Parts Manual Manual

ManualsBrandsJLG ManualsSpecial machinery40RTS ANSI

Illustrated Parts Manual

Models

25RTS

33RTS

40RTS

P/N - 3120692

March 15, 2012

Summary of content (220 pages)

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Illustrated Parts Manual Models 25RTS 33RTS 40RTS P/N - 3120692 March 15, 2012
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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) (40RTS Manual edited to 0010452 Revision 34) 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) (33RTS Manual edited to 0010451 Revision 40) (40RTS Manual edited to 0010452 Revision 42) April 8, 2002 - Revised (25RTS Manual edited
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REVISION LOG B 3120692
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TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 FRAME, STEERING AND AXLE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 LOCKOUT VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. 5-4 5-5 5-6 5-7 TITLE PAGE NO. LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH INTERLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 LIFT CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 STEER CYLINDER ASSEMBLY (MACHINES BUILT PRIOR TO JUNE 1993). . . . . . . . .
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SECTION 1 FRAME S E C T I O N TABLE OF CONTENTS FIGURE 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 3120692 DESCRIPTION FRAME, STEERING AND AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCKOUT VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE MOTOR ASSEMBLY . . . . . . . . . . .
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S E C T I O N 1 F R A M E SECTION 1 FRAME FIGURE 1-1.
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SECTION 1 FRAME FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS FIG & ITEM # 1 51 52 PART NUMBER 2360352 2360465 See Note 0961664 2360347 2360466 See Note 0961664 0961029 0252790 0255005 0252790 0253059 0255006 0253059 101 101A 102 102A 3120692 4130287 4130317 4030287 0960523 4130288 4130316 4030288 0960523 DESCRIPTION QTY.
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S E C T I O N SECTION 1 FRAME FIGURE 1-1.
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SECTION 1 FRAME FIGURE 1-1.
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S E C T I O N SECTION 1 FRAME FIGURE 1-1.
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SECTION 1 FRAME FIGURE 1-1. FRAME, STEERING AND AXLE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 516 517 518 519 520 521 522 523 524 525 526 527 528 0641632 3311605 Not Used 3841143 Not Used 4640273 4740185 0100019 3780183 4640812 3820030 3311605 0641612 529 0641614 530 531 532 533 4280298 0902214 0902215 3440616 3120692 DESCRIPTION QTY.
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S E C T I O N SECTION 1 FRAME FIGURE 1-2.
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SECTION 1 FRAME FIGURE 1-2. LOCKOUT VALVE ASSEMBLY FIG & ITEM # PART NUMBER 4640485 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 3860037 3430407 3840833 3960047 0560679 3790231 3840854 0320008 4160078 3421284 3790116 2180658 0641518 4761500 0560467 2200222 Not Used 3450203 0100011 3120692 DESCRIPTION LOCKOUT VALVE ASSEMBLY QTY. REV. Ref.
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S E C T I O N SECTION 1 FRAME FIGURE 1-3.
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SECTION 1 FRAME FIGURE 1-3.
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S E C T I O N SECTION 1 FRAME FIGURE 1-3.
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SECTION 1 FRAME FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 0251261 0258395 0251260 0258393 0251259 0258394 401 402 403 404 4520129 4860126 4640113 1702698 0258661 401 402 403 404 0258660 0258659 4520207 4843635 4640392 Not Required 0255660 0255661 0255662 401 4520123 0253089 0253088 0253087 401 3120692 4520129 DESCRIPTION TIRE AND WHEEL INSTALLATION - OPTIONAL 12 x 16.
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S E C T I O N SECTION 1 FRAME FIGURE 1-4.
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SECTION 1 FRAME FIGURE 1-4.
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S E C T I O N SECTION 1 FRAME FIGURE 1-5.
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SECTION 1 FRAME FIGURE 1-5.
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S E C T I O N SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 2900766 2900768 2900767 7018608 DESCRIPTION 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) Lining Kit Options (Includes Items 5,6,7,8,22 and 23): 0920084 Brake (Prior to S/N36660) 0920110 Brake (S/N36660 to Present) QTY. REV.
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SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-6.
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SECTION 1 FRAME FIGURE 1-6.
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S E C T I O N SECTION 1 FRAME FIGURE 1-6.
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SECTION 1 FRAME FIGURE 1-6.
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S E C T I O N SECTION 1 FRAME FIGURE 1-7.
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SECTION 1 FRAME FIGURE 1-7.
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S E C T I O N SECTION 1 FRAME FIGURE 1-7.
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SECTION 1 FRAME FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER 303 Use 70001111 Not Required 304 Use 70001111 Use 70001349 305 Use 70001111 Use 70001349 306 Use 70001111 Use 70001349 307 Use 70001111 Use 70001349 308 Use 70001111 Use 70001349 Use 70001111 Use 70001349 7007650 7000250 401 402 403 404 7007651 7000260 7000261 7000262 7000263 7010469 501 502 503 3120692 7014100 7014101 7014102 DESCRIPTION QTY.
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S E C T I O N SECTION 1 FRAME FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
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SECTION 1 FRAME FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-8.
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SECTION 1 FRAME FIGURE 1-8.
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S E C T I O N SECTION 1 FRAME FIGURE 1-8.
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SECTION 1 FRAME FIGURE 1-8. FRAME MOUNTED COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 1540002 0253449 0253448 301 302 303 304 305 3120692 3536092 4844186 0641510 4751500 4761500 3311501 DESCRIPTION Capacitor (Not Shown - Located at Ground Control) AXLE COVERS INSTALLATION (2WS) (STANDARD PARTS) Diesel Machines Gas/Dual Fuel Machines Plate, Cover Options: Diesel Machines Gas/Dual Fuel Machines Bolt 5/16"-18NC x 1 1/4" Flatwasher 5/16" Lockwasher 5/16" Nut 5/16"-18NC QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-9.
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SECTION 1 FRAME FIGURE 1-9.
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S E C T I O N SECTION 1 FRAME FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION (FRAME MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER 112 113 114 115 116 117 4762000 3312001 3911040 4771000 4751000 3311001 1 1060341 3740049 F R A M E 1-36 DESCRIPTION Lockwasher 5/8" Nut 5/8"-20NC Screw, Machine #10-24NC x 2 1/2" Starwasher #10 Flatwasher #10 Nut #10-24NC —————————— Cable, Electrical - 16/2 Relay, Bosch (Not Shown - Located at Ground Control) QTY. REV. 2 2 4 4 4 4 30 ft.
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SECTION 1 FRAME FIGURE 1-9. LEVELING JACK (WITH INTERLOCK) AND LIGHTS INSTALLATION (FRAME MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-10.
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SECTION 1 FRAME FIGURE 1-10.
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S E C T I O N SECTION 1 FRAME FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0255785 0271583 101-105 LEVELING JACK COMPONENTS INSTALLATION (Prior to S/N 101615 (S/N 101615 to Present) QTY. REV. Ref. Ref. Ref.
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SECTION 1 FRAME FIGURE 1-10. LEVELING JACK (WITHOUT INTERLOCK) INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-11.
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SECTION 1 FRAME FIGURE 1-11.
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S E C T I O N SECTION 1 FRAME FIGURE 1-11. TOW PACKAGE INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM # PART NUMBER 225 226 227 228 0642018 3312005 4752000 3340841 DESCRIPTION Bolt 5/8” - 11NC Nut 5/8” - 11NC Flatwasher 5/8” Pad (Not Shown) QTY. REV.
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SECTION 2 GROUND COMPONENTS S E C T I O N TABLE OF CONTENTS FIGURE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 DESCRIPTION CONTROL VALVES AND TANKS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY (Prior to S/N 26763) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE ASSEMBLY (S/N 26763 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 2 GROUND COMPONENTS 353 352 351A 351B 351 354 FIGURE 2-1.
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SECTION 2 GROUND COMPONENTS FIGURE 2-1.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-1.
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SECTION 2 GROUND COMPONENTS FIGURE 2-1.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-1.
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SECTION 2 GROUND COMPONENTS FIGURE 2-1. CONTROL VALVES AND TANKS INSTALLATION (CONTINUED) FIG & ITEM # 401 402 401 402 PART NUMBER 7020257 7016649 Not Required 0270492 1120485 Not Required DESCRIPTION S/N 80985 to Present Installations: Standard Cap Installation Cap, Fuel Seal, Fuel Cap Protectoseal Cap Installation Cap, Protectoseal (Not Shown) QTY. Ref. Ref. 1 1 Ref. 1 REV.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-2.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-2.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
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SECTION 2 GROUND COMPONENTS FIGURE 2-2. CONTROL VALVE ASSEMBLY (PRIOR TO S/N 26763) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-3.
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SECTION 2 GROUND COMPONENTS FIGURE 2-3.
PAGE 64
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-4.
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SECTION 2 GROUND COMPONENTS FIGURE 2-4. CONTROL VALVE ASSEMBLY - FPS 4 STACK (LEVELING JACKS OPTION) FIG & ITEM # PART NUMBER 4640352 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7000585 7000586 7006002 7006039 7000600 Kit 7006041 7006037 7006036 7006034 Kit Kit 4640049 7006033 Kit 7006056 7006053 Not Used Kit 7000549 7006062 3120692 DESCRIPTION CONTROL VALVE ASSEMBLY - FPS 4 STACK (LEVELING JACKS OPTION) QTY. REV. Ref.
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SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-5.
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SECTION 2 GROUND COMPONENTS FIGURE 2-5.
PAGE 68
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-5.
PAGE 69
SECTION 2 GROUND COMPONENTS FIGURE 2-5.
PAGE 70
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-5.
PAGE 71
SECTION 2 GROUND COMPONENTS FIGURE 2-5.
PAGE 72
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-5.
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SECTION 2 GROUND COMPONENTS FIGURE 2-5. ENGINE INSTALLATION - FORD VSG-411 (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 74
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-6.
PAGE 75
SECTION 2 GROUND COMPONENTS FIGURE 2-6.
PAGE 76
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-6.
PAGE 77
SECTION 2 GROUND COMPONENTS FIGURE 2-6.
PAGE 78
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-6.
PAGE 79
SECTION 2 GROUND COMPONENTS FIGURE 2-6.
PAGE 80
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-6.
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SECTION 2 GROUND COMPONENTS FIGURE 2-6. ENGINE INSTALLATION - FORD VSG-413 (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 82
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-7.
PAGE 83
SECTION 2 GROUND COMPONENTS FIGURE 2-7.
PAGE 84
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION) (CONTINUED) FIG & ITEM # PART NUMBER 104 105 106 107 108 109 3311501 0641610 4751600 4761600 3311601 1320023 DESCRIPTION Nut 5/16"-18NC Bolt 3/8"-16NC x 1 1/4" Flatwasher 3/8" Lockwasher 3/8" Nut 3/8"-16NC Clamp, LP Tank QTY. REV.
PAGE 85
SECTION 2 GROUND COMPONENTS FIGURE 2-7. DUAL FUEL COMPONENTS INSTALLATION (FORD ENGINE OPTION) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 86
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-8.
PAGE 87
SECTION 2 GROUND COMPONENTS FIGURE 2-8.
PAGE 88
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-9.
PAGE 89
SECTION 2 GROUND COMPONENTS FIGURE 2-9.
PAGE 90
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-9.
PAGE 91
SECTION 2 GROUND COMPONENTS FIGURE 2-9.
PAGE 92
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-9. ENGINE INSTALLATION - DEUTZ F2L1011 (CONTINUED) FIG & ITEM # PART NUMBER 0251801 0255038 401 2 G R O U N D 501 2180730 2180749 2180537 4360037 2180360 2200261 C O M P O N E N T S 601 701 702 703 Fitting, Adapter (Prior to August 1994 Only) Fitting, 45° Fitting, Nipple (Prior to August 1994 Only) Switch, Pressure (Prior to August 1994 Only) Fitting, Tee (Prior to August 1994 Only) Fitting, Coupling (Prior to August 1994 Only) REV. Ref. Ref.
PAGE 93
SECTION 2 GROUND COMPONENTS FIGURE 2-9.
PAGE 94
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-10.
PAGE 95
SECTION 2 GROUND COMPONENTS FIGURE 2-10.
PAGE 96
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-10. GENERATOR INSTALLATIONS (DEUTZ ENGINE OPTION) (CONTINUED) FIG & ITEM # PART NUMBER 29 30 31 32 33 34 4751500 4761500 3251476 0681610 4761600 4751600 DESCRIPTION Flatwasher 5/16" Lockwasher 5/16" Nematic - On/Off Bolt 3/8"-16NC x 1 1/4" (Grade 8) Lockwasher 3/8" Flatwasher 3/8" QTY. REV.
PAGE 97
SECTION 2 GROUND COMPONENTS FIGURE 2-10. GENERATOR INSTALLATIONS (DEUTZ ENGINE OPTION) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 98
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-11.
PAGE 99
SECTION 2 GROUND COMPONENTS FIGURE 2-11.
PAGE 100
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-11.
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SECTION 2 GROUND COMPONENTS FIGURE 2-11. PISTON PUMP ASSEMBLY - SUNSTRAND (CONTINUED) FIG & ITEM # PART NUMBER 87 88 89 7007477 7007476 7010120 2900752 7007412 2900826 2900827 DESCRIPTION Plug, Orifice - .
PAGE 102
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-12. GEAR PUMP ASSEMBLY - JSB.
PAGE 103
SECTION 2 GROUND COMPONENTS FIGURE 2-12. GEAR PUMP ASSEMBLY - JSB. FIG & ITEM # PART NUMBER 3600206 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7007477 Kit 7010956 Kit Kit 7010957 Kit 7010963 7010959 Not Used 7010982 7010973 7010960 7010961 7010953 DESCRIPTION GEAR PUMP ASSEMBLY - JSB QTY. REV. Ref.
PAGE 104
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-13.
PAGE 105
SECTION 2 GROUND COMPONENTS FIGURE 2-13.
PAGE 106
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-13.
PAGE 107
SECTION 2 GROUND COMPONENTS FIGURE 2-13.
PAGE 108
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-14.
PAGE 109
SECTION 2 GROUND COMPONENTS FIGURE 2-14.
PAGE 110
SECTION 2 GROUND COMPONENTS S E C T I O N FIGURE 2-14. HOODS AND BEACON LIGHT INSTALLATION (CONTINUED) FIG & ITEM # 201 202 PART NUMBER DESCRIPTION QTY. Ref. 0253299 0257910 HOOD INSTALLATIONS - RIGHT SIDE (GAS MACHINES) Ford VSG-411 Ford VSG-413 Note: Replacement Decals Must Be Ordered Separately - See Section 8.
PAGE 111
SECTION 3 SIZZOR ARMS TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 S E C T I O N DESCRIPTION SIZZORS ARMS INSTALLATION - 40RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 SIZZORS ARMS INSTALLATION - 33RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 SIZZORS ARMS INSTALLATION - 25RTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 112
SECTION 3 SIZZOR ARMS FIGURE 3-1.
PAGE 113
SECTION 3 SIZZOR ARMS FIGURE 3-1. SIZZOR ARMS INSTALLATION - 40RTS FIG & ITEM # PART NUMBER 0252957 0254091 0252960 0254092 101 Use 1683466 1683466 102 Use 3422735 3422735 103 Use 3422738 3422738 104 105 to 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 3120692 0200458 0200629 Not Used 0200454 0200556 0200464 0200452 0200628 0200463 0200462 0200461 3422271 3422267 3422273 3422268 3422272 3422269 3422270 3422274 1440227 0200403 0641528 3311505 4843248 DESCRIPTION QTY.
PAGE 114
SECTION 3 SIZZOR ARMS FIGURE 3-1.
PAGE 115
SECTION 3 SIZZOR ARMS FIGURE 3-1. SIZZOR ARMS INSTALLATION - 40RTS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 116
SECTION 3 SIZZOR ARMS FIGURE 3-2.
PAGE 117
SECTION 3 SIZZOR ARMS FIGURE 3-2. SIZZOR ARMS INSTALLATION - 33RTS FIG & ITEM # PART NUMBER 0252956 0254088 0252959 0254089 101 Use 1683465 1683465 102 Use 3422735 3422735 103 104 105 to 106 107 108 109 Use 3422738 3422738 0100011 Not Used 0200454 0200556 0200464 0200368 0200452 0200630 110 111 112 113 114 115 116 117 118 119 3120692 0200458 0200631 0200457 0200456 0200557 3422271 3422267 3422273 3422268 3422272 3422269 3422270 3422274 1440227 DESCRIPTION QTY.
PAGE 118
SECTION 3 SIZZOR ARMS FIGURE 3-2.
PAGE 119
SECTION 3 SIZZOR ARMS FIGURE 3-2. SIZZOR ARMS INSTALLATION - 33RTS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 120
SECTION 3 SIZZOR ARMS FIGURE 3-3.
PAGE 121
SECTION 3 SIZZOR ARMS FIGURE 3-3. SIZZOR ARMS INSTALLATION - 25RTS FIG & ITEM # PART NUMBER 0252955 0254086 0254086 0258576 0252958 0254087 0254087 0258577 101 Use 1683465 1683465 102 Use 3422735 3422735 103 104 105 106 107 108 Use 3422738 3422738 0681714 3311705 4751700 Not Used 0200454 0200556 0200556 0200620 109 0200455 0200464 110 0200458 0200458 0200631 0200621 111 0200372 0200519 3120692 DESCRIPTION QTY. REV.
PAGE 122
SECTION 3 SIZZOR ARMS FIGURE 3-3.
PAGE 123
SECTION 3 SIZZOR ARMS FIGURE 3-3. SIZZOR ARMS INSTALLATION - 25RTS (CONTINUED) FIG & ITEM # PART NUMBER 0252586 0258967 201 3340841 3340848 DESCRIPTION SIZZOR ARM PADS INSTALLATION OPTIONS: PRIOR TO S/N 53927 S/N 53927 TO PRESENT Pad Options: Prior to S/N 53927 S/N 53927 to Present QTY. REV. Ref. Ref. Ref.
PAGE 124
SECTION 3 SIZZOR ARMS FIGURE 3-3. SIZZOR ARMS INSTALLATION - 25RTS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 125
SECTION 4 PLATFORM TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 4-6 DESCRIPTION FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATION . . . . . . . . . . PLATFORM EXTENSION INSTALLATION (Prior to S/N 50308) . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM EXTENSION INSTALLATION (S/N 50308 to Present) . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 126
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 127
SECTION 4 PLATFORM FIGURE 4-1. FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATIONS FIG & ITEM # PART NUMBER DESCRIPTION FIXED PLATFORM (STANDARD) & OPTIONAL COMPONENTS INSTALLATIONS Ref. 3510653 Ref. Ref.
PAGE 128
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 129
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 130
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 131
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 132
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308) (CONTINUED) FIG & ITEM # PART NUMBER 36 37 38 39 3312202 3760348 4752200 3520072 S E C T I O N DESCRIPTION Nut, Jam 3/4"-10NC Ring, Retaining Flatwasher 3/4" Plug, Cap (Prior to S/N44592 Only) QTY. REV.
PAGE 133
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM EXTENDABLE INSTALLATIONS (PRIOR TO S/N 50308) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 134
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 135
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 136
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 137
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION FIG & ITEM # PART NUMBER 0253701 1 0860799 0861377 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Use 3252310 3252310 3252620 4420008 0901897 0902456 4845938 0641404 4791400 1060380 3760170 3421453 2560141 0181847 3520082 4460470 4460471 4460463 4360339 7012593 4360267 0100035 Use 0610114 0610114 7012658 0610110 0902514 18 3310601 3311001 19 20 21 4770600 4761000 3900177 1600157 1600290 3120692 QTY. REV.
PAGE 138
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 139
SECTION 4 PLATFORM FIGURE 4-4. PLATFORM CONSOLE BOX INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0252532 301 4360314 3790012 4060802 0253821 401 4360329 3790042 DESCRIPTION OPTIONAL 4WS CONTROLS INSTALLATION Switch, Toggle (Rear Steer) O-Ring Guard, Switch OPTIONAL LIGHTS INSTALLATION Switch, Toggle O-Ring QTY. REV. Ref. 7 1 1 1 Ref.
PAGE 140
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 141
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 142
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 143
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 144
SECTION 4 PLATFORM FIGURE 4-6. DRIVE/LIFT CONTROLLER ASSEMBLY (S/N 57701 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 5 CYLINDERS TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (Hydraulic Jack Option without Interlock - Production Cylinders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 5 CYLINDERS FIGURE 5-1.
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SECTION 5 CYLINDERS FIGURE 5-1.
PAGE 148
SECTION 5 CYLINDERS FIGURE 5-2.
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SECTION 5 CYLINDERS FIGURE 5-2. LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (HYDRAULIC JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS) FIG & ITEM # PART NUMBER 1682720 1683966 1 2 3 4 5 6 1682721 1683967 1682723 Use 2902023 Use 2902023 0320015 0100011 3760261 3760453 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3120692 0681506 0681606 0100035 Kit 1120108 Kit 1681283 Kit Kit 4565647 Kit Kit Kit 4640613 2900770 4641156 2900770 3480092 DESCRIPTION QTY.
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SECTION 5 CYLINDERS FIGURE 5-2.
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SECTION 5 CYLINDERS FIGURE 5-2. LEVELING JACK CYLINDER ASSEMBLY WITH SCREW-IN PIVOT PAD (HYDRAULIC JACK OPTION WITHOUT INTERLOCK - PRODUCTION CYLINDERS) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 152
SECTION 5 CYLINDERS FIGURE 5-3.
PAGE 153
SECTION 5 CYLINDERS FIGURE 5-3.
PAGE 154
SECTION 5 CYLINDERS FIGURE 5-4.
PAGE 155
SECTION 5 CYLINDERS FIGURE 5-4. LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH INTERLOCK) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NUMBER DESCRIPTION QTY. REV. 1682657 LEVELING JACK CYLINDER ASSEMBLY (HYDRAULIC JACK OPTION WITH INTERLOCK) Ref.
PAGE 156
SECTION 5 CYLINDERS FIGURE 5-5.
PAGE 157
SECTION 5 CYLINDERS FIGURE 5-5. LIFT CYLINDER ASSEMBLIES FIG & ITEM # PART NUMBER DESCRIPTION Note: Machines built prior to S/N28190 use cylinders 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.
PAGE 158
SECTION 5 CYLINDERS FIGURE 5-5. LIFT CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 159
SECTION 5 CYLINDERS FIGURE 5-5. LIFT CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 160
SECTION 5 CYLINDERS FIGURE 5-6.
PAGE 161
SECTION 5 CYLINDERS FIGURE 5-6.
PAGE 162
SECTION 5 CYLINDERS FIGURE 5-7.
PAGE 163
SECTION 5 CYLINDERS FIGURE 5-7. STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT) FIG & ITEM # PART NUMBER 1682967 1 2 3 4 5 to 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1682682 1682987 1120108 1681344 Not Used 3860056 3300357 Kit Kit Kit Kit Kit Not Used Kit 0440085 0100011 0100035 4568055 2901261 3120692 DESCRIPTION STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT) QTY. REV. Ref.
PAGE 164
SECTION 5 CYLINDERS FIGURE 5-7. STEER CYLINDER ASSEMBLY (MACHINES BUILT JUNE 1993 TO PRESENT) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 165
SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 FIGURE 6-1 DESCRIPTION HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - STANDARD 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - STANDARD 4WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - STANDARD 4WD/4WS . . . . . . . . . . . . . . . . . . . . .
PAGE 166
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 167
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 168
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 169
SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - 2WD/2WS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 170
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 171
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 172
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 173
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 174
SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - 4WD/2WS (CONTINUED) FIG & ITEM # PART NUMBER 226 227 228 229 2752532 2750759 2750968 2752523 DESCRIPTION Hose Hose Hose Hose QTY. REV.
PAGE 175
SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - 4WD/2WS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 176
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 177
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 178
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 179
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 180
SECTION 6 HYDRAULICS FIGURE 6-5.
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SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - AXLE (OSCILLATING) FIG & ITEM # PART NUMBER 2791574 2792519 1 2 3 4 5 6 7 8 9 10 2220472 2220414 2750760 2751010 2220582 Not Used 2750900 2220605 0100020 2220472 2750897 DESCRIPTION HYDRAULIC DIAGRAM - AXLE (OSCILLATING) Prior to S/N 97717 S/N 97717 to Present Fitting Options: Prior to S/N 54201 S/N 54201 to Present Hose Hose Fitting Hose Fitting, Tee Sealant, Pipe (Not Shown) Fitting, 90° Hose QTY. REV. Ref. Ref.
PAGE 182
SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - AXLE (OSCILLATING) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 183
SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 DESCRIPTION ELECTRICAL DIAGRAMS AND COMPONENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - DUAL FUEL (Ford Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - 110V GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - 0610114 CIRCUIT CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 184
SECTION 7 ELECTRICAL FIG & ITEM # PART NUMBER 7—1 S E C T I O N ALARMS ELECTRICAL DIAGRAMS (DWG ONLY) Descent Alarm (B/M Only) Motion Alarm (B/M Only) Travel Alarm (B/M Only) Alarm, Horn Diode - 6 Amp Relay (Located in Ground Control Box) Capacitor Ref. Ref. Ref. Ref. 1 A/R 1 1 C B A A 0254000 AUXILIARY LIFT ELECTRICAL DIAGRAM (OPTIONAL) Ref.
PAGE 185
SECTION 7 ELECTRICAL FIG & ITEM # PART NUMBER 4921561 4922248 1060459 1060825 1060459 1060825 1060459 1060825 4460473 4460468 4460481 4460464 4460466 1060308 0610103 0610114* DESCRIPTION QTY.
PAGE 186
SECTION 7 ELECTRICAL FIG & ITEM # PART NUMBER Ref. Ref. Ref. C/D D E 0257913 0253852 LIGHTS ELECTRICAL DIAGRAM (OPTIONAL) Headlights and Taillights Headlights, Taillights, Brake Lights & Signal Lights Panel Lights - Ground Control Box Panel Lights - Platform Console Box Platform Worklights with 2 Lights (25RTS) Platform Worklights with 2 Lights (33RTS) Platform Worklights with 2 Lights (40RTS) Platform Worklights with 4 Lights Platform Worklights with Cable Reels Ref. Ref. Ref. Ref. Ref. Ref. Ref.
PAGE 187
SECTION 7 ELECTRICAL FIG & ITEM # PART NUMBER 4932758/1283062* 3990010 4921562 4921563 4921718 4460457 4460460 1060341 4932758/1282348* 4932758/1283062* 3990010 4921562 4921718 4922044 3990010 4460457 4460460 4460589 4460608 4460587 4460588 4460183 1060341 4933042/1282951 4933043/1282951 1282137 0254111 0254262 3120692 DESCRIPTION Ford VSG-411 Engine Machines (S/N 61097 to Present) Diode - 6 Amp Harness (Valves to Ground Control Box) QTY. REV. Ref.
PAGE 188
SECTION 7 ELECTRICAL FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 189
SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL DIAGRAM - DUAL FUEL (FORD ENGINE OPTION).
PAGE 190
SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL DIAGRAM - 110V GENERATOR.
PAGE 191
SECTION 7 ELECTRICAL FIGURE 7-4. ELECTRICAL DIAGRAM - 0610114 CIRCUIT CARD.
PAGE 192
SECTION 7 ELECTRICAL FIGURE 7-5.
PAGE 193
SECTION 7 ELECTRICAL FIGURE 7-5.
PAGE 194
SECTION 7 ELECTRICAL FIGURE 7-6.
PAGE 195
SECTION 7 ELECTRICAL FIGURE 7-6.
PAGE 196
SECTION 7 ELECTRICAL FIGURE 7-7.
PAGE 197
SECTION 7 ELECTRICAL FIGURE 7-7.
PAGE 198
SECTION 7 ELECTRICAL FIGURE 7-8.
PAGE 199
SECTION 7 ELECTRICAL FIGURE 7-8.
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SECTION 7 ELECTRICAL S E C T I O N “THIS PAGE INTENTIONALLY LEFT BLANK” 7 E L E C T R I C A L 7-18 3120692
PAGE 201
SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 8-2 DESCRIPTION DECALS INSTALLATIONS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 DECALS INSTALLATIONS - COUNTRY SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 202
SECTION 8 DECALS FIGURE 8-1.
PAGE 203
SECTION 8 DECALS FIGURE 8-1.
PAGE 204
SECTION 8 DECALS FIGURE 8-1.
PAGE 205
SECTION 8 DECALS FIGURE 8-1.
PAGE 206
SECTION 8 DECALS FIGURE 8-2.
PAGE 207
SECTION 8 DECALS FIGURE 8-2.
PAGE 208
SECTION 8 DECALS FIGURE 8-2.
PAGE 209
SECTION 8 DECALS FIGURE 8-2.
PAGE 210
SECTION 8 DECALS FIGURE 8-2.
PAGE 211
SECTION 8 DECALS FIGURE 8-2.
PAGE 212
SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATIONS - COUNTRY SPEC (CONTINUED) FIG & ITEM # PART NUMBER 2900966+ DESCRIPTION Decal Kit - Japanese 40RTS (Includes Items with Plus +) QTY. REV.
PAGE 213
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODEL 25/33/40RTS 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 inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
PAGE 214
S E C T I O N 9 R E C O M M E N D E D S E R V I C E P A R T S S T O C K SECTION 9 RECOMMENDED SERVICE PARTS MODEL 25/33/40RTS 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 inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
PAGE 215
SECTION 10 SPECIAL OPTIONS LIST FIG & ITEM # PART NUMBER 10—1 QTY. SPECIAL OPTIONS LIST Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact the JLG Parts Department. Ref. Ref. REV. 0254242 0250914 0256425 Airline to Platform Installation - 1/2" (25RTS) Airline to Platform Installation - 1/2" (33RTS) Airline to Platform Installation - 1/2" (40RTS) Ref. Ref. Ref. 0253877 0254090 Ref. Ref.
PAGE 216
SECTION 10 SPECIAL OPTIONS LIST FIG & ITEM # PART NUMBER 0254131 S E C T I O N Ref. Ref. Ref.
PAGE 217
SECTION 10 SPECIAL OPTIONS LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. 0257380 Platform Door Return Spring Installation Ref. 0254110 Platform Handrails with Inner Rails Installation Ref. 0254112 Platform Proximity Switches Installation Ref. 0253852 Platform Worklights with Automatic Retract Cords Installation Ref. 0257913 Platform Worklights with Four Worklights Installation Ref. 0254925 Terminal Boots Installation Ref. 2901813 Tie Strap Kit Ref.
PAGE 218
SECTION 10 SPECIAL OPTIONS LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 219
PAGE 220
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) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.