Parts Manual User guide

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Illustrated Parts Manual

Model

3606

P/N - 8990299

Revised May 25, 2007

Summary of content (238 pages)

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Illustrated Parts Manual Model 3606 P/N - 8990299 Revised May 25, 2007
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EFFECTIVITY PAGE May 25, 2007 - A - Revised Manual 8990299 3606 i
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EFFECTIVITY PAGE -ii 3606 8990299
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Table of Contents Page SECTION 1 – MAIN FRAME AND COVERS Main Frame ............................................................... 1.1 Covers And Guards ................................................... 1.3 SECTION 2 – OPERATOR’S CAB AND CONTROLS Open Cab - Outer Panels .......................................... 2.1 Open Cab - Inner Console & Dash Panel ................. 2.3 Operator’s Seat And Seat Belt .................................. 2.5 Operator’s Seat And Seat Belt (Optional) ...................
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Page Frame Tilt & Stabilizer Circuit (S/N 9883 and Before) ........................................ 5.9 Frame Tilt & Stabilizer Circuit (S/N 9884 and After) ......................................... 5.11 Service Brake & De-Clutch Circuit........................... 5.13 Valve Plate Assy. w/o Aux. Hydraulics .................... 5.15 Valve Plate Assy. w/ Aux. Hydraulics ...................... 5.17 Transmission Cooling Circuit (Cummins) ........................................................ 5.
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Table of Contents Page Page T of C 3 3606 Origin 7/98
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SECTION 1 – MAIN FRAME AND COVERS MAIN FRAME Hoist Cylinder 11 12 Orient Fracture In Bearing Race at Clock Position Shown For Each Application 1 2 10 9 Boom Pivot Frame Tilt Cylinder Stabilizer Cylinder Slave Cylinder 3 4 8 7 6 2 11 5 39 10 34 37 1 12 38 36 2 3 2 5 33 4 5 6 7 8 4 41 9 3 27 32 2 31 30 41 26 5 11 10 21 27 29 10 12 See Kits 2 21 13 20 14 11 4 20 5 3 11 12 10 12 5 2 13 2 26 Torque Item 23 to 680 lb/ft.
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MAIN FRAME Item No. Part Number Qty.
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COVERS AND GUARDS 10 1 9 2 40 7 39 34 33 11 3 48 6 47 7 15 5 4 14 11 19 3 46 12 13 37 10 35 36 16 32 18 13 14 17 45 8 13 20 38 13 14 21 24 25 13 23 22 14 33 31 26 4 22 13 14 25 22 23 13 30 13 27 42 43 23 40 41 25 29 28 13 23 28 5 41 44 40 22 23 13 PS0061 1.
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COVERS AND GUARDS Item No.
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SECTION 2 – OPERATOR’S CAB AND CONTROLS OPEN CAB - OUTER PANELS 4 5 3 1 2 25 6 7 8 4 9 5 6 8 13 7 9 12 7 8 10 11 6 15 16 24 5 4 4 6 14 17 19 5 6 18 20 19 6 5 4 S/N 8373 and Before 21 20 21 23 22 22 26 PF0780 Torque to 280 lb/ft. (380 Nm) PS0331 2.
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OPEN CAB - OUTER PANELS Item No. Part Number Qty.
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OPEN CAB - INNER CONSOLE & DASH PANEL 24 2 17 16 23 13 16 17 13 15 16 16 20 16 13 17 10 17 16 11 21 9 15 19 22 8 6 7 Torque to 6-8 lb/ft (8-11 Nm) 6 5 13 16 17 2 15 16 17 18 2 1 4 2 3 13 2 14 2 12 14 15 PS0701 2.
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OPEN CAB - INNER CONSOLE & DASH PANEL Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7130724 8305906 7130773 8310353 8310016 8310402 8310360 8310085 8580421 8310358 7131003 7130744 7057141 8305626 8307203 8307004 8303739 7130862 7130734 8310009 8630010 8307206 7124531 7132751 Qty.
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OPERATOR’S SEAT AND SEAT BELT 14 1 2 3 4 5 6 7 8 9 12 9 10 11 15 10 12 15 11 13 16 18 17 18 19 23 24 22 Torque to 20 lb/ft (27 Nm) 21 20 25 18 Kit PF0791 19 Kit PF0791 Items 20 thru 23 Not Required On Early Production Cabs With A Threaded Hole For Tether Mounting PS0120 2.
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OPERATOR’S SEAT AND SEAT BELT Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8864053 8036009 8036010 8036011 8036013 8036014 8036015 8036017 7130412 7096491 8864057 NSS NSS NSS NSS 7121543 8303670 8307106 8305626 8305404 8307204 7057141 8305645 8864058 8864019 Qty. 1 1 1 1 4 1 1 1 2 2 1 2 1 1 2 1 4 12 8 2 2 2 2 1 1 Description Seat Boot, 60/76mm (Not Shown) Adjuster, 6" (Not Shown) Damper (Not Shown) Rollers, Up Stop Bumper/Down Stop Bumper- 7/16" Dia.
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OPERATOR’S SEAT AND SEAT BELT (Optional) 2 1 6 7 3 5 4 5 2 3 4 7 8 6 9 14 11 12 13 Torque to 20 lb/ft (27 Nm) 15 9 10 16 Kit PF0791 Items 11 thru 14 Not Required On Early Production Cabs With A Threaded Hole For Tether Mounting Kit PF0791 PS0310 2.
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OPERATOR’S SEAT AND SEAT BELT (Optional) Item No. Part Number 1 8864055 8864056 7130412 7096491 8864060 NSS NSS NSS 8303670 8307106 8305626 8305404 8307204 7057141 8305645 8864058 8864019 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Qty. 1 1 2 2 1 2 2 2 4 8 4 2 2 2 2 1 1 Description Seat, Deluxe Cloth with Supension Seat, Deluxe Vinyl with Supension Tether Spacer Seat Belt Assembly - 2" Retractable (Includes Items 5 thru 7) Nut, Hex Hex Hd Capscrew Washer, Flat HHCS, 5/16-18 x 1" Gr.
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MIRRORS 1 3 5 4 2 12 9 11 10 8 4 7 3 14 6 4 13 4 15 3 4 CLOSED CAB ONLY PS0321 2.
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MIRRORS Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 8866514 8866515 8303548 8307024 8307109 8866529 8866530 8303799 7136742 8303836 8307003 8866516 7138366 8303799 8305047 Qty.
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THROTTLE PEDAL CONTROL (Cummins) 3 4 9 1 5 10 8 11 6 12 20 2 19 7 6 15 13 18 14 16 17 PS0430 2.
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THROTTLE PEDAL CONTROL (Cummins) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number 8162003 8033178 8303615 8307002 8307109 8305402 8700116 8160073 8303837 8160610 8303799 8307024 8340034 7127091 8305650 8303790 8307025 7127102 8305002 8307003 Qty.
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THROTTLE PEDAL CONTROL (Perkins) 3 1 10 9 4 5 8 6 12 11 2 7 14 13 Throttle Lever For Reference Only 6 15 5 16 PS0470 2.
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THROTTLE PEDAL CONTROL (Perkins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8162003 8033178 8303615 8307002 8307109 8305402 8700116 8160073 7128252 8303837 8162213 8160610 8307003 8305002 8340034 8305650 Qty. 1 1 3 3 5 2 1 1 1 2 2 1 2 2 1 1 Description Pedal, Throttle (Includes Item 2) Bellows, Throttle Pedal HHCS, 1/4-20 x 1-1/4" Washer, Lock 1/4" Washer, Flat SAE 1/4 Narrow Nut, Hex Jam 1/4-28 NF Spring, Extension Cable, Throttle Bracket, Throttle Screw, Slotted Pan Hd.
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SERVICE BRAKE PEDAL MOUNTING See “Directional Control Valves” 1 8 7 6 5 3 2 4 PS0530 2.
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SERVICE BRAKE PEDAL MOUNTING Item No. Part Number 1 2 3 4 5 6 7 8 7128403 8305644 8307206 7129521 8303755 8307023 8303658 8307112 Qty. 1 2 2 2 4 4 2 2 Description Pedal, Service Brake Nut, Hex Lock Elastic 1/2-13 Washer, Flat 1/2" Pivot, Brake Pedal HHCS, M10-1,5 x 30mm Washer, Lock M10 HHCS, 1/2-13 x 2" Washer, Flat 1/2" Narrow 2.
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JOYSTICK MOUNTING 4 2 5 1 3 Torque to 8 lb/ft (11 Nm) 3 Places Front Dash for Reference Only PS0730 2.
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JOYSTICK MOUNTING Item No. Part Number 1 2 3 4 5 7133942 7133932 8035777 8303705 8307002 Qty. 1 1 1 3 3 Description Joystick Assembly (Includes Item 2 and 3) Handle Assembly Rubber Boot Flange Hd. Capscrew 1/4-20 x 3/4" Washer, Lock 1/4" 2.
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STEERING COLUMN, STEERING WHEEL & SHIFTER 1 2 17 18 16 17 15 14 3 13 4 12 6 10 11 9 8 7 5 Power Steering Valve See “Directional Control Valves” PS0541 2.
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STEERING COLUMN, STEERING WHEEL & SHIFTER Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8720017 8310315 8720016 8310350 7130763 7121523 8035803 8035804 8580118 8307003 8305003 8223029 7131961 8307005 8304672 8310359 8310372 7130753 Qty. 1 1 1 2 1 1 1 1 1 2 2 1 2 4 4 4 4 1 Description Cover, Horn Button Nut, Thin M18-1,5 Wheel, Steering Screw, Hex Socket Hd.
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CAB DOOR (Optional) 2 20 1 41 17 32 31 5 37 28 42 7 23 18 9 31 29 32 5 12 12 34 39 40 19 32 31 35 14 15 16 10 5 13 30 22 8 43 33 6 25 24 11 8 26 8 3 4 10 21 27 36 38 8 PS0860 2.
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CAB DOOR (Optional) Item No.
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CLOSED CAB - OUTER PANELS (Optional) 2 27 4 14 See Rear Window & Rear Windshield Wiper 31 5 24 3 1 6 26 31 7 13 25 9 8 7 8 9 10 12 7 8 11 5 6 4 6 28 6 16 23 33 5 4 15 30 18 5 29 4 PF0810 32 6 34 PF0810 17 PF0780 19 6 18 5 4 S/N 8373 and Before 20 19 21 20 22 21 Torque to 280 lb/ft. (380 Nm) PS0870 2.
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CLOSED CAB - OUTER PANELS (Optional) Item No. Part Number 1 2 3 4 NSS 7131412 7130663 8310301 5 8310124 6 7 8 9 10 11 12 13 14 8305906 8303670 8307004 7057141 7130653 8307203 8310067 7136342 8035474 8035606 8035524 7138234 8310353 7130643 7134453 8278026 7129441 8310375 8307010 7137733 8035294 8035721 8035525 8035527 8035526 8035528 8035529 8035490 8526042 8035523 8035723 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Qty.
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CLOSED CAB - INNER CONSOLE & DASH PANEL (Optional) Steering Weldment Inside Cab - Ref. Holder Is 10 11 Shown 18 Rotated For Clarity 9 21 30 24 2 8 1 22 6 7 Torque to 6-8 lb/ft (8-11 Nm) 20 16 6 5 13 30 30 40 17 16 13 42 26 17 16 30 30 2 13 2 19 35 4 39 30 30 39 2 3 37 13 16 17 36 31 30 39 32 33 29 23 25 38 39 27 12 13 26 14 15 34 28 43 2 2 41 PS0880 2.
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CLOSED CAB - INNER CONSOLE & DASH PANEL (Optional) Item No.
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CAB HEATER (Optional) 26 Seat Deck- Ref. 25 3 12 13 36 27 24 Apply Threadlocker 37 19 14 15 7 23 6 5 4 1 9 3 17 11 21 8 18 4 5 6 22 10 32 33 20 14 4 5 16 6 PS0890 32 Outboard Side of Engine 35 32 32 32 29 2 35 32 29 Inboard Side of Engine 38 39 31 34 PH0940 31 34 32 30 PERKINS ENGINE 28 32 CUMMINS ENGINE 2.
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CAB HEATER (Optional) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 8035412 8035413 8035414 8035415 8035416 8035417 8035418 8035419 8035420 8035421 8035422 8035423 8035424 8035425 8035426 8035388 8035427 8035428 8035429 8035430 8035431 8035397 8035432 8035433 8035389 8035434 8035435 7137741 7137751 7129881 8541036 8410009 8033032 8360005 8420201 8584018 8584001 8035406 8526036 Qty.
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FRONT WINDSHIELD WIPER (Optional) Wet Arm Kit Included in Item 10 43 37 Skylight Windshield Washer Pump Motor (Ref.) 41 36 35 38 40 Front Windshield Washer Pump Motor 36 39 30 34 21 33 9 23 18 1 42 44 19 32 20 10 18 27 28 PS0900 19 Cab (Ref.) 8 17 31 16 12 11 2 3 22 6 4 13 24 7 29 5 10 26 15 14 Kit PF0791 25 SUB-ASSEMBLY ROTATED FOR CLARITY 2.
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FRONT WINDSHIELD WIPER (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Part Number 8866492 NSS NSS NSS NSS NSS NSS NSS 8035408 8035393 8034815 NSS 8033856 NSS 8310029 8307052 8303839 NSS NSS 8035409 8305006 7112511 8033102 NSS NSS 8310002 NSS 8305005 8307203 8035411 8033110 8035391 91334019 8035394 8035392 8035395 8035410 8035531 8303670 8307203 8305626 8584001 7138250 8584018 Qty.
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SKYLIGHT WINDSHIELD WIPER (Optional) 9 10 8 Cab Ref. 9 9 11 13 3 7 1 6 12 5 4 2 14 16 18 Front Windshield Washer Pump Motor (Ref.) 15 13 17 11 Skylight Windshield Washer Pump Motor PS0910 2.
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SKYLIGHT WINDSHIELD WIPER (Optional) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8035492 8035493 8035390 8035494 8035495 8035496 8035497 8035498 8035499 8035500 8035501 8035502 8035503 8035504 8035505 8035410 8035531 7138250 Qty.
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REAR WINDOW & REAR WINDSHIELD WIPER (Optional) 26 27 36 28 27 29 35 1 Comes with Wiper Motor 33 Glass (Ref) 25 Kit 30 31 PF0791 Comes with Wiper Arm 32 3 5 4 34 23 8 11 24 6 7 8 21 9 23 22 13 2 15 10 16 17 12 18 19 14 Glass (Ref.) 20 PS0920 2.
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REAR WINDOW & REAR WINDSHIELD WIPER (Optional) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 8035606 8035474 8035475 8035476 8035414 8035477 8035478 8035468 8035479 8035480 8035481 8035482 8035483 8035484 8035485 8035486 8035415 8035416 8035487 8037206 8035488 8035489 8035490 8035491 8035506 8035507 8033087 8034803 8034805 8034808 8035500 8035508 8035509 8035510 8035511 8035501 Qty.
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SOFT CAB ENCLOSURE (Optional) 1 2 3 4 5 PS0840 2.
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SOFT CAB ENCLOSURE (Optional) Item No. Part Number 1 2 3 4 5 7135682 7136352 7136832 7136822 7136302 Qty. 1 1 1 1 1 Description Soft Cab Enclosure Kit - Complete (Includes Items 2 and 5) Soft Cab Enclosure Kit (Includes Items 3 & 4 plus Installation Instructions) Main Cab Enclosure - Soft Door Section- Soft Front Windshield Kit (Includes Installation Instructions) 2.
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FENDERS (Optional) 14 7 8 8 3 3 2 12 11 8 8 5 5 Torque to 222lb/ft (300 Nm) 10 10 6 Right Side 4 Left Side 9 13 15 PS0850 Front of Vehicle RIGHT SIDE SHOWN 1 17 16 Kit Kit Kit PF0791 2.
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FENDERS (Optional) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 7140600 7132653 7132921 7138350 8307005 7138351 8303675 8307110 8310388 8305008 8406201 7134922 8307049 8303621 8520031 7142800 7144500 Qty.
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SECTION 3 – DRIVE TRAIN DRIVE SHAFT - TRANSFER BOX TO FRONT AXLE 8 To Transfer Box 9 1 7 Apply Threadlocker and Torque to 83 lb/ft. (112,5 Nm) Typ. Both Ends 2 3 4 5 7 9 8 10 6 PH0940 3 This Is A Balanced Assembly, If Replacing Items 2, 4 or 6 Order Item1 2 To Front Axle PS0151 3.
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DRIVE SHAFT - TRANSFER BOX TO FRONT AXLE Item No. Part Number 1 2 3 4 5 6 7 8 9 10 7128952 NSS 8035106 NSS 8035109 NSS 8310297 8310356 8307025 8526036 Qty. 1 2 2 1 1 1 8 8 8 AR Description Drive Shaft Assembly (Consists of Items 2 thru 6) Yoke, Flange (See Note) Cross and Bearing Assembly Tube Assembly (See Note) Dust Cap Kit Yoke, Slip (See Note) HHCS, M12-1,75 x 35mm Washer, Flat M12 Hardened Washer, Lock M12 Threadlocker 242 General Purpose (.02 fl. oz.) NOTE: This is a balanced assembly.
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DRIVE SHAFT - TRANSFER BOX TO REAR AXLE 8 To Transfer Box 9 1 7 Apply Threadlocker and Torque to 83 lb/ft. (112,5 Nm) Typ. Both Ends 2 3 4 7 5 9 8 10 6 PH0940 3 2 This Is A Balanced Assembly, If Replacing Items 2, 4 or 6 Order Item1 To Rear axle PS0161 3.
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DRIVE SHAFT - TRANSFER BOX TO REAR AXLE Item No. Part Number 1 2 3 4 5 6 7 8 9 10 7128932 NSS 8035106 NSS 8035109 NSS 8310297 8310356 8307025 8526036 Qty. 1 2 2 1 1 1 8 8 8 AR Description Drive Shaft Assembly (Consists of Items 2 thru 6) Yoke, Flange (See Note) Cross and Bearing Assembly Tube Assembly (See Note) Dust Cap Kit Yoke, Slip (See Note) HHCS, M12-1,75 x 35mm Washer, Flat M12 Hardened Washer, Lock M12 Threadlocker 242 General Purpose (.02 fl. oz.) NOTE: This is a balanced assembly.
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DRIVE SHAFT - TRANSMISSION TO TRANSFER BOX 8 1 To Transfer Box 9 7 Apply Threadlocker and Torque to 83 lb/ft. (112,5 Nm) Typ. Both Ends 2 3 4 5 7 9 8 10 6 PH0940 3 This Is A Balanced Assembly, If Replacing Items 2, 4 or 6 Order Item1 2 To Transmission PS0171 3.
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DRIVE SHAFT - TRANSMISSION TO TRANSFER BOX Item No. Part Number 1 2 3 4 5 6 7 8 9 10 7128942 NSS 8035106 NSS 8035109 NSS 8310297 8310356 8307025 8526036 Qty. 1 2 2 1 1 1 8 8 8 AR Description Drive Shaft Assembly (Consists of Items 2 thru 6) Yoke, Flange (See Note) Cross and Bearing Assembly Tube Assembly (See Note) Dust Cap Kit Yoke, Slip (See Note) HHCS, M12-1,75 x 35mm Washer, Flat M12 Hardened Washer, Lock M12 Threadlocker 242 General Purpose (.02 fl. oz.) NOTE: This is a balanced assembly.
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TRANSFER BOX HOUSING AND COVERS 1 2 3 5 4 9 10 6 7 8 3 11 6 7 8 12 13 3 12 6 7 8 13 14 15 16 PS0190 3.
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TRANSFER BOX HOUSING AND COVERS Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number 8841031 8035240 8033626 8033631 8033623 8033628 8033629 8033630 8033627 8033622 8033604 8033618 8035241 8035242 8033624 8033625 Qty. 1 1 3 1 1 AR AR AR 1 1 3 2 8 1 1 1 Description Transfer Box Assembly (Consists of Items 2 thru 16) Housing, Transfer Box Bearing Washer Snap Ring Shim, 0,30mm Shim, 0,10mm Shim, 0,05mm O-ring Cover, Shaft Bolt, M12 x 30mm Cover Bolt, M8 x 22mm Shaft Ring, Oil Seal Bearing 3.
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TRANSFER BOX GEARS AND SHAFTS 1 9 10 11 2 12 15 14 13 23 22 24 18 15 14 13 19 25 12 26 3 27 28 29 4 20 6 5 7 21 16 8 12 2 17 2 PS0180 3.
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TRANSFER BOX GEARS AND SHAFTS Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Part Number 8841031 8035243 8033608 8033613 8033609 8033612 8033619 8033610 8035244 8033624 8033625 8033633 8033632 8033626 8033614 8033611 8033594 8033591 8033599 8033603 8033620 8033590 8033596 8033597 8033595 8035245 8033615 8033616 8033617 Qty.
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AXLE HOUSING - FRONT AXLE 1 31 27 Front Of Vehicle 6 14 2 28 10 11 3 2 33 30 9 27 36 32 28 34 6 35 37 29 4 20 27 15 4 7 5 13 8 12 21 2 22 16 2 9 23 18 17 19 25 24 26 PS0200 3.
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AXLE HOUSING - FRONT AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Part Number 8035114 8035115 8035116 8035117 8035118 8035119 8035120 8035121 8035122 8035123 8035124 8035125 8035126 8035127 8035128 8035129 8035130 8035131 8035132 8035133 8035134 8035135 8035136 8035137 8035138 8035139 8033582 8033561 8035140 8035141 8035142 8035143 8035144 8035145 8035146 8035147 8035148 Qty.
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AXLE HOUSING - REAR AXLE 31 27 6 14 11 28 2 10 2 9 30 1 27 3 6 7 32 28 29 4 13 27 20 15 12 5 4 21 2 16 8 2 22 23 9 18 Front Of Vehicle 17 19 25 24 26 PS0280 3.
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AXLE HOUSING - REAR AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Part Number 8035114 8035115 8035236 8035117 8035118 8035119 8035120 8035121 8035122 8035123 8035124 8035125 8035126 8035127 8035128 8035237 8035130 8035131 8035132 8035133 8035134 8035135 8035136 8035137 8035138 8035139 8033582 8033561 8035140 8035141 8035142 8035143 Qty.
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STEER CYLINDER AND SWIVELS - FRONT AXLE 18 1 20 19 2 17 3 8 10 16 21 22 4 5 6 7 18 19 23 26 24 25 11 12 13 14 10 9 15 Looking Toward Front of Vehicle (Input Side Of Axle) PS0210 3.
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STEER CYLINDER AND SWIVELS - FRONT AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part Number 8035149 8033510 8035302 8035150 8035303 8035249 8035248 8035152 8035151 8035304 8035250 8035252 8035305 8035152 8035254 8035151 8035152 8035251 8035253 8035153 8035154 8035155 8035156 8035157 8035158 8035159 8035255 8035256 8035223 91474088 Qty.
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STEER CYLINDER AND SWIVELS - REAR AXLE 18 1 19 20 16 2 3 8 17 21 22 10 4 5 6 7 18 19 23 26 24 25 9 14 13 12 11 10 15 Looking Toward Rear of Vehicle (Input Side Of Axle) PS0210 3.17 3606 Rev.
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STEER CYLINDER AND SWIVELS - REAR AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part Number 8035149 8033510 8035302 8035150 8035303 8035249 8035248 8035152 8035151 8035304 8035250 8035252 8035305 8033894 8035254 8035151 8035152 8035251 8035253 8035153 8035154 8035155 8035156 8035157 8035158 8035159 8035255 8035256 8035223 91474088 Qty.
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DIFFERENTIAL ASSEMBLY - FRONT AXLE 5 6 9 4 1 7 2 3 8 10 11 12 8 2 6 5 7 PS0230 3.
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DIFFERENTIAL ASSEMBLY - FRONT AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number 8035176 8035177 8035178 8035179 8035180 8035181 8035182 8035183 8033544 8035184 8035185 8035186 Qty. 1 4 2 1 2 2 2 2 12 2 10 8 Description Kit, Differential (Includes Items 2 and 3) Washer, Thrust Shaft Differential Housing - Two Halves Bolt, M6-1 x 10mm Plate, Locking Nut, Ring Bearing Bolt, M10-1,5 x 75mm Plate Plate, Drive Plate 3.
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BEVEL GEAR AND PINION SET - FRONT/REAR AXLES 19 18 3 4 5 6 20 21 1 2 5 22 17 17 7 8 9 10 11 12 13 14 15 16 PS0220 3.
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BEVEL GEAR AND PINION SET - FRONT/REAR AXLES Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 8035257 8035258 8033536 8033537 8033541 8033540 8035160 8035161 8035162 8035163 8035164 8035165 8035166 8035167 8035168 8035169 8035170 8035171 8035172 8035173 8035174 8035175 Qty.
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BRAKE ASSEMBLY - FRONT AXLE 19 20 21 22 8 11 10 9 14 12 15 13 16 2 17 2 1 18 3 4 5 6 5 6 5 6 7 PS0250 3.
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BRAKE ASSEMBLY - FRONT AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 8033575 8035196 8035197 8035198 8035199 8035200 8035201 8035216 NSS NSS NSS NSS NSS 8035207 8035208 8035209 8035210 8035211 8035212 8035213 8035214 8035215 Qty.
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BRAKE ASSEMBLY - REAR AXLE 8 12 11 10 9 13 1 2 3 4 5 6 14 7 PS0300 3.
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BRAKE ASSEMBLY - REAR AXLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number 8033575 8035196 8035197 8035198 8035199 8035200 8035201 8035216 NSS NSS NSS NSS NSS 8035239 Qty. 2 4 2 2 2 2 2 2 3 3 3 18 3 4 Description NOTE: Quantities listed below are for one complete axle Quadring Quadring Piston, Brake (Positive) Plate, Drive Disc, Brake Plate, Drive Sleeve Kit, Self-Adjust (Includes Items 9 thru 13) Washer, Belleville Pin, Split Spacer Washer, Belleville Bolt Plate, Drive 3.
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REDUCTION GEARS - FRONT/REAR AXLES 2 3 4 5 6 7 9 8 10 PS0270 3.
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REDUCTION GEARS - FRONT/REAR AXLES Item No. 1 2 3 4 5 6 7 8 9 10 11 Part Number 8035226 8035227 8035228 8035229 8035230 8035231 8035232 91474169 8035234 8033582 8035235 Qty. 6 6 6 6 6 17 6 2 1 2 4 Description NOTE: Quanties listed below are for one complete axle Bolt, M10-1,25 x 50mm Pin Washer, Thrust Washer, Thrust Gear, Planetary Bearing, Needle (sold in sets of ten - 168 bearings required) Washer, Thrust Planetary Carrier Assembly (Includes Item 8) Pad Plug, Oil M30-2 Bolt, M8 x 20mm 3.
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WHEEL HUB ASSEMBLY - FRONT/REAR AXLES 1 2 10 12 11 4 6 7 3 4 5 8 PS0260 9 3.
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WHEEL HUB ASSEMBLY - FRONT/REAR AXLES Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number 8035218 8035217 8035219 8030464 8035220 8035221 8035222 8030470 8035223 8035224 8035225 8033557 Qty. 2 10 2 4 2 2 2 16 16 20 20 2 Description NOTE: Quantities listed below are for one complete axle Wheel Hub Assembly (Includes Item 2) Stud O-Ring Bearing Lockring Carrier, Wheel Gear, Crown Z=77 Bushing, Centering Bolt, M14-1,5 x 65mm Washer Nut, M22-1,5 Seal, Cassette 3.
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AXLE SHAFTS - FRONT/REAR AXLES 1 2 5 4 3 8 5 9 7 6 4 PS0240 3.
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AXLE SHAFTS - FRONT/REAR AXLES Item No. 1 2 3 4 5 6 7 8 9 Part Number 8035187 8035188 8035189 8035190 8035191 8035192 8035193 8035194 8035195 Qty. 2 1 1 2 4 1 4 2 2 Description NOTE: Quanties listed below are for one complete axle Drive Shaft Assembly (Includes Items 2 thru 6) Shaft, Half - Differential Side Body, Central Spider Assembly (Includes Item 5) Snap Ring Shaft, Half - Wheel Side Washer, Thrust Washer Snap Ring 3.
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DIFFERENTIAL ASSEMBLY - REAR AXLE 1 10 5 9 6 2 7 3 8 4 6 7 2 4 5 8 PS0290 3.
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DIFFERENTIAL ASSEMBLY - REAR AXLE Item No. Part Number 1 2 3 4 5 6 7 8 9 10 8036488 8035177 8035178 8035238 8035180 8035181 8035182 8035183 8033544 8035179 Qty. 1 4 2 2 2 2 2 2 12 1 Description Kit, Differential (Includes Items 2, 3 and 4) Washer, Thrust Shaft Plate, Drive Bolt, M6-1 x 10mm Plate, Locking Nut, Ring Bearing Bolt, M10-1,5 x 75mm Differential Housing - Two Halves 3.
PAGE 84
TRANSMISSION CASE, PLATE & CONVERTER HOUSING (4 Speed) 42 1 33 32 25 41 40 21 39 25 34 32 31 2 3 4 4 38 3 4 24 3 5 33 36 31 6 7 6 35 21 7 37 26 8 28 17 12 16 10 21 30 29 14 21 27 9 15 26 3 4 4 3 13 24 11 12 25 4 21 18 23 22 19 21 22 21 43 4 20 4 PF0760 3 PS0010 3.
PAGE 85
TRANSMISSION CASE, PLATE & CONVERTER HOUSING (4 Speed) Item No. Part Number Qty.
PAGE 86
TORQUE CONVERTER AND DRIVE PLATES (4 Speed) 1 3 5 2 4 6 7 13 8 9 11 11 12 19 20 10 14 14 18 15 16 21 17 22 24 23 PF0760 PS0030 3.
PAGE 87
TORQUE CONVERTER AND DRIVE PLATES (4 Speed) Item No. Part Number Qty.
PAGE 88
CHARGING PUMP, DRIVE, FILTER & REVERSE IDLER (4 Speed) 12 13 12 11 13 9 14 15 10 9 16 8 1 7 4 3 1 17 18 6 2 19 21 5 23 22 24 35 37 25 26 34 20 36 38 27 28 31 30 29 32 33 39 40 PF0760 PS0940 PS0050 3.
PAGE 89
CHARGING PUMP, DRIVE, FILTER & REVERSE IDLER (4 Speed) Item No. Part Number Qty.
PAGE 90
FORWARD AND REVERSE SHAFT GROUP (4 Speed) 13 11 10 9 8 12 7 13 E 4 3 2 2 S ER V RE 6 2 17 3 2 1 14 15 5 5 2 16 17 2 21 18 2 3 20 19 15 14 20 2 16 22 3 7 8 11 9 10 F R WA R O D 25 12 24 23 26 PF0760 PS0070 3.
PAGE 91
FORWARD AND REVERSE SHAFT GROUP (4 Speed) Item No. Part Number Qty.
PAGE 92
FIRST AND SECOND SHAFT GROUP (4 Speed) 6 7 8 4 5 6 3 5 1 15 5 12 5 2 13 14 10 ST 21 FIR 19 11 16 25 17 9 19 18 6 20 5 18 5 6 23 17 10 16 24 5 22 5 9 11 ND O EC S 14 13 12 27 26 PF0760 PS0090 3.
PAGE 93
FIRST AND SECOND SHAFT GROUP (4 Speed) Item No. Part Number Qty.
PAGE 94
HIGH, THIRD AND OUTPUT SHAFT GROUP (4 Speed) 8 9 13 10 10 8 7 6 5 12 7 11 4 7 22 7 3 1 23 2 21 18 25 24 20 8 19 16 14 7 7 17 15 12 15 13 GH HI IRD TH 18 14 28 16 17 29 32 19 31 30 20 22 21 28 33 27 PF0760 26 PS0080 3.
PAGE 95
HIGH, THIRD AND OUTPUT SHAFT GROUP (4 Speed) Item No. Part Number Qty.
PAGE 96
OUTPUT SHAFT GROUP (4 Speed) 11 3 4 10 9 7 3 6 4 8 7 12 3 5 3 PF0760 2 1 PS0101 3.
PAGE 97
OUTPUT SHAFT GROUP (4 Speed) Item No. Part Number Qty.
PAGE 98
ELECTRIC CONTROL GROUP (4 Speed) 2 3 4 16 5 15 14 13 12 11 6 7 8 1 10 9 29 PF0760 24 17 27 18 25 28 26 21 22 23 19 22 20 PS0110 3.
PAGE 99
ELECTRIC CONTROL GROUP (4 Speed) Item No. Part Number Qty.
PAGE 100
WHEELS AND TIRES ! Warning Mis-Matched tire sizes, ply ratings or mixing of tire types (Radial and Bias ply) may compromise vehicle stability and may result in vehicle tipover. 1 Front Of Vehicle 5 3 2 6 7 4 8 PS0340 3.
PAGE 101
WHEELS AND TIRES Item No. Part Number 1 2 3 4 5 6 7 8 7128282 7128263 8780031 8786514 7128272 7128263 8780031 8786514 Qty. 2 1 1 1 2 1 1 1 Description Tire And Wheel Assembly, Right Side, 13.00-24, 12 Ply (Includes Items 2 thru 4) Wheel, 9024GR Tire, 13.00-24, 12 Ply Stem, Valve Tire And Wheel Assembly, Left Side, 13.00-24, 12 Ply (Includes Items 6 thru 8) Wheel, 9024GR Tire, 13.00-24, 12 Ply Stem, Valve 3.
PAGE 102
TRANSMISSION & TRANSFER BOX MOUNTING 5 4 1 3 2 6 7 8 Apply Item 9 Threadlocker to Threads of Item 8 9 PH0940 PS0351 3.
PAGE 103
TRANSMISSION & TRANSFER BOX MOUNTING Item No. Part Number 1 8841030 8841032 8303755 8307023 8307005 8303116 8310038 8841031 8307049 8310317 8526007 2 3 4 5 6 7 8 9 Qty. 1 1 12 12 8 8 8 1 4 4 AR Description Transmission - 4 Speed (Used On Cummins and Perkins Turbo Only) Transmission - 3 Speed (Used On Perkins Naturally Aspirated Only) HHCS, M10-1,5 x 30mm PC 8,8 Washer, Lock M10 Washer, Lock 3/8" HHCS, 3/8-24 x 2" NF Gr.8 (Perkins Engines Only) HHCS, 3/8-24 x 1-3/4" NF Gr.
PAGE 104
SECTION 4 – POWER PLANT ENGINE MOUNTING - CUMMINS (S/N 9179 and Before) Right Side of Engine 40 41 39 14 38 37 36 35 43 34 10 34 10 4 42 5 Supplied With Engine 3 2 33 1 15 14 32 12 13 14 15 16 17 6 28 7 14 8 20 9 31 10 30 29 20 19 18 14 19 28 11 26 27 19 44 25 46 45 24 23 PS0940 PS0950 Torque to 180 lb/ft (244 Nm) 21 22 Torque to 60 lb/ft (81 Nm) PS0361 4.
PAGE 105
ENGINE MOUNTING - CUMMINS (S/N 9179 and Before) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Qty.
PAGE 106
ENGINE MOUNTING - CUMMINS (S/N 9180 and After) Right Side of Engine 31 32 4 5 3 Supplied With Engine 33 30 2 34 1 11 10 28 8 24 6 9 10 7 10 27 16 11 15 12 13 14 26 25 29 10 16 24 35 23 15 22 21 37 17 20 36 PS0940 PS0950 19 Torque to 180 lb/ft (244 Nm) 18 Torque to 60 lb/ft (81 Nm) PS0980 4.
PAGE 107
ENGINE MOUNTING - CUMMINS (S/N 9180 and After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Part Number Qty.
PAGE 108
RADIATOR AND OIL COOLER (Cummins) 34 1 40 30 35 37 38 39 8 33 32 31 30 29 28 4 36 2 20 3 27 4 5 25 20 8 18 19 21 22 25 6 10 7 26 23 11 9 17 16 24 7 12 13 13 14 7 15 PS0371 4.
PAGE 109
RADIATOR AND OIL COOLER (Cummins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 7131952 7132002 7131443 7132012 7129973 8278024 7057141 8305626 8278023 7130131 7130042 8310104 8307204 8305645 8305603 7130422 8303621 8278008 7131253 8405104 8310026 8307109 7130532 8305624 8405203 7126693 7126703 7126514 8180311 8307106 8307004 8303697 7085422 8866341 7130052 8580420 8307202 8307002 8303743 4108981 Qty.
PAGE 110
EXHAUST SYSTEM (Cummins) 11 10 To Engine Exhaust Manifold 12 9 1 2 3 4 8 5 7 6 6 6 PS0131 4.
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EXHAUST SYSTEM (Cummins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 8275240 7128102 8405209 8275037 7128092 8275212 8275036 7128072 8310412 8307006 8310415 7128142 Qty. 1 1 2 1 1 2 1 1 1 1 1 1 Description Clamp, V-Band Pipe, Exhaust Clamp, T Bolt Band - Heavy Duty Bellows, Exhaust Pipe, Exhaust Clamp, Muffler 2-1/2" Heavy Duty Muffler, Exhaust Pipe, Tail Exhaust HHCS, 7/16-14 x 1-3/4" Gr. 5 Washer, Lock 7/16" Nut, Hex 7/16-14 Clamp, Muffler - Welded 4.
PAGE 112
AIR CLEANER (Cummins) 14 15 5 19 20 16 4 19 17 18 6 7 8 3 9 2 11 1 10 12 13 21 PS0940 PS0420 4.
PAGE 113
AIR CLEANER (Cummins) Item No. Part Number Qty.
PAGE 114
FUEL SYSTEM (Cummins) Engine Rotated For Clarity 1 3 20 4 18 2 5 17 19 3 6 3 29 16 3 3 12 13 11 29 8 34 9 18 15 3 21 11 14 10 3 22 32 30 7 28 33 23 33 31 27 24 3 25 25 32 32 26 PH0940 35 36 PS0950 PS0940 PS0442 4.
PAGE 115
FUEL SYSTEM (Cummins) Item No. Part Number Qty.
PAGE 116
ENGINE MOUNTING (Perkins Natural & Turbo) 30 Supplied With Engine 29 28 1 25 26 Supplied With Engine 27 3 2 23 18 4 19 24 5 6 7 11 10 8 10 9 22 21 20 11 10 Supplied With Engine 19 18 17 16 10 9 31 32 12 15 PS0950 PS0940 14 Torque to 180 lb/ft (244 Nm) 13 Torque to 60 lb/ft (81 Nm) PS0501 4.
PAGE 117
ENGINE MOUNTING (Perkins Natural & Turbo) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Qty.
PAGE 118
RADIATOR AND OIL COOLER (Perkins Natural & Turbo) 33 38 39 30 34 32 31 30 29 28 27 4 37 36 8 1 35 18 2 3 4 24 5 26 19 17 8 20 21 24 25 22 15 23 7 6 10 7 12 9 16 13 11 13 14 7 14 PS0491 4.
PAGE 119
RADIATOR AND OIL COOLER (Perkins Natural & Turbo) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 7131952 7132002 7131443 7132012 7129973 8278024 7057141 8305626 8278023 7130131 7130042 8310104 8307204 8305645 7130422 8303621 8278008 7131253 8405104 8310026 8307109 7130532 8305624 8405203 7133383 7119613 7119744 8180311 8307106 8307004 8303697 7085422 8866341 7130052 8580420 8307202 8307002 8303743 4108981 Qty.
PAGE 120
EXHAUST SYSTEM (Perkins Natural & Turbo) 11 1 10 12 9 2 Exhaust Manifold 3 4 8 3 7 6 5 6 6 PS0141 4.
PAGE 121
EXHAUST SYSTEM (Perkins Natural & Turbo) Item No. Part Number 1 7128342 7132722 8866471 8405209 8275037 7128332 7132732 8275212 8275036 7128072 8310412 8307006 8310415 7128142 2 3 4 5 6 7 8 9 10 11 12 Qty.
PAGE 122
AIR CLEANER (Perkins Natural & Turbo) 21 20 Perkins Natural Air Cleaner Mounting Perkins Turbo Air Cleaner Mounting Lift Hook (Ref.) 22 5 19 4 14 15 17 18 16 6 2 3 7 8 10 9 11 13 1 12 23 PS0940 PS0481 4.
PAGE 123
AIR CLEANER (Perkins Natural & Turbo) Item No. Part Number 1 2 3 4 5 6 7 Qty.
PAGE 124
FUEL SYSTEM (Perkins Natural & Turbo) 7 5 38 8 38 38 10 9 11 4 10 1 3 38 12 2 32 10 13 30 14 29 6 31 28 15 6 25 23 24 22 10 21 20 42 40 43 16 19 6 26 23 33 34 6 41 35 18 44 PS0950 30 27 36 6 17 40 17 40 37 39 PH0940 PS0940 PS0452 4.
PAGE 125
FUEL SYSTEM (Perkins Natural & Turbo) Item No. Part Number Qty. Description Separator, Fuel/Water HHCS, 5/16-18 x 1-1/4" Washer, Flat 5/16" Narrow Nut, Hex Lock Elastic 5/16-18 Union, 5/16" -13/32" Tube Clamp, Hose, SAE Type F Hose, Fuel 3/8 x 4" Strainer, Fuel Hose, Fuel 3/8 x 68" (Fuel Supply From Tank) Clamp, Hose, Minature 7/32" Dia.
PAGE 126
COLD START KIT (Cummins) RIGHT SIDE OF ENGINE 11 1 Ground Wire From Thermostat Seat Riser Inside Cab - Ref. 18 12 8 13 17 2 13 10 9 7 5 6 13 3 4 14 13 7 PS0990 PS0991 Engine Block Thermostat Momentary Switch Starter Relay Ether Cylinder Ground Wire 4.
PAGE 127
COLD START KIT (Cummins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8310026 8277098 8303725 8307113 8303533 8307025 7138529 8277101 7138531 8584018 8310002 8530024 8584001 8310109 8229244 7138538 8223454 8305624 Qty. 2 1 2 2 1 1 1 1 1 3 2 1 8 2 1 1 1 2 Description HHCS, 1/4-20 x 3/4" Cylinder, Ether Fluid 18oz. HHCS, 7/16-14 x 3/4" Gr.
PAGE 128
SECTION 5 – HYDRAULIC CIRCUITS POWER STEERING CIRCUIT 33 24 34 25 42 Auxiliary Function Valve 12 43 17 T 12 27 P PS 41 P PS T G 14 19 PP PP 28 G 9 18 19 13 18 A Unloader Valve 30 15 16 VIEW FROM REAR OF VEHICLE 40 33 PB B 34 12 Rear Axle 29 UNDERSIDE VIEW 21 11 32 35 37 10 9 20 27 25 24 15 48 29 28 30 31 38 52 39 53 54 21 46 48 52 29 47 15 44 35 32 37 30 55 28 22 25 27 Case 52 15 46 47 49 51 51 46 46 23 4 5 49 32 36 31 45 15 51 46 46 49 49
PAGE 129
POWER STEERING CIRCUIT Item No.
PAGE 130
UNLOADER VALVE CIRCUIT 23 21 10 15 5 Oil Cooler 10 Load Sense Port 3 5 4 35 34 18 1 23 35 VIEW FROM REAR 16 29 6 9 36 21 7 9 38 37 Hydraulic Reservoir 40 11 40 25 26 27 9 20 22 22 20 7 13 14 2 11 13 20 20 22 8 Auxiliary Function Manifold 12 22 32 6 11 13 32 25 Front Of Vehicle 33 30 31 28 Torque to Maximum 20 lb/ft. (27 Nm) 17 Load Sense Port Bypass Port Primary Port 2 Aux. Supply Port 39 19 24 Inlet Port PS0671 5.
PAGE 131
UNLOADER VALVE CIRCUIT Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 8440154 8904056 7054902 8405210 2715512 2715502 2716517 2715482 2715472 8530036 8530035 8530030 8630008 8640123 8630009 8770078 8307203 8307206 8307004 8307005 8307007 8303675 8303626 8310380 8430032 8430081 8770112 8035288 8770084 8430082 8770126 2715462 8770116 8770106 2715102 8770079 8770132 2716547 8307106 8584003 Qty.
PAGE 132
BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT 4 Port “R” 8 4 8 See “Extend Cylinder” Port “E” 5 Bulkhead (Ref.) 3 5 4 1 2 7 4 6 Port “R” 3 7 Port “L” 3 2 8 6 5 3 Front Of Vehicle See “Hoist Cylinder” Boom Raise Port Boom Lower Port Boom Retract Port Boom Extend Port PS0690 PS0461 5.
PAGE 133
BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT Item No. 1 2 3 4 5 6 7 8 Part Number 2715072 2715062 2715052 2715042 8770079 8770085 8770086 8770070 Qty. 1 1 2 2 3 2 2 5 Description Hose, 3/4" I.D. x 21-1/2" Long Hose, 3/4" I.D. x 27" Long Hose, 3/4" I.D. x 45" Long Hose, 3/4" I.D. x 36" Long Elbow, 90°, SAE 12 - str. thd. ORB x o-ring face seal Nut, Bulkhead, SAE 12 - o-ring face seal Connector, Bulkhead, SAE 12 - o-ring face seal Connector, SAE 12 - str. thd. ORB x o-ring face seal PS0830 5.
PAGE 134
ATTACHMENT TILT AND SLAVE CIRCUIT 13 15 6 20 23 11 Inner Boom 24 7 3 10 16 26 3 5 23 25 Inner tube at bulkhead 19 15 16 Inner tube under boom 11 Outer tube at bulkhead 16 24 14 7 17 22 Front Of Vehicle 15 22 Outer tube under boom 14 21 29 18 29 29 21 See “Main Control Valve” or “Valve Plate Assembly” 22 To Attachment Tilt Cylinder 3 Attachment Tilt Cylinder 3 28 27 1 1 22 20 22 20 29 17 1 4 2 27 8 9 12 2 RH 18 28 2 LH PS0390 PS0711 5.
PAGE 135
ATTACHMENT TILT AND SLAVE CIRCUIT Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 2715222 2715132 2715372 7132402 8750016 8769136 8303715 8307202 8305624 8305626 8769123 8770074 8770076 8770072 7134062 7134072 7132312 7132302 8310357 8770075 8770115 2715292 8750014 8307004 8769128 8750009 8770124 8770118 8770114 Qty. 2 2 2 1 1 2 4 2 2 1 4 2 2 2 1 1 1 1 1 4 2 2 4 4 1 1 2 2 4 Description Hose, 1/2" I.D. x 33-1/2" Long Hose, 1/2" I.D.
PAGE 136
FRAME TILT & STABILIZER CIRCUIT (S/N 9883 and Before) 23 See “Control Valve Assy.” or “Valve Plate Assembly” 16 8 20 17 17 22 21 18 NOTE: With Optional Auxiliary Hydraulics, a Tee replaces the 90° Elbow (See Item 17). 8 VIEW FROM REAR OF VEHICLE 4 7 5 11 19 4 7 5 41 39 37 32 4 33 34 35 35 38 3 34 6 6 PH0940 31 26 43 4 14 12 FT B 2 FT R 35 33 8 42 43 36 40 Front Of Vehicle 9 38 13 25 NOTE: Apply Item 42 to threads and torque to 37 lb/ft.
PAGE 137
FRAME TILT & STABILIZER CIRCUIT (S/N 9883 and Before) Item No.
PAGE 138
FRAME TILT & STABILIZER CIRCUIT (S/N 9884 and After) 23 See “Control Valve Assy.” or “Valve Plate Assembly” 16 8 20 17 17 22 21 18 NOTE: With Optional Auxiliary Hydraulics, a Tee replaces the 90° Elbow (See Item 17).
PAGE 139
FRAME TILT & STABILIZER CIRCUIT (S/N 9884 and After) Item No.
PAGE 140
SERVICE BRAKE & DE-CLUTCH CIRCUIT Front Of Vehicle 10 T 14 9 7 6 9 13 6 VIEW FROM REAR 8 12 Port “T” VIEW FROM REAR OF VEHICLE 8 30 Hydraulic Reservoir 14 2 Rear Axle 26 30 24 12 17 12 16 21 20 11 7 13 15 2 1 14 27 25 17 22 23 18 28 16 16 25 22 16 19 23 22 29 22 23 2 18 1 17 13 16 23 25 16 Shuttle Valve (Ref.) 18 3 4 6 Front Axle Front Of Vehicle 5 5.
PAGE 141
SERVICE BRAKE & DE-CLUTCH CIRCUIT Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Part Number 8902164 8770068 8770111 8770105 8430081 8430032 8902169 8770106 8430043 8770114 7129582 2715452 2715442 2715402 2715392 2715342 2715212 2715202 2715192 8770091 8770093 8770097 8770100 8770116 8902691 8770069 8770096 8770095 8770098 2715262 Qty. 1 1 1 1 1 3 1 2 2 1 1 1 1 1 1 3 1 1 1 1 1 7 4 1 6 1 1 1 1 1 Description Valve, Brake Elbow, 90°, SAE 6 - str. thd.
PAGE 142
VALVE PLATE ASSY. w/o AUX. HYDRAULICS 26 41 40 27 34 29 21 22 16 43 35 39 30 11 31 12 37 36 17 18 7 15 15 5 7 16 4 28 28 30 32 33 FRAME 9 6 19 Front Of Vehicle 3 17 12 See “Directional Control Valves” 6 See “Main Control Valve” 2 6 17 8 15 13 1 23 24 19 25 38 21 27 10 19 20 7 Front Of Vehicle 12 42 15 15 14 12 6 12 3 16 8 6 14 42 6 7 15 6 19 16 16 13 7 6 12 14 15 17 17 17 15 6 7 19 15 7 44 REAR VIEW OF VALVE PLATE AND VEHICLE 5.
PAGE 143
VALVE PLATE ASSY. w/o AUX. HYDRAULICS Item No.
PAGE 144
VALVE PLATE ASSY. w/ AUX.
PAGE 145
VALVE PLATE ASSY. w/ AUX. HYDRAULICS Item No. Part Number 1 2 Qty. Description 29 30 8902174 7137104 7132453 8307005 8303675 8303681 2716012 2716022 2716042 2716052 2716062 2716072 7133051 8770068 8770125 8770111 8770106 8770105 8770108 8770047 8770137 8035101 8035104 8430082 8430032 8902181 8307202 8307002 8303758 8303090 8305004 8305008 1 1 1 3 3 2 1 1 1 1 1 1 1 4 3 3 2 5 3 2 1 1 1 1 1 1 2 2 2 2 2 5 Valve, Auxiliary Control Bracket, Auxiliary Control Valve Mtg.
PAGE 146
TRANSMISSION COOLING CIRCUIT (Cummins) 2 1 5 3 4 13 12 7 3 Attach Item 7 With Top Mtg. Bolt of Pump 3 Engine Mount (Ref.) 10 5 6 4 7 11 8 9 PS0741 Front Of Vehicle 5.
PAGE 147
TRANSMISSION COOLING CIRCUIT (Cummins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 7126514 8180311 8770070 2715422 2715362 8584003 8406302 8307025 8310164 8770083 8770081 8770077 8770080 Qty. 1 1 3 1 1 1 2 1 1 1 1 1 1 Description Radiator Assembly (Includes Item 2) Cap, Radiator - 13 psi (89,6 kPa) Connector, SAE 12 - str. thd. ORB x o-ring face seal Hose, 3/4 I.D. x 41" Long Hose, 3/4 I.D. x 62-1/2" Long Tie Wrap Clip, Tube 1-1/4" Dia.
PAGE 148
TRANSMISSION COOLING CIRCUIT (Perkins) 2 1 3 4 3 5 6 10 5 9 7 8 Front Of Vehicle 3 8 4 PS0751 5.
PAGE 149
TRANSMISSION COOLING CIRCUIT (Perkins) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 7119744 8180311 8770070 2715362 2715432 8584003 8770081 8770083 8770077 8406302 Qty. 1 1 3 1 1 1 2 2 1 1 Description Radiator Assembly (Includes Item 2) Cap, Radiator - 13 psi (89,6 kPa) Connector, SAE 12 - str. thd. ORB x o-ring face seal Hose, 3/4" I.D. x 62-1/2" Long Hose, 3/4" I.D. x 41" Long Tie Wrap Cap, SAE 12 - o-ring face seal Tee, Swivel Run, SAE 12 - o-ring face seal Connector, SAE 12-10 - str. thd.
PAGE 150
AUXILIARY HYDRAULIC CIRCUIT (Optional) 15 31 12 11 13 11 12 31 15 19 22 3 10 20 7 21 Front Of Vehicle 18 4 10 6 Auxiliary Hydraulics Bulkhead 8 14 3 5 4 33 23 6 9 36 29 30 40 7 14 2 17 16 39 See “Valve Plate Assembly With Auxiliary Hydraulics” 37 34 1 35 40 39 41 42 43 23 38 23 38 26 25 24 28 27 32 44 43 36 41 44 32 37 PS0521 5.
PAGE 151
AUXILIARY HYDRAULIC CIRCUIT (Optional) Item No.
PAGE 152
JOYSTICK CIRCUIT 5 1 Front Of Vehicle UNDERSIDE 9 8 2 2 3 6 5 4 8 Pilot Select Valve 7 6 10 Auxiliary Function Valve 9 8 7 8 VIEW FROM REAR OF VEHICLE See “Valve Plate Assembly” Port “PP” 11 4 5 6 Front Of Vehicle PS0760 5.
PAGE 153
JOYSTICK CIRCUIT Item No. 1 2 3 4 5 6 7 8 9 10 11 Part Number 7133942 8770106 8770107 2715272 2715312 2715302 8770111 8770108 8770112 8770068 8770103 Qty. 1 4 1 1 2 2 2 4 2 2 1 Description Valve, Joystick Connector, SAE 6 - str. thd. ORB x o-ring face seal Connector, Long, SAE 6 - str. thd. ORB x o-ring face seal Hose, 3/8" I.D. x 67" Long Hose, 3/8" I.D. x 120-1/2" Long Hose, 3/8" I.D. x 116" Long Tee, Swivel Run, SAE 6 - o-ring face seal Cap, SAE 6 - o-ring face seal Tee, Branch, SAE 6 - str. thd.
PAGE 154
SECTION 6 – HYDRAULIC COMPONENTS MAIN PUMP 3 2 1 5 6 8 5 4 5 6 7 9 10 9 11 8 5 6 10 15 16 12 6 14 13 7 PF0760 PF0760 PS0020 6.
PAGE 155
MAIN PUMP Item No. Part Number Qty.
PAGE 156
DIRECTIONAL CONTROL VALVES 2 Optional Auxiliary Hydraulics Only 4 8 6 7 8 1 7 8 9 5 6 10 18 3 P2 FT B G2 P3 19 P1 20 FT R G1 FT R 21 13 26 22 14 27 11 P PS T 23 G PS PP PP G 28 G PB PB 15 25 29 PF0760 17 24 16 PS0400 6.3 3606 Rev.
PAGE 157
DIRECTIONAL CONTROL VALVES Item No. Part Number 1 2 3 4 5 6 8902170 8640017 8902175 8902272 8035101 8908701 7 8 8035103 8035104 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Qty.
PAGE 158
UNLOADER VALVE 2 Torque to Maximum 20 lb/ft. (27 Nm) 3 4 8 5 6 1 7 PS0510 6.5 3606 Rev.
PAGE 159
UNLOADER VALVE Item No. Part Number 1 2 3 4 5 6 7 8 8904056 N.S.S. N.S.S. N.S.S. N.S.S. N.S.S. N.S.S. N.S.S. Qty. 1 1 1 1 1 1 1 1 Description Valve, Unloader (Includes Items 2 thru 8) Cap O-Ring Spring, Spool Spacer, Tube Spool Housing, Valve Relief Valve Assembly - Preset at 3500 psi ± 100 psi (241 bar ± 7 bar) 6.
PAGE 160
SLAVE CYLINDER 1 Torque to 250-300 lb/ft. (339-407 Nm) 14 15 11 10 13 7 12 Apply Loctite #271and Torque to 445-515 lb/ft. (603-698 Nm) 9 8 6 3 4 5 PF0760 16 2 PS0560 6.7 3606 3606Origin Rev.
PAGE 161
SLAVE CYLINDER Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2714503 NSS 8037080 See Kits 8035329 See Kits See Kits See Kits See Kits 8035330 See Kits See Kits See Kits See Kits 8035331 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Cylinder, Slave (Includes Items 2 thru 15) Tube Nut, Lock 1.
PAGE 162
FRAME TILT/STABILIZER CYLINDER 1 Torque to 300-400 lb/ft. (407-542 Nm) 14 15 10 16 9 8 13 12 11 Apply Loctite #271 and Torque to 1100-1250 lb/ft. (1492-1695 Nm) 7 6 4 5 4 3 17 PF0760 2 PS0570 6.
PAGE 163
FRAME TILT/STABILIZER CYLINDER Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 7134593 N.S.S. 8035322 See Kits 8035323 See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits 8035324 See Kits 8035328 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Cylinder, Frame Tilt/Stabilizer (Includes Items 2 thru 16) Tube Nut, Lock 1.
PAGE 164
ATTACHMENT TILT CYLINDER 17 1 Torque to 300-400 lb/ft. (407-542 Nm) 16 14 18 17 8 Apply Loctite #271 and Torque to 1100-1250 lb/ft. (1492-1695 Nm) 12 13 15 11 10 9 3 5 6 2 7 19 5 4 2 Torque to 30-35 lb/ft. (41-47 Nm) - 2 Places 20 PF0760 PS0580 6.
PAGE 165
ATTACHMENT TILT CYLINDER Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2715722 8035321 NSS 8035322 See Kits 8035323 See Kits See Kits See Kits See Kits See Kits See Kits See Kits 8035324 See Kits See Kits 7089722 8035325 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 Cylinder, Attachment Tilt w/Bushings (Includes Items 2 thru 18) Counterbalance Valve - Set at 4000 psi (276 bar) Tube Nut, Lock 1.
PAGE 166
HOIST CYLINDER 11 1 10 Apply Loctite #271 and Torque to 1550-1750 lb/ft. (2102-2373 Nm) 1 12 Orient Fracture In Bearing Race at Clock Position Shown 2 9 3 Hoist Cylinder 4 8 7 6 5 17 8 7 E 6 3 4 5 19 16 5 18 15 20 13 12 10 9 14 E 15 2 Torque to 45-50 lb/ft (61-68 Nm) 11 21 Torque to 300-400 lb/ft (407-542 Nm) PF0760 PS0590 6.
PAGE 167
HOIST CYLINDER Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2716562 8902271 N.S.S. 8035308 See Kits 8035309 See Kits See Kits See Kits See Kits See Kits See Kits See Kits 8035310 See Kits See Kits 8065640 8035311 8520013 1 1 1 1 2 1 1 1 1 1 1 2 1 1 2 1 1 1 1 Cylinder, Hoist w/Bearing (Includes Items 2 thru 18) Counterbalance Valve - Set at 4000 psi (276 bar) Tube Nut, Lock 2.
PAGE 168
EXTEND CYLINDER Apply Loctite #271 and Torque to 1500-1700 lb/ft. (2034-2305 Nm) 18 Torque to 150-160 lb/ft. (203-217 Nm) 1 Torque to 250-300 lb/ft. (339-407 Nm) 15 Torque to 72-82 lb/in. (8-9 Nm) 12 16 17 18 14 13 11 10 5 9 2 7 3 4 6 6 20 8 19 21 PF0760 PS0600 6.
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EXTEND CYLINDER Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2716253 See Kits See Kits 8035314 8035315 See Kits See Kits 8035316 See Kits See Kits See Kits See Kits See Kits 8035317 See Kits See Kits 8035318 8035293 NSS 1 2 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 2 1 Cylinder, Extend (Includes Items 2 thru 19) Hytrel Backup Ring O-Ring Piston Setscrew 5/16-18 UNC x .
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SWING CARRIAGE CYLINDER (Optional) 3 2 1 4 Apply Locktite #271 to Inside Threads Torque to 250 lb/ft. (339 Nm) 11 Retract Port 5 6 7 “X” Port 14 Extend Port 8 15 9 Torque to 30-35 lb/ft. (40,7-47,5 Nm) 13 16 10 PF0760 17 12 PH0441 6.
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SWING CARRIAGE CYLINDER (Optional) Item No. Part Number Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2713363 N.S.S.
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SIDE TILT CARRIAGE CYLINDER (Optional) 13 1 14 4 5 12 11 9 3 10 6 15 Torque to 30-35 lb/ft. (40,7-47,5 Nm) 15 2 Apply Locktite #271 to Threads and Torque to 350 lb/ft. (474,6 Nm) and Stake 4 Places 8 7 Extend Port Retract Port 16 PF0760 17 PH0800 6.
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SIDE TILT CARRIAGE CYLINDER (Optional) Item No. Part Number Qty.
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HYDRAULIC RESERVOIR 4 12 1 4 5 12 3 13 14 7 S/N 10016 and Before 6 3 12 9 3 1 2 15 11 8 Torque to 4-5 lb/ft. (5 - 7Nm) Front Of Vehicle 16 10 PS0940 PS0721 6.
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HYDRAULIC RESERVOIR Item No. 1 2 3 4 Part Number Qty.
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MAIN CONTROL VALVE (Boom Raise/Lower & Extend/Retract Sections) Attachment Tilt and Frame Tilt Sections for Reference Only 1 24 14 25 24 37 25 10 26 16 14 11 39 27 12 13 15 20 17 6 18 38 42 19 28 21 27 4 2 19 20 7 3 9 40 41 23 11 22 21 8 43 44 23 5 PF0760 36 30 29 31 29 27 28 33 30 34 32 35 PS0770 6.
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MAIN CONTROL VALVE (Boom Raise/Lower & Extend/Retract Sections) Item No. Part Number Qty.
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MAIN CONTROL VALVE (Attachment Tilt & Frame Tilt Sections) 38 39 PF0760 1 7 14 14 17 4 8 13 2 27 13 3 12 15 20 21 16 5 12 23 18 11 19 22 25 24 11 6 9 10 24 26 16 Boom Raise/Lower & Extend/Retract Sections for Reference Only 29 30 37 31 27 36 28 33 35 32 34 PS0780 6.
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MAIN CONTROL VALVE (Attachment Tilt & Frame Tilt Sections) Item No. Part Number Qty.
PAGE 180
SECTION 7 – ELECTRICAL ELECTRICAL SYSTEM - CAB HARNESS (S/N 8249 and Before) 4 3 5 2 35 34 1 6 10 11 8 33 7 9 11 36 12 31 32 8 19 22 29 28 27 26 13 9 11 20 24 23 25 24 30 21 16 17 22 15 14 37 18 24 PS0790A 7.
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ELECTRICAL SYSTEM - CAB HARNESS (S/N 8249 and Before) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 7133774 8270621 8305624 8307109 7130682 8223025 8220346 8310358 8580421 8223037 8223046 8220345 8223036 8310366 8467017 8310300 8223436 8223438 8229233 8229238 8229237 8225117 8303837 8307111 8303836 8310085 8307202 8307002 8305004 8584003 8305439 8307024 8270620 8406302 8305644 8223048 7133783 Qty.
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ELECTRICAL SYSTEM - CAB HARNESS (S/N 8250 and After) 3 5 4 2 34 33 32 30 31 1 6 11 7 8 9 11 13 8 22 21 20 (13) Places 27 28 29 36 37 11 17 22 9 18 19 16 15 36 37 23 24 25 26 SIDE VIEW OF STEERING WELDMENT 14 38 12 39 40 41 35 10 PS0791 7.
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ELECTRICAL SYSTEM - CAB HARNESS (S/N 8250 and After) Item No.
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ELECTRICAL SYSTEM - ENGINE HARNESS 17 23 24 20 22 21 18 19 22 23 21 17 26 20 19 18 15 25 16 16 15 14 14 Perkins Cummins 11 3 10 9 12 8 13 7 6 1 3 4 2 5 PS0801 7.
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ELECTRICAL SYSTEM - ENGINE HARNESS Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 7130444 7132042 8305645 8406302 8305644 8307204 8305603 8270135 8270136 8310318 7129501 8270134 8270137 8223228 8223229 8223533 8223529 8305004 8307002 8305003 8310026 7138510 8277162 8305624 8223045 8035276 8036479 8035719 Qty.
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ELECTRICAL SYSTEM - CLOSED CAB 8 14 5 3 16 13 CabDoor Opening (Ref.) 4 15 2 21 7 Window Motor 11 Light Package (A) 11 Light Package (B) 20 30 6 25 Blower Motor 7.5 10 20 7.5 7.5 7.5 8 Front Wiper 8 Skylight Wiper 8 Rear Wiper 8 Switch Lamps 1 9 9 Power Accessory Power Window Motor Starter (Ref.) 12 20 19 17 18 PS0960 7.
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ELECTRICAL SYSTEM - CLOSED CAB Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7135694 8501046 8223044 8223043 8223040 8229247 8229245 8229243 8225117 7133732 8229246 8035456 8582008 8229244 8229247 8229245 6621412 8303620 8307110 8305645 7138250 Qty. 1 1 1 1 1 1 1 5 2 1 2 1 4 1 1 1 1 1 1 1 1 Description Harness, Closed Cab Switch, Headlight/Worklight Switch, Front Washer Switch, Front Wiper Switch, Skylight Wiper/Washer Mini-Fuse, 25 Amp Mini-Fuse, 30 Amp Mini-Fuse, 7.
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LIGHTING SYSTEM (Optional) Steering Column 6 9 6 9 11 For Use In Booms W/O Weld Studs, Use Item 29 thru Wearpad to Mount Item 7- Apply Threadlocker-Item 32 25 23 30 18 29 1 14 24 22 8 32 10 28 24 Weld Studs 13 14 3 PH0940 24 25 7 17 12 25 15 30 14 4 26 27 24 25 PS0930 31 24 1 14 1 30 TO TURN SIGNAL SWITCH 14 2 TO HEADLIGHT SWITCH 19 TO FUSE BLOCK 20 TO CAB GRD.
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LIGHTING SYSTEM (Optional) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 7129722 7137411 7137374 7138369 8303735 8307112 7133242 7133312 8500009 8501046 8305604 7138367 8500036 8500060 8305645 8229245 8307110 7131961 8303632 8307207 8305643 8310387 8501045 8584001 8584018 7134671 8582426 7138493 8303620 7138368 8229246 8526036 Qty.
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SECTION 8 – DECALS AND PAINT DECALS AND PAINT (Early Production) 8 17 22 23 24 6 A 7 10 13 11 B 4 25 26 27 19 14 15 1 16 5 28 12 21 18 11 20 3 10 2 17 29 30 31 18 9 35 32 33 34 lK ca De it PF0790 PF0770 PF0780 PS0620 8.
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DECALS AND PAINT (Early Production) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number Qty.
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DECALS AND PAINT (Current Production) 7 16 21 22 23 5 A 6 9 12 10 B 4 24 25 26 18 13 14 1 15 27 11 20 17 10 19 3 9 2 16 28 29 30 17 8 34 31 32 33 it lK ca De PF0790 PF0770 PF0780 PS0621 8.
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DECALS AND PAINT (Current Production) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number Qty.
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SECTION 9 – BOOM AND ATTACHMENTS INNER BOOM 4 3 5 6 2 7 6 5 5 1 8 4 9 12 Apply Item 13 to All Wear Pad Mounting Capscrews and Torque to 31 ± 3 lb/ft. (42 ± 4 Nm) 9 10 14 13 10 PH0940 11 Front Of Vehicle PS0631 9.1 3606 Rev.
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INNER BOOM Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7120204 7126172 7126182 7120082 8307005 8303620 8303681 7120092 8642224 7095312 8520013 7095522 8526036 7132631 Qty. 1 2 2 4 20 12 8 4 2 2 2 1 AR 1 Description Boom, Inner Shim, Wear Pad .13 Thk. Shim, Wear Pad .07 Thk. Pad, Wear w/Inserts Washer, Lock 3/8” HHCS, 3/8-16 x 1” Gr.5 HHCS, 3/8-16 x 3/4” Gr.
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INTERMEDIATE BOOM 2 3 4 8 7 5 6 9 10 8 11 1 5 12 14 13 6 5 15 5 16 2 Apply Item 17 to All Wear Pad Mounting Capscrews and Torque to 31 ± 3 lb/ft. (42 ± 4 Nm) 17 14 5 6 2 PH0940 16 Front Of Vehicle 15 PS0640 9.
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INTERMEDIATE BOOM Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 7120923 7120082 7126182 7126172 8307005 8303620 8303713 8307007 7121461 8303625 7121511 7120092 7120182 8303681 7121622 7121842 8526036 Qty. 1 10 2 2 32 16 4 6 2 2 2 4 2 16 6 6 AR Description Boom, Intermediate Pad, Wear w/Inserts Shim, Wear Pad .07 Thk. Shim, Wear Pad .13 Thk. Washer, Lock 3/8” HHCS, 3/8-16 x 1” Gr.5 HHCS, 1/2-13 x 2-1/4” Gr.
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OUTER BOOM Orient Fracture In Bearing Race at Clock Position Shown 11 12 Torque to 295 lb/ft. (400 Nm) 1 2 10 9 3 3 Slave Cylinder 4 8 7 6 5 4 5 6 7 2 8 9 6 4 11 9 12 1 10 4 4 10 4 14 13 Torque to 295 lb/ft. (400 Nm) 25 19 15 20 21 22 24 16 19 19 23 22 21 Apply Item 26 to All Wear Pad Mounting Capscrews and Torque to 31 ± 3 lb/ft. (42 ± 4 Nm) 17 18 26 PH0940 20 Front Of Vehicle PS0651 9.
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OUTER BOOM Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part Number 7121173 7120592 8303794 8307703 8310269 5713331 7121183 7120602 8642234 8310067 8305643 8050001 8303660 8520013 8305644 7120662 8303782 8303681 8307005 7121622 7121842 7120082 8303622 7121632 8303620 8526036 Qty. 1 1 2 12 1 4 1 1 2 4 1 2 2 2 1 1 1 8 18 6 6 8 6 2 4 AR Description Boom, Outer Pin, Boom Pivot HHCS, 3/4-10 x 3-1/2” Gr.8 Washer, Hardened 3/4” HHCS, 5/8-11 x 6-1/2” Gr.
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BOOM EXTEND CHAIN Outer Boom For Reference Only 1 2 3 4 5 6 22 7 11 10 17 Extend Cylinder For Reference Only 21 20 13 8 19 2 11 18 17 9 12 14 10 15 13 16 12 Inner Boom For Reference Only Apply Item 23 to All Wear Pad Mounting Capscrews and Torque to 31± 3 lb/ft. (42 ± 4 Nm) 23 PH0940 Front Of Vehicle PS0661 9.
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BOOM EXTEND CHAIN Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 8303771 8307005 7121851 7120471 8310355 8310061 7131731 8302418 7120232 8127012 7121501 8310284 8065062 7120512 7120092 8303735 8307007 7120672 8303620 7121243 8303625 7120502 8526036 Qty. 2 8 1 2 1 1 1 1 1 1 2 2 2 1 2 1 5 1 6 1 4 1 AR Description HHCS, 3/8-16 x 2-1/4” Gr.
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BOOM RETRACT CHAIN 14 Intermediate Boom For Reference Only 15 14 4 10 13 8 Inner Boom For Reference Only 6 9 Outer Boom For Reference Only 8 4 12 11 4 5 7 6 5 4 3 2 Front Of Vehicle 1 PS0680 9.
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BOOM RETRACT CHAIN Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 8305646 8307104 7119362 8642237 8124126 8127013 8305645 7121531 7119372 8310019 8303624 8307007 7110642 8065061 7110582 Qty. 1 1 1 4 2 1 2 2 1 2 1 1 1 2 1 Description Nut, Hex Lock Elastic 3/4-16 NF Washer, Flat 3/4” Narrow Clevis, Retract Chain E-Ring, Retaining Pin, Retract Chain Clevis Chain, Retract, Leaf 6x6 Lacing Nut, Hex Lock Elastic 3/8-16 Link, Retract Chain Anchor Clevis, Retract Chain Bolt, Shoulder, Hex Socket Hd.
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QUICK ATTACH 1 18 9 13 12 11 14 2 16 10 15 17 9 3 19 7 4 5 6 8 21 22 20 PS0610 9.
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QUICK ATTACH Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 7121412 8303638 8307104 7121422 7085571 7085552 8305619 7120983 8307918 8310093 8303772 8303666 8307904 8305643 8305644 7083992 8520013 7095352 7118892 8310266 8310276 7118882 Qty. 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Quick Attach Assembly (Includes Items 2 thru 8) HHCS, 3/4-10 x 2-3/4” Gr.
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48” CARRIAGE 2 1 3 4 2 3 4 6 7 8 5 9 10 PA0744 9.
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48” CARRIAGE Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7083054 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128772 7097523 7097533 7085073 Qty. 1 2 2 2 1 1 1 1 1 2 2 6 Description Carriage, 48” HHCS, 5/8-11 x 4” Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer Bolt, Eye w/Nut Shaft, 48” Fork, Pallet 48” x 4” x 2” (4,000 lb Rating) Fork, Lumber (Not Shown) Fork, Block (Not Shown) 9.
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60” CARRIAGE (Optional) 1 2 3 4 2 3 4 6 7 8 9 5 10 PA0744 9.
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60” CARRIAGE (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7086304 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128792 7097523 7097533 7085073 Qty. 1 2 2 2 1 1 1 1 1 2 2 6 Description Carriage, 60” HHCS, 5/8-11 x 4” Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer Bolt, Eye w/Nut Shaft, 60” Fork, Pallet 48” x 4” x 2” (4,000 lb Rating) Fork, Lumber (Not Shown) Fork, Block (Not Shown) 9.
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72” CARRIAGE (Optional) 2 1 3 4 2 3 4 6 7 8 5 9 10 PA0744 9.
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72” CARRIAGE (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7090814 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128802 7097523 7097533 7085073 Qty. 1 2 2 2 1 1 1 1 1 2 2 6 Description Carriage, 72” HHCS, 5/8-11 x 4” Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer Bolt, Eye w/Nut Shaft, 72” Fork, Pallet 48” x 4” x 2” (4,000 lb Rating) Fork, Lumber (Not Shown) Fork, Block (Not Shown) 9.
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SWING CARRIAGE (Optional) 16 17 24 18 19 20 21 23 12 LH Cylinder X E 40 R 27 RH Cylinder 27 38 38 28 37 39 R 14 13 37 E X 2 42 29 3 12 5 See “Swing Carriage Cylinder” 35 33 8 4 9 33 6 32 33 41 42 32 31 25 22 1 32 11 8 9 9 10 15 7 8 25 36 8 10 Attach to Port “R” RH Cylinder 9 12 26 Attach to Port “R” LH Cylinder 4 12 33 30 31 32 34 PH0560 9.
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SWING CARRIAGE (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Part Number Qty.
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SIDE TILT CARRIAGE (Optional) 24 18 19 20 21 25 15 16 17 23 15 37 14 13 14 1 26 See “Side Tilt Carriage Cylinder” 33 8 9 11 10 28 7 31 11 27 11 8 12 32 29 6 35 3 2 36 22 5 30 38 4 33 31 32 34 PA1592 9.
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SIDE TILT CARRIAGE (Optional) Item No.
PAGE 216
12 FT. TRUSS BOOM (Optional) 6 8 1 7 Torque to 85 lb/ft. (115 Nm) 5 9 3 2 4 PG0980 9.
PAGE 217
12 FT. TRUSS BOOM (Optional) Item No. 1 2 3 4 5 6 7 8 9 Part Number 7113024 8382017 8310195 8307112 8305644 4107182 4107822 4107832 4107812 Qty. 1 1 4 4 4 2 2 2 1 Description 12 ft. Truss Boom (Includes Items 2 thru 9) Hook, Pintle HHCS, 1/2-13 x 1-3/4” Washer, Flat SAE 1/2” Nut, Hex Lock Elastic 1/2-13 Decal, Name Decal, Swinging Load Decal, Length/Capacity Chart, Capacity 9.
PAGE 218
UTILITY BUCKET (Optional) 1 2 PA0782 9.
PAGE 219
UTILITY BUCKET (Optional) Item No. 1 2 Part Number 7110744 4106561 Qty. 1 1 Description Bucket, Utility, 1-1/4 cu. yd. (Includes Item 2) Plate, Capacity 9.
PAGE 220
SHEET MATERIAL HANDLER (Optional) 3 4 8 4 5 6 3 4 5 1 10 5 6 7 9 4 8 2 7 9 10 5 PK0041 9.
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SHEET MATERIAL HANDLER (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7112533 7112523 7112642 8303626 8307007 8305012 8301456 7114941 8305644 8307112 Qty. 1 1 2 6 6 4 2 2 2 2 Description Support, Fork, RH Support, Fork, LH Extension, Backrest, Top HHCS, 1/2-13 x 1-1/2” Washer, Lock 1/2” Nut, Hex 1/2-13 Pin, Hitch Bar, Lock Nut, Hex Lock Elastic 1/2-13 Washer, Flat 1/2” LT 9.
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9.
PAGE 223
SECTION 1 RECOMMENDED SPARE PARTS RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with 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 224
RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with 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 225
RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with 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 226
RECOMMENDED SPARE PARTS The following list will service fleets of machines (built to current production per date on the front cover) with 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. Part Number 1-4 Description 6036 Qty.
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PART NUMBER INDEX PART NUMBER INDEX Part Number Page 2711613 ...................... 6.20 2711992 ...................... 9.22 2713363 ...................... 6.18 2714503 ........................ 6.8 2714943 ...................... 5.10 2715042 ........................ 5.6 2715052 ........................ 5.6 2715062 ........................ 5.6 2715072 ........................ 5.6 2715082 ........................ 4.2 2715092 ...................... 5.24 2715102 ........................ 5.4 2715112 .........
PAGE 228
PART NUMBER INDEX Part Number Page 7120182 ........................ 9.4 7120204 ........................ 9.2 7120232 ........................ 9.8 7120471 ........................ 9.8 7120502 ........................ 9.8 7120512 ........................ 9.8 7120592 ........................ 9.6 7120602 ........................ 9.6 7120613 ...................... 4.12 4.22 7120662 ........................ 1.2 9.6 7120672 ........................ 9.8 7120923 ........................ 9.4 7120983 ...............
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PART NUMBER INDEX Part Number Page 7137733 ...................... 2.24 7138234 ...................... 2.24 7138285 ...................... 4.22 7138286 ...................... 4.22 7138288 ...................... 4.12 7138298 ...................... 4.12 7138510 ........................ 7.6 7138736 ...................... 4.12 4.22 8030464 ...................... 3.30 8030470 ...................... 3.30 8032398 ...................... 4.10 4.20 8032508 ...................... 3.36 8032509 ......................
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PART NUMBER INDEX Part Number Page 3.46 8035028 ...................... 3.42 8035029 ...................... 3.42 3.44 3.46 8035030 ...................... 3.42 3.44 3.46 8035031 ...................... 3.42 8035032 ...................... 3.42 8035033 ...................... 3.42 3.44 3.46 8035034 ...................... 3.42 8035035 ...................... 3.42 8035036 ...................... 3.44 3.46 8035037 ...................... 3.46 8035038 ...................... 3.44 3.46 8035039 ...................... 3.
PAGE 231
PART NUMBER INDEX Part Number Page 8035196 ...................... 3.24 3.26 8035197 ...................... 3.24 3.26 8035198 ...................... 3.24 3.26 8035199 ...................... 3.24 3.26 8035200 ...................... 3.24 3.26 8035201 ...................... 3.24 3.26 8035207 ...................... 3.24 8035208 ...................... 3.24 8035209 ...................... 3.24 8035210 ...................... 3.24 8035211 ...................... 3.24 8035212 ...................... 3.24 8035213 .....
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PART NUMBER INDEX Part Number Page 8036009 ........................ 2.6 8036010 ........................ 2.6 8036011 ........................ 2.6 8036013 ........................ 2.6 8036014 ........................ 2.6 8036015 ........................ 2.6 8036017 ........................ 2.6 8036479 ........................ 7.6 8036488 ...................... 3.34 8037080 ........................ 6.8 8037206 ...................... 2.22 8040252 ........................ 1.2 8040253 ........................
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PART NUMBER INDEX Part Number Page 8303837 ...................... 2.12 2.14 4.12 4.22 7.2 8304672 ...................... 2.20 8305002 ...................... 2.12 2.14 7.4 8305003 ...................... 2.20 7.6 8305004 ...................... 5.16 7.2 7.4 7.6 8305006 ........................ 5.2 8305008 ...................... 5.16 8305012 ...................... 5.16 9.28 8305402 ...................... 2.12 2.14 8305404 ........................ 2.6 2.8 8305439 ........................ 7.2 7.4 8305603 ......
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PART NUMBER INDEX Part Number Page 8310067 ........................ 1.2 2.2 2.24 9.6 8310085 ........................ 1.4 2.4 7.2 8310089 ........................ 5.2 8310093 ...................... 9.12 8310104 ........................ 4.6 4.16 8310109 ........................ 4.2 4.4 4.14 8310116 ........................ 1.2 8310124 ........................ 2.2 2.24 8310160 ...................... 9.20 8310161 ...................... 9.20 8310164 ........................ 4.2 4.4 4.14 5.20 8310165 .........
PAGE 235
PART NUMBER INDEX Part Number Page 5.12 8640017 ........................ 6.4 8640028 ...................... 9.20 9.22 8640029 ...................... 9.20 9.22 8640032 ...................... 9.20 9.22 8640123 ........................ 5.4 8642001 ...................... 9.22 8642207 ...................... 9.20 8642224 ........................ 9.2 8642234 ........................ 9.6 8642235 ...................... 9.22 8642237 ...................... 9.10 8660010 ...................... 4.12 4.22 8660011 ......
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PART NUMBER INDEX Part Number Page Part Number Page Part Number Page Part Number Page 8902169 ...................... 5.14 6.4 8902170 ........................ 5.2 6.4 8902172 ...................... 5.16 8902174 ...................... 5.18 8902175 ........................ 5.2 5.16 5.24 6.4 8902181 ...................... 5.18 8902271 ...................... 6.14 8902511 ...................... 6.20 8902691 ...................... 5.14 8904056 ........................ 5.4 6.6 8904057 .....................
PAGE 237
PAGE 238
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 265 811 111 Fax: (61) 265 810 122 JLG Latino Americana Ltda. Rua Eng.