Catalogo Plataforma JLG 25-33-40

Illustrated Parts Manual
Models
25RTS
33RTS
40RTS
P/N - 3120692
June 5, 2009
REVISION LOG
March 1993 - Original Issue Of Manual

October 1998 - Revised
January 7, 2000 - Revised (25RTS Manual edited to 0010450 Revision 35)
(33RTS Manual edited to 0010451 Revision 33)
March 1, 2000 - Updated Page 1-2
May 16, 2000 - Updated Page 4-16 & 4-19
April 1, 2001 - Revised (25RTS Manual edited to 0010450 Revision 43)
April 8, 2002 - Revised (25RTS Manual edited to 0010450 Revision 48)
March 21, 2003 - Revised (25RTS Manual edited to 0010450 Revision 49)
December 31, 2006 - Revised (25RTS Manual edited to 0010450 Revision 50)
June 5, 2009 - Revised (25RTS Manual edited to 0010450 Revision 50)
3120692 A
REVISION LOG
B 3120692
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 FRAME, STEERING AND AXLE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 LOCKOUT VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-4 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1-6 DRIVE HUB ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
1-7 DRIVE HUB/BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1-8 FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
1-9 LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION
(FRAME MOUNTED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
1-10 LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION . . . . . . . . . . . . . . . . . . . . . .1-38
1-11 TOW PACKAGE INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES AND TANKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763) . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-3 CONTROL VALVE ASSEMBLY (S/N 26763 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . .2-12
2-4 CONTROL VALVE ASSEMBLY - FPS 4 STACK (LEVELING JACKS OPTION) . . . . . . . .2-14
2-5 ENGINE INSTALLATION - FORD VSG-411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-6 ENGINE INSTALLATION - FORD VSG-413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-7 DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION). . . . . . . . . . . .2-30
2-8 GENERATOR INSTALLATION (FORD ENGINE OPTION). . . . . . . . . . . . . . . . . . . . . . . .2-34
2-9 ENGINE INSTALLATION - DEUTZ F2L1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
2-10 GENERATOR INSTALLATIONS (DEUTZ ENGINE OPTION). . . . . . . . . . . . . . . . . . . . . .2-42
2-11 PISTON PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
2-12 GEAR PUMP ASSEMBLY - JSB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
2-13 GROUND CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
2-14 HOODS AND BEACON LIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
SECTION 3 - SIZZOR ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 SIZZOR ARMS INSTALLATION - 40RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATIONS . . . .4-2
4-2 PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308) . . . . . . . . . . . . . .4-6
4-3 PLATFORM EXTENDABLE INSTALLATIONS (S/N 50308 TO PRESENT) . . . . . . . . . . .4-10
4-4 PLATFORM CONSOLE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-5 DRIVE/LIFT CONTROLLER ASSEMBLY (PRIOR TO S/N 57701) . . . . . . . . . . . . . . . . . .4-16
4-6 DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT) . . . . . . . . . . . . . . .4-18
SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY (OSCILLATING AXLE OPTION). . . . . . . . . . .5-2
5-2 LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (HYDRAULIC
JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS) . . . . . . . . . . . .5-4
5-3 LEVELING JACK CYLINDER ASSEMBLY WITH WELDED ON PIVOT PAD (HYDRAULIC
JACK OPTION WITHOUT INTERLOCK - RECOMMENDED SERVICE REPLACEMENT
CYLINDERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
3120692 i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
5-4 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH

INTERLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 LIFT CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6 STEER CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO JUNE 1993). . . . . . . . . 5-16
5-7 STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT) . . . . . . 5-18
SECTION 6 - HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 HYDRAULIC DIAGRAM - 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-5 HYDRAULIC DIAGRAM - AXLE (OSCILLATING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 ELECTRICAL DIAGRAMS AND COMPONENTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 ELECTRICAL DIAGRAM - DUAL FUEL (FORD ENGINE OPTION). . . . . . . . . . . . . . . . . 7-7
7-3 ELECTRICAL DIAGRAM - 110V GENERATOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-4 ELECTRICAL DIAGRAM - 0610114 CIRCUIT CARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-5 ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (PRIOR TO S/N 61097). . . . . . 7-10
7-5 ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (PRIOR TO S/N 61097). . . . . . 7-11
7-6 ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (S/N 61097 TO PRESENT) . . . 7-12
7-6 ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (S/N 61097 TO PRESENT) . . . 7-13
7-7 ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (PRIOR TO S/N 61097) . . . . . . 7-14
7-7 ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (PRIOR TO S/N 61097) . . . . . . 7-15
7-8 ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (S/N 61097 TO PRESENT). . . . 7-16
7-8 ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (S/N 61097 TO PRESENT). . . . 7-17
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 DECALS INSTALLATIONS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 DECALS INSTALLATIONS - COUNTRY SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SECTION 10 - SPECIAL OPTIONS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
ii 3120692
SECTION 1 FRAME
S
E
TABLE OF CONTENTS C
FIGURE DESCRIPTION
T
I
1-1 FRAME, STEERING AND AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 LOCKOUT VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
O
1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 N
1-4 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-6 DRIVE HUB ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1
1-7 DRIVE HUB/BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-8
1-9
FRAME MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVELING JACKS (WITH INTERLOCK) AND LIGHTS INSTALLATION . . . . . . . . . . . . . . . . . .
1-30
1-34
F
1-10 LEVELING JACKS (WITHOUT INTERLOCK) INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 1-38 R
1-11 TOW PACKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 A
M
E
3120692 1-1
S SECTION 1 FRAME
E FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS
C
T 306
307 514
521
303 512
I 301 505
513
513
505
O 52
514
502
N 308 521
507
309
1 310 508
510 509
F 519
511
R 304 312
317 313
A 305
318 51
319
M 320
402 1
E 302
515
516
417
504 411 533
517 413
414
504 410
527 526
403 418
407 503 404 529
507 504 401 530
505
522 501 415 (LEFT)
406 102 531 (LEFT)
506 408 501B 102A 416 (RIGHT)
524 411 532 (RIGHT)
112 412
414
105 104 109 504
113 110 527
528
108 219
409 217
101 525 220
101A 408 212 218
524
117 103 213
119 107
202
118 106 403
503 404 209
115 505 504 401 210
114 522
501
407 406
507 506 408 501B
524
204
401A 205
501A
208
125 127
124
118
119 116 409
126 408 525
121 524
123 120 207 203
122
201 206
1-2 3120692
SECTION 1 FRAME S
FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS
E
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. C
FRAME WELDMENTS - 2WS Ref. T
2360352
2360465
Prior to S/N44593
S/N44593 to Present
Ref.
Ref.
B
5/D
I
1 See Note Bushing, Bronze (Sizzor Arm Pivot) 4 O
0961664 Bushing, Composite (Sizzor Arm Pivot) 2 N
Note: Use 1 composite-type bushing in place of 2 Ref.
bronze bushings on machines built prior to May
1993. When using existing pins and new composite
type bushings, Graphokote Lube (P/N 3020028) is
1
required at installation. When replacing pivot pins,
use chrome pivot pins and composite type bushings.
Chrome pivot pins require no lubrication at installa-
F
tion. R
FRAME WELDMENTS - 4WS Ref.
A
2360347 Prior to S/N44593 Ref. I M
2360466 S/N44593 to Present Ref. 5/D E
51 See Note Bushing, Bronze (Sizzor Arm Pivot) 4
0961664 Bushing, Composite (Sizzor Arm Pivot) 2
52 0961029 Bushing, Bronze (Kingpin Pivot) 4
Note: Use 1 composite-type bushing in place of 2 Ref.
bronze bushings on machines built prior to May
1993. When using existing pins and new composite
type bushings, Graphokote Lube (P/N 3020028) is
required at installation. When replacing pivot pins,
use chrome pivot pins and composite type bushings.
Chrome pivot pins require no lubrication at installa-
tion.
STEERING INSTALLATION - 2WD FRONT Ref.

0252790 2WD/2WS Common Machines Built Prior to June Ref. B
1994
0255005 2WD/2WS Common Mach Built June 1994 to Ref. 2/B
Present
0252790 2WD/2WS CSA Machines Ref. 3/C
0253059 2WD/4WS Common Machines Built Prior to June Ref. 5/D
1994
0255006 2WD/4WS Common Mach Built June 1994 to Ref. 6/D
Present
0253059 2WD/4WS CSA Machines Ref. 8/F
101 Spindle Weldment (Right Side) Options: 1

4130287 Common Machines Built Prior to June 1994
4130317 Common Machines Built June 1994 to Present
4030287 CSA Machines - All
101A 0960523 Bushing, Bronze (Kingpin Pivot) 2
102 Spindle Weldment (Left Side) Options: 1
4130288 Common Machines Built Prior to June 1994
4130316 Common Machines Built June 1994 to Present
4030288 CSA Machines - All
102A 0960523 Bushing, Bronze (Kingpin Pivot) 2
3120692 1-3
S SECTION 1 FRAME
E FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS (CONTINUED)
C FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
T 103 1682967 Steer Cylinder Assembly (See Section 5 for Break-

down)
1
I 104 1660204 Rod-End (Right Side) 1

O 105
106
3322602
1660205
Nut, Jam 1" - 12NF Right Hand Threads (Left Side)
Rod-End (Left Side)
1
1
N 107 3300228 Nut, Jam 1"-12" NF Left Hand Threads (Right 1
Side)
108 2160002 Fitting, Grease 2
1 109 0642622 Bolt 1" - 8NC x 2 3/4" 2
110 4712600 Flatwasher 1" Narrow 2
F 111
112
0100019
3421243
Loctite (Not Shown)
Kingpin
A/R
2
R 113 0440183 Bearing, Thrust 2
A 114 3323403 Nut, Slotted 1 1/2"-12NF 2
115 3451012 Pin, Cotter 5/16" x 3" 2
M 116 2780177 Hub, Wheel 2
E 117 3960353 Seal, Oil 2
118 0440174 Cup, Bearing 4
119 0440175 Cone, Bearing 4
120 3322603 Nut, Slotted 1" -12NF 2
121 4740034 Washer, Hardened 2
122 3450610 Pin, Cotter 3/16" x 2 1/2" 2
123 1120311 Cap, Hub 2
124 0721004 Screw, Machine #10-24NC x 1/2" 6
125 4761000 Lockwasher #10 6
126 3300012 Nut, Wheel 18
127 0630137 Stud, Wheel 18
STEERING INSTALLATION - 4WD FRONT Ref.

0253078 4WD/2WS Ref. 5/D
0252532 4WD/4WS Ref. 7/E
201 4130279 Spindle Weldment (Right Side) 1

202 4130280 Spindle Weldment (Left Side) 1
203 1682967 Steer Cylinder Assy (See Section 5 for Breakdown) 1
204 1660204 Rod-End (Right Side) 1
205 3322602 Nut, Jam 1"-12NF 1
206 1660205 Rod-End (Left Side) 1
207 3300228 Nut, Jam 1"-12NF Left Hand Thread 1
208 2160003 Fitting, Grease - 45° 4
209 0642622 Bolt 1"-8NC x 2 3/4" 2
211 0100019 Loctite (Not Shown) A/R
212 3421190 Kingpin 4
213 0440161 Bearing, Thrust 4
214 Not Used
215 Not Used
216 Not Used
217 0641608 Bolt 3/8"-16NC x 1" 8
218 4751600 Flatwasher 3/8" 8
1-4 3120692
SECTION 1 FRAME S
FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS (CONTINUED) E
219 1380124 Clip, Retainer (Prior to S/N 69836)
Wire, Safety (4 Pieces 1 ft./30 cm Long)
8
T
220 4920385
(Prior to S/N 69836)
4 ft./1.2m
I
221 0100011 Loctite #242 (S/N 69836 to Present) (Not Shown) A/R
O
STEERING INSTALLATION - 4WS REAR Ref. N
(OPTIONAL)
0253059 2WD/4WS Common Machines Built Prior to June Ref. 5/D
1994 1
0255006 2WD/4WS Common Mach Built June 1994 to Ref. 6/D
Present
0253059 2WD/4WS CSA Machines Ref. 8/F F
0252532 4WD/4WS Ref. 7/E R
301 4130279 Spindle Weldment (Left Side) 1
A
302 4130280 Spindle Weldment (Right Side) 2 M
303 1682967 Steer Cylinder Assy (See Section 5 for Breakdown) 2 E
304 1660204 Rod-End (Right Hand) 2
305 3322602 Nut, Jam 1"-12NF 2
306 1660205 Rod-End (Left Hand) 2
307 3300228 Nut, Jam 1"-12NF Left Hand Thread 2
308 2160003 Fitting, Grease - 45° 8
309 0642622 Bolt 1"-8NC x 2 3/4" 4
312 3421190 Kingpin 8
313 0440161 Bearing, Thrust 8
314 Not Used
315 Not Used
316 Not Used
317 0641608 Bolt 3/8"-16NC x 1" 16
318 4751600 Flatwasher 3/8" 16
319 1380124 Clip, Retainer (Prior to S/N 69836) 16
320 4920385 Wire, Safety (8 Pieces 1 ft./30cm long) 8ft/2.4m
321 0100011 Loctite #242 (S/N 69836 to Present) (Not Shown) A/R
FIXED AXLE INSTALLATION OPTIONS Ref.

0253171 2WD Ref. 4
0253172 4WD Ref. 4
401 Axle Weldment Options: 1

4844129 2WD (Prior to October 1994) 1
4844868 2WD (October 1994 to Present) 1
4844059 4WD (Prior to October 1994) 1
4844867 4WD (October 1994 to Present) 1
401A 0961029 Bushing, Bronze (Kingpin Pivot) (4WD Only) 4
402 0560901 Block, Stop 2
403 0641610 Bolt 3/8"-16NC x 1 1/4" 1
404 4740185 Flatwasher 2
3120692 1-5
S SECTION 1 FRAME
E FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS (CONTINUED)
T 405
406
0100019
4842621
Loctite (Not Shown)
Pin Weldment (Prior to October 1994)
A/R
1
I 3422401 Pin Weldment (October 1994 to Present) 1
O 407 2160002 Fitting, Grease 1
408 3780183 O-Ring (October 1994 to Present) 2
N 409 4640812 Valve, Relief (October 1994 to Present) 1
410 3820030 Rivet, Pop 3/16" (September 1995 to Present) 6
1 411
412
3311605
0641612
Nut 3/8"-16NC (September 1995 to Present)
Bolt 3/8" x 1 1/2"-16NC (September 1995 to
8
4
Present)
F 413 0641614 Bolt 3/8" x 1 3/4"-16NC (September 1995 to
Present)
4
R 414 4751600 Flatwasher (September 1995 to Present) 16

A 415 0902214 Bracket, L.H. (September 1995 to Present) 1
416 0902215 Bracket, R.H. (September 1995 to Present) 1
M 417 3440616 Pin, Roll 3/16" x 1" (September 1995 to Present) 4
E 418 4280298 Strip, Wear 2
OSCILLATING AXLE INSTALLATION - OPTION Ref.

(STANDARD PARTS WHEN EQUIPPED)
0252772 2WD (Prior to S/N 97717) Ref. 11
0271467 2WD (S/N 97717 to Present) Ref. 1
0252525 4WD (Prior to S/N 97717) Ref. 12
0271468 4WD (S/N 97717 to Present) Ref. 1
501 Axle Weldment Options: 1

4844129 2WD (Prior to October 1994)
4844868 2WD (October 1994 to Present)
4844059 4WD (Prior to October 1994)
4844867 4WD (October 1994 to Present)
501A 0961029 Bushing, Bronze (Prior to October 1994) 4
(4WD Machines Only)
0961938 Bushing, Bronze (October 1994 to Present) 2
501B
(2WD & 4WD)
502 1682185 Axle Lockout Cylinder Assembly 2
(See Section 5 for Breakdown)
503 0641608 Bolt 3/8"-16NC x 1" 2
504 4751600 Flatwasher 3/8" 18
505 4761600 Lockwasher 3/8" 4
506 4842621 Pin, Axle Pivot (Prior to October 1994) 1
3422401 Pin, Axle Pivot (October 1994 to Present) 1
508 3422137 Pin, Attach (Bottom) 2
509 0641510 Bolt 5/16"-18NC x 1 1/4" 2
510 3311505 Locknut 5/16"-18NC 2
511 4751500 Flatwasher 5/16" 2
512 3421335 Pin, Attach (Top) 2
513 4740308 Flatwasher, Special 4
514 Use 0641608 Bolt 3/8"-16NC x 3/4" (Was 0641606) 4
515 4640485 Lockout Valve Assembly 1
(See Figure 1-2 for Breakdown)
1-6 3120692
SECTION 1 FRAME S
FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS (CONTINUED) E
516
517
0641632
3311605
Bolt 3/8"-16NC x 4"
Locknut 3/8"-16NC
2
2
T
518 Not Used I
519 3841143 Pin, Keeper 2 O
520 Not Used
521 4640273 Bleeder 6
N
522 4740185 Washer (October 1994 to Present) 2
523
524
0100019
3780183
Loctite (Not Shown)
O-Ring (October 1994 to Present)
A/R
2
1
525 4640812 Valve, Relief (October 1994 to Present) 1
526 3820030 Rivet, Pop 3/16" (September 1995 to Present) 6 F
527
528
3311605
0641612
Nut 3/8"-16NC (September 1995 to Present)
Bolt 3/8" x 1 1/2"-16NC
8
4
R
(September 1995 to Present) A
529 0641614 Bolt 3/8" x 1 3/4" - 16NC
(September 1995 to Present)
4
M
530 4280298 Strip, Wear (September 1995 to Present) 2 E
531 0902214 Bracket, L.H. (September 1995 to Present) 1
532 0902215 Bracket, R.H. (September 1995 to Present) 1
533 3440616 Pin, Roll (September 1995 to Present) 4
3120692 1-7
S SECTION 1 FRAME
E FIGURE 1-2. LOCKOUT VALVE ASSEMBLY
C
T
I
O
N
F
R
A
M
E
1-8 3120692
SECTION 1 FRAME S
FIGURE 1-2. LOCKOUT VALVE ASSEMBLY
E
4640485 LOCKOUT VALVE ASSEMBLY Ref. B T
1 3860037 Roller, Cam 1
I
2 3430407 Pin, Clevis 1/4" x 1" 1 O
3 3840833 Rod, Plunger 1 N
4 3960047 Seal, Rod 1
5 0560679 Block, Valve Top 1
6 3790231 O-Ring 1 1
7 3840854 Rod 4
8 0320008 Ball, Valve 4
9 4160078 Spring 4
F
10 3421284 Pin 2 R
11
12
3790116
2180658
O-Ring
Plug, Modified
1
4
A
13 0641518 Bolt 5/16"-18NC x 2 1/4" 2 M
14 4761500 Lockwasher 5/16" 2 E
15 0560467 Block, Valve 1
16 2200222 Plug 1/4" NPT 1
17 Not Used
18 3450203 Pin, Cotter 1
——————————
0100011 Loctite (Not Shown) A/R
3120692 1-9
S SECTION 1 FRAME
E FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
C
T
I
O
N
F
R
A
M
E
1-10 3120692
SECTION 1 FRAME S
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
E
TIRE AND WHEEL DRIVE INSTALLATIONS Ref. T
0252484 WHEEL DRIVE INSTALLATION - 2WD/2WS Ref. 3
I
O
1 2780169 Drive Hub Assembly (See Figure 1-6 for Breakdown) 2 N
2 3300012 Nut, Wheel 18
3 0642014 Bolt 5/8"-11NC x 1 3/4" 12
4 4762000 Lockwasher 5/8" 12 1
5 Drive Brake Assembly Options 2
(See Figure 1-5 for Breakdown):
0920084 Prior to S/N36660 2 F
0920110 S/N36660 to Present 2 R
6 3160158 Drive Motor Assembly 2
(See Figure 1-4 for Breakdown) A
7 3311801 Nut 1/2"-13NC 4 M
8
9
4761800
4300092
Lockwasher 1/2"
Stud 1/2"-13NC x 5 1/2"
4
4
E
10 4711800 Flatwasher 1/2" Narrow 4
11 0100011 Loctite #242 (Not Shown) A/R
0251661 WHEEL DRIVE INSTALLATION - 2WD/4WS Ref. B
101 2780195 Drive Hub/Brake Assembly 2

103 0642014 Bolt 5/8"-11NC x 1 3/4" 12
104 4762000 Lockwasher 5/8" 12
105 0641810 Bolt 1/2"-13NC x 1 1/4" 4
106 4761800 Lockwasher 1/2" 4
107 3300012 Nut, Wheel 18
0253545 WHEEL DRIVE INSTALLATION - 4WD/2WS FRONT Ref. 2

AND REAR (2MPH)

203 0642014 Bolt 5/8"-11NC x 1 7/8" 24
204 4762000 Lockwasher 5/8" 24
205 0641810 Bolt 1/2"-13NC x 1 1/4" 4
206 4761800 Lockwasher 1/2" 8
207 3300012 Nut, Wheel 36
208 2780167 Drive Hub Assembly (See Figure 1-6 for Breakdown) 2
209 4300092 Stud 1/2"-13NC x 5 1/2" 4
0920084 Prior to S/N36660
0920110 S/N36660 to Present
3120692 1-11
S SECTION 1 FRAME
E FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)
T 211
212
3311801
4711800
Nut 1/2"-13NC
Flatwasher 1/2"
4
4
I 213 0100011 Loctite #242 (Not Shown) A/R
O
0255103 WHEEL DRIVE INSTALLATION - 4WD/2WS FRONT Ref. 2/B
N AND REAR (4MPH)
1 201 2780193 Drive Hub/Brake Assembly

2

F 203 0642014 Bolt 5/8"-11NC x 1 7/8" 24
R 204 4762000 Lockwasher 5/8" 24
A 205
206
0641810
4761800
Bolt 1/2"-13NC x 1 1/4"
Lockwasher 1/2"
4
8
M 207 3300012 Nut, Wheel 1/2"-20NC 36
E 208 2780175 Drive Hub Assembly (See Figure 1-6 for Breakdown) 2
209 4300092 Stud 1/2"-13NC x 5 1/2" 4
0920084 Prior to S/N36660
211 3311801 Nut 1/2"-13NC 4
212 4711800 Flatwasher 1/2" 4
0100011 Loctite #242 (Not Shown) A/R
0251660 WHEEL DRIVE INSTALLATION - 4WD/4WS FRONT Ref. B

FRONT AND REAR (2MPH)

303 0642014 Bolt 5/8" - 11NC x 1 3/4" 24
304 4762000 Lockwasher 5/8" 24
305 0641810 Bolt 1/2"-13NC x 1 1/4" 8
306 4761800 Lockwasher 1/2" 8
307 3300012 Nut, Wheel 36
0250888 TIRE AND WHEEL INSTALLATION - STANDARD Ref. —

31-15.5 x 15
0250886 Tire and Wheel Assembly - Left Side 2 B

0250887 Tire and Wheel Assembly - Right Side 2 B
401 4520123 Tire 4
402 4843635 Wheel 4
403 4640392 Stem, Valve 4
404 Not Required
1-12 3120692
SECTION 1 FRAME S
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) E
TIRE AND WHEEL INSTALLATION - OPTIONAL 12 x
16.5 LOADER LUG:
Ref.
T
0251261 Prior to S/N44591 Ref. — I
0258395 S/N44591 to Present Ref. 1
O
0251260 Tire & Wheel Assy - Left Side (Prior to S/N44591) 2 A N
0258393 Tire & Wheel Assy - Left Side 2 1/A
(S/N44591 to Present)
0251259 Tire & Wheel Assy - Right Side (Prior to S/N44591) 2 —
1
0258394 Tire & Wheel Assy - Right Side 2 1/A
401 4520129 Tire 4
F
402 4860126 Wheel 4 R
403
404
4640113
1702698
Stem, Valve
Decal - Air Pressure (Not Shown)
4
4
A
(Prior to S/N44591 Only) M
E
0258661 TIRE AND WHEEL INSTALLATION - OPTIONAL Ref. 1
31 x 15.50 x 15 (S/N 49250 TO PRESENT)
0258660 Tire & Wheel Assy - Left Side 2 1

0258659 Tire & Wheel Assy - Right Side 2 1
401 4520207 Tire 4
402 4843635 Wheel 4
403 4640392 Stem, Valve 4
404 Not Required
0255660 TIRE AND WHEEL INSTALLATION - OPTIONAL Ref. —

FOAM FILLED 31 x 15.50 x 15
0255661 Tire and Wheel Assembly - Left Side 2 —
0255662 Tire and Wheel Assembly - Right Side 2 —
Note: Assemblies may require ballast/foam filling
to manufacturer’s specifications prior to install-
ing on a machine. Refer to Operation & Safety or
Service & Maintenance Manuals. Purchase indi-
vidual tire and/or rim only if able to foam fill tire &
wheel assembly, otherwise, purchase complete
assembly.
401 4520123 Tire - 31 x 15.50 x 15 4
0253089 TIRE AND WHEEL INSTALLATION - OPTIONAL Ref. —

FOAM FILLED 12 x 16.5 LOADER LUG
0253088 Tire and Wheel Assembly - Left Side 2 —
0253087 Tire and Wheel Assembly - Right Side 2 —
Note: Assemblies may require ballast/foam filling
to manufacturer’s specifications prior to install-
ing on a machine. Refer to Operation & Safety or
Service & Maintenance Manuals. Purchase indi-
vidual tire and/or rim only if able to foam fill tire &
wheel assembly, otherwise, purchase complete
assembly.
401 4520129 Tire - 12 x 16.5 Loader Lug 4
3120692 1-13
S SECTION 1 FRAME
E FIGURE 1-4. DRIVE MOTOR ASSEMBLY
C
T
I
O
N
F
R
A
M
E
1-14 3120692
SECTION 1 FRAME S
FIGURE 1-4. DRIVE MOTOR ASSEMBLY
E
3160158 DRIVE MOTOR ASSEMBLY Ref. A T
1 Kit Ring, Retaining 1
I
2 Kit Seal, Shaft 1 O
3 7004906 Washer 1 N
5 7004907 Race, Thrust 2
6 7004908 Bearing, Thrust 1 1
7 7007874 Shaft, Splined 1
8 7004910 Bearing 1
9 7007875 Housing Assembly (Includes Item 8) 1
F
10 7007876 Insert, Camplate 1 R
11
12
7004917
Kit
Bearing
O-Ring
1
1
A
13 7007878 Back Plate Assembly (Includes Item 11) 1 M
14 7007879 Bolt 6 E
15 7007880 Rotating Kit Assembly (Sold As An Assembly Only) 1
——————————
2900714 Seal Kit (Includes Items 1,2,4 and 12) 1
3120692 1-15
S SECTION 1 FRAME
E FIGURE 1-5. DRIVE BRAKE ASSEMBLY
C
T
I
O
N
F
R
A
M
E
1-16 3120692
SECTION 1 FRAME S
FIGURE 1-5. DRIVE BRAKE ASSEMBLY
E
DRIVE BRAKE ASSEMBLY OPTIONS: Ref. T
0920084
0920110
Prior to S/N 36660
S/N 36660 to Present
Ref.
Ref.
A
C
I
O
1 7011712 Shaft 1 N
2 Guide, Spring Options: 1
7011717 0920084 Brake (Prior to S/N36660)
7018606 0920110 Brake (S/N36660 to Present) 1
3 Spring Options: A/R
7007979 0920084 Brake (Inner) (Prior to S/N36660) 6
7007980 0920084 Brake (Outer) (Prior to S/N36660) 6
F
7007970 0920110 Brake (Red) (S/N36660 to Present) 6 R
4
7018602 0920110 Brake (Blue) (S/N36660 to Present)
Housing Options:
3
1
A
7011713 0920084 Brake (Prior to S/N36660) M
7018605 0920110 Brake (S/N36660 to Present) E
5 Return Plate and Separator Assembly Options: A/R
Kit Plate, Return - 0920084 Brake (Prior to S/N36660) 1
7011715 Separator Assy - 0920084 Brake 2
(Prior to S/N36660)
7011714 Pin 4
7007983 Separator 2
Kit Return Plate/Separator - 0920110 Brake 1
6 Kit Rotor 2
7 Kit Stator 2
8 Kit Seal, Case 1
9 Bolt Options: 4
7007985 0920084 Brake (Prior to S/N36660)
7018607 0920110 Brake (S/N36660 to Present)
10 7007986 Cover 1
11 7007914 Screw, Bleeder (Prior to S/N37659) 1
7018609 Plug, Pipe (S/N37659 to Present) 1
12 7007987 Pin, Dowel 2
13 Kit Seal, Oil 1
14 7011716 Ring, Retainer 1
15 Kit Bearing 1
16 7007977 Ring, Retaining 1
17 Kit Ring, Back-up 1
19 Kit O-Ring 1
20 Kit O-Ring 1
21 Piston Options: 1
7007923 0920084 Brake (Prior to S/N36660)
22 7007933 Gasket 2
23 Kit O-Ring 2
24 7007924 Plug, Pipe 1
——————————
3120692 1-17
S SECTION 1 FRAME
E FIGURE 1-5. DRIVE BRAKE ASSEMBLY (CONTINUED)
T 2900766
2900768
Seal Kit (Includes Items 8,13,17,18,19,20,22 and 23)
Bearing Kit (Includes Items 8,13,14,15,16,22 and 23)
1
1
I Lining Kit Options (Includes Items 5,6,7,8,22 and 23): 1
O 2900767 0920084 Brake (Prior to S/N36660)
N
F
R
A
M
E
1-18 3120692
SECTION 1 FRAME S
FIGURE 1-5. DRIVE BRAKE ASSEMBLY (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120692 1-19
S SECTION 1 FRAME
E FIGURE 1-6. DRIVE HUB ASSEMBLIES
C
T
I
O
N
F
R
A
M
E
1-20 3120692
SECTION 1 FRAME S
FIGURE 1-6. DRIVE HUB ASSEMBLIES
E
DRIVE HUB ASSEMBLIES Ref. T
DRIVE HUB ASSEMBLY OPTIONS: Ref.
I
2780169 2WD/2WS GAS/DIESEL (2MPH) Ref. — O
2780167 4WD/2WS REAR DRIVE ONLY (2MPH) Ref. — N
2780175 4WD/2WS REAR DRIVE ONLY (4MPH) Ref. —
1 7010428 Hub-Spindle Sub Assembly 1 1

(See Items 101-111 for Breakdown)
2 7000246 Gear, Internal 1
3 Carrier Assembly Options: 1 F
7000247
2MPH Machines
R
7000202 4MPH Machines A
4 Gear, Ring Options: 1 M
7007634
7000248
2780175 Hubs
2780167/2780169 Hubs
E
5 7000230 O-Ring 2
6 Cover Assembly (Includes Items 301-308) 1
7 Input Shaft Assembly Options: 1
7000250 2WD Machines
8 Gear, Input Options: 1
9 Spacer, Thrust Options: 1
10 Spacer, Thrust Options: 1
Not Required 2WD Machines
11 7000253 Washer, Thrust 2
7017096 Spacer (S/N 93772 to Present Only) 1
12 Bolt Options: 12
7000217 Prior to S/N 93772
7017067 S/N 93772 to Present
13 Hardware Options: 4
7000214 Bolt Used Prior to S/N 93772
7017080 Dowel Pin Used S/N 93772 to Present
14 7000206 Coupling 1
15 Not Used
7010428 HUB - SPINDLE SUB-ASSEMBLY Ref.
101 7001997 Spindle 1

102 Kit Seal 1
103 Kit Cone, Bearing 1
3120692 1-21
S SECTION 1 FRAME
E FIGURE 1-6. DRIVE HUB ASSEMBLIES (CONTINUED)
T 104
105
Kit
7007697
Cup, Bearing
Bolt, Wheel
1
9
I 106 7000242 Plug, Pipe 2
O 107 7007601 Hub 1
108 7000257 Cup, Bearing 1
N 109 7000258 Cone, Bearing 1
110 Kit Spacer 1
1 111 Kit Ring, Retaining 1
CARRIER ASSEMBLY OPTIONS Ref.

F 7000202 2780175 Hubs Ref.
R 7000247 2780167/2780169 Hubs Ref.
A 201 7001931 Carrier 1

M 202 7001911 Shaft 3
203 7001913 Pin, Roll 3
E 204 7001985 Washer, Thrust 6
205 7001909 Roller, Needle 96
206 7000263 Spacer 3
207 Gear, Cluster Options: 3
7007643 2780175 Hubs
7001912 2780167/2780169 Hubs
COVER ASSEMBLY Ref.

See Kit Options Prior to S/N 93772
See Kit Options S/N 93772 to Present
301 Cover Options: 1

See Kit Options Prior to S/N 93772 (Was p/n 7000226)
7017091 S/N 93772 to Present
302 O-Ring Options: 1
Kit Prior to S/N 93772
7017070 S/N 93772 to Present
303 Cap, Cover 1
Not Required S/N 93772 to Present
7017095 S/N 93772 to Present
305 Rod, Disconnect Options: 1
7017092 S/N 93772 to Present
306 Cap, Disconnect 1
7017093 S/N 93772 to Present
307 Bolt Options: A/R
7000216 Prior to S/N 93772 4
7000216 S/N 93772 to Present 2
1-22 3120692
SECTION 1 FRAME S
FIGURE 1-6. DRIVE HUB ASSEMBLIES (CONTINUED) E
308
7000243
Plug, Pipe Options:
Prior to S/N 93772
A/R
1
T
7017094 S/N 93772 to Present 2 I
O
INPUT SHAFT ASSEMBLY Ref.
7000250 2WD Ref.
N
7007650 4WD Ref.
401 Shaft Options: 1

1
7000260 2WD
7007651 4WD F
402
403
7000263
7000262
Spacer
Spring
2
1
R
404 7000261 Ring, Retaining 1 A
—————————— M
KIT OPTIONS: Ref.
7010429 Bearing Kit (Includes Items 103 and 104) 1
E
7017063 Seal Kit with Old Cover (Includes Items 5, 11, 102, 111,
302, 304) (Prior to S/N 93772)
2900034 Seal Kit (Includes Items 5, 102, 110 and 111) (S/N 1
93772 to Present)
Disconnect and Seal Kit Options (Includes Items 5, 1
102, 110, 111& 302-306):
2900137 Prior to S/N 93772
Not Available S/N 93772 to Present (Purchase Individual Parts)
Cover Kit Options: 1
No Longer Available Prior to S/N 93772 Cast Cover (Was p/n 7001989)
7017099 Prior to S/N 93772 Aluminum Replacement for Cast
Cover (Includes 5, 11 (Spacer), 12, 13 (Dowel Pins),
301, 302 & 304-308)
7017090 S/N 93772 to Present Aluminum Cover (Includes 5,
301 & 304-307)
3120692 1-23
S SECTION 1 FRAME
E FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES
C
T
I
O
N
F
R
A
M
E
1-24 3120692
SECTION 1 FRAME S
FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES
E
DRIVE HUB/BRAKE ASSEMBLY OPTIONS: Ref. T
2780195
2780191
2WD/4WS GAS/DIESEL MACHINES (2MPH)
4WD GAS/DIESEL MACHINES (2MPH)
Ref.
Ref.
—
—
I
2780193 4WD/2WS GAS/DIESEL MACHINES (4MPH) Ref. — O
N
1 See Note Hub/Spindle/Brake Assembly (Note: Not sold as a 1
complete assembly) (See Items 101-113 for
Breakdown) 1
2 7007691 Gear, Internal 1
3 Carrier Assembly Options (See Items 201-207 for 1
Breakdown): F
Not Available
7000247
2WD/4WS Machines
4WD with 2MPH Machines
R
See Note 4WD with 4MPH Machines (Note: Purchase A
7000247 & install (3) 7007643 Cluster Gears to
make this carrier assembly)
M
4 7000248 Gear, Internal 1 E
5 Kit O-Ring 2
6 Cover Assembly 1
7 In put Shaft Assembly Options 1
(See Items 401-404 for Breakdown):
7000250 2WD/4WS Machines
8 Gear, Input Options: 1
9 Spacer, Input Options: 1
10 Spacer, Input Options: 1
Not Required 2WD/4WS Machines
7017096 Spacer (S/N 93772 to Present Only) 1
12 Bolt Options: 12
7000217 Prior to S/N 93772
7017067 S/N 93772 to Present
13 Hardware Options: 4
7000214 Bolt Used Prior to S/N 93772
7017080 Dowel Pin Used S/N 93772 to Present
14 to 15 Not Used
17 7007692 Gasket 1
18 Not Used
19 7010470 Coupling 1
20 Not Used
3120692 1-25
S SECTION 1 FRAME
E FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)
T HUB/SPINDLE/BRAKE SUB-ASSEMBLY Ref.
I 101 Brake Assembly Options: 1

O 7010473 2WD/4WS Machines and 4WD Machines with I.D.
Plate (Item 309) Stamped July 1992 or Later (See
N Items 601-604 for Breakdown)
7010469 4WD Machines with I.D. Plate (Item 309) Stamped
Prior to July 1992 (See Items 501-514 for
1 Breakdown)
102 Kit Seal, Lip 1
103 7007683 Cup, Bearing 1
F 104 7007684 Cone, Bearing 1
R 105 7007685 Cup, Bearing 1
A 106
107
7007686
7007687
Cone, Bearing
Housing
1
1
M 108 7007688 Flatwasher, Tanged 1
E 109 7007689 Flatwasher, Tanged 1
110 7007690 Nut, Bearing 1
111 7000242 Plug, Pipe 1/4" NPT 2
112 7000241 Stud, Wheel 9
113 7007617 Plug, Pipe 3/8" NPT (Magnetic) 2
7000247 CARRIER ASSEMBLY - 4WD(2MPH) MACHINES Ref.

NPN CARRIER ASSEMBLY - 4WD(4MPH) MACHINES Ref.
NPN CARRIER ASSEMBLY - 2WD/4WS MACHINES Ref.
201 7001931 Carrier 1

202 7001985 Washer, Thrust - Tanged 6
203 7001909 Bearing, Needle 96
204 7000263 Spacer, Thrust 3
205 7001911 Shaft, Planet 3
206 Gear, Cluster Options: 3
7001912 4WD with 2MPH Hub and 2WD/4WS
7007643 4WD with 4MPH Hub
207 Rollpin Options: 3
COVER ASSEMBLY Ref.

See Kit Options Prior to S/N 93772
See Kit Options S/N 93772 to Present
301 Cover Options: 1

See Kit Options Prior to S/N 93772 (Was p/n 7000226)
7017091 S/N 93772 to Present
7017070 S/N 93772 to Present
1-26 3120692
SECTION 1 FRAME S
FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED) E
303
Kit
Cap, Cover
Prior to S/N 93772
1
T
Not Required S/N 93772 to Present I
304 O-Ring Options: 1 O
7017095 S/N 93772 to Present
N
305 Rod, Disconnect Options: 1
Kit
7017092
Prior to S/N 93772
1
306 Cap, Disconnect 1
Kit Prior to S/N 93772 F
307
7017093 S/N 93772 to Present
Bolt Options: A/R
R
7000216 Prior to S/N 93772 4 A
7000216 S/N 93772 to Present 2 M
308 Plug, Pipe Options: A/R
7000243 Prior to S/N 93772 1
E
7017094 S/N 93772 to Present 2
———————————
Cover Kit Options: 1
No Longer Available Prior to S/N 93772 Cast Cover (Was p/n 7001989)
7017099 Aluminum Replacement for Prior to S/N 93772 Cast
Cover (Includes 5, 11 (Spacer), 12, 13 (Dowel Pins),
301, 302 & 304-308)
7017090 S/N 93772 to Present Aluminum Cover (Includes 5,
301 & 304-307)
7007650 INPUT SHAFT ASSEMBLY - 4WD MACHINES Ref.

7000250 INPUT SHAFT ASSEMBLY - 2WD/4WS MACHINES Ref.
401 Shaft Options: 1

403 7000262 Spring 1
404 7000263 Spacer, Thrust 2
7010469 BRAKE ASSEMBLY - 4WD MACHINES WITH I.D. Ref.

PLATE (ITEM 309) STAMPED JUNE 1992 OR
EARLIER
501 7014100 Spindle 1

502 7014101 Spacer 1
503 7014102 Disc, Stationary 7
504 7014103 Disc, Rotating 6
506 Kit O-Ring 1
507 Kit Ring, Back-up Ring 1
508 Kit O-Ring 1
509 7014108 Piston 1
3120692 1-27
S SECTION 1 FRAME
E FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED)
T 510 7014109
7014110
Spring
Spring
6
2
I 511 Kit O-Ring 1
O 512 7014112 Cover 1
513 Not Available Bolt, Socket Head 3/8"-16NC x 1 1/4" 8
N 514 7014113 Expander 1
——————————
1 2900816 Brake O-Ring Kit (Includes Items 505-508 and 511) 1
7010473 BRAKE ASSEMBLY - 2WD/4WS MACHINES AND Ref.

F 4WD MACHINES WITH I.D. PLATE (ITEM 309)
STAMPED JULY 1992 OR LATER
R
A 601 7010475 Brake Lining Kit 1
602 7010476 Brake O-Ring Kit 1
M 603 7010477 Brake Spring Repair Kit 1
E 604 7010478 Brake Piston Repair Kit 1
——————————
Seal Kit - Hub (Includes Items 5,17,102, 109, 302
70001940 1
and 304)
1-28 3120692
SECTION 1 FRAME S
FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120692 1-29
S SECTION 1 FRAME
E FIGURE 1-8. FRAME MOUNTED COMPONENTS INSTALLATION
C
T
I
O
N
F
R
A
M
E
1-30 3120692
SECTION 1 FRAME S
FIGURE 1-8. FRAME MOUNTED COMPONENTS INSTALLATION
E
FRAME MOUNTED COMPONENTS INSTALLATION Ref. T
0253080 LIMIT SWITCH INSTALLATIONS Ref. B
I
(PRIOR TO S/N34504) O
N
1 0901855 Bracket, Mounting 1
2 4360300 Switch, Limit 1
3 4460049 Connector, Strain Relief 1 1
4 4751500 Flatwasher 5/16" 2
5 4761500 Lockwasher 5/16" 2
6 3311501 Nut 5/16"-18NC 2 F
7 3440413 Rollpin 1/8" x 13/16" 1 R
8 1100062 Cam (Hi-Drive Cutout) 1
9 0641612 Bolt 3/8"-16NC x 1 1/2" 2
A
10 4761600 Lockwasher 3/8" 2 M
11
12
Not Used
Not Used
E
13 4751600 Flatwasher 3/8" 2
14 Not Used
15 Not Used
16 3931032 Capscrew, Socket Head #10-24NC x 2" 4
17 4751000 Flatwasher #10 4
18 4761000 Lockwasher #10 4
19 3311001 Nut #10-24NC 4
20 Not Used
21 4300038 Stud (Welded on Part) 2
0256924 LIMIT SWITCH INSTALLATION Ref. 2

(S/N34504 TO PRESENT)
51 1100101 Cam (Hi-Drive Cutout) 1

52 0641408 Bolt 1/4"-20NC x 1" 2
53 4761400 Lockwasher 1/4" 2
55 1320237 Clamp 1
56 3440410 Rollpin 1/8" x 5/8" 1
57 3931032 Screw, Machines #10-24NC x 2" 4
58 4751000 Flatwasher #10 4
59 4761000 Lockwasher #10 4
60 3311001 Nut #10-24NC 4
61 to 63 Not Used
66 3440420 Rollpin 1/8" x 1 1/4" 1
67 4360300 Switch, Limit 1
68 4460049 Connector, Strain Relief 1
69 4751500 Flatwasher 5/16" 2
70 4761500 Lockwasher 5/16" 2
71 3311501 Nut 5/16"-18NC 2
3120692 1-31
S SECTION 1 FRAME
E FIGURE 1-8. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED)
T 72 4300038 Stud (Welded on Part) 2
I LADDER INSTALLATION OPTIONS Ref.

O 0252739 25RTS With Fixed & Manual Extended Platform Ref. 5
0252740 25RTS With Traversing Platform Ref. 5
N 0252740 33RTS With Fixed & Manual Extended Platform Ref. 5
0252741 33RTS With Traversing Platform Ref. 5
1 0252741
0252742
40RTS With Fixed & Manual Extended Platform
40RTS With Traversing Platform
Ref.
Ref.
5
5
F 101 Ladder Weldment Options: 1
R 4844119
Prior to S/N 65031
A 4846041 S/N 65031 to Present
M 25RTS With Traversing Platform
4844120 Prior to S/N 65031
E 4846047 S/N 65031 to Present
4844120 Prior to S/N 65031
4846047 S/N 65031 to Present
4844121 Prior to S/N 65031
4846047 S/N 65031 to Present
4844121 Prior to S/N 65031
Use 4846048 S/N 65031 to Present (was p/n 4846047)
4844122 Prior to S/N 65031
4846048 S/N 65031 to Present
102 0641612 Bolt 3/8"-16Nc X 1 1/2" 2
103 4751600 Flatwasher 3/8" 8
104 4761600 Lockwasher 3/8" 4
105 3311605 Locknut 3/8"-16NC 4
106 0641610 Bolt 3/8"-16NC x 1 1/4" 2
107 3520071 Cap-Plug (Prior to S/N 65031) 2
OPTIONAL ALARM INSTALLATION Ref.

0253727 Descent Alarm Installation Ref. B
0253728 Motion Alarm Installation Ref. A
0253446 Travel Alarm Installation Ref. A
201 0140032 Alarm 1

203 4761500 Lockwasher 5/16" 2
204 3311501 Nut 5/16"-18NC 2
205 4751500 Flatwasher 5/16" 2
——————————
3990010 Diode - 6 Amp (Not Shown - Located at Ground A/R
Control)
3740049 Relay (Not Shown - Located at Ground Control) 1
1-32 3120692
SECTION 1 FRAME S
FIGURE 1-8. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED) E
1540002 Capacitor (Not Shown - Located at Ground Con-
trol)
1
T
I
AXLE COVERS INSTALLATION (2WS) (STANDARD
PARTS)
Ref.
O
0253449 Diesel Machines Ref. — N
0253448 Gas/Dual Fuel Machines Ref. —
301 Plate, Cover Options: 2 1

3536092 Diesel Machines
302
4844186
0641510
Gas/Dual Fuel Machines
Bolt 5/16"-18NC x 1 1/4" 8
F
303 4751500 Flatwasher 5/16" 16 R
304 4761500 Lockwasher 5/16" 8 A
305 3311501 Nut 5/16"-18NC 8
M
E
3120692 1-33
S SECTION 1 FRAME
E FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION
C (FRAME MOUNTED)
T
I
O
N
1
41
F
R
A
M 18
27
43
E 22
20
21
19 23
25
24
23
26
40
41
27
18
43
20
22
21
19 23
25
24
23
26
40
1-34 3120692
SECTION 1 FRAME S
FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION (FRAME
E
MOUNTED) C
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. T
0254076 LEVELING JACKS INSTALLATION Ref. 9
I
1 4844554 Jack Cylinder Weldment 2 O
2 1682657 Jack Cylinder Assembly (See Section 5 for Breakdown) 4 N
3 0630327 U-Bolt 16
4 4751700 Flatwasher 7/16" 16
5 3311805 Locknut 1/2-13NC 16 1
6 0642016 Bolt 5/8"-11NC x 2" 8
8 4762000 Lockwasher 5/8" 16 F
9 3312001 Nut 5/8"-11NC 16 R
10 to 14
15
Not Used
1701785 Decal - Caution (Prior to S/N 71528) 4
A
16 to 17 Not Used M
18 Connector, Strain Relief Options: 4 E
4460428 4360321 Switch
4460968 4360548 Switch
19 4360548 Switch, Limit (was p/n 4360321) 4
20 3911020 Screw, Machine #10-24NC x 1 1/4" 8
21 4751000 Flatwasher #10 8
22 3311005 Lock Nut #10-24NC 8
23 3440420 Rollpin 8
25 4160116 Spring 4
26 3841221 Rod 4
27 1060341 Cable, Electrical - 16/2 44ft/13.4m
28 to 39 Not Used
40 4420052 Tape, Safety 8.5ft/2.6m
41 0902293 Bracket 4
42 4921586 Harness, Valve (Not Shown) 1
43 0642018 Bolt 5/8"-11NC x 2 1/4" 8
0253821 HEADLIGHTS & TAILLIGHTS INSTALLATION Ref. 3

(OPTIONAL)
See Section 10 for headlights/taillights at front & rear. Ref.
101 2920110 Headlight Assembly 2
7016628 Lamp, Replacement (1 Per Assembly) 2
102 0901927 Bracket - Headlight 2
104 4761400 Lockwasher 1/4" 4
105 4751400 Flatwasher 1/4" 4
106 3311401 Nut 1/4"-20NC 4
107 2920113 Taillight Assembly 2
Not Available Bulb, Replacement (1 Per Assy) (was p/n 7016626)
108 Not Used
109 0901928 Bracket - Taillight 2
110 0642012 Bolt 5/8"-11NC x 1 1/2" 2
111 4752000 Flatwasher 5/8" 2
3120692 1-35
S SECTION 1 FRAME
E FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION (FRAME
C MOUNTED) (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
T 112 4762000 Lockwasher 5/8" 2
I 113 3312001 Nut 5/8"-20NC 2
O 114 3911040 Screw, Machine #10-24NC x 2 1/2" 4
115 4771000 Starwasher #10 4
N 116 4751000 Flatwasher #10 4
117 3311001 Nut #10-24NC 4
1 1060341
——————————
Cable, Electrical - 16/2 30 ft./9m
3740049 Relay, Bosch (Not Shown - Located at Ground Control) 1
F
R
A
M
E
1-36 3120692
SECTION 1 FRAME S
FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION (FRAME E
MOUNTED) (CONTINUED) C
T
I
O
N
F
R
A
M
E
3120692 1-37
S SECTION 1 FRAME
E FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION
C
T
I
O
N
F
R
A
M
E
1-38 3120692
SECTION 1 FRAME S
FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION
E
LEVELING JACKS INSTALLATION T
0253678
0258290
(S/N 44592 to 101615)
Ref.
Ref.
B
4/B
I
0271581 (S/N 101615 to Present) Ref. 3/B O
N
1 4844346 Jack Cylinder Weldment 2
Jack Cylinder Assembly Options:
2
4
1
Use 1684216 Prior to S/N 101615 (Was P/N 1682720)
Use 1684217 S/N 101615 to Present (Was P/N 1683966)
3 0641828 Bolt 1/2"-13NC x 3 1/2" 16 F
4 Not Used R
5 4761800 Lockwasher 1/2" 16
6 0642016 Bolt 5/8"-11NC x 2" (Prior to S/N 69771) 16
A
0642014 Bolt 5/8"-11NC x 1 3/4" (S/N 69771 to Present) 16 M
7
8
4712000
4762000
Flatwasher 5/8" Narrow
Lockwasher 5/8" (Prior to S/N 69771)
16
16
E
9 3312001 Nut 5/8"-11NC (Prior to S/N 69771) 16
3312005 Locknut 5/8"-11NC (S/N 69771 to Present) 16
10 4420052 Tape, Safety 8.5 ft.
11 4360548 Switch, Limit (was p/n 4360321) 8
12 3930820 Bolt, Socket Head #8-32NC 1 1/4" 16
13 3310805 Lock Nut #8-32NC 16
14 4750800 Flatwasher #8 16
15 Connector, Strain Relief Options: 8
4460428 4360321 Switch
4460968 4360548 Switch
16 Rod Options: 4
3841208 Prior to S/N 44592
3841326 S/N 44592 to Present
17 4160116 Spring 4
18 4740415 Washer, Special 4
19 3440420 Rollpin 8
20 4060848 Cover 4
21 0641406 Bolt 1/4"-20NC x 3/4" 16
22 4751400 Flatwasher 1/4" 16
23 4761400 Lockwasher 1/4" 16
24 Decal - Crushing Danger
1701785 (S/N45396 to 101615) 8
1703875 (S/N 101615 to Present 4
25 Decal, Tie Down Options: 4
Use 1703814 S/N45396 to S/N 71528 (was p/n 1702300)
1703814 S/N 71528 to Present
26 3520082 Plug, Cap (S/N 101615 to Present) 8
3120692 1-39
S SECTION 1 FRAME
E FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION (CONTINUED)
T 0255785
LEVELING JACK COMPONENTS INSTALLATION
(Prior to S/N 101615
Ref.
Ref. 5
I 0271583 (S/N 101615 to Present) Ref. 1
O
101-105 Not Used
N
106 Harness, Valve Options: (Not Shown) 1
1 4921586
4922584
(S/N 101615 to Present)
F
R
A
M
E
1-40 3120692
SECTION 1 FRAME S
FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION (CONTINUED) E
T
I
O
N
F
R
A
M
E
3120692 1-41
S SECTION 1 FRAME
E FIGURE 1-11. TOW PACKAGE INSTALLATION (OPTIONAL)
C
T
I
O
N
F
R
A
M
E
1-42 3120692
SECTION 1 FRAME S
FIGURE 1-11. TOW PACKAGE INSTALLATION (OPTIONAL)
E
TOW PACKAGE INSTALLATION Ref. T
0253079
(STANDARD PARTS WHEN EQUIPPED)
Prior to S/N 98953 Ref. E
I
0271499 S/N 98953 to Present Ref. 1 O
N
1 0362080 Bar 1
2 3536156 Plate, Hitch Attach 1
3 4712600 Flatwasher 1" 4 1
4 2620037 Hitch, Tow 1
5 1660114 Coupling, Tie-Rod 2
6 3323002 Nut, Jam 1 1/4"-12NF 2 F
7 3841184 Tie-Rod 1 R
8 0642624 Bolt 1"-8NC x 3" 1
9 0642636 Bolt 1"-8NC x 4 1/2" 1
A
10 3422091 Pin 1 M
11
12
3841143
2160002
Keeper, Pin
Fitting, Grease
1
1
E
13 0900479 Bracket, Valve Mounting 1
14 4640261 Valve 1
15 0641507 Bolt 5/16"-18NC x 7/8" 2
16 4751500 Flatwasher 5/16" 3
17 4761600 Lockwasher 5/16" 3
18 3250872 Nameplate - Steer/Tow 1
19 3820001 Rivet 4
20 0641508 Bolt 5/16” - 18NC
0253079 Tow Bar Installation (Prior to S/N 98953) Ref. E
101 to 119 Not Used

120 3420292 Pin, Quick Release 2
121 1260017 Chain 2
122 3536157 Plate 2
123 0361651 Bar (Prior to January 1994) 2
3537973 Plate (January 1994 to S/N 98953) 2
124 0362126 Tow Bar Assembly 1
124A 3420352 Pin, Tow 1
3420158 Hairpin 1
125 Not Used
126 Not Used
127 3420372 Hairpin (January 1994 to S/N 98953) 1
0271499 Tow Bar Installation (S/N 98953 to Present) Ref. 1
201 to 221 Not Used

222 0363019 Tow Bar Assembly 1
222A 3420372 Pin, Cotter 1
223 0902733 Bracket 1
224 0902734 Bracket 1
3120692 1-43
S SECTION 1 FRAME
E FIGURE 1-11. TOW PACKAGE INSTALLATION (OPTIONAL) (CONTINUED)
T 225
226
0642018
3312005
Bolt 5/8” - 11NC
Nut 5/8” - 11NC
4
4
I 227 4752000 Flatwasher 5/8” 8
O 228 3340841 Pad (Not Shown) 1
F
R
A
M
E
1-44 3120692
SECTION 2 GROUND COMPONENTS
TABLE OF CONTENTS S
FIGURE DESCRIPTION
E
2-1 CONTROL VALVES AND TANKS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
C
2-2 CONTROL VALVE ASSEMBLY (Prior to S/N 26763) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 T
2-3 CONTROL VALVE ASSEMBLY (S/N 26763 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 I
2-4 CONTROL VALVE ASSEMBLY - FPS 4 STACK (Leveling Jacks Option) . . . . . . . . . . . . . . . . . . 2-14
2-5 ENGINE INSTALLATION - FORD VSG-411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
O
2-6 ENGINE INSTALLATION - FORD VSG-413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 N
2-7 DUAL FUEL INSTALLATION (Ford Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-8 GENERATOR INSTALLATION (Ford Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2-9 ENGINE INSTALLATION - DEUTZ F2L1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2-10 GENERATOR INSTALLATION (Deutz Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 2
2-11 PISTON PUMP ASSEMBLY - SUNSTRAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2-12 GEAR PUMP ASSEMBLY - JSB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2-13 GROUND CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 G
2-14 HOOD AND BEACON LIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-1
FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION
S
E
353
352
354
C
351
T
OR
351A
351B
I
O
N
2 351C
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-2 3120692
FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION
S
CONTROL VALVES AND TANKS INSTALLATION Ref.
E
OPTIONS: C
0253070 2WD/2WS Ref. 14
0253069 2WD/4WS Ref. 13
T
0253063 4WD/2WS Ref. 15 I
0253061 4WD/4WS Ref. 14 O
1 4640123 Solenoid Valve Assembly 1 N
7004368 Coil (Hydraforce Version) 1
7000558 Coil (FPS Version) 1
7012518 Seal Kit (Hydraforce Version) 1
7006075 Seal Kit (FPS Version) 1 2
2 0641420 Bolt 1/4”-20NC x 2 1/2” 1
3 4751400 Flatwasher 1/4” 1
4 3311405 Locknut 1/4”-20NC 1
G
5 1320202 Clamp, Hose A/R R
6 Valve, Flow Divider Options:
2WD Machines:
A/R
O
4640629 Valve (Prior to July 1993) 1 U
4640443 Valve (July 1993 to Present) 1 N
2900745 Seal Kit - 4640629 & 4640443 Valves 1
4WD/2WS Machines:
D
4640260 Valve (Prior to May 1993) 2
Not Available Cartridge (Vickers/Modular Control Version) 1 C
7009739 Seal Kit (Vickers/Modular Control Version) 1
7007321 Cartridge (Fluid Control Version) 1 O
7007323 Seal Kit (Fluid Control Version) 1 M
4640841
7007321
Valve (May 1993 to Present)
Cartridge - 4640481 Valve
2
1
P
4WD/4WS Machines: O
4640260 Valve (Prior to July 1993) 2 N
Not Available Cartridge (Vickers/Modular Control Version) 1
7009739 Seal Kit (Vickers/Modular Control Version) 1
E
7007321 Cartridge (Fluid Control Version) 1 N
7007323
4640847
Seal Kit (Fluid Control Version)
Valve (Not Field Serviceable) (July 1993 to
1
2
T
Present) S
7 4751500 Flatwasher 5/16” A/R
8 3311505 Locknut 5/16”-18NC A/R
9 4751600 Flatwasher 3/8” 16
10 3311605 Locknut 3/8”-16NC 6
11 Control Valve Assembly (Bang-Bang) Options: 1
2WS Machines:
4640578 Prior to July 1993 (See Figure 2-2 for
Breakdown)
4640844 July 1993 to S/N 26763 (See Figure 2-2 for
Breakdown)
4640943 S/N 26763 To Present (See Figure 2-3 for
Breakdown)
3120692 2-3
FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED)
S FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
E 11 (cont’d) 4WS Machines:
C 4640767 Prior to July 1993 (See Figure 2-2 for Break-
down)
T 4640845 July 1993 to S/N 26763 (See Figure 2-2 for
I 4640944
Breakdown)
S/N 26763 To Present (See Figure 2-3 for
O Breakdown)
N 12
13
3100071
0641506
Manifold
Bolt 5/16"-18NC x 3/4"
1
2
14 4761500 Lockwasher 5/16" 2
2 15 2120109 Filter Assembly 1
2120110 Element - 25 Micron 1
2120129 Element - 10 Micron 1
G 16 0901853 Bracket, Valve Mounting 1
R 17 0641608 Bolt 3/8"-16NC x 1" A/R
18 Fuel Tank Options: 1
O 4400273 Prior to S/N 34451
U 4400402 S/N 34451 to S/N 80985
N 19
4400430
Not Used
D 20 2200222 Plug, Pipe 1/4" NPT 3

21 Hydraulic Tank Assembly Options: (See Items 101- 1
112 for Breakdown)
C 4400282 Prior to S/N 82560
O 4400432 S/N 82560 to Present
22 1120361 Cap, Hydraulic Tank 1
M 23 Breather Options: 1
P 1340021 2WD/2WS, 2WD/4WS (Prior to S/N 63184)
O 1340062 2WD/2WS, 2WD/4WS, 4WD/4WS (S/N 63184 to
Present)
N 1340021 4WD/2WS (Prior to S/N 82560)
E 1340062 All Machines (S/N 82560 to Present)
24 4761600 Lockwasher 3/8" 8
N 25 0641511 Bolt 5/16"-18NC x 1 3/8" A/R
T 26 1320187 Clamp, 5/8" Twin Hole A/R
S 27
28
1320188
1320189
Bolt, Stacking
Lockwasher, Stacking
5
5
29 1320190 Plate, Clamp Cover A/R
30 0641514 Bolt 5/16"-18NC x 1 3/4" A/R
31 1320192 Clamp, 7/8" Twin Hole 5
32 1320193 Bolt, Stacking A/R
33 1320194 Lockwasher, Stacking A/R
34 1320195 Plate, Cover A/R
35 Clamp Options: A/R
Not Required 2WD/2WS & 4WD/2WS 0
1320198 2WD/4WS 1
1320197 4WD/4WS 2
Not Required 2WD/2WS, 4WD/2WS & 4WD/4WS 0
1320200 2WD/4WS 1
2-4 3120692
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. S
37 Bolt Options: A/R E
Not Required
0641530
2WD/2WS, 4WD/2WS & 4WD/4WS
2WD/4WS (Bolt 5/16"-18NC x 3 3/4")
0
1
C
38 Link Options: 1 T
3010099 2WD/2WS, 2WD/4WS (July 1993 to S/N 63539) I
3010099 4WD/2WS, 4WD/4WS (July 1993 to Present)
O
Not Required 2WD/2WS & 2WD/4WS 0 N
1320197 4WD/2WS 2
1320198 4WD/4WS 1
Not Required 2WD/2WS & 2WD/4WS 0 2
1320199 2WD/4WS & 4WD/4WS 1
Shield, Flex Trim (Not Shown)
41 4060807
6.75ft/2.05m
G
HYDRAULIC TANK ASSEMBLY OPTIONS: Ref.
R
4400282 Prior to S/N 82560 Ref. C O
4400432 S/N 82560 to Present Ref. A U
101 Tank Options: 1
N
4400274 Prior to S/N 82560 D
4400431 S/N 82560 to Present
102 to 105 Not Used
106 2420115 Gauge, Sight 2 C
107 Plug Options: 1 O
2220240 Prior to S/N 82560
M
108 Plug 1 P
2220242 Prior to S/N 82560 O
109 Plug Options: 1 N
3520022 Prior to S/N 82560 E
110
2200233
0100020
Sealant, Pipe A/R
N
111 2210066 Fitting 1 T
112 2180745 Fitting, Modified 1 S
TILT INDICATOR INSTALLATION OPTIONS: Ref.
0253733 Standard Tilt Indicator Ref. 4
0254111 Tilt Indicator with Drive/Lift Lockout Ref. 4
(w/o Outriggers)
0254262 Tilt Indicator with Drive/Lift Lockout Ref. 4
(w/ Outriggers)
201 Sensor, Level Options: 1
4360348 Prior to S/N 71528
4360354 S/N 71528 to Present
202 0641405 Bolt 1/4"-20NC x 3/4" 2
203 Use 4751400 Lockwasher 1/4"(Was 4761400) 2
204 Use 3311405 Nut 1/4" -20NC (Was 3311401) 2
3120692 2-5
E CONTROL VALVE INSTALLATION - HYDRAULIC Ref.
LEVELING JACKS OPTIONS:
C 0253195 (Prior to S/N 101615) Ref. 3
T
I 301 4640352 Control Valve Assembly - FPS 4 Stack
1
O 302 0641608 Bolt 3/8"-16NC x 1" 2

N 303 4761600 Lockwasher 3/8" 2
304 4711600 Flatwasher 3/8" 2
305 3311605 Locknut 3/8"-16NC 2
2
0271582 (S/N 101615 to Present) Ref. 1
G 351 4641191 Control Valve Assembly 1

R 351A 7023937 Cartridge 1
2900756 Seal Kit 1
O 351B 7017454 Cartridge 4
U 7012903 Seal Kit 4
N 351C 7000645 Coil 8
352 4711600 Flatwasher 3/8” 2
D 353 3311605 Locknut 3/8” - 16NC 2
354 0641626 Bolt 3/8” - 16NC x 3 1/4” 2
C FUEL CAP INSTALLATIONS Ref.

O Prior To S/N 34451 Installation: Ref.
M 401 1120362 Cap, Fuel 1
402 Not Required
P S/N 34451 to S/N 80985 Installations: Ref.
O 0257412 Standard Cap Installation Ref. 2
N 401
402
1120486
2200108
Cap, Fuel
Plug
1
1
E 0257413 Protectoseal Cap Installation Ref. 1
N 401 1120485 Cap, Protectoseal (Not Shown) 1
402 2420183 Gauge, Fuel (Not Shown) 1
T S/N 80985 to Present Installations: Ref.
S Standard Cap Installation Ref. —
401 7020257 Cap, Fuel 1
7016649 Seal, Fuel Cap 1
402 Not Required
0270492 Protectoseal Cap Installation Ref. 1
401 1120485 Cap, Protectoseal (Not Shown) 1
402 Not Required
2-6 3120692
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-7
FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763)
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-8 3120692
FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763)
S
4640578 Bang-Bang Valve Assy (2WS) (Prior to July 1993) Ref. —
E
4640844 Bang-Bang Valve Assy (2WS) (July 1993 to Ref. — C
S/N 26763)
4640767 Bang-Bang Valve Assy (4WS) (Prior to July 1993) Ref. —
T
(Not Shown) I
4640845 Bang-Bang Valve Assy (4WS) (July 1993 to S/N
26763) (Not Shown)
Ref. —
O
N
1 7002304 Dump Section - Complete 1
Solenoid Assembly 1
2 7004823 Seat 1
Kit O-Ring 1 2
3 7002229 Ball 1
Guide Tube Assembly 1
4 7004822 Cone, Female 1 G
Kit O-Ring 1 R
5 7002346 Pin, Push 1
6 7004839 Plunger 1 O
7 7004838 Tube, Guide 1 U
8 7004841
Kit
Pin, Push
O-Ring
1
1
N
9 7002340 Guide, External Push Pin 1 D
Kit O-Ring 1
10 7004834 Sleeve, Inner Flux 1
11 7002334 Spring 1
C
12 7004835 Sleeve, Outer Flux 1 O
13
14
7000417
7004836
Coil
Case, Solenoid
1
1
M
15 7002338 Plate, End 1 P
16 7004837 Screw 4 O
17 7002322 Seat 1
Kit O-Ring 1
N
Main Relief (Poppet) Valve 1 E
18 7002321 Case, Poppet 1 N
19 7002328 Spring 1
20 7002294 Poppet 1 T
21 7002320 Seat, Adjustable 1 S
Kit O-Ring 1
22 7002329 Spring 1
23 7002323 Plug 1
Kit O-Ring 1
24 7002326 Orifice 1
25 7002324 Plug 1
26 7004894 Working Section-Complete (Prior to July 1993) 1
7002444 Working Section-Complete (July 1993 to S/N 26763) 1
26A 7000468 Relief Valve Block Assembly (No Internal Compo- 1
nents Serviced Due to Various Vendors)
26B 7004859 Solenoid Assembly (Refer to Items 30-45 for Ser- 2
viced Parts)
27 7002315 Working Section - Complete 1
3120692 2-9
FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763) (CONTINUED)
E 28 7000468 Relief Valve Block Assembly (No Internal Compo- 1
C 29 7004859 Solenoid Assembly 2
T 30 7003825 Washer, Hat (2 Per Section) 4
I 31 7002348 Spring (2 Per Section) 4
32 7004821 Guide Tube Assembly (2 Per Section) 4
O 33 7002345 Cone, Female (2 Per Section) 4
N Kit O-Ring (2 Per Section) 4
34 7002346 Pin, Push (2 Per Section) 4
35 7002344 Plunger (2 Per Section) 4
2 36 7000470 Tube, Guide (2 Per Section) 4
37 7002341 Pin, Actuator (2 Per Section) 4
Kit Ring, Quad (2 Per Section) 4
G 38 7002340 Guide, External Push Pin (2 Per Section) 4
R Kit O-Ring (2 Per Section) 4
O 39
40
7002333
7002334
Sleeve, Inner Flux (2 Per Section)
Spring (2 Per Section)
4
4
U 41 7002336 Sleeve, Outer Flux (2 Per Section) 4
N 42 7000418 Coil (2 Per Section) 4
43 7002335 Case, Solenoid (2 Per Section) 4
D 44 7002338 Plate, End (2 Per Section) 4
45 7002339 Screw (4 Per Section) 8
C 46 Not Used
47 2220237 Plug 1
O 48 2220238 Plug 1
M 7000414 Seal Kit - Working Section 2
P 7000413 Seal Kit - Dump Section 1
O
N
E
N
T
S
2-10 3120692
FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763) (CONTINUED)
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-11
FIGURE 2-3. CONTROL VALVE ASSEMBLY (S/N 26763 TO PRESENT)
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-12 3120692
FIGURE 2-3. CONTROL VALVE ASSEMBLY (S/N 26763 TO PRESENT)
S
4640943 BANG-BANG VALVE ASSEMBLY (2WS) Ref. —
E
4640944 BANG-BANG VALVE ASSEMBLY (4WS) Ref. — C
(NOT SHOWN)
T
1 7002447 Dump Section - Complete 1 I
2 7002448 Cartridge 1 O
7002449 Seal Kit - 7002448 Cartridge 1
3 7000645 Coil 1 N
4 7002451 Cartridge without Coil 1
7011118 Seal Kit - 7002451 Cartridge 1
5 7000448 O-Ring (Between Items #1 & #151) (Not Shown) 2
6 to 23 Not Used 2
24 7002444 Working Section-Complete 1
25 7011161 Relief Valve Block Assembly (No Internal Compo- 1
nents Serviced Due to Various Vendors) G
26 7004859 Solenoid Assembly (Refer to Items 30-45 for Ser- 2 R
viced Parts)
27 7002315 Working Section - Complete 1 O
28 7000468 Relief Valve Block Assembly (No Internal Compo- 1 U
29 7004859 Solenoid Assembly 2
N
30 7003825 Washer, Hat (2 Per Section) 4 D
31 7002348 Spring (2 Per Section) 4
32 7004821 Guide Tube Assembly (2 Per Section) 4
33 7002345 Cone, Female (2 Per Section) 4 C
Kit O-Ring (2 Per Section) 4 O
34 7002346 Pin, Push (2 Per Section) 4
35 7002344 Plunger (2 Per Section) 4
M
36 7000470 Tube, Guide (2 Per Section) 4 P
37 7002341 Pin, Actuator (2 Per Section) 4 O
Kit Ring, Quad (2 Per Section) 4
38 7002340 Guide, External Push Pin (2 Per Section) 4 N
Kit O-Ring (2 Per Section) 4 E
39
40
7002333
7002334
Sleeve, Inner Flux (2 Per Section)
Spring (2 Per Section)
4
4
N
41 7002336 Sleeve, Outer Flux (2 Per Section) 4 T
42 7000418 Coil (2 Per Section) 4 S
43 7002335 Case, Solenoid (2 Per Section) 4
44 7002338 Plate, End (2 Per Section) 4
45 7002339 Screw (4 Per Section) 8
46 Not Used
47 2220237 Plug 1
48 2220238 Plug 1
7000414 Seal Kit - Working Section 2
3120692 2-13
FIGURE 2-4. CONTROL VALVE ASSEMBLY - FPS 4 STACK (LEVELING JACKS
S OPTION)
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-14 3120692
FIGURE 2-4. CONTROL VALVE ASSEMBLY - FPS 4 STACK (LEVELING JACKS OPTION)
S
4640352 CONTROL VALVE ASSEMBLY - FPS 4 STACK Ref. C
E
(LEVELING JACKS OPTION) C
1 7000585 Nut 6
T
2 7000586 Washer 2 I
3 7006002 Rod, Tie 3 O
5 7000600 Section, Valve - Outlet 1 N
6 Kit O-Ring 5
7 7006041 Section, Valve - Complete 4
8 Spool (Not Sold Separately) (1 Per Section) 4
9 7006037 Retainer, Spring (2 Per Section) 8 2
10 7006036 Spring (2 Per Section) 8
11 7006034 Tube Assembly (2 Per Section) 8
12 Kit O-Ring (2 Per Section) 8
G
13 Kit O-Ring (2 Per Section) 8 R
14
15
4640049 Coil, Solenoid (2 Per Section)
Nameplate (Not Sold Separately) (2 Per Section)
8
8
O
16 7006033 Nut (2 Per Section) 8 U
17 Kit O-Ring (2 Per Section) 8 N
18 7006056 Section, Valve - Inlet 1
19 7006053 Cartridge, Relief 1
D
20 Not Used
21 Kit O-Ring (5 Per Section) 20 C
——————————
7000549 Seal Kit - Single Section 5 O
(Includes Items 12,13,17 and 21) M
7006062 Seal Kit - Standard Outlet (Includes Items 6) 1
P
O
N
E
N
T
S
3120692 2-15
FIGURE 2-5. ENGINE INSTALLATION - FORD VSG-411
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-16 3120692
S
ENGINE ASSEMBLY OPTIONS: Ref.
E
0253688 STANDARD GAS Ref. 15 C
0253690 DUAL FUEL Ref. 16
T
1 Engine Options: 1 I
2000118 Prior to January 1995 O
2000130 January 1995 to September 1995
2000133 September 1995 to S/N 30660
N
2000147 S/N 30660 to Present
2 Pump Options - Sunstrand 1
3600164 Prior to S/N 30660 (13 Teeth) 2
3600260 S/N 30660 to Present (15 Teeth)
3 3600206 Pump Assembly - Barnes 1
(See Figure 2-12 for Breakdown) G
4 4843497 Bracket, Engine Mounting 1 R
5 3533445 Plate, Governor and Carburetor Mounting 1
6 Use 2902064 Controller, Governor (Was P/N 1600117) 1
O
7 2500005 Governor, Precision 1 U
8 0641410 Bolt 1/4"-20NC x 1 1/4" 4 N
9 4761400 Lockwasher 1/4" 9
10 3311401 Nut 1/4"-20NC 9 D
11 0901419 Bracket, Controller 2
12
13
4751400
0641408
Flatwasher 1/4"
Bolt 1/4"-20NC x 1"
5
1
C
14 3911012 Screw, Machine #10-24NC x 3/4" 4 O
15 3311001 Nut #10-24NC 4 M
16 4751000 Flatwasher #10 6
17 4761000 Lockwasher #10 8
P
18 0100009 Adhesive A/R O
19
20
3533291
0701014
Plate, Engine
Bolt, Metric M10 x 30MM
1
5
N
21 4832000 Lockwasher, Metric M10 5 E
22 3200202 Mount, Engine - Rear 2 N
23 3200201 Mount, Engine - Front 1
24 4740273 Washer, Snubbing 2
T
25 4751700 Flatwasher 7/16" 4 S
26 0641726 Bolt 7/16" - 14NC x 3 1/4" 2
27 3311705 Locknut 7/16" - 14NC 2
29 0641826 Bolt 1/2"-13NC x 3 1/4" 1
30 4751800 Flatwasher 1/2" 1
31 3311805 Locknut 1/2"-13NC 2
32 0641608 Bolt 3/8"-16NC x 1" 8
33 4761600 Lockwasher 3/8" 8
34 3311601 Nut 3/8"-16NC 8
35 1060221 Cable, Battery (Engine to Ground) 1
36 0641812 Bolt 1/2"-13NC x 1 1/2" 3
37 4761800 Lockwasher 1/2" 2
3120692 2-17
FIGURE 2-5. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED)
E 38 to 39 Not Used
C 40
0901858
Bracket, Exhaust Support Options:
Standard Gas (Prior to S/N42208)
1
T 4845246 Standard Gas (S/N42208 to Present)

I 0901858 Dual Fuel (Prior to September 1995)
4845246 Dual Fuel (September 1995 to Present)
O 41 Adapter, Carburetor Options: 1
N 0080092 Standard Gas
See Note Dual Fuel (Note: See Figure 2-7 for Call-out)
42 3311405 Locknut 1/4"-20NC 1
2 43 Stud Options: 1
4300056 Standard Gas
G 44
See Note
3841049
Dual Fuel (Note: See Figure 2-7 for Call-out)
Rod, Throttle 1
R 45 3321402 Nut, Jam 1/4"-28NF 2
O 46 1660157 Ball-joint 2
47 Not Used
U 48 2220273 Fitting, Reducer 1
N 49 2180360 Fitting, Tee 1
D 50
51
2420033
4360357
Sender, Oil Pressure
Switch, Pressure
1
1
52 2120135 Filter, Pressure 1
C 2120136 Element, Filter 1
53 1320014 Clamp, Hose 2
O 54 Adapter, Air Intake Options: 1
M 0080175 Standard Gas
P See Note Dual Fuel (Note: See Figure 2-7 for Call-out)
55 3520046 Plug 1
O 56 2720341 Hose - Air Cleaner Outlet 1
N 57 1320058 Clamp, Hose 1
E 58
59
2180537
2200261
Fitting, Nipple
Fitting, Pipe Coupling (Prior to S/N42036 Only)
1
1
N 60 0901778 Bracket 1
T 61 3790152 O-Ring 1
62 0641610 Bolt 3/8"-16NC x 1 1/4" 2
S 63 4740185 Washer, Hardened 2
64 to 66 Not Used
68 Not Used
69 2720042 Hose 18in/46cm
70 1320032 Clamp 2
71 4300090 Stud (Supplied with Engine) 2
72 3321501 Nut 5/16"-24NF 2
73 3536481 Plate, Engine Mounting 1
74 2420118 Sender, Temperature 1
75 0140001 Horn 1
76 2060019 Fan and Spacer Kit (Prior to S/N40684) 1
2901541 Fan and Spacer Kit (S/N40684 to Present) 1
77 Not Used
2-18 3120692
78 0641405 Bolt 1/4"-20NC x 5/8" 2 E
79 to 82
83
Not Used
0641632 Bolt 3/8"-16NC x 4" 2
C
84 3311605 Locknut 3/8"-16NC 2 T
85 4751600 Flatwasher 3/8" 4 I
86 0961378 Bushing 2
87 4460663 Housing, Terminal 1
O
88 4460660 Housing, Terminal 1 N
90 0100020 Sealant, Pipe (Not Shown) A/R
91 4031709 Capscrew, Metric M6-1.25 x 25mm 1
92 3290607 Locknut M6-1.25 1 2
93 7023676 Water Temperature Sender (Not Shown) 1
ENGINE INSTALLATION OPTIONS: Ref. G

0253689/0254153 STANDARD GAS Ref. 1/1 R
0253691/0254154 DUAL FUEL Ref. 1/1
O
101 Not Used U
102
103
4565830
3220084
Tube, Manifold
Muffler
1
1
N
104 1320026 U-Clamp 1 D
105 0901387 Bracket, Exhaust Hanger (Prior to S/N 34962) 1
0902382 Bracket, Exhaust Hanger (S/N 34962 to Present) 1
106 4565956 Tailpipe 1
C
107 1320058 Clamp, Hose 3 O
108
109
4843533
0080039
Tube, Air Intake
Elbow, Rubber
1
1
M
110 1340020 Air Cleaner Assembly 1 P
7004214 Element 1 O
111 0340002 Band, Air Cleaner Mounting 2
112 1120161 Cap, Air Inlet 1
N
113 0641406 Bolt 1/4"-20NC x 3/4" 4 E
114 4761400 Lockwasher 1/4" 4 N
115 3311401 Nut 1/4"-20NC 4
116 2220675 Fitting, 90° 1 T
117 4761600 Lockwasher 3/8" 9 S
118 3311601 Nut 3/8"-16NC 9
119 0641710 Bolt 7/16"-14NC x 1 1/4" 2
120 3533663 Plate, Radiator Mounting 1
121 0630403 Bolt, Carriage 7/16"-14NC x 1 1/2" 2
122 4751700 Flatwasher 7/16" 2
123 3311705 Locknut 7/16"-14NC 2
124 4761700 Lockwasher 7/16" 2
125 3311701 Nut 7/16"-14NC 2
126 3533664 Plate, Radiator Support 1
128 4751500 Flatwasher 5/16" 5
129 3311501 Nut 5/16"-18NC 5
3120692 2-19
E 130 0641508 Bolt 5/16"-18NC x 1" 1
C 131
132
4761500
0641610
Lockwasher 5/16"
Bolt 3/8"-16NC x 1 1/4"
2
6
T 133 4751600 Flatwasher 3/8" 15
I 134 4060713 Shield 1
135 3536151 Guard, Exhaust 1
O 136 1320022 Clamp 2
N 137 2720058 Hose, Fuel Line 6 ft./1.8m
138 0721004 Bolt #10-24NC x 1/2" 3
139 Not Used
2 140 0400003 Battery 1
141 3980003 Masonite 1
G 142
143
1060254
3300029
Cable, Battery (Battery + to Starter Solenoid)
Wingnut 3/8"-16NC
1
2
R 144 3536144 Cover, Battery 1
O 145 1060360 Cable, Battery (Battery Neg to Ground) 1
146 0630370 Rod, Tie-Down 2
U 147 0400002 Tie-Down, Battery 1
N 148 3620027 Radiator 1
D 149
150
Not Used
1320020 U-Clamp 1 1/2" 1
151 1320026 U-Clamp 1 3/4" 1
C
PUMP COUPLING INSTALLATION Ref.
O 0252808 2000118 Engine Assemblies (Prior to Sept. 1995) Ref. —
M Supplied with 2000130/2000133/2000147 Engine Assemblies Ref.
P Engine (Sept. 1995 to Present)
O 201 Pump Coupling Options: 1

N 1660207 13 Teeth Pump
7016661 15 Teeth Pump
E 202 0080163 Adapter, Pump Mounting 1
N 203 0700808 Bolt, Metric 8mm 1.25 x 16mm 6
T 204
205
4831900
0641610
Lockwasher, Metric 8mm
Bolt 3/8"-16NC x 1 1/4"
6
8
S 206 4761600 Lockwasher 3/8" 8
207 3020021 Grease, Coupling (Not Shown) A/R
Note: Coupling Spline must be greased with lithium Ref.
soap based grease prior to installation.
SPARE COMPONENTS Ref.
7014680 Spare Components Kit (Includes Carburetor, Fuel 1

Pump, Water Pump, Bosch Alternator, Starter & Igni-
tion Control)
7014687 Spare Components Kit (Includes Carburetor, Fuel 1
Pump, Water Pump, Prestolite Alternator, Starter &
Ignition Control
300 7019665 Control, Ignition 1
2-20 3120692
301 7000892 Carburetor (Standard Gas) 1 E
7023471
Use 7019933
Assembly, Float (Not Shown)
Carburetor Rebuild Kit (Was 7000878)
1
1
C
301A 7000894 Choke, Automatic 1 T
301 1140009 Carburetor (LP Gas Only) (Not Included in 1 I
Components Kits)
302 Alternator Options: 1
O
7000893 Bosch N
Use 7019670 Prestolite (was p/n 7012653)
303 7012577 Fitting, Vacuum Line 1
304 7012578 Vacuum Line Assembly 1
305 7000884 Fuel Shut-Off 1 2
306 7023668 Tune-Up Kit (Includes Oil and Fuel Filters, Spark 1
Plugs and Wire Set)
7014500 Filter, Oil - Case of 12 (Only 1 included in Kit) 1 G
307 7014681 Engine Kit
(Includes Hoses, Gasket Set Belt and Coil)
1
R
308 7012564 Wiring Harness (Not Shown) 1 O
309
310
7019666
7019668
Pump, Fuel (Not Shown)
Starter
1
1
U
311 3960423 Gasket, Thermostat 1 N
D
0251945 ENGINE DISTRESS SWITCH INSTALLATION Ref. A
(OPTIONAL)
C
401 to 403
404
Not Used
2420131 Sender, Oil Pressure 1
O
M
0254736 HIGH TEMPERATURE WARNING INSTALLATION
(OPTIONAL)
Ref. — P
O
501 4360157 Switch, Water Temperature 1 N
0080200 Adapter (Not Shown) 1
3960423 Gasket, Adapter (Not Shown) 1
E
0700819 Capscrew 8mm x 55mm 2 N
4831900 Lockwasher 8mm 2 T
0253875 SPARK ARRESTOR INSTALLATION (OPTIONAL) Ref. — S
601 3220083 Arrestor, Spark (Includes Mounting Hardware) 1
0255037 GENERATOR INSTALLATION Ref. C
701 4360037 Sender, Oil 1

702 2180749 Fitting, 45° 1
703 2180360 Fitting, Tee 1
3120692 2-21
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-22 3120692
S
ENGINE ASSEMBLY OPTIONS: Ref.
E
0257872 STANDARD GAS Ref. 9 C
0257911 DUAL FUEL Ref. 8
T
1 Engine Options: 1 I
2000155 Prior to S/N 89177 O
2000177 S/N 89177 to Present
2 3600260 Pump - Sunstrand (See Figure 2-11 for Breakdown) 1
N
3 3600206 Pump Assembly - Barnes 1
4 4843497 Bracket, Engine Mounting 1
5 3533445 Plate, Governor and Carburetor Mounting 1 2
6 Controller, Governor Options: 1
1600269 Prior to S/N 74487
1600325 S/N 74487 to Present
G
7 2500005 Governor, Precision 1 R
8
9
0641410
4761400
Bolt 1/4"-20NC x 1 1/4"
Lockwasher 1/4"
4
8
O
10 3311401 Nut 1/4"-20NC 8 U
11 0901419 Bracket, Controller 2 N
12 4751400 Flatwasher 1/4" 4
13 0641507 Bolt 5/16"-18NC x 1" 1
D
15 3311001 Nut #10-24NC 7 C
16 4751000 Flatwasher #10 8
17 4761000 Lockwasher #10 10 O
18 0100009 Adhesive A/R M
19
20
3533291
0701012
Plate, Engine
Bolt, Metric M10 x 33MM
1
3
P
21 4832000 Lockwasher, Metric M10 5 O
22 3200202 Mount, Engine - Rear 2 N
23 3200201 Mount, Engine - Front 1
E
25 4751700 Flatwasher 7/16" 4 N
26
27
0641726
3311705
Bolt 7/16" - 14NC x 3 1/4"
Locknut 7/16" - 14NC
2
2
T
28 4740274 Washer, Snubbing 1 S
29 0641826 Bolt 1/2"-13NC x 3 1/4" 1
30 4751800 Flatwasher 1/2" 1
31 3311805 Locknut 1/2"-13NC 2
32 0641608 Bolt 3/8"-16NC x 1" 7
33 4761600 Lockwasher 3/8" 8
34 3311601 Nut 3/8"-16NC 8
35 1060221 Cable, Battery (Engine to Ground) 1
36 0641812 Bolt 1/2"-13NC x 1 1/2" 3
37 4761800 Lockwasher 1/2" 2
38 0700808 Bolt, Metric M8 x 16MM (S/N 61515 to Present) 1
39 4711500 Flatwasher 5/16" (S/N 61515 to Present) 1
40 4845246 Bracket, Exhaust Support 1
3120692 2-23
E 41 Adapter, Carburetor Options: 1
C 0080092
See Note
Standard Gas
T 42 3311405 Locknut 1/4"-20NC 1
I 43 Stud Options: 1
4300056 Standard Gas
O See Note Dual Fuel (Note: See Figure 2-7 for Call-out)
N 44 3841049 Rod, Throttle 1
45 3321402 Nut, Jam 1/4"-28NF 2
46 1660157 Ball-joint 2
2 47 4831900 Lockwasher Metric 8mm (S/N 61515 to Present) 1
48 2220273 Fitting, Reducer 1
G 49
50
2180360
2420033
Fitting, Tee
Sender, Oil Pressure
1
1
R 51 4360357 Switch, Pressure 1
O 52 2120135 Filter, Pressure 1
2120136 Element, Filter 1
U 53 1320014 Clamp, Hose 2
N 54 Adapter, Air Intake Options: 1
D 0080175
See Note
Standard Gas
55 3520046 Plug 1
C 56 2720341 Hose - Air Cleaner Outlet 1
57 1320058 Clamp, Hose 1
O 58 2180537 Fitting, Nipple 1
M 59 0701015 Bolt, Metric M10 x 35MM (S/N 61515 to Present) 2
P 60 0901778 Bracket 1
61 3790152 O-Ring 1
O 62 0641610 Bolt 3/8"-16NC x 1 1/4" 2
N 63 4740185 Washer, Hardened 2
E 64 to 66
67
Not Used
3911014 Screw, Machine #10-24NC x 7/8" 3
N 68 Not Used
T 69 2720042 Hose 18in/46cm
70 1320032 Clamp 2
S 71 4300090 Stud (Supplied with Engine) 2
72 3321501 Nut 5/16"-24NF 3
73 3536481 Plate, Engine Mounting 1
74 2420118 Sender, Temperature 1
75 0140001 Horn 1
76 Fan and Spacer Kit Options: 1
Use 2060030 Standard Gas (was P/N 2060019)
Use 2060030 Dual Fuel (was P/N2060016) (Prior to S/N 46254)
Use 2060030 All Machines (was P/N 2060029)
(S/N 46254 to S/N 75495)
2060030 All Machines (S/N 75495 to Present)
77 Not Used
78 0641405 Bolt 1/4"-20NC x 5/8" 2
79 to 80 Not Used
2-24 3120692
81 4761500 Lockwasher 5/16" 3 E
82
83
4751500
0641632
Flatwasher 5/16"
Bolt 3/8"-16NC x 4"
3
2
C
84 3311605 Locknut 3/8"-16NC 2 T
85 4751600 Flatwasher 3/8" 4 I
86 0961378 Bushing 2
O
88 4460660 Housing, Terminal 1 N
91 3900275 Capscrew, Metric M6-1.25 x 25mm 1
92 3290607 Locknut M6-1.25 1 2
93 3911024 Screw #10-24NC x 1 1/2” (Not Shown) 2
94 0100048 Silicone (Not Shown) A/R
G
ENGINE INSTALLATION OPTIONS: Ref. R
0257873 STANDARD GAS Ref. 5
0257912 DUAL FUEL Ref. 7 O
U
101
102
Not Used
Tube, Manifold Options: 1
N
4565830 Prior to S/N 62155 D
4567910 S/N 62155 to Present
103 3220084 Muffler 1
104 1320026 U-Clamp 1
C
105 0901387 Bracket, Exhaust Hanger (Prior to S/N 34962) 1 O
106
0902382
4565956
Bracket, Exhaust Hanger (S/N 34962 to Present)
Tailpipe
1
1
M
107 1320180 Clamp, Hose 3 P
108 4845649 Tube, Air Intake 1 O
109 0080039 Elbow, Rubber 1
110 1340020 Air Cleaner Assembly 1
N
7004214 Element 1 E
111 0340002 Band, Air Cleaner Mounting 2 N
112 1120161 Cap, Air Inlet 1
113 0641406 Bolt 1/4"-20NC x 3/4" 4 T
114 4751400 Lockwasher 1/4" 4 S
115 3311405 Locknut 1/4"-20NC 4
116 2220675 Fitting, 90° 1
117 4761600 Lockwasher 3/8" 9
118 3311601 Nut 3/8"-16NC 9
119 0641710 Bolt 7/16"-14NC x 1 1/4" 2
120 3533663 Plate, Radiator Mounting 1
122 4751700 Flatwasher 7/16" 2
123 3311705 Locknut 7/16"-14NC 2
124 4761700 Lockwasher 7/16" 2
125 3311701 Nut 7/16"-14NC 2
126 3533664 Plate, Radiator Support 1
3120692 2-25
E 127 0630360 Bolt, Carriage 5/16"-18NC x 1 1/4" 1
C 128
129
4711500
3311501
Flatwasher 5/16" Narrow
Nut 5/16"-18NC
5
5
T 130 0641508 Bolt 5/16"-18NC x 1" 1
I 131 4761500 Lockwasher 5/16" 2
132 0641610 Bolt 3/8"-16NC x 1 1/4" 6
O 133 4751600 Flatwasher 3/8" 15
N 134 4060713 Shield 1
135 3536151 Guard, Exhaust 1
136 1320022 Clamp 2
2 137 2720058 Hose, Fuel Line 6 ft./1.8m
138 3921008 Bolt #10-24NC x 1/2" 3
G 139
140
Not Used
0400075 Battery 1
R 141 3980007 Masonite 1
O 142 1060254 Cable, Battery (Battery + to Starter Solenoid) 1
143 3300029 Wingnut 3/8"-16NC 2
U 144 1670841 Cover, Battery 1
N 145 1060360 Cable, Battery (Battery Neg to Ground) 1
D 146
147
0630370
0400174
Rod, Tie-Down
Tie-Down, Battery
2
1
148 3620027 Radiator 1
C 149 Not Used
150 1320020 U-Clamp 1 1/2" 1
O 151 1320026 U-Clamp 1 3/4" 1
M 152 3252356 Nameplate - Important (LP Only) (S/N 71528 to 1
P Present) (Not Shown Located Inside of Lower Access
Door)
O 153 1703162 Decal - Fan Blade (S/N 71528 to Present) 2
(Not Shown Located on Radiator Shield)
N 154 0840046 Boot, Battery (Positive) (Not Shown) 1
E 155 0840047 Boot, Battery (Negative) (Not Shown) 1
N
PUMP COUPLING INSTALLATION Ref.
T
S 201 7016661 Pump Coupling 1
202 0080163 Adapter, Pump Mounting 1
203 0700808 Bolt, Metric 8mm 1.25 x 16mm 6
204 4831900 Lockwasher, Metric 8mm 6
205 0641610 Bolt 3/8"-16NC x 1 1/4" 8
206 4761600 Lockwasher 3/8" 8
207 3020021 Grease, Coupling (Not Shown) A/R
Note: Coupling Spline must be greased with lithium Ref.
2-26 3120692
SPARE COMPONENTS Ref. E
2000155
2000177
Prior to S/N 89177
Ref.
Ref.
B
A
C
T
300 Control, Ignition Options: 1 I
7019665 Prior to S/N 89177
7023650 S/N 89177 to Present
O
301 7000892 Carburetor (Standard Gas) 1 N
7024321 Gasket (Top) 1
7019933 Carburetor Rebuild Kit 1
301A 7000894 Choke, Automatic 1
301 1140009 Carburetor (LP Gas Only) 1 2
(Not Included in Components Kits)
302 7019670 Alternator (Leese-Nuville) 1
303 7012577 Fitting, Vacuum Line 1 G
304
305
7012578
7000884
Vacuum Line Assembly
Fuel Shut-Off
1
1
R
306 7022174 Filter, Fuel 1 O
307 Not Used U
308 7012564 Wiring Harness (Not Shown) 1
309 7019666 Pump, Fuel (Not Shown) 1
N
310 7019668 Starter 1 D
311 7021869 Filter, Oil (Not Shown) 1
7014500 Filter, Oil (1 Dozen) 1
312 7019959 Dipstick (Not Shown) 1 C
313 7019951 Pump, Water (Not Shown) 1 O
314 Plug Wire Kit Options: (Not Shown) 1
7019989 Through 1999
M
7022176 2000 to Present P
315 Coil, Ignition Options: (Not Shown) 1 O
7019953 Through 1999
7019998 2000 to Present N
316 7019943 Hose, Lower Radiator 1 E
317 3960423 Gasket, Thermostat 1
N
0251945 ENGINE DISTRESS SWITCH INSTALLATION Ref. B T
(OPTIONAL)
S
401 to 403 Not Used
404 2420131 Sender, Oil Pressure 1
0254736 HIGH TEMPERATURE WARNING INSTALLATION Ref. —

(OPTIONAL)
501 4360157 Switch, Water Temperature 1

0080200 Adapter (Not Shown) 1
3960423 Gasket, Adapter (Not Shown) 1
0700819 Capscrew 8mm x 55mm 2
4831900 Lockwasher 8mm 2
3120692 2-27
E 0253875 SPARK ARRESTOR INSTALLATION (OPTIONAL) Ref. —
C 601 3220083 Arrestor, Spark (Includes Mounting Hardware) 1
T 0255037 GENERATOR INSTALLATION (OPTIONAL) Ref. 3/B
I
701 4360037 Sender, Oil 1
O 702 2180749 Fitting, 45° 1
N 703 2180360 Fitting, Tee 1
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-28 3120692
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-29
FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE
S OPTION)
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-30 3120692
FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION)
S
0250790 DUAL FUEL INSTALLATION Ref. 12
E
C
1 3720011
7017516
Regulator, LPG
Rebuilt Kit
1
1
T
2 2220364 Fitting, Adapter 2 I
3 2180535 Fitting, Barbed 2 O
4 2220648 Fitting, 90° 1
5 2120077 Filter-Lock 1
N
6 2220003 Fitting, Swivel 1
7 2220675 Fitting, 90° 1
8 2720112 Hose, LP A/R
9 2720042 Hose, Heater 28in/71m
2
10 2720118 Hose, LP (48 in./1.22m Length) (Prior to S/N 27430) 1
11
2720437
1320032
Hose, LP (52 in./1.32m Length) (S/N 27430 to Present)
Clamp
1
4
G
12 2180104 Fitting, Nipple 1 R
13 2180360 Fitting, Tee 1 O
14 4360188 Switch, Vacuum 1
15 2180536 Fitting, Barbed 1
U
16 2180623 Fitting, Tee 1 N
17
18
0641405
4761400
Bolt 1/4"-20NC x 5/8"
Lockwasher 1/4"
2
2
D
19 2180387 Fitting, Tank Connector 1
20 to 22 Not Used C
23 0080167 Adapter, Air Intake 1
24 0080092 Adapter, Carburetor 1
O
25 3840979 Rod 1 M
26 Not Used P
27 1700818 Decal - Liquid LPG 1
28 to 30 Not Used O
31 4640391 Valve, Gasoline 1 N
32
33
1320095
2220805
Clamp, Support
Fitting, Straight
1
3
E
34 1320022 Clamp 2 N
35 2220290 Fitting, Tee 1 T
36 2180389 Fitting, Pressure Relief 1
37 Tank, LP Options: (Optional - Not Supplied with 2
S
Installation)
4400040 Aluminum - 33.5 Lbs. Tank (Prior to S/N 60261)
4400281 Aluminum - 33.5 Lbs. Tank (S/N 60261 to Present)
4400421 Steel - 33.5 Lbs. Tank (S/N 60261 to Present)
4400275 Aluminum - 43.5 Lbs. Tank
4400420 Steel - 43.5 Lbs. Tank (S/N 60261 to Present)
0253447 LP TANK BRACKETS INSTALLATION Ref. 3
101 4844185 Support, Tank Bracket 2

102 0641522 Bolt 5/16"-18NC x 2 3/4" 2
103 4761500 Lockwasher 5/16" 2
3120692 2-31
FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION) (CONTINUED)
E 104 3311501 Nut 5/16"-18NC 2
C 105
106
0641610
4751600
Bolt 3/8"-16NC x 1 1/4"
Flatwasher 3/8"
8
8
T 107 4761600 Lockwasher 3/8" 8
I 108 3311601 Nut 3/8"-16NC
109 1320023 Clamp, LP Tank 2
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-32 3120692
FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION) (CONTINUED)
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-33
FIGURE 2-8. GENERATOR INSTALLATION (FORD ENGINE OPTION)
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-34 3120692
FIGURE 2-8. GENERATOR INSTALLATION (FORD ENGINE OPTION)
S
GENERATOR INSTALLATION Ref.
E
(FORD ENGINE OPTION) C
0250444 Prior to August 1994 Ref. D
0255037 August 1994 to Present Ref. 3/B
T
I
1 Not Used O
2 2460011 Generator and Control Box Assembly 1
2A 7012558 Generator 1 N
7026199 Armature w/Slip Rings 1
2B 7003657 Box, Control 1
Note: Replacement 110V Control Box comes
with 2 std Receptacles p/n 4460190. Optional 2
Industrial Twist Lock Receptacles p/n 4460027
must be ordered separately.
7020194 Circuit Breaker (Not Shown) 1 G
2C
7012616
7010699
Lamp Assembly
Voltmeter
1
1
R
2D 3580134 Pulley 1 O
3 2860012 Keystock 1 U
4 0901650 Bracket, Generator Mounting 1
5 4340569 Support, Adjustable 1
N
6 0480057 V-Belt 1 D
7 Not Used
8 4761600 Lockwasher 3/8" 4
9 3311601 Nut 3/8" - 16NC 2 C
10 0641511 Bolt 5/16"-18NC x 1 3/8" 1 O
11 4751500 Flatwasher 5/16" 2
12 4761500 Lockwasher 5/16" 2
M
13 0961247 Bushing 1 P
14 0641507 Bolt 5/16"-18NC 2 O
15 0901609 Bracket, Box Mounting 1
16 3911004 Screw, Machine #10-24NC x 1/2" 2 N
17 3311001 Nut #10-24NC 2 E
18
19
4761000
Not Used
Lockwasher #10 2
N
20 0681610 Bolt 3/8"-16NC x 1 1/4" (Grade 8) 2 T
21 4751600 Flatwasher 3/8" 2 S
22 to 23 Not Used
24 3311501 Nut 5/16"-16NC 2
3120692 2-35
FIGURE 2-9. ENGINE INSTALLATION - DEUTZ F2L1011
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-36 3120692
FIGURE 2-9. ENGINE INSTALLATION - DEUTZ F2L1011
S
0253361 ENGINE INSTALLATION - DEUTZ F2L1011 Ref. 18
E
C
1
2000106
Engine - Deutz F2L1011
Prior to August 1995
1
T
2000137 August 1995 to Present I
2 4843934 Tray, Engine Mounting 1 O
3 Not Used
4 Pump Assembly - Sunstrand 1
N
3600164 13 Tooth Spline (Prior to S/N 30660)
3600260 15 Tooth Spline (S/N 30660 to Present)
5 0361817 Spacer, Engine Mounting 4 2
6 0080177 Adapter, Air Intake 1
7 Adapter, Throttle 1
0080172 Prior to August 1995
G
4460302 August 1995 to Present R
8
9
3450202
3951003
Pin, Cotter 1/16" x 1/2"
Setscrew #10-24NC x 3/8" (Prior to August 1995)
1
1
O
0902244 Bracket, Throttle (August 1995 to Present) 1 U
10 0641840 Bolt 1/2"-13NC x 5" 4 N
11 3311805 Locknut 1/2"-13NC 4
12 4751800 Flatwasher 1/2" 4
D
13 0641406 Bolt 1/4"-20NC x 3/4" 4
14 4711400 Flatwasher 1/4" 24 C
15 3311405 Locknut 1/4"-20NC 4
16 0641512 Bolt 3 O
17 Cable, Battery Options: 1 M
1060406
1060254
Prior to S/N 70832
P
18 1060093 Cable, Battery 1 O
19 0140001 Horn 1 N
20 0641610 Bolt 3/8"-16NC x 1 1/4" 2
21 4751600 Flatwasher 3/8" 18
E
22 0060023 Actuator, Throttle 1 N
23
7008828
0901817
Cable, Throttle
Bracket, Fuel Filter
1
1
T
24 0701010 Bolt, Metric M10 x 20mm 4 S
25 4832000 Lockwasher 10m 4
26 0641508 Bolt 5/16"-18NC x 1" 2
27 3311501 Nut 5/16"-18NC 5
28 4761500 Lockwasher 5/16" 5
29 4751600 Lockwasher 3/8" 12
30 0400003 Battery (Prior to S/N44593) 1
0400075 Battery (S/N44593 to Present) 1
31 0400002 Tie-Down, Battery (Prior to S/N44593) 1
0400174 Tie-Down, Battery (S/N44593to Present) 1
32 3980003 Seat, Battery (Prior to S/N44593) 1
3980007 Seat, Battery (S/N44593to Present) 1
33 0630370 Rod, Tie-Down 2
3120692 2-37
FIGURE 2-9. ENGINE INSTALLATION - DEUTZ F2L1011 (CONTINUED)
E 34 3300029 Wingnut 3/8"-16NC 2
C 35
36
1060360
4740195
Cable, Battery
Washer, Hardened
1
2
T 37 3311601 Nut 3/8"-16NC 6
I 38 0641612 Bolt 3/8"-16NC x 1 1/2" 6
39 4843513 Air Intake Weldment 1
O 40 2180730 Fitting, Adapter 1
N 41 2420110 Sender, Oil Pressure 1
42 3960407 Gasket 1
43 1340020 Air Cleaner Assembly 1
2 7004214 Element, Air Cleaner 1
44 0340002 Band, Mounting - Air Cleaner 2
G 45
46
1320180
2720351
Clamp, Hose
Hose
6
3in./7.6cm
R 47 4565347 Tube, Air Cleaner 1
O 48 0080039 Elbow 1
49 0080046 Elbow 1
U 50 0362043 Bar, Spacer 4
N 51 0641424 Bolt 1/4"-20NC x 3" 4
D 52
53
2720342
1320059
Hose, Air Intake
Clamp, Hose
9in./23cm
3
54 3535551 Plate, Cover 1
C 55 4565348 Tube, Exhaust 1
56 1320019 U-Clamp 1
O 57 0901705 Bracket, Muffler 1
M 58 1320176 Clamp, Muffler 1
P 59 Not Used
60 0901778 Bracket, Charge Filter 1
O 61 2120135 Filter, Charge Pressure 1
N 2120136 Element, Charge Filter 1
E 62
2720271
Line, Fuel (Return)
Prior to S/N 26785
8ft./2.44m
N 2720058 S/N 26785 to Present

T 63 2720058 Line, Fuel (Supply) 6ft./1.83m
64 1320022 Clamp, Hose 4
S 65 2200462 Fitting, 90° (Prior to S/N 28604 Only) 2
66 Fitting, Barbed 2
2180348 Prior to S/N 28604
2220317 S/N 28604 to S/N 101993
2220805 S/N 101993 to Present
67 0100043 Sealant, Fuel Line (Not Shown) A/R
68 2180666 Fitting, Barbed (Prior to S/N 28604 Only) 1
69 0641406 Bolt 1/4"-20NC x 3/4" A/R
70 Not Used
71 4280280 Strip, Air Intake 1
72 3600206 Gear Pump Assembly (See Figure 2-12 for Breakdown) 1
73 3790152 O-Ring 1
74 0641812 Bolt 1/2"-13NC x 1 1/2" 2
75 4761800 Lockwasher 1/2" 2
2-38 3120692
76 3536144 Cover, Battery (Prior to S/N44593) 1 E
77
1670841
0641405
Cover, Battery (S/N44593 to Present)
Bolt 1/4"-20NC x 5/8"
1
4
C
78 4761400 Lockwasher 1/4" 4 T
79 Hardware Options: A/R I
4751400 Flatwasher 1/4" (Prior to S/N 60098) 4
1320060 Clamp (S/N 60098 to Present) 2
O
80 3740067 Relay 1 N
81 4751400 Flatwasher 1/4" (Prior to S/N 60098) 8
82 3311405 Locknut 1/4"-20NC 4
83 4711400 Flatwasher 1/4" Narrow (S/N 26766 to Present Only) 1
84 0700605 Bolt, Metric 6mm x 10mm (S/N 26766 to Present Only) 2 2
85-94 Not Used
96 0701016 Bolt Metric 10mm x 40mm (S/N 55667 to Present) 2 G
97 4832000 Lockwasher (S/N 55667 to Present) 2 R
98 4740308 Spacer (S/N 55667 to Present) 2
99 0840046 Boot, Battery (Positive) (Not Shown) 1 O
100 0840047 Boot, Battery (Negative) (Not Shown) 1 U
101 2220273 Fitting, Reducer (Not Shown) 2
N
ENGINE COMPONENTS - DEUTZ F2L1011 Ref. D
2000106 Prior to August 1995 Ref.
2000137 August 1995 to Present Ref.
C
101 7000693 Muffler (Not Shown) 1 O
102 7014683 Filter and Gasket Kit (Includes Fuel Line Washer, Oil
Plug Washer, Oil Filter, Fuel Filter, Injector Tip
1
M
Gasket and Valve Cover Gasket) P
102A
102B
7016331
7012598
Filter, Oil (Kit includes 1 Filter)
Filter, Fuel (Not Shown)
1
1
O
103 7012599 Pump, Fuel Injector (Not Shown) 1 N
7020426 Injector (Not Shown) 2 E
7020425 Nozzle, Injector (Not Shown) 2
7020424 Gasket, Injector Tip (Not Shown) 2
N
104 1670680 Cover, Timing Belt 1 T
105
7012626
Starter Options: (Not Shown)
Prior to August 1995
1
S
7020416 August 1995 to Present
106 Use 7024413 Pump, Fuel (Main) (Was 7012698) 1
107 7020417 Alternator (Not Shown) 1
108 7020465 Oil Filler Cap 1
PUMP COUPLING INSTALLATION OPTIONS: Ref.

0250597 13 Tooth Spline Pump (Prior To S/N 30660) Ref. —
0256848 15 Tooth Spline Pump (S/N 30660 to Present) Ref. —
201 Coupling Options: 1

1660184 13 Tooth Pump Spline (Prior To S/N 30660)
1660234 15 Tooth Pump Spline (S/N 30660 to Present)
3120692 2-39
E Note: Coupling Spline must be greased with lithium Ref.
C 202 0080163 Adapter, Pump Mounting 1
T 203 0700810 Bolt, Metric 8mm x 20mm 6
I 204 4831900 Lockwasher 8mm 6
205 0701013 Bolt 10mm x 28mm 8
O 206 4832000 Lockwasher 10mm 8
N 207 3020021 Grease, Coupling (Not Shown) (Prior to S/N 103575) A/R
0251548 ENGINE DISTRESS SWITCH INSTALLATION Ref. 4

2 (OPTIONAL)
301 4360358 Switch, Pressure 1

G 2180360 Fitting, Tee 1
R 2180749 Fitting, 45° 1
O 0258686 ENGINE SHUTDOWN INSTALLATION (OPTIONAL) Ref. 2

U
N 301 4360065 Switch, Pressure 1
2180360 Fitting, Tee 1
D 2180318 Fitting, 90° 1
2180643 Fitting, Nipple 1
C GENERATOR INSTALLATIONS (OPTIONAL) Ref.

O 0251801 Prior To August 1994 Ref. G
M 0255038 August 1994 To Present Ref. 2
P 401 2180730 Fitting, Adapter (Prior to August 1994 Only) 1

O 2180749 Fitting, 45° 1
N 2180537
4360037
Fitting, Nipple (Prior to August 1994 Only)
Switch, Pressure (Prior to August 1994 Only)
1
1
E 2180360 Fitting, Tee (Prior to August 1994 Only) 1
N 2200261 Fitting, Coupling (Prior to August 1994 Only) 1
T 0253875 SPARK ARRESTOR INSTALLATION (OPTIONAL) Ref —

S (PRIOR TO OCTOBER 1995)
501 3220083 Arrestor, Spark (Includes Mounting Hardware) 1
0256898 SPARK ARRESTOR MUFFLER INSTALLATION Ref. —

(OPTIONAL) (OCTOBER 1995 TO S/N 65404)
551 4567159 Pipe, Exhaust 1

552 1320021 U-Clamp 1
553 3220036 Arrestor, Spark 1
0259488 SPARK ARRESTOR MUFFLER INSTALLATION Ref. 1

(OPTIONAL) (S/N 65404 TO PRESENT)
601 3220118 Pipe, Exhaust 1
2-40 3120692
0255114 SPARK ARRESTOR MUFFLER INSTALLATION Ref. 2 E
(OPTIONAL) (OCTOBER 1995 TO PRESENT)
C
701 4566617 Pipe, Exhaust 2 T
702
703
1320019
3220086
U-Clamp
Purifier, Exhaust
2
1
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-41
FIGURE 2-10. GENERATOR INSTALLATIONS (DEUTZ ENGINE OPTION)
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-42 3120692
FIGURE 2-10. GENERATOR INSTALLATIONS (DEUTZ ENGINE OPTION)
S
GENERATOR INSTALLATIONS Ref.
E
(DEUTZ ENGINE OPTION) C
0251801 Prior to August 1994 Ref. G
0255038 August 1994 to Present Ref. 2
T
I
1 3580158 Pulley 1 O
3 0701012 Bolt, Metric 10MM x 25MM 2 N
4 4812000 Flatwasher, Metric 10MM 2
5 0480059 V-Belt 1
6 4751500 Flatwasher 5/16" 1
7 4761500 Lockwasher 5/16" 2 2
8 0681510 Bolt 5/16"-18NC x 1 1/4" (Grade 8) 2
9 2860012 Key, Woodruff 1
10 Not Used
G
11 2460011 Generator and Control Box Assembly 1 R
11A 7012558
7026199
Generator
Armature w/Slip Rings
1
1
O
11B 7003657 Box, Control 1 U
Note: Replacement 110V Control Box comes N
with 2 std Receptacles p/n 4460190. Optional
Industrial Twist Lock Receptacles p/n 4460027 D
must be ordered separately.
7020194 Circuit Breaker (Not Shown) 1
11C 7010699 Voltmeter 1 C
11D 3580134 Pulley 1 O
12 0361815 Arm, Adjustment 1
13 4843410 Bracket, Generator Mounting 1
M
14 3311501 Nut 5/16"-18NC 1 P
15 to 20 Not Used O
21 0701414 Bolt, Metric 14MM x 30MM 1
22 1060515 Cable, Electrical - 12/4 4ft/1.2m N
23 Not Used E
24
25
3911004
3311001
Screw, Machine #10-24NC x 1/2"
Nut #10-24NC
2
2
N
26 4761000 Lockwasher #10 2 T
27 0901609 Bracket, Control Box Mounting 1 S
28 0641507 Bolt 5/16"-18NC x 7/8" 2
29 4751500 Flatwasher 5/16" 2
30 4761500 Lockwasher 5/16" 2
31 3251476 Nematic - On/Off 1
32 0681610 Bolt 3/8"-16NC x 1 1/4" (Grade 8) 2
33 4761600 Lockwasher 3/8" 2
34 4751600 Flatwasher 3/8" 2
3120692 2-43
FIGURE 2-11. PISTON PUMP ASSEMBLY - SUNSTRAND
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-44 3120692
FIGURE 2-11. PISTON PUMP ASSEMBLY - SUNSTRAND
S
PISTON PUMP ASSEMBLY - SUNSTRAND Ref.
E
3600164 13 Tooth Pump Spline (Prior to S/N 30660) Ref. A C
3600260 15 Tooth Pump Spline (S/N 30660 to Present) Ref. B
T
1 7007413 Shim Kit - Relief Valve 1 I
2 7007414 Plug 1 O
3 Kit O-Ring 1
4 7007416 Spring, Relief Valve 1
N
5 7007417 Valve, Relief 1
6 Kit O-Ring 2
7 7007419 Plug 2
8 Not Used 2
9 Not Used
10
11
7007420
7007208
Plug
Plug
2
2
G
12 7007421 Screw 10 R
13 Not Used O
14 7007422 Gasket, Servo Cover 2
15 7007423 Nut, Special 1
U
16 7007424 Cover, Adjustment 1 N
17
18
Not Used
7007425 Bearing, Needle 1
D
20 Kit Washer 1 C
21 Kit Spring 1
22 Not Used
O
23 Kit Washer 1 M
24 Kit Retainer 1 P
25 Kit Pin, Slipper Holddown 3
26 Kit Piston Assembly 7 O
27 Kit Guide, Slipper 1 N
28
29
Kit
7007435
Guide, Retainer
Pin, Spring
1
1
E
30 7007436 Screw - 12 Point Head 1 N
31 7007437 Bearing, Ball 1 T
32 7007438 Ring 2
33 7007439 Ring 2
S
34 7007440 Pin, Spring 2
35 7007441 Handle, Pin 1
36 7007442 Sleeve, Bearing 1
37 Kit Gasket, Front Cover 1
38 7007444 Pin 1
39 7007445 Plug, Expansion 1
40 Kit Pin 1
41 Kit O-Ring 1
42 Kit Ring, Load Temper 1
43 7007449 Housing, Pump 1
44 Kit Ring, Back-Up 1
45 Kit O-Ring 1
3120692 2-45
FIGURE 2-11. PISTON PUMP ASSEMBLY - SUNSTRAND (CONTINUED)
E 46 Kit Cover, Gerotor 1
C 47
48
7007453
7007208
Bolt, Hex
Plug
3
1
T 49 7007454 Cover, Front 1
I 50 Kit Block, Cylinder 1
51 7007456 Screw - 12 Point Head 6
O 52 7001438 Washer 10
N 53 Kit Swashplate 1
54 7007458 Journal, Bearing 1
55 Kit Seal, Lip 1
2 56 Kit O-Ring 1
57 Shaft, Main Pump 1
G 7007461
7010121
13 Tooth Spline (Prior to S/N 30660)
15 Tooth Spline (S/N 30660 to Present)
R 58 Kit Plate, Valve 1
O 59 Kit Gerotor Assembly 1
60 Kit Pin 1
U 61 Kit Key, Woodruff 1
N 62 7007466 Adaptor, Remote Filtration (Without Bypass) 1
D 63
64
Kit
7007468
O-Ring
Screw
3
2
65 7007469 Screw 2
C 66 7007470 Plug 1
67 7007471 Cover, Servo (With Adjuster) 1
O 7007490 Stop, Servo (Not Shown) 2
M 7007491 Nut, Special (Not Shown) 2
P 7007492 Ring, External (Not Shown) 2
68 7007482 Cover, Servo (Without Adjuster) 1
O 69 7007483 Guide, Spring 1
N 70 7007484 Stop, Servo 1
E 71
72
7007485
7007486
Spring
Screw
1
1
N 73 7007487 Guide, Spring 1
T 74 7007488 Ring, Retaining 1
75 7007499 Locknut 1
S 76 Kit Ring, Piston 2
77 7007494 Piston, Servo 1
78 Kit O-Ring 2
79 7007472 Valve, By-Pass 1
Valve, Pressure Release (Includes Item 6)
80 Use 7010122 2
(Was 7007473)
81 7007474 Control, Dual Oil-Filled 1
7007496 Coil Assembly (Pilot) 1
7007497 Plug (Pump) 1
7007498 Plug (Valve Harness) 1
82 7007478 Screw 2
83 7001498 Screw 2
84 Kit O-Ring 2
85 Kit O-Ring 1
86 7007475 Plug, Orifice/Screen -.156 1
2-46 3120692
FIGURE 2-11. PISTON PUMP ASSEMBLY - SUNSTRAND (CONTINUED)
87 7007477 Plug, Orifice - .37 2 E
88
89
7007476
7010120
Adapter, Auxiliary Pump
Spacer/Gasket
1
1
C
—————————— T
2900752 Seal Kit - Complete (Includes Items
3,6,14,15,37,41,42, 44,45,55,56,63,76,78,84 and 85)
1 I
7007412 Seal Kit - Servo Piston (Includes Items 76 and 78) 1 O
2900826 Charge Pump Kit (Includes Items 41,42,46,59,60,61) 1 N
2900827 Cylinder Block Kit (Includes Items 19-28, 1
40,50,53,55,58)
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-47
FIGURE 2-12. GEAR PUMP ASSEMBLY - JSB.
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-48 3120692
FIGURE 2-12. GEAR PUMP ASSEMBLY - JSB.
S
3600206 GEAR PUMP ASSEMBLY - JSB Ref.
E
C
1
2
7007477
Kit
Ring, Retaining
Seal, Shaft
1
1
T
3 7010956 Flange, Mounting 1 I
4 Kit Ring, Back-up 2 O
5 Kit E-Seal 2
6 7010957 Bearing 2
N
7 Kit O-Ring 2
8 7010963 Housing, Gear 1
9 7010959 Pin, Dowel 4
10 Not Used 2
11 7010982 Gear, Idler 1
12
13
7010973
7010960
Gear, Drive
Cover, End
1
1
G
14 7010961 Bolt 4 R
—————————— O
7010953 Seal Kit (Includes Items 2, 4, 5 and 7) 1
U
N
D
C
O
M
P
O
N
E
N
T
S
3120692 2-49
FIGURE 2-13. GROUND CONTROL BOX INSTALLATION
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-50 3120692
FIGURE 2-13. GROUND CONTROL BOX INSTALLATION
S
GROUND CONTROL BOX INSTALLATION OPTIONS: Ref.
E
0253724 Deutz Engine Machines (Prior To April 1993) Ref. — C
0254102
0253723
Deutz Engine Machines (April 1993 To Present)
Ford Engine Machines (Prior To April 1993)
Ref.
Ref.
12
—
T
0254101 Ford Engine Machines (April 1993 To Present) Ref. 11 I
O
1 Box, Ground Control Options: 1
4843375 Prior To April 1993
N
4844562 April 1993 To S/N 70902
0861338 S/N 70902 To Present
2 Lid Options: 1
3252252 Prior To April 1993 2
3252308 April 1993 To S/N 65031
3
3252635
4420037
S/N 65031 To Present
Strip, Rubber A/R
G
4 3740049 Relay A/R R
5 4761400 Lockwasher 1/4" A/R O
6 3311401 Nut 1/4"-20NC A/R
7 Rail, Mounting Options: 1
U
3640621 Prior To April 1993 N
8
3640865
4460298
April 1993 To Present
Block, Terminal A/R
D
9 4460301 Marker, Terminal 1
10 4460299 Stop, Terminal 2 C
11 4460300 Barrier, Terminal 1
12 4460309 Bar, Buss - 3 Position 1
O
13 4460305 Screw 3 M
14 4460306 Washer 3 P
15 4460307 Sleeve 3
16 4360216 Breaker, Circuit - 30 Amp 1 O
17 4770600 Starwasher #6 2 N
18
19
3310601
4360232
Nut #6-32NC
Breaker, Circuit - 15 Amp
2
1
E
20 4761000 Lockwasher #10 A/R N
21 3311001 Nut #10-24NC A/R T
22 4460051 Connector, Strain Relief A/R
23 4460071 Connector, Strain Relief 1
S
24 3300048 Locknut, Conduit 4
25 0960238 Bushing 4
26 2420009 Hourmeter 1
27 2420091 Voltmeter 1
28 3520028 Plug, Hole 1
29 4360274 Switch, Push Button (Start) 1
30 0100035 Loctite #222 A/R
31 3790012 O-Ring A/R
3120692 2-51
FIGURE 2-13. GROUND CONTROL BOX INSTALLATION (CONTINUED)
E 32 4360284 Switch, Key (Select) (Prior to S/N 45155) 1
C 4360290
4360469
Switch, Key (Select) (S/N 45155 to S/N 65031)
Switch, Key (Select) (S/N 65031 to Present)
1
1
T 7010698 Key, Replacement (4360284 & 4360290) 1
I 2860030 Key, Replacement (4360469)
33 Switch, Push/Pull (Emergency Stop) Options: 1
O 4360289 Prior to S/N 65031
N 4360475 S/N 65031 to Present
34 4360314 Switch, Toggle (Lift) 1
35 2600161 Hinge 1
2 36 3911008 Screw, Machine #10-24NC x 1 1/2" 7
37 Block, Contact Options: A/R
G Not Required
4460267
Prior to April 1993
April 1993 to S/N 81217
0
1
R 4360478 S/N 81217 to Present 1
O 38 3300177 Nut, Tinnerman 2
39 4740120 Washer, Nylon 5
U 40 0750806 Screw, Round Head 2
N 41 4460303 Terminal, Ground Block (Not Shown) 1
D 42
43
Not Used
Oil Pressure Gauge Assembly Options: 1
2420111 Deutz Engine Machines
C 2420164 Ford Engine Machines
2420084 Gauge Light Kit 1
O 44 Water Temperature Gauge Assembly Options: 1
M 3520070 Deutz Engine Machines (Hole Plug)
P 2420159 Ford Engine Machines
2420084 Gauge Light Kit 1
O 45 Not Used
N 46 Breaker, Circuit 1
E 4360212
Not Required
Deutz Engine Machines (3 Amp)
Ford Engine Machines
N 47 1701683 Decal, Relay Function 1
T 48 Block, Contact Options: 1
See Note Prior to S/N 28604 (Note: Use 4360267 as
S replacement for original 4360237)
4360267 S/N 28604 to Present
49 4360281 Block, Contact 1
50 Relay Options: 1
Not Required Deutz Engine Machines (Prior to April 1993)
3740077 Deutz Engine Machines (April 1993 to Present)
Not Required Ford Engine Machines
51 to 53 Not Used
54 Washer, Bronze Options: A/R
Not Required Prior to S/N37155 0
4740066 S/N37155 to Present 1
55 4070987 Shim, Nylon (S/N 65031 to Present) 5
56 3910804 Screw #8-32 NC x 1/4” (S/N 65031 to Present) 6
57 0641406 Bolt 1/4”-20NC x 3/4” (S/N 70902 to Present) A/R
58 0721004 Bolt #10-24NC x 1/2” (S/N 70902 to Present) 3
2-52 3120692
FIGURE 2-13. GROUND CONTROL BOX INSTALLATION (CONTINUED)
59 0720603 Bolt #6-32NC x 3/8” (S/N 70902 to Present) 4 E
60
61
0641408
0721006
Bolt 1/4”-20NC x 1” (Not Shown)
Bolt #10-24NC x 3/4”
1
1
C
62 4751000 Flatwasher #10 1 T
63 3340841 Pad, PVC (Not Shown) 4 I
64 2420084 Light Kit, Gauge (Not Shown) 3
65 3790012 O-Ring (Not Shown) 1
O
N
GROUND CONTROL BOX INSTALLATION Ref.
OPTIONS:
0253720 Deutz Engines Machines (Prior to April 1993) Ref. —
0253719 Ford Engines Machines (Prior to April 1993) Ref. — 2
0254106 Deutz Engines Machines (April 1993 to Present) Ref. B
0254105 Ford Engines Machines (April 1993 to Present) Ref. C
Note: For United Airlines Machines see Section 10. Ref. G
101 Not Used
R
102 0641410 Bolt 1/4"-20NC x 1 1/4" 2 O
103 4751400 Flatwasher 1/4" 4 U
104 4761400 Lockwasher 1/4" 2
105 3311401 Nut 1/4"-20NC 2
N
106 0362591 Bar, Brace 1 D
0250790 OPTIONAL DUAL FUEL CONTROLS INSTALLATION Ref. 12
C
201 4360331 Switch, Toggle (Select) 1 O
202 3790012 O-Ring 1
M
0253821 HEADLIGHT/TAILLIGHT COMPONENTS Ref. 3 P
INSTALLATION
O
301 3740049 Relay, Bosch (Not Shown) 1 N
E
0254076 LEVELING JACK COMPONENTS INSTALLATION Ref. 9
(OPTIONAL) (NOT SHOWN) N
T
401 to 426 Not Used
427 1060341 Cable, Electrical - 16/2 44ft/13.4m
S
428 4460035 Splice, Terminal 3
429 4460051 Connector 1
430 3300048 Locknut, Conduit 1
431 0960238 Bushing 4
432 4460470 Locknut 1
433 4460471 Washer 1
434 4460480 Receptacle 1
435 4460465 Socket 10
436 4460259 Terminal, Positive Lock 24
438 4460298 Strip, Terminal 8
439 4460301 Strip, Terminal Marking 1
3120692 2-53
FIGURE 2-14. HOODS AND BEACON LIGHT INSTALLATION
S
E
C
T
I
O
N
G
R
O
U
N
D
C
O
M
P
O
N
E
N
T
S
2-54 3120692
FIGURE 2-14. HOODS AND BEACON LIGHT INSTALLATION
S
HOODS AND BEACON LIGHT INSTALLATION Ref.
E
C
0250687 HOOD INSTALLATION - LEFT SIDE (STANDARD ON
ALL MACHINES)
Ref. 4/D
T
I
1 2680387 Hood Weldment - Left Side 1 O
2 3534073 Plate - Left Side Rear 1
3 3534074 Plate - Left Side Front 1 N
4 to 7 Not Used
8 0641406 Bolt 1/4"-20NC x 3/4" 27
9 4751400 Flatwasher 1/4" 33
10 4761400 Lockwasher 1/4" 11 2
11 3311405 Locknut 1/4"-20NC 16
12 3534089 Plate - Left Side Inside 1
13 1670560 Cover 1
G
14 0751006 Screw, Self-Tapping #10 x 3/4" 2 R
15
16
2940042
0100011
Latch
Loctite #242 (Not Shown)
3
A/R
O
U
0251978 HOOD INSTALLATION - RIGHT SIDE (DIESEL Ref. 9 N
MACHINES)
D
101
102
2680396
3535353
Hood Weldment - Right Side
Plate - Air Exhaust
1
1
C
103 4844024 Snorkel, Exhaust 1 O
104 3535348 Plate - Right Side Rear 1 M
105 3535352 Plate - Air Intake 1
106 2680395 Plate - Right Side Front 1
P
107 0641406 Bolt 1/4"-20NC x 3/4" 39 O
108
109
4761400
4751400
Lockwasher 1/4"
Flatwasher 1/4"
6
72
N
110 3311405 Locknut 1/4"-20NC 37 E
111 Not Used N
112 2940042 Latch, Flush Mounting 2
113 0641408 Bolt 1/4"-20NC x 1" 4
T
114 0100011 Loctite #242 (Not Shown) A/R S
115 3535350 Plate - Right Side Inside 1
116 0181637 Angle 2
117 2820047 Foam, Acoustical 2
119 3311401 Nut 1/4"-20NC 6
120 3300353 Nut, Tinnerman (Prior to S/N 59270) 8
121 4060969 Shield (S/N48785 to Present) 1
122 3820019 Rivet (S/N48785 to Present) 6
3120692 2-55
FIGURE 2-14. HOODS AND BEACON LIGHT INSTALLATION (CONTINUED)
E HOOD INSTALLATIONS - RIGHT SIDE Ref.
(GAS MACHINES)
C 0253299 Ford VSG-411 Ref. 2
T 0257910 Ford VSG-413 Ref. 4/E
I
201 2680406 Hood Weldment - Right Side 1
O 202 Plate Options - Right Side Front 1
N 3536349 Ford VSG-411
3570421 Ford VSG-413
203 Plate Options - Right Side Rear 1
2 3536350 Ford VSG-411
3570420 Ford VSG-413
204 3536351 Plate, - Inside Cover 1
G 205 3536622 Cover, Pump (Prior to S/N47067 Only) 1
R 206 3300353 Nut, Tinnerman 10
O 207
208
0641406
4751400
Bolt 1/4"-20NC x 3/4"
Flatwasher 1/4"
16
23
U 209 4761400 Lockwasher 1/4" 16
N 210 3311405 Locknut 1/4"-20NC 4
211 0641408 Bolt 1/4"-20NC x 1" A/R
D 212 Not Used
213 2940042 Latch, Flush Mount 2
C 214 0100011 Loctite #242 (Not Shown) A/R
215 0362100 Bar 1
O 216 0641410 Bolt 1/4"-20NC x 1 1/4" 1
M
P BEACON LIGHT INSTALLATION (HOOD MOUNTED)
(OPTION)
Ref.
O 0253445 Single Beacon Ref. 2/B

N 0270365 Dual Beacon (Not Shown - Left/Right Side) Ref. 1/A
E
N 301 2920105 Light, Strobe - Amber A/R
302 4060829 Guard, Wire A/R
T 303 3941404 Screw, Self-Tap 1/4" x 1/2" A/R
S 304 0641406 Bolt 1/4"-20NC x 3/4" A/R
305 4751400 Flatwasher 1/4" A/R
306 3311405 Locknut 1/4"-20NC A/R
307 4460035 Terminal, Butt (Not Shown - Dual Beacon Only) 4
308 1060341 Cable, 16/2 (Not Shown - Dual Beacon Only) 20ft/7m
309 4460043 Terminal, Eyelet (Not Shown - Dual Beacon Only) 1
2-56 3120692
SECTION 3 SIZZOR ARMS
TABLE OF CONTENTS
FIGURE DESCRIPTION S
3-1 SIZZORS ARMS INSTALLATION - 40RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 E
3-2 SIZZORS ARMS INSTALLATION - 33RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 C
3-3 SIZZORS ARMS INSTALLATION - 25RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3120692 3-1
FIGURE 3-1. SIZZOR ARMS INSTALLATION - 40RTS
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3-2 3120692
SIZZOR ARMS INSTALLATIONS - 40RTS Ref.
0252957 Standard Machines Built Prior to May 1993 Ref. A S
0254091 Standard Machines Built May 1993 to Present Ref. 8 E
0252960
0254092
CSA Machines Built Prior to May 1993
CSA Machines Built May 1993 to Present
Ref.
Ref.
A
7
C
Note: When using existing pins, Graphokote Ref. T
Lube (P/N 3020028) is required at installation on
machines built prior to May 1993. When replacing
I
pivot pins, use chrome pivot pins which require O
no lubrication at installation.
N
101 Lift Cylinder Assembly 1
Use 1683466 Prior to S/N23500 (was p/n 1682243)
3
102
Use 3422735
Pin, Attach (Bottom Lift Cylinder)
Prior to S/N44841 (was p/n 3422073)
1 S
3422735 S/N44841 to Present I
103 Pin, Attach (Top Lift Cylinder) 1 Z
Use 3422738
3422738
S/N44841 to Present
Z
104 Arm Weldment (2nd Inboard) 1 O
0200458 Prior to S/N S/N50201 R
0200629 S/N 50201 to Present
105 to 106 Not Used
107 Arm Weldment (Bottom Inboard) 1 A
0200454
0200556
Prior to S/N33431
S/N33431 to Present
R
108 0200464 Arm Weldment (Bottom Outboard) 1 M
109 Arm Weldment (4th Outboard) 2 S
0200452 Prior to S/N 50201
0200628 S/N 50201 to Present
110 0200463 Arm Weldment (4th Inboard) 1
111 0200462 Arm Weldment (3rd Inboard) 1
112 0200461 Arm Weldment (Top Inboard) 1
113 3422271 Pin, Attach 1
114 Pin, Attach 11
3422267 Standard Machines
3422273 CSA Machines
115 3422268 Pin, Attach 1
116 3422272 Pin, Attach 1
117 3422269 Pin, Attach 1
118 Pin, Attach 4
119 1440227 Collar 30
120 0200403 Arm Weldment (2nd Outboard - Left Side) 1
121 0641528 Bolt 5/16"-18NC x 3 1/2" 30
122 3311505 Locknut 5/16"-18NC 49
123 4843248 Prop, Safety 2
3120692 3-3
FIGURE 3-1. SIZZOR ARMS INSTALLATION - 40RTS (CONTINUED)
124 Not Used
S 125 0200402 Arm Weldment (2nd Outboard - Right Side) 1
126 4751700 Flatwasher 7/16" 2
E 127 3340579 Pad, Sliding 4
C 128 0681714 Bolt 7/16"-13NC x 1 3/4" (Grade 8) 2
T 129 3311705 Locknut 7/16"-13NC 2
130 0200404 Arm Weldment (3rd Outboard) 2
I 131 0200465 Arm Weldment (Top Outboard) 1
O 132 1320061 Clamp, Hose 4
N 133
134
0641508
Not Used
Bolt 5/16"-18NC x 1" 4
135 Pin, Keeper A/R

3 3841144 Prior to June 1993 2
3841203 June 1993 to S/N44841 2
Not Required S/N44841 to Present 0
S 136 3340674 Pad, Mounting Block 2
I 137
0961335
Bushing, Spacer
Prior to June 1993
2
Z 0961783 June 1993 to Present

Z 138 0641624 Bolt 3/8"-16NC x 3" 8
139 4751600 Flatwasher 3/8" 16
O 140 3311605 Locknut 3/8"-16NC 8
R 141 0961664 Bushing, Composite 26
142 4740229 Washer, Bronze 2
143 0641526 Bolt 5/16"-18NC x 3 1/4" 19
A 144 0641608 Bolt 3/8"-16NC x 1" 2
R 145 4740401 Washer, Special 2
M 2901331
———————————
Sizzor Arm Kit - 40RTS (Includes Items 1
S 4,7,8,9,10,11,12,20,23,25,30 & 31)
0252588 SIZZOR ARM PADS INSTALLATION Ref. 3
201 Pad Options: 32

3340841 Prior to S/N 53927
3340848 S/N 53927 to Present
3-4 3120692
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3120692 3-5
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3-6 3120692
0254088 Standard Machines Built May 1993 to Present Ref. 7 E
0252959
0254089
CSA Machines Built Prior to May 1993
CSA Machines Built May 1993 to Present
Ref.
Ref.
A
7
C
Note: See Section 10 for 30Ft Height Machines. T
Note: When using existing pins, Graphokote
Ref. I
machines built prior to May 1993. When replacing O
pivot pins, use chrome pivot pins which require
no lubrication at installation.
N
101 Lift Cylinder Assembly (See Section 5 for Break-
down)
1
3
102
Pin, Attach (Bottom Lift Cylinder) 1
S
Use 3422735 Prior to S/N44592 (was p/n 3422073) I
3422735 S/N445592 to Present Z
103
Use 3422738
Pin, Attach (Top Lift Cylinder)
1
Z
3422738 S/N44592 to Present O
104 0100011 Loctite #242 Not Shown) A/R R
105 to 106 Not Used
107 Arm Weldment (Bottom Inboard) 1
0200454 Prior to S/N33431 A
108
0200556
0200464
S/N33431 to Present
Arm Weldment (Bottom Outboard) 1
R
109 Arm Weldment (Upper Mid Outboard) 2 M
0200368 Prior to May 1993 S
0200452 May 1993 to S/N 50201
0200630 S/N 50201 to Present
110 Arm Weldment (Lower Mid Inboard) 1
0200458 Prior to S/N 50201
0200631 S/N 50201 to Present
111 0200457 Arm Weldment (Upper Mid Inboard) 1
112 Arm Weldment (Top Inboard) 1
0200456 Prior to S/N35678
113 3422271 Pin, Attach 1
114 Pin, Attach 8
115 3422268 Pin, Attach 1
116 3422272 Pin, Attach 1
117 3422269 Pin, Attach 1
118 Pin, Attach 4
119 1440227 Collar 24
3120692 3-7
120 Arm Weldment (Lower Mid Outboard - Left Side) 1
S 0200373 Prior to May 1993
0200520 May 1993 to Present
E 121 0641528 Bolt 5/16"-18NC x 3 1/2" 25
C 122 3311505 Locknut 5/16"-18NC 44
T 123 4843248 Prop, Safety 2
124 Not Used
I 125 Arm Weldment (Lower Mid Outboard - Right Side) 1
O 0200372 Prior to May 1993
N 126
0200519
4751700
May 1993 to Present
Flatwasher 7/16" 2
127 3340579 Pad, Sliding 4
3 128 0681714 Bolt 7/16"-13NC x 1 3/4" (Grade 8) 2
129 3311705 Locknut 7/16"-13NC 2
130 1320061 Clamp, Hose 4
S 131 0641608 Bolt 3/8"-16NC x 1" 2
I 132
133
0641508 Bolt 5/16"-18NC x 1"
Pin, Keeper
4
A/R
Z 3841144 Prior to June 1993 2
Z 3841203 June 1993 to S/N44841 2
Not Required S/N44841 to Present 0
O 134 3340674 Pad, Mounting Block 2
R 135 Bushing, Spacer 2
0961335 Prior to June 1993
0961783 June 1993 to Present
A 136 0641624 Bolt 3/8"-16NC x 3" 8
R 137 4751600 Flatwasher 3/8" 16
M 138
139
3311605
0961664
Locknut 3/8"-16NC
Bushing, Composite
8
20
S 140 4740229 Washer, Bronze 2
141 0641526 Bolt 5/16"-18NC x 3 1/4" 19
———————————
2901330 Sizzor Arm Kit - 33RTS (Includes Items 7,8,9,10,11, 1
12,20,23 & 25)
SIZZOR ARM PADS INSTALLATION OPTIONS: Ref.

0252587 PRIOR TO S/N 53927 Ref. 2
0258968 S/N 53927 TO PRESENT Ref. 1
201 Pad Options: 24

3340841 Prior to S/N 53927
3340848 S/N 53927 to Present
3-8 3120692
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3120692 3-9
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3-10 3120692
0254086 Standard Machines with Ford Engine Built May Ref. 7 E
1993 to Present
0254086 Standard Machines with Deutz Engines Built May Ref. 7
C
1993 to S/N46902 T
0258576 Standard Machines with Deutz Engines Built S/ Ref. 1
N46902 to Present I
0252958 CSA Machines Built Prior to May 1993 Ref. A O
0254087 CSA Machines with Ford Engine Built May 1993 to
Present
Ref. 7
N
0254087 CSA Machines with Deutz Engines Built May 1993 Ref. 7
to S/N46902
0258577 CSA Machines with Deutz Engines Built S/N46902 Ref. 1
3
to Present
Note: When using existing pins, Graphokote
Ref.
S
machines built prior to May 1993. When replacing
pivot pins, use chrome pivot pins which require
I
no lubrication at installation. Z
Z
101 Lift Cylinder Assembly (See Section 5 for Break- 1
down) O
Use 1683465 Prior to S/N23500 (was p/n 1682593) R
102 Pin, Attach (Bottom Lift Cylinder) 1
Use 3422735 Prior to S/N44592 (was p/n 3422073) A
103
3422735 S/N445592 to Present
Pin, Attach (Top Lift Cylinder) 1
R
Use 3422738 Prior to S/N44592 (was p/n 3422074) M
3422738 S/N44592 to Present S
104 0681714 Bolt 7/16"-13NC x 1 3/4" (Grade 8) 2
105 3311705 Locknut 7/16"-13NC 2
106 4751700 Flatwasher 7/16" 2
107 Not Used
108 Arm Weldment (Bottom Inboard) 1
0200454 Prior to S/N33431
0200556 S/N33431 to S/N46902
0200556 S/N46902 to Present with Ford Engine
0200620 S/N46902 to Present with Deutz Engine
109 Arm Weldment (Bottom Outboard) 1
0200455 Prior to May 1993
110 Arm Weldment (Mid Inboard) 1
0200458 Prior to S/N46902
0200458 S/N46902 to S/N 50201 with Ford Engine
0200631 S/N 50201 to Present with Ford Engine
0200621 S/N46902 to Present with Deutz Engine
111 Arm Weldment (Mid Outboard - Right Side) 1
0200372 Prior to May 1993
3120692 3-11
112 Arm Weldment (Mid Outboard - Left Side) 1
S 0200373 Prior to May 1993
E 113 0200460 Arm Weldment (Top Inboard) 1
C 114 Arm Weldment (Top Outboard) 1
T 0200459 Prior to May 1993
I 115 3422271 Pin, Attach 1
O 116 Pin, Attach 5
N 3422267
3422273
Standard Machines
CSA Machines
117 3422268 Pin, Attach 1
3 118 3422272 Pin, Attach 1
119 3422269 Pin, Attach 1
120 Pin, Attach 4
S 3422270 Standard Machines
I 121
3422274
1440227
CSA Machines
Collar 18
Z 122 0641528 Bolt 5/16"-18NC x 3 1/2" 20
Z 123 3311505 Locknut 5/16"-18NC 33
124 Not Used
O 125 4843248 Prop, Safety 2
R 126 3340579 Pad, Sliding 4
127 1320061 Clamp, Hose 4
128 0641508 Bolt 5/16"-18NC x 1" 4
A 129 Pin, Keeper A/R
R 3841144 Prior to June 1993 2
M 3841203
Not Required
June 1993 to S/N44841
S/N44841 to Present
2
0
S 130 3340674 Pad, Mounting Block 2
131 Bushing, Spacer 2
0961335 Prior to June 1993
0961783 June 1993 to Present
132 0641624 Bolt 3/8"-16NC x 3" 8
133 4751600 Flatwasher 3/8" 16
134 3311605 Locknut 3/8"-16NC 8
135 0961664 Bushing, Composite 14
136 4740229 Washer, Bronze 2
137 0641526 Bolt 5/16"-18NC x 3 1/4" 11
139 0641608 Bolt 3/8"-16NC x 1" 2
———————————
Sizzor Arm Kits - 25RTS (Includes Items 8-14 & 25) 1
2901332 Ford Engine Machines
2901648 Deutz Engine Machines
3-12 3120692
SIZZOR ARM PADS INSTALLATION OPTIONS: Ref.
0252586 PRIOR TO S/N 53927 Ref. 2 S
0258967 S/N 53927 TO PRESENT Ref. 1
E
201 Pad Options: 16 C
3340841
3340848
Prior to S/N 53927
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3120692 3-13
S
E
C
T
I
O
N
S
I
Z
Z
O
R
A
R
M
S
3-14 3120692
SECTION 4 PLATFORM
TABLE OF CONTENTS
FIGURE DESCRIPTION
4-1 FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATION . . . . . . . . . . 4-2

4-2 PLATFORM EXTENSION INSTALLATION (Prior to S/N 50308) . . . . . . . . . . . . . . . . . . . . . . . . 4-6 S
4-3 PLATFORM EXTENSION INSTALLATION (S/N 50308 to Present) . . . . . . . . . . . . . . . . . . . . . . 4-10
4-4 PLATFORM CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
E
4-5 DRIVE/LIFT CONTROLLER ASSEMBLY (Prior to S/N 57701) . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 C
4-6 DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 to Present) . . . . . . . . . . . . . . . . . . . . . . . 4-18 T
I
O
N
P
L
A
T
F
O
R
M
3120692 4-1
SECTION 4 PLATFORM
FIGURE 4-1. FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS
INSTALLATIONS
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-2 3120692
SECTION 4 PLATFORM
FIGURE 4-1. FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATIONS

FIXED PLATFORM (STANDARD) & OPTIONAL Ref.
COMPONENTS INSTALLATIONS
PLATFORM WELDMENTS Ref. 1

S
3510381 Standard E
3510407 Option With Tread Grip Flooring & Bolt-on Attach
Rings
C
3510653 Option With Harness Attach Points T
HANDRAILS INSTALLATIONS Ref.
I
Note: See Section 10 for Handrails with Inner Grip Ref. O
Rails N
0253655 Fixed Platform Ref. 11
0253026 Extendable Platform Ref. 12
4
1 3640810 Handrail - Side 2
2 3640811 Handrail - Rear 1
3 0901870 Bracket A/R P
4 1260136 Chain 2ft/.61m L
5 3010088 Link 2
6 2940064 Snap-Hook 1
A
7 Not Used T
8
9
4711400
Not Used
Flatwasher 1/4" Narrow A/R F
10 3311405 Locknut 1/4"-20NC A/R O
11 Not Used R
12
13
0641416
3422219
Bolt 1/4"-20NC x 2"
Pin, Spring
A/R
A/R
M
14 1060379 Cable, Lanyard A/R
15 Not Used
16 0641406 Bolt 1/4"-20NC x 3/4" A/R
17 Kickplate - Front A/R
3536299 Fixed Platform 1
Not Required Extendable Platform 0
18 3520072 Cap-Plug A/R
19 Rail Weldment - Front A/R
20 3252234 Decal - Gate (Prior to S/N 71528) 1
21 Bracket A/R
22 Not Used
23 Tubing, Cover 2 ft./.6m
2820024 Vinyl (Prior to S/N42124)
2820097 Mesh (S/N42124 to Present)
24 to 29 Not Used
30 3760170 Ring (S/N 55667 to Present) A/R
31 Not Used
3120692 4-3
SECTION 4 PLATFORM
(CONTINUED)
32 4060807 Shield, Flex Trim (Not Shown) 1.25’/.4m
--------------------------------------------------------------------
S 2902025 Kit, Platform Rails (Includes Items 1 & 2) 1
E 2902024 Kit, Platform Rail (Includes Items 1, 2 & 19) 1
C OPTIONAL WORKLIGHTS INSTALLATIONS Ref.

T Note: See Section 10 for Worklights with Automatic
Reel.
Ref.
I 0253792 25RTS Ref. —

O 0253793 33RTS Ref. —
0253794 40RTS Ref. —
N
101 2920111 Worklight 2
4 102
7016627
4460206
Bulb, Replacement (1 per Assembly)
Terminal, Male
2
2
103 4460185 Terminal, Female 2
P 104 1060341 Cable, Electrical - 16/2 A/R
L 25RTS
33RTS
80ft/24.4m
94ft/28.7m
A 40RTS 100ft/30.5m
T 105 4240033 Tie Strap 10

F 107 0641416 Bolt 1/4"-20NC x 2" 2
O 108 4751400 Flatwasher 1/4" 2
R 109
110
4761400
3311401
Lockwasher 1/4"
Nut 1/4"-20NC
2
2
M
0250999 OPTIONAL WELDED ON ATTACH RINGS Ref. 2
INSTALLATION
201 3534309 Plate (Welded on Parts) 2

202 3760274 Ring, Swivel 2
OPTIONAL BOLT-ON ATTACH RINGS Ref.

INSTALLATION
0253850 Standard Ref. A
0257433 GM Spec Ref. 1
251 3760321 Ring, Swivel 6

252 0630476 Screw, Button Head 5/16"-18NC x 1 1/4" 24
253 4761500 Lockwasher 5/16" 24
255 1703175 Decal - Lanyard (GM Spec Only) 6
0250317 OPTIONAL CIRCULAR LEVEL INSTALLATION Ref. —
301 4842981 Mounting Weldment 1

302 2420038 Level, Circular 1
4-4 3120692
SECTION 4 PLATFORM
(CONTINUED)
304 4770600 Starwasher #6 3
305 0641406 Bolt 1/4"-20NC x 3/4" 4
306 3311401 Nut 1/4"-20NC 4 S
307 4761400 Lockwasher 1/4" 4 E
OPTIONAL RECEPTACLE INSTALLATION Ref. C
0253913 110V All Models Ref. 5 T
0254380
0254381
220V 25RTS
220V 33RTS
Ref.
Ref.
3
3
I
0254382 220V 40RTS Ref. 3 O
N
401 0860038 Box, Receptacle 1
402 Receptacle 1
4460190 110V 4
Not Available 220V
403 4060092 Shield, Cover 1
404 3900256 Screw, Self-Tapping #10-16NC x 1 1/4" 4 P
405 4761000 Lockwasher #10 4 L
406 Reducer, Bushing 1
0960407 110V Prior to October 1995
A
Use 4460051 110V October 1995 to Present T
407
Not Required 220V
Connector, Strain Relief 1
F
Use 4460051 110V Prior to S/N44684 (was p/n 4460049) O
4460051 110V S/N44684 to Present R
408 to 411
4460049
Not Used
220V
M
412 Connector, Plug 1
4460138 110V
Not Available 220V
413 1700598 Decal - Ground (Prior to S/N 55984) 2
414 1700599 Decal - Neutral (Prior to S/N 55984) 2
415 0641507 Bolt 5/16"-18NC x 7/8’ A/R
416 4711500 Flatwasher 5/16" Narrow A/R
417 4761500 Lockwasher 5/16" A/R
418 3311501 Nut 5/16"-18NC A/R
419 1320061 Clamp A/R
420 4711000 Flatwasher #10 4
421 1060308 Cable, Electrical 12/3 A/R
25RTS (110V) 60ft/18.3m
25RTS (220V) 55ft/16.8m
33RTS (110V) 70ft/21.3m
33RTS (220V) 65ft/19.8m
40RTS (110V) 80ft/24.4m
40RTS (220V) 75ft/22.9m
3120692 4-5
SECTION 4 PLATFORM
FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-6 3120692
SECTION 4 PLATFORM
FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308)
EXTENDABLE PLATFORM INSTALLATIONS Ref.
0253033 Standard Flooring Prior to S/N12925 Ref. B
0254881 Standard Flooring S/N12925 to 50308 Ref. B
0253803 Optional Tread Grip Flooring Ref. 3
S
1 Platform Extension Weldments 1 E
3510382 Standard Flooring Prior to S/N12925 C
3510478 Standard Flooring S/N12925 to 50308
3510408 Optional Tread Grip Flooring
T
2 0641416 Bolt 1/4"-20NC x 2" 12 I
3
4
4751400
3311405
Flatwasher 1/4"
Locknut 1/4"-20NC
40
22
O
5 4200004 Channel, Hinge 4 N
6 3421453 Pin, Spring 5
7
8
1060379
3860057
Cable, Lanyard
Roller
5
A/R
4
9 0641514 Bolt 5/16"-18NC x 1 3/4" A/R
10 4751500 Flatwasher 5/16" A/R P
11 3311505 Locknut 5/16"-18NC A/R
12 Angle, Stop 2
L
Use 0181684 Prior to July 1995 (was p/n0181586) A
13
0181684
0641408
July 1995 to Present
Bolt 1/4"-20NC x 1" 4
T
14 Extension, Roller Mount 4 F
4843706 Prior to February 1994 (Adjusts by using washers) O
3537619 February 1994 to S/N 50308 (Has adjusting screw)
15 0641511 Bolt 5/16"-18NC x 1 3/8" 16
R
16 4565790 Tube, Side 2 M
17 3860059 Roller, Extension 4
18 3340653 Pad, Slide 2
19 0641420 Bolt 1/4"-20NC x 2 1/2" 4
20 4843336 Handle Weldment 2
21 3941004 Screw, Self-Tapping #10 x 1/2" 2
22 0641620 Bolt 3/8"-16NC x 2 1/2" 4
23 4751600 Flatwasher 3/8" 4
24 3311605 Locknut 3/8"-16NC 4
25 0200409 Arm, Latch 2
26 3841180 Rod, Latch 2
27 1380132 Clip, Gripper 2
28 2560088 Grip, Handle 2
29 0641516 Bolt 5/16"-18NC x 2" 2
30 0901916 Bracket - Front Handrail 1
31 3640846 Handrail - Front 1
32 3252235 Decal - Capacity (Prior to S/N44593 Only) 1
33 4070829 Shim A/R
34 4280284 Strip, Rubber (Prior to S/N27422 Only) 12in/30.5cm
35 3841233 Rod, Roller Support (February 1994 to S/N 50308) 4
36 3312202 Nut, Jam 3/4"-10NC 4
3120692 4-7
SECTION 4 PLATFORM
FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308) (CONTINUED)
38 4752200 Flatwasher 3/4" 4
39 3520072 Plug, Cap (Prior to S/N44592 Only) 2
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-8 3120692
SECTION 4 PLATFORM
FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308) (CONTINUED)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
3120692 4-9
SECTION 4 PLATFORM
FIGURE 4-3. PLATFORM EXTENDABLE INSTALLATIONS (S/N 50308 TO
PRESENT)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-10 3120692
SECTION 4 PLATFORM
FIGURE 4-3. PLATFORM EXTENDABLE INSTALLATIONS (S/N 50308 TO PRESENT)
EXTENDABLE PLATFORM INSTALLATIONS Ref.
0258697 Standard Flooring Ref. 6
0258719 Optional Tread Grip Flooring Ref. 6
1 to 2 Not Used
S
3 4711500 Flatwasher 5/16" 16 E
4 3311505 Locknut 5/16"-18NC 16 C
5 0181684 Angle, Stop 2
6 0641408 Bolt 1/4"-20NC x 1" 4
T
7 4751400 Flatwasher 1/4" 64 I
8
9
3311405
3537619
Locknut 1/4"-20NC
Extension, Roller Mount
32
4
O
10 3860059 Roller, Extension 4 N
11 0641511 Bolt 5/16"-18NC x 1 3/8" 16
12
3510700
Platform Extension Weldment Options:
Standard Flooring
1
4
3510701 Optional Tread Grip Flooring
13 4565790 Tube, Side 2 P
14 3640846 Handrail - Front 1
15 1320061 Clamp 3
L
16 0641418 Bolt 1/4"-20NC x 2 1/4" 3 A
17
18
0641416
4200004
Bolt 1/4"-20NC x 2"
Channel, Hinge
26
4
T
19 3421453 Pin, Spring 5 F
20 1060379 Cable, Lanyard 5 O
21 3340653 Pad, Slide 2
22 0641420 Bolt 1/4"-20NC x 2 1/2" 4
R
23 4070829 Shim 4 M
24 0901916 Bracket - Front Handrail 1
25 3841233 Rod, Roller Support 4
26 3322202 Nut, Jam 3/4"-16NF 4
28 4752200 Flatwasher 3/4" 4
29 4845855 Handle Weldment (RH) 1
30 4845854 Handle Weldment (LH) 1
31 3520072 Plug, Cap 2
32 Not Used
33 3571078 Latch Plate - Rear 2
34 3571077 Latch Plate - Front 2
35 Not Used
36 1380132 Clip, Gripper 2
37 3820020 Pop Rivet 2
38 3537609 Plate, Pivot 2
39 2560088 Grip, Handle 2
40 0641676 Bolt 3/8"-16NC x 9 1/2" 2
41 3311605 Locknut 3/8"-16NC 2
42 4751600 Flatwasher 3/8" 4
43 3760170 Ring 5
3120692 4-11
SECTION 4 PLATFORM
FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION
S
E
C
T
I
O
N
P 27
L 17
A 19
T 41 18
F 19
O OR 40 42
R
M
4-12 3120692
SECTION 4 PLATFORM
FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION
0253701 CONSOLE BOX INSTALLATION Ref. 14
Note: See Section 10 for Non-Standard Console Ref.
Boxes.
1 Box, Control Options: 1

S
0860799 Prior to S/N 80670 E
2
0861377 S/N 80670 to Present
Nameplate, Lid 1
C
Use 3252310 Prior to July 1993 (Was P/N 3252229) T
3252310 July 1993 to S/N 57701 (was p/n3252310) I
3
3252620
4420008
Tape, Insulation 38in/96.5cm
O
4 Bracket, Hanger 2 N
0901897 Prior to S/N46418
0902456 S/N46418 to S/N 57701
4845938 S/N 57701 to Present
4
5 0641404 Bolt 1/4"-20NC x 1/2" A/R
6
7
4791400
1060380
Starwasher 1/4"
Lanyard - 10" (Prior to S/N46418 Only)
A/R
1
P
8 3760170 Ring (Prior to S/N46418 Only) 1 L
3421453 Pin, Snap (Prior to S/N46418 Only) 1 A
9 2560141 Thumbscrew (S/N46418 to Present Only) 1
0181847 Angle (S/N46418 to Present Only) 1
T
10 3520082 Plug, Hole 1 F
11
12
4460470
4460471
Nut, Conduit
Lockwasher, Conduit
1
1
O
13 4460463 Receptacle 1 R
14 4360339 Switch, Push Button (Enable) 1 M
7012593 Cap, Rubber 1
15 4360267 Block, Contact - N.O. 1
16 0100035 Loctite #222 A/R
17 Circuit Card Assembly 1
Use 0610114 Prior to February 1995 (was p/n 0610103)
0610114 February 1995 to S/N 57701
7012658 Fuse - 7.5 Amp 1
0610110 Bracket Replacement Kit 1
0902514 Bracket, Relay (S/N 57701 to Present) 1
18 Nut Options: 2
3310601 Nut #6-32NC (Prior to S/N 57701)
3311001 Nut #10-24NC (S/N 57701 to Present)
19 Lockwasher Options: A/R
4770600 Lockwasher #6 (Prior to S/N 57701) 2
4761000 Lockwasher #10 (S/N 57701 to Present) 4
20 3900177 Screw, Machine #8 x 1/2" 8
21 Controller, PQ Options: (Drive/Steer) 1
1600157 Prior to S/N 57701 (See Figure 4-5 for
Breakdown)
1600290 S/N 57701 to Present (See Figure 4-6 for
Breakdown)
3120692 4-13
SECTION 4 PLATFORM
FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION (CONTINUED)
22 4740120 Washer, Nylon 4
24 4360336 Switch, Toggle (Drive Speed and Engine Speed) 2
25 4060802 Shield, Switch 3
S 26 3790012 O-Ring 3
E 27 4360274 Switch, Push Button (Horn) 2
28 4360314 Switch, Toggle (Lift) 1
C 29 Switch, Emergency Stop Options: 1
T 4360289 Prior to S/N 65031
I 4360475 S/N 65031 to Present

Cap Options: 1
O 7012611 Cap, Mushroom Head (Used on Switch p/n
N 7012612
4360289)
Boot (Used on Switch p/n 4360289) 1
7020175 Cap, Red (Used on Switch p/n 4360475)
4 7020176 Contact Block (Used on Switch p/n 4360475)
30 Not Used
31 3520079 Plug, Hole 5
P 32 0100009 Sealant, Silicon A/R
L 33 2920029 Bulb, Light 1
34 2920026 Lamp, Indicator - Red 1
A 35 to 36 Not Used
T 37 3520081 Plug, Hole 1
F 38
4360282
Block, Contact Options: (Not Shown)
Prior to S/N 47996
1

R 39 Not Used
40 3740049 Relay (S/N 57701 to Present) 4
M 41 3911008 Screw Machine #10-24NC x 1/2” (S/N 57701 to 2
Present)
42 3321001 Nut #10-24NC (S/N 57701 to Present) 2
43 to 44 Not Used
45 4750600 Flatwasher (Not Shown) 2
OPTIONAL TILT ALARM INSTALLATIONS Ref.

0253733 Without Drive/Lift Lockout Ref. 3
0254262 With Lift Lockout Ref. 3
0254111 With Drive/Lift Lockout Ref. 2
101 0140011 Alarm 1

103 2920029 Bulb, Light 1
0254076 OPTIONAL LEVELING JACK CONTROLS Ref. 9

INSTALLATION
201 4360314 Switch, Toggle 4

3790012 O-Ring 4
203 2920029 Bulb, Light 1
4-14 3120692
SECTION 4 PLATFORM
FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION (CONTINUED)
0252532 OPTIONAL 4WS CONTROLS INSTALLATION Ref. 7
301 4360314 Switch, Toggle (Rear Steer) 1

3790012 O-Ring 1
4060802 Guard, Switch 1 S
E
0253821 OPTIONAL LIGHTS INSTALLATION Ref. 3
C
401 4360329 Switch, Toggle 1 T
3790042 O-Ring 1
I
O
N
P
L
A
T
F
O
R
M
3120692 4-15
SECTION 4 PLATFORM
FIGURE 4-5. DRIVE/LIFT CONTROLLER ASSEMBLY (PRIOR TO S/N 57701)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-16 Updated 5/16/00 3120692

SECTION 4 PLATFORM
FIGURE 4-5. DRIVE/LIFT CONTROLLER ASSEMBLY (PRIOR TO S/N 57701)
1600157 CONTROLLER ASSEMBLY Ref. B
7011931 Handle/Stem Assembly (Includes Items 1-9) 1

1
2
7011932
7011933
Stem Assembly
Slidelock Assembly (Includes Items 3 and 4)
1
1
S
3 7003772 Boot 1 E
4 7011934 Spring 1 C
5 7011935 Handle Assembly (Includes Items 6-8) 1
6 7003789 Switch, Rocker 1
T
7 7003790 Cap, Rubber 1 I
8
9
7003791
7011936
Actuator, Switch
Gasket
1
1
O
10 7011938 Electrical Assembly 1 N
Not Serviced Harness Assembly (Not Shown) 1
4460367
4460226
Receptacle, Female 12 Position
Socket, Female
1
12
4
4460343 Plug, Male 12 Position (Part of Platform Console 1
Box Wiring Harness) P
4460227 Pin, Male 12
11 7011923 Electrical Assembly (Includes Items 12-13) 1
L
12 7011940 Gear, Pinion 1 A
13 7003751 Poteniometer 1
T
F
O
R
M
3120692 4-17
SECTION 4 PLATFORM
FIGURE 4-6. DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-18 3120692
SECTION 4 PLATFORM
FIGURE 4-6. DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT)
1600290 CONTROLLER ASSEMBLY Ref. B
7020503 Mechanical Assembly 1

1
1A
Not Serviced
7020520
Handle Assembly
Boot 1
1
S
1B 7020504 Mounting Plate 1 E
1C 7020502 Gasket 1 C
2 7011991 Grip Assembly 1
2A 7020500 Switch, Rocker 2
T
2B 7020501 Switch, Push Button - Red 1 I
2C
2D
7020531
7020532
Grip - Right Half
Grip - Left Half 1
1 O
2E 7003791 Actuator, Switch 1 N
2F 7011997 Trigger 1
2G
3
7003790
7011938
Cap, Rubber
Electrical Assembly
1
1
4
4460367 Receptacle, Female - 12 Pin (Not Shown) 1
4460226 Socket, Female (Not Shown) 12 P
4460343 Plug, Male 12 Position (Not Shown) 1
4460227 Pin, Male (Not Shown) 12
L
4 7011923 Electrical Assembly 1 A
4A
4B
7020509
7003751
Potentiometer, Mounting Plate
Potentiometer
1
1
T
4C 7011940 Gear, Pinion 1 F
4D 7020511 Setscrew #6-32NC x 1/8” 1 O
4E 7011982 Board, Circuit (Not Shown) 1
R
M
3120692 4-19
SECTION 4 PLATFORM
FIGURE 4-6. DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT) (CONTINUED)
S
E
C
T
I
O
N
P
L
A
T
F
O
R
M
4-20 3120692
SECTION 5 CYLINDERS
TABLE OF CONTENTS
FIGURE DESCRIPTION
5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (Hydraulic Jack
Option without Interlock - Production Cylinders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-3 LEVELING JACK CYLINDER ASSEMBLY WITH WELDED ON PIVOT PAD (Hydraulic Jack S
Option without Interlock - Recommended Service Replacement Cylinders) . . . . . . . . . . . . . . . . 5-8
5-4 LEVELING JACK CYLINDER ASSEMBLY (Hydraulic Jack Option with Interlock) . . . . . . . . . . . 5-10
E
5-5 LIFT CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 C
5-6
5-7
STEER CYLINDER ASSEMBLY (Machines Built Prior to June 1993) . . . . . . . . . . . . . . . . . . . . 5-16
STEER CYLINDER ASSEMBLY (Machines Built June 1993 to Present) . . . . . . . . . . . . . . . . . . 5-18
T
I
O
N
C
Y
L
I
N
D
E
R
S
3120692 5-1
SECTION 5 CYLINDERS
FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (OSCILLATING AXLE
OPTION)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-2 3120692
SECTION 5 CYLINDERS
FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (OSCILLATING AXLE OPTION)

1682185 AXLE LOCKOUT CYLINDER ASSEMBLY (OSCILLAT- Ref. 6
ING AXLE OPTION)
1 1682186 Barrel Weldment 1

2 1681609 Rod Weldment 1
3 1120108 Retainer, Head 1 S
4 1681322 Head 1 E
5
6
3480116
4564606
Piston
Tube, Spacer
1
1
C
7 3300273 Nut 1 T
8 3900170 Setscrew 3/8"-16NC x 3/8" 1 I
9 4640273 Bleeder 3
10 Kit Wiper, Rod 1
O
11 Kit Seal, Rod 1 N
12 Kit Ring, Wear 1
13 Kit O-Ring 1
14 Kit Ring, Lock 2 5
15 Kit O-Ring 1
16 Kit Seal 2
C
18 Not Used Y
2900379
——————————
Seal Kit (Includes Items 10-16) 1
L
I
N
D
E
R
S
3120692 5-3
SECTION 5 CYLINDERS
FIGURE 5-2. LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT
PAD (HYDRAULIC JACK OPTION WITHOUT INTERLOCK - PRODUCTION
CYLINDERS)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-4 3120692
SECTION 5 CYLINDERS
FIGURE 5-2. LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (HYDRAULIC
JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS)
LEVELING JACK CYLINDER ASSEMBLY Ref.
(HYDRAULIC JACK OPTION WITHOUT INTERLOCK)
1682720 Prior to S/N 101615 (Production) Ref. 3
1683966 S/N 101615 to Present (Production) Ref. G
Note: Leveling Jack Cylinders p/n 1682720 &
1683966 with screw-in pad pivot ball were used in S
regular production. In place of the production cylin-
ders, JLG recommends using p/n 1684216 for
E
machines built prior to S/N 101615 and 1684217 for C
machines built S/N 101615 to present when replac-
ing a complete cylinder. Replacement cylinders T
have the pad pivot ball welded to the cylinder rod.
Parts for both the production and the recom-
I
mended replacement cylinders are shown in Sec- O
tion 5. Identify your cylinder before ordering parts.
N
1 Barrel Weldment Options: 1
1682721
1683967
Prior to S/N 101615
5
2 1682723 Rod, Cylinder 1
3 Pad, Jack Options: 1 C
Use 2902023
Use 2902023
Prior to S/N 91552 (was p/n 3340650)
S/N 91552 to Present (was p/n 3340904)
Y
4 0320015 Ball, Pivot 1 L
5 0100011 Loctite #242 A/R I
6 Ring, Retainer Options: 1
3760261 Prior to S/N 91552
N
3760453 S/N 91552 to Present D
7
0681506
Bolt Options:
Prior to S/N 91552 (5/16-18NCx3/4)
6
E
0681606 S/N 91552 to Present (3/8-16NCx3/4) R
8 0100035 Loctite #222 A/R S
9 Kit Wiper, Rod 1
10 1120108 Retainer 1
11 Kit Seal, Rod 1
12 1681283 Head 1
13 Kit O-Ring 1
14 Kit Ring, Wear 1
15 4565647 Spacer 1
16 Kit Ring, Guidelock 2
17 Kit O-Ring 1
18 Kit Seal 2
19 Cartridge, Pilot Operated Check Valve Options: A/R
4640613 Prior to S/N 101615 1
2900770 Seal Kit 1
4641156 S/N 101615 to Present 1
2900770 Seal Kit 1
20 3480092 Piston 1
3120692 5-5
SECTION 5 CYLINDERS
JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS) (CONTINUED)
21 Plug Options: 1
2220885 Prior to S/N 101615
2220883 S/N 101615 to Present
22 3900170 Setscrew 1
23 3300281 Nut 1
S 24 0100038 Primer, Loctite A/R
E 25
26
Not Used
3536708 Plate, Actuator 1
C
T 27 Valve, Counter Balance Options: A/R
Not Used Prior to S/N 101615 0
I 4640495 S/N 101615 to Present 1
O 2900770 Seal Kit - 4640495 Valve 1
N 2901941
——————————
Seal Kit (Includes Items 9, 11,13, 14 and 16-18) 1
C
Y
L
I
N
D
E
R
S
5-6 3120692
SECTION 5 CYLINDERS
JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS) (CONTINUED)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
3120692 5-7
SECTION 5 CYLINDERS
FIGURE 5-3. LEVELING JACK CYLINDER ASSEMBLY WITH WELDED ON PIVOT
PAD (HYDRAULIC JACK OPTION WITHOUT INTERLOCK - RECOMMENDED SER-
VICE REPLACEMENT CYLINDERS)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-8 3120692
SECTION 5 CYLINDERS
FIGURE 5-3. LEVELING JACK CYLINDER ASSEMBLY WITH WELDED ON PIVOT PAD (HYDRAULIC
JACK OPTION WITHOUT INTERLOCK - RECOMMENDED SERVICE REPLACEMENT CYLINDERS)
LEVELING JACK CYLINDER ASSEMBLY Ref.
1684216 Prior to S/N 101615 (Service Replacement Cylinder) Ref. A
1684217 S/N 101615 to Present (Service Replacement Ref. A
Cylinder)
Note: Leveling Jack Cylinders p/n 1682720 &
1683966 with screw-in pad pivot ball were used in S
regular production. In place of the production cylin-
ders, JLG recommends using p/n 1684216 for
E
machines built prior to S/N 101615 and 1684217 for C
machines built S/N 101615 to present when replac-
ing a complete cylinder. Replacement cylinders T
have the pad pivot ball welded to the cylinder rod.
Parts for both the production and the recom-
I
mended replacement cylinders are shown in Sec- O
tion 5. Identify your cylinder before ordering parts.
N
3 to 5
6
Not Used
1120108 Retainer 1
5
7 1681283 Head 1
8 1684206 Rod, Cylinder 1 C
9 1682721
1683967
Barrel Weldment (Cylinder p/n 1684216)
Barrel Weldment (Cylinder p/n 1684217)
1
1
Y
10 2220885 Plug (Cylinder p/n 1684216) 1 L
2220883 Plug (Cylinder p/n 1684217) 2 I
11 Not Used
12 3300465 Locknut 1
N
13 4846584 Pad, Jack 1 D
14
15
3480092
3573513
Piston
Plate
1
1
E
16 to 17 Not Used R
18 Kit Ring, Wear 1 S
19 Kit Ring, Guidelock 2
20 Kit O-Ring 1
21 Kit O-Ring 1
22 Kit Wiper, Rod 1
23 Kit Seal, Rod 1
24 Kit Seal 2
25 Not Used
26 Not Required Valve, Counter Balance (Cylinder p/n 1684216) 0
4640495 Valve, Counter Balance (Cylinder p/n 1684217) 1
27 4640613 Valve, Check (Cylinder p/n 1684216) 1
4641156 Valve, Check (Cylinder p/n 1684217) 1
7011345 Cartridge (Cylinder p/n 1684217) 1
2900770 Kit, Seal (Cylinder p/n 1684217) 1
29 3900321 Screw 1/2”-13NC x 1 1/4” 3
30 4713000 Washer 1 1/4” 1
——————————
2901941 Seal Kit (Includes Items 18-24) 1
3120692 5-9
SECTION 5 CYLINDERS
FIGURE 5-4. LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK
OPTION WITH INTERLOCK)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-10 3120692
SECTION 5 CYLINDERS
FIGURE 5-4. LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH
INTERLOCK)
1682657 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC Ref. A
JACK OPTION WITH INTERLOCK)

3 1120387 Retainer, Head 1 S
4 1682364 Head 1 E
5
6
3480123
3300270
Piston
Nut
1
1
C
7 4565686 Tube, Spacer 1 T
8 4640438 Valve, Cartridge Check 1 I
2900770 Seal Kit - 4640438 Valve 1
9 3900170 Setscrew 3/8"-16NC x 3/8" 1
O
10 2200221 Plug, Pipe - 1/8" NPT 1 N
11 Kit Wiper, Rod 1
12 Kit Seal, Rod 1
13 Kit O-Ring 1 5
14 Kit Ring, Wear 1
15 Kit Ring, Wear 1
16 Kit O-Ring 1
C
17 Kit T-Seal 1 Y
18
19
0100011
0100038
Primer, Locking (Not Shown)
A/R
A/R
L
20 0100035 Loctite #222 (Not Shown) A/R I
21 0100020 Sealant, Pipe (Not Shown) A/R N
2901208
——————————
Seal Kit (Includes Items 11-17) 1
D
E
R
S
3120692 5-11
SECTION 5 CYLINDERS
FIGURE 5-5. LIFT CYLINDER ASSEMBLIES
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-12 3120692
SECTION 5 CYLINDERS
FIGURE 5-5. LIFT CYLINDER ASSEMBLIES
LIFT CYLINDER ASSEMBLIES Ref.
Note: Machines built prior to S/N28190 use cylin- Ref.
ders p/n 1682243 or 1682593 which use a T-seal.
When rebuilding these cylinders JLG recommends
using the seal kit listed below per specific model
(40RTS or 33/25RTS) and a p/n 3480214 piston in
place of the original components. The p/n 3480214
piston uses 1 lock ring and 1 seal. If the p/n
S
3480214 piston has already been installed, the new, E
unused piston can be returned to JLG. Machines
built S/N 28190 to present use cylinders p/n
C
1683465 or 1683466 which already use the p/n
3480214 piston.
T
I
LIFT CYLINDER ASSEMBLIES Ref. O
1683466
1683465
40RTS
33RTS and 25RTS
Ref.
Ref.
B
B
N
1 Barrel Weldment 1 5
1682080 40RTS
1682594 33RTS and 25RTS
0961379 Bushing, Bronze 2 C
2
1682100
Rod Weldment
40RTS
1
Y
1682082 33RTS and 25RTS L
0961380 Bushing, Bronze 2 I
3 1120358 Retainer, Head 1
4 Head 1
N
1682076 40RTS D
5
1682098 33RTS and 25RTS
Tube, Spacer 1
E
4564707 40RTS R
4565605 33RTS and 25RTS S
6 3480214 Piston 1
7 3300286 Nut 1
8 3900170 Setscrew 3/8"-16NC x 3/8" 1
9 Not Used
10 Kit Wiper, Rod 1
11 Kit Seal, Rod 1
12 Kit Ring, Wear 1
13 Kit O-Ring 1
14 Kit O-Ring 1
15 Kit Ring, Lock 2
16 Kit Seal, Piston 2
18 2180527 Plug, Pipe (Located on Rod End) 1
19 0100011 Loctite #242 A/R
20 0100020 Sealant, Pipe A/R
21 0100035 Loctite #222 A/R
22 0100038 Primer, Locking A/R
——————————
3120692 5-13
SECTION 5 CYLINDERS
FIGURE 5-5. LIFT CYLINDER ASSEMBLIES (CONTINUED)
2901442 Seal Kit - 40RTS (Includes Items 10-16) 1
2901323 Seal Kit - 33RTS & 25RTS (Includes Items 10-16) 1
0251791 MANUAL DESCENT VALVE INSTALLATION Ref. 11

(OPTIONAL)
S 101 4640699 Valve, Pull 1
E 102
2900503
0080190
Seal Kit - 4640699 Valve
Adapter
1
1
C 103 3311402 Nut, Jam 1/4"-20NC 1
T 104 Not Used
105 0902720 Bracket, Cable Mounting 1
I 106 3321402 Nut, Jam 1/4"-28NF 4
O 107 Not Used
N 108
Use 1060643
Cable, Manual Descent
Prior to S/N 28149 (Was P/N 1060377)
1
1060643 S/N 28149 to S/N 38795

5 1060664 S/N 38795 to Present
109 0641416 Bolt 1/4"-20NC x 2" 2
110 3311401 Nut 1/4"-20NC 2
C 111 4761400 Lockwasher 1/4" 2
Y 112
113 to 119
3760170
Not Used
Ring 1
L 120 1701437 Decal - Manual Descent (Not Shown) 1

I 121 3841127 Rod 1
N 122
123
3450405
4220044
Pin, Cotter 1/8" x 1 1/4"
Stop, Throttle
1
1
D 124 to 125 Not Used
E 126 4751000 Washer 4
R HOLDING VALVE INSTALLATION Ref.

S
201 4640382 Cartridge, Holding Valve 1
7009742 Coil (Vickers/Modular Controls Version) 1
2900503 Seal Kit (Vickers/Modular Controls Version) 1
5-14 3120692
SECTION 5 CYLINDERS
FIGURE 5-5. LIFT CYLINDER ASSEMBLIES (CONTINUED)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
3120692 5-15
SECTION 5 CYLINDERS
FIGURE 5-6. STEER CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO JUNE
1993)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-16 3120692
SECTION 5 CYLINDERS
FIGURE 5-6. STEER CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO JUNE 1993)
1682681 STEER CYLINDER ASSEMBLY (MACHINES BUILT Ref. C
PRIOR TO JUNE 1993)

4 1681344 Head 2
S
5 3480164 Piston 1 E
6
7
4565716
3760143
Tube, Spacer
Ring, Retainer
2
2
C
8 3860056 Follower, Cam 1 T
9 3300357 Nut, Special 1 I
10 Kit Wiper, Rod 2
11 Kit Seal, Rod 2
O
12 Kit O-Ring 2 N
13 Kit Ring, Wear 2
14 Kit Ring, Wear 1
15 Kit T-Seal 1 5
16 Kit O-Ring 1
17
18
0440085
0100011
Bearing
2
A/R
C
19 0100035 Loctite #222 (Not Shown) A/R Y
—————————— L
2901210 Seal Kit (Includes Items 10-16) 1
I
N
D
E
R
S
3120692 5-17
SECTION 5 CYLINDERS
FIGURE 5-7. STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO
PRESENT)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-18 3120692
SECTION 5 CYLINDERS
FIGURE 5-7. STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT)
1682967 STEER CYLINDER ASSEMBLY (MACHINES BUILT Ref. 5
JUNE 1993 TO PRESENT)

4 1681344 Head 2
S
5 to 7 Not Used E
8
9
3860056
3300357
Follower, Cam
Nut, Special
1
1
C
10 Kit Wiper, Rod 2 T
11 Kit Seal, Rod 2 I
12 Kit O-Ring 2
13 Kit Ring, Wear 2
O
14 Kit Ring, Wear 1 N
15 Not Used
16 Kit “T” Seal 1
17 0440085 Bearing 2 5
19
20
0100035
4568055
Tube, Spacer
A/R
2
C
—————————— Y
2901261 Seal Kit (Includes Items 10-14 and 16) 1 L
I
N
D
E
R
S
3120692 5-19
SECTION 5 CYLINDERS
FIGURE 5-7. STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT)
S
E
C
T
I
O
N
C
Y
L
I
N
D
E
R
S
5-20 3120692
SECTION 6 HYDRAULICS
TABLE OF CONTENTS
FIGURE DESCRIPTION
6-1 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 HYDRAULIC DIAGRAM - STANDARD 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-5 HYDRAULIC DIAGRAM - OSCILLATING AXLE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
S
E
C
T
I
O
N
FIGURE DESCRIPTION PAGE NO.
6
6-1 HYDRAULIC DIAGRAM LIST Ref.
Note: Copies of Hydraulic Diagrams are available through JLG Service Department. Ref. H
PART NO. Ref.
Y
0254000 HYDRAULIC DIAGRAM - AUXILIARY LIFT (OPTIONAL) D
2792024
HYDRAULIC DIAGRAM - LEVELING JACKS (OPTIONAL)
PRIOR TO S/N 101615
R
2792538 S/N 101615 TO PRESENT A
0251791 HYDRAULIC DIAGRAM - MANUAL DESCENT (OPTIONAL) U
0253569 HYDRAULIC DIAGRAM - OIL COOLER (OPTIONAL)
HYDRAULIC DIAGRAM - OSCILLATING AXLE (OPTIONAL) (SEE FIGURE 6-5)
L
2791574 PRIOR TO S/N 97717 I
2792519
2791939
S/N 97717 TO PRESENT
HYDRAULIC DIAGRAM - STANDARD 2WD/2WS (SEE FIGURE 6-2)
C
2791938 HYDRAULIC DIAGRAM - STANDARD 2WD/4WS S
2791937 HYDRAULIC DIAGRAM - STANDARD 4WD/2WS (SEE FIGURE 6-3)
2791936 HYDRAULIC DIAGRAM - STANDARD 4WD/4WS (SEE FIGURE 6-4)
2791962 HYDRAULIC DIAGRAM - TOW PACKAGE (OPTIONAL)
2792370 HYDRAULIC SCHEMATIC
3120692 6-1
FIGURE 6-2. HYDRAULIC DIAGRAM - 2WD/2WS
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
6-2 3120692
2791939 HYDRAULIC FITTINGS INSTALLATION Ref. 11

102 2220377 Fitting, Straight 5
103 1320033 Clamp, Hose 8
104 Not Used 1
105 3100075 Block, Manifold 1
106 to 107 Not Used
108 2720373 Hose, Suction 1" (2.54cm) x 8 3/4" (20cm) 2
S
109 2220403 Fitting, 90° E
110
111
Not Used
C
112 2220275 Fitting, Reducer 1 T
113 2220710 Fitting, Reducer 1 I
114
2220451
Fitting, Straight Options:
Prior to S/N 54201
A/R
1
O
2220498 S/N 54201 to Present 4 N
115 2220646 Fitting, 90° 1
117 2220635 Fitting, Tee 1
6
118 2220578 Fitting, 90° 4
119
120
2220451
2220408
Fitting, Straight
Fitting, Straight
4
2
H
121 2220495 Fitting, 90° 1 Y
122 Not Used D
R
125 2220700 Fitting, Tee 1 A
126
127
2220621
2220374
Fitting, Reducer
Fitting, Straight
1
1
U
128 2220386 Fitting, 90° 1 L
129 2220446 Fitting, Reducer 1 I
130
131
2220438
2220428
Fitting, Nipple
Fitting, Coupling
1
1
C
132 2220429 Cap, Dust 1 S
135 2220238 Fitting, Plug 1
136 2220113 Fitting, 90° 1
137 2220280 Fitting, Nipple 1
138 4640216 Valve, Adjustable Colorflow 1
139 2220580 Fitting, 90° 1
142 2220679 Fitting, Tee 1
144 2220507 Fitting, 90° 1
145 Not Used
3120692 6-3
FIGURE 6-2. HYDRAULIC DIAGRAM - 2WD/2WS (CONTINUED)
146 4640382 Valve, Cartridge 1
147 2220796 Fitting, 90° 1
148 2220473 Fitting, 90° 1
149 2220466 Fitting, 90° 2
S 150 2220504 Fitting, Tee 1
E 151
152
2220371
2220362
Fitting, Straight
Fitting, Tee
2
1
C 153 2220435 Fitting, Straight 2
T 154 2220472 Fitting, 90° 2
155 2220568 Fitting, 45° 1
I 156 2220345 Fitting, Straight 1
O 157 2220512 Fitting, Straight 1
N 158
159
2220373
4360449
Fitting, 90°
Switch, Temperature
1
1
6 2901224 HYDRAULIC HOSE KIT Ref. E
201 2752340 Hose 1

H 202 2752341 Hose 1
Y 203 2752254 Hose 2
204 2752255 Hose 2
D 205 2750990 Hose 1
R 206 2750919 Hose 1
A 207
208
2751021
2751427
Hose
Hose
1
1
U 209 2751410 Hose 1
L 210 2752491 Hose 1
211 2752242 Hose 2
I 212 Not Used
C 213 2750778 Hose 1
S 214
215
2750918
2752531
Hose
Hose
1
1
216 2752520 Hose 1
217 2752532 Hose 1
218 2750968 Hose 1
219 2750759 Hose 1
220 2750896 Hose 2
221 2752460 Hose 1
222 2752490 Hose 1
6-4 3120692
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
3120692 6-5
FIGURE 6-3. HYDRAULIC DIAGRAM - 4WD/2WS (SHEET 1 OF 2)
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
6-6 3120692
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
3120692 6-7

103 1320033 Clamp, Hose 8
104 Not Used
106 to 107 Not Used
S 108 2720373 Hose, Suction 1" (2.54cm) x 8 3/4" (20cm) 2
E 109 2220403 Fitting, 90° 1
C 110
111
Not Used
T 112 2220275 Fitting, Reducer 1
I 113 2220710 Fitting, Reducer 1
O 114
115
2220451
2220646
Fitting, Straight
Fitting, 90°
1
2
N 116 2220609 Fitting, Reducer 1
117 2220635 Fitting, Tee 1
118 2220578 Fitting, 90° 2
6 119 2220451 Fitting, Straight 3
H 121
122
2220495
2220250
Fitting, 90°
Fitting, Reducer
1
1
Y 123 2220584 Fitting, Tee 1
D 124 2220343 Fitting, Straight 1
125 2220700 Fitting, Tee 1
R 126 2220621 Fitting, Reducer 1
A 127 2220374 Fitting, Straight 1
U 128
129
2220386
2220446
Fitting, 90°
Fitting, Reducer
1
1
L 130 2220438 Fitting, Nipple 1
I 131 2220428 Fitting, Coupling 1
C 132
133
2220429
2220758
Cap, Dust
Fitting, Straight
1
1
S 134 2220468 Fitting, Straight 2
136 2220113 Fitting, 90° 1
139 2220580 Fitting, 90° 1
142 2220679 Fitting, Tee 2
144 2220507 Fitting, 90° 1
145 Not Used
6-8 3120692
147 2220796 Fitting, 90° 1
148 2220473 Fitting, 90° 1
150 2220504 Fitting, Tee 2 S
151
152
2220371
2220366
Fitting, Straight
Fitting, 90°
4
8
E
153 2220375 Fitting, Straight 2 C
154 2220622 Fitting, Reducer 4 T
155 2220695 Fitting, Tee 2
156 2220490 Fitting, Tee 2
I
157 2220472 Fitting, 90° 2 O
158
159
Not Used
2220375 Fitting, Straight 4
N
161 2220373 Fitting, 90° 1 6
162 4360449 Switch, Temperature 1
2901225 HYDRAULIC HOSE KIT Ref. C H

Y
201 2752321 Hose 1
202 2752330 Hose 1
D
203 2752339 Hose 1 R
204
205
2752385
2752386
Hose
Hose
1
2
A
206 2752388 Hose 1 U
207 2752387 Hose 1 L
208 2752390 Hose 2
209 2752389 Hose 1
I
210 2750896 Hose 2 C
211
212
2750894
2750918
Hose
Hose
1
1
S
213 2750778 Hose 1
214 2751398 Hose 1
215 2752430 Hose 2
216 2752432 Hose 1
217 2752431 Hose 1
218 2750910 Hose 2
219 2751006 Hose 1
220 2751110 Hose 2
221 2751111 Hose 1
222 2752490 Hose 1
223 2752460 Hose 1
224 2752520 Hose 1
225 2752531 Hose 1
3120692 6-9
226 2752532 Hose 1
227 2750759 Hose 1
228 2750968 Hose 1
229 2752523 Hose 2
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
6-10 3120692
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
3120692 6-11
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
6-12 3120692
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
3120692 6-13

3 1320033 Clamp, Hose 8
4 Not Used
S 7 Not Used
E 8 2720373 Hose, Suction 1" (2.54cm) x 8 3/4" (20cm) 2
C 9
10
2220403
Not Used
Fitting, 90° 1
T 11 2220642 Fitting, Tee 1

I 12 2220275 Fitting, Reducer 1
O 13
14
2220710
2220498
Fitting, Reducer
Fitting, 45°
1
1
N 15 2220646 Fitting, 90° 2
17 2220635 Fitting, Tee 1
6 18 2220578 Fitting, 90° 2
H 20
21
2220408
2220495
Fitting, Straight
Fitting, 90°
2
1
Y 22 2220250 Fitting, Reducer 1
D 23 2220584 Fitting, Tee 1
R 25 2220700 Fitting, Tee 1
A 26 2220621 Fitting, Reducer 1
U 27
28
2220373
2220386
Fitting, Straight
Fitting, 90°
1
1
L 29 2220446 Fitting, Reducer 1
I 30 2220438 Fitting, Nipple 1
C 31
32
2220428
2220429
Fitting, Coupling
Cap, Dust
1
1
S 33 2220758 Fitting, Straight 1
36 2220113 Fitting, 90° 1
39 2220580 Fitting, 90° 1
44 2220507 Fitting, 90° 1
45 Not Used
6-14 3120692
46 (cont’d) 2900503 Seal Kit (Vickers/Modular Controls Version) 1
47 2220796 Fitting, 90° 1
48 2220473 Fitting, 90° 1
52 2220366 Fitting, 90° 10 S
53
54
2220375
2220622
Fitting, Straight
Fitting, Reducer
2
4
E
55 2220695 Fitting, Tee 2 C
57 2220472 Fitting, 90° 2
I
60 2220373 Fitting, 90° 1 O
61 4360449 Switch, Temperature 1 N
2901222 HYDRAULIC HOSE KIT Ref. B
6
101 2752321 Hose 1
102 2752330 Hose 1
103 2752339 Hose 1 H
104 2752385 Hose 1 Y
105 2752386 Hose 2
106 2752388 Hose 1
D
107 2752387 Hose 1 R
108
109
2752390
2752389
Hose
Hose
2
1
A
110 2750896 Hose 2 U
111 2750894 Hose 3 L
112 2750918 Hose 1
113 2750778 Hose 1
I
114 2751398 Hose 1 C
115
116
2752430
2752432
Hose
Hose
2
1
S
117 2752431 Hose 1
118 2750910 Hose 2
119 2751006 Hose 1
120 2751110 Hose 2
121 2751111 Hose 1
122 2752490 Hose 1
123 2752460 Hose 1
124 2752520 Hose 1
125 2752531 Hose 1
126 2752532 Hose 1
127 2750759 Hose 1
128 2750968 Hose 1
129 2752242 Hose 2
3120692 6-15
FIGURE 6-5. HYDRAULIC DIAGRAM - AXLE (OSCILLATING)
S
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N
H
Y
D
R
A
U
L
I
C
S
6-16 3120692
FIGURE 6-5. HYDRAULIC DIAGRAM - AXLE (OSCILLATING)
HYDRAULIC DIAGRAM - AXLE (OSCILLATING)
2791574 Prior to S/N 97717 Ref. 5
2792519 S/N 97717 to Present Ref. 1
1 Fitting Options: 4
2220472 Prior to S/N 54201
2220414 S/N 54201 to Present
2 2750760 Hose 2
3 2751010 Hose 2
S
4 2220582 Fitting 4 E
5
6
Not Used
2750900 Hose 1
C
8 0100020 Sealant, Pipe (Not Shown) A/R I
9
10
2220472
2750897
Fitting, 90°
Hose
2
1
O
N
H
Y
D
R
A
U
L
I
C
S
3120692 6-17
FIGURE 6-5. HYDRAULIC DIAGRAM - AXLE (OSCILLATING) (CONTINUED)
S
E
C
T
I
O
N
H
Y
D
R
A
U
L
I
C
S
6-18 3120692
SECTION 7 ELECTRICAL
TABLE OF CONTENTS
FIGURE DESCRIPTION
7-1 ELECTRICAL DIAGRAMS AND COMPONENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 WIRING DIAGRAM - DUAL FUEL (Ford Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-3 WIRING DIAGRAM - 110V GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-4 WIRING DIAGRAM - 0610114 CIRCUIT CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-5 WIRING DIAGRAM - STANDARD (Deutz Diesel Machines) (Prior to S/N 61097) . . . . . . . . . . . 7-10
7-6 WIRING DIAGRAM - STANDARD (Deutz Diesel Machines) (S/N 61097 to Present). . . . . . . . . 7-12
7-7 WIRING DIAGRAM - STANDARD (Ford Gas Machines) (Prior to S/N 61097) . . . . . . . . . . . . . . 7-14
7-8 WIRING DIAGRAM - STANDARD (Ford Gas Machines) (S/N 61097 to Present) . . . . . . . . . . . 7-16
S
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I
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N
E
L
E
C
T
R
I
C
A
L
3120692 7-1

7—1 ELECTRICAL DIAGRAMS AND COMPONENTS LIST Ref.
Note: Electrical Diagrams shown in the following Ref.
pages indicated by an asterisk. Electrical Diagrams
are available through the JLG Service Department.
1282015 ALARMS ELECTRICAL DIAGRAMS (DWG ONLY) Ref. C

0253727 Descent Alarm (B/M Only) Ref. B
0253728 Motion Alarm (B/M Only) Ref. A
0253446 Travel Alarm (B/M Only) Ref. A
0140032 Alarm, Horn 1
3990010 Diode - 6 Amp A/R
S 3740049 Relay (Located in Ground Control Box) 1
E 1540002 Capacitor 1
C 0254000 AUXILIARY LIFT ELECTRICAL DIAGRAM (OPTIONAL) Ref. B

T
I CABLES AND HARNESSES Ref.
Lift Cylinder to Ground Control Box Ref.
O 1060341 33RTS (16/2) 25ft/7.6m
N 1060016 25RTS & 40RTS (16/3) (Prior to S/N 70343) 24ft/7.3m
Platform to Ground Control Box Harnesses Ref.
40RTS without Jacks and Drive Lights Options: 1
7 4921556 Prior to S/N 58038 2
4922255 S/N 58038 to Present 2
E 4921558
33RTS without Jacks and Drive Lights Options:
Prior to S/N 58038
1
2
L 4922254 S/N 58038 to Present 2
E 25RTS without Jacks and Drive Lights Options: 1
4921560 Prior to S/N 58038 2
C 4922253 S/N 58038 to Present 2
T Cable, Electrical - 16/24 A/R
R 1060458
1060826
40TS (Prior to S/N 75287)
40TS (S/N 75287 to Present)
96ft/29.3m
96ft/29.3m
I 1060458 33TS (Prior to S/N 75287) 86ft/26.2m
C 1060826 33TS (S/N 75287 to Present) 86ft/26.2m
1060458 25TS (Prior to S/N 75287) 75ft/22.9m
A 1060826 25TS (S/N 75287 to Present) 75ft/22.9m
L 4460473 Clamp, Cable 1
4460468 Cap, Dust 1
4460462 Plug, Socket - 23 Position 1
4460465 Socket, Female 23
40RTS with Jacks and Drive Lights 1
4921557 Prior to S/N 58038 3
4922250 S/N 58038 to Present 2
4921559 Prior to S/N 58038 3
4922249 S/N 58038 to Present 2
7-2 3120692

4921561 Prior to S/N 58038 3
4922248 S/N 58038 to Present 2
Cable, Electrical - 16/20 A/R
1060459 40TS (Prior to S/N 75287) 96ft/29.3m
1060825 40TS (S/N 75287 to Present) 96ft/29.3m
1060459 33TS (Prior to S/N 75287) 86ft/26.2m
1060459 25TS (Prior to S/N 75287) 75ft/22.9m
4460473 Clamp, Cable 1
4460468 Cap, Dust 1 S
4460481 Plug, Socket - 23 Position 1 E
4460464
4460466
Pin, Male
Seal, Plug
20
3
C
1060308 Receptacle 110V Platform to Ground - 12/3 Cable Ref. T
40RTS (Prior to S/N 70343) 75ft/22.9m I
40RTS (S/N 70343 to Present) 80ft/24.4m
33RTS (Prior to S/N 70343) 65ft/19.8m
O
33RTS (S/N 70343 to Present) 70ft/21.3m N
25RTS (Prior to S/N 70343) 55ft/16.8m
25RTS (S/N 70343 to Present) 60ft/18.3m
7
CIRCUIT CARD ELECTRICAL DIAGRAM Ref.
0610103 Prior to February 1995 Ref.
0610114* February 1995 to Present Ref.
E
L
4932451/1281738* DUAL FUEL ELECTRICAL DIAGRAM (OPTIONAL ON
FORD ENGINES)
Ref. —/H
E
C
0258916 ENGINE COLD START DIAGRAM (DEUTZ ENGINE
MACHINES) (OPTIONAL)
Ref. 1/A T
R
0258686 ENGINE SHUTDOWN ELECTRICAL DIAGRAM
(DEUTZ ENGINE MACHINES) (OPTIONAL)
Ref. A I
C
GENERATOR ELECTRICAL DIAGRAM (OPTIONAL) Ref. A
4932387
4932734*
110V and Deutz Engines (Prior to August 1994)
110V and Deutz Engines (August 1994 to Present)
Ref.
Ref.
—
3
L
4932041 110V and Ford Engines (Prior to August 1994) Ref. B
4932735* 110V and Ford Engines (August 1994 to Present) Ref. 5
3990010 Diode 6 Amp 1
3740049 Relay (Located in Ground Control Box) 2
Not Used
0254736 HIGH TEMPERATURE WARNING ELECTRICAL Ref. —

DIAGRAM
3120692 7-3

LEVELING JACKS ELECTRICAL DIAGRAM Ref.
(OPTIONAL)
0254076/1282105 With Interlock Ref. C/D
4932810 Without Interlock (Prior to S/N 76372) Ref. D
4933144 Without Interlock (S/N 76372 to Present) Ref. E
LIGHTS ELECTRICAL DIAGRAM (OPTIONAL) Ref.

0253821/1282038 Headlights and Taillights Ref. 3/E
0253818/1282038 Headlights, Taillights, Brake Lights & Signal Lights Ref. 3/E
4932624 Panel Lights - Ground Control Box Ref. —
4932623 Panel Lights - Platform Console Box Ref. —
S 0253792/1282033 Platform Worklights with 2 Lights (25RTS) Ref. —/B
E 0253793/1282033
0253794/1282033
Platform Worklights with 2 Lights (33RTS)
Platform Worklights with 2 Lights (40RTS)
Ref.
Ref.
—/B
—/B
C 0257913 Platform Worklights with 4 Lights Ref. 1
T 0253852 Platform Worklights with Cable Reels Ref. B
I 0253569 OIL COOLER ELECTRICAL DIAGRAM Ref. A

O
N OVERLOAD PROTECTION INSTALLATION
(JAPANESE SPECS)
Ref.
0257772 Prior to S/N 83966 Ref. A

7 0270785 S/N 83966 to Present Ref. E
PLATFORM ELECTRICAL DIAGRAMS Ref.

E 4932602/1282009* Deutz Engine Machines (Prior to S/N 57701) Ref. B/N
L 4933095/1283063*
4932602/1282008
Deutz Engine Machines (S/N 57701 to Present)
Ford Engine Machines (Prior to S/N 57701)
Ref.
Ref.
2/F
B/N
E 4933095/1283062* Ford Engine Machines (S/N 57701 to Present) Ref. 2/F
C 3990010 Diode - 6 Amp A/R
T 0254112 PROXIMITY SWITCHES ELECTRICAL DIAGRAM Ref. B

R
I STANDARD ELECTRICAL DIAGRAM Ref.
4932604/1282009* Deutz Engine Machines (Prior to S/N 61097) Ref. 9/N
C 4932604/1283063* Deutz Engine Machines (S/N 61097 to Present) Ref. 9/F
A 3990010 Diode - 6 Amp 5
L 4921562 Harness (Valves to Ground Control Box)

Harness (Engine to Ground Control Box)
1
1
B
4921564 Prior to August 1995 A

4921787 August 1995 to Present
4460460 Plug, Male - 4 Position 1
1060341 Cable, Electrical - 16/2 (To Limit Switches and Lift 64ft/19.5m
Down Coil)
3730003 Resistor - 20 ohm 1
4932603/1282008 Ford VSG-411 Engine Machines (Prior to January Ref. 7/H
1995)
4932758/1282348* Ford VSG-411 Engine Machines (Jan. 1995 to S/N Ref. 6/D
61097)
7-4 3120692

4932758/1283062* Ford VSG-411 Engine Machines (S/N 61097 to Ref. 6/F
Present)
3990010 Diode - 6 Amp 5
4921562 Harness (Valves to Ground Control Box) 1 B
Harness Options: (Engine to Ground Control Box) 1 4

4921563 Prior to January 1995 A
4921718 January 1995 to Present B
4460460 Plug, Male - 4 Position 1
1060341 Cable, Electrical - 16/2 (To Limit Switches and Lift 64ft/19.5m
Down Coil) S
4932758/1282348*
4932758/1283062*
Ford VSG-413 Engine Machines (Prior to S/N 61097)
Ford VSG-413 Engine Machines
Ref.
Ref.
6/D
6/F
E
(S/N 61097 to Present) C
3990010
4921562
Diode - 6 Amp
Harness (Valves to Ground Control Box)
5
1 B
T
Harness (Engine to Ground Control Box) 1 I
4921718 Prior to S/N44593 — O
4922044
3990010
S/N44593 to Present
Diode - 6 Amp 1
4
N
4460460 Plug, Male - 4 Position 1 7
4460608 Seal, Pin 7
4460587 Plug, Male - 8 Position 1 E
4460588
4460183
Lock, Terminal
Terminal, Connector
1
3
L
1060341 Cable, Electrical - 16/2 64ft/19.5m E
(To Limit Switches and Lift Down Coil) C
4933042/1282951 STATIC STEER ELECTRICAL DIAGRAM (4WD/2WS) Ref. 1/A T
4933043/1282951 STATIC STEER ELECTRICAL DIAGRAM (4WD/4WS) Ref. 2/A R
1282137 TILT INDICATOR ELECTRICAL DIAGRAM (OPTIONAL) Ref. A
I
0254111 With Drive/Lift Lockout Ref. A C
0254262 With Lift Lockout Ref. 3 A
L
3120692 7-5
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E
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I
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A
L
7-6 3120692
FIGURE 7-2. ELECTRICAL DIAGRAM - DUAL FUEL (FORD ENGINE OPTION).
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120692 7-7
FIGURE 7-3. ELECTRICAL DIAGRAM - 110V GENERATOR.
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-8 3120692
FIGURE 7-4. ELECTRICAL DIAGRAM - 0610114 CIRCUIT CARD.
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120692 7-9
FIGURE 7-5. ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (PRIOR TO S/
N 61097) (SHEET 1 OF 2)
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-10 3120692
FIGURE 7-5. ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (PRIOR TO S/
N 61097) (SHEET 2 OF 2)
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120692 7-11
FIGURE 7-6. ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (S/N 61097 TO
PRESENT) (SHEET 1 OF 2)
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-12 3120692
FIGURE 7-6. ELECTRICAL DIAGRAM - DEUTZ ENGINE MACHINES (S/N 61097 TO
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120692 7-13
FIGURE 7-7. ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (PRIOR TO S/N
61097) (SHEET 1 OF 2)
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-14 3120692
FIGURE 7-7. ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (PRIOR TO S/N
61097) (SHEET 2 OF 2)
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
3120692 7-15
FIGURE 7-8. ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (S/N 61097 TO
S
E
C
T
I
O
N
E
L
E
C
T
R
I
C
A
L
7-16 3120692
FIGURE 7-8. ELECTRICAL DIAGRAM - FORD ENGINE MACHINES (S/N 61097 TO
S
E
C
T
I
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N
E
L
E
C
T
R
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A
L
3120692 7-17
S
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N “THIS PAGE INTENTIONALLY LEFT BLANK”
E
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7-18 3120692
SECTION 8 DECALS
TABLE OF CONTENTS
FIGURE DESCRIPTION
8-1 DECALS INSTALLATIONS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECALS INSTALLATIONS - COUNTRY SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
S
E
C
T
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D
E
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A
L
S
3120692 8-1
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATIONS - STANDARD
S
E
C
T
I
O
N
D
E
C
A
L
S
8-2 3120692
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATIONS - STANDARD
DECALS INSTALLATION Ref.
0253661 Decal Installation - Common Parts Ref. 10
0271148 Decal Installation - JLG Ref. 1
1 Decal - JLG Options: 2

1701832 (Prior to S/N 81608)
1701871 (S/N 81608 to Present)
2 4420039 Tape, Safety Tread (Prior to S/N 65031) 3ft/.9m
3 1701871 Decal - JLG (Prior to S/N 81608) 3
4 0860520 Box, Manual Storage 1
5 1060279 Cable, Lanyard 1
6 Decal - Manual Options: 1
Use 1701509
1701509
Prior to S/N 102555 (was p/n 1703788)
S
7 0641405 Bolt 1/4"-20NC x 5/8" 4 E
8 4751400 Flatwasher 1/4" 4 C
9 4761400 Lockwasher 1/4" (Prior to S/N 71528) 4
10 3311405 Locknut 1/4"-20NC 4
T
11 1701843 Decal - Sizzor (Prior to S/N 81608) 2 I
12
13
1701837
Not Available
Decal - Stripe (Black) (Prior to S/N 67941)
Decal - Bar Code
30ft/9m
1
O
14 Decal - Tie Down Options: 4 N
Use 1703814 S/N45396 to S/N 71528 (was p/n 1702300)
15
1703814
1703811
Decal - Lifting Lug (S/N 71528 to Present) 4
8
16 4420067 Tape, Safety Tread (S/N 71528 to Present) 2ft/.6m
--------------------------------------------------------------- D
2902075 Kit, Decal (Includes Items 6,14 & 15) 1
E
DECAL INSTALLATIONS - MODEL SPECIFIC Ref. C
0253662
0253669
25RTS
33RTS
Ref.
Ref.
9
9
A
0253676 40RTS Ref. 8 L
S
26 Decal - Model Designation Options: 2
1701885 *25RTS
1701886 *33RTS
1701887 *40RTS
27 Nameplate - Danger Options: 4
Use 1703818 Prior to S/N 71528 (was p/n 3250873)
1703818 *S/N 71528 to Present
28 1701841 *Decal - Crushing Hazard (Prior to S/N 71528) 4
29 Decal - Inspection Options: 1
1702153 *S/N23500 to Present
30 Decal - Safety Prop Options: 1
1704526 *S/N 71528 to Present
31 Not Available Nameplate - Serial Number 1
3120692 8-3
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATIONS - STANDARD (CONTINUED)
32 Use 2080057 Amtak (Was 3820001) 4
33 Decal - Capacity Options: 3
25RTS Options:
3252754 Fixed Deck
3252750 Extension Deck
33RTS Options:
3252755 Fixed Deck
40RTS Options:
3252756 Fixed Deck
34 3340564 Pad 1
35 2820024 Tubing Options:
S 2820024 Tubing, Vinyl (Prior to S/N 71528) 30in./76cm
E 2820097 Tubing, Mesh (S/N 71528 to Present) 2ft/.6m

36 Nameplate - Billboard 1
C Use 3252309 Prior to June 1993 (was p/n 3252223)
T Use 3252309 June 1993 to S/N 71528 (was p/n 3252309)
I 37
3572123
Not Used
*S/N 71528 to Present
O 38 1701840 *Decal - Ground/Emergency Controls 1

N 39 1701504 *Decal - Hydraulic Fluid 1
40 3251249 Nameplate - Daily Safety Check List (Prior to S/N 1
71528)
8 1704478 *Decal - Safety Prop (S/N 71528 to Present) 1
41 Decal - Manual Lowering Options: 1
D Use 1703822 S/N 26763 to S/N 71528 (was p/n 1701510)
E 1703822 *S/N 71528 to Present 1
42 3820019 Rivet 4
C 43 Decal - Battery Options: 1
A Use 1704479 Prior to S/N 71528 (was p/n 1700719)
L 44 to 46
1704479*
Not Used
S 47 Decal - Attach Lanyard Here Options: 4

1704277 *S/N 71528 to Present
48 1703821 *Decal - Control Box Location 1
49 1702249 *Decal - Gate (S/N 71528 to Present) 1
50 1704480 *Decal - Legend (S/N 71528 to Present) 1
51 1703816 *Decal - Danger/Warning (S/N 71528 to Present) 1
52 3251813 *Nameplate - USA (S/N 71528 to Present) 1
53 1704521 *Decal - Gradeability (S/N 71528 to Present) 1
54 Decal - Max Tire Load Options: 4
1704522 *25RTS
1704523 *33RTS
1704524 *40RTS
---------------------------------------------------------------------
2902076 Kit, Decal (Includes Items 27,29,30, 38-41, 43, 47-53) 1
8-4 3120692
SECTION 8 DECALS
FIGURE 8-1. DECALS INSTALLATIONS - STANDARD (CONTINUED)
DECAL INSTALLATION - OPTIONAL Ref.
101 Decal - Fuel Options: 1

Use 1701542 Gas Machines (Prior to May 1993 was
p/n1700430)
1701542 Gas Machines (May 1993 to Present)
Use 1701505 Diesel Machines (Prior to May 1993 was
p/n1700428)
1701505 Diesel Machines (May 1993 to Present)
102 Decal - Drive/Steer Designation Options: 2
1701833 Decal - 4x2x2 (2WD/2WS Machines)
1701836 Decal - 4x4x4 (4WD/4WS Machines) S
103 1702137 Decal - Tire Pressure (with Pneumatic Tires) 4
104 1703792 Decal - Platform Extension Capacity 1
E
105 Decal - Leveling Jack Maximum Load Options: 4 C
1703875
1703874
25RTS
33RTS/40RTS
T
106 1701214 Decal - O/R Warning (S/N 71528 to Present) 8 I
—————————— O
2910009* *Decal Kit - Domestic 25/33/40RTS (Includes Items
with Asterisk *)
1
N
D
E
C
A
L
S
3120692 8-5
SECTION 8 DECALS
FIGURE 8-2. DECALS INSTALLATIONS - COUNTRY SPEC
S
E
C
T
I
O
N
D
E
C
A
L
S
8-6 3120692
SECTION 8 DECALS
FIGURE 8-2. DECALS INSTALLATIONS - COUNTRY SPEC
DECALS INSTALLATION Ref.
0253661 Decal Installation - Common Parts Ref. 9
0271148 Decal Installation - JLG Ref. 1
1 Decal - JLG Options: 2

1701832 (Prior to S/N 81608)
1701871 (S/N 81608 to Present)
2 4420039 Tape, Safety Tread (Prior to S/N 65031) 3ft/.9m
3 1701871 Decal - JLG (Prior to S/N 81608) 3
4 0860520 Box, Manual Storage 1
5 1060279 Cable, Lanyard 1
6 Decal - Manual Options: 1
Use 1701509
1701509
Prior to S/N 102555 (was p/n 1703788)
S
7 0641405 Bolt 1/4"-20NC x 5/8" 4 E
8 4751400 Flatwasher 1/4" 4 C
9 4761400 Lockwasher 1/4" (Prior to S/N 71528) 4
10 3311405 Locknut 1/4"-20NC 4
T
11 1701843 Decal - Sizzor (Prior to S/N 81608) 2 I
12
13
1701837
Not Available
Decal - Stripe (Black) (Prior to S/N 67941)
Decal - Bar Code
30ft/9m
1
O
14 Decal - Tie Down Options: 4 N
Use 1703814 S/N45396 to S/N 71528 (was p/n 1702300)
15
1703814
1703811
Decal - Lifting Lug (S/N 71528 to Present) 4
8
16 4420067 Tape, Safety Tread (S/N 71528 to Present) 2ft/.6m
--------------------------------------------------------------- D
2902075 Kit, Decal (Includes Items 6,14 & 15) 1
E
DECAL INSTALLATIONS - MODEL SPECIFIC Ref. C
0257552
0257553
Brazilian Portugese 25RTS
Brazilian Portugese 33RTS
Ref.
Ref.
6
6
A
0257554 Brazilian Portugese 40RTS Ref. 6 L
0257543 Canadian French 25RTS Ref. 5 S
0257544 Canadian French 33RTS Ref. 5
0257545 Canadian French 40RTS Ref. 5
0257673 Japanese 25RTS Ref. 4
0255882 Latin American Spanish 25RTS Ref. 5
26 Decal - Model Designation Options: 2

1701885# 25RTS
1701886*= 33RTS
1701887+ 40RTS
3120692 8-7
SECTION 8 DECALS
FIGURE 8-2. DECALS INSTALLATIONS - COUNTRY SPEC (CONTINUED)
27 Nameplate - Danger Options: 2
Brazilian Portugese
Use 1703833 Prior to S/N 71528 (was p/n 1703612*)
1703833 S/N 71528 to Present
Canadian French
1703865 S/N 71528 to Present
Japanese
Use 1703849 Prior to S/N 71528 (was p/n 1701620=+#)
1703849 S/N 71528 to Present
Latin American Spanish
1703841 S/N 71528 to Present
S 28 Decal - Crushing Hazard Options: 4
E 1703612* Brazilian Portugese (Prior to S/N 71528)
Not Required Brazilian Portugese (S/N 71528 to Present)
C Not Required Canadian French
T 1702350=+# Japanese (Prior to S/N 71528)
I Not Required
1702559
Japanese (S/N 71528 to Present)
Latin American Spanish (Prior to S/N 71528)
O Not Required Latin American Spanish (S/N 71528 to Present)
N 29 Decal - Inspection Options: 1
Not Required Brazilian Portugese (Prior to S/N 71528)
1703833 Brazilian Portugese (S/N 71528 to Present)
8 1703074 Canadian French
1701621=+# Japanese
1702552 Latin American Spanish
D 30 Decal - Safety Prop Options: 2
E Brazilian Portugese
C Use 1704526
1704526
Prior to S/N 71528 (was p/n 1703550*)
A Canadian French
L Use 1704526 Prior to S/N 71528 (was p/n 1701512)
1704526 S/N 71528 to Present
S Japanese
1704526 S/N 71528 to Present
1704526 S/N 71528 to Present
31 Not Available Nameplate - Serial Number 1
32 Use 2080057 Amtak (Was 3820001) 4
33 Decal - Capacity Options: 1
3252548 Brazilian Portugese & Latin American Spanish
25RTS with Fixed Deck
25RTS with Extendable Deck
8-8 3120692
SECTION 8 DECALS
33 (cont’d) 3252551 Brazilian Portugese & Latin American Spanish
Canadian French 25RTS
3252667 S/N 71528 to Present
3252686 S/N 71528 to Present
Use 3252687 Prior to S/N 71528 (was p/n 3252233) S
3252687 S/N 71528 to Present E
1703628 Japanese 25RTS
1703629 Japanese 33RTS
C
1703630 Japanese 40RTS T
34
35
3340564*
2820024
Pad
Tubing, Vinyl
1
30in/76cm
I
36 Nameplate - Billboard Options: 1 O
Brazilian Portugese & Canadian French N
3252123 S/N 71528 to Present
Japanese 8
3252123 S/N 71528 to Present
Latin American Spanish D
Use 3252123 Prior to S/N 71528 (was p/n 3252487) E
37
3252123 S/N 71528 to Present
Nameplate - Caution Options: 1
C
1703552* Brazilian Portugese (Prior to S/N 71528) A
Not Required Brazilian Portugese (S/N 71528 to Present) L
1701511 Canadian French (Prior to S/N 71528)
Not Required Canadian French (S/N 71528 to Present)
S
Not Required Japanese
Not Required Latin American Spanish
38 Decal - Ground/Emergency Controls Options: 1
Brazilian Portugese
1704542 S/N 71528 to Present
1701515 Canadian French
1701624=+# Japanese
1704549 S/N 71528 to Present
39 1701504*=+# Decal - Hydraulic Fluid 1
3120692 8-9
SECTION 8 DECALS
40 Nameplate - Daily Safety Check List Options: 1
Not Required Brazilian Portugese & Canadian French
1702351=+# Japanese
1704478 Decal - Safety Prop Options: (S/N 71528 to 1
Present)
41 Decal - Manual Lowering Options: 1
Use 1703822 Prior to S/N 71528 (was p/n 1701510*=+#)
1703822 S/N 71528 to Present
42 3820019 Rivet 4
43 Decal - Battery Options: 1
Brazilian Portugese
S Use 1704550 Prior to S/N 71528 (was Not Used)
1704550 S/N 71528 to Present
E Canadian French
C Use 1704552 Prior to S/N 71528 (was p/n 1703077)
T 1704552 S/N 71528 to Present
Japanese
I Use 1704553 Prior to S/N 71528 (was p/n 1701625=+#)
N Use 1704551
Prior to S/N 71528 (was p/n 1702560)
1704551 S/N 71528 to Present
8 44 to 46 Not Used
47 Decal - Attach Lanyard Here Options: 4
Brazilian Portugese
D Use 1704277 Prior to S/N 71528 (was p/n 1703900)
E 1704277 S/N 71528 to Present

Canadian French
C Use 1704277 Prior to S/N 71528 (was p/n 1703860)
A 1704277 S/N 71528 to Present
Not Required Japanese (Prior to S/N 71528)
L 1704277 Japanese (S/N 71528 to Present)
S Latin American Spanish
1704277 S/N 71528 to Present
48 Decal - Control Box Location Options: 1
1703861 Canadian French (S/N 71528 to Present)
1703845 Japanese (S/N 71528 to Present)
1703837 Latin American Spanish (S/N 71528 to Present)
49 Decal - Gate Options: 1
Not Required Canadian French (S/N 71528 to Present)
Not Required Japanese (S/N 71528 to Present)
8-10 3120692
SECTION 8 DECALS
50 Decal - Legend Options: 1
51 Decal - Danger/Warning Options: 1
52 3251813 Nameplate - USA 1
53 Decal - Gradeability Options: 1
1704558 Canadian French (S/N 71528 to Present) S
1703845 Japanese (S/N 71528 to Present) E
54 Decal - Max Tire Load Options: 4
C
1704522 25RTS T
1704523
1704524
33RTS
40RTS
I
O
DECAL INSTALLATION - OPTIONAL Ref. N
101 Decal - Fuel Options: 1
1701542 Gas Machines 8
1701505 Diesel Machines
102 Decal - Drive/Steer Designation Options: 2
1701833 Decal - 4x2x2 (2WD/2WS Machines) D
1701834 Decal - 4x2x4 (2WD/4WS Machines) E
1701835
1701836
Decal - 4x4x2 (4WD/2WS Machines)
Decal - 4x4x4 (4WD/4WS Machines)
C
103 1702137 Decal - Tire Pressure (with Pneumatic Tires) 4 A
104 1703792 Decal - Platform Extension Capacity 1 L
105 Decal - Leveling Jack Maximum Load Options: 4
1703875 25RTS
S
1703874 33RTS/40RTS
106 Decal - O/R Warning Options: (S/N 71528 to 8
Present)
1704535 Brazilian Portugese
1704537 Canadian French
1704536 Japanese
——————————
2900946* Decal Kit - Brazilian Portugese 33RTS (Includes Items 1
with Asterisk *)
2900964# Decal Kit - Japanese 25RTS (Includes Items with 1
Number Symbol #)
2900965= Decal Kit - Japanese 33RTS (Includes Items with 1
Equal =)
3120692 8-11
SECTION 8 DECALS
2900966+ Decal Kit - Japanese 40RTS (Includes Items with 1
Plus +)
S
E
C
T
I
O
N
D
E
C
A
L
S
8-12 3120692
SECTION 9 RECOMMENDED SERVICE PARTS STOCK
S
E
MODEL 25/33/40RTS
The following list will service fleets of machines (built to current production per date on the front cover) with
C
emergency repair parts which can be installed in the field. Parts from the list should be replaced when inven- T
tory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the
JLG Industries Parts Department.
I
O
JLG PART
NUMBER
DESCRIPTION
QTY PER FLEET N
1-4 5-9 10 OR MORE
STANDARD PARTS Ref. Ref. Ref. 9

1340062 Breather (Figure 2-1) (S/N 63184 to Present) 1 1 1 R
7000417
7000418
Coil (Figure 2-2)
Coil (Figure 2-2 & 2-3)
1
1
1
1
1
1
E
7000450 Coil (Figure 2-3) 1 1 1 C
2120136 Element, Pressure Filter (Figure 2-5,2-6 & 2-9) 1 1 1 O
7004214 Element, Air Filter (Figure 2-5,2-6 & 2-9) 4 8 12
7007496 Coil Assembly - 3600260 Pump (Figure 2-11) 1 1 1
M
3740049 Relay (Figure 2-13 & 4-4) 1 1 1 M
4360216
4360232
Breaker, Circuit 30-Amp (Figure 2-13)
Breaker, Circuit 10-Amp (Figure 2-13)
1
1
1
1
1
1
E
4360274 Switch, Push Button (Start) (Figure 2-13 & 4-4) 1 1 1 N
4360469 Switch, Key (S/N 65031 to Present) (Figure 2-13) 1 1 1 D
7010698 Key, Replacement (All Machines) (Figure 2-13) 1 1 1
4360475 Switch, Push/Pull (Emergency Stop) (S/N 65031 to 1 1 1
E
Present) (Figure 2-13 & 4-4) D
4360314 Switch, Toggle (Lift) (Figure 2-13 & 4-4) 1 1 1
4360339 Switch, Push Button (Enable) (Figure 4-4) 1 1 1 S
7012658
1600290
Fuse 7.5-Amp (Figure 4-4)
Controller, PQ (S/N 57701 to Present) (Figure 4-4)
2
1
2
1
2
1
E
4360336 Switch, Toggle - SPDT (Figure 4-4) 1 1 1 R
4360329 Switch, Toggle - SPST (Figure 4-4) 1 1 1 V
7003789 Switch, Rocker - 1600157 Controller (Figure 4-5) 1 1 1
7003791 Switch, Actuator - 1600157 Controller (Figure 4-5 & 4-6) 1 1 1
I
7003751 Poteniometer - 1600157 Controller (Figure 4-5) 1 1 1 C
7020500
7020510
Switch, Rocker - 1600290 Controller (Figure 4-6)
Poteniometer - 1600290 Controller (Figure 4-6)
1
1
1
1
1
1
E
7009742 Coil - 4640382 Valve (Vickers/Modular Controls Version)
(Figure 5-4)
1 1 1
P
7000645 Coil - 4640382 Valve (Hydraforce Version) (Figure 5-4) 1 1 1 A
3990010 Diode 6-Amp (Figure 7-1) 2 2 2 R
T
S
S
T
O
C
K
3120692 9-1
SECTION 9 RECOMMENDED SERVICE PARTS
S
E MODEL 25/33/40RTS
C The following list 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 inven-
T tory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the
I JLG Industries Parts Department.
O JLG PART QTY PER FLEET

DESCRIPTION
N NUMBER 1-4 5-9 10 OR MORE
VARIABLE PARTS Ref. Ref. Ref.

9
4360300 Switch, Limit (Figure 1-8) 1 1 1
R 4360321 Switch, Limit (Figure 1-9 & 1-10) 1 1 1
E 7004368 Coil - 4640123 Valve (Hydraforce Version) (Figure 2-1) 1 1 1
7000558 Coil - 4640123 Valve (FPS Version) (Figure 2-1) 1 1 1
C 4640049 Coil (Machines with Leveling Jacks) (Figure 2-4) 1 1 1
O 2120110 Element, Hydraulic - 25 Micron (Figure 2-1) 4 8 12
M 2120129 Element, Hydraulic - 10 Micron (Figure 2-1) 4 8 12
7014500 Filter, Oil (1 Dozen) (Figure 2-5 & 2-6) (Ford Engine 12 12 12
M Machines)
E 7022174 Filter, Fuel (Figure 2-6) (VSG- 413 Ford Engine Machines) 4 8 12
3740067 Relay (Figure 2-9) (Deutz Engine Machines) 1 1 1
N 7016331 Filter, Oil (Figure 2-9) (Deutz Engine Machines) 12 12 12
D 7012598 Filter, Fuel (Figure 2-9) 4 8 12
E 4360212 Breaker, Circuit (Deutz Engine Machines Only) (Figure

2-13)
1 1 1
D 3740077 Relay (Deutz Engine Machines Only) (April 1993 to 1 1 1

Present) (Figure 2-13)
S
E
R
V
I
C
E
P
A
R
T
S
S
T
O
C
K
9-2 3120692
SECTION 10 SPECIAL OPTIONS LIST

10—1 SPECIAL OPTIONS LIST Ref.
Note: This list is to accommodate machines ordered Ref.
with special equipment. Options may not be applica-
ble to all models. For more specific parts information
contact the JLG Parts Department.
S
0254242 Airline to Platform Installation - 1/2" (25RTS) Ref. E
0250914 Airline to Platform Installation - 1/2" (33RTS) Ref. C
0256425 Airline to Platform Installation - 1/2" (40RTS) Ref.
T
0253877 Arms Installation - 30 ft. Height Limit Ref. I
0254090 Arms Installation - 30 ft. Height Limit
Note: See note in Section 5 regarding lift cylinders.
Ref.
Ref.
O
Use 1683469 Lift Cylinder Assembly (Prior to S/N 23500 was p/n 1 N
1682917)
1683469 Lift Cylinder Assembly (S/N 23500 to Present) 1
2901323 Seal Kit - Lift Cylinder 1 10
0251798 Arm Stops Installation Ref.
S
0254000 Auxiliary Lift Installation Ref. P
E
Cylinder Bellows Installation Options Ref.
0460068 Lift Cylinder (25RTS & 33RTS) Ref.
C
0253787/1282031 Steer Cylinders - 2WS Ref. I
0253790/1282031 Steer Cylinders - 4WS Ref.
A
0253815 Counterweight Installation - 70 MPH Wind Speed/30 Ref. L
ft. Height Requirement (United Airline Specs)
Decal Options Ref. O

1702788 Decal - Biodegradable Oil Use Ref. P
0273257
0254226
Decal - Hertz
Decals - United Airlines
Ref.
Ref.
T
2910157 Decal Kit - United Airlines Ref. I
0271911 Decal - United Rentals Ref. O
0256487/1282593 Decals - Warning Prop 65 (Diesel Machines) Ref.
(California Specs) N
0256488/1282593 Decals - Warning Prop 65 (Gas Machines)
(California Specs)
Ref. S
0257919 Engine Installation (Ford Engine Gas Machines) Ref. L
(United Airline Specs)
0257918 Engine Installation (Ford Engine Dual Fuel Ref.
I
Machines) (United Airline Specs) S
0258916 Engine Cold Start Kit Installation (Deutz Engine Ref.
T
Machines)
0250815 Engine Heater Installation (Ford Engine Machines) Ref.
3120692 10-1

0254131 Fan Guard Installation (Ford Engine Machines) Ref.
Fluids Ref.
2300014 Mobil 424 A/R
2300027 Mobil 224H Bio A/R
S 2300016 Mobil DTE 13M A/R
E 2300021 Union Carbide Ucon HP5046 Fire Resistant A/R
C 0257763 Footswitch Installation (Japanese Spec) Ref.

T
I 0253902 Fuel Filter Installation (Spin-On Type) Ref.
O 0253901 Ground Control Box Installation (United Airlines Ref.

N Specs)
0253818/1282038 Headlights/Taillights at Both Front and Rear of Ref.
Machine
10
0259219 Hose Shield Installation (4WD/2WS) Ref.
0259220 Hose Shield Installation (4WD/4WS) Ref.
S
P 0254132
0254152
Hood Installation - Left Side (United Airline Specs)
Hood Installation - Right Side (United Airline Specs)
Ref.
Ref.
E
C 0253569 Oil Cooler Installation Ref.
I Overload Protection Installation (Japanese Spec) Ref.

A 0257772 Prior to S/N 83966 Ref. A
L 0270785 S/N 83966 to Present Ref. E
0256972 Pipe Rack Installation(25RTS & 33RTS) Ref.

O Not Available Pipe Rack Installation (40RTS) Ref.
P 0253826 Platform Bumpers Installation - Extendable Plat- Ref.

T form Machines
I 0253878 Platform Console Box Assembly (United Ref.
O Airlines Specs)
N
0257380 Platform Door Return Spring Installation Ref.
S
0254110 Platform Handrails with Inner Rails Installation Ref.
L 0254112 Platform Proximity Switches Installation Ref.

I
S 0253852 Platform Worklights with Automatic Retract Cords
Installation
Ref.
T
0257913 Platform Worklights with Four Worklights Installa- Ref.
tion
10-2 3120692

0254925 Terminal Boots Installation Ref.
2901813 Tie Strap Kit Ref.
Tools for Service Ref.

7002820 Arbor Set (For Installation of Bushings) 1 S
7002821 Crimper, Wire 1
7002823 Extractor, Pin - Universal 1
E
4460467 Extractor, Pin #16 Gauge A/R C
4460510
7004275
Extractor, Pin #12 Gauge
Installer, Cylinder Seal - 1"
A/R
1
T
7004276 Installer, Cylinder Seal - 1 1/2" 1 I
7002826 Installer, Cylinder Seal - 2" 1 O
7016654 Screwdriver, Magnetic 1
7002822 Screwdriver, Potentiometer 1
N
7002828 Stripper, Wire 1
10
S
P
E
C
I
A
L
O
P
T
I
O
N
S
L
I
S
T
3120692 10-3
S
E
C
T
I
O
N
10
S
P
E
C
I
A
L
O
P
T
I
O
N
S
L
I
S
T
10-4 3120692
3120692
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
Australia M24 2GP - England +33 (0) 5 53 88 31 70
+55 19 3295 0407
+61 2 65 811111 +44 (0) 161 654 1000 +33 (0) 5 53 88 31 79
+55 19 3295 1025
+61 2 65 810122 +44 (0) 161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Polska
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 UI. Krolewska
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 00-060 Warsawa
Germany Sheung Shui N. T. Italy Poland
+49 (0) 421 69 350 20 Hong Kong +39 029 359 5210 +48 (0) 914 320 245
+49 (0) 421 69 350 45 (852) 2639 5783 +39 029 359 5845 +48 (0) 914 358 200
(852) 2639 5797
JLG Industries (Scotland) Oshkosh -JLG Singapore Plataformas Elevadoras JLG Sverige AB
Wright Business Centre Technology Equipment Pte Ltd JLG Iberica, S.L. Enkopingsvagen 150
1 Lonmay Road 29 Tuas Ave 4 Trapadella, 2 Box 704
Queenslie, Glasgow G33 4EL Jurong Industrial Estate P.I. Castellbisbal Sur SE - 176 27 Jarfalla
Scotland Singapore, 639379 08755 Castellbisbal, Barcelona Sweden
Spain +46 (0) 850 659 500
+44 (0) 141 781 6700 +65-6591 9030
+34 93 772 4700 +46 (0) 850 659 534
+44 (0) 141 773 1907 Not Available
+34 93 771 1762
www.jlg.com

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Illustrated Parts Manual

March 1993 - Original Issue Of Manual

FIGURE NO. TITLE PAGE NO.

SECTION 2 - GROUND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

SECTION 3 - SIZZOR ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

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

SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

FIGURE NO. TITLE PAGE NO.

5-4 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH

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

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

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

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

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

STEERING INSTALLATION - 2WD FRONT Ref.

101 Spindle Weldment (Right Side) Options: 1

T 103 1682967 Steer Cylinder Assembly (See Section 5 for Break-

I 104 1660204 Rod-End (Right Side) 1

STEERING INSTALLATION - 4WD FRONT Ref.

201 4130279 Spindle Weldment (Right Side) 1

FIXED AXLE INSTALLATION OPTIONS Ref.

401 Axle Weldment Options: 1

R 414 4751600 Flatwasher (September 1995 to Present) 16

OSCILLATING AXLE INSTALLATION - OPTION Ref.

501 Axle Weldment Options: 1

0251661 WHEEL DRIVE INSTALLATION - 2WD/4WS Ref. B

101 2780195 Drive Hub/Brake Assembly 2

0253545 WHEEL DRIVE INSTALLATION - 4WD/2WS FRONT Ref. 2

201 2780191 Drive Hub/Brake Assembly 2

1 201 2780193 Drive Hub/Brake Assembly

202 3160158 Drive Motor Assembly 4

0251660 WHEEL DRIVE INSTALLATION - 4WD/4WS FRONT Ref. B

301 2780191 Drive Hub/Brake Assembly 4

0250888 TIRE AND WHEEL INSTALLATION - STANDARD Ref. —

0250886 Tire and Wheel Assembly - Left Side 2 B

0258660 Tire & Wheel Assy - Left Side 2 1

0255660 TIRE AND WHEEL INSTALLATION - OPTIONAL Ref. —

0253089 TIRE AND WHEEL INSTALLATION - OPTIONAL Ref. —

1 7010428 Hub-Spindle Sub Assembly 1 1

7010428 HUB - SPINDLE SUB-ASSEMBLY Ref.

101 7001997 Spindle 1

CARRIER ASSEMBLY OPTIONS Ref.

R 7000247 2780167/2780169 Hubs Ref.

A 201 7001931 Carrier 1

COVER ASSEMBLY Ref.

301 Cover Options: 1

401 Shaft Options: 1

T HUB/SPINDLE/BRAKE SUB-ASSEMBLY Ref.

I 101 Brake Assembly Options: 1

7000247 CARRIER ASSEMBLY - 4WD(2MPH) MACHINES Ref.

201 7001931 Carrier 1

COVER ASSEMBLY Ref.

301 Cover Options: 1

7007650 INPUT SHAFT ASSEMBLY - 4WD MACHINES Ref.

401 Shaft Options: 1

7010469 BRAKE ASSEMBLY - 4WD MACHINES WITH I.D. Ref.

501 7014100 Spindle 1

7010473 BRAKE ASSEMBLY - 2WD/4WS MACHINES AND Ref.

0256924 LIMIT SWITCH INSTALLATION Ref. 2