (Not Shown - Located on Frame) 15in/38cm
107 2540017 Grommet (S/N 33269 to Present Only) 1
108 3311501 Nut 5/16"-18NC 2
109 1320239 Clamp, Loop (S/N 33269 to Present Only) 1
110 0902383 Bracket, Recovery Tank (S/N 33269 to Present Only) 1
111 4420008 Tape, Neoprene (S/N 33269 to Present Only) 7in/18cm
112 2420047 Service Indicator Kit (S/N 33269 to Present Only) 1
113 2220063 Fitting, 90° 1
114 3960389 Seal (S/N 33820 to Present Only) 1.42ft/0.44m
116 3960477 Seal Foam Gasket (S/N 33820 to Present Only) 1
2000140 ENGINE COMPONENTS Ref. D
201 7017617 Carburetor 1

7017640 Rebuild Kit - 7017617 Carburetor 1
7017641 Gasket - Air Intake to Carburetor 1
70002087 Float Assembly 1
70000209 Gasket - Carburetor Float Bowl 1
201A 7017639 Solenoid, Fuel 1
201B 7017637 Switch, Choke 1
201C 7017638 Choke, Vacuum 1
7017632 Link, Choke 1
7017644 Shaft, Choke 1
7017645 Orifice, Vacuum Limiter 1
3120853 1-27
S SECTION 1 FRAME
E FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED)
T 202 7017620 Starter (Not Shown) 1
I
203 7017603 Dipstick 1
204 Use 7019932 Plug, Spark (was p/n 7017608) 3
O 205 7017600 Filter, Oil 1
N 206
207
7017606
7017607
Coil, Ignition
Boot, Spark Plug
3
3
208 Use 7017629 Gasket - Exhaust (Not Shown) (was p/n 7024414) 1
1 209
210
7017612
7017613
Gasket - Outlet (Not Shown)
Gasket - Inlet (Not Shown)
1
1
211 7017614 Gasket - Water Pump (Not Shown) 1
F 212 7017602 Tube, Dipstick 1
R 213 Use 7017641

Gasket -Carburetor to Intake (Not Shown) (was p/n
7017618)
1
A 214 7017627 Switch, Water Temperature 1
M 215 7017616 V-Belt 1
E
216 7017636 Filter, Fuel 1
217 7017610 Regulator (Not Shown) 1
218 Use 7017657 Pump, Fuel (was p/n 7017619) 1
219 7017621 Module, Ignition 1
220 7017622 Trigger, Ignition (Not Shown) 1
221 7017605 Cap, Oil Fill 1
222 7017604 Plug, Oil Drain 1
223 7017615 Pump, Water 1
224 7017611 Thermostat 1
225 7017609 Alternator 1
226 1600229 Coupling, Pump 1
227 7017630 Link, Governor 1
228 7017635 Spring, Link 1
229 7017634 Lever, Governor 1
230 7017633 Bracket, Control 1
231 7017642 Spring, Governor 1
232 Use 4360405 Switch, Oil Pressure (Not Shown) (was p/n 7017601) 1
233 7017643 Shaft, Throttle (Not Shown) 1
234 7017646 Flywheel/Ring Gear Assembly (Not Shown) 1
235 7017669 Elbow, Carburetor to Air Intake (Not Shown) 1
0256919/0256910 OIL COOLER INSTALLATION Ref. C/C
301 3620039 Cooler, Oil 1

302 1320202 Clamp 2
303 3311605 Locknut 3/8"-16NC 2
304 4711600 Flatwasher 3/8" 2
305 3570105 Plate, Cover 1
1-28 3120853
SECTION 1 FRAME S
FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120853 1-29
S SECTION 1 FRAME
E FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS
C MACHINES).
T
I
O
N
F
R
A
M
E
1-30 3120853
SECTION 1 FRAME S
E
FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES).(CONT.)
C
T
2901456 DUAL FUEL KIT ASSEMBLY Ref. A
I
1 3720011 Regulator, Beam 1
O
N
2 7017513 Fitting, 90° 1
3 7017517 Fitting, 90° Barbed 1
4 7017518 Fitting, 90° 1
5
6
7017508
7017501
Bushing
Thermostat
1
1
1
7 7017519 Fitting, Straight Barbed 1
8 7017514 Fitting, 90° (Prior to S/N 37463) 1 F
R
7017522 Fitting, 90° (S/N 37463 to Present) 1
9 7017500 Solenoid, Fuel Shut-Off 1
10 7017520 Fitting, Straight Nipple 1 A
11
12
7017521
Not Available
Fitting, 90°
Hose, Vapor
3
M
E
12in/30.5cm
13 Not Available Hose, Water 16in/41cm
14 Not Available Hose, Water 22in/59cm
15 Not Available Hose, Vacuum 20in/51cm
16 Not Available Clamp 2
17 Not Available Clamp 4
18 7017512 Fitting, Tee 1
19 Not Available Tie-Strap 1
20 7017511 Adapter 1
21 7017510 Venturi 1
22 7017513 Fitting, 90° 1
23 7017504 Filter, Fuel 1
24 7017521 Fitting, 90° 1
25 7017505 Valve, Relief 1
26 Not Used
27 Not Available Clamp (Not Shown) 2
Fitting, 90° (Not Shown - Located at Oil Pressure
28 7017521 1
Switch)
3120853 1-31
S SECTION 1 FRAME
E FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES).(CONT.)
T 0256000 DUAL FUEL INSTALLATION Ref. G
I 101 2901456 Dual Fuel Kit Assembly (Includes Items 1-28) 1

O 102 2720175 Hose 1
N 103
104
2720190
2180387
Hose
Fitting, Tank Connector
1
1
105 Not Used
1 106 4360336
Switch, Toggle (Not Shown - Located at Platform
Box)
1
107 4060802 Guard, Switch (Not Shown - Located at Platform Box) 1

F 108 3790012 O-Ring (Not Shown - Located at Platform Box) 1
R 109
110
1701543
1700818
Decal - LP (Not Shown - Located near Tank)
Decal - Liquid Withdrawal (Not Shown - Located near
1
1
A Tank)
M 111 2720433 Hose 2
E
112 1320016 Clamp 2
113 2220082 Fitting, Adapter 1
114 0641405 Bolt 1/4"-20NC x 5/8" 2
1-32 3120853
SECTION 1 FRAME S
FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES).(CONT.) E
T
I
O
N
F
R
A
M
E
3120853 1-33
S SECTION 1 FRAME
E FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION.
C
T
I
O
N
F
R
A
M
E
1-34 3120853
SECTION 1 FRAME S
E
FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION.
C
T
0256002 ENGINE ASSEMBLY AND INSTALLATION Ref. 14/K
1 4845223 Tray, Engine 1 I
2 4845238 Arm, Swing-Out 2
O
N
3 3422426 Pin 4
4 2000145 Engine, Yanmar 3TNE68 1
5 3600256 Piston Pump Assembly (See Figure 1-11 for 1
6 3600199
Breakdown)
Gear Pump Assembly (See Figure 1-12 for 1
1
Breakdown)
7 0902263 Bracket, Mounting (Rear) 1 F
R
8 0080222 Adapter, Spacer - Flywheel Housing 1
9 0902265 Bracket, Mounting (Front) 1
10 3200381 Mount, Motor 3 A
11
11A
1340057
7015004
Air Cleaner Assembly
Element, Filter
1
1
M
11B 7015005 Cover Assembly 1 E
11C 7015006 Valve, Vacuator 1
11D 7015007 Latch 2
12 0340045 Band, Mounting 1
13 3539692 Plate, Mounting (Air Cleaner) 1
14 0641509 Bolt 5/16"-18NC x 1 1/8" 4
15 4566987 Tube, Spacer 4
16 3620037 Radiator 1
17 2060027 Fan, Electric Cooling 1
19 4845391 Pipe, Exhaust 1
20 3841143 Pin, Keeper 4
21 2540031 Grommet 2
22 0641506 Bolt 5/16"-18NC x 3/4" 2
23 3311505 Locknut 5/16"-18NC 12
24 0641608 Bolt 3/8"-16NC x 1" 6
25 3311605 Locknut 3/8"-16NC 6
26 0641820 Bolt 1/2"-13NC x 2 1/2" 3
27 3311805 Locknut 1/2"-18NC 3
28 1660228 Coupling, Pump 1
Actuator Assembly (was p/n 0060038) (See Section 7
29 Use 2910000 1
for Breakdown)
30 3841307 Rod, Throttle 1
31 3220109 Muffler 1
32 0080225 Elbow, Air Intake 1
33 4740274 Washer, Snubbing 3
34 4751600 Flatwasher 3/8" 33
36 4751500 Flatwasher 5/16" 6
38 0700605 Bolt 8mm x 10mm 8
39 0641508 Bolt 5/16"-18NC x 1" 5
40 2720058 Hose, Fuel Line (5/16") 7ft/2.1m
41 1320022 Clamp, Hose 6
3120853 1-35
S SECTION 1 FRAME
E
C FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED)
T
42 0641810 Bolt 1/2"-13NC x 1 1/4" 2
I 43 4751800 Flatwasher 1/2" 2
O 44 0641608 Bolt 3/8"-16NC x 1" 2
N
45 1320031 Clamp, Hose 3
46 1701505 Decal - Diesel Fuel (Not Shown - Located on hood) 1
47 2720271 Hose 1ft/30.5cm
1 48
49
0080221
1320026
Adapter, Pump Mounting
Clamp, U-Bolt
1
1
50 0641406 Bolt 1/4"-20NC x 3/4" 12
F 51 4751400 Flatwasher 1/4" 12
R
52 3311405 Locknut 1/4"-20NC 12
53 3539663 Plate, Mounting (Cooling Fan) 1
A 54 Not Used
M 55
56
1320014
1660222
Clamp, Hose
Coupling, Throttle
4
1
E 57 3321402 Nut, Jam 1/4"-28NF 1
58 3321602 Nut, Jam 3/8"-24NF 1
59 1660220 Swivel, Throttle 1
60 4740442 Washer, Belleville 1
61 3900217 Bolt, Socket Head Shoulder 1
63 Not Used
66 2720271 Hose, Fuel (3/16") 10ft/3m
67 Mounting Plate Options (Radiator): 1
3539681 Prior to S/N23060
4845433 S/N23060 to Present
69 2200213 Plug, Pipe 1
70 2220648 Fitting, 90° 2
73 4360330 Switch, Toggle (Glow Plugs) (Not Shown - Located at 2
Platform and Ground Control Boxes)
74 4060802 Guard, Switch (Not Shown - Used with Item 73) 2
75 3790152 O-Ring (Not Shown - Used with Item 73) 2
76 4740397 Spacer 1
77 1060221 Strap, Ground 1
Harness, Engine (Not Shown - See Section 7 for
78 4921853 1
Breakdown)
79 Not Used
80 0721008 Bolt #10-24NC x 1/2" 2
81 3311005 Locknut #10-24NC 2
82 4400395 Tank, Coolant Overflow 1
83 3539816 Plate, Overflow Tank 1
84 2720430 Hose, Radiator (Top) 1
85 2720431 Hose, Radiator (Bottom) 1
86 4320002 Stud, Rubber Mounted 1
1-36 3120853
SECTION 1 FRAME S
FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED) E
87 1320040 Clamp 1
T
I
88 0701015 Bolt, Metric M8 x 35mm 8
89 0701014 Bolt, Metric M10 x 30mm 4
90 0641820 Bolt 1/2"-13NC x 2 1/2" 2 O
91
92
4751800
0940070
Flatwasher 1/2"
Bumper, Rubber
2
2
N
93 4751000 Flatwasher #10 8
94
95
4791600
4060807
Starwasher 3/8"
Flex-Trim (Not Shown - Located on Frame)
2
15in/38cm
1
97 3311501 Nut 5/16"-18NC 2 F
98
99
1320239
0902383
Clamp, Loop (S/N 33269 to Present Only)
Bracket, Recovery Tank (S/N 33269 to Present Only)
1
1
R
100 4420008 Tape, Neoprene (S/N 33269 to Present Only) 7in/18cm A
101 2420047 Service Indicator Kit (S/N 33269 to Present Only) 1 M
102
103
2220063
0257589
Fitting, 90°
Timer Module, Assy (See Section 7 For Breakdown)
1
1
E
106 3960477 Seal, Foam Gasket (S/N 33820 to Present Only) 1
107 0181932 Angle (Not Shown) 1
108 1320241 Clamp (Not Shown) 1
2000145 ENGINES COMPONENTS Ref. B
201 7018100 V-Belt 1

202 7018101 Cap, Oil Fill 1
203 7018102 Gasket, Valve Cover (Not Shown) 1
204 7018103 Filter, Oil 1
205 7018104 Dipstick, Engine Oil Level 1
206 7018105 Pump, Water 1
207 7018106 Gasket, Thermostat (Not Shown) 1
208 7018107 Thermostat 1
209 7018108 Switch, Water Temperature 1
210 7018111 Element, Fuel Filter 1
211 7018112 Starter 1
212 7018113 Alternator - 40 Amp 1
213 7018116 Solenoid, ETR Stop (Not Shown) 1
214 7018117 Pump, Injector 1
215 7018118 Pump, Fuel 1
7018119 Lever, 1
216 7018145 Switch, Oil Pressure 1
217 7018146 Fuel Strainer Assembly 1
218 7018147 Plug, Glow (Not Shown) 3
219 7018144 Gasket, Muffler 1
220 7018119 Lever, Regulator (Not Shown) 1
3120853 1-37
S SECTION 1 FRAME
E FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED)
T 0256919/0256910 OIL COOLER INSTALLATION Ref. C/C
I 301 3620039 Cooler, Oil 1

O 302 1320202 Clamp 2
N 303
304
3311605
4711600
Locknut 3/8"-16NC
Flatwasher 3/8"
2
2
305 3570105 Plate, Cover 1
1
F
R
A
M
E
1-38 3120853
SECTION 1 FRAME S
FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120853 1-39
S SECTION 1 FRAME
E FIGURE 1-11. PISTON PUMP ASSEMBLY.
C
T
I
O
N
F
R
A
M
E
1-40 3120853
SECTION 1 FRAME S
E
FIGURE 1-11. PISTON PUMP ASSEMBLY.
C
T
3600256 PISTON PUMP ASSEMBLY Ref. D
I
1 7018925 Rotary Group Assembly 1
O
N
2 7018926 Port Plate Assembly (Includes Items 10 and 11) 1
3 7018927 Stroking Cylinder Assembly 1
4 Not Used
5
6
7018929
7018930
Connecting Plate Assembly
Ring, Retaining
1
1
1
7 7018931 Seal, Shaft 1
8 7018932 Proportional Valve Assembly (Includes Item 9) 1 F
R
9 7018933 Coil, Solenoid 2
10 7018934 Cartridge, Valve - High Pressure Relief 2
11 7018935 Cartridge, Valve - Boost Oil Pressure Relief 1 A
12
13
7018936
7018937
Orifice
Fitting, Adapter
2
2
M
14 7018938 Fitting, Adapter 2 E
15 7018939 Fitting, Adapter 1
16 7018953 O-Ring 1
17 7024016 Screw M6 x 55 4
––––––––––
7018940 Seal Kit -Complete External 1
3120853 1-41
S SECTION 1 FRAME
E FIGURE 1-12. GEAR PUMP ASSEMBLY
C
T
I
O
N
F
R
A
M
E
1-42 3120853
SECTION 1 FRAME S
E
FIGURE 1-12. GEAR PUMP ASSEMBLY
C
T
3600199 GEAR PUMP ASSEMBLY Ref. –
I
O
N
2 Kit Seal, Shaft 1
3 7010956 Flange, Mounting 1
4 Kit Ring, Backup 2
5
6
Kit
7010957
E-Seal
Bearing
2
2
1
7 Kit O-Ring 2
8 7010958 Housing 1 F
R
9 7010959 Pin, Dowel 4
10 Not Used
11 7010954 Gear, Idler 1 A
12
13
7010978
7010960
Gear, Drive
Cover, End
1
1
M
14 7010961 Bolt 4 E
––––––––––
7010953 Seal Kit (Includes Items 2,4,5 and 7) 1
3120853 1-43
S SECTION 1 FRAME
E FIGURE 1-13. TANK INSTALLATIONS
C
T
I
O
N
F
R
A
M
E
1-44 3120853
SECTION 1 FRAME S
E
FIGURE 1-13. TANK INSTALLATIONS
C
T
TANK INSTALLATIONS Ref.
0255993
Fuel and Hydraulic Tanks and Filter Installation
Ref. E/5
I
(Without Locking Cap)
Fuel and Hydraulic Tanks and Filter Installation
O
0257341
(With Locking Cap)
Ref. B/2
N
1 4400371 Tank, Fuel (Prior to S/N 30747) 1
4400401 Tank, Fuel (S/N 30747 to Present) 1
1A 1120477 Cap, Fuel 1 1
2 4400383 Tank, Hydraulic Oil 1
2A
2B
7014802
7014803
Gauge, Sight
Breather/Filler
1
1
F
3 2120157 Hydraulic Oil Filter Assembly 1 R
3A 2120158 Element, Filter 1
A
M
3B 7016313 Switch, Electrical Pressure (Clogging Indicator) 1
4 4240118 Strap, Hold-Down (Hydraulic Tank) 1
5 4240117 Strap, Hold-Down (Fuel Tank) 1 E
6 Not Used
7 2180117 Fitting, 90° 1
9 3311601 Nut 3/8"-16NC 4
12 4280295 Strip, Bumper 30in/76cm
13 4420038 Moulding, Rubber 20in/51cm
14 0641406 Bolt 1/4"-20NC x 3/4" 2
16 3311602 Nut, Jam 3/8"-16NC 2
17 to 50 Not Used
51 Cap, Fuel Options: 1

1120477 Without Locking Cap
1120485 With Locking Cap (Self Closing)
52 0100019 Loctite #271 (Not Shown) (With Locking Cap Only) A/R
53 2420185 Sender, Fuel (With Locking Cap Only) 1
54 4771000 Lockwasher, Star #10 (With Locking Cap Only) 1
0256272 LP TANK INSTALLATION (DUAL FUEL OPTION) Ref. B
101 1320228 Clamp Kit 1

102 0641608 Bolt 3/8"-16NC X 1" 4
103 4751600 Flatwasher 3/8" 8
104 3311605 Locknut 3/8"-16NC 4
105 LP Tank Options: 1
4400275 43.5 Lbs Tank (Alum)
4400420 43.5 Lbs Tank (Steel)
4400281 33.5 Lbs Tank (Alum)
4400421 33.5 Lbs Tank (Steel)
106 0902275 Bracket 1
3120853 1-45
S SECTION 1 FRAME
E FIGURE 1-14. FRAME COVERS INSTALLATIONS.
C
T
I
O
N
F
R
A
M
E
1-46 3120853
SECTION 1 FRAME S
E
FIGURE 1-14. FRAME COVERS INSTALLATIONS.
C
T
ENGINE TRAY AND TANK COVERS INSTALLATION Ref.
0256003 Engine Tray and Tank Covers Installation - Ref. G/6 I
0256144
Gas / Diesel
Engine Tray and Tank Covers Installation - Ref. G
O
Duel Fuel N
1 4845305 Cover, Engine Tray 1
2 Not Used
3 1780294 Door 1 1
4 2600218 Hinge 1
5
6
2080040
2940090
Fastener, Huck
Latch, Paddle
4
1
F
7 2940080 Latch, Draw 4 R
8 0721005 Screw, Machine #10-24NC x 5/8" 12
A
M
9 4761000 Lockwasher #10 12
10 2560147 Handle, Retractable 4
11 4060803 Trim, Flexible A/R E
12 0940072 Bumper 4
13 to 50 Not Used
51 Cover, Tank Tray Options: 1

4845306 Standard Gas / Diesel
4845307 Duel Fuel
52 2940096 Catch, Magnetic (Not Shown - Located on #51)
1
(Duel Fuel Only)
53 2901497 Kit, Hood Insulation 1
2820090 Insulation, Top 1
2820091 Insulation, Drive Wheel Side 1
2820092 Insulation, Steer Wheel Side 1
2820093 Insulation, Front 1
0256136 REAR FRAME COVER INSTALLATION Ref. –
101 3535959 Cover 2

102 3900174 Screw, Special 5
103 3760308 Retainer 5
104 1380138 Cup, Receptacle 5
105 4844602 Cover, Axle 1
106 0940036 Bumper 2
107 3960447 Seal, Self-Gripping 8ft/2.5m
108 3960433 Seal 3.7ft/1.1m
109 3300371 Wingnut, Locking 4
110 3520026 Plug 3
3120853 1-47
S SECTION 1 FRAME
E FIGURE 1-14. FRAME COVERS INSTALLATIONS.
T
I
O
N
F
R
A
M
E
1-48 3120853
SECTION 2 TURNTABLE
TABLE OF CONTENTS
S
2-1 TURNTABLE MOUNTED COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
E
C
T
2-2 CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . 2-8

I
2-4 SWING MOTOR ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
O
2-5 SWING BEARING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
N
2-6 GROUND CONTROL COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-7 TURNTABLE AND HOODS INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2
T
U
R
N
T
A
B
L
E
3120853 2-1
SECTION 2 TURNTABLE
FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-2 3120853
SECTION 2 TURNTABLE
FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION.
S
E
0256033 VALVES AND HORN INSTALLATION Ref. B
C
1 Control Valve Assembly (See Figure 2-2 for 1
T
I
Breakdown)
See Note Prior to S/N 33963) (Note: Recommend using
4641023 in place of original 4640966 O
2
4641023
4711500
S/N 33963 to Present
Flatwasher 5/16" Narrow 14
N
3 0641506 Bolt 5/16"-18NC x 3/4" 5
4 4844365 Bracket, Valve Mounting 2 2
5 0140001 Horn 1
6 3311505 Locknut 5/16"-18NC 8
7 0641514 Bolt 5/16"-18NC 4 T
8 3311401 Nut 1/4"-20NC 2
U
R
9 4761400 Lockwasher 1/4" 2
10 4751400 Flatwasher 1/4" 4
11 3311501 Nut 5/16"-18NC 1 N
12 4640814
Use 7011322
Relief Valve Assembly
Cartridge, Valve (was P/N 7011321)
1
1
T
13 4060854 Shield, Valve 1 A
14 0641508 Bolt 5/16"-18NC x 1" 2
B
L
16 4640866 Manual Valve Assembly 1
2900708 Seal Kit - 4640866 VAlve 1 E
17 0641418 Bolt 1/4"-20NC x 2 1/4" 2
18 0902051 Bracket, Decal Mounting 1
0253708 MANUAL DESCENT COMPONENTS INSTALLATION Ref. C
101 3600179 Pump Assembly 1

2900779 Seal Kit 1
7010652 Handle 1
7016673 Pump - W/O Handle 1
102 Not Used
103 0641518 Bolt 5/16"-18NC x 2 1/4" 2
104 Not Used
105 Not Used
106 4751500 Flatwasher 5/16" 4
107 3311501 Nut 5/16"-18NC 2
108 1380132 Clip, Gripper 1
109 4300106 Stud, Special 1
2901249 MOTION ALARM KIT Ref. A

2901250 TILT ALARM KIT Ref. A
Alarm, Horn (Remove ground strap before

201 0140031 1
installation)
202 3311405 Locknut 1/4"-20NC 2
203 4711400 Flatwasher 1/4" 4
3120853 2-3
SECTION 2 TURNTABLE
FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION. (CONTINUED)
S FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
E 0256577 LIGHT PANEL INSTALLATION Ref. A
C 301 3380426 Panel, Mounting 1

T 302 1702963 Decal - Light Panel 1
I 303
304
0641404
3311405
Bolt 1/4"-20NC x 1/2"
Locknut 1/4"-20NC
1
1
O 305 1320043 Clamp 1
N 306 2920028 Lamp, Indicator 5
307 2920029 Bulb, Light 5
308 3990001 Diode (Not Shown) 6
2 309 to 316 Not Used
317 4460265 Plug, Connector 1
T
318 4460268 Socket, Female 7
U
R
N
T
A
B
L
E
2-4 3120853
SECTION 2 TURNTABLE
FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION. (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
3120853 2-5
SECTION 2 TURNTABLE
FIGURE 2-2. CONTROL VALVE ASSEMBLY.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-6 3120853
SECTION 2 TURNTABLE
FIGURE 2-2. CONTROL VALVE ASSEMBLY.
S
E
CONTROL VALVE ASSEMBLY (STANDARD PARTS) Ref.
4640966 Control Valve Assembly (Prior to S/N 33963) Ref. A C
4641023 Control Valve Assembly (S/N 33963 To Present) Ref. A
T
1 7012997 Cartridge, Flow Control Valve (Lower Lift Down) 1 I
7012901 Seal Kit - 7012997 Valve 1 O
2 7012981
7012998
Cartridge, Relief Valve (Upper Lift Down and Swing)
2
2
N
Cartridge, Relief Valve (Platform Level, Telescope
3 7012912 4
7012998
and Lower Lift Down)
Seal Kit - 7012912 Valve 4
2
4 7010542 Cartridge, Shuttle Valve (Swing) 2
7012907 Seal Kit - 7010542 Valve 2 T
5 7017401
Cartridge, Solenoid Valve (Less Coils) (Platform
Level )
1 U
7017402 Seal Kit - 7017401 Valve 1 R
7017403
7012944
Waterproofing Kit
Coil
1
2
N
6 7012948 Cartridge, Solenoid Valve (Less Coils) (Lift) 2 T
7012903 Seal Kit - 7012948 Valve 2 A
7017403
7012944
Waterproofing Kit
Coil (2 Per Assembly)
1
4 B
7 7012999 Cartridge, Solenoid Valve (Less Coil) (Telescope) 2 L
7012907
7017403
Waterproofing Kit
2
1
E
7012944 Coil (1 Per Assembly) 2
8 Not Used
9 7012914 Cartridge, Check Valve (Platform Level) 2
7012918 Seal Kit - 7012914 Valve 2
10 7012947 Cartridge, Valve (Manual Descent) 1
7012918 Seal Kit - 7012947 Valve 1
11 7012949 Knob 1
12 4460499 Connector, Electrical 8
13 to 50 Not Used
51 Cartridge, Solenoid Valve Options (Less Coils) (Swing): 1
See Note 4640966 Valve (Prior to S/N 33963) (Note:
Recommend using 7017433 in place of original
7017401)
7017433 4641023 Valve (S/N 33963 to Present)
7017402 Seal Kit - 7017433 Valve 1
7017403 Waterproofing Kit 1
7012944 Coil 2
3120853 2-7
SECTION 2 TURNTABLE
FIGURE 2-3. SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-8 3120853
SECTION 2 TURNTABLE
FIGURE 2-3. SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS.
S
E
0253508 SWING DRIVE INSTALLATION Ref. B
C
1 Use 0440339
Turntable Bearing and Rotation Box Assembly (See
Figure 2-5 for Breakdown) (was p/n 0440203)
1 T
2 0100019 Loctite A/R I
3 3160182 Swing Motor Assembly (See Figure 2-4 for Breakdown) 1 O
4
5
0681814
4740171
Bolt 1/2"-13NC x 1 3/4" (Grade 8)
Washer, Hardened
2
2 N
6 0682026 Bolt 5/8"-11NC x 3 1/4" 18
7
8
4740393
3020027
Washer, Hardened
Grease, Bearing (5 gallon bucket) (Prior to S/N 31641)
42
A/R
2
3020036 Grease, Bearing (S/N 31641 to Present) A/R
9 3020029 Grease, Bearing A/R T
10 0682028 Bolt 5/8"-11NC x 3 1/2" Grade 8 24
U
R
N
T
A
B
L
E
3120853 2-9
SECTION 2 TURNTABLE
FIGURE 2-4. SWING MOTOR ASSEMBLY.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-10 3120853
SECTION 2 TURNTABLE
FIGURE 2-4. SWING MOTOR ASSEMBLY.
S
E
3160182 SWING MOTOR ASSEMBLY Ref. –
C
1 Kit Seal, Dust 1
T
I
2 Kit Ring, Retainer 1
3 Kit Shim, Back-up 1
4 Kit Seal, Housing 1 O
5
6
Kit
Kit
Seal, Body
Seal, Shaft
3
1
N
Kit Ring, Teflon Back-up 1
Kit Shim, Back-up 1 2
7 Not Available Washer, Thrust 1
8 7005809 Bearing, Thrust 1
9 7005812 Plate, Wear 1 T
10 7005874 Cover, End 1
U
R
11 Not Available Ball (Part of Item 10) A/R
12 7005876 Plug, Cooling 1
13 7005804 Housing 1 N
14
15
7005811
7005877
Link, Drive
Rotor Set Assembly
1
1
T
16 7005878 Pin, Drive Link A/R A
17 7005821 Bolt 4
B
L
18 7005879 Shaft 1
19 7005880 Key 1
–––––––––– E
7005881 Seal Kit (Includes Items 1-6) 1
3120853 2-11
SECTION 2 TURNTABLE
FIGURE 2-5. SWING BEARING ASSEMBLY.
S 9
E
C
T 2
18
I 1 14
O
N
2
3
T 7
U
12
5
R 10
11
N 13
T 10
6
A 3
B 1
17
L 16
15 8
E
4
116
6
111
110
107
108
115
109
114 117
112
112
104 113
101 103
109
107
108
106
102 105
2-12 3120853
SECTION 2 TURNTABLE
S
E
Note: Visually identify the brand before ordering Ref.
replacement parts. C
0440339 SWING BEARING ASSEMBLY (PERFECTION GEAR) Ref. C
T
I
1 7026042 Bearing, Cup 2 O
2
7026043
7027356
Bearing, Cone
Adapter, Motor
2
1 N
3 7027361 Seal 2
4
5
7027354
0641510
Cap, End
Bolt 5/16”-18NC x 1 1/4”
1
2
2
6 0641812 Bolt 1/2”-13NC x 1 1/2” 2
7 70000865 Plug 1 T
8
9
7027360
7027359
Seal
Straight Fitting, Grease
1
2
U
2160003 Fitting, Grease - 45° 2 R
10 7027358 90° Fitting, Grease 2
N
T
11 Not Available Housing 1
12 4891500 Flatwasher 5/16” (Hardened) 2
13 7027363 Gear, Worm 1 A
14
15
70000868
7027352
Ring, Bearing
Gasket (.010 - Brown)
1
A/R
B
16 7027351 Gasket (.0075 - Clear) A/R L
17 7027350 Gasket (.005 - Blue) A/R E
18 7027353 Gasket (.020 - Yellow) 1
0440203 SWING BEARING ASSEMBLY (KAYDON) Ref. G

Note: When replacing major components, consider
replacing with p/n 0440339 Complete Bearing
Assembly.
101 7012597 Swing Rotation Box Assembly 1

102 7023484 Cap, End 1
103 Not Available Bolt 1/2”-13NC x 1 1/2” Grade 8 2
104 Not Available Gear, Worm 1
105 7012654 Seal, Outer - Capped End (1.75 O.D.) 1
106 7016682 Shims Kit (Includes Qty 3 each of .005, .0075 & 1
.010 Shims)
107 70001677 Cup, Bearing 2
108 90206369 Cone, Bearing 2
109 7016676 Seal, Outer - Capped End (2.063 O.D.) 1
111 7012655 Seal, Outer - Motor End 1
112 2160001 Fitting, Grease - 90° 2
113 Not Available Lockwasher 1/2” 2
114 Component Options: 1
Not Available Plug, Pipe
2160001 Fitting, Grease - 45°
115 7012596 Bearing, Turntable 1
3120853 2-13
SECTION 2 TURNTABLE
E 116 2160003 Fitting, Grease - 45° 2
C
117 Not Available Capscrew, Socket Head 5/16”-18NC 4
Not Available Washer 5/16” (Not Shown) 4
T
I
O
N
T
U
R
N
T
A
B
L
E
2-14 3120853
SECTION 2 TURNTABLE
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
3120853 2-15
SECTION 2 TURNTABLE
FIGURE 2-6. GROUND CONTROL COMPONENTS INSTALLATION.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-16 3120853
SECTION 2 TURNTABLE
FIGURE 2-6. GROUND CONTROL COMPONENTS INSTALLATION. (CONTINUED)
43 4460310 Bar, Buss - 5 Position 1
E
C
44 4460305 Screw, Terminal Strip 7
45 4460306 Washer, Terminal Strip 7
46 4460307 Sleeve, Terminal Strip 7 T
47
48
4460301
4460300
Strip, Marking
Barrier, Terminal
2
1
I
O
0256035 GROUND CONTROL BOX INSTALLATION Ref. – N
101 Not Used
102 0641605 Bolt 3/8"-16NC x 5/8" 4 2
103 4761600 Lockwasher 3/8" 4
T
104 4751600 Flatwasher 3/8" 4
GROUND CONTROL BOX OPTIONS Ref. U

201 4360330 Switch, Toggle - Glow Plugs (Diesel Only) 1
R
4060802 Guard, Switch 1 N
3790012 O-Ring 1
T
A
B
L
E
3120853 2-17
SECTION 2 TURNTABLE
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-18 3120853
SECTION 2 TURNTABLE
FIGURE 2-6. GROUND CONTROL COMPONENTS INSTALLATION.
S
E
0861036 GROUND CONTROL BOX ASSEMBLY Ref. A
C
1 3252490 Lid, Nameplate 1
T
I
2 3960438 Seal 50 in./1.3m
3 0630464 Screw #10-24NC x 1/2" 6
4 4740120 Washer, Nylon 6 O
5 2420172
7012665
Hourmeter
Guard, Domed (Optional)
1
1
N
6 4360314 Switch, Toggle 7
7 4060802 Guard, Switch 7 2
8 4740397 Spacer 7
9 4360289 Switch, Push-Pull (Emergency Stop) 1
9A 7012611 Mushroom Head 1 T
9B 7012612 Boot 1
U
R
10 4360319 Switch, Master Key (Select) 1
10A 7012560 Key, Replacement 1
11 0860883 Box N
12
13
4460425
4460426
Connector, Strain Relief
2
1
T
14 3910608 Screw, Round Head #6-32NC x 1/2" 2 A
15 4760600 Lockwasher #6 2
B
L
16 4750600 Flatwasher #6 2
17 3310601 Nut #6-32NC 2
18 3640862 Rail 1 E
19 Not Used
20 3300365 Nut, Retainer 6
21 4921813 Harness - Chassis and Valve (See Section 7 for 1
Breakdown)
22 4420008 Tape, Seal 4ft/1.2m
23 0100048 Silicone (Not Shown) A/R
24 2540016 Grommet 1
25 4360282 Block, Contact 1
26 1060584 Cable, Lanyard 1
27 3311011 Nut, Push #10 1
28 4360216 Breaker, Circuit - 30 Amp 1
30 3520028 Plug, Hole 1
31 0100035 Loctite #272 (not Shown) A/R
32 3911040 Screw, Round Head #10-24NC x 2 1/2" 1
33 3911012 Screw, Round Head #10-24NC x 3/4" 12
34 4761000 Lockwasher #10 13
35 4751000 Flatwasher #10 26
36 3311001 Nut #10-24NC 13
37 3740049 Relay 8
39 4460299 Stop, Terminal 2
40 4460298 Block, Terminal 50
41 4460300 Barrier, Terminal A/R
3120853 2-19
SECTION 2 TURNTABLE
S FIGURE 2-6. GROUND CONTROL COMPONENTS INSTALLATION. (CONTINUED)
E
C 44 4460305 Screw, Terminal Strip 7
T 45 4460306 Washer, Terminal Strip 7
I
46 4460307 Sleeve, Terminal Strip 7
47 4460301 Strip, Marking 2
O 48 4460300 Barrier, Terminal 1
N 0256035 GROUND CONTROL BOX INSTALLATION Ref. –
2 101 Not Used

102 0641605 Bolt 3/8"-16NC x 5/8" 4
103 4761600 Lockwasher 3/8" 4
T 104 4751600 Flatwasher 3/8" 4
U
R
GROUND CONTROL BOX OPTIONS Ref.
N 201 4360330 Switch, Toggle - Glow Plugs (Diesel Only) 1
T 4060802
3790012
Guard, Switch
O-Ring
1
1
A
B
L
E
2-20 3120853
SECTION 2 TURNTABLE
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
3120853 2-21
SECTION 2 TURNTABLE
FIGURE 2-7. TURNTABLE AND HOODS INSTALLATIONS.
S
E
C
T
I
O
N
T
U
R
N
T
A
B
L
E
2-22 3120853
SECTION 2 TURNTABLE
S
E
4620088 TURNTABLE 1
C
0253709 HOODS INSTALLATION Ref. E
T
I
Note: Replacement decals must be ordered sepa-
rately - See Section 8.
O
1
2
2680410
2680411
Hood (Left Side)
Hood (Right Side)
1
1 N
3 2940071 Latch 2
4
5
3430840
0253687
Pin, Clevis
Swing Hinge Assembly
2
2
2
6 3420156 Hairpin 4
7 4751800 Flatwasher 1/2" A/R T
8
9
0940049
3311501
Bumper
Nut 5/16"-18NC
2
7
U
10 0630468 Screw, Button Head 5/16"-18NC x 1" 3 R
11 4751500 Flatwasher 5/16" 3
N
T
12 0901923 Bracket, Mounting - Right Front 1
13 0901923 Bracket, Mounting - Right Side Bottom 1
14 0901921 Bracket, Mounting - Right Side Top 1 A
15
16
3960453
3311601
Seal, Door
Nut 3/8"-16NC
2.5 Ft./.8m
3
B
17 4751600 Flatwasher 3/8" 3 L
18 1320043 Clamp 1 E
19 Not Used
20 4751400 Flatwasher 1/4" 1
21 3311401 Nut 1/4"-20NC 1
0253984 STORAGE COMPARTMENT INSTALLATION Ref. B
101 4761600 Lockwasher 3/8" 4

102 0641605 Bolt 3/8"-16NC x 5/8" 4
103 3536691 Box, Storage 1
104 2940042 Latch 1
105 3960438 Seal 50 in./1.3m
106 4844404 Door Front Weldment 1
107 4740120 Washer, Nylon 6
108 0630464 Screw, Button Head #10-24NC x 1/2" 6
109 3300365 Retainer, Nut #10-24NC 6
110 0100011 Loctite #242 A/R
111 4751600 Flatwasher 4
3120853 2-23
SECTION 2 TURNTABLE
E 0256478 OPTIONAL STROBE LIGHT INSTALLATION Ref. –
C 201 4220162 Spacer, Stop (Used with ECCO Model 6640 Only) 1
T 202 Adapter Options: 1
I 0630491
0080241
Adapter used with ECCO Model 6640
Adapter used with ECCO Model 6650
O 203 3539281 Plate, Mounting (Used with ECCO Model 6640 Only) 1
N 204 0741606
Screw, Flathead 3/8"-16NC x 3/4" (Used with ECCO
Model 6640 Only)
1

2 206 4240032 Tie-Strap (Not Shown) 1
207 Use 0272507 Strobe Light Assembly (was p/n 0255917) 1
Bulb, Replacement Options: 1
T 7016380 Bulb for ECCO Model 6640
U 70001941 Bulb for ECCO Model 6650
R
207A Guard, Strobe Options: 1
4060907 Guard used with ECCO Model 6640
N 2920215 Guard used with ECCO Model 6650
T 208
209
4460234
0100048
Clamp
Sealant, Silicone (Not Shown)
1
A/R
A
B
L
E
2-24 3120853
SECTION 3 BOOM
TABLE OF CONTENTS
S
3-1 BOOM AND LIMIT SWITCHES INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 MAIN BOOM COMPONENTS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

E
C
T
I
O
N
B
O
O
M
3120853 3-1
SECTION 3 BOOM
FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS.
S
E
C
T
I
O
N
B
O
O
M
3-2 3120853
SECTION 3 BOOM
FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS.
BOOM INSTALLATION (STANDARD PARTS) Ref. S
0253455
0255587
Booms Installation - Model 40ic
Booms Installation - Model 45ic
Ref.
Ref.
J
3
E
C
1 to 3 Not Used T
I
4 4844304 Upright Weldment (Top) 1
5 to 8 Not Used
9 1683337 Cylinder Assembly - Upper Lift (See Section 5 for 1 O
1683506
Breakdown) (Prior to S/N 29899)
Cylinder Assembly - Upper Lift (See Section 5 for 1
N
Breakdown) (S/N 29899 to Present)
10 1683325 Cylinder Assembly - Master (See Section 5 for 1 3
Breakdown)
11 Not Used
12 3422176 Pin, Pivot 2 B
13 Not Used
O
O
14 3422178 Pin, Pivot 1
15 3422179 Pin, Pivot 1
16 3422180 Pin, Pivot 1 M
17 4844467 Boom Rest Weldment 1
18 0561076 Block, Boom Rest 1
19 3841203 Keeper, Pin - 1/2" 15
20 3841143 Keeper, Pin - 3/8" 2
21 3780184 O-Ring - 2" 30
22 3780181 O-Ring - 1" 4
23 3020022 Grease A/R
24 0641506 Bolt 5/16"-18NC x 3/4" 4
25 3311505 Locknut 5/16"-18NC 4
26 0641608 Bolt 3/8"-16NC x 1" 3
27 0641610 Bolt 3/8"-16NC x 1 1/4" 1
28 4751600 Flatwasher 3/8" 2
29 Not Used
30 3311605 Locknut 3/8"-16NC 1
31 0641812 Bolt 1/2"-13NC x 1 1/2" 6
32 0940048 Bumper 1
33 0641806 Bolt 1/2"-13NC x 3/4" 2
34 Not Used
35 3311805 Locknut 1/2"-13NC 3
36 to 41 Not Used
42 4751500 Flatwasher 5/16" 4
43 Not Used
45 0641810 Bolt 1/2"-13NC x 1 1/4" 12
46 to 50 Not Used
3120853 3-3
SECTION 3 BOOM
FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS. (CONTINUED)
51 Tower Boom Weldment Options: 2
S 0800831 Model 40ic
E 0800852 Model 45ic
C
0961726 Bushing, Teflon (4 Per Assembly) 8
52 Link, Level (Base and Mid) Options: 2
T 4844302 Model 40ic
I 4844541
0961726
Model 45ic
Bushing, Teflon (4 Per Assembly) 8
O 53 Upright Weldment (Bottom) Options: 1
N 4844303 Model 40ic
4844427 Model 45ic
54 Not Used
3 55
Main Boom Assembly Options: (See Figure 3-2 for
1
Breakdown)
0800832 Model 40ic
B 0800853 Model 45ic
O 56 Plate, Hose Guard Options: 1
O
3536491 Model 40ic
3537045 Model 45ic
M 57
Cylinder Assembly - Lower Lift Options: (See Section 5
1
for Breakdown) Model 40ic
1682855 (Prior to S/N 29899)
1683518 (S/N 29899 to Present) 1
Cylinder Assembly - Lower Lift Options: (See Section 5
for Breakdown) Model 45ic
1683013 (Prior to S/N 29899)
1683521 (S/N 29899 to Present)
58 Cylinder Assembly - Mid Lift (See Section 5 for 1
Breakdown) Model 40ic
1682861 (Prior to S/N 29899)
1683519 (S/N 29899 to Present)
Cylinder Assembly - Mid Lift (See Section 5 for
Breakdown) Model 45ic
1683018 (Prior to S/N 29899)
1683522 (S/N 29899 to Present)
59 Pin, Pivot Options: 3
3422175 Model 40ic
3422481 Model 45ic
60 Pin, Pivot Options: 9
3422177 Model 40ic
3422480 Model 45ic
61 Tube Options: 1
4566427 Model 40ic
4566356 Model 45ic
3-4 3120853
SECTION 3 BOOM
FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS. (CONTINUED)
0254875 BOOM LIMIT SWITCHES INSTALLATION Ref. 4
S
101 4360321 Switch, Limit 2 E
C
102 4460428 Connector, Strain Relief 2
103 3311005 Locknut #10-24NC 4
104 Not Used T
105
106
3900168
3900097
Screw, Socket Head #10-24NC x 1 1/2"
Screw, Socket Head #10-24NC x 2 1/8"
2
2
I
107 1060341 Cable, Electrical - 16/2 48’14.7m O
108 1670832 Cover, Lower Switch 1 N
109 1680833 Cover, Upper Switch 1
B
O
O
M
3120853 3-5
SECTION 3 BOOM
FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY.
S
E
C
T
I
O
N
B
O
O
M
3-6 3120853
SECTION 3 BOOM
FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY.
MAIN BOOM ASSEMBLY Ref. S
0800832
0800853
Main Boom Assembly Model 40ic
Main Boom Assembly Model 45ic
Ref.
Ref.
O/12
J/12
E
C
1 to 4 Not Used T
I
5 1180302 Power-Track 1
7019698 Links 40
7019699 Bracket, End (Sold in Pairs) 1 O
6
7
4844579
3340663
Holder, Wear Pad (Base Front Bottom)
Pad, Wear (Base Front Top and Sides/Fly Rear Sides
1
8
N
and Bottom)
8 3340666 Pad, Wear (Fly Rear Top) 2 3
9 Not Used
10 1760160 Disc 8
11 0630487 Bolt, Special 6 B
12 3311602 Nut, Jam 3/8"-16NC 8
O
O
13 0641818 Bolt 1/2"-13NC x 2 1/4" 4
14 4761800 Lockwasher 1/2" 4
15 3760115 Ring, Retaining 2 M
16 0641405 Bolt 1/4"-20NC x 5/8" 2
17 0641404 Bolt 1/4"-20NC x 1/2" 2
18 4761400 Lockwasher 1/4" 7
19 0641606 Bolt 3/8"-16NC x 3/4" 7
20 4761600 Lockwasher 3/8" 7
21 0100011 Loctite #242 A/R
22 1670678 Cover, Boom 1
23 1670698 Cover, Boom 1
24 4751400 Flatwasher 1/4" 7
25 3311401 Nut 1/4"-20NC 3
Casting, Wear Pad Holder (Base Front Left Side)
26 1
Options:
4844383 Prior to S/N 35014
1220038 S/N 35014 to Present
Casting, Wear Pad Holder (Base Front Right Side)
27 1
Options:
4844384 Prior to S/N 35014
1220039 S/N 35014 to Present
28 Casting, Wear Pad Holder (Base Front Top) Options: 1
4844386 Prior to S/N 35014
1220040 S/N 35014 to Present
29 0630399 Bolt 3/8"-16NC x 2 1/4" 2
31 4740413 Spacer 5
32 4751600 Flatwasher 3/8" 5
33 0641608 Bolt 3/8"-16NC x 1" 5
34 3520034 Plug, Hole 4
35 to 50 Not Used
3120853 3-7
SECTION 3 BOOM
FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY. (CONTINUED)
51 Base Weldment Options: 1
S 0800833 Model 40 ic
E 0800854 Model 45 ic
C
0961726 Bushing, Teflon 2
52 Fly Weldment Options: 1
T 0800834 Model 40 ic
I 0800855
0961726
Model 45 ic
Bushing, Teflon 2
O Telescope Cylinder Assembly Options: (See Section 5
N
53 1
for Breakdown)
1682887 Model 40 ic
1682947 Model 45 ic
3 54 3422185 Pin, Mounting 1
55 Not Used
56 3340682 Pad, Wear (Base Front Bottom) 1
B
O
O
M
3-8 3120853
SECTION 4 PLATFORMS
TABLE OF CONTENTS
4-1 PLATFORM COMPONENTS INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 ROTATOR MOTOR/PUMP/TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 PLATFORM CONSOLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4 CONTROLLER ASSEMBLY - DRIVE/STEER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
S
3120853 4-1
SECTION 4 PLATFORMS
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
S
4-2 3120853
SECTION 4 PLATFORMS
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
0255995 ROTATOR AND SUPPORT INSTALLATION Ref. C
1 4844465 Support Weldment 1
S
1A 0961608 Bushing, Bronze (Platform Pivot) 2
1B 0961749 Bushing, Bronze (Rotator Cylinder Pivot) 2
1C 1320050 Clamp, Hose 2 E
2
2A
4844466
0961749
Pivot Weldment
Bushing, Bronze (Rotator Cylinder Pivot)
1
2
C
3 1683285
Slave Cylinder Assembly (See Section 5 for
1
T
Breakdown)
I
O
4 1682930 Rotator Cylinder Assembly (See Section 5 for 1
Breakdown)
5 3600253
Rotator Pump, Motor and Tank Assembly
(See Figure 4-2 for Breakdown)
1 N
6 3422176 Pin, Pivot 1
7 3422180 Pin, Pivot 1 4
8 3422181 Pin, Pivot 1
9 3422191 Pin, Pivot 1
10 3841143 Pin, Keeper 3 P
11 3841203 Pin, Keeper 1 L
12
13
4740007
0641607
Washer, Thrust
Bolt 3/8"-16NC x 7/8"
1
8 A
14 0641608 Bolt 3/8"-16NC x 1" 1 T
15 0641810 Bolt 1/2"-13NC x 1 1/4" 1
F
O
16 0641605 Bolt 3/8"-16NC x 5/8" 2
17 Not Used
18 Not Used R
19
20
4751600
4751800
Flatwasher 3/8"
Flatwasher 1/2"
9
2
M
21 3311605 Locknut 3/8"-16NC 9 S
22 3430816 Pin, Clevis 1/2" x 2" 2
23 3450405 Pin, Cotter 2
24 3780181 O-Ring 6
25 3780184 O-Ring 2
26 0460106 Bellows 1
27 1320017 Clamp, Hose 1
28 1320031 Clamp, Hose 1
29 1670690 Cover, Motor 1
30 3941405 Screw, Self-Tapping 1/4" x 5/8" 4
31 4751400 Flatwasher 1/4" 4
32 4761400 Lockwasher 1/4" 4
33 4060855 Shield 1
34 0641505 Bolt 5/16"-18NC x 5/8" 1
35 0641516 Bolt 5/16"-18NC x 2" 2
36 4751500 Flatwasher 5/16" 6
37 3311505 Locknut 5/16"-18NC 3
39 1320159 Clamp, Hose 1
40 0641610 Bolt 3/8"-16NC x 1 1/4" 1
3120853 4-3
SECTION 4 PLATFORMS
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION. (CONTINUED)
101 PLATFORM WELDMENT OPTIONS: 1
Note: Replacement decals must be ordered sepa-
rately - See Section 8.
3510505 Platform - 26" x 48" (Prior to S/N 33712) –
S 3510597
3510501
Platform - 26" x 48" (S/N 33712 to Present)
Platform - 26" x 60" (Prior to S/N 33712)
A/1
–
E 3510595 Platform - 26" x 60" (S/N 33712 to Present) A/1
C
T
0252408 FOOTSWITCH INSTALLATION Ref. D
I 201 4360031 Footswitch Assembly 1
O 202
7000625
4460422
Block, Contact
Connector
2
1
N 203 0641408 Bolt 1/4"-20NC x 1" 3
204 3311401 Nut 1/4"-20NC 3
4
205 4751400 Flatwasher 1/4" 3
206 Not Used
207 4060803 Flex-Trim 2 in./5cm
P OPTIONAL 110VAC RECEPTACLE BOX INSTALLA-

L TION
Ref.
A Optional 110VAC Receptacle Box Installation -

Model 40ic
Ref.
T 0254043
Optional 110VAC Receptacle Box Installation -
Ref. A
F Model 45ic
O 301 Not Available Box, Electrical 1

R 302 Not Available Receptacle, Electrical 1
M 303
304
Not Available
Not Available
Cover, Receptacle
1
1
S 305 Not Available Plug 1
306 Not Used
307 Not Available Screw, Machine #6-32NC x 3/8" 4
308 Not Available Lockwasher #6 4
309 Not Available Gasket 1
310 to 350 Not Used
Harness (Main Boom) Options: (See Section 7 for
351 1
Breakdown)
Not Available Model 40ic
4921595 Model 45ic
Harness (Tower Boom) Options: (See Section 7 for
352 1
Breakdown)
Not Available Model 40ic
4921594 Model 45ic
4-4 3120853
SECTION 4 PLATFORMS
FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION. (CONTINUED)
2901406 OPTIONAL PLATFORM WORKLIGHT KIT Ref. –
401 3536089 Plate, Mounting 2

402 0641414 Bolt 1/4"-20NC x 1 3/4" 4
403
404
3311405
4711400
Locknut 1/4"-20NC
Flatwasher 1/4" Narrow
4
4
S
405 2920140 Floodlight 2 E
406 4240099 Tie-Strap 10 C
407 4360070 Breaker, Circuit - 15 Amp (Not Shown - Located in
Platform Console Box)
1
T
408 Not Used I
409 2820035 Loom, Vinyl (Not Shown) 9 ft./2.7m
O
N
410 4460598 Connector, Strain Relief (Not Shown - Located in 1
Platform Console Box)
0254955 OPTIONAL CONSOLE COVER KIT Ref. A

4
501 1670732 Cover, Console 1
1020005 Button, Tear Away A/R
P
L
1670688 Cover, Tear Away A/R
A
T
F
O
R
M
S
3120853 4-5
SECTION 4 PLATFORMS
FIGURE 4-2. ROTATOR MOTOR/PUMP/TANK ASSEMBLY.
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
S
4-6 3120853
SECTION 4 PLATFORMS
FIGURE 4-2. ROTATOR MOTOR/PUMP/TANK ASSEMBLY.
3600253 ROTATOR MOTOR/PUMP/TANK ASSEMBLY Ref. –
1 Not Serviced Stud, Motor Mounting 2
S
2 7003563 Motor (Includes Mounting Bolts) 1
Not Available Brush/Spring Kit 1
3 7003551 Coupling 1 E
4
5
Kit
Not Serviced
O-Ring
Adapter
1
1
C
6 7003576 Ball, Steel 3 T
7 7003564 Spool 1 I
8
9
7003565
7003566
Body, Check Valve (Includes O-Ring)
Poppet Assembly
1
2 O
10 7003567 Spring 2 N
11 7003568 Retainer, Hex 2
4
12 Not Used
13 7003569 Ball 2
14 7003570 Eyelet 4
15
16
7003571
7003572
Spring
Screw, Thermal Relief Adjusting
4
2
P
17 Kit Seal, Shaft 1 L
18 Kit O-Ring 1
A
T
19 7003573 Pump 1
20 Not Serviced Capscrew, Torx 2
21 Not Used F
22
23
7003554
Not Used
Filter 2
O
24 Not Used R
25 Not Used M
26
27
Not Used
7003574 Ball, Steel 1 S
28 Not Serviced Nut 7/16"-20 2
29 7003575 Screw, Relief Valve Adjusting 2
30 Kit Seal, Reservoir 1
31 7003556 Cap, Reservoir 1
32 7003557 Reservoir 1
33 Not Serviced Spacer 1
34 Kit O-Ring 1
35 Not Serviced Bolt, Self-Tapping 1
––––––––––
Seal Kit (Includes Items 4, 17, 18, 30, 34 & Pump Seals
7003562 1
& O-Rings)
3120853 4-7
SECTION 4 PLATFORMS
FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY.
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
S
4-8 3120853
SECTION 4 PLATFORMS
FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY.
PLATFORM CONSOLE ASSEMBLY Ref.
0861049 Platform Console Assembly - Gas Machines Ref. E
0861068 Platform Console Assembly - Diesel Machines Ref. B
1 0861028 Box Assembly 1 S

1A Not Available Lid 1 E
1B
2
2900859
1600245
Hinge Pin/Retainer/Gasket Kit
Controller Assembly - Drive/Steer (See Figure 4-4 for
1
1
C
Breakdown) T
3 4360407 Potentiometer/Switch (Function Speed) 1 I
4
5
4360387
2560136
Switch, Push Button
Knob
1
1 O
6 4360289 Switch, Push/Pull (Emergency Stop) 1 N
6A 7012611 Head, Mushroom 1
4
6B 7012612 Boot 1
7 4360282 Block, Contact 1
8 4360314 Switch, Toggle 7
9
10
4460234
0140026
Mount, Cable Tie
Alarm
4
1
P
11 1600218 Card, Control 2 L
12 4060802 Guard, Switch 7
A
T
13 3740049 Relay 4
14 3640930 Rail 1
15 4460522 Block, Terminal 3 F
16
17
4460525
4460524
Markers, Terminal
Lock, Terminal
1
3
O
18 3640834 Rail 1 R
19 4460387 Strip, Terminal - 2 Level 10 M
20
21
4460388
4120012
Barrier, Terminal
Base, Relay
5
3 S
22 3740057 Relay 2DPT 3
23 3740066 Spring, Relay 6
25 3300396 Nut, Special 3
28 4460442 Stop, Terminal 2
31 Not Used
32 1702734 Decal, Lid 1
33 3740113 Relay, Time Delay 1
34 3740115 Relay, Time Delay 1
35 3520028 Plug, Hole 1
36 2920120 Light, Indicator - Red 1
37 2920141 Light, Indicator - Green 1
38 Not Used
39 2920108 Bulb 2
40 3790012 O-Ring 7
3120853 4-9
SECTION 4 PLATFORMS
FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY. (CONTINUED)
41 3910616 Screw #6-32NC x 1" 8
43 3911024 Screw #10-24NC x 1 1/2" 2
44 1060329 Lanyard 1
S 45
46
0731003
4751000
Bolt #10-28NF x 3/8"
Flatwasher #10
1
9
E 47 4761000 Lockwasher #10 5
C 48 0641520 Bolt 5/16"-18NC x 2 1/2" 4
T 49
50
4751500
4761500
Flatwasher 5/16"
Lockwasher 5/16"
4
4
I 51 4360161 Breaker, Circuit - 20 Amp 1
O 52 3250028 Plug, Hole 1
N
53 3910608 Screw #6-32NC x 1/2" 4
54 4760600 Lockwasher #6 16
55 4750600 Flatwasher #6 36
4 56
57
3310601
3311001
Nut #6-32NC
Nut #10-24NC
20
4
58 3911012 Screw #10-24NC x 3/4" 2
P 59 0100035 Loctite #272 (Not Shown) A/R
L
A 62 4460305 Screw, Terminal 13
T 63
64
4460306
4460307
Washer, Terminal
Sleeve, Terminal
13
13
F 65 4460301 Number, Terminal Strip 1
O 66 4567058 Spacer 2
R 67
68
4460299
3910620
Stop, Terminal
Screw #6-32NC x 1 1/4"
1
4
M
S 69 to 80 Not Used
81 Card, Control Options: 1

1600251 Gas Machines
1600252 Diesel Machines
7016379 Fuse - 1 Amp 1
7016608 Plug, Connector 1
7016609 Pin 8
4-10 3120853
SECTION 4 PLATFORMS
FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY. (CONTINUED)
CONSOLE OPTIONS: Ref.
101 Not Used

102 4360330 Switch, Toggle - Glow Plugs (Diesel Only) 1
4060802
3790012
Guard, Switch
O-Ring
1
1
S
103 4360112 Breaker, Circuit - 15 Amp (With Worklights) 1 E
104 4360336 Switch, Toggle - Fuel Select (Dual Fuel Only) 1 C
4060802
3790012
Guard, Switch
O-Ring
1
1 T
I
O
N
P
L
A
T
F
O
R
M
S
3120853 4-11
SECTION 4 PLATFORMS
FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER.
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
S
4-12 3120853
SECTION 4 PLATFORMS
FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER.
1600245 OEM CONTROLLER ASSEMBLY (DRIVE/STEER) Ref. C
1 7003978 Handle Assembly 1
S
1A 7003973 Half, Handle 2
1B 7003972 Boot, Switch 1
1C 7003981 Rocker 1 E
1D
2
7003982
7003984
Switch, Micro (Not Shown)
Coupling
2
1
C
3 7003966 Boot 1 T
4 Not Used I
5
6
7003957
7003967
Ring, Retainer
Flatwasher
1
1 O
7 7003968 Detent Assembly 1 N
8 Not Used
4
9 Not Used
10 7003950 Plate, Base 1
11 Not Serviced Pin 1
12
13
Not Serviced
Not Serviced
Shaft/Gear Assembly
Micro Cam Assembly (Includes Items 14-25)
1
1
P
14 Not Serviced Screw 1 L
15 Not Serviced Cam, 4 Hole 1
A
T
18 Not Serviced Cam, 4 Hole 1 F
19
20
Not Serviced
Not Serviced
Spacer, Cam
Spacer, Cam
1
1
O
21 Not Serviced Plate, Cam - Left Side 1 R
22 Not Serviced Coupling, Cam 1 M
23
24
Not Serviced
Not Serviced
Spacer, Cam
Coupling, Cam
1
1 S
25 Not Serviced Spacer, Cam 1
26 Not Serviced Screw 4
Not Serviced Washer 4
27 Not Serviced Screw 4
Not Serviced Washer 4
28 7003961 Micro-Switch 1
29 Not Serviced Insulator 2
30 Not Serviced Insulator, Black 2
31 Not Serviced Nut, Tinnerman 4
32 7003946 Spring, Return 1
34 Not Serviced Bearing 1
35 Not Serviced Washer, Cam Retainer 1
36 7003935 Gear, Slave 1
37 Not Serviced Nut/Cam Assembly 1
38 Not Serviced Coupling, Potentiometer 1
39 Not Serviced Stand-Off 2
40 7003974 Potentiometer 1
41 Not Serviced Washer, Cam Retainer 1
3120853 4-13
SECTION 4 PLATFORMS
FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER. (CONTINUED)
42 Not Serviced Bearing 1
44 Not Serviced Plate, Mounting 1
45 Not Serviced Plate, Potentiometer 1
S 46 Not Serviced
Not Serviced
Screw
Washer
2
2
E 47 Not Serviced Heatsink 1
C 48 Not Serviced Screw 2
T 49
Not Serviced
4460266
Washer
Connector, AMP (9 Pin)
2
1
I 4460268 Socket, Female (9 Pin) 9
O 50 7003986 Strip, Terminal - 3 Position 1
N
51 7003985 Brace 1
52 7019161 Lever Lock 1
P
L
A
T
F
O
R
M
S
4-14 3120853
SECTION 5 CYLINDER
TABLE OF CONTENTS
5-1 UPPER LIFT CYLINDER ASSEMBLIES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 MID LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 LOWER LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-4 MASTER CYLINDER ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-5 PLATFORM ROTATOR CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6 SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-7 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

S
5-8 TELESCOPE CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 E
5-9 OPTIONAL CYLINDER BELLOWS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 C
T
I
O
N
C
Y
L
I
N
D
E
R
3120853 5-1
SECTION 5 CYLINDER
FIGURE 5-1. UPPER LIFT CYLINDER ASSEMBLIES.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-2 3120853
SECTION 5 CYLINDER
FIGURE 5-1. UPPER LIFT CYLINDER ASSEMBLIES.
UPPER LIFT CYLINDER ASSEMBLIES Ref.
1683337 Upper Lift Cylinder Assembly (Prior to S/N 29899) Ref. –
Upper Lift Cylinder Assembly
1683506 Ref. –
(S/N 29899 TO S/N 33090)
Upper Lift Cylinder Assembly
1683520 Ref. 1/A
(S/N 33090 To Present)
1 Not Used
2 Not Used
3 1120108 Retainer 1
4
5
3480115
Not Used
Piston 1
S
6 3300279 Nut, Hex 1 E
7 to 9 Not Used C
T
10 4640936 Cartridge, Holding Valve 1
2900770 Seal Kit - 4640936 Valves 1
11 2220885 Plug 1 I
12
13
3900170
3951402
Setscrew 3/8"-16NC x 3/8"
1
1
O
14 Kit Ring, Lock 2 N
15 Kit Seal, Piston 2
16
17
Kit
Kit
O-Ring
Ring, Wear
1
1
5
18 Kit O-Ring 1
19 Kit Seal, Rod 1
C
Y
20 Kit Wiper Rod 1
21 0100011 Loctite #242 A/R
22 0100038 Primer, Locking A/R L
23
24 to 50
0100035
Not Used
Loctite #222 A/R
I
51 Barrel Weldment Options: 1 N
1682868 Prior to S/N 29899 D
E
1683514 S/N 29899 to Present
51A 0961726 Bushing, Teflon 2
52 Rod Weldment Options: 1 R
1682870 Prior to S/N 29899
1683505 S/N 29899 to Present
53 Head Options: 1
1681344 Prior to S/N 29899
1683504 S/N 29899 to Present
54 4740394 Washer 1
55 Spacer Options: 1
4566009 Prior to S/N 29899
4567177 S/N 29899 to Present
56 to 99 Not Used
100 Seal Kit Options: (Not Shown) 1
2900371 1683337 Cylinder (Prior to S/N 29899)
1683506 & 1683520 Cylinders (S/N 29899 to
2901496
Present)
3120853 5-3
SECTION 5 CYLINDER
FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-4 3120853
SECTION 5 CYLINDER
FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES.
MID LIFT CYLINDER ASSEMBLY - MODEL 45IC Ref.
1683018 (Prior to S/N 33090) Ref. C
1683522 (S/N 33090 To Present) Ref. 1/A
1 Not Used
2 1683021 Rod Weldment 1
4 3480113 Piston 1
5 1682209 Head 1 S
6
7
3300281
4740207
Nut, Hex
Washer
1
1
E
8 4566435 Spacer 1 C
T
I
2900770 Seal Kit - 4640634 1
2900770 Seal Kit - 4640771 Valve 1 O
11
12
2220885
3900170
Plug
2
1
N
13 Not Required
14
15
Kit
Kit
Ring, Lock
Seal, Piston
2
2
5
16 Kit O-Ring 1
17 Kit Ring, Wear 1 C
18
19
Kit
Kit
O-Ring
Seal, Rod
1
1
Y
20 Kit Wiper Rod 1 L
21 0100011 Loctite #242 A/R I
22
23
0100038
0100035
Primer, Locking
Loctite #222
A/R
A/R
N
24 to 50 Not Used D
51 Barrel Weldment Options: 1
E
R
1683019 Prior to S/N 33090
1683516 S/N 33090 to Present
3120853 5-5
SECTION 5 CYLINDER
FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES. (CONTINUED)
MID LIFT CYLINDER ASSEMBLY - MODEL 40IC Ref.
1682861 (Prior to S/N 33090) Ref. B
101 Not Used

103 1120108 Retainer 1
104 3480115 Piston 1
S 105 1681344 Head 1
E 106
107
3300279
4740394
Nut, Hex
Washer
1
1
C 108 4565994 Spacer 1
T 109 4640634 Cartridge, Holding Valve 1
I
2900770 Seal Kit - 4640634 Valve 1
O 2900770 Seal Kit - 4640816 Valve 1
N 111
112
2220885
3900170
Plug
2
1
113 3951402 Setscrew 1/4"-20NC x 1/4" 1
5 114 Kit Ring, Lock 2
116 Kit O-Ring 1
C 117 Kit Ring, Wear 1
Y 118 Kit O-Ring 1
L
119 Kit Seal, Rod 1
120 Kit Wiper, Rod 1
I 121 0100011 Loctite #242 A/R
N 122
123
0100038
0100035
Primer, Locking
Loctite #222
A/R
A/R
D 124 to 150 Not Used
E 151 Barrel Weldment Options: 1
R
1682862 Prior to S/N 33090
1683513 S/N 33090 to Present
5-6 3120853
SECTION 5 CYLINDER
FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES. (CONTINUED)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
3120853 5-7
SECTION 5 CYLINDER
FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-8 3120853
SECTION 5 CYLINDER
FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES.
LOWER LIFT CYLINDER ASSEMBLY - MODEL 45IC Ref.
1683013 (Prior to S/N 33090) Ref. –
1 Not Used
4 3480102 Piston 1
5 1682323 Head 1 S
6
7
3300281
Not Required
Nut, Hex 1
E
8 4566432 Spacer 1 C
T
I
2900770 Seal Kit - 4640634 Valve 1
2900770 Seal Kit - 4640816 Valve 1 O
11
12
2220885
3900170
Plug
2
1
N
13 Not Used
14
15
Kit
Kit
Ring, Lock
Seal, Piston
2
2
5
16 Kit O-Ring 1
17 Kit Ring, Wear 1 C
18
19
Kit
Kit
O-Ring
Seal, Rod
1
1
Y
20 Kit Wiper, Rod 1 L
21 0100011 Loctite #242 A/R I
22
23
0100038
0100035
Primer, Locking
Loctite #222
A/R
A/R
N
24 to 50 Not Used D
51 Barrel Weldment Options: 1
E
R
1683014 Prior to S/N 33090
1683515 S/N 33090 to Present
3120853 5-9
SECTION 5 CYLINDER
FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES. (CONTINUED)
LOWER LIFT CYLINDER ASSEMBLY - MODEL 40IC Ref.
1682855 (Prior to S/N 33090) Ref. C
1683518 (S/N 33090 To Present Ref. 1/A
101 Not Used

103 1120305 Retainer 1
S 104
105
3480113
1682209
Piston
Head
1
1
E 106 3300281 Nut, Hex 1
C 107 4740207 Washer 1
T 108
109
4565992
4640634
Spacer
Cartridge, Holding Valve
1
1
I 2900770 Seal Kit - 4640634 Valve 1
O 110 4640816 Cartridge, Holding Valve 1
N
2900770 Seal Kit - 4640816 Valve 1
111 2220885 Plug 2
112 3900170 Setscrew 3/8"-16NC x 3/8" 1
5 113
114
Not Used
Kit Ring, Lock 2
C 116 Kit O-Ring 1
Y
117 Kit Ring, Wear 1
118 Kit O-Ring 1
L Kit Ring, Back-up 1
I 119
120
Kit
Kit
Seal, Rod
Wiper, Rod
1
1
N 121 0100011 Loctite #242 A/R
D 122 0100038 Primer, Locking A/R
E 123
124 to 150
0100035
Not Used
Loctite #222 A/R
R 151 Barrel Weldment Options: 1

1682856 Prior to S/N 33090
1683512 S/N 33090 to Present
5-10 3120853
SECTION 5 CYLINDER
FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES. (CONTINUED)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
3120853 5-11
SECTION 5 CYLINDER
FIGURE 5-4. MASTER CYLINDER ASSEMBLY.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-12 3120853
SECTION 5 CYLINDER
FIGURE 5-4. MASTER CYLINDER ASSEMBLY.
1683325 MASTER CYLINDER ASSEMBLY Ref. –
1 1682879 Barrel Weldment 1

4 3480217 Piston 1
5 1682154 Head 1
6 3300308 Nut, Hex 1 S
7
8
4566023
3900170
Spacer, Tube
1
1
E
9 Kit T-Seal 1 C
10 Kit Ring, Wear 1
T
I
11 Kit O-Ring 1
12 Kit O-Ring 1
13 Kit Ring, Wear 1 O
14
15
Kit
Kit
Seal, Rod
Wiper, Rod
1
1
N
16 0100038 Primer, Locking A/R
17
18
0100011
0100035
Loctite #242
Loctite #222
A/R
A/R
5
––––––––––
2901147 Seal Kit (Includes Items 9-15) 1 C
Y
L
I
N
D
E
R
3120853 5-13
SECTION 5 CYLINDER
FIGURE 5-5. PLATFORM ROTATOR CYLINDER ASSEMBLY.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-14 3120853
SECTION 5 CYLINDER
FIGURE 5-5. PLATFORM ROTATOR CYLINDER ASSEMBLY.
1682930 PLATFORM ROTATOR CYLINDER ASSEMBLY Ref. –
1 7001609 Nut, Hex 1

2 7001610 Piston 1
3 Kit Seal 1
4 Kit O-Ring 1
6 7001612 Rod 1
7 7001613 Head 1
8 Kit O-Ring 1 S
9
10
Kit
Kit
Ring, Back-up
Seal
1
1
E
11 Kit Wiper 1 C
12 7001614 Ring, Retainer 1
T
I
––––––––––
Seal Kit - 1682930 Cylinder (Includes Items 3,4, and 8-
O
7001608 1
11)
C
Y
L
I
N
D
E
R
3120853 5-15
SECTION 5 CYLINDER
FIGURE 5-6. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-16 3120853
SECTION 5 CYLINDER
FIGURE 5-6. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY.
1683285 SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY Ref. –

4 3480217 Piston 1
5 1682154 Head 1
6 3300308 Nut, Hex 1 S
7
8
4566023
4640932
Spacer, Tube
Cartridge, Holding Valve
1
1
E
7011112 Seal Kit - 4640932 Valve C
9 3900170 Setscrew 3/8"-16NC x 3/8" 1
T
I
10 2200222 Plug, Pipe 1
11 Kit T-Seal 1
12 Kit Ring, Wear 1 O
13
14
Kit
Kit
O-Ring
O-Ring
1
1
N
15 Kit Ring, Wear 1
16
17
Kit
Kit
Seal, Rod
Wiper, Rod
1
1
5
18 0100038 Primer, Locking A/R
19 0100011 Loctite #242 A/R C
20
21
0100035
0100020
Loctite #222
Sealant, Pipe
A/R
A/R
Y
22 Not Used L
23 2220883 Plug, Socket Hex 2 I
2901147
–––––––––
Seal Kit - 1683285 Cylinder (Includes Items 11-17) 1
N
D
E
R
3120853 5-17
SECTION 5 CYLINDER
FIGURE 5-7. STEER CYLINDER ASSEMBLY
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-18 3120853
SECTION 5 CYLINDER
FIGURE 5-7. STEER CYLINDER ASSEMBLY
STEER CYLINDER ASSEMBLY (Was P/N 1683487
Use 1683698 Ref. 2
Prior to S/N 37950)
Barrel Weldment (Was P/N 1682528 Prior to

1 Use 1683694 1
S/N 37950)
2 1682530 Rod 1
3 3480153 Piston 1
4 1682364 Head 2
6
7
4565275
3760141
Spacer
Ring, Retaining
2
2
S
8 Kit Seal, Wiper 2 E
9 Kit Seal, Rod 2 C
T
10 Kit O-Ring 2
11 Kit Ring, Wear 2
12 Kit T-Seal 1 I
13
14
Kit
3860054
O-Ring
Follower, Cam (Prior to S/N 31325)
1
1
O
Use 3860080
Follower, Cam (Was P/N 3860076
1
N
Prior to S/N 37950)
5
15 3321801 Nut 1/2"-20NF 1
16 0100035 Loctite #222 A/R
17 Not Used
18 2220237 Fitting
––––––––––
2
C
2901178 Seal Kit (Includes Items 8-13) 1 Y
L
I
N
D
E
R
3120853 5-19
SECTION 5 CYLINDER
FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLIES.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-20 3120853
SECTION 5 CYLINDER
FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLIES.
TELESCOPE CYLINDER ASSEMBLIES Ref.
1682947 Telescope Cylinder Assembly - 45ic Ref. 3/A
1682887 Telescope Cylinder Assembly - 40ic Ref. D
1 Not Used
2 Not Used
3 3480170 Piston 1
4 1682892 Head 1
5 4566027 Spacer, Tube 1
Counterbalance Valve Assembly (See Items 101-103
6 4640807 1
for Breakdown)
S
E
7 0641512 Bolt 5/16"-18NC x 1 1/2" 4
8 2220883 Plug, O-Ring 2
9 3951402 Setscrew 1/4"-20NC x 1/4" 1 C
10
11
3322205
3760318
Locknut
Ring, Retaining
1
1
T
12 Kit Ring, Wear 2 I
13 Kit Seal, Cap 1 O
N
14 Kit O-Ring 1
15 Kit Ring, Wear 1
16 Kit O-Ring 1
17
18
Kit
Kit
Seal, Rod
Wiper
1
1
5
19 0100011 Loctite #242 A/R
20 Not Used C
21
22
2220628
2220516
Fitting, 90°
Fitting, Cap
2
2
Y
23 3340679 Wear Pad Assembly 1 L
24 0641604 Bolt 3/8"-16NC x 1/2" 2
I
N
25 4761600 Lockwasher 3/8" 2
26 0100011 Loctite #242 A/R
27 to 50 Not Used D
51
1682948
Barrel Weldment Options:
Model 45ic
1
E
1682888 Model 40ic R
52 Rod Weldment Options: 1
1682950 Model 45ic
1682890 Model 40ic
4640807 COUNTERBALANCE VALVE ASSEMBLY Ref. B
101 4640771 Cartridge, Counterbalance 1

102 4640709 Cartridge, Vented Counterbalance 1
103 3790113 O-Ring (Between Valve and Cylinder Block) 2
–––––––––
2900770 Seal Kit (1 Per Cartridge)
3120853 5-21
SECTION 5 CYLINDER
FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION.
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-22 3120853
SECTION 5 CYLINDER
FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION.
0254851 OPTIONAL CYLINDER BELLOWS INSTALLATION - Ref. –
MODEL 45IC
0254028 OPTIONAL CYLINDER BELLOWS INSTALLATION - Ref. –
MODEL 40IC
1 0460110 Bellows, Cylinders (Slave and Master Cylinders) 2

2 0460111 Bellows, Cylinders (Upper Lift Cylinder) 1
3 Bellows, Cylinders (Mid Lift Cylinder) Options: 1
0460113 Model 45ic
0460112 Model 40ic
4 Bellows, Cylinders (Tower Lift Cylinder) 1 S
0460114 Model 45ic
E
C
0460113 Model 40ic
5 0460102 Bellows, Cylinders (Steer Cylinder - Right Side) 1
6 0460103 Bellows, Cylinders (Steer Cylinder - Left Side) 1 T
7
8
1320033
1320037
Clamp
Clamp
2
7
I
O
N
C
Y
L
I
N
D
E
R
3120853 5-23
SECTION 5 CYLINDER
FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION. (CONTINUED)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
5-24 3120853
SECTION 6 HYDRAULIC
TABLE OF CONTENTS
6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 HYDRAULIC DIAGRAM - MANUAL ASCENT (DUTCH AND GERMAN SPEC) . . . . . 6-8
6-3 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
3120853 6-1
SECTION 6 HYDRAULIC
FIGURE 6-1.HYDRAULIC DIAGRAM
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
6-2 3120853
SECTION 6 HYDRAULIC
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
3120853 6-3
SECTION 6 HYDRAULIC
FIGURE 6-1. HYDRAULIC DIAGRAM

2792244 HYDRAULIC DIAGRAM (40IC) Ref. 11
2792277 HYDRAULIC DIAGRAM (45IC) Ref. I

2 2752522 Hose, Suction 1
3 2752486 Hose 2
4 2750834 Hose 1
5 Not Used
6 2220603 Fitting, Straight 10
S 9 2220473 Fitting, 90° 4
E 10 2220738 Fitting, Tee 1
C 11
12
2220622
2752488
Fitting, Reducer
Hose
3
2
T 13 2220657 Fitting, 45° 6
I 14 2750993 Hose 1
O
15 2220416 Fitting, 90° 2
16 2220466 Fitting, 90° 3
N 17 2752433 Hose 1
19 2220502 Fitting, 45° 4
6 20 2752459 Hose 2
H
23 2220873 Fitting, Pipe 2
Y 24 2220428 Fitting, Quick Disconnect 6
D 25
26
2220429 Cap, Dust
Hose Options: 2
6
R 2752619 40ic
A 2752482 45ic (Prior to S/N 28755)
U 27
2753050
2220899
45ic (S/N 28755 to Present)
Fitting, Tee 4
L 28 2752620 Hose 1
I 29 2752580 Hose 2
C
30 2220472 Fitting, 90° 13
31 2752614 Hose 1
33 Hose Options: 1
2753115 40ic
2753113 45ic
34 Hose Options: 1
2753116 40ic
2753114 45ic
35 2752462 Hose 1
36 Hose Options: 2
2752621 40ic
2752426 45ic
6-4 3120853
SECTION 6 HYDRAULIC
FIGURE 6-1. HYDRAULIC DIAGRAM (CONTINUED)

37 Hose Options: 2
2752579 40ic
2752585 45ic
39 2753005 Hose 2
40 2220727 Fitting, Pipe 2
42 2752435 Hose 1
43 2752573 Hose 1
44 2220677 Fitting, 45° 2
45 2752574 Hose 1
S
E
49 2752575 Hose 1 C
50
51
2752581
4566188
Hose
Tube
1
1
T
52 Tube Options: 1 I
4566187 40ic O
53
4566623
4100026
45ic
Sleeve, Nylon 4 N
54 2752438 Hose 1
55
56
1702124
2221020
Tags, Hose (Not Shown)
Fitting, Straight
1
2
6
58 2220934 Fitting, Tee 1 H
59
60
4640861 Bleeder Kit
Hose Options:
1
1
Y
2752441 40ic D
2752440 45ic
R
A
63 2220578 Fitting, 90° 1 U
64
65
2220451
2220600
Fitting, Straight
Fitting, Straight
1
3
L
66 2750763 Hose 1 I
67 2752472 Hose 1 C
68 2752984 Hose 2
70 2752648 Hose 1
71 2752611 Hose 1
72 2752476 Hose 1
73 2752503 Hose 1
74 2752255 Hose 2
76 2751409 Hose 1
77 2751010 Hose 1
79 2752403 Hose 4
3120853 6-5
SECTION 6 HYDRAULIC

81 2752931 Hose 2
82 2752935 Hose 1
83 2752591 Hose 2
84 2752445 Hose 1
85 2752982 Hose 1
86 2752983 Hose 2
87 2752981 Hose 3
89 2220240 Fitting, Plug (Prior to S/N 28820) 1
2220221 Fitting, Plug (S/N 28820 to Present) 1
S 90 2220408 Fitting, Straight 1
E
92 2752404 Hose 1
C 93 2220414 Fitting, Straight 2
T 94
95
2220374
4640994
Fitting, Straight
Valve, Check
2
1
I 96 2752937 Hose 1
O 97 2752938 Hose 1
N 98
99
2752504
2220385
Hose
Fitting, Tee
1
1
100 2220383 Fitting, Tee 1
6 101
102
2220386
0100038
Fitting, 90°
Primer, Loctite
1
A/R
103 0100011 Loctite #242 A/R
H
Y
D
R
A
U
L
I
C
6-6 3120853
SECTION 6 HYDRAULIC

S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
3120853 6-7
SECTION 6 HYDRAULIC
FIGURE 6-2. HYDRAULIC DIAGRAM - MANUAL ASCENT (DUTCH AND GERMAN

SPEC)
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
6-8 3120853
SECTION 6 HYDRAULIC
FIGURE 6-2. HYDRAULIC DIAGRAM - MANUAL ASCENT (DUTCH AND GERMAN SPEC)
HYDRAULIC DIAGRAM - MANUAL ASCENT (DUTCH A
0255522 Ref.
AND GERMAN SPEC)
1 2752478 Hose 2
3 2220775 Fitting, 90° 1
4 2752461 Hose 1
6 4640933 Valve, Manual Lift 1
7012686 Valve Section - Manual Pump 1
7012981 Valve, Cartridge - Relief 1
7010541 Seal Kit - 7010541 Valve 1 S
7 0641514 Bolt 5/16"-18NC x 1 3/4" 2
E
C
8 4751500 Flatwasher 5/16" 2
9 4761500 Lockwasher 5/16" 2
T
I
O
N
H
Y
D
R
A
U
L
I
C
3120853 6-9
SECTION 6 HYDRAULIC
FIGURE 6-3.HYDRAULIC DIAGRAM LIST

Note: Diagrams with asterisk (*) are shown in the
preceding pages. Information on diagrams not
shown are available from JLG Service/Parts Depart-
ments.
2792244* Hydraulic Diagram - 40IC Ref.

2792277* Hydraulic Diagram - 45IC Ref.
2792243 Hydraulic Diagram - 45IC Ref.
Hydraulic Diagram - Manual Ascent
0255522* Ref.
(Dutch and German Spec)
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
6-10 3120853
SECTION 7 ELECTRICAL
TABLE OF CONTENTS
7-1 ELECTRICAL DIAGRAMS AND DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 HARNESS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120853 7-1
FIGURE 7-1. ELECTRICAL DIAGRAMS AND DIAGRAM LIST.

Note: Items with * indicate electrical drawings
shown in this manual. All other electrical drawings
are available from JLG Service Department upon
request.
2901249/4932338 ALARM ELECTRICAL COMPONENTS (MOTION) Ref. –/–

(OPTIONAL - EURO SPEC/ STANDARD -
AUSTRALIAN SPEC)
4921425 Harness 1
0140031 Alarm 1
4392338 BEACON ELECTRICAL DIAGRAM Ref. C
DRIVE CUT-OUT ELECTRICAL DIAGRAMS Ref.

4932859/1282596 ABOVE ELEVATION (B/M ONLY) (ITALIAN SPEC) Ref. –/B
ABOVE ELEVATION TILT (B/M ONLY)
S 4932860/1282596
(FRENCH SPEC)
Ref. –/B
E 4932865/1282581 8 METER (B/M ONLY) (DUTCH & GERMAN SPEC) Ref. –/–
C 4932838 GROUND CONTROL BOX ELECTRICAL DIAGRAM Ref. E/5

T 3730099 Resistor - 20 Ohm/12Watts 1
I
3990010 Diode 6 Amp 12
O 0256524 LIGHT PANEL ELECTRICAL DIAGRAM Ref. A
N 4932870 PLATFORM ELECTRICAL DIAGRAM Ref. 6
7 2901406 PLATFORM WORKLIGHTS ELECTRICAL DIAGRAM Ref. –

4921428 Harness 1
2920140 Worklight 2
E 4360070 Breaker, Circuit - 15 Amp 1
L
E
1870041* STANDARD ELECTRICAL SCHEMATIC Ref. J
C
T
R
I
C
A
L
7-2 3120853
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120853 7-3
FIGURE 7-2. ELECTRICAL DIAGRAM - STANDARD (SHEET 1 OF 4).
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-4 3120853
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120853 7-5
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-6 3120853
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120853 7-7
FIGURE 7-3. HARNESS INSTALLATIONS.
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-8 3120853
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120853 7-9
4932870 PLATFORM ELECTRICAL DIAGRAM Ref. 6
1 to 39 Not Used
40 4460418 Connector - (6 Pin) (To Switches) 7
41 4460419 Terminal, Female 40
42 to 43 Not Used
44 4460267 Pin, Male 14
45 Not Used
46 4460265 Connector - 9 Pin 1
47 4460225 Connector - 6 Pin 1
48 to 49 Not Used
50 3990010 Diode - 6 Amp (Not Shown) 12
51 Not Used
52 4460620 Connector - 15 Socket 3
53 4460621 Socket, Female 25
54 to 63 Not Used
S 64 1060515 Cable, Electrical - 12/4 7ft/2.2m
E
65 1060514 Cable, Electrical - 12/3 8ft/2.5m
66 to 67 Not Used
C 68 4460652 Connector - 15 Position 1
T 69
70
4460653
3730114
Pin, Male
Resistor - 6.8 Ohms 1/4 Watt (Not Shown)
3
1
I
O BOOM HARNESSES AND CLAMPS INSTALLATION Ref.
N
0256142 Model - 40ic Ref. 2
0256138 Model - 45ic Ref. 2
7 101 to 103 Not Used

Block, Hose Clamp (Not Shown - Located on Main
104 0561090 2
Boom)
E 105 0561091 Block, Hose Clamp (Not Shown - Located on Upper 1
L
Upright)
106 Not Used
E 107 3536999 Shield 1
C 108 to 114
115
Not Used
4060805 Trim 1/4" (Not Shown - Located on Upper Upright) 3.58ft/1.09m
T 116 4060808 Trim 1/2" (Not Shown - Located on Mid Boom) 7.74ft/2.36m
R 117 4240099 Tie-Strap (Not Shown - Located on Mid Boom) 26
I
118 to 120 Not Used
121 4566243 Roller (Not Shown - Located on Mid Boom) 1
C 122 to 123 Not Used
A 124 1320205
Clamp, Hose (Not Shown - Located on Lower
Upright)
1
L 125 1670697
Cover, Hose (Not Shown - Located on Upper
1
Upright)
126to 127 Not Used
128 1320040 Clamp, Cable (Not Shown - Located on Lower Boom) 1
129 to 131 Not Used
132 1320195 Cover, Clamp (Not Shown - Located on Main Boom) 1
133 1320199 Clamp (Not Shown - Located on Main Boom) 1
7-10 3120853
FIGURE 7-3. HARNESS INSTALLATIONS. (CONTINUED)
134 to 150 Not Used
Harness Assembly - 16/30 Options: (Main Boom)
151 1
(Includes Items 201 to 204)
4921840 Model - 40ic
4921841 Model - 45ic
Harness Assembly - 16/30 Options: (Tower Boom)
152 1
4921581 Model - 40ic
4921591 Model - 45ic
Harness Assembly - 12/4 Options: (Main Boom)
153 1
4921846 Model - 40ic
4921847 Model - 45ic
Harness Assembly - 12/4 Options: (Tower Boom)
154 1
S
4921844 Model - 40ic
4921845 Model - 45ic E
4921840 HARNESS ASSEMBLY - 16/30 (MAIN BOOM) (40ic) Ref. –
C
4921841 HARNESS ASSEMBLY - 16/30 (MAIN BOOM) (45ic) Ref. – T
I
201 Use 1060516 Cable, Electrical - 16/30 (was P/N 1060229)
Model 40ic
A/R
26 ft./8m O
Model 45ic 27.5 ft./8.4m N
202 4460501 Connector - 31 Pin (Female) 1
7
203 4460464 Pin, Male 30
204 4450466 Seal, Terminal 1
4921581
HARNESS ASSEMBLY - 16/30 (TOWER BOOM)
(40ic)
Ref. A E
4921591
HARNESS ASSEMBLY - 16/30 (TOWER BOOM)
Ref. A L
(45ic)
E
301 Use 1060516 Cable, Electrical - 16/30 (was P/N 1060229) A/R C
Model 40ic 36 ft./11m
T
R
302 Not Used
303 4460500 Connector - 31 Pin (Male) 1 I
304
305
4460465
4460466
Socket, Female
Seal, Terminal
30
1
C
306 Not Used A
307
308
4460470
4460471
Nut, Receptacle (Model 40ic Only)
Lockwasher, Receptacle (Model 40ic Only)
1
1
L
3120853 7-11
4921846 HARNESS ASSEMBLY - 12/4 (MAIN BOOM) (40ic) Ref. A
4921847 HARNESS ASSEMBLY - 12/4 (MAIN BOOM) (45ic) Ref. A
401 1060515 Cable, Electrical - 12/4 A/R

Model 45ic 27.5 ft./8.4m
402 4460505 Connector - 8 Pin (Female) 1
403 4460508 Pin, Male 4
404 4450466 Seal, Terminal 4
4921844 HARNESS ASSEMBLY - 12/4 (TOWER BOOM) (40ic) Ref. A

4921845 HARNESS ASSEMBLY - 12/4 (TOWER BOOM) (45ic) Ref. A
501 1060515 Cable, Electrical - 12/4 A/R

Model 40ic 34 ft./10.4m
Model 45ic 38 ft./11.6m
S 502 4460504 Connector - 8 Pin (Male) 1
E 503
504
4460509
4460466
Socket, Female
Seal, Terminal
4
4
C 505 to 508 Not Required
T 4932838 GROUND CONTROL BOX ELECTRICAL DIAGRAM Ref. 5/E
I 601 to 639 Not Used

O 640 4460418 Connector - (6 Pin (To Switches) 7
N 641
642 to 645
4460419
Not Used
Terminal, Female 40
646 3730099 Resistor 20 Ohm 12 Watt (Not Shown) 1

7 647to 649 Not Used
650 3990010 Diode 6 Amp (Not Shown) 12
E 4921813 HARNESS ASSEMBLY - CHASSIS AND VALVE Ref. B/2
L
E
701 4921794 Valve Harness Assembly 1 2/B
3990001 Diode - 3.5 Amp 2
C 701A 4460499 Connector, DIN 10
T 702
702A
4921795
4460268
Frame Harness Assembly
Socket, Female (To Engine Harness)
1
9
C
R 702B 4460266 Connector - 9 Pin (To Engine Harness/Light Panel) 2

I 702C 4460267 Pin, Male (To Light Panel and Tilt Sensor) 11
C
702D 4460225 Connector - 3 Pin (To Tilt Sensor) 1
702E 4460499 Connector, DIN with Diode 4
A 702F 4460449 Connector, DIN without Diode 4
L 703
704
Not Used
4460426 Connector, Strain Relief 1
705to 709 Not Used
710 3990001 Diode - 3.5 Amp (Not Shown) 1
7-12 3120853
800 4921852 HARNESS ASSEMBLY - VANGUARD Ref. 9/H
801 to 831 Not Used

832 Not Required
833 to 836 Not Used
837 4460265 Connector - 9 Pin 1
838 Not Used 11
839 to 840 Not Used
841 4460656* Housing, Terminal - 2 Position 3
842 4460657* Terminal 18
843 to 845 Not Used
846 4460654* Housing, Terminal - 2 Position 1
847 Not Used 1
848 4460374 Plug, Weatherproof Relay 4
849 4460375 Terminal 18 S
850
851
Not Used
Not Used
E
852 4460658* Housing, Terminal - 4 Position 1 C
853 4460659* Housing, Terminal - 6 Position 1 T
854
855
Not Used
4460655 Terminal - Male 2 I
856 to 869 Not Used O
870
871
3730113
Not Used
Resistor - 10K Ohms/1/2 Watt 1
N
872 3990010 Diode - 6 Amp 1
–––––––––– 7
2901447* Terminal Kit (Includes Items with *Asterisk)
800 4921853 HARNESS ASSEMBLY - YANMAR Ref. 7/G E

L
E
801 to 831 Not Used
Relay - 75 Amp SPST (Glow Plug Relay) (Not
C
832 3740112 1
Shown)
833 to 836
837
Not Used
4460265 Connector - 9 Pin 1 T
838 4460267 Pin, Male 16 R
839 to 842 Not Required
I
C
843 to 845 Not Used
846 Not Required
847 4460445 Connector - 3 Position 2 A
848 to 849
850 to 851
Not Required
Not Used
L
854 Not Used
855 Not Required
856 to 869 Not Used
870 Not Required
871 Not Used
872 Not Required
3120853 7-13
MISCELLANEOUS HARNESS AND CABLES Ref.
901 Not Available Throttle Actuator/Controller Harness (Deutz & Isuzu) 1

Use 2910000 Throttle Actuator & Controller Assembly 1
(was p/n 0060037 / 0060038)
7008833 Mounting Clamp Kit (Not Shown) 1
7008836 Spring, Retract (Not Shown) 1
901A Not Available Throttle Actuator & Harness (Purchase p/n 2910000) 1
7016336 Boot Kit 1
901B Not Serviced Pin, Male 9
901C Not Serviced Connector, Male 1
901D 2910001 Controller & Harnesses (Purchase p/n 2910000) 1
901E Not Serviced Socket, Female 9
901F Not Serviced Connector, Female 1
901G Not Available Connector - 4 Position 1
4460693 Pin, Male 4
S 4460591 Clip 1
E 902
4460608
Not Available
Seal, Terminal
Tilt Indicator Harness
4
1
C 902A 4460205 Connector - 6 Position 1
T 4460268 Socket, Female 6
I
903 Not Available Potentiometer Harness 1
903A 4460205 Connector - 6 Position 1
O 4460268 Socket, Female 6
N 904
904A
Not Available
4460654
Fuel Pump Harness
Connector - 2 Position
1
1
4460655 Terminal 2
7 905 Not Available Trigger Harness 1
4460326 Terminal 3
E 906 Not Available Controller Harness 1
L 906A 4460266 Connector - 9 Position 1
E
4460268 Socket, Female 9
907 Not Available Boom Limits Harness 1
C 1060341 Cable, Electrical - 16/2 49ft/15m
T 908
908A
Not Available
4460654
Fan Harness
Connector - 2 Position
1
1
R 4460655 Terminal 2
I 909 Not Available Timer Module Harness 1
C
4460267 Terminal 3
A 909B 4460326 Connector - 3 Position 1
L 4460268 Socket, Female 3
7-14 3120853
OPTIONAL HARNESS ASSEMBLIES Ref.
1001 Harness Options - 110V Receptacle (Main Boom): 1

4921569 Model 40ic
4921593 Model 45ic
1001A 4460205 Plug, Twistlock 1
1002 Harness Options - 110V Receptacle (Tower Boom): 1
4921568 Model 40ic
4921592 Model 45ic
1002A 4460134 Receptacle, Twistlock 1
1003 Not Available Harness, Light Panel 1
1003A 4460265 Plug, Connector 1
4460268 Socket, Female 7
1004 Not Available Harness, Worklights 1
S
Tools For Service
E
7002822 Screwdriver, Potentiometer (To Adjust Drive 1 C
Controllers) T
7016654
4921850
Screwdriver, Magnetic
Harness For Controller, Service
1
1 I
4922012 Harness For Rexroth Control Cards, Service 1 O
1101
1102
7002828
7002821
Wire Stripper
Wire Crimper (To Install Wire Ends to Wires)
1
1
N
1103 7002823 Pin/Socket Extractor - Universal (To Remove Pins/ 1
Sockets from Connectors) 7
1104 4460467 Extractor - 16-18 Gauge (For Removal of 1
Pins/Sockets for Deutsch Connectors)
4460510 Extractor - 12-14 Gauge (For Removal of 1 E
L
E
C
T
R
I
C
A
L
3120853 7-15
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-16 3120853
SECTION 8 DECALS
TABLE OF CONTENTS
8-1 DECALS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
S
E
C
T
I
O
N
D
E
C
A
L
S
3120853 8-1
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATION.
S
E
C
T
I
O
N
D
E
C
A
L
S
8-2 3120853
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATION.
1282497 DECALS INSTALLATION (STANDARD) Ref. G
1 1701892 Decal - JLG Lift 3

2 to 4 Not Used
5 1701518 Decal - Crushing 6
6 1700584 Decal - Patent 1
7 Not Available Nameplate - Manufacturer’s Serial Number 1
8 3820001 Rivet A/R
9 1701504 Decal - Hydraulic Oil 1
10 1701642 Decal - Arrow 2
11 to 12 Not Used
13 1702631 Decal - Bar Code 1
14 1702928 Decal - CE 1
15 to -18 Not Used
19 0961127 Bushing, Snap 1
20 Not Used
21 0100010 Loctite A/R
22 1701691 Decal - No Step 3
23 1702049 Decal - Manual Descent 1
24 to 27 Not Used
28 1702300 Decal - Tie Down 4
29 1701500 Decal - Lift 4
30 1701640 Decal - Manual 1
31 1580008 Box, Manual Storage 1 S
32 1060279 Lanyard 1
E
C
33 3941003 Screw, Self-Tapping 1
34 3911408 Screw, Round Head 1/4"-20NC x 1/2" 1
35 4711400 Flatwasher 1/4" 1 T
36
37
3311401
4420052
Nut 1/4"-20NC
Tape, Safety
1
16.5ft/4m
I
38 to 44 Not Used O
45
46
1701502
1701503
Decal - High (Hydraulic Oil Level)
Decal - Low (Hydraulic Oil Level)
1
1
N
47 1703248 Decal - Max Wheel Load 4
8
DECAL INSTALLATION (OPTIONAL PARTS) Ref.
100 Decal - Model 2 D

1702934 JLG 40ic E
101
1702932 JLG 45ic
Decal - Fuel 1
C
1701505 Diesel A
1701542 Gas
L
S
102 1701543 Decal - LP Gas 1
103 1702251 Decal - LP Gas Liquid Withdrawal System 1
3120853 8-3
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATION. (CONTINUED)
0256363 DECALS INSTALLATION - AUSTRALIAN SPEC Ref. 5
201 1702258 Decal - Caution 1
202 1701649 Decal - Capacity 1
203 1702265 Decal 1
206 1701818 Decal - Access Forbidden (Prior to S/N 33735) 1
0256359 DECALS INSTALLATION - DUTCH SPEC Ref. 4

202 1701906 Decal - General Caution 1
203 1702268 Decal 1
204 1703518 Decal - Footswitch 1
205 1702545 Decal - Manual Ascent (Prior to S/N 32473) 1
206 Not Required
0256356 DECALS INSTALLATION - ENGLISH (UK) SPEC Ref. 3

203 1702265 Decal 1
204to 206 Not Required
0256357 DECALS INSTALLATION - FRENCH SPEC Ref. 4
S 201 1702259 Decal - Caution 1
E
203 1702270 Decal 1
C 204 1693292 Decal - Footswitch 1
T 205 to 206 Not Required
I 0256360 DECALS INSTALLATION - GERMAN SPEC Ref. 3

O 201 1702262 Decal - Caution 1
N
203 1702267 Decal 1
8 205
206
Not Required
Not Required
D 0256358 DECALS INSTALLATION - ITALIAN SPEC Ref. 3
E 201
202
1702260
1701649
Decal - Caution
Decal - Capacity
1
1
C 203 1702269 Decal 1
A 204 1701600 Decal - Footswitch 1
L
S 0256361 DECALS INSTALLATION - SPANISH SPEC Ref. 3

203 1702266 Decal 1
8-4 3120853
S
SECTION 9 RECOMMENDED SERVICE PARTS STOCK
E
C
MODELS 40ic/45ic Lifts
T
The following lists will service fleets of machines (built to current production per date on the front cover) I
with emergency repair parts which can be installed in the field. Parts from the list should be replaced when
inventory is depleted to keep service parts stock supplied. For further information, contact your JLG
O
dealer or the JLG Industries Parts Department. N
QTY PER FLEET
JLG PART
NUMBER
DESCRIPTION
1-10 10-20 20 OR MORE
9
STANDARD PARTS
R
3740067 Relay, Continuous Duty (Figure 1-6) 1 1 1 E
7012944
7012772
Coil - 4640969 Valve (Figure 1-7)
Coil - 4640969 Valve (Figure 1-7)
1
1
1
1
1
1
C
7015004 Element, Air Filter (Figure 1-8 and 1-10) 12 12 12 O
7014803 Breather/Filler Assembly (Figure 1-13) 1 2 3 M
2120158
3990001
Element, Hydraulic Filter (Figure 1-13)
Diode - 3.5 Amp (Figure 2-1)
4
2
8
2
12
2
M
7017403 Coil (Figure 2-2) 1 1 1 E
7012944 Coil (Figure 2-2) 1 1 1 N
7012943
4360314
Coil (Figure 2-2)
Switch, Toggle (Figures 2-5 and 4-3)
1
1
1
1
1
1
D
4360289 Switch, Emergency Stop (Figures 2-5 and 4-3) 1 1 1 E
4360319 Switch, Key (Figure 2-5) 1 1 1 D
7012560 Key, Replacement (Figure 2-5) 1 1 1
S
4360282 Block, Contact (Figures 2-5 and 4-3) 1 1 1
4360216 Breaker, Circuit - 30 Amp (Figure 2-5) 1 1 1
4360232 Breaker, Circuit - 15 Amp (Figure 2-5) 1 1 1 E
4360164 Breaker, Circuit - 5 Amp (Figure 2-5) 1 1 1 R
3740049
2940006
Relay (Figures 2-5 and 4-3)
Latch (Figure 4-1)
1
1
1
1
1
1
V
4360407 Potentiometer (Figure 4-3) 1 1 1 I
4360387 Switch, Push Button (Figure 4-3) 1 1 1 C
3740057
4360069
Relay - 2DPT (Figure 4-3)
Breaker 10 Amp (Figure 4-3) 1
1
1
1 1
1
E
3740113 Relay, Time Delay (Figure 4-3) 1 1 1
3740115 Relay, Time Delay (Figure 4-3) 1 1 1 P
4360161
7016379
Breaker 20 Amp (Figure 4-3)
Fuse - 1 Amp (Figure 4-3)
1
2
1
2
1
2
A
7003961 Switch, Micro - 1600245 Controller (Figure 4-4) 1 1 1 R
7003782 Switch, Steer - 1600245 Controller (Figure 4-4) 1 1 1 T
7003974
3990010
Potentiometer - 1600245 Controller (Figure 4-4)
Diode - 6 Amp (Figure 7-4)
1
2
1
2
1
2
S
S
T
O
C
K
3120853 9-1
S SECTION 9 RECOMMENDED SERVICE PARTS STOCK
E
C MODELS 40ic/45ic Lifts
T The following lists will service fleets of machines (built to current production per date on the front cover)
with emergency repair parts which can be installed in the field. Parts from the list should be replaced when
I inventory is depleted to keep service parts stock supplied. For further information, contact your JLG
O dealer or the JLG Industries Parts Department.
N VARIABLE PARTS
9 7017600
7018103
Filter, Oil (Vanguard Engine) (Figure 1-8)
Filter, Oil (Yanmar Engine) (Figure 1-10)
12
12
12
12
12
12
3740080 Relay (Vanguard Engine) (Figure 1-8) 1 1 1
R 3740112 Relay (Yanmar Engine) (Figures 1-10 and 7-5) 1 1 1
E 7017500
7017636
Solenoid (Duel Fuel Units) (Figure1-9)
Filter, Fuel (Vanguard Units) (Figure 1-8)
1
1
1
1
1
1
C 7017504 Filter, Fuel (Duel Fuel Units) (Figure 1-9) 1 1 1
O 7018111 Filter, Fuel (Yanmar Engines) (Figure 1-10) 1 1 1
M 4360336 Switch, Toggle (Duel Fuel Units) (Figure 1-9) 1 1 1
M
4360330 Switch, Toggle (Yanmar Engine - Glow Plugs) (Figure 1-10) 1 1 1
4360321 Switch, Limit (Figures 3-1) 1 1 1
E
N
D
E
D
S
E
R
V
I
C
E
P
A
R
T
S
S
T
O
C
K
9-2 3120853
SECTION 10 SPECIAL OPTIONS
S
NOTE: THIS LIST IS TO ACCOMMODATE MACHINES ORDERED WITH SPECIAL EQUIPMENT. OPTIONS MAY NOT BE
APPLICABLE TO ALL MODELS. FOR MORE SPECIFIC PARTS INFORMATION CONTACT THE JLG PARTS DEPARTMENT.
E
C
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. T
10–1 SPECIAL OPTIONS LIST Ref. I
0255027/1282324 Airline Installation - 1/2" (40ic)
Airline Installation - 1/2" (45ic)
Ref.
Ref.
A/B
A/B
O
N
0255015/1282324
0270723 Amber Beacon Installation (Platform) Ref.
1703479 Biodegradable Hydraulic Fluid Decal (German) Ref. 1

10
0256789 Camera Mounting Installation Ref. –
S
Filter Kits (Yanmar Engine) Ref. P
1001110988
Combined Filter Kit (Hydraulic/Air & Fuel/Engine Oil
1 E
1001109678
Filter)
Air Filter Kit 1 C
1001110134 Fuel/Engine Oil Filter Kit 1 I
0255167 Platform Padding Installation - 26" x 48" Platform Ref.
A
– L
Tools For Service
8896941 Wire Stripper 1

O
7002821 Wire Crimper (To Install Wire Ends to Wires) 1 P
7002823 Pin/Socket Extractor - Universal (To Remove Pins/ 1
T
I
Sockets from Connectors)
4460467 Extractor - 16-18 Gauge (For Removal of 1
Pins/Sockets for Deutsch Connectors) O
4460510 Extractor - 12-14 Gauge (For Removal of
1
N
7002822 Screwdriver, Potentiometer (To Adjust Drive 1 S
Controllers)
7016654 Screwdriver, Magnetic 1
7004275 Seal Installation Tool - 1" 1
7004276 Seal Installation Tool - 1 1/2" 1
7002826 Seal Installation Tool - 2" 1
4921850 Harness For Controller, Service 1
4922012 Harness For Rexroth Control Cards, Service 1
0257728 Tube Rack (Installation) Ref.
2900838 U.S. Standards Fastener (Hardware) Kit 1
7014676 U.S. Standards Tool Kit 1
3120853 10-1
E
C
T
I
O
N
10
S
P
E
C
I
A
L
O
P
T
I
O
N
S
10-2 3120853
3120853
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI Ltd
Germany Sheung Shui N. T. Italy 29 Tuas Ave 4,
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Jurong Industrial Estate
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 Singapore, 639379
(852) 2639 5797 +65-6591 9030
+65-6591 9031
Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755 Castellbisbal, Barcelona Sweden
Spain +46 (0)850 659 500
+34 93 772 4700 +46 (0)850 659 534
+34 93 771 1762
www.jlg.com

JGL 45

Uploaded by

Copyright:

Available Formats

JGL 45

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

JGL 45

Uploaded by

Copyright:

Available Formats

Illustrated Parts Manual

August 1, 1996 - Original Issue of Manual

FIGURE NO. TITLE PAGE NO.

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

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

SECTION 4 -PLATFORMS................................................................................................... 4-1

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

SECTION 6 -HYDRAULICS.................................................................................................. 6-1

FIGURE NO. TITLE PAGE NO.

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

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

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

1-2 TIRE AND WHEEL DRIVE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-12 GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1-13 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

1-14 FRAME COVERS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

2780201 HUB ASSEMBLY Ref. D

101 Kit Cup, Bearing - Inner (1 Per Hub) 2

SPINDLE ASSEMBLY Ref.

201 0961621 Bushing (2 Per Spindle) 4

Tire and Wheel Assembly (G78-15 X28 Foam-Filled

T TIRE AND WHEEL INSTALLATIONS - MODEL 45IC Ref.

N Note: Assemblies may require ballast/foam fill-

HUBCAP INSTALLATION - 40IC (G78-15 X28 TIRES)

201 Hubcap Options: 4

0920084 DRIVE BRAKE ASSEMBLY - MICO PRIOR TO S/N 33476 Ref. –

0256405 TILT INDICATOR INSTALLATION Ref. B

101 4360442 Switch, Tilt Indicator 1

O 38 0760605 Bolt 6mm x 10mm 8

2000140 ENGINE COMPONENTS Ref. D

201 7017617 Carburetor 1

T 202 7017620 Starter (Not Shown) 1

R 213 Use 7017641

A 214 7017627 Switch, Water Temperature 1

M 215 7017616 V-Belt 1

0256919/0256910 OIL COOLER INSTALLATION Ref. C/C

301 3620039 Cooler, Oil 1

T 0256000 DUAL FUEL INSTALLATION Ref. G

I 101 2901456 Dual Fuel Kit Assembly (Includes Items 1-28) 1

107 4060802 Guard, Switch (Not Shown - Located at Platform Box) 1

M 111 2720433 Hose 2

O 44 0641608 Bolt 3/8"-16NC x 1" 2

2000145 ENGINES COMPONENTS Ref. B

201 7018100 V-Belt 1

T 0256919/0256910 OIL COOLER INSTALLATION Ref. C/C

I 301 3620039 Cooler, Oil 1

51 Cap, Fuel Options: 1

0256272 LP TANK INSTALLATION (DUAL FUEL OPTION) Ref. B

101 1320228 Clamp Kit 1

51 Cover, Tank Tray Options: 1

0256136 REAR FRAME COVER INSTALLATION Ref. –

101 3535959 Cover 2

2-3 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . 2-8

2-7 TURNTABLE AND HOODS INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

0253708 MANUAL DESCENT COMPONENTS INSTALLATION Ref. C

101 3600179 Pump Assembly 1

2901249 MOTION ALARM KIT Ref. A

Alarm, Horn (Remove ground strap before