SECTION THREE ILLUSTRATED PARTS MANUAL
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1 SECTION THREE ILLUSTRATED PARTS MANUAL CONTENTS: MACHINE LEFT SIDE VIEW 3-2 MACHINE RIGHT SIDE VIEW 3-4 MACHINE FRONT VIEW 3-5 MACHINE REAR VIEW 3-6 MACHINE FRONT VIEW 3-8 FRONT PANEL 3-10 TRAILER AXLE AND WHEEL HUBS 3-11 RIGHT SIDE VIEW KUBOTA D905 ENGINE 3-12 LEFT SIDE VIEW KUBOTA D905 ENGINE 3-14 FUEL TANK & ACCESSORIES 3-15 RADIATOR OVERFLOW BOTTLE 3-17 MAST ASSEMBLY 3-18 MAST HYDRAULIC CYLINDERS 3-21 MAST HYDRAULIC POWERPACK 3-23 HYDRAULIC OUTRIGGERS + FRONT LEG (OPTION) 3-25 ELECTRICAL EQUIPMENT - MACHINE 3-27 ELECTRICAL EQUIPMENT DROOP LED LIGHTS JLG Industries (Australia) Pty Ltd Page 3-1
2 MACHINE LEFT SIDE VIEW A DETAIL A JLG Industries (Australia) Pty Ltd Page 3-2
3 MACHINE LEFT SIDE VIEW PARTS LIST FRAME, LED TRAILER FRAME P DOOR LH, PAINTED HANDLE, T-DOOR HANDLE, LOCKING TAB A/R P PLATE, CONTROL BOX COVER LATCH, LIFT AND TURN LOCKING TAB DECAL, OPERATING INSTRUCTIONS DECAL, GROUND CONTROL CHOCK, URETHANE WHEEL BRACKET, WHEEL CHOCK MOUNTING WHEEL RIM TYRE, 205/80 X SHIELD, MUDGUARD, LH EMERGENCY STOP SWITCH MOUNT BRACKET, 4.5 kg FIRE EXTINGUISHER FIRE EXTINGUISHER, 4.5 kg STOP BLOCK, JACK STORAGE DECAL, ( SHOWN) MOUNT, GAS STRUT BALL STRUT, DOOR GAS SEAL, DOOR RUBBER BUMPER, DOOR RUBBER JLG Industries (Australia) Pty Ltd Page 3-3
4 MACHINE RIGHT SIDE VIEW 03 C 04 B Detail B Detail C JLG Industries (Australia) Pty Ltd Page 3-4
5 MACHINE RIGHT SIDE VIEW PARTS LIST DOOR, ASSEMBLY RH SHIELD, MUDGUARD RH DECAL, LIFT POINT DECAL, TIE-DOWN POINT PLUG, 1/4" BSPP DRAIN DECAL, ENGINE OIL AND BUNDING DRAIN COCK, 1/4 BSPP M-F DRAIN HANDLE, T-DOOR HANDLE, LOCK TAB A/R DECAL, JUMP START DECAL, CAUTION BATTERY ISOLATOR STARTER ISOLATOR, COLE HERSEE SWITCH, DOUBLE POLE BATTERY ISOLATOR TAPE, PRISMATIC REFLECTIVE 50 mm A/R DECAL, VIN PLATE IDENTIFICATION JLG Industries (Australia) Pty Ltd Page 3-5
6 MACHINE REAR VIEW PANEL, LED SERIES LT ROOF FINISHED PANEL, REAR FINISHED CRADLE, MAST SUPPORT WEAR PAD, MAIN BOOM (MAST REST) LAMP, LICENCE PLATE TAIL LAMP ASSEMBLY LED DECAL, TIE-DOWN POINT BEACON, LED LIGHTING TOWER TAPE, RETRO-REFLECTIVE YELLOW JLG Industries (Australia) Pty Ltd Page 3-6
7 MACHINE LOWER REAR VIEW A3300 OUTRIGGER, SIDE JACK ASSEMBLY OUTRIGGER, SIDE EXTENSION ARM PIN, SPRING LOADED PLUNGER 2 04 A OUTRIGGER, REAR JACK ASSEMBLY OUTRIGGER, REAR EXTENSION ARM TAPE, REFLECTIVE BLACK/YELLOW DECAL, FORK LIFT POINT JLG Industries (Australia) Pty Ltd Page 3-7
8 MACHINE FRONT E D F Detail D Detail E JLG Industries (Australia) Pty Ltd Page 3-8
9 MACHINE FRONT Detail H 17 Detail F WELDMENT, FRONT DRAWBAR EXTENSION COUPLING, OVERRIDE TOWBALL CYLINDER, HYDRAULIC BRAKE CAP, HYDRAULIC BRAKE RESERVOIR HANDLE, PARKING BRAKE WHEEL, JOCKEY CABLE, 5C21B TRAILER 1 08 A3304 CIRCLIP, OUTRIGGER GRIP, MAST ROTATE HANDLE DECAL, MAST ROTATION LOCK PIN, MAST INDEXING PLUNGER KNOB, MAST ROTATE LOCKING LEG, TRANSPORT PIN, HITCH TRANSPORT LEG CHAIN, HITCH PIN RETAINING BUBBLE, LEVELLING PIN, DRAWBAR ASSEMBLY 1 17 A6535 JACK, FRONT OUTRIGGER (DRAWBAR) BOLT, HEX SCREW 1/2" UNC-1.5 SAE GRADE NUT,HEX NYLOC 1/2"UNC GRADE JLG Industries (Australia) Pty Ltd Page 3-9
10 FRONT PANEL A B P PANEL, FINISHED FRONT 1 A PANEL, FRONT LED LT (FROM S/N: 2300L00311) 1 B PANEL, FRONT LED W/HYD OUTRIGGERS GLAND, TERMINAL 25 mm NYLON GLAND, TERMINAL 32 mm NYLON EYEBOLT, M10 x 100 mm Zn PLATED TURNBUCKLE, GALVANISED 16 mm LED LT GROMMET, RUBBER BLACK LED LT JLG Industries (Australia) Pty Ltd Page 3-10
11 TRAILER AXLE AND WHEEL HUBS AXLE ASSEMBLY C/W BRAKES (1650 kg RATING) HUB, BRAKE DRUM KIT, WHEEL BEARING AND SEAL KIT, BRAKE SHOE PLATE, PAIR BACKING NIPPLE, BRAKE LINE BLEED CYLINDER, WHEEL BRAKE DRUM STUD, WHEEL NUT, WHEEL CAP, DUST NUT, AXLE 3/4"UNF WASHER, FLAT 3/4" PIN, SPLIT 3.2 x SEAL, WHEEL BEARING SEAL KIT, BRAKE LINE (FOR AXLE ASSEMBLY ) INCLUDES FOLLOWING ITEMS TUBE, DRAW BAR TUBE, SHORT LEFT TUBE, SHORT RIGHT FITTING, TEE HOSE, DRAWBAR BRAKELINE HOSE, AXLE BRAKELINE CLIP RETAINING JLG Industries (Australia) Pty Ltd Page (1) (1) (1) (1) (1) (2) (3)
12 RIGHT SIDE VIEW - KUBOTA D905 ENGINE C A 05B JLG Industries (Australia) Pty Ltd Page 3-12
13 RIGHT SIDE VIEW PARTS LIST KUBOTA D905 ENGINE ENGINE, D905 KUBOTA DIESEL KU CAP, PRESSURE RELEASE RADIATOR RADIATOR, ENGINE D HOSE, RADIATOR TOP HOSE HOUSING, D905 ENGINE AIR FILTER 1 05A 762 BAND, AIR CLEANER A/R 05B BOLT, WING A/R 05C FILTER, PRE-CLEANER BOWL (DONALDSON) A/R FILTER ELEMENT, D905 ENGINE AIR BELT, D905 ENGINE FAN UPPER GUARD, D905 ENGINE FAN BELT LOWER GUARD, D905 ENGINE FAN BELT HOSE, RADIATOR LOWER HOSE ALTERNATOR, DENSO 12 V MOTOR, D905 ENGINE STARTER SENSOR, OIL PRESSURE MUFFLER, EXHAUST CLAMP, MUFFLER LED LT BRACKET, EXHAUST MOUNT TUBE, EXHAUST LED LT (MUFFLER KIT) INSULATION, EXHAUST PIPE (MUFFLER KIT) CLAMP, INSULATION (MUFFLER KIT) PLATE, EXHAUST SHIELD (NOT SHOWN) JLG Industries (Australia) Pty Ltd Page 3-13
14 LEFT SIDE VIEW- KUBOTA D905 ENGINE A B 03 05C D 05E 05A 05B JLG Industries (Australia) Pty Ltd Page 3-14
15 LOOM, KUBOTA 905 ENGINE P BRACKET, ENGINE MOUNTINGS FILTER, D905 ENGINE OIL SOLENOID, ENGINE RUN 1 05 MOUNT, GPM7FS-12B (50) VIBRATION ISOLATION (REPLACE MOUNTS IN PAIRS) 2 05A BOLT, HEX HEAD M12 x 35 CLASS B WASHER, FLAT M C BOLT, HEX HEAD M8 x 30 CLASS D NUT, HEX NYLOC M8 CLASS E WASHER, FLAT M GLOW PLUGS D SENSOR, D905 ENGINE TEMPERATURE BRACKET, RADIATOR MOUNT DIPSTICK, ENGINE OIL MOUNT, RADIATOR TOP MOUNT, RADIATOR BOTTOM BRACKET, FUEL FILTER FILTER, ENGINE FUEL FILTER DRAIN COCK, FUMOTO F103N HOSE, ENGINE OIL DRAIN 1 FUEL TANK AND ACCESSORIES JLG Industries (Australia) Pty Ltd Page 3-15
16 KIT, FUEL TANK REPLACEMENT (KIT INCLUDES THE FOLLOWING PARTS) TANK, LED LT FUEL HARNESS, FUEL LEVEL SWITCH CAP & GAUGE, LED LT FUEL TANK BRACKET, FUEL FILTER FILTER, ENGINE FUEL FILTER PRIMER BULB, FUEL LINE HOSE, FUEL DELIVERY-LINE 5/ HOSE, FUEL RETURN-LINE 3/ ELBOW FITTING, 5/16 HOSETAIL 1/4" BSPT ELBOW FITTING, 1/4 HOSETAIL - 1/4 BSPT BOX. MANUALS STORAGE DECAL, PICTOGRAM STORAGE BOX DECAL, DIESEL FUEL SWITCH, FUEL LEVEL JLG Industries (Australia) Pty Ltd Page 3-16
17 RADIATOR OVERFLOW (HEADER) BOTTLE BOTTLE, RADIATOR OVERFLOW SENSOR, WATER LEVEL KIT, WATER LEVEL SENSOR 1 KIT, RUBBER STRAP BRACKET, STRAP MOUNTING HOOK, STRAP HANGING TUBING, HEADER TANK /RADIATOR P-CLAMP, MODIFIED CHECK-VALVE, COOLANT BOTTLE JLG Industries (Australia) Pty Ltd Page 3-17
18 MAST ASSEMBLY JLG Industries (Australia) Pty Ltd Page 3-18
19 JLG Industries (Australia) Pty Ltd Page 3-19
20 MAST ASSEMBLY PARTS LIST LOWER MAST INNER (WELDMENT) BUMPER, MAST SUPPORT WELDMENT, MAST UPPER INNER FLANGED BUSH, ROUND MAST FLANGED BUSH PIN, OUTER LINK ARM PIVOT HEX NUT, NYLOC 1/4" UNC HEX BOLT, 1/4"-20 UNC 2.0 LONG SPACER, COLLAR ARM, INNER LH LINK ARM, INNER RH LINK HYDRAULIC CYLINDER, MAST LIFT GREASE NIPPLE, 45 ANGLE 1/8 NPT CIRCLIP, EXTERNAL PIN, TELE-CYLINDER LOWER PIVOT PIN, INNER LINK ARM PIVOT PIN, LIGHT DROOP PIVOT HYDRAULIC CYLINDER, TELE-MAST TELE-MAST, OUTER SQUARE TELE-MAST, INNER SQUARE CAP, INNER SQUARE MAST GALVANISED ROLLER, MAST CARRIER BOLT, HEX HEAD 5/16-18UNC 2.75 LONG NYLOC NUT, HEX HEAD 5/16 SAE GRADE TUBE, CABLE CARRIER ASSEMBLY, ENERGY CHAIN WASHER, M6 FLAT WASHER NYLOC NUT, HEX M6 x 1.0P FLAT WASHER, 1/4" STEEL SCREW, HEX HEAD 1/4"-20 UNC 5/8 LONG HYDRAULIC CYCLINDER, DROOP TILT LIGHT DROOP PIN, TILT CYLINDER PIVOT PIN, 3/8 KEEPER SCREW, HEX HEAD 3/8-16 UNC 1.0 LONG CAP, LIGHT BAR END DECAL, LED (NOT SHOWN) DECAL, JLG (NOT SHOWN) 3.5 HIGH WASHER THRUST MAST BASE (NOT SHOWN) HEX NUT NYLOC 1.0 UNC GRADE 8 (NOT SHOWN) JLG Industries (Australia) Pty Ltd Page 3-20
21 HYDRAULIC CYLINDERS MAST LIFT CYLINDER HYDRAULIC CYLINDER, MAST LIFT (COMPLETE) BARREL, LIFT CYLINDER ROD, LIFT CYLINDER PISTON SEAL KIT, TILT/LIFT CYCLINDER (NOT SHOWN) VALVE, DOUBLE PILOT CHECK TUBING, LIFT CYLINDER HYDRAULIC ELBOW, M/M 1/4 x 7/ ADAPTOR, STRAIGHT UNION M/F 1/4" x 7/ NIPPLE, M/M ENCAPSUALTED SEAL 1/4 x 7/16 3 LIGHT DROOP TILT CYLINDER HYDRAULIC CYLINDER, DROOP TILT (COMPLETE) BARREL, TILT CYLINDER ROD, TILT CYLINDER PISTON SEAL KIT, TILT/LIFT CYCLINDER (NOT SHOWN) VALVE, DOUBLE PILOT CHECK TUBING, LIFT CYLINDER HYRAULIC ELBOW, M/M 1/4 x 7/ ADAPTOR, STRAIGHT UNION M/F 1/4" x 7/ NIPPLE, M/M ENCAPSULATED SEAL 1/4 x 7/ JLG Industries (Australia) Pty Ltd Page 3-21
22 TELE-MAST HYDRAULIC CYLINDER HYDRAULIC CYLINDER, MAST TELE (COMPLETE) BARREL, TELE CYLINDER ROD, TELE CYLINDER PISTON SEAL KIT, TILT/LIFT CYCLINDER (NOT SHOWN) VALVE, CHECK CARTRIDGE NIPPLE, M/M ENCAPSUALTED SEAL 1/4 x 7/ JLG Industries (Australia) Pty Ltd Page 3-22
23 MAST HYDRAULIC POWERPACK HYDRAULIC POWERPACK ASSEMBLY (3-DCV) SOLENOID, MOTOR RUN 12 V MOTOR, 12 V DC ELECTRIC VALVE, PRESSURE RELIEF CARTRIDGE TANK, KMD1-S1-P12 HYDRAULIC OIL FILLER, BREATHER CAP 1 07 COVER, PRESSURE RELIEF VALVE DECAL, HYDRAULIC OIL DECAL, HYDRAULIC PRESSURE MPa HOSE KIT, MAST LIFT CYLINDER (GREEN/BLACK) HOSE KIT, TELE-MAST CYLINDER (RED/SILVER) HOSE KIT, DROOP TILT CYLINDER (BLUE/WHITE) BRACKET, POWERPACK MOUNTING JLG Industries (Australia) Pty Ltd Page 3-23
24 HYDRAULIC POWERPACK 6 or 7 DCV (HYDRAULIC OUTRIGGER ARMS OPTION) A B D C HYDRAULIC POWERPACK ASSEMBLY (3-DCV) DCV, SV08-D12-B SLICE (COMPLETE) A/R A COIL, SV08B VALVE 12 V A/R B VALVE, SV08B CARTRIDGE (NOT SHOWN) A/R C VALVE, SV08B BODY (SLICE) A/R D VALVE, SV08B 7-SLICE BOLT A/R JLG Industries (Australia) Pty Ltd Page 3-24
25 HYDRAULIC OUTRIGGERS AND FRONT LEG (OPTION) JLG Industries (Australia) Pty Ltd Page 3-25
26 HYDRAULIC OUTRIGGERS AND FRONT LEG (OPTION) CYLINDER ASSEMBLY, REAR OUTRIGGER CYLINDER ASSEMBLY, FRONT DRAWBAR KIT, HYDRAULIC OUTRIGGER HOSE + FITTINGS PIN, CYLINDER ROD END PIN, LUG END PIN, KEEPER CIRCLIP, (RETAINING RING) BOLT, HEX HEAD 1/2"UNC 5½ SAE GRADE NUT, 1/2" UNC HEX NYLOC SAE GRADE WASHER, STEEL 1/2" FLAT TUBE, CLEAR VINYL PLASTIC WELDMENT, OUTRIGGER LH REAR INSERT WELDMENT, OUTRIGGER RH REAR INSERT LEG, LH OUTRIGGER LEG, RH OUTRIGGER FOOT PAD, OUTRIGGER SCREW, HEX HEAD 3/8 UNC 1.0 LONG WASHER, 3/8 SPRING 6 19 GREASE NIPPLE, STRAIGHT ¼ DECAL, CAUTION CRUSHING HAZARD REFLECTIVE TAPE, BLACK/YELLOW JLG Industries (Australia) Pty Ltd Page 3-26
27 ELECTRICAL EQUIPMENT - CONTROL BOX Control box prior to November Control box after November MOUNT, CONTROL BOX CONTROL BOX, LED LT BASE COVER (3-HYDRAULIC OUTRIGGER) COVER (4-HYDRAULIC OUTRIGGER) COVER, LED LT RELAY 1 04 RELAY LIGHT, LED LT INTERIOR FUSE, ELECTRICAL 20 A TERMINAL, 21 PIN SOCKET TERMINAL, 21 PIN PLUG JLG Industries (Australia) Pty Ltd Page 3-27
28 ELECTRICAL EQUIPMENT MACHINE CONTROL PANEL(S) CONTROL, LED LIGHTING TOWER/ENGINE DECAL, LED TOWER CONTROL BOX SWITCH, PUSH BUTTON (YELLOW) SWITCH, TOGGLE 2-POSITION 1 05 SWITCH, TOGGLE 3-POSITION CENTRE-OFF (MACHINES WITH HYDRAULIC OUTRIGGERS) (6) DECAL MAST CONTROL PANEL DECAL MAST AND OUTRIGGER CONTROL PANEL JLG Industries (Australia) Pty Ltd Page 3-28
29 ELECTRICAL EQUIPMENT - BATTERY JLG Industries (Australia) Pty Ltd Page 3-29
30 ELECTRICAL EQUIPMENT BATTERY TRAY, BATTERY BOX, LARGE BATTERY L/T BATTERY, 12 V (ENGINE) TERMINAL, BATTERY LUG (+)/ TERMINAL, BATTERY LUG (-)/ CLAMP, BATTERY HOLD-DOWN LIMIT SWITCH, ROLLER LEVER PLUG, ANDERSON JUMP-START BRACKET, JUMP-START SOCKET FUSE, STARTER MOTOR 25 A (NOT SHOWN) BOOT, BATTERY TERMINAL 1/0 & 2/0 - RED BOOT, BATTERY TERMINAL 1/0 & 2/0 - BLACK SWITCH, DOUBLE POLE BATTERY ISOLATING STARTER ISOLATOR, COLE HERSEE (1-PHASE) JLG Industries (Australia) Pty Ltd Page 3-30
31 ELECTRICAL EQUIPMENT GENERATOR A B C 05 05A 05D 05E 04 05B GENERATOR, FB4 48 V / 100 A DC 1 A FB4/DC TERMINAL BOX UPPER SECTION * B FB4/DC TERMINAL BOX LOWER SECTION * LEAD, GENERATOR EARTHING HARNESS, ENGINE LED LT WIRING DECAL, MAIN EARTH TAG 1 05 MOUNT, GPM7FS-12B (50) VIBRATION ISOLATION (REPLACE MOUNTS IN PAIRS) 2 05A BOLT, HEX HEAD M12 x 35 CLASS B WASHER, FLAT M C BOLT, HEX HEAD M8 x 30 CLASS D WASHER, FLAT M8 8 05E NUT, HEX NYLOC M8 CLASS CONTROL, SINCRO AVR DBC1 CARD BASE, SINCRO AVR CARD A/R BACK PLATE, SINCRO AVR CARD 7006 A/R KIT, DC LED CAPACITOR MOUNT A/R * When ordering replacement generator parts please quote the generator s make, type, code and serial number listed on the maker s label affixed to the generator terminal box JLG Industries (Australia) Pty Ltd Page 3-31
32 ELECTRICAL EQUIPMENT GENERATOR D C C BOX, SINCRO FB4 TERMINAL SINCRO S/N PRIOR TO 4346 * D TOP COVER, SINCRO FB4 TERMINAL BOX SINCRO S/N PRIOR TO 4346 * For Reference Only Sincro Alternator FB4 Exploded View Sincro Parts Manual (Extract) See /8 Manual Section Recommended Spares List JLG Industries (Australia) Pty Ltd Page 3-32
33 ELECTRICAL EQUIPMENT DROOP JUNCTION BOX & LED LIGHTS G E D H JLG Industries (Australia) Pty Ltd Page 3-33
34 LAMP ASSEMBLY, 48 V / 100 A LED A ELECTRONICS ASSY, LED-MODULE Z93612 A/R B REFLECTOR, LED LENS Z DEGREE A/R C ELECTRONIC ASSY, STABILISER Z93613 A/R D MOUNT, TETHYS Z77045 TRUNNION A/R E LENS GLASS, TETHYS MKI A/R F REGULATOR, TVS MODULE (LED) BOX (UPGRADE) A/R F PC BOARD, /8 TVS MODULE A/R G LATCH, LED LIGHT FIXTURE A/R H KIT, TVS MODULE MK II (FIELD) A/R TVS MODULE FUSE, E 20 A/250 V P-314 (NOT SHOWN) A/R BOLT, HEX HEAD M16 x 2.0P 110 LG CLASS NUT, HEX HEAD NYLOC M16 x 2.0P CLASS FLAT WASHER, STEEL M HV (MIN) TERMINAL BOX, LED LIGHT DROOP SOCKET, HIRSCH C PE CHASS PLUG, HIRSCH C PE LINE 6 (8) DUSTCAP, HIRSCH C (0) CABLE, LED MAST JZ CORE 2.5 mm CABLE, LED LIGHT JZ CORE 2.5 mm 6(8) GLAND, TERMINAL BOX 32 mm 1 A G F B C D JLG Industries (Australia) Pty Ltd Page 3-34
35 E I C D C H G B J F A K M L JLG Industries (Australia) Pty Ltd Page 3-35
36 LAMP, LED 400W 48VDC SINCRO A LAMP, LED SOURCE IWE 400 A/R B LAMP, GASKET LED IWE 400 A/R C LAMP, LENS 110 DEGREE LED IWE 400 W A/R D LAMP, LENS GASKET LED IWE 400 W A/R E LAMP, LENS COVER, IWE 400 W A/R F LAMP, HEAT SINK LED IWE 400 W A/R G LAMP, DRIVER LED IWE 400 W A/R H LAMP, 3WAY CONNECTOR LED IWE A/R I LAMP, CABLE LED IWE 300W & 400 W A/R J LAMP, CONNECTOR LED IWE 400 W A/R K LAMP, TRUNNION LED IWE 400 W A/R L LAMP, TRUNNION MOUNT IWE 400 W A/R M LAMP, TRUNNION TEE-BOLT S/S IWE 400 W A/R LAMP, LED 400W 48VDC SINCRO 45 4 C LAMP, LENS 45 DEGREE LED IWE 400W A/R JLG Industries (Australia) Pty Ltd Page 3-36
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