Telehander TL642 CAT Parts

Parts Manual

Model TL642 S/N TBK00100 & After P/N 31200255 Revised November 15, 2010

EFFECTIVITY PAGE October 20, 2006 - A - Original Issue of Manual November 9, 2006 - B - Revised Manual February 23, 2007 - C - Revised Manual June 29, 2007 - D - Revised Manual November 1, 2007 - E - Revised Manual April 25, 2008 - F - Revised Manual October 24, 2008 - G - Revised Manual February 6, 2009 - H - Revised Manual September 18, 2009 - I - Revised Manual November 15, 2010 - J - Revised Manual

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TL642

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EFFECTIVITY PAGE

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TL642

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TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 1 – FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-3

Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Outrigger Mounting, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SECTION 2 – BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9

First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Pads, Spacers and Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Pads, Spacers and Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push Beam/Extend Chain & Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 2-4 2-6 2-8 2-12 2-14 2-16 2-18 2-20

SECTION 3 – ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9

50” & 72” Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50” & 72” Side Tilt Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48” Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3-4 3-6 3-8 3-10 3-12 3-14 3-16 3-18

SECTION 4 – ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12

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Engine Assembly, L.H. View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly, R.H. View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission - ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Converter & Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Reversing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-2 4-6 4-8 4-12 4-16 4-18 4-22 4-26 4-30 4-32 4-34 4-36

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TABLE OF CONTENTS FIGURE NO. 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22

TITLE

PAGE NO.

ZF Transmission - Reverse Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - 1st Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - 4th Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Control Unit & Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Gearshift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Oil Pump, Filter & Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission - Transfer Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-38 4-40 4-42 4-44 4-46 4-48 4-50 4-52 4-54 4-56

SECTION 5 – DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22

Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Gear Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Double Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Gear Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Double Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 5-6 5-8 5-10 5-12 5-14 5-16 5-18 5-20 5-22 5-24 5-26 5-28 5-30 5-32 5-34 5-36 5-38 5-42 5-44 5-46 5-48

SECTION 6 – CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7

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Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6-2 6-10 6-14 6-16 6-20 6-24 6-26

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TITLE

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SECTION 7 – CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-2 7-3 7-4 7-5

Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Joystick w/Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Controller - Outrigger, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2 7-4 7-6 7-8 7-10

SECTION 8 – HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12

Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service/Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extend/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt & Tilt Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outrigger Controller, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outrigger Cylinders, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 8-6 8-12 8-14 8-16 8-18 8-20 8-22 8-24 8-26 8-28 8-30

SECTION 9 – HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15 9-16

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Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Coupler Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outrigger Cylinder, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outrigger Control Valve, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Shift Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9-2 9-6 9-10 9-14 9-16 9-20 9-24 9-26 9-30 9-34 9-36 9-38 9-40 9-42 9-44 9-46

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TITLE

PAGE NO.

SECTION 10 – ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9

Battery & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Disconnect Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2 10-4 10-6 10-10 10-12 10-14 10-16 10-18 10-20

SECTION 11 – DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1 11-2

Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

SECTION 12 – OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12-1 12-2 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 12-11 12-12 12-13 12-14 12-15 12-16 12-17

Block Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8” Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Reducer Valve - 1360 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fender Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beacon Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Road Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skylight Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cooler Bypass Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beacon Light Mount w/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-2 12-4 12-8 12-10 12-12 12-14 12-16 12-24 12-26 12-30 12-32 12-34 12-36 12-40 12-42 12-44 12-46

SECTION 13 – RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

vi

TL642

31200255

SMCS CODES - TELEHANDLER 1350 ENGINE COOLING SYSTEM

3000 TRANSMISSION & DRIVE LINE

1351 RADIATOR & OIL COOLER

3013 AXLE ARRANGEMENT

1353 RADIATOR

3020 DRIVE & STEERING AXLE

1354 EXPANSION TANK

3061 TRANSMISSION GEARS

1360 FAN GUARD

3063 TRANSMISSION SHAFT

1374 HYDRAULIC OIL COOLER

3064 TRANSMISSION CASE

1375 TORQUE CONVERTER / TRANSMISSION OIL COOLER

3065 TRANSMISSION CONTROL

1380 COOLANT HOSE / LINES 1381 RADIATOR AND GUARD 1382 RADIATOR CAP 1384 ENGINE COOLANT HEATER 1386 HYDRAULIC FAN MOTOR 1387 HYDRAULIC FAN PUMP

3066 TRANSMISSION OIL PUMP 3067 TRANSMISSION OIL FILTER 3068 TRANSMISSION OIL FILTER BASE 3075 TRANSMISSION OUTPUT GEARS 3080 TRANSMISSION OIL 3081 TRANSMISSION OIL LEVEL 3082 TRANSMISSION MOUNT

1395 ENGINE COOLANT

1400 ELECTRICAL SYSTEM

3100 TORQUE CONVERTER, TORQUE DIVIDER, RETARDER

1401 BATTERY

3101 TORQUE CONVERTER

1402 BATTERY CABLE

3115 TORQUE CONVERTER/TRANSMISSION SCAVENGE PUMP

1408 WIRING HARNESS 1416 START SWITCH 1417 FUSE / CIRCUIT BREAKER PANEL 1428 BACKUP LIGHT(S)

3133 TORQUE CONVERTER RELIEF VALVE 3139 MODULATING VALVE 3141 TORQUE CONVERTER SPEED SENSOR

1429 LIGHT(S) 1430 DIRECTIONAL LIGHT 1431 BEACON LIGHT(S) 1432 STOP /LIGHT / TAILLIGHT 1434 CAB LIGHT 1434 FLOODLIGHT

3030 POWER SHIFT / HYDROSTATIC TRANSMISSION 3063 TRANSMISSION SHAFT 3064 TRANSMISSION CASE 3065 HYDROSTATIC CONTROL LINKAGE (EXTERNAL) 3066 POWER SHIFT TRANSMISSION OIL PUMP 3067 HYDROSTATIC TRANSMISSION OIL FILTER

OTHER ENGINE COMPONENTS 1801 ENGINE SOUND SUPPRESSION 1802 REFRIGERANT COMPRESSOR 1805 REFRIGERANT CONDENSER 1807 AIR CONDITIONER COMPRESSOR DRIVE 1808 AIR CONDITIONER LINES 1810 RADIATOR & REFRIGERANT CONDENSER 1812 HEATER / HOSE LINES 1813 RADIATOR HOSE

3073 HYDROSTATIC MAIN CONTROL VALVE 3151 TRANSMISSION GOVERNOR 3154 TRANSMISSION LINES/HOSES 3155 TRANSMISSION CLUTCH 3157 TRANSMISSION SELECTOR VALVE 3159 TRANSFER GEARS 3160 TRANSMISSION PLANETARY 3167 TRANSMISSION HYDRAULIC CONTROL 3168 TRANSMISSION ELECTRONIC CONTROL 3174 SHIFT SOLENOID 3175 TRANSMISSION SPEED SENSOR

vii

SMCS CODES - TELEHANDLER 3181 TRANSMISSION NEUTRALIZER CONTROL VALVE

3269 PINION HOUSING

3182 TRANSMISSION LUBRICATION RELIEF VALVE

3274 CONSTANT VELOCITY UNIVERSAL JOINT

3184 TRANSMISSION OIL COOLER BYPASS VALVE

3275 DRIVE LINE BRAKE

3186 TRANSMISSION PLANET CARRIER

3276 DRIVE LINE BRAKE DISC

3187 TRANSMISSION CARRIER THRUST DISC/PLATE

3278 DRIVE AXLE

3190 TRANSMISSION CLUTCH PLATE

3281 BEVEL GEAR CASE

3191 TRANSMISSION NEUTRALIZER

3282 AXLE

3194 TRANSMISSION TEMPERATURE SENSOR

3283 DIFFERENTIAL CASE

3202 TRANSMISSION FLOW CONTROL VALVE

3284 DIFFERENTIAL CARRIER

3203 DRIVE PUMP 3204 CHARGE PUMP

4000 DRIVE TRAIN

3205 SERVO CONTROL VALVE

4004 BRAKE & AXLE

3206 MANIFOLD/METERING VALVE

4005 STEERING & BRAKING SYSTEM

3207 SERVO CYLINDER 3210 HIGH PRESSURE RELIEF VALVE

4050 FINAL DRIVE

3213 CHARGE & MAIN RELIEF VALVE

4051 FINAL DRIVE & WHEEL

3214 SYNCHRONIZING VALVE

4052 FINAL DRIVE SEAL

3215 POWER UNIT CONTROL LINKAGE

4053 DRIVE AXLE HUB/GEAR ASSEMBLY

3216 TRANSMISSION UNDERSPEED/OVERSPEEDVALVE

4054 FINAL DRIVE HUB

3219 TRANSMISSION PILOT OVERSPEED VALVE

4055 FINAL DRIVE GEARS

3220 TRAVEL SPEED CONTROL VALVE

4056 FINAL DRIVE - DRIVE SHAFT

3221 HYDROSTATIC POWER CASE

4057 FINAL DRIVE PINION FLANGE

3222 PUMP HEAD

4059 FINAL DRIVE CASE/BORE

3223 TRANSMISSION UNDERSPEED OVERRIDE VALVE

4084 FINAL DRIVE PLANETARY CARRIERS, HUB & RING GEAR

3225 TRAVEL ELECTRONIC CONTROL 3226 DOWNSHIFT INHIBITOR

4091 FINAL DRIVE PINION 4092 PLANETARY FINAL DRIVE CARRIER

3250 DRIVE LINE/DRIVE AXLE 3251 UNIVERSAL JOINT

4093 FINAL DRIVE PLANETARY CARRIER THRUST SURFACE 4094 FINAL DRIVE PINION & FLANGE

3252 FLEXIBLE COUPLING 3253 DRIVE SHAFT 3254 DRIVE LINE PINION 3256 BEVEL GEAR/SHAFT 3257 BEVEL GEAR SHAFT BEARING 3258 DIFFERENTIAL 3259 AXLE SHAFT 3260 AXLE HOUSING ASSEMBLY 3263 LIMITED SLIP DIFFERENTIAL 3267 DRIVE SHAFT SUPPORT 3268 AXLE HOUSING SUPPORT/TRUNNION

viii

4200 WHEEL & TIRE 4201 WHEEL 4202 RIM & TIRE 4203 TIRE 4208 WHEEL ASSEMBLY 4209 WHEEL RIM 4210 WHEEL STUD/BOLT/NUT 4220 MUD GUARD 4233 STEER TIRE, PNEUMATIC

SMCS CODES - TELEHANDLER 4250 BRAKING SYSTEM

5000 IMPLEMENT CONTROLS

4251 SERVICE BRAKE

5001 IMPLEMENT CONTROL LOCK

4255 BRAKE DISC

5002 HYDRAULIC & FUEL TANK

4256 BRAKE CALIPER, HEAD ASSEMBLY

5004 RIDE CONTROL SYSTEM

4257 BRAKE LINES

5005 AUXILIARY HYDRAULIC CIRCUIT

4258 BRAKE MASTER CYLINDER 4262 BRAKE ACTUATOR

5050 HYDRAULIC SYSTEM

4265 SERVICE BRAKE CONTROL VALVE

5051 HYDRAULIC CONTROL VALVE

4267 PARKING BRAKE

5056 HYDRAULIC TANK

4269 SERVICE BRAKE CONTROL

5057 HYDRAULIC HOSES/LINES

4273 FRICTION PADS

5059 PILOT CONTROL VALVE

4282 PARKING/SECONDARY BRAKE CONTROL VALVE

505C PISTON CYLINDER

4284 PARKING BRAKE CONTROL

5063 IMPLEMENT CONTROL

4291 BRAKE HYDRAULIC RESERVOIR

5068 HYDRAULIC OIL FILTER 5069 MAIN SYSTEM RELIEF VALVE

4300 STEERING SYSTEM

506P IMPLEMENT PRIORITY VALVE

4301 STEERING GEAR

5070 PISTON PUMP

4303 STEERING CYLINDER

5071 HYDRAULIC OIL COOLER BYPASS VALVE

4307 STEERING VALVE

5072 PILOT SYSTEM RELIEF VALVE

4309 STEERING WHEEL

5084 IMPLEMENT PUMP

430S STEERING SENSOR

5086 COMPENSATOR VALVE

4310 STEERING COLUMN

5093 HYDRAULIC FILTER BYPASS VALVE

4312 STEERING METERING PUMP

5095 HYDRAULIC OIL

4313 STEERING AXLE

509T HYDRAULIC OIL TEMPERATURE SENSOR

4314 KINGPIN 4318 TIE ROD

5100 LIFT, TILT, TIP & OTHER CONTROLS

4321 STEERING KNUCKLE

5102 LIFT/HOIST CYLINDER

4322 STEERING RELIEF VALVE

5103 LIFT CYLINDER TRUNNION

4329 TIE ROD END

5104 TILT CYLINDER

4338 ADJUSTABLE STEERING COLUMN

5106 TIP CYLINDER

4349 STEERING SELECTOR & PRESSURE CONTROL VALVE

5116 ATTACHMENT CYLINDER 5130 LOCK VALVE 5141 HITCH LIFT CYLINDER

4350 HYDROSTATIC DRIVE 4351 HYDRAULIC PROPEL/DRIVE MOTOR

5144 FRAME LEVEL VALVE 5486 EXTENSION CYLINDER

4352 DRIVE CONTROL VALVE 4267 HYDROSTATIC DRIVE PARKING BRAKE 4354 BRAKE RELEASE PUMP 4355 HYDROSTATIC DRIVE GEAR REDUCER 4356 BRAKE & SHIFT VALVE

ix

SMCS CODES - TELEHANDLER 5700 IMPLEMENT ELECTRONIC CONTROLS

7165 CAB/CANOPY SCREEN

5701 IMPLEMENT ELECTRONIC CONTROL MODULE (PREPROGRAMMED)

7170 RADIATOR GRILLE

5702 IMPLEMENT HYDRAULIC ELECTRONIC CONTROL

7177 ROPS ROLL BAR 7192 WHEEL CHOCK

5705 JOYSTICK 5734 HYDRAULIC SYSTEM WIRING HARNESS 5735 FRAME LEVEL CONTROL

5800 OTHER CONTROLS 5804 SIDESHIFT CYLINDER 5811 LOAD CONTROL VALVE 5816 COMPENSATING CYLINDER 5823 FORK LEVEL CYLINDER

7200 SUSPENSION 7221 OUTRIGGER

7250 BODY 7251 HOOD 7252 FENDER 7253 PLATFORM/DECK 7257 BATTERY BOX/SUPPORT 7261 PLATFORM SOUND SUPPRESSION

6400 MATERIAL HANDLING ATTACHMENTS 6402 STANDARD CARRIAGE 6404 LIFT CHAIN 6405 LIFT FORK 6408 ROTATING CARRIAGE 6409 WIDE CARRIAGE 6416 BALE CLAMP 6425 SIDESHIFT CARRIAGE 6459 LIFTING HOOK 6460 TELESCOPING BOOM 6461 MAN BASKET

7050 FRAME 7051 MAIN FRAME 7056 COUNTERWEIGHT 7059 FUEL TANK, SEAT & FRAME 7078 FRAME LEVEL CYLINDER

7262 FIREWALL 7263 ENGINE ENCLOSURE 7264 ROPS MOUNT REAR SUPPORT 7265 FLOORPLATE 7266 ROPS MOUNT 7267 BODY PANEL 726A ACCESS PANEL 726M FLOORMAT 7272 RADIATOR ENCLOSURE/SHROUD 7273 COMPARTMENT DOOR 7276 MACHINE ENCLOSURE

7300 OPERATOR STATION 7301 CAB 7302 CANOPY 7304 CAB HEATER 7305 WINDSHIELD WIPER 7306 WINDSHIELD WASHER

7100 HITCH 7105 FIXED DRAWBAR 7116 HITCH/TOW PIN

7307 SEAT/ARM CUSHION 7308 CAB DOOR 7309 HEATER & AIR CONDITIONER 7310 WINDOW GLASS

7150 GUARD 7151 CRANKCASE GUARD 7154 ENGINE GUARD 7155 RADIATOR GUARD 7159 OVERHEAD GUARD

x

7312 SEAT ASSEMBLY 7314 DASH 7316 CAB AIR FAN 7319 MIRROR

SMCS CODES - TELEHANDLER 731S SEAT AIR COMPRESSOR

7481 FUEL LEVEL GAUGE

7320 AIR CONDITIONER

7483 LOW FUEL LEVEL INDICATOR

7321 SEAT FRAME

7485 ENGINE LOW OIL PRESSURE INDICATOR

7322 AIR CONDITIONER RECEIVER/DRYER

7486 PARKING BRAKE INDICATOR LIGHT

7323 ROPS/FOPS CANOPY

7488 HYDRAULIC OIL TEMPERATURE GAUGE

7324 SUSPENSION SEAT

7490 ELECTRONIC MONITORING SYSTEM/PANEL

7325 ROPS/FOPS CAB

7493 GROUND SPEED SENSOR

7327 SEAT BELT

7496 ALTERNATOR INDICATOR

7329 CAB LINER/SOUND SUPPRESSION 7330 CANOPY SOUND SUPPRESSION

7500 MAINTENANCE

7332 ELECTRIC SWITCH (MANUAL)

7501 FIRST SERVICE INTERVAL

7338 RADIO

7502 SECOND SERVICCE INTERVAL

7340 WINDSHIELD

7503 THIRD SERVICE INTERVAL

7342 CAB AIR FILTER

7504 FOURTH SERVICE INTERVAL 7507 LIFT ARM SUPPORT

7400 PROTECTION DEVICES, ALARMS & INDICATORS

751B BATTERY CHARGER

7402 WARNING HORN

7524 250 SERVICE HOUR MAINTENANCE

7405 INSTRUCTION/WARNING PLATE/FILM


7406 BACK-UP ALARM


7407 ACTION ALARM


7420 LOW COOLANT TEMPERATURE ALARM


7421 LOW ENGINE OIL PRESSURE SHUTOFF

7542 SOS

7431 WARNING/INDICATOR LIGHT 7550 COMMON SUBJECTS 7450 GAUGES & INDICATORS

7551 BEARINGS

7451 INSTRUMENT PANEL/CONTROL PANEL

7552 GEARS

7452 AIR FILTER INDICATOR

7553 FASTENERS, CONNECTORS & HARDWARE

7453 ENGINE COOLANT TEMPERATURE GAUGE

7554 HOSES & LINES

7455 ENGINE OIL PRESSURE GAUGE

7555 SEALS & GASKETS

7459 TRANSMISSION GEAR/SHIFT INDICATOR

7556 WIRE

7462 TACHOMETER

7557 INFORMATION/IDENTIFICATION PLATES & TRANSFERS

7463 SPEEDOMETER 7464 ODOMETER 7467 AMMETER 7470 COOLANT LEVEL GAUGE 7475 OIL FILTER INDICATOR 7477 TRANSMISSION/TORQUE CONVERTER TEMPERATURE GAUGE

7558 WEAR SLEEVES 7559 PAINTED SURFACES 755R RETAINER SYSTEM 7560 COMPARTMENT FLUID LEVEL 7561 DUO-CONE SEAL 7562 HYDRAULIC CYLINDERS

7478 SERVICE METER

7569 TROUBLESHOOTING PROCEDURE

7479 SIGHT GAUGE

756P MAINTENANCE PARTS

7480 ELECTRIC HOUR METER

7570 PRODUCT UPDATE PROGRAM

xi

SMCS CODES - TELEHANDLER 7571 SOS ENGINE PRODUCT INFORMATION

7771 SOS "URGENT" REPORTS

7573 SOS TRANSMISSION PRODUCT INFORMATION

7851 FUEL FILTER INDICATOR

7574 SOS DRIVE TRAIN PRODUCT INFORMATION

7856 STABILITY INDICATOR

7575 SOS HYDRAULIC PRODUCT INFORMATION

7858 ANGLE INDICATOR

7576 SOS OTHER PRODUCT INFORMATION

7859 ENGINE OIL TEMPERATURE GAUGE

7577 SOS FLUID INFORMATION

7942 PERSONALITY MODULE - UPDATE ELECTRONIC COMPONENTS

7578 SOS FILTER INFORMATION 7579 FLUID 7581 PAINTING & LUBRICATION 7588 PRE-DELIVERY INSPECTION 7589 PRE-DELIVERY WARRANTY 7590 DELIVERY 7591 FIRST REVISIT 7592 SECOND REVISIT 7593 USER ACCEPTANCE/FIELD FOLLOW 7594 CONTRACT FIELD FOLLOW RECORDS 7595 GENERAL OVERHAUL (NO FAILURE)

7600 MACHINE ELECTRONIC CONTROLS & DATA MANAGEMENT SYSTEMS 7606 PRODUCT LINK SYSTEM 7610 PROGRAMMABLE CONTROL 7620 SOFTWARE 7630 INTERLOCK ELECTRONIC CONTROL MODULE 7631 MACHINE SECURITY SYSTEM 7700 SERVICE CLAIM CATEGORIES 7714 ROLL OVER PROTECTION STRUCTURE DECERTIFIED 7715 ROLL OVER PROTECTION STRUCTURE RECERTIFIED 7729 HEUI ACTUATION (OIL) 7730 REPAIR PROCEDURE (RP) PROGRAM 7750 DEFECTIVE PARTS STOCK 7751 PRODUCT IMPROVEMENT PROGRAM (PIP) 7752 PARTS STOCK CLAIM 7754 REMANUFACTURED COMPONENT 7755 PRODUCT SUPPORT PROGRAM (PSP) 7756 SERVICE ENGINEERING REQUESTED WORK 7760 INFORMATION RECORD ONLY 7762 DELIVERY DATE/SERVICE FEE 7770 SOS GENERAL INFORMATION

xii

7950 MISCELLANEOUS 79M4 OTHER ADJUSTMENTS

SECTION 1 FRAME & ATTACHING PARTS

31200255

TL642

Before S/N TBK01167 excluding TBK01162

FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim

48 63 46

9 44

8

11 63 12

19 10

49

11

3 6

4

2 43

4

18 51 40

5 58 66 1 65

7 56 52 53 54

57 66

47

MACHINES EQUIPPED WITH OUTRIGGERS

18

18 40

51 51

11 63

18 40 11 63

26

40

19

41

40

48 18 63 15 14

11 63

13

47 59 61

45 70

55 24

20 63 69

25

22

59

59 68

63 67

16 17

60

18 19

21 72 37 64

23

1-2

49

51

50

11 63

48 63

TL642

PAL0016

31200255


FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

39

38

42

FRAME MOUNT WELDMENT CAB WALL

27

30

28 29

31

32 33

29

UPPER CAB MOUNT

CAB MOUNT WELDMENT

34

FRAME MOUNT WELDMENT

35

105 106 107 110 111 104

36

108 109 103

101

LOWER CAB MOUNT

SHOWN WITH WORK LIGHT

102

PAL1441

31200255

TL642

1-3


FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim Item

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 43 44 45 46 47

1-4

Qty. 1

303-8660 303-8567 298-8777 303-8661 303-4981 303-8659 299-0330 297-7032 298-8612 298-6870 298-1586 298-7990 298-8205 298-8124 298-7374 298-8049 298-7897 298-7913 298-7875 303-4989 298-7293 298-8048 298-7991 298-1746 298-8053 298-8581 298-1750 298-7845 303-4744 298-7976 298-7030 298-1740 298-8052 298-8119 299-0402 298-7840 303-4798 298-8126 298-0551 298-1579 303-5003 298-1628 300-6114

14 1 2 1 1 2 1 6 1 15 1 1 1 1 1 1 12 5 4 4 4 1 1 1 2 2 2 2 4 2 2 4 4 4 4 4 1 1 4 15 1 Ref 1 6 1 6 1

Description ENGINE COVER, (includes items 2, 3, 4, 6, 7, 8, 9, 43, 44, 52, 53, 54, 57, 58, 65 & 66) HEX HD CAPSCREW, 8X3/4 PROP BRACKETS PROP CLIPS MIRROR MOUNT BACK PLATE GAS PROP BALL STUD, (13mm) HINGE, 36” SOCKET BUTTON HD CAPSCREW, 3/8-16X1-1/4 MIRROR HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 MIRROR BRACKET WELDMENT HORN LOCKWASHER, 5/16 HEX HD CAPSCREW, 5/16-18X1/2, GR5 LATCH BRACKET LATCH MOUNTING BRACKET FLAT WASHER, 3/8 HEX NUT, 3/8-16 WHIZ-LOCK SCREW, 3/8-16X1-1/2 HEX HD CAPSCREW, 1/8X3-1/2 WASHER COUNTERWEIGHT, (no pintle hook) COUNTERWEIGHT, (with pintle hook) BACK-UP ALARM HEX NUT, 5/16-18 HEX HD CAPSCREW, 5/16-18X3/4, GR5 REBOUND WASHER HEX NUT, 7/8-9 SHOCK MOUNT HARDENED WASHER HEX HD CAPSCREW, 7/8-9X5 HEX HD CAPSCREW, 3/4-10X3-3/4 HARDWASHER, 13/16 CAB ISOLATOR MOUNT TAIL WASHER HEX LOCKNUT, 3/4-10 OIL PAN COVER CAB FENDER WHIZ-LOCK BOLT, 3/8-16X1 LOCKWASHER, 3/8 PLATE VALVE COVER CAB ASSY, (see Figure 6-1 for details) WHIZ-LOK NUT, 5/16-18 LOCK NUT, 3/8-16 TANK BRACKET FLAT WASHER, 3/8 FRAME WELDMENT, (no outriggers)

TL642

Rev. I

31200255



Figure 1-1 Frame Shrouding & Trim (Continued) Item

Part Number

48 49

298-8034 298-8267 303-4890 298-8140 298-1609 303-4836 303-4864 303-4779 298-7363 298-7373 298-0551 304-3805 304-3177 298-7976 303-4966 297-7084

50 51 52 53 54 55 56 57 58 59 60 61 63 64 65 66 67 68 69 70 71 72

101 102 103 104 105 106 107 108 109 110 111

297-7040 303-8654 304-2618 298-1360 298-8011 298-8052 299-0387 8T-7008

Qty. 1 10 1 1 1 8 1 1 4 4 2 1 1 1 16 1 18 AR 8 13’ 1

315-3423

2 4 4 60” 3 AR 1

323-1647

1

315-3422 317-0088 317-0089 317-0090 315-3424 298-7375 298-7382 8T-4970 2Y-6141 298-8050 298-1755

1 1 1 A/R 1 1 1 2 2 1 1

Description FRAME WELDMENT, (with outriggers) SOCKET BUTTON HD CAPSCREW, 3/8-16X3/4 FRONT COVER, (no outriggers) FRONT COVER, (with outriggers) COVER MAIN VALVE NUT LATCH, (includes items 53 & 54) KEY LOCKNUT LOCKWASHER FLAT WASHER, 5/16 HEX NUT, 5/16-18 PERFERATED SCREEN EXHAUST SCREEN KIT HARDENED WASHER, 3/4 ENGINE POD WELDMENT HEX HD CAPSCREW, 3/4-10X2 LOCTITE, #242 HEX HD CAPSCREW, 1/2-13X1-1/8, GR5 BULB SEAL ADHESIVE KIT, (includes 3 tubes and applicator), (enough to do exhaust screen kit) WHIZ-LOCK CAPSCREW, .375-16X1.25 HEX HD CAPSCREW, 3/4-10X4.5, GR5 HEX NUT, 3/4-10 TRIM-LOK HEX HD CAPSCREW, 3/8-16X3, GR5 LOCTITE, #271 LH MIRROR INSTALLATION, (includes items 101 thru 111), (Before S/N TBK00765) LH MIRROR INSTALLATION, (includes items 102, 103, 108 & 109), (S/N TBK00765 & After) MIRROR BRACKET MIRROR MOUNT ARM ASSY MIRROR HEAD DOUBLE SIDED TAPE BOLT, 1/2-13 FLAT WASHER, 1/2 LOCKWASHER, 1/2 HEX HEAD CAP SCREW, M6X1X14mm GR8.8 LOCKWASHER, M6 HEX NUT, 1/2-13 SPACER

Rev.

B A

NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE

31200255

TL642

1-5

S/N TBK01167 & After including TBK01162

FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim 2 4 25 609

604 605

1

607

403 405 6

406

402

604 605 608

401 404 404 964 962 601 602 603

960 961 959

501 828 827 825 826

829

726 728 731

827 830 831

826 826

827 830

831 832 830

831

725 727

501

729 732

11 10 8

9

730

12 713 13 712

724 723

502

201 301

1-6

TL642

PAL5500

31200255



552

551

150

106 104 108 109 107 105 105

103 110 111

151 153 152

112 154

PAL1441

31200255

TL642

1-7


FRAME & ATTACHING PARTS Figure 1-1 Frame Shrouding & Trim Item

1 2 4 8 9 10 11 12 13 15 16 19 20 21 22 24 25 26 27 28 29

103 104 105 106 107 108 109 110 111 112 150 151 152 153 154

201 202 203 204 301

1-8

Part Number

Qty.

364-5671

Ref

364-5674 298-7365 297-7031 364-5679 303-4751 364-5678 298-1360 298-7374 298-8049 298-7378

1 10 10 1 4 1 2 2 2 8 8 Ref

Description

Rev. F

Ref Ref Ref 2 1 AR 1 1 1

ENGINE COVER INSTALL, (not available to order, see items 1 thru 29 for service) ENGINE COVER, (includes items 601 thru 609) WASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1, GR5 LATCH MOUNT BRACKET SCREW, 3/8-16X1.5 LATCH CATCH BRACKET SCREW, 3/8-16X1.25 WASHER, 3/8 HEX NUT, 3/8-16 LOCK WASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1.125, GR5 R.H. MIRROR INSTALL, (not available to order, see items 401 thru 406 for service) AIR FILTER INTAKE ADAPTER, (not shown), (see Figure 4-7 for details) FOAM SEAL, (not shown), (see Figure 4-7 for details) BAND CLAMP, (not shown), (see Figure 4-7 for details) ENGINE HOOD SHIM HOOD HINGE SUPPORT PLATE BULB SEAL GAS STRUT REAR BRACKET GAS STRUT FRONT BRACKET HOOD HINGE MOUNT PLATE

Ref 2 2 4 2 2 4 4 4 4 4 Ref 2 1 2 1

CAB INSTALL, (not available to order, see items 103 thru 112 for service) HEX HD CAPSCREW, 7/8-9X5, GR8 WASHER SHOCK MOUNT REBOUND WASHER HEX NUT, 7/8-9 HEX HD CAPSCREW, 3/4-10X3.75, GR8 WASHER, 3/4 CENTER MOUNT WASHER HEX NUT, 3/4-10 CAB ASSY, (see Figure 6-1 for details) HEX HD CAPSCREW, M6X20, GR8.8 RECTANGULAR MIRROR LOCK WASHER, M6 MIRROR ARM

D

304-2660

Ref

B

308-7035 299-0361 298-7922 303-4799 303-4989

1 1 4 4 1

PINTLE HOOK INSTALL W/ COUNTERWEIGHT, (not available to order, see items 201 thru 204 for service) COUNTERWEIGHT PINTLE HOOK HEX HD CAPSCREW, 1/213X1.75 LOCKWASHER, 1/2 COUNTERWEIGHT, ( no pintle hook

364-5698

367-3291

364-5703 309-6238 352-4588 298-8581 298-1746 298-8053 303-4744 298-1631 298-7030 298-1740 298-8052 297-7088 329-0046 2Y-6141

TL642

31200255



Item

Part Number

401 402 403 404 405 406 501

298-0549 298-0565 298-7372 309-2991 364-5697

502 551 552 601 602 603 604 605 606 607 608 609 650 651 712 713 723 724 725 726 727 728 729 730 731 732 825 826 827 828 829 830 831 832 959 960 961 962

360-6624 299-0402 298-7840 303-4836 303-4864 8T-4205 303-4779 298-7365 298-0570 364-5685 364-5686 364-5687 364-5688 303-4779 298-7363 298-7395 298-7875 298-7913 297-7011 300-6074 298-7363 298-7379 298-7293 298-7900 298-6870 367-4967 360-7796 298-1609 298-7374 298-8034 298-8140 298-7380 297-7032 298-1609 298-7374 298-7380 297-7032

Qty. 2 2 2 4 1 1 1 1 1 1 4 1 1 4 4 8 8 2 1 1 1 4 4 8 8 4 4 2 1 2 1 1 2 1 1 1 10 10 4 1 9 9 1 10 10 13 10

Description

Rev.

HEX HD CAPSCREW, 1/4-20x1.125, GR5 HEX LOCK NUT, 1/4-20, GR2 PLUG WASHER, 1/4 MIRROR MIRROR BRACKET FRAME WELDMENT, (with outrigger) FRAME WELDMENT, (without outrigger) ENGINE POD CAB FENDER WHIZ-LOCK BOLT, 3/8-16X1 COMPRESSION LATCH, (includes items 650 & 651) KEY WASHER, 6MM HEX LOCK NUT, M6X1 WASHER, 3/8 BUTTON HD SCREW, 3/8-16X1 GAS SPRING ENGINE COVER FRONT HINGE ENGINE COVER REAR HINGE ENGINE COVER SUPPORT BAR LOCKNUT LOCKWASHER HEX HD CAPSCREW, 7/8-9X2.5, GR8 WASHER, 7/8 WASHER HEX HD CAPSCREW, 1/8X3.5 HEX HD CAPSCREW, 1/4-20X3/4, GR5 HEX HD CAPSCREW, 5/16-18X1/2, GR5 WASHER, 1/4 LOCK WASHER, 5/16 BACKUP ALARM HEX LOCK NUT HORN MOLDED RESISTOR FRONT COVER TINNERMAN NUT WASHER, 3/8 BUTTON HD SCREW, 3/8-16X3/4 MAIN VALVE COVER LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1.25, GR5 VALVE COVER PANEL TINNERMAN NUT WASHER, 3/8 LOCK WASHER HEX HD CAPSCREW, 3/8-16X1.25, GR5 NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE

31200255

TL642

1-9

FRAME & ATTACHING PARTS Figure 1-2 Axle Mounting

4 3

5 3 4 3

2

1 3 2

1-10

PAL0020

TL642

31200255

FRAME & ATTACHING PARTS Figure 1-2 Axle Mounting Item

Part Number

Qty.

1 2 3 4 5

298-1751 298-1631 298-8052

Ref 8 16 8 Ref

31200255

Description

Rev.

FRONT AXLE ASSY, (see Figure 5-1 for details) HEX HD CAPSCREW, 3/4-10X5, GR8, (loctite & torque to 340-365 lb-ft) HARDENED FLAT WASHER, 3/4 HEX NUT, 3/4-10 REAR AXLE ASSY, (see Figure 5-11 for details)

TL642

1-11

FRAME & ATTACHING PARTS Figure 1-3 Outrigger Mounting, (if equipped)

12 6 13

15 16

5

15 16

7

5 14 11

4 9

2

8 15 16

15 16

12 10

3

PAL3390

1-12

TL642

31200255

FRAME & ATTACHING PARTS Figure 1-3 Outrigger Mounting, (if equipped) Item 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Number

Qty.

345-2161 299-0277 299-0278

1 2 2 Ref 4 2 2 2 2 2 4 4 2 4 4 AR Ref

298-6891 2987-8429 298-8430 298-8431 298-6849 297-7036 297-7039 298-0541 298-0574 298-7382 298-1612

Description OUTRIGGER ASSEMBLY, (includes all items) ARM WELDMENT OUTRIGGER SHOE OUTRIGGER CYLINDER & VALVE, (see Figure 9-13 for details) BUSHING OUTRIGGER CYLINDER PIN ARM PIN SHOE PIN KEEPER HEX HD CAPSCREW, 3/8-16X4-1/4, GR5 HEX HD CAPSCREW, 1/2-13X1, GR5 HEX LOCKNUT, 3/8-16 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8 LOCKWASHER, 1/2 LUBE FITTING, STRAIGHT, 1/8 LOCTITE, #242 HOSE ASSEMBLY, (not shown), (see Figure 8-12 for details)

Rev. C


31200255

TL642

1-13


This Page Intentionally Left Blank

1-14

TL642

31200255

SECTION 2 BOOM

31200255

TL642

BOOM Figure 2-1 First Boom Section

6

4

3 1

27 26

5

7

2 8 22

1

28

9 21

10 24 20

12 18

16 17

2-2

19

15

1

11

25

Coat Anchor Bolt Threads on items 2 & 12 with Mystik XD2, (14404818). Tighten to collapse washers.

13

Coat bores for item 8 with Never Seeze Lube, (14403323S).

14

PAL1191

TL642

31200255

BOOM Figure 2-1 First Boom Section Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28

304-2658

1 Ref 1 8 2 2 1 Ref 8 8 1 Ref 1 4 4 1 Ref 1 8 2 2 Ref 1 1 2 2 2

298-8578 298-1786 298-1754 297-7029 331-3810 298-7368 298-8009 298-7027 298-6922 297-7041 298-7367 298-8063 298-8059 298-1781 298-7031 298-1612 298-7925 298-8070 298-7380 298-7374 331-1596

Description

Rev.

FIRST BOOM SECTION CHAIN CLEVIS ROD, (see Figure 2-7, item 4 for details) STRONG BACK SPRING WASHER, 7/8 HEAVY HEX NUT, 7/8-14, (torque to 100-110 lb-ft) HEX HD CAPSCREW, 3/8-16X3/4, GR5 REAR COVER EXTEND/RETRACT CYLINDER PIN, (see Figure 9-2 for details) FLAT WASHER, 5/8 HEX HD CAPSCREW, 5/8-11X1-1/2, GR5, (torque to 140-155 lb-ft) BOOM PIVOT PIN CHAIN ANCHOR, (see Figure 2-3, item 12 for details) ANCHOR PLATE HEX HD CAPSCREW, 1/2-13X1-1/4, GR5 FLAT WASHER, 1/2 HEX JAM NUT, 5/8-18, (torque to 100-110 lb-ft) SECOND BOOM SECTION, (see Figure 2-3 for details) HEX NUT, 5/8-18 SPRING WASHER, 5/8 BOOM PIVOT BUSHING LUBE FITTING, STRAIGHT, 1/8 PUSH BEAM ASSY, (see Figure 2-7 for details) HEX HD CAPSCREW, 5/8-11X6 HEX NUT, 5/8-11 SPRING LOCKWASHER, 3/8 FLAT WASHER, 3/8 HEX HD FLANGE SCREW, 3/8-16X1-1/4, GR5


31200255

TL642

2-3

BOOM Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)

16 5 13 11

14

15

5 12 10

5 9 8 19 1

6 7

17 18

2 2 2 4

21 PAL1170

20

3 SERVICE NOTES: 1. Add bearing pad shims & spacers as required to shim boom to within 1/16” of a tight fit. Whenever a shim is used with a pad, a spacer must be inserted between pad & shim. No pads shall sit directly on slotted surface of shims. 2. The length of pad bolts depend on the amount of shims used. Bolt cannot exceed past chamfer on bearing pad. 3. Add grease, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.

2-4

TL642

31200255

BOOM Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section) Item

Part Number

1 2 3 4

298-1629 297-7039

5 6 7 8 9

10 11

297-7069 297-7070 298-1628 298-8208 298-7014 298-1729 298-1726 298-1727 298-7015 297-7056 297-7057 298-8015

12 298-8015 298-8016 13

14 15 16 17 18

19 20 21

298-1787 298-1788 298-1728 298-7073 297-7030 298-1732 298-1736 298-1737 298-7075 298-1613 298-1626 298-1689

31200255

Qty. Ref 8 4 4 AR AR 16 2 1 2 2 AR AR 1 8 AR AR AR 4 AR AR 4 AR AR 4 4 4 2 AR AR AR 2 2 2 AR AR

Description

Rev.

FIRST BOOM SECTION, (see Figure 2-1 for details) HARDENED WASHER, 1/2 HEX HD CAPSCREW, 1/2-13X1, GR5 HEX HD CAPSCREW OPTIONS, GR5, (torque to 76-86 lb-ft) 1/2-20X1-1/4 1/2-20X1-1/2 HARDENED WASHER, 3/8 BEARING PAD MOUNT PLATE SPACER SHIM OPTIONS 2X8X.0598 2X8X.0359 MOUNT PLATE HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft) 3/8-24X3/4 3/8-24X7/8 3/8-24X1 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft) 3/8-24X1 3/8-24X1-1/4 SHIM OPTIONS 2X4X.0598 2X4X.0359 SPACER BEARING PAD HEX HD CAPSCREW, 3/8-16X7/8, GR5 SPACER SHIM OPTIONS 2X8X.0598 2X8X.0359 BEARING PAD LUBE FITTING, STRAIGHT, 1/4-28 LUBE BOLT OPTIONS, (torque to 45-50 lb-ft) 1/2-20X1-1/4 1/2-20X1-1/2

TL642

2-5

BOOM Figure 2-3 Second Boom Section

1

2 24

3 4

20

19 17

9

5

21 22

20

19 23

18

6

10 16

7

8

11

15

1

14

9 25 26 13

12

10

11

PAL1150

NOTE: FOR PART NUMBER AND MOUNTING HARDWARE OF ITEM 13 REFER TO FIGURE 2-1, ITEMS 13, 14, & 15.

2-6

TL642

31200255

BOOM Figure 2-3 Second Boom Section Item

Part Number

Qty.

1 2 3 4 5

303-8668 298-6862 297-7047 298-7382

1 2 2 2 1 1 1 4 4 1 1 1 1 2 4 1 Ref Ref Ref Ref 1 1 AR AR 2 1 1 1 2 1 AR

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

31200255

298-7011 298-7067 298-8030 298-8067 298-7023 298-1612 298-6830 299-0853 298-7108 298-7318 303-4929

298-7380 298-8003 298-1741 298-1742 298-8576 298-7069 303-5001 298-7246 298-7375 300-6071

Description SECOND BOOM SECTION PUSH BEAM PIN HEX HD CAPSCREW, 1/2-13X3-5/8, GR5 LOCKWASHER, 1/2 HOSE RETAINER, (includes the following items) L.H. HOSE RETAINER PAD SOCKET FLAT HD CAPSCREW, #10-24X5/8 HEX NUT, #10-24 RETRACTION SHEAVE PIN LUBE FITTING - STRAIGHT, 1/8 RETAINING RING LEAF CHAIN 643 ANCHOR PIN RETAINING RING CHAIN ANCHOR ANCHOR PLATE, (see Figure 2-1, item 13 for details) THIRD BOOM SECTION, (see Figure 2-5 for details) LEAF CHAIN 866, (see Figure 2-7, item 101 for details) CLEVIS 866-634, (see Figure 2-7, item 102 for details) LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X4, GR5 THRUST WASHER THRUST WASHER SEAL RETRACT ROLLER ASSY, (includes items 20 & 22) BUSHING HOSE SHEAVE FLAT WASHER, 1/2 CHAIN INSTALLATION, (includes items 9 thru 12 & item 26) ANTI-SEIZE LUBE

TL642

Rev.

C

2-7

BOOM Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)

11 8 9 10

13

12

14

17

15

3 7

2 22 23

25 5

18 22

3

16

26

6

3

27 4

22 24

8 9

2 1

3 21 20 19

SERVICE NOTES:

10 PAL1180

1. Add bearing pad shims & spacers as required to shim boom to within 1/16” of a tight fit. Whenever a shim is used with a pad, a spacer must be inserted between the pad & shim. No pads shall sit directly on slotted surface of shims. 2. The length of pad bolts depend on the amount of shims used. Bolt cannot extend past chamfer on bearing pad. 3. Add grease, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.

2-8

TL642

31200255

BOOM Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section) Item

Part Number

1 2

3 4 5 6

7 8

9 10 11 12 13 14 15 16

297-7056 297-7057 298-8015 298-1628 298-7075 298-1732 298-1726 298-1727 298-6924 298-1787 298-1788 298-1728 298-7073 297-7038 298-7367 298-8209 299-0493 298-1733 298-1735 297-7060 297-7061

17

18 19 20 21

22 23

298-8012 298-8013 297-7056 298-1615 298-7074 298-1730 298-1789 298-1790 298-1629 298-1626 298-1689

24

25 26

299-7118 297-7066 297-7067 298-8208 298-8019 298-8020 297-7068

31200255

Qty. Ref 8 AR AR AR 20 2 2 2 AR AR 1 6 AR AR 6 6 4 4 2 2 AR AR 4 AR AR 8 AR AR AR 2 2 2 2 AR AR 10 2 AR AR 4 AR AR AR 2 4 AR AR AR

Description

Rev.

SECOND BOOM SECTION, (see Figure 2-3 for details) HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft) 3/8-24X3/4 3/8-24X7/8 3/8-24X1 HARDENED WASHER, 3/8 BEARING PAD SPACER SHIM OPTIONS 2X8X.0598 2X8X.0359 MOUNT PLATE SHIM OPTIONS 2X4X.0598 2X4X.0359 SPACER BEARING PAD HEX HD CAPSCREW, 1/2-13X7/8, GR5, (torque to 76-86 lb-ft) FLAT WASHER, 1/2 BEARING PAD SPACER SPACER SHIM, 2X8X.0359 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft) 3/8-24X1-3/4 3/8-24X2 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft) 3/8-24X1/2 3/8-24X5/8 3/8-24X3/4 LUBE FITTING, 90 DEGREES, 1/4-28 BEARING PAD SPACER SHIM OPTIONS 2X4X.0598 2X4X.0359 HARDENED WASHER, 1/2 LUBE BOLT OPTIONS, (torque to 45-50 lb-ft) 1/2-20X1-1/4 1/2-20X1-1/2 HEX HD CAPSCREW OPTIONS, (torque to 76-86 lb-ft) 1/2-20X5/8 1/2-20X3/4 1/2-20X7/8 BEARING PAD HEX HD CAPSCREW OPTIONS, GR5, (torque to 76-86 lb-ft) 1/2-20X3/4 1/2-20X7/8 1/2-20X1

TL642

2-9


Part Number

Qty.

27

297-7069 297-7070 298-1729

AR AR 2

2-10

Description

Rev.

1/2-20X1-1/4 1/2-20X1-1/2 SPACER

TL642

31200255


31200255

Part Number

Qty.

Description

TL642

Rev.

2-11

BOOM Figure 2-5 Third Boom Section

11 10 9 3 4 7

3

11

6 2 3

5 14

8

13 12

1 11 101 102 103 104

1

SERVICE NOTES: 1. Add bearing pad shims & spacers as required to shim boom to within 1/16” of a tight fit. Whenever a shim is used with a pad, a spacer must be inserted between the pad & shim. No pads shall sit directly on slotted surface of shims. 2. The length of pad bolts depend on the amount of shims used. Bolt cannot extend past chamfer on bearing pad. 3. Add grease, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.

PAL1121

2-12

TL642

31200255

BOOM Figure 2-5 Third Boom Section Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

101 102 103 104

Part Number

Qty.

298-7063 297-7029 298-7380

1 2 6 1 1 1 2 Ref 2 Ref Ref 1 1 1

340-4184

1

340-4180 340-4182

Ref 1 1 1

297-7030 298-7365 298-7016 298-8579 299-0401 303-4743 297-7060

Description

Rev.

THIRD BOOM SECTION HEX HD CAPSCREW, 3/8-16X7/8, GR5, (torque to 28-30 lb-ft) FLAT WASHER, 3/8 GUIDE BAR PUSH BEAM BEARING PAD CHAIN RETAINER HEX HD CAPSCREW, 3/8-16X1-1/4, (torque to 25-30 lb-ft) CLEVIS 866-634, (see Figure 2-7, item 102 for details) HEX HD CAPSCREW, 3/8-24X1-3/4, GR5, (torque to 28-30 lb-ft) PUSH BEAM ASSY, (see Figure 2-7 for details) LEAF CHAIN 866, (see Figure 2-7, item 101 for details) ANCHOR PIN HEX HD CAPSCREW, 3/8-16X3/4, GR5 LOCKWASHER, 3/8 FRONT BOOM COVER INSTALLATION, (if equipped,) (not available to order, see items 101 thru 104 for service) CAT THREADLOCK LANYARD CABLE COMPRESSION LATCH FRONT BOOM COVER

A


31200255

TL642

2-13

BOOM Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section)

12 3 4

16 1

15 13 6

11 5

7 5

14 2

8

9 10

PAL1130

SERVICE NOTES: 1. Add bearing pad shims & spacers as required to shim boom to within 1/16” of a tight fit. Whenever a shim is used with a pad, a spacer must be inserted between the pad & shim. No pads shall sit directly on slotted surface of shims. 2. The length of pad bolts depend on the amount of shims used. Bolt cannot extend past chamfer on bearing pad. 3. Add grease, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.

2-14

TL642

31200255

BOOM Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section) Item

Part Number

1 2 3 4

298-7076 298-1733

5 6

298-1734 298-1735 298-1628

Qty. Ref 2 2 2 AR AR 8 4

297-7069 298-8021 7

8 9 10 11

12 13 14 15 16

4 298-8013 297-7056 298-8014 298-1789 298-1730 298-7074 298-8037 298-8038 298-8209 298-1629 298-1731 298-1615 298-1626 298-1689

31200255

2 2 2 4

2 4 2 2 2

Description

Rev.

THIRD BOOM SECTION, (see Figure 2-5 for details) BEARING PAD SPACER SHIM OPTIONS 2X8X.0598 2X8X.0359 FLAT WASHER, 3/8 HEX HD CAPSCREW OPTIONS, (torque to 76-86 lb-ft) 1/2-20X1-1/4, GR5 1/2-20X1-1/2, GR5 HEX HD CAPSCREW OPTIONS, (torque to 28-30 lb-ft) 3/8-24X5/8, GR5 3/8-24X3/4, GR5 3/8-24X7/8, GR5 SHIM, 2X4X.0598 SPACER BEARING PAD SOCKET BUTTON HD CAPSCREW OPTIONS, (torque to 28-30 lb-ft) 3/8-24X1 3/8-24X1-1/4 BEARING PAD HARDENED WASHER, 1/2 SPACER LUBE FITTING, 45 DEGREES, 1/4-28 LUBE BOLT OPTIONS, (torque to 45-50 lb-ft) 1/2-20X1-1/4 1/2-20X1-1/2

TL642

2-15

BOOM Figure 2-7 Push Beam/Extend Chain & Roller Assembly

NOTE: THE CHAIN CLEVIS ROD (item 4), ATTACHES TO THE STRONG BACK (item 3), IN FIGURE 2-1

7

4

8 16

NOTE: SEE FIGURE 2-5 FOR PUSH BEAM, CHAIN RETAINER & BEARING PADS.

20

10 3 101

22

312 8 21

103 105

102 104

1 9

13

3 101

15 19

14 12

203 18

202

203 7 17

2-16

NOTE: THE CLEVIS ROD (item 102), SEATS IN THE REAR OF THE THIRD BOOM SECTION, ILLUSTRATED IN FIGURE 2-5.

1 5 6

2 8 11 PAL1111

TL642

31200255

BOOM Figure 2-7 Push Beam/Extend Chain & Roller Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 101 102 103 104 105 202 203 312

Part Number

Qty.

300-6073

1 AR AR Ref

304-3165 305-3763 297-7039 298-7382

298-8062 298-7312 298-1612 298-1650 298-1651 298-6920 298-6921 298-7022 298-7028 298-1739 298-8257 298-8767 298-7106 298-8583 303-4935 298-7107 298-7312 303-5000 298-7032

1 2 2 AR AR 1 2 1 1 1 1 1 Ref 1 1 1 13’ 1 1 1 1 1 2 AR 1 2 Ref

Description PUSH BEAM ASSY, (includes items 1 thru 22) LOCTITE, #242 LOCTITE, #545 LEAF CHAIN ASSY, (not available to order, see items 101 thru 105 for service) CHAIN CLEVIS ROD HEX HD CAPSCREW, 1/2-13X1, GR5 LOCKWASHER, 1/2 NEVER SEEZ LUBE MYSTIK TETRIMOLY GREASE HEX NUT, 1-3/8-12, (torque to 155-195 lb-ft) SNAP RING, 3/8 LUBE FITTING, STRAIGHT, 1/8 SHIM SHIM KEEPER TAB WASHER EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details) EXTEND SHEAVE PIN CHAIN ROLLER ASSY, (includes items 202 & 203) HARD WASHER UHMW TAPE, (order by the ft.) PUSH BEAM WELDMENT ANCHOR PIN LEAF CHAIN, 866 CLEVIS, 866-634 ANCHOR PIN SNAP RING, 3/8 ANTI SEEZE LUBE BUSHING SEAL ANCHOR PIN, (see Figure 2-5 for details)

Rev. B

C


31200255

TL642

2-17

BOOM Figure 2-8 Quick Coupler Assembly

7 9

8

6

101

5 102 3 1

2

8 3

14

11 12

7 9

4

10 13

SERVICE NOTES: Use loctite, (0100011S), on all bolt threads

PAL1251

2-18

TL642

31200255

BOOM Figure 2-8 Quick Coupler Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101 102

Part Number

Qty.

304-3176 303-4926 365-9208 298-8734 298-8724 299-0305 298-7057 298-1612 297-7039

1 1

300-6103 300-6078 300-6084 300-6079 300-6095

1 1 1 1 2 2 2 AR 1 1 1 1 2 Ref Ref

Description QUICK COUPLER INSTALLATION, (includes items 1 thru 14) QUICK ATTACH COUPLER ASSY, (Before S/N TBK01134) QUICK ATTACH COUPLER ASSY, (S/N TBK01134 & After) HEAD PIN ASSY PIN ASSY PIN PIN WELDMENT GREASE FITTING, STRAIGHT HEX HD CAPSCREW, 1/2-13X1 HARDENED WASHER, 1/2 CAT THREADLOCK DUST CAP QUICK DISCONNECT COUPLING, FEMALE DUST PLUG QUICK DISCONNECT COUPLING, MALE FITTING THIRD BOOM SECTION, (see Figure 2-5 for details) TILT CYLINDER, (see Figure 9-3 for details)

Rev. C


31200255

TL642

2-19

BOOM Figure 2-9 Hydraulic Quick Coupler Assembly 14 102 105

105 111

19 S/N TBK01134 & After

2 13

8 12 15

102 105

9 1

4

19

103

101

104

106 108 109 106 107 110

8 10 11 12 21 15

5

2-20

202

16 6 201

TL642

7

15 17 18 20

PAL1201

31200255

BOOM Figure 2-9 Hydraulic Quick Coupler Assembly Item

1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 101 102 103 104 105 106 107 108 109 110 111 201 202

Part Number

Qty.

304-2595

1

365-9209

1

303-4926 365-9208 298-8734 298-7228 365-9207 298-7356 308-0608 298-0407 297-7039 298-1358 298-7057 299-6623

1 1 1 1 1 2 2 2 2 2 1 AR 2 2 1 AR 1 1 1 2 2 1 AR 1 2 1 2 2 2 2 1 1 1 1 1 Ref 1 1

298-1612 299-1349 299-1351 298-7437 299-6644 298-0413 365-9211 297-7020 299-6624 334-3738 298-7355 298-0471 298-0466 298-0414 298-0416 300-6095 300-6078 300-6079 300-6103 300-6084 309-6353 299-0308 299-0285

Description HYDRAULIC QUICK COUPLER ASSEMBLY, (Before S/N TBK01134), (includes items 1 thru 21) HYDRAULIC QUICK COUPLER ASSEMBLY, (S/N TBK01134 & After), (includes items 1 thru 10 & 12 thru 21) QUICK COUPLER ASSEMBLY, (Before S/N TBK01134) QUICK COUPLER ASSEMBLY, (S/N TBK01134 & After) HEAD PIN ASSEMBLY CYLINDER COVER, (Before S/N TBK01134) CYLINDER COVER, (S/N TBK01134 & After) CONNECTOR DOWEL PIN QUICK ATTACH PIN HEX HD CAPSCREW, 1/2-13X1, GR5 SERRATED HEX HD SCREW, 3/8-16X3/4 WELDMENT PIN FLEX TRIM SHIELD, (Before S/N TBK01134) HARDENED WASHER, 1/2 GREASE FITTING, (straight), 1/8 QUICK COUPLER VALVE ASSEMBLY, (includes items 101 thru 111) CAT THREADLOCK QUICK COUPLER CYLINDER ASSEMBLY, (includes items 201 thru 202) CLAMP SET COVER PLATE HOSE ASSY, (Before S/N TBK01134) HOSE ASSY, (S/N TBK01134 & After) HEX HD CAPSCREW, 5/16-18X1-1/2, GR5 FLEX TRIM SHIELD QUICK COUPLER VALVE CONNECTOR, (Before S/N TBK01134) CONNECTOR, (S/N TBK01134 & After) CONNECTOR SWIVEL ADAPTER STRAIGHT THREAD REDUCER/EXPANDER ELBOW, 90 DEGREES QUICK DISCONNECT COUPLING, FEMALE QUICK DISCONNECT COUPLING, MALE DUST CAP DUST PLUG ELBOW, 90 DEGREES, (includes o-ring) QUICK COUPLER CYLINDER, (see Figure 9-12 for details) CHECK PILOT VALVE SEAL KIT

Rev. E A

F B


31200255

TL642

2-21

BOOM


2-22

TL642

31200255

SECTION 3 ATTACHMENTS

31200255

TL642

ATTACHMENTS Figure 3-1 50” & 72” Carriage Assembly

6

1

3

4

5 2

6

1

3

4

5 2 PAL0730

3-2

TL642

31200255

ATTACHMENTS Figure 3-1 50” & 72” Carriage Assembly Item

1 2 3 4 5 6 101

Part Number

Qty.

301-9757 301-9758 303-4741 303-4782 303-4957 303-4958 303-4988 305-3783 305-3784 305-3785 305-3786

1 1 2 2 1 1 2 1 1 1 1 Ref

Description 50” CARRIAGE ASSY, (includes items 1 thru 6) 72” CARRIAGE ASSY, (includes items 1 thru 6) HEX HD CAPSCREW, 5/8-11X4, GR5 LOCKNUT, 5/8 FORK PIN, (50” carriage) FORK PIN, (72” carriage) COLLAR 50” CARRIAGE WELDMENT 72” CARRIAGE WELDMENT 50” CARRIAGE SERIAL NO. PLATE 72” CARRIAGE SERIAL NO. PLATE FORK, (see Figure 3-2 for details)

Rev. A A


31200255

TL642

3-3

ATTACHMENTS Figure 3-2 Forks

PAL1210

3-4

TL642

31200255

ATTACHMENTS Figure 3-2 Forks Item

Part Number

Qty.

301-9752 301-9755 301-9753 301-9754 301-9756 324-5262 311-2854

2 2 2 2 2 2 2

Description 48” CUBING FORK, 2X2, 3,880 lbs. 48” PALLET FORK, 2.36X4, 10,950 lbs. 48” PALLET FORK, 2.36X5, 13,700 lbs. 60” LUMBER FORK, 2.36X6, 16,300 lbs. 60” LUMBER FORK, 1-3/4X7, 10,800 lbs. 60” LUMBER FORK, 2X7, 13,700 lbs. DUAL TAPER FORKS, 2X6X72, 11,300 lbs.

Rev. A A A A A A A

NOTE: FORKS RATED LESS THAN THE ATTACHMENT OR MACHINE’S CAPACITY DECREASE CAPACITY OF THE ATTACHMENT OR MACHINE TO THAT OF THE FORKS. FORKS RATED MORE THAN THE ATTACHMENT OR MACHINE’S CAPACITY DO NOT INCREASE ATTACHMENT OR MACHINE’S CAPACITY. NOTE: PLEASE CONSULT THE JLG PARTS DEPARTMENT TO DETERMINE THE CORRECT FORKS APPLICABLE TO YOUR SPECIFIC CARRIAGE ASSEMBLY AND APPLICATION.

31200255

TL642

3-5

ATTACHMENTS Figure 3-3 Winch Installation

1

9 11 12

8 9 11

9 11 13

20 B A

B

3 17 19

21 27 28 29

5 18 19

6

19

10 14 15

24 2

19

4

A AUXILIARY LINE "UP/RIGHT"

AUXILIARY LINE "DOWN/LEFT"

VIEW A-A

7

2

3 1

21

22

10 25

20

26 24

PAL0740

VIEW B-B

3-6

TL642

31200255

ATTACHMENTS Figure 3-3 Winch Installation Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 24 25 26 27 28 29

Part Number

Qty.

305-3768 303-4999 303-4898

1 1 1 Ref 1 1 1 1 2 6 Ref 6 2 2 2 2 1 1 2 1 1 2 2 1 1 4 4 4

299-0362 298-7055 298-6832 298-1660 298-7918 298-1630 298-8051 298-7916 298-7919 298-7995 298-7379 300-6078 300-6079 304-2581 304-2582 350-0995 298-0475 298-0474 303-4755 298-0497 303-4737 298-7365 298-8049

Description WINCH INSTALLATION, (includes all items) WINCH MOUNTING PLATE WINCH HOOK STOWAGE WINCH W/MOTOR, (see Figures 12-2 & 12-3 for details) HOOK & BALL CABLE WIRE ROPE CLIP, 7/16 CAUTION DECAL HEX HD CAPSCREW, 5/8-11X2-3/4, GR8, (torque to 200-215 lb-ft) HARDENED WASHER PRESSURE REDUCER VALVE, 1360 PSI, (see Figure 12-4 for details) HEX NUT, 5/8-11 HEX HD CAPSCREW, 5/8-11X2-1/4, GR8, (torque to 200-215 lb-ft) HEX HD CAPSCREW, 5/8-11X2-1/2, GR8, (torque to 200-215 lb-ft) HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 FLAT WASHER, 5/16 FEMALE QUICK DISCONNECT MALE QUICK DISCONNECT HOSE ASSY HOSE ASSY HOSE ASSY ELBOW, 90 DEGREES, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) SWIVEL NUT RUN TEE, 1/2 TUBE HEX HD CAPSCREW, 3/8-16X1-3/8, GR5 FLAT WASHER, 3/8 HEX NUT, 3/8-16

Rev. A, 4


31200255

TL642

3-7

ATTACHMENTS Figure 3-4 50” & 72” Side Tilt Carriage Assembly

22

6 4 15

18 24 5 11

14

2 3 7 8 23 21

19 20

12 13 1 3 9 10 16 17

22

FRONT VIEW OF CARRIAGE

6

15

4 18 24

2 11 5

14 3 7 8

23 21

3-8

19 20

TL642

PAL3220

31200255

ATTACHMENTS Figure 3-4 50” & 72” Side Tilt Carriage Assembly Item

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

31200255

Part Number

Qty.

309-4315 309-4316 297-7033 303-4741 297-7077 309-4320 309-4321 303-4782 303-4957 303-4958 309-4322 309-4323 298-7392 298-1612 303-4988 309-4311 309-4312 309-4313 309-4317 309-4318 309-4319 298-7358 313-3349 300-6078 300-6079

1 1 4 2 3 1 1 2 1 1 2 2 1 1 2 2 2 1 1 1 1 2 2 1 1 1 2 2

330-8325 298-0507

Description 50” SIDE TILT CARRIAGE ASSEMBLY, (includes items 1 thru 24) 72” SIDE TILT CARRIAGE ASSEMBLY, (includes items 1 thru 24) HEX HD CAPSCREW, 3/8-16X1-1/2, GR5 HEX HD CAPSCREW, 5/8-11X4, GR5 HEX HD CAPSCREW, 1/2-13X1-1/4, GR8 50” CARRIAGE 72” CARRIAGE NYLON COLLAR LOCKNUT, 5/8-11 FORK PIN, (50” carriage) FORK PIN, (72” carriage) CYLINDER PIN KEEPER, 1/2 FLAT WASHER, 1/2 LUBE FITTING, STRAIGHT, 1/8 FORK COLLAR WEAR PAD ASSEMBLY SHIM CARRIAGE PIVOT BASE HYDRAULIC CYLINDER BEARING PIN CONNECTOR, (includes o-ring) HOSE ASSEMBLY QUICK DISCONNECT, (female) QUICK DISCONNECT, (male) S/N PLATE CONNECTOR ELBOW, 90 DEGREES, (includes o-ring)

TL642

Rev. D D

3-9

ATTACHMENTS Figure 3-5 Fork Clamp Installation

2

1

PAL3210

3-10

TL642

31200255

ATTACHMENTS Figure 3-5 Fork Clamp Installation Item 1 2

31200255

Part Number

Qty.

310-6250 310-6251

1 4 4

Description FORK CLAMP INSTALLATION, (includes all items) FORK CLAMP HEX HD CAPSCREW, 5/8-18X1-1/2

TL642

Rev. A

3-11

ATTACHMENTS Figure 3-6 Fork Mounted Platform

1 110 111

101 102 107 109 11

4

17

2

114 10 112

113

3 105 103

108 104 106 101 201 214 209

1 110 111

11 203 210 212

4 17

2

218

3 10 102 103

211

108

104 106 PAL3231

3-12

TL642

31200255

ATTACHMENTS Figure 3-6 Fork Mounted Platform Item

Part Number

10

11

17 101 102 103 104 105 106 107 108 109 110 111 112 113 114 201 203 209 210 211 212 214 218

Description

Rev.

Ref

FORK MOUNTED PLATFORM, (Before S/N TBK01108), (no longer available, see items 1 thru 17 for service; order 1001108938, 1001108939 or 1001108940 for replacement) FORK MOUNTED PLATFORM,(includes items 1, 4 thru 17) FORK MOUNTED PLATFORM, (ISO), (includes items 1, 4 thru 17) FORK MOUNTED PLATFORM, (FRENCH), (includes items 1, 4 thru 17) FORK MOUNTED PLATFORM, (Before S/N TBK01108), (no longer available, order items 101 thru 114 for service, order 1001108938 for replacement) FORK MOUNTED PLATFORM, (S/N TBK01108 & After), (includes items 2, 3, 101 thru 104, 106,108, 110,111 & 201 thru 218) MANUAL DECAL LANYARD ATTACH DECAL MANUAL DECAL MANUAL DECAL, (ISO) MANUAL DECAL, (FRENCH) MANUAL DECAL MANUAL DECAL, (ISO) MANUAL DECAL, (FRENCH) MANUAL DECAL MANUAL DECAL, (ISO) MANUAL DECAL, (FRENCH) S/N PLATE MANUAL STORAGE BOX RIVNUT, 1/4-20 HINGE LATCH PLUG RIVET WASHER, 1/4 GATE WHIZ LOCK SCREW, 1/4-20X0.5 WORK PLATFORM GATE, (Before S/N TBK01108) WORK PLATFORM GATE, (S/N TBK01108 & After) PLATFORM BASE, (Before S/N TBK01108) PLATFORM BASE, (S/N TBK01108 & After) SUPPORT PIN SAFETY SNAP PIN W/LANYARD LYNCH PIN W/LANYARD, 3/16 HEX HD CAPSCREW, 1/4-20X5/8, GR5 LANYARD CABLE, 6 in HEX NUT, 1/4-20, GR2 PIN PLUG RING WASHER, 1/4 HITCH PIN

D

343-9736 343-9737 343-9738

1 1 1 1

340-8976

1

338-9997 335-8059 338-9996 328-7293 328-7292 338-9999 328-7290 328-7288 339-0000 328-7291 328-7289

1 8 1 1 1 1 1 1 1 1 1 1 1 4 2 1 21 20 4 1 4 1 1 1 1 2 2 2 4 2 4 2 10 4 8 2

1

2 3 4

Qty.

304-2566 335-8066 336-2804 335-8078 335-8080 298-7372 335-8098 339-0003 340-8975 339-0004 340-8974 327-6271

297-7010 340-8977 298-0548 340-8978 335-8077 298-7363 340-8979

A A A B

E

NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE.

31200255

TL642

3-13

ATTACHMENTS Figure 3-7 Fork Mounted Hook

3

7

4

1 5

6

2 PAL3450

3-14

TL642

31200255

ATTACHMENTS Figure 3-7 Fork Mounted Hook Item 1 2 3 4 5 6 7

31200255

Part Number

Qty.

321-0556 327-6270 327-6335 327-6317 327-6271 327-6272 327-6318

1 1 1 2 2 1 1 1

Description FORK MOUNTED HOOK, (includes all items) FORK MOUNTED HOOK WELDMENT HOOK COTTER PIN PIN WELDMENT SPRING BUSHING CHAIN SHACKLE SERIAL NUMBER PLATE

TL642

Rev. A

3-15

ATTACHMENTS Figure 3-8 100 Degree Swing Carriage

3-16

TL642

31200255

ATTACHMENTS Figure 3-8 100 Degree Swing Carriage Item 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

31200255

Part Number

Qty.

318-9222

1 1 1 1 2 4 4 1 2 2 2 1 1 5 5 Ref 2 4 4 4 4 2 2 2 2 2 2 2 1 1 1 1 2 1 2 4 4

327-6320 327-6329 327-6321 327-6327

327-6326 327-6323

327-6330 327-6324 327-6333 327-6273 327-6274 362-2111 362-2109 362-2110 327-6325 362-2106 327-6328

Description 100 DEGREE SWING CARRIAGE, (includes all items) SWING CARRIAGE SWING WELDMENT FORK PIN FORK PIN RETAINER LOCKWASHER, 1/2 HEX HD CAPSCREW, 1/2X1-1/4 SWING POST LUBE FITTING, 1/8 BEARING THRUST WASHER CASTLE NUT COTTER PIN HEX HD CAPSCREW, 3/4-3 HEX LOCKNUT, 3/4-16 CYLINDER, (see Figure 9-15 for details) SPACER LOCKING PIN FLAT WASHER, 3/8 LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8X1 ELBOW, 90 DEGREES ELBOW, 90 DEGREES HOSE ASSY HOSE ASSY RUN TEE HOSE ASSY CONNECTOR FEMALE QUICK COUPLER MALE QUICK COUPLER WARNING DECAL, HIGH PRESSURE MADE IN USA DECAL PINCH POINT DECAL S/N PLATE STOP BLOCK HEX HD CAPSCREW, 3/4X2-1/4, GR8 LOCKWASHER, 3/4

TL642

Rev. D

3-17

ATTACHMENTS Figure 3-9 48” Side Shift Carriage

3-18

TL642

31200255

ATTACHMENTS Figure 3-9 48” Side Shift Carriage Item 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

31200255

Part Number

Qty.

314-8479 362-2110 362-2109 362-2111 362-2119 362-2104 362-2118 362-2117 327-6333

1 1 1 2 2 2 1 1 2 Ref 1 1 2 1 1 6 1 1 1 1 1 1 1 1 1 2 2 2 3 6

327-6287 362-2122 362-2108 362-2116 362-2114 362-2100 362-2115 327-6277 362-2112 362-2113 327-6305 362-2101 327-6325 362-2106 327-6328 362-2107 362-2103 362-2102 327-6329

Description 48” SIDE SHIFT CARRIAGE, (includes items 1 thru 29) MALE QUICK COUPLER FEMALE QUICK COUPLER CONNECTOR HOSE ASSY BULKHEAD STRAIGHT CONNECTOR HOSE ASSY HOSE ASSY ELBOW, 90 DEGREES CYLINDER, (see Figure 9-16 for details) PIN PIN HEX HD CAPSCREW, 0.3X1 RIGHT PIN RETAINER LEFT PIN RETAINER HEX HD CAPSCREW, 0.5X1.5 SIDE SHIFT PIN FORK PIN S/N PLATE REAR FRAME FRONT FRAME HOSE CLAMP HEX HD CAPSCREW, 0.31X1.75 HI PRESSURE WARNING DECAL MADE IN USA DECAL PINCH POINT DANGER DECAL GREASE ZERK FLAT WASHER, 0.31 LOCK WASHER, 0.31 LOCK WASHER, 0.5

TL642

Rev. C

3-19

ATTACHMENTS


3-20

TL642

31200255

SECTION 4 ENGINE & ATTACHING PARTS

31200255

TL642


ENGINE & ATTACHING PARTS Figure 4-1 Engine Assembly, L.H. View

244 275 280

6

260

A

A

209 210 243

112

1 105

205 232 280

306 315 305 250

251

226 251 278 279

301 322 325 327

209 102 104 107 402 109 405 414

408 305

412 413 403

201 227 264 280

277

3 4

216

101 110 111

237 258 103 106 109

202 208 226 280 214 215

108

219 224

115 116 117 STARTER

239 235

211 217

226 231 278 279 280

252

501 502 503

GLOW PLUG VIEW A-A

246

212

SERVICE NOTES: 1) Use loctite 242, 0100011S, on all bolt threads.

4-2

203 218 234 254 280

207 233 276 280

213

TL642

253

PAL1012

31200255


ENGINE & ATTACHING PARTS Figure 4-1 Engine Assembly, L.H. View

Item

Part Number

Qty.

1 3 4

331-2460

1 Ref 1

6 101 102 103 104 105 106 107 108 109 110 111 112 115 116 117 201 202 203 205 207 208 209 210 211 212 213 214 215 216 217 218 219 224 226 227 231 232 233 234 235 237 239 243 244

31200255

300-6082

8T-4136 303-8559 297-7098 298-7368 8T-4121 299-0271 298-8410 298-8412 331-2385 341-2966 303-8599 297-7011 303-4742 303-4743 8T-4136 8T-4956 304-2567 299-0309 298-1633 303-4769 298-0516 298-0517 303-4951 303-4952 298-0532 303-4953 303-4774 303-4776 303-4785 298-7364 298-7378 298-7387 298-7388 298-7389 303-4789 303-4790 303-4753 299-0326 299-0378 298-1666

Ref AR 4 6 12 Ref 6 12 1 AR 1 1 Ref 1 1 1 2 2 1 2 1 1 4 1 1 1 1 1 1 AR 1 1 2 2 4 2 2 2 1 2 5 1 2 1 1

Description ZF TRANSMISSION ASSEMBLY, (includes items 101 thru 117) ENGINE, (see Figure 4-4 for details) ENGINE ASSEMBLY, (includes items 201 thru 280 on Figure 4-1 and all items on Figure 4-2) RADIATOR ASSEMBLY, (see Figure 4-6 for details) LOCTITE, #242 HEX HD CAPSCREW, 10-1.50X25mm, GR8.8, (torque to 26-29 lb-ft) HEX HD CAPSCREW, 16-2.00X45mm, GR8.8, (torque to 125-140 lb-ft) HEX HD CAPSCREW, 10-1.50X35mm, GR10.9, (torque to 53-58 lb-ft) ZF TRANSMISSION, (see Figure 4-9 for details) FLAT WASHER, 5/8 FLAT WASHER, 10mm TRANSMISSION BRACKET LOCTITE, # 242 FITTING TRANSMISSION TEMPERATURE SENSOR TRANSMISSION HARNESS, (see Figure 10-4 for details) OIL DRAIN VALVE HOSE CLAMP HEX HD CAPSCREW, 1/4-20X3/4, GR5 HEX HD CAPSCREW, 5/16-18X1-1/4, GR8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR8 HEX HD CAPSCREW, 10-1.50X25mm, GR8.8 HEX HD CAPSCREW, 12-1.75X35mm, GR8.8 ELECTRIC RELAY BRACKET BAND CLAMP LAMP CLAMP HOSE FITTING FITTING FITTING TEE FUSE HOLDER FUSE, 50 AMP FUEL LINE HOSE HEX LOCKNUT, 3/8-16, GR2 HEX LOCKNUT, 3MM-1/2 POSI-DRIVE MACHINE SCREW, 3MM-.5X16 FLAT WASHER, 5/16 LOCKWASHER, 1/4 SPRING LOCKWASHER, 8mm SPRING LOCKWASHER, 10mm SPRING LOCKWASHER, 12mm WASHER, 3/8 RIPPBOLT, 6-36X10mm LOCKWASHER, .500 RELAY FUEL STRAINER SUPPORT CLAMP

TL642

Rev. B B C C

4-3


ENGINE & ATTACHING PARTS

Figure 4-1 Engine Assembly, L.H. View (Continued) Item

Part Number

Qty.

246 250 251 252 253 254 258 260 264 275 276 277 278 279 280 301 305 306 315 322 325 327 402 403 405 408 412 413 414

299-0390 298-8732 298-8733

298-8379 298-8380 298-8435

1 1 1 Ref 1 1 1 1 1 1 1 1 2 2 AR AR 5 Ref 1 3 3 1 4 4 4 Ref 4 4 4

310-8508 303-8599 310-8507 341-1835

1 1 1 1

501 502 503

298-0402 303-4821 303-4826 298-0419 298-0425 8T-4200 298-0526 298-7974 303-4792 8T-4189

298-0467 303-4758 8T-4956 298-7392 298-7890 297-7048 298-0559 298-7375

Description

Rev.

OIL PRESSURE SENSOR R.H. ENGINE MOUNT L.H. ENGINE MOUNT RELAY, (Fuel Pump), (see Figure 10-3 for details) OIL PRESSURE SENDER MOUNT PLATE BRACKET CAB GROUND CABLE TURBO INTAKE BRACKET THROTTLE INTAKE BRACKET HEX HD CAPSCREW, 8-1.25X16mm, GR8.8 SUPPORT CLAMP SUPPORT CLAMP SUPPORT CLAMP HEX HD CAPSCREW, 8-1.25X20mm, GR8.8 LOCTITE, #242 DIELECTRIC GREASE CONNECTOR IMPLEMENT PUMP, (see Figure 9-7 for details) ELBOW, 90 DEGREES HEX HD CAPSCREW, 12-1.75X35mm, GR8.8 WASHER, 1/2 O-RING, (located between pump and transmission) HEX HD CAPSCREW, 1/2-13X3-3/4, GR5 HEX LOCKNUT, 1/2-13 FLAT WASHER, 1/2 BATTERY, (see Figure 10-1 for details) ENGINE MOUNT SHIM ENGINE MOUNT WASHER ENGINE MOUNT RUBBER OIL DRAIN INSTALLATION, (includes items 501 thru 503) CLAMP OIL DRAIN VALVE HOSE

B


4-4

TL642

31200255



Figure 4-1 Engine Assembly, L.H. View (Continued) Item

31200255

Part Number

Qty.

Description

TL642

Rev.

4-5


ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly, R.H. View

70 76

20 21 29 30

71

57

55

56

5 28 45

4 31 85

7 33 67

6

84

32 85 86

66

5 32 85 86

62

63

HEAT SHIELD SHOWN TRANSPARENT FOR CLARITY

PAL1022

SERVICE NOTES: 1) Use loctite 242, 0100011, on all bolt threads.

4-6

TL642

31200255


ENGINE & ATTACHING PARTS Figure 4-2 Engine Assembly, R.H. View

Item

4 5 6 7 20 21 28 29 30 31 32 33 45 55 56 57 61 62 63 66 67 70 71 76 80 84 85 86

Part Number

Qty.

Description

Rev.

300-6082

1

F

8T-4908 8T-4136 8T-4196 8T-4956 303-4777 5C-2890 8T-4121 304-2604 303-4787 298-7387 298-7388 298-7389 303-4827

1 8 2 2 1 1 3 1 1 1 7 2 1 Ref Ref Ref Ref 1 1 1 1 1 Ref 2 AR 2 7 4

ENGINE ASSEMBLY, (includes items 201 thru 280 on Figure 4-1 & all items on Figure 4-2) HEX HD CAPSCREW, 8X25, GR8.8 HEX HD CAPSCREW, 10X25, GR8.8 HEX HD CAPSCREW, 10X35, GR8.8 HEX HD CAPSCREW, 12X35, GR8.8 HEX NUT, M5X0.8 HEX NUT, M6X1 FLAT WASHER, 10mm SPRING LOCKWASHER, 5mm SPRING LOCKWASHER, 6mm SPRING LOCKWASHER, 8mm SPRING LOCKWASHER, 10mm SPRING LOCKWASHER, 21mm ENGINE TEMPERATURE SENSOR NEGATIVE BATTERY CABLE, (see Figure 10-1 for details) NEGATIVE BATTERY CABLE, (see Figure 10-1 for details) POSITIVE BATTERY CABLE, (see Figure 10-1 for details) EXHAUST INSTALLATION, (see Figure 4-8 for details) OUTLET ADAPTER ELBOW MOUNTING BRACKET HEAT SHIELD HEAT SHIELD AIR CLEANER INSTALLATION, (see Figure 4-7 for details) SUPPORT CLAMP LOCTITE, #242 HEX HD CAPSCREW, M10X40 FLAT WASHER, 3/8 HEX NUT, M10X1.5

302-0581 299-0303 298-8737 298-8738 298-8740 298-0526 8T-4186 298-7365 8T-4133


31200255

TL642

4-7


ENGINE & ATTACHING PARTS Figure 4-3 Engine Assembly

206 228

431 432 433

231 206 229

408 409 410 257 237 151 152 153 156 159

232 271 272

232 272

256

262

225 263 304

261 234 268 258

227

401 402 403 404

313

151 152 153 156 159

205 311 207 230

303

307 308

306 309

209 215 211

301 305 314

208 301 312

151 152 153 156 159

4-8

204 207 230

TL642

238 151 152 153 156 159 PAL5540

31200255



Item

Part Number

1

Qty.

Description

Rev.

Ref

ENGINE POD COMMON HARDWARE INSTALLATION, (not available to order, see items 151 thru 159 for service) ENGINE COMPONENTS INSTALL, (not available to order, see items 205 thru 278 for service) ENGINE, (see Figure 4-4 for details) ZF TRANSMISSION INSTALL, (not available to order, see items 301 thru 314 for service) HEX HD CAPSCREW, 7/8-9X5, GR8, (torque to 575-635 lb-ft) WASHER, 7/8 HEX LOCKNUT, 7/8-9 REBOUND WASHER LORD MOUNT ENGINE MOUNT SUPPORT, RH ENGINE SUPPORT MOUNT, LH WASHER, 3/8 HEX HD CAPSCREW, 12X35mm, GR8.8 RADIATOR HOSE, LOWER, (see Figure 4-6 for details) UPPER RADIATOR HOSE, (see Figure 4-6 for details) AIR INTAKE PIPE, (see Figure 4-7 for details) EXHAUST TUBE, (see Figure 4-8 for details) NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE HEX HD CAPSCREW, 3/8-16X2-1/2, GR5 HEX LOCKNUT, 13/8-16 WASHER, 12mm FUEL/WATER SEPERATOR MOUNT GEAR CLAMP HOSE CLAMP ENGINE MOUNT SUPPORT, LH ENGINE MOUNT SUPPORT, RH ENGINE HARNESS, (not shown), FUEL HOSE FUEL HOSE FUEL LINE GROUND WIRE, ENGINE BLOCK VEC HARNESS GROUND WIRE, CAB NEGATIVE CABLE, (see Figure 10-1 for details) QUICK CONNECT, FEMALE QUICK CONNECT, FEMALE LOCTITE, #242 ELBOW, 90 DEGREES, (includes o-ring) TRANSMISSION, (see Figure 4-9 for details) WASHER, 10mm GEAR CLAMP CONNECTOR TRANSMISSION OIL TEMPERATURE SWITCH OIL DRAIN VALVE RUN TEE, (includes o-ring)

A

2

360-6616

Ref

3 4

364-5702

Ref Ref

151 152 153 156 159 204 205 206 207 208 209 211 215 225 227 228 229 230 231 232 234 237 238 250 256 257 258 261 262 263 268 271 272 301 303 304 305 306 307 308 309 311

31200255

309-6238

364-5699 360-6613 360-6614 298-7365 8T-4956

4L-6459 8T-4133 8T-4223 361-2868 303-8599 298-7980 360-6610 360-6612 360-6625 340-3225 298-0532 360-0051 360-0050 360-0053 307-9602 307-9603 303-4757 8T-4121 303-8599 298-8410 298-8412 331-2385 6V-8776

4 4 4 4 4 1 1 4 8 Ref Ref Ref Ref Ref Ref 2 2 8 1 4 2 1 1 Ref 1 1 AR Ref Ref Ref Ref 1 2 AR 1 Ref 12 1 1 1 1 1

TL642

Q

F

4-9


ENGINE & ATTACHING PARTS Figure 4-3 Engine Assembly Item

Part Number

Qty.

312 313 314 401 402 403 404 408 409 410 431 432 433

8T-4136 341-2966 297-7097

4 1 12 Ref 1 3 3 Ref 3 3 1 1 1

298-7392 8T-4956 298-7380 297-7032

Description

Rev.

HEX HD CAPSCREW, 10X25mm, GR8.8, (torque to 26-23 lb-ft) DRAIN HOSE HEX HD CAPSCREW, 10X30mm PUMP, (see Figure 9-7 for details) O-RING WASHER, 1/2 HEX HD CAPSCREW, M12X35, GR5.5 PRIORITY VALVE, (see Figure 9-10 for details) LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1.25, GR5 CLAMP SCREW, 1/2-13X1 HEX NUT, 0.5-13


4-10

TL642

31200255



Item

31200255

Part Number

Qty.

Description

TL642

Rev.

4-11



Figure 4-4 Cat Engine

PAL0980

4-12

TL642

31200255


ENGINE & ATTACHING PARTS Figure 4-4 Cat Engine

Item

Part Number

Qty.

284-4636 268-0867 1R1804 130-1161 124-7702 7W2326 268-3633 329-0290 303-4891 254-2267 9L0895 103-5916

1 1 1 1 1 1 1 1 1 1 1 1

CAT ENGINE - 3054C, 99HP, (includes all items), (Before S/N TBK01051) SHORT BLOCK FUEL FILTER KIT (Perkins #26560201) DIPSTICK (Perkins #3178C077) DIPSTICK TUBE (Perkins #3577A125) OIL FILTER (Perkins #2654407) STARTER MOTOR (Perkins #2873K405), (Before S/N TBK00975) STARTER MOTOR (Perkins #2873K634), (S/N TBK00975 & After) ALTERNATOR (Perkins #2871A303), (Before S/N TBK01051) THERMOSTAT (Perkins #4133L507) FAN BELT (Perkins #2614B953) FAN (Perkins #2485C518)

F

330-3035 268-0867 1R1804 130-1161 124-7702 7W2326 329-0290 339-7766 254-2267 9L0895 103-5916

1 1 1 1 1 1 1 1 1 1 1

CAT ENGINE, 99HP, (includes all items), (S/N TBK01051 & After) SHORT BLOCK FUEL FILTER KIT (Perkins #26560201) DIPSTICK (Perkins #3178C077) DIPSTICK TUBE (Perkins #3577A125) OIL FILTER (Perkins #2654407) STARTER MOTOR (Perkins #2873K634) ALTERNATOR, (S/N TBK01051 & After) THERMOSTAT (Perkins #4133L507) FAN BELT (Perkins #2614B953) FAN (Perkins #2485C518)

G

SEBU7655 RENR2437 RENR2438 RENR2433

31200255

Description

Rev.

FOR ADDITIONAL ENGINE INFORMATION REFER TO THE FOLLOWING: OPERATION AND MAINTENANCE MANUAL (O&MM) SPECIFICATIONS MANUAL (SPEC) SYSTEMS OPERATION TEST AND ADJUST (SOTA) DISASSEMBLY & ASSEMBLY (D&A)

TL642

4-13



Figure 4-4 Cat Engine

PAL5460

4-14

TL642

31200255


ENGINE & ATTACHING PARTS Figure 4-4 Cat Engine

Item

Part Number

Qty.

335-1530 298-5894 311-2376 299-8229 335-2204 230-8218 329-0290 346-9824 285-2040 103-5916

1 1 1 1 1 1 1 1 1 1

SEBU8180 RENR9961 RENR9965 KENR6216

31200255

Description CAT ENGINE, 99 HP, (includes all items) SHORT BLOCK SECONDARY FUEL FILTER PRIMARY FUEL FILTER DIPSTICK DIPSTICK TUBE ASSY STARTER MOTOR ALTERNATOR FAN BELT FAN, (Perkins # 2485C518)

Rev. E

FOR ADDITIONAL ENGINE INFORMATION REFER TO THE FOLLOWING: OPERATION AND MAINTENANCE MANUAL (O&MM) SPECIFICATIONS MANUAL (SPEC) SYSTEMS OPERATION TEST AND ADJUST (SOTA) DISASSEMBLY & ASSEMBLY (D&A)

TL642

4-15

ENGINE & ATTACHING PARTS Figure 4-5 Fuel Tank & Lines

2 8

1 3

4

9 7

319 320

308 6

316

321 320 319 310

NOTE:

4-16

7

204 402 401 203 RETURN LINE, (from L.H. side of engine)

USE LOCTITE 30512 #1 GASKET SEALANT; P/N 0100093, ON ALL PIPE TREADS; EXCEPT FILLER CAP, OR AS NOTED.

TL642

402

401 202

201

201

PAL0581

SUCTION LINE,

31200255

ENGINE & ATTACHING PARTS Figure 4-5 Fuel Tank & Lines Item 1 2 3 4 6 7 8 9 201 202 203 204 308 310 316 319 320 321 401 402

Part Number

Qty.

299-1340 298-1540 298-7224

1 1 1 AR 1 1 1 5 1 2 1 1 1 1 1 3 5 5 2 2 Ref

298-7243 298-7251 298-7254 298-8042 310-7936 304-3810 304-2652 303-4805 299-0400 298-8250 297-7032 298-7374 298-7380 297-7031 298-7980

Description FUEL TANK ASSY, (includes items 1 thru 9) FILLER NECK LOCKING FUEL TANK CAP LOCTITE, 30512 #1 GASKET SEALANT FUEL TANK HOOD FUEL TANK FUEL GAUGE HARNESS WHIZ-LOK BOLT, 5/16-18X5/8 FUEL LEVEL SENDER ELBOW, 90 DEGREES HOSE BARB HOSE BARB HEX SOCKET PIPE PLUG, 1/2 FUEL TANK HOLD DOWN FUEL TANK STRAP WELDMENT HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 FLAT WASHER, 3/8 LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1, GR5 HOSE CLAMP FUEL LINE, (see Figure 4-1 for details)

Rev. F, 3


31200255

TL642

4-17


ENGINE & ATTACHING PARTS Figure 4-6 Radiator Assembly

4

S/N BEFORE TBK00795

S/N TBK00795 & AFTER

4 5

14

10

23

28 20 101

102

14 11 229

18

9

16 228 304

303

18

302

6 11

1

21

S/N BEFORE TBK00795

10

29

301

3

4

11

7

11

22

13 3

30


26

14 10

17

19

12

15 25

27 PAL0151

14

4-18

TL642

31200255



Item 1 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 27 28 30 101 102 228 229

301 302 303 304

Part Number

Qty.

299-1350 297-7021 298-0468 298-0468 298-0476 298-0476 298-0477 298-7364 298-7373 298-7992 298-7840 298-7841 299-0353 298-7297 298-7981 298-0541 298-6833 3P-8517 299-0373 298-1674 298-8580 298-8118 298-8121 298-8598 298-8605 298-0421 298-0423 298-8739 299-0912 298-7364 298-0526

1 1 1 2 2 1 1 2 1 2 10 7 2 1 4 2 AR 2 2 4 1 1 2 1 1 1 1 1 1 38” 1 1

331-0795 298-8603 297-7030 298-7374 298-7380

1 1 3 3 3

Description

Rev.

RADIATOR ASSY, (includes items 1 thru 30) HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 CONNECTOR, (includes o-ring) S/N Before TBK 00795 CONNECTOR, (includes o-ring) S/N TBK00795 & After ELBOW, 90 DEGREE, (includes o-ring) S/N Before TBK 00795 ELBOW, 90 DEGREE, (includes o-ring) S/N TBK 00795 & After ELBOW, 90 DEGREES FLAT WASHER, 5/16 FLAT WASHER, 5/16 HEX HD CAPSCREW, 5/16-18X7/8 WHIZ LOCK SCREW, 5/16-18X5/8 WHIZ LOCK NUT, 5/16-18 MOUNTING PAD DRAIN COCK HOSE CLAMP LOCKNUT, 3/8-16 GASKA-TAPE FLAT WASHER, REBOUND SHOCK MOUNT BAR CLAMP RADIATOR, (includes items 101 & 102) RADIATOR BRACKET AIR DAM BRACKET HYDRAULIC OIL COOLER RUBBER AIR DAM LOWER RADIATOR HOSE UPPER RADIATOR HOSE RADIATOR FAN SHROUD RADIATOR CAP OVERFLOW HOSE FLAT WASHER, 5/16 SUPPORT CLAMP

D

FAN GUARD INSTALLATION, W/O A/C, (includes items 301 thru 304) FAN GUARD HEX HD CAPSCREW, 3/8-16x7/8, GR5 FLAT WASHER, 3/8 LOCKWASHER, 3/8

A


31200255

TL642

4-19



260

26

30

26

30 5

101 123

116 118

275 108

107

9 276

310 36 309 28

24

103

116

336 401 105 336

102

34

336 308

299

33

18 35

31 17

27 25

18 1 18 32 17

4-20

293

TL642

294 PAL5530

31200255



Item

1 5 9 10 17 18 24 25 26 27 28 30 31 32 33 34 35 36 101 102 103 105 107 108 116 118 123 260 275 276 293 294 299 308 309 310 336 401

Part Number

Qty.

364-5667

Ref

364-5690 298-7841 299-0373 364-5700 298-0557

2 1 1 1 4 6 1 1 4 2 1 4 1 2 2 2 1 1 1 1 2 1 1 1 AR 1 3 AR 2 1 1 1 1 1 1 1 3 1 1

368-0511 297-7016 297-7045 298-0468 298-7364 303-4761 298-7375 367-4055 367-4056 303-4759

364-5694 298-7342 368-0510 360-6617 367-4087 361-2861 361-2863 298-7884 364-5689 364-5695

Description RADIATOR INSTALLATION, (not available to order, see items 1 thru 36 for service) ISOLATOR MOUNT WHIZ-LOK NUT, 5/16-18 SHOCK MOUNT RADIATOR, (includes items 101 thru 123) HEX NUT, 1/2-13 SPECIAL WASHER AIR DAM RADIATOR MOUNT BRACKET HEX HD CAPSCREW, 5/16-18X3/4, GR5 HEX HD CAPSCREW, 1/2-13X2-1/2, GR5 CONNECOTR, (includes o-ring) WASHER, 5/16 ELBOW, 45 DEGREE, (includes o-ring) WASHER, 1/2 SHIM, 5/64 SHIM, 3/16 ELBOW, 90 DEGREE, (includes o-ring) CONNECTOR, (includes o-ring) RADIATOR HYDRAULIC/TRANSMISSION OIL COOLER MOUNTING ANGLE PETCOCK SIGHT GAUGE RADIATOR CAP, (16 psi) HOSE SHROUD ASSY FOAM RUBBER BULB SEAL SCREW, 5/16-18X3/4 ISOLATOR MOUNT SUPPORT FOAM GASKET SEAL FOAM GASKET SEAL FOAM GASKET SEAL RADIATOR HOSE, LOWER RADIATOR HOSE, UPPER HEAVY DUTY BAND CLAMP T-BOLT CLAMP FAN GUARD, (no A/C) FAN GUARD, (with A/C)

Rev. J

B


31200255

TL642

4-21


ENGINE & ATTACHING PARTS Figure 4-7 Air Cleaner and Installation

506 507

102

4 7 9

203

201

8

5

6

101

202

3 204

1 103

2 503

502

504 506 507 515

505

305

638

659

304 305

647 672

671

PAL0671

4-22

TL642

31200255



Item 1 2 3 4 5 6 7 8 9 101 102 103 201 202 203 204 304 305 502 503 504 505 506 507 515 638 647 659 671 672

Part Number

Qty.

299-1345 299-1344 298-1684 298-7854 298-8243 298-7364 298-7841 297-7018 298-7379

1 1 1 1 1 4 4 4 4 AR 1 1 1 1 1 1 1 2 1 2 1 1 1 2 4 4 2 1 1 1 1 1

299-7099 299-0352 298-8729 206-5234 206-5235 298-8728 299-0842 298-0435 298-7037 298-1696 298-8143 298-1697 298-8122 298-0530 297-7029 298-7380 298-7374 298-0530 298-1696 298-0418 298-7229 298-7343

Description AIR CLEANER ASSY, (includes items 1 thru 9) AIR FILTER ASSY, (includes items 101 thru 103) ELBOW, 90 DEGREES BAND CLAMP MOUNTING BRACKET FLAT WASHER, 5/16 WHIZ-LOCKNUT, 5/16-18 HEX HD CAPSCREW, 5/16-18X1-1/4, GR5 LOCKWASHER, 5/16 LOCTITE, #242 SERVICE INDICATOR AIR INLET HOOD, (includes clamp) AIR CLEANER, (includes items 201 thru 204) ELEMENT, (outer) (JLG #206-5234) ELEMENT, (inner) (JLG #206-5235) COVER ASSY VACTUATOR MOUNTING BAND STRAIGHT HUMP BAND CLAMP AIR INTAKE TUBE BAND CLAMP INTAKE SUPPORT BRACKET CLAMP HEX HD CAPSCREW, 3/8-16X3/4, GR5 LOCKWASHER, 3/8 FLAT WASHER, 3/8 MUFFLER CLAMP BAND CLAMP AIR INTAKE TUBE AIR INTAKE ELBOW BAND CLAMP

Rev. A, 2 D

B, 2


31200255

TL642

4-23



2

201 421

420 5

422 204 202

500

501

203

502 102

103 3 101 303

311

313

4-24

PAL5360

TL642

31200255



Item

Part Number

Qty.

2 3

360-6608 360-6609 360-6607

1 1 Ref

5 101 102 103 201 202 203 204 303 311 313 420 421 422 500 501 502

360-6606

299-6634 299-6633 298-7855 360-6611 364-5676 364-5675 299-0557 8T-4205 5C-9553

4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description AIR CLEANER ASSY, (includes items 2 thru 5) BRACKET AIR CLEANER INSTALLATION, (not available to order, see items 101 thru 103 for service) RIPP BOLT, 8X30mm AIR CLEANER, 11 INCH, (includes items 201 thru 204) RESTRICTION INDICATOR ELBOW, 90 DEGREES COVER ASSY PRIMARY ELEMENT, (JLG 299-6634) SAFETY ELEMENT, (JLG 299-6633) VACUATOR VALVE BAND CLAMP AIR INTAKE PIPE T-BOLT CLAMP AIR FILTER INTAKE ADAPTER FOAM SEAL BAND CLAMP WASHER, 6mm AIR FILTER SUPPLY HEX HD CAPSCREW, 6X16mm, GR8.8

Rev. D A

D


31200255

TL642

4-25


ENGINE & ATTACHING PARTS Figure 4-8 Exhaust Installation

6

7

5

168

7

202

4

132

7 15 16 201

105 161

7

149 148 165

148

138 PAL0691

4-26

TL642

31200255



Item

Part Number

Qty.

Description

4 5 6 7 15 16 105 132 138 148 149 161 165 168

298-8156 299-0392 298-7066 298-0530 298-8789 298-7374 8T-4136 298-7388 298-0530 298-1758 298-8145 298-0422 298-0426 299-0304

1 1 1 5 1 4 3 3 1 2 1 1 1 1

MUFFLER TUBE MUFFLER TAIL PIPE MUFFLER CLAMP HEAT SHIELD FLAT WASHER, 3/8 HEX HD CAPSCREW, 10X25 LOCKWASHER, 10mm MUFFLER CLAMP CLAMP PIPE FLEX TUBE EXHAUST TUBE MUFFLER TUBE METAL GASKET

201 202

325-1345 325-1351 325-1352

1 1 2

MUFFLER COVER INSTALLATION, (inccludes items 210 & 202) MUFFLER COVER WORM CLAMP

Rev.

A


31200255

TL642

4-27



3 2 201 202

101

2

4 2 1 5

2 PAL5520

4-28

TL642

31200255



Item 1 2 3 4 5 101

201 202

Part Number

Qty.

Description

Rev.

299-0392

EXHAUST INSTALL, (not available to order, see items 1 thru 5 for service) MUFFLER CLAMP EXHAUST CLAMP TAIL PIPE TUBE EXHAUST PIPE SHIELD EXHAUST PIPE MUFFLER

A

298-0530 298-7066 361-2859

1 1 5 1 1 1 1

325-1345 325-1351 325-1352

1 1 2

MUFFLER COVER INSTALLATION, (inccludes items 210 & 202) MUFFLER COVER WORM CLAMP

A


31200255

TL642

4-29

ENGINE & ATTACHING PARTS Figure 4-9 Transmission - ZF Transmission

8 1

13

2 11

12

3 4

11

10 5 6 7 8

4-30

PAL1750

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-9 Transmission - ZF Transmission Item

1 2 3 4 5 6 7 8 9 10 11 12 13

31200255

Part Number

Qty.

299-0321 299-0479

1 1 Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref

Description ZF THREE SPEED TRANSMISSION, (includes all items) SEAL KIT, (includes all seals required for rebuild) TORQUE CONVERTER & INPUT, (see Figure 4-10 for details) GEARBOX HOUSING, (see Figure 4-11 for details) FORWARD GEAR GROUP, (see Figure 4-12 for details) REVERSE GEAR GROUP, (see Figure 4-13 for details) 1ST SHAFT GROUP, (see Figure 4-14 for details) 2ND SHAFT GROUP, (see Figure 4-15 for details) 3RD SHAFT GROUP, (see Figure 4-16 for details) 4TH SHAFT GROUP, (see Figure 4-17 for details) POWER TAKE-OFF, (see Figure 4-18 for details) CONTROL UNIT & PRESSURE REGULATOR, (see Figure 4-19 for details) GEARSHIFT SYSTEM, (see Figure 4-20 for details) OIL PUMP, FILTER & DIPSTICK, (see Figure 4-21 for details) TRANSFER BOX, (see Figure 4-22 for details)

TL642

Rev. A

4-31

ENGINE & ATTACHING PARTS Figure 4-10 ZF Transmission - Converter & Input

4-32

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-10 ZF Transmission - Converter & Input Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12

298-7410 298-7411 299-0899 299-0918 299-0638 299-0592 299-0637 N/S N/S 299-0836 299-0639 299-0593

4 8 2 1 1 1 1 2 2 1 1 1

31200255

Description

Rev.

HEX HD CAPSCREW, M10X16, GR8.8 WASHER DIAPHRAGM CONVERTER STATOR SHAFT BEARING BUSHING TURBINE SHAFT CAPSCREW, M8X16, GR8.8 SHACKLE RETAINING RING PISTON RING BALL BEARING

TL642

4-33

ENGINE & ATTACHING PARTS Figure 4-11 ZF Transmission - Gearbox Housing

4-34

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-11 ZF Transmission - Gearbox Housing Item

Part Number

Qty.

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

298-7257 298-7347 298-7881 298-7256 298-7258 298-7239 298-7876 N/S N/S 298-7237 N/S N/S 298-7235 298-7877 298-7349 299-7091 299-7090 N/S 298-7259 298-7346 298-7260 N/S N/S N/S N/S 299-0896 N/S N/S 299-0469

1 11 8 1 1 7 7 1 1 1 6 1 4 31 5 1 1 3 1 2 1 1 2 1 6 1 4 1 1

31200255

Description

Rev.

PIPE HEX HD CAPSCREW, M8X16, GR8.8 O-RING PIPE PIPE PLUG O-RING ORIFICE HOUSING BRACKET HEX HD CAPSCREW, M10X50, GR8.8 PLUG PIN HEX HD CAPSCREW, M10X30, GR8.8 HEX HD CAPSCREW SCREEN SHEET SCREEN SHEET CAPSCREW, M8X12, GR8.8 SUCTION TUBE O-RING PIPE HOUSING O-RING HOUSING CAPSCREW, M10X30,GR8.8 BREATHER GROOVED STUD, 3X5 TYPE PLATE SHAFT SEAL

TL642

4-35

ENGINE & ATTACHING PARTS Figure 4-12 ZF Transmission - Reversing Gear

4-36

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-12 ZF Transmission - Reversing Gear Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12

299-0643 299-0598 299-0640 299-0841 299-0594 299-0599 299-0600 299-0602 299-0641 299-0642 298-7412 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 299-0605 298-0444 298-0445 298-0446 298-0447 298-0448 298-0449 298-0450 303-8562 303-8563 304-2597 304-2598 304-2599 299-0604

2 1 1 1 7 1 1 1 11 11 1 AR AR AR AR AR AR AR AR AR 1 AR AR AR AR AR AR AR AR AR AR AR AR 1

13 14

15

31200255

Description

Rev.

PISTON RING ROLLER BEARING COUPLING PISTON CUP SPRING SUPPORT SHIM ROLLER BEARING ROLLER BEARING FRICTION DISC STATIC DISC END SHIM SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 DISC CARRIER RETAINING RING, 3.20 RETAINING RING, 3.10 RETAINING RING, 3.00 RETAINING RING, 2.90 RETAINING RING, 2.80 RETAINING RING, 2.70 RETAINING RING, 2.60 RETAINING RING, 2.50 RETAINING RING, 2.40 RETAINING RING, 2.30 RETAINING RING, 2.20 RETAINING RING, 2.10 ROLLER BEARING

TL642

4-37

ENGINE & ATTACHING PARTS Figure 4-13 ZF Transmission - Reverse Gear Group

4-38

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-13 ZF Transmission - Reverse Gear Group Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11

299-0643 299-0598 299-0644 299-0841 299-0594 299-0599 299-0600 299-0641 299-0642 298-7412 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 299-0605 299-0602 298-0444 298-0445 298-0446 298-0447 298-0448 298-0449 298-0450 303-8562 303-8563 304-2597 304-2598 304-2599 299-0604

2 1 1 1 7 1 1 11 11 1 AR AR AR AR AR AR AR AR AR 1 1 AR AR AR AR AR AR AR AR AR AR AR AR 1

12 13 14

15

31200255

Description

Rev.

PISTON RING ROLLER BEARING COUPLING PISTON CUP SPRING SUPPORT SHIM ROLLER BEARING FRICTION DISC STATIC DISC END SHIM SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 DISC CARRIER ROLLER BEARING RETAINING RING, 3.20 RETAINING RING, 3.10 RETAINING RING, 3.00 RETAINING RING, 2.90 RETAINING RING, 2.80 RETAINING RING, 2.70 RETAINING RING, 2.60 RETAINING RING, 2.50 RETAINING RING, 2.40 RETAINING RING, 2.30 RETAINING RING, 2.20 RETAINING RING, 2.10 ROLLER BEARING

TL642

4-39

ENGINE & ATTACHING PARTS Figure 4-14 ZF Transmission - 1st Shaft Group

4-40

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-14 ZF Transmission - 1st Shaft Group Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11

299-0643 299-0596 298-7238 299-0841 299-0594 298-7348 298-7233 299-0641 299-0642 298-7412 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 299-6620 299-0595 304-2621 304-2622

2 1 1 1 5 1 2 12 12 1 AR AR AR AR AR AR AR AR AR 2 1 1 1

12 13 14 15

31200255

Description

Rev.

PISTON RING ROLLER BEARING COUPLING PISTON CUP SPRING SHIM RETAINING RING FRICTION DISC STATIC DISC END SHIM SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 ROLLER CAGE DISC CARRIER OUTER RING INNER RING

TL642

4-41

ENGINE & ATTACHING PARTS Figure 4-15 ZF Transmission - 2nd Shaft Group

4-42

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-15 ZF Transmission - 2nd Shaft Group Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11

299-0643 299-0598 299-0645 299-0841 299-0594 298-7348 298-7233 299-0641 299-0642 298-7412 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 299-6620 299-0597 304-2621 304-2622

2 1 1 1 5 1 2 8 8 1 AR AR AR AR AR AR AR AR AR 2 1 1 1

12 13 14 15

31200255

Description

Rev.

PISTON RING ROLLER BEARING COUPLING PISTON CUP SPRING SHIM RETAINING RING FRICTION DISC STATIC DISC END SHIM SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 ROLLER CAGE DISC CARRIER OUTER RING INNER RING

TL642

4-43

ENGINE & ATTACHING PARTS Figure 4-16 ZF Transmission - 3rd Shaft Group

4-44

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-16 ZF Transmission - 3rd Shaft Group Item

Part Number

1 321-5023 321-5024 2

3 4

5 6 7 8 9 10 11 12 13 14

31200255

321-5021 321-5022 299-0601 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 298-7412 299-0641 299-0642 299-0835 298-7413 299-0647 299-0841 299-0646 299-0650 299-0643

Qty. 1 1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR 1 8 8 2 1 7 1 1 1 2

Description

Rev.

ROLLER BEARING ASSY OUTER BEARING RING INNER BEARING RING ROLLER BEARING ASSY BEARING RING BEARING ROLLER CAGE DISC CARRIER SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 END SHIM FRICTION DISC STATIC DISC RETAINING RING WASHER CUP SPRING PISTON COUPLING ROLLER BEARING PISTON BEARING

TL642

4-45

ENGINE & ATTACHING PARTS Figure 4-17 ZF Transmission - 4th Shaft Group

4-46

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-17 ZF Transmission - 4th Shaft Group Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11

299-0643 299-0598 299-0651 299-0841 299-0594 298-7348 298-7233 299-0641 299-0642 298-7412 298-0439 304-2633 298-0440 304-2632 298-0441 304-2635 298-0442 304-2634 298-0443 299-6620 299-0603 299-0604

2 1 1 1 5 1 2 12 12 1 AR AR AR AR AR AR AR AR AR 2 1 1

12 13 14

31200255

Description

Rev.

PISTON RING ROLLER BEARING COUPLING PISTON CUP SPRING SHIM RETAINING RING FRICTION DISC STATIC DISC END SHIM SNAP RING, 4.0 SNAP RING, 3.75 SNAP RING, 3.5 SNAP RING, 3.25 SNAP RING, 3.0 SNAP RING, 2.75 SNAP RING, 2.5 SNAP RING, 2.25 SNAP RING, 2.0 ROLLER CAGE DISC CARRIER ROLLER BEARING

TL642

4-47

ENGINE & ATTACHING PARTS Figure 4-18 ZF Transmission - Power Take-Off

4-48

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-18 ZF Transmission - Power Take-Off Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11

299-0468 331-0104 298-7235 298-7414 298-7877 299-0655 299-0650 299-0652 299-0653 299-0596 299-0654

1 1 2 15 21 1 2 1 1 2 1

31200255

Description

Rev.

SHAFT SEAL HOUSING CYLINDRICAL PIN HEX HD CAPSCREW, M10X80, GR8.8 HEX HD CAPSCREW, M10X30, GR8.8 GASKET ROLLER BEARING SHAFT PISTON RING ROLLER BEARING SHAFT

TL642

4-49

ENGINE & ATTACHING PARTS Figure 4-19 ZF Transmission - Control Unit & Pressure Regulator

4-50

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-19 ZF Transmission - Control Unit & Pressure Regulator Item

Part Number

Qty.

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

299-0658

1 Ref 3 4 4 1 1 1 1 46 1 1 1 Ref 16 16 1

VALVE HOUSING, (see Figure 4-11 for details) SOLENOID VALVE CAPSCREW, M6X12, GR8.8 BRACKET COMPRESSED SPRING PISTON GASKET PLATE HEX HD CAPSCREW INTERMEDIATE SHEET COMPRESSED SPRING BALL VALVE HOUSING, (see Figure 4-20 for details) WASHER HEX HD CAPSCREW, M8X60, GR10.9 SOLENOID VALVE

31200255

299-0840 N/S N/S 299-0660 299-0659 299-0656 299-6635 298-7415 299-7092 299-0657 299-0897 298-7344 298-7416 299-0839

TL642

Rev.

4-51

ENGINE & ATTACHING PARTS Figure 4-20 ZF Transmission - Gearshift System

4-52

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-20 ZF Transmission - Gearshift System Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13

298-0456 298-7351 298-7354 299-0919 299-0662 298-7417 299-0606

2 6 4 1 1 1 1 2 2 2 1 1 AR AR AR AR AR 1 1 1 1 2 2 2 2 2 2 2 2 2 1 1

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

31200255

299-0663 298-0451 298-0452 298-0453 298-0454 298-0455 298-7241 298-7240 299-6636 299-0661 299-0839 N/S N/S 298-7239 298-7876 N/S 304-2605 298-7234 299-0898 348-2862 299-6621

Description

Rev.

HEX HD CAPSCREW, M6X25,GR10.9 WASHER HEX HD CAPSCREW, M6X55, GR10.9 COVER GASKET SPACER VALVE ASSY, (includes items 8 thru 11) SNAP RING SPRING SLEEVE COMPRESSED SPRING PISTON PISTON WASHER, 2.0 WASHER, 1.0 WASHER, 0.5 WASHER, 0.3 WASHER, 0.2 COMPRESSED SPRING COMPRESSED SPRING SLEEVE CONTROL PISTON SOLENOID VALVE HEX HD CAPSCREW, M6X12, GR8.8 BRACKET PLUG, M10 O-RING PLUG, M24 O-RING COMPRESSED SPRING BALL VALVE HOUSING ORIFICE

TL642

4-53

ENGINE & ATTACHING PARTS Figure 4-21 ZF Transmission - Oil Pump, Filter & Dipstick

4-54

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-21 ZF Transmission - Oil Pump, Filter & Dipstick Item

Part Number

Qty.

1 2 3 4 5 6

298-7239 298-7876 298-7419 298-7877 298-7418 299-0920

7 8 9 10 11 12 13 14 15

298-7261 298-7352 299-0900 299-0359 335-3833 298-7347 298-7346

2 2 1 1 4 1 1 3 1 1 1 1 2 1 Ref 1

31200255

344-7016

Description

Rev.

PLUG, M10X1 O-RING HEX HD CAPSCREW, M10X50, GR8.8 HEX HD CAPSCREW, M10X30, GR8.8 CAPSCREW, M12X80, GR10.9 PUMP O-RING, (located between two halves of oil pump) O-RING O-RING FILTER DIPSTICK DIPSTICK TUBE CAPSCREW, M8X16, GR8.8 O-RING O-RING, (see Figure 4-1 for details) O-RING, (located between oil pump and transmission)

TL642

4-55

ENGINE & ATTACHING PARTS Figure 4-22 ZF Transmission - Transfer Box

4-56

TL642

31200255

ENGINE & ATTACHING PARTS Figure 4-22 ZF Transmission - Transfer Box Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

19 20

21 22 23

Part Number

Qty.

315-2004 298-7345 N/S 298-7350 303-8568 299-7086 299-0470 298-7235 N/S 303-8561 304-2596 N/S 299-0591 N/S N/S 299-0650 304-2631

1 4 2 2 2 2 3 2 15 2 4 1 1 1 1 4 1 4 1 1 1 1 1 1 1 1 1

311-9612 311-9613 304-2617 314-7795 314-7798 N/S 304-2615 304-2614

Description

Rev.

TRANSFER BOX, (includes all items) HEX HD CAPSCREW, M8X25, GR10.9 TAB WASHER WASHER FLANGE SCREEN SHEET SHAFT SEAL CYLINDRICAL PIN HEX HD CAPSCREW, M10X50, GR8.8 PLUG STUD, 3X5 PLATE BREATHER HEX HD CAPSCREW, M10X30, GR8.8 HOUSING ROLLER BEARING OUTPUT SHAFT TAPERED ROLLER BEARING CUP CONE IDLER GEAR INPUT SHAFT INPUT GEAR SEAL HOUSING HEX NUT, M16 SLEEVE


31200255

TL642

4-57



4-58

TL642

31200255

SECTION 5 DRIVE TRAIN

31200255

TL642


DRIVE TRAIN Figure 5-1 Front Axle Assembly 12 1

9 7 101

8

6

13

7 9

11

2

10 14 15 14 15 16

11 3 4

204

5

205

202 201

203 202 201

203 PAL0182

5-2

TL642

31200255


DRIVE TRAIN Figure 5-1 Front Axle Assembly

Item

Part Number

Qty.

299-1338

298-1394 298-0474 298-1397 298-0496 298-7249 298-0496 325-8143 298-6865

1 Ref 1 2 8 4 1 4 1 2 1 2 1 1 AR 3 1 2

331-0804

1

201 202 203

298-1632 298-8127 298-1793

204 205

331-0803

11 4 8 AR 1 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 101

298-8783 298-8127 298-1632 298-1793 298-0498 298-1610 298-0507

Description FRONT AXLE ASSY, (includes items 1 thru 101) FRONT AXLE, (see Figure 5-2 for details) SWAY LUG ASSY, (if equipped), (includes item 101) RETAINING PLATE, (if equipped) HARDENED WASHER, 1, (if equipped) HEX HD CAPSCREW, 1-8X9, GR8, (if equipped) SWIVEL NUT BRANCH TEE, 3/8 TUBE CONNECTOR SWIVEL NUT ELBOW HOSE ASSY HOSE ASSY ELBOW, 90 DEGREES, (includes o-ring) HOSE ASSY SWIVEL NUT RUN TEE NYLON SLEEVE TY-WRAP HOSE ASSY BUSHING, (if equipped) HOIST LUGS INSTALL, (if equipped), (includes items 201 thru 205 & items 101 thru 104 on Figure 5-11) WASHER RETAINER PLATE HEX HD CAPSCREW, 1X8X9 CAT THREADLOCK AXLE HOIST LUG LIFT LUG SWAY PIVOT BEARING BRACKET

Rev. C, 5

5 4

C,4

C


31200255

TL642

5-3



3 11

3 5 11 13 4 6

2 12 101

10

2 12 9 1 7 8

204

205

202 201

203

202 201

203

5-4

PAL5560

TL642

31200255



Item

Part Number

Qty.

298-6865

1 4 2 3 1 1 1 8 2 Ref 1 2 2 1 2

331-0804

1

201 202 203

298-1632 298-8127 298-1793

204 205

331-0803

11 4 8 AR 1 1

1 2 3 4 5 6 7 8 9 10 11 12 13 101

298-0474 298-1610 298-0496 298-0498 298-1632 298-8127 298-8783 298-1393 298-1394

Description

Rev.

FRONT AXLE ASSY, (includes items 1 thru 13) HEX HD CAPSCREW, 1-8X9.5, GR8 ADAPTER, 90 DEGREES, (includes o-ring) ADAPTER, STRAIGHT, (includes o-ring) ADAPTER, TEE, (includes o-ring) ADAPTER, TEE, (includes o-ring) ADAPTER, 90 DEGREES, (includes o-ring) WASHER RETAINER PLATE FRONT AXLE, (see Figure 5-2 for details) SWAY LUG ASSY, (includes items 101) HOSE ASSY HOSE ASSY HOSE ASSY BUSHING, (if equipped)

A

HOIST LUGS INSTALL, (if equipped), (includes items 201 thru 205 & items 101 thru 104 on Figure 5-11) WASHER RETAINER PLATE HEX HD CAPSCREW, 1X8X9 CAT THREADLOCK AXLE HOIST LUG LIFT LUG SWAY PIVOT BEARING BRACKET

C


31200255

TL642

5-5

DRIVE TRAIN Figure 5-2 Front Axle

4 2

3 6

1

5

7

8 PAL0190

5-6

TL642

31200255

DRIVE TRAIN Figure 5-2 Front Axle Item 1 2 3 4 5 6 7 8

31200255

Part Number

Qty.

298-8138

1 Ref Ref Ref Ref Ref Ref Ref Ref

Description

Rev.

FRONT AXLE, (includes all items) AXLE HOUSING ASSY, (see Figure 5-3 for details) STEERING COMPONENTS, (see Figure 5-4 for details) BEVEL GEAR SET, (see Figure 5-5 for details) DIFFERENTIAL, (see Figure 5-6 for details) DOUBLE JOINT, (see Figure 5-7 for details) BRAKES, (see Figure 5-8 for details) WHEEL HUB, (see Figure 5-9 for details) REDUCTION GEARS, (see Figure 5-10 for details)

TL642

5-7

DRIVE TRAIN Figure 5-3 Front Axle Housing Assembly

5-8

TL642

31200255

DRIVE TRAIN Figure 5-3 Front Axle Housing Assembly Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

298-1799

5 Ref 8 1 1 1 1 1 5 3 2 2 2 4 1 1 2 32 24 2 2 32

16 17 18 19 20 21

31200255

298-8178 304-4581 299-0790 299-7161 299-7134 299-0821 299-7170 304-2241 299-7103 298-1857 299-0196 299-0197 299-0793 299-0794 299-0199 304-3231 298-8179 298-1853 304-3230 298-1854

Description

Rev.

O-RING COVER, (see Figure 5-8 for details) STUD INTERMEDIATE COVER HOUSING PLUG VENT CIRCLIP PLUG MAGNET PLUG PLUG GREASE FITTING THRUST BUSHING REDUCTION BUSHING SUPPORT ASSY, REAR, (includes items 11 thru 14) SUPPORT ASSY, FRONT, (includes items 11 thru 14) AXLE CASE WASHER STUD NUT BOLT NUT

TL642

5-9

DRIVE TRAIN Figure 5-4 Front Steering Components

5-10

TL642

31200255

DRIVE TRAIN Figure 5-4 Front Steering Components Item

4 5 6 7 8 9 10 11 12

14 15 16 17 18 19 20 21

Part Number

Qty.

Description

299-0796 299-0795 299-7136 298-1800 299-0808 304-2620 299-7137 298-1865 299-7103 298-1857 299-0228 298-1860 298-1861 298-1862 303-8572 303-8570 299-0201 299-0202 299-0223 303-8571

1 1 2 4 1 1 2 24 2 4 2 2 2 2 4 2 1 1 2 2 4 4

STEERING CASE ASSY, L.H., (includes item 17) STEERING CASE ASSY, R.H., (includes item 16) TIE ROD, (includes hex nut) CYLINDER BOLT CYLINDER SEAL KIT COVER BOLT PLUG GREASE FITTING PIVOT PIN, (includes item 10) SHIM SHIM SHIM DUST EXCLUDER OUTER RACE STEERING CASE, L.H. STEERING CASE, R.H. BEARING PIVOT PIN, (includes items 10, 14 & 18) NUT BOLT

305-5426

4

STEERING ADJUST BOLT KIT, (includes items 20 & 21)

299-0253

1

NUT & COTTER PIN KIT

Rev.


31200255

TL642

5-11

DRIVE TRAIN Figure 5-5 Front Gear Components

5-12

TL642

31200255

DRIVE TRAIN Figure 5-5 Front Gear Components Item

Part Number

Qty.

1 2 3 4 5 6 7 8

298-1801 298-1802 299-7138 299-7139 299-0508 298-1803 304-2603 298-1804 298-1805 298-1806 298-1807 298-1808 298-1809 298-1810 298-1811 298-1812 298-8181

1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1

9 10

11

31200255

Description

Rev.

NUT O-RING FLANGE COVERPLATE SEAL RING NUT TAPER ROLLER BEARING SHIM SHIM SHIM SHIM SPACER SHIM SHIM SHIM SHIM BEVEL GEAR SET

TL642

5-13

DRIVE TRAIN Figure 5-6 Front Differential

5-14

TL642

31200255

DRIVE TRAIN Figure 5-6 Front Differential Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

304-3232 298-1813 298-8182 298-1865 304-2265 304-2264 299-0788 299-0511 304-3220 304-3221 299-0789 298-1814 304-3222

2 2 2 12 Ref 1 1 4 2 4 4 4 4 4

304-2243

1

31200255

Description

Rev.

CYLINDER BOLT RING NUT ROLLER BEARING BOLT BEVEL GEAR, (see Figure 5-5 for details) CLUTCH DISC KIT DIFFERENTIAL CARRIER DIFFERENTIAL PINION DIFFERENTIAL SIDE GEAR CIRCLIP CIRCLIP PIN FRICTION WASHER CYLINDER BOLT

DIFFERENTIAL KIT, (includes items 6 thru 13)

TL642

5-15

DRIVE TRAIN Figure 5-7 Front Double Joint

5-16

TL642

31200255

DRIVE TRAIN Figure 5-7 Front Double Joint Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9

299-0827 299-0821 299-0235 299-0520 299-0236 298-1877 299-7140 303-8573 299-0227

2 2 2 2 2 2 2 2 2

CIRCLIP CIRCLIP BALL BEARING SEAL REDUCTION BUSHING, (includes items 2, 3, 4 & 6) O-RING JOINT & SHAFT ASSY SEAL THRUST BUSHING

1

CROSS KIT, (includes cross for double joint, circlips & needle bearings)

31200255

Description

TL642

Rev.

5-17

DRIVE TRAIN Figure 5-8 Front Brakes

5-18

TL642

31200255

DRIVE TRAIN Figure 5-8 Front Brakes Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

298-1815 298-8186 298-8187 298-1816 298-1883 299-7165 299-7103 298-7873 298-1878 298-1879 299-7142 298-1817 299-7141 298-8188 298-8189 299-0241

2 4 2 2 4 4 4 4 4 4 2 2 2 2 2 6 6

298-7430 299-0240 298-1881 298-8191 298-8192 298-1819 298-1820 298-1821 298-1822 298-7870 298-7867 304-2244

6 6 6 8 8 2 2 2 2 4 4 4

18 19 20 21 22 23

24 25 26

31200255

Description

Rev.

SPACER SPRING PISTON O-RING O-RING BACK-UP RING PLUG BLEEDING BOLT BOLT SEAL WASHER INTERMEDIATE COVER O-RING BACK-UP RING PISTON INTERMEDIATE BRAKE DISC SPRING ADJUSTING BOLT, (Before Axle S/N HITA-725998), (298-1818 is no longer available; order qty. 6 of 298-7430 for replacement) ADJUSTING BOLT, (Axle S/N HITA-725998 & After) SPRING ADJUSTING BOLT BRAKE DISC INTERMEDIATE BRAKE DISC SPACER SHIM SHIM SHIM LOCKWASHER NUT BOLT

TL642

5-19

DRIVE TRAIN Figure 5-9 Front Wheel Hub

5-20

TL642

31200255

DRIVE TRAIN Figure 5-9 Front Wheel Hub Item

Part Number

Qty.

1 2 3 4 6 7 8 9 10 11 12

303-8574 298-8193 298-7274 299-6639 298-8297 298-8194 298-8195 298-8196 298-8197 298-8198 298-1825

2 4 20 2 2 2 2 2 2 20 20

Description

Rev.

SEAL BEARING WHEEL STUD WHEEL HUB O-RING CIRCLIP RING GEAR RING GEAR SUPPORT LOCKING PLATE STUD NUT


31200255

TL642

5-21

DRIVE TRAIN Figure 5-10 Front Reduction Gears

5-22

TL642

31200255

DRIVE TRAIN Figure 5-10 Front Reduction Gears Item

Part Number

Qty.

Description

1 2 3 4 6 7

299-0205 299-0206 299-0207 299-0797 299-7170 298-8300

8 8 8 2 4 4

CIRCLIP PLANETARY GEAR BEARING PLANETARY GEAR CARRIER PLUG COUNTERSUNK BOLT

350-8580

2

299-0813

2

PLANETARY CARRIER KIT, (includes items 1 thru 4 and items 7, 8 & 9 on Figure 5-9) RING GEAR SUPPORT, (includes items 7, 8 & 9 on Figure 5-9)

Rev.


31200255

TL642

5-23

DRIVE TRAIN Figure 5-11 Rear Axle Assembly 1

3 4

2

2

6 5 6

5

104

104

101 102

103 101 102

5-24

103

PAL0281

TL642

31200255

DRIVE TRAIN Figure 5-11 Rear Axle Assembly Item

Part Number

Qty.

299-1337

298-0498 298-0474 298-1394

1 Ref 2 1 1 2 2

331-0804

1

101 102 103

298-1632 298-8127 298-1793

104

331-0803

12 4 8 AR 2

1 2 3 4 5 6

298-1610

Description REAR AXLE ASSY, (includes items 1 thru 6) REAR AXLE, (see Figure 5-12 for details) ADAPTER, M14 HOSE ASSY SWIVEL NUT BRANCH TEE, 3/8 TUBE ELBOW, 90 DEGREES, (includes o-ring) HOSE ASSY HOIST LUGS INSTALL, (if equipped), (includes items 101 thru 104 & items 201 thru 205 on Figure 5-1) WASHER RETAINER PLATE HEX HEAD CAPSCREW, 1-8X9 CAT THREADLOCK AXLE HOIST LUG

Rev. B, 5 3 5 3

C


31200255

TL642

5-25

DRIVE TRAIN Figure 5-12 Rear Axle

4 2

3 6

1

5

7

8 PAL0290

5-26

TL642

31200255

DRIVE TRAIN Figure 5-12 Rear Axle Item

1 2 3 4 5 6 7 8

31200255

Part Number

Qty.

298-8139 331-3989

1 1 Ref Ref Ref Ref Ref Ref Ref Ref

Description REAR AXLE, (includes all items), (Before S/N TBK01105) REAR AXLE, (includes all items), (S/N TBK01105 & After) AXLE HOUSING ASSY, (see Figure 5-13 for details) STEERING COMPONENTS, (see Figure 5-14 for details) BEVEL GEAR SET, (see Figure 5-15 for details) DIFFERENTIAL, (see Figure 5-16 for details) DOUBLE JOINT, (see Figure 5-17 for details) REAR BRAKES, (see Figure 5-18 for details) WHEEL HUB, (see Figure 5-19 for details) REDUCTION GEARS, (see Figure 5-20 for details)

TL642

Rev. B A

5-27

DRIVE TRAIN Figure 5-13 Rear Axle Housing Assembly

1

18


5-28

TL642

31200255

DRIVE TRAIN Figure 5-13 Rear Axle Housing Assembly Item

Part Number

Qty.

1

298-1799 298-1799

5 3 Ref 8 1 1 1 1 1 3 3 3 2 2 2 4 1 1 2 2 32 24 32 2 2 32

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

31200255

298-8178 304-4581 299-0790 299-7161 299-7134 299-0821 299-7170 304-2241 299-0195 299-7103 298-1857 299-0196 299-0197 299-0793 299-0794 299-0199 350-8568 304-3231 298-8179 350-8569 298-1853 304-3230 298-1854

Description

Rev.

O-RING, (Before S/N TBK01105) O-RING, (S/N TBK01105 & After) COVER, (see Figure 5-18 for details), (Before S/N TBK01105) STUD INTERMEDIATE COVER HOUSING PLUG VENT CIRCLIP PLUG MAGNET PLUG, (Before S/N TBK01105) MAGNET PLUG, (S/N TBK01105 & After) PLUG GREASE FITTING THRUST BUSHING REDUCTION BUSHING FRONT SUPPORT ASSY, (includes items 11 thru 14) REAR SUPPORT ASSY, (includes items 11 thru 14) AXLE CASE, (Before S/N TBK01105) AXLE CASE, (S/N TBK01105 & After) WASHER, (Before S/N TBK01105) STUD, (Before S/N TBK01105) BOLT, (S/N TBK01105 & After) NUT BOLT NUT, (Before S/N TBK01105)

TL642

5-29

DRIVE TRAIN Figure 5-14 Rear Steering Components

5-30

TL642

31200255

DRIVE TRAIN Figure 5-14 Rear Steering Components Item

Part Number

Qty.

4 5 6

299-7136 298-1800 299-0808 304-2620 299-7137 298-1865 299-7103 298-1857 299-0228 298-1860 298-1861 298-1862 303-8572 303-8570 299-0795 299-0796 299-0223 303-8571 298-7868 298-1863

2 4 1 1 2 24 2 4 2 2 2 2 4 2 1 1 2 2 4 4

TIE ROD, (includes hex nut) CYLINDER BOLT CYLINDER SEAL KIT COVER BOLT PLUG GREASE FITTING PIVOT PIN, (includes item 10) SHIM SHIM SHIM DUST EXCLUDER BUSHING STEERING CASE ASSY, L.H., (includes thrust bushing 299-0227) STEERING CASE ASSY, R.H., (includes thrust bushing 299-0227) BEARING PIVOT PIN, (includes items 10, 14 & 18) NUT BOLT

305-5426

4

STEERING ADJUST BOLT KIT, (includes items 20 & 21)

7 8 9 10 11 12

14 15 16 17 18 19 20 21

Description

Rev.


31200255

TL642

5-31

DRIVE TRAIN Figure 5-15 Rear Gear Components

5-32

TL642

31200255

DRIVE TRAIN Figure 5-15 Rear Gear Components Item

Part Number

Qty.

1 2 3

298-1801 298-1802 299-7138 350-8570 299-7139 299-0508 298-1803 304-2603 298-1804 298-1805 298-1806 298-1807 298-1808 298-1809 298-1810 298-1811 298-1812 298-8200

1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1

4 5 6 7 8

9 10

11

31200255

Description

Rev.

NUT O-RING FLANGE, (Before S/N TBK01105) FLANGE, (S/N TBK01105 & After) COVERPLATE SEAL RING NUT TAPER ROLLER BEARING SHIM SHIM SHIM SHIM SPACER SHIM SHIM SHIM SHIM BEVEL GEAR SET

TL642

5-33

DRIVE TRAIN Figure 5-16 Rear Differential

5-34

TL642

31200255

DRIVE TRAIN Figure 5-16 Rear Differential Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

304-3222 304-3232 298-1813 298-8182 298-1865

4 2 2 2 12 Ref 2 2 4 4 4 4 4 1

304-3221

350-8571

31200255

1

Description

Rev.

CYLINDER BOLT CYLINDER BOLT RING NUT ROLLER BEARING BOLT BEVEL GEAR, (see Figure 5-15 for details) FRICTION WASHER DIFFERENTIAL SIDE GEAR CIRCLIP CIRCLIP, (Before axle S/N IITA769001) PIN FRICTION WASHER DIFFERENTIAL PINION DIFFERENTIAL CARRIER

DIFFERENTIAL ASSY, (includes items 7, 8, 9 & 11 thru 14)

TL642

5-35

Before S/N TBK01105

DRIVE TRAIN Figure 5-17 Rear Double Joint

5-36

TL642

31200255

Before S/N TBK01105

DRIVE TRAIN Figure 5-17 Rear Double Joint Item

Part Number

Qty.

1 2 3 4 5 6 7

299-0827 299-0821 299-0235 299-0520 299-0236 298-1877 299-7140

8 9

350-8572 303-8573 299-0227

2 2 2 2 2 2 2 2 2 2 2

31200255

Description

Rev.

CIRCLIP CIRCLIP BALL BEARING SEAL REDUCTION BUSHING, (includes items 2, 3, 4 & 6) O-RING JOINT & SHAFT ASSY, (Before S/N TBK01105) CROSS KIT, (includes circlips), (Before S/N TBK01105) JOINT & SHAFT ASSY, (S/N TBK01105 & After) SEAL THRUST BUSHING

TL642

5-37

S/N TBK01105 & After

DRIVE TRAIN Figure 5-18 Rear Brakes

5-38

TL642

31200255


DRIVE TRAIN Figure 5-18 Rear Brakes Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

304-3225 299-7165 298-1883 299-7103 298-7873 298-1878 298-1879 304-3226 298-1817 299-7141 304-3819 298-8189 299-0241

2 2 2 2 2 2 2 2 2 2 2 2 6 6

298-7430 299-0240 298-1881 298-8191 298-8192 298-1819

6 6 6 8 8 2

15 16 17 18 19

31200255

Description

Rev.

SPACER BACK-UP RING O-RING PLUG BLEEDING BOLT BOLT SEAL WASHER INTERMEDIATE COVER O-RING BACK-UP RING PISTON INTERMEDIATE BRAKE DISC SPRING ADJUSTING BOLT, (Before Axle S/N HITA-726032), (298-1818 is no longer available; order qty. 6 of 298-7430 for replacement) ADJUSTING BOLT, (Axle S/N HITA-726032 & After) SPRING ADJUSTING BOLT BRAKE DISC INTERMEDIATE BRAKE DISC SPACER

TL642

5-39

DRIVE TRAIN Figure 5-18 Rear Brakes

1 10

2

3 4 6

17 16 12

7 9

8

11

18 5

13

PY3780

5-40

TL642

31200255

DRIVE TRAIN Figure 5-18 Rear Brakes Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18

298-8191 350-8573 299-0241 350-8575 299-0240 350-8576 350-8577 350-8578 350-8579 298-8192 298-7873 299-7103 350-2524 350-8574 298-1879 298-1878 298-1881

8 6 6 2 6 2 2 2 2 10 2 2 2 2 2 2 6

Description

Rev.

BRAKE DISC ADJUSTING BOLT TUBE PISTON SPRING BACK-UP RING O-RING BACK-UP RING O-RING INTERMEDIATE BRAKE DISC BLEEDING BOLT PLUG PILOT BOLT PISTON KIT, (includes items 3, 4 & 6 thru 9) SEAL WASHER BOLT ADJUSTING BOLT


31200255

TL642

5-41

DRIVE TRAIN Figure 5-19 Rear Wheel Hub

5-42

TL642

31200255

DRIVE TRAIN Figure 5-19 Rear Wheel Hub Item

Part Number

Qty.

1 2 3 4 6 7 8 9 10 11 12

303-8574 298-8193 298-7274 299-6639 298-8297 298-8194 298-8195 298-8196 298-8197 298-8198 298-1825

2 4 20 2 2 2 2 2 2 20 20

Description

Rev.

SEAL BEARING WHEEL STUD WHEEL HUB O-RING CIRCLIP RING GEAR RING GEAR SUPPORT LOCKING PLATE STUD NUT


31200255

TL642

5-43

DRIVE TRAIN Figure 5-20 Rear Reduction Gears

5-44

TL642

31200255

DRIVE TRAIN Figure 5-20 Rear Reduction Gears Item

Part Number

Qty.

Description

1 2 3 4 6 7

299-0205 299-0206 299-0207 299-0797 299-7170 298-8300

8 8 8 2 4 4

CIRCLIP PLANETARY GEAR BEARING PLANETARY GEAR CARRIER PLUG COUNTERSUNK BOLT

350-8580

2

299-0813

2

PLANETARY CARRIER KIT, (includes items 1 thru 4 and items 7, 8 & 9 on Figure 5-19) RING GEAR SUPPORT, (includes items 7, 8 & 9 on Figure 5-19)

Rev.


31200255

TL642

5-45

DRIVE TRAIN Figure 5-21 Drive Shaft Assembly

5 4

2

3

2 2

7

6

1 2

PAL0380

5-46

TL642

31200255

DRIVE TRAIN Figure 5-21 Drive Shaft Assembly Item

Part Number

Qty.

1 2 3 4 5 6 7

299-0317 303-8584 299-0316

1 4 1 Ref Ref 8 16

31200255

298-8599 298-1791

Description

Rev.

DRIVESHAFT, (front), (includes item 2) UNIVERSAL JOINT KIT DRIVESHAFT, (rear), (includes item 2) FLANGE, (see Figure 5-15 for details) REAR AXLE ASSY, (see Figure 5-11 for details) BEARING STRAP STRAP BOLT

TL642

5-47

DRIVE TRAIN Figure 5-22 Tires & Rims TREAD PATTERNS MAY VARY

5 7

8

11 12

9

13 14

3 10

2

4

1 6

5-48

PAL3581

TL642

31200255

DRIVE TRAIN Figure 5-22 Tires & Rims Item

1 2 3 4 5 6 7 8

31200255

Part Number

Qty.

Description

Rev.

4520368 91405035 91405036 4520369 91535017

1 2 2 1 4

A H H A B

4520455 91475031 91475032 4520458 4520451

1 2 2 1 4

4520374 91515056 4520461 4520453 4520370 91475054

1 4 1 4 1 2

91475055

2

4520375 91475093

1 4

4520371 91535019

1 4

4520459 91475105

1 4

4520456 4520449

1 2

4520450

2

4520462 91515066

1 4

4520645 1001121519CP 370-7770 1001120963CP 1001100323 8780031 298-7311 298-8780 298-1744 8780045 8780036 8780050 8780264

1 1 1 1 1 1 1 1 10 1 1 1 1

TIRE SET, 13.00-24 BIAS R.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, (includes items 1 thru 3) L.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, (includes items 1 thru 3) TIRE SET, 13.0-24 BIAS, ROCK TREAD TIRE & WHEEL ASSY, 13.00-24 BIAS, ROCK TREAD, (includes items 2, 3 & 5) TIRE SET, 15.50-25 BIAS R.H. TIRE & WHEEL ASSY, 15.5-25 BIAS, (includes items 2, 6 & 10) L.H. TIRE & WHEEL ASSY, 15.5-25 BIAS, (includes items 2, 6 & 10) TIRE SET, 13.0-24 BIAS TIRE & WHEEL ASSY, 15.5-25 BIAS, ROCK TREAD, (includes items 2, 7&10) TIRE SET, 13.0-24 RADIAL TIRE & WHEEL ASSY, 13.0-24 RADIAL, (includes items 2, 3 & 8) TIRE SET, 13.0-24 RADIAL TIRE & WHEEL ASSY, 15.5-25, RADIAL, (includes items 2, 9 & 10) TIRE SET, 13.0-24 BIAS, FOAM FILLED R.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, FOAM FILLED, 542#, (includes items 1 thru 3) L.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, FOAM FILLED, 542#, (includes items 1 thru 3) TIRE SET, 13.0-24 RADIAL, FOAM FILLED TIRE & WHEEL ASSY, 13.0-24 RADIAL, FOAM FILLED, 542#, (includes items 2, 3 and 8) TIRE SET, 13.0-24 BIAS, ROCK TREAD, FOAM FILLED TIRE & WHEEL ASSY, 13.0-24 BIAS, ROCK TREAD, FOAM FILLED, 542#, (includes items 2, 3 & 5) TIRE SET, 15.5-25, FOAM FILLED TIRE & WHEEL ASSY, 15.5-25, ROCK TREAD, FOAM FILLED, 600# (includes items 2, 7 & 10) TIRE SET, 15.5-25, FOAM FILLED R.H. TIRE & WHEEL ASSY, 15.5-25, FOAM FILLED, G-2, (includes items 2, 6 & 10) L.H. TIRE & WHEEL ASSY, 15.5-25, FOAM FILLED, G-2, (includes items 2, 6 & 10) TIRE SET, 15.5-25, FOAM FILLED TIRE & WHEEL ASSY, 15.5-25, RADIAL, FOAM FILLED, 600# (includes items 2, 9 & 10) SOLID TIRE SET, 13.0-24, (includes items 11 & 12) TIRE SET, 370/75-28, FOAM FILLED TIRE & WHEEL ASSY, 370/75-28, (includes items 2, 13 &14) TIRE SET, 370/75-28, PNEUMATIC TIRE & WHEEL ASSY, 370/75-28, (includes items 2, 13 & 14) TIRE, 13.0-24 BIAS, DIRECTIONAL VALVE STEM WHEEL, 24X9 LUG NUT TIRE, 13.0-24 BIAS, ROCK TREAD, NON-DIRECTIONAL TIRE, 15.5-25 BIAS, DIRECTIONAL TIRE, 15.5-25 BIAS, ROCK TREAD, NON-DIRECTIONAL TIRE, 13.0-24 RADIAL, NON-DIRECTIONAL

TL642

A C C A A A B A A A D D A E A D A B A A A A D A B B B D

5-49


Part Number

Qty.

9 10 11 12 13 14

8780048 298-8781 4520646 4520647

1 1 1 1 1 1

5-50

1001100284

Description TIRE, 15.5-25 RADIAL, L-2 WHEEL, 25X13 R.H. SOLID TIRE & WHEEL ASSY L.H. SOLID TIRE & WHEEL ASSY WHEEL, 28X11 TIRE, 370/75-28

TL642

Rev.

B B

31200255


31200255

Part Number

Qty.

Description

TL642

Rev.

5-51

DRIVE TRAIN


5-52

TL642

31200255

SECTION 6 CAB

31200255

TL642


CAB Figure 6-1 Cab Assembly

41 14 4 66 67 4 14 17

13 1 2 7

65 53 12

54 52

26 27 28

27 28 29

6

30

27 28 3 32

CLAMP MOUNT BEHIND SEAT

45 49 61

33 41 68 69

28 34 56

25

37 57 58

35 59 60

101 112 16 9 10 31 42

15

62 63 64

36 39 40 41 42 43

104 106 113

34

72

28 55 56 38

102 105 107 108

107 108 109 110


106 111

4 24

18 19 20 21 22 50 51

A

23

A VIEW A-A

48

50 70 71

11 14 38

PAL2083

SIDE VIEW OF CAB

6-2

TL642

31200255



Item

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 45 48

31200255

Part Number

344-7161 298-8041 298-7372 298-7079 298-1770 298-8152 298-8141 305-2028 298-1772 298-0552 297-7012

304-2566 298-1738 298-1359 297-7016 298-1643 297-7021 298-8761 297-7010 298-8608 298-8609 6V-7978 298-7880

309-6321 299-0395 298-7105 303-4865 298-8644 298-8149 298-7039 350-2520 315-5502 297-7014 298-7378 298-8047 298-8043 299-0369

Qty. Ref Ref 1 1 2 11 1 2 1 1 1 1 2 4 Ref 9 Ref Ref 1 1 2 1 2 1 1 4 1 1 1 16 12 Ref Ref 3 2 Ref 1 1 1 1 1 1 1 3 6 6 AR 4 AR

Description

Rev.

OPEN CAB ASSY, (includes items 1 thru 61) ENCLOSED CAB ASSY, (includes items 1 thru 67) CAB WELDMENT, (see Figure 6-2 for details) ACCESS COVER PLATE MACHINE HD SCREW, 1/4-20X5/8 FLAT WASHER, 1/4 TILT ON JOYSTICK CAB HARNESS, (not shown) SELF-TAPPING SCREW, #6X1/2 VENT COVER PLATE JOYSTICK ENGINE HARNESS, (not shown) CABLE LH BRACKET FENDER WASHER LOCKNUT, 5/16-18 SUSPENSION SEAT, (see Figure 6-3 for details) HEX HD CAPSCREW, 1/4-20X1, GR5 BRAKE PEDAL ASSY, (see Figure 7-3 for details) ACCELERATOR PEDAL ASSY, (see Figure 7-1 for details) MANUAL STORAGE BOX DASH CLAMP SCREW, 3/8-16X1 HEX HD CAPSCREW, 5/16-18X3/4, GR5 FENDER WASHER, 5/16 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 DASH BRACE HEX HD CAPSCREW, 1/4-20X5/8, GR5 DASH, (open cab) DASH, (enclosed cab) LH VERTICAL DASH PANEL FLAT HD CAPSCREW, #10-24X1 TINNERMAN NUT, #10-24 INSTRUMENT PANEL, (see Figure 6-4 for details) STEERING COMPONENTS, (see Figure 7-2 for details) HEX HD CAPSCREW, 1/4-20X2-1/2 LOAD CHART BRACKET BOOM JOYSTICK w/TILT, (see Figure 7-4 for details) CONTROL PANEL, (no outriggers) CONTROL PANEL, (with outriggers) RH HORZ CONTROL ASSY CABLE LH VERTICAL CONTROL ASSY RH CONSOLE RH SWAY BRACKET HEX HD CAPSCREW, 1/4-20X2 LOCKWASHER, 1/4 HEX NUT, 1/4-20 LOCTITE, #242 PAN HD SCREW, 6-32X1/2, (self tap) TRIM-LOK

TL642

6-3


CAB Figure 6-1 Cab Assembly (Continued) Item

Part Number

Qty.

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 101 102 104 105 106 107 108 109 110 111 112 113 222

298-7017 297-7018 298-7373 298-1362 298-7364 297-7008 298-8133 298-7101 297-7039 298-7367 297-7017 298-7379 298-7286 298-1770 298-0529 298-7362

334-3559 334-3558 297-7009 297-7012 298-7363 298-7372 298-7378 298-8047 309-6321 298-7050 299-6623 334-3560 298-8047

1 3 1 1 4 6 1 10 2 2 3 3 1 2 2 2 Ref 1 AR 4 4 2 2 Ref 1 1 2 2 2 4 3 1 1 1 14” 1 1

314-6130

1

349-6874 298-7292 298-7372 297-7012 299-6644 298-7438

Ref

Description

Rev.

MOUNTING PLATE HEX HD CAPSCREW, 5/16-18X1-1/4, GR5 FLAT WASHER, 5/16 FLOOR MAT FLAT WASHER, 5/16 SOCKET BUTTON HD CAPSCREW, 1/4-20X5/8 COVER PANEL SELF TAPPING SCREW, 10X3/4 HEX HD CAPSCREW, 1/2-13X1, GR5 FLAT WASHER, 1/2 HEX HD CAPSCREW, 5/16-18X1, GR5 FLAT WASHER, 5/16 RHEOSTAT TILT SWITCH SELF TAP SCREW, #6 SUPPORT CLAMP FLAT WASHER, #10 HEATING COMPONENTS, (see Figure 6-5 for details) WASHER FLUID BOTTLE WASHER FLUID HOSE FLAT WASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1, GR5 COVER PLATE CLAMP SET OUTRIGGER CONTROLLER, (see Figure 8-11 for details) LOWER CONSOLE, RH LOWER CONSOLE MOUNTING BRACKET SOCKET BUTTON HD CAPSCREW, 1/4-20X1 HEX HD CAPSCREW, 1/4-20X1, GR5 FLAT WASHER, 1/4 FLAT WASHER, WIDE, 1/4 LOCKWASHER, 1/4 HEAVY HEX NUT, 1/4-20 HEX HD CAPSCREW, 1/4-20X2-1/2, GR5 HEATER PLENUM TRIM LOC, 3/16 RETAINING NUT, .25-20 HEAVY HEX NUT, 1/2-20

CAB ENCLOSURE KIT, (includes items 4, 14, 41, 62 thru 66, 107 thru 111 & 222) CAB ENCLOSURE, (see Figure 6-2 for details)

A, 1


6-4

TL642

31200255


CAB Figure 6-1 Cab Assembly (Continued)

Item

31200255

Part Number

Qty.

Description

TL642

Rev.

6-5


CAB Figure 6-1 Cab Assembly 58 59 60

192

57

13 14 15

44 8 41 43 67 40

113 120 155 160 164

48 49

51 69

45 46

56

33 423 424

31 32 33

32 33 62

4

34 35

418 419 420

409 410 411 412 421 423

23

633 637 638 639 404 413 414

38 415 416 417

3

501 504 506 510 512

614 635 636

666

2

39 52 54 52

16 17 18 19 20 21

667

502 507 508 502

24 39 52 53 54 55


A

A

28 29 30

14 37 36 VIEW A-A

SIDE VIEW OF CAB

55

PAL5620

6-6

TL642

31200255



Item 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 43 44 45 46 48 49

31200255

Part Number

298-7373 298-7379 297-7017 298-7380 297-7031 299-0562 298-1694 298-7036 298-7372 297-7012 297-7012 332-3847 298-7362 298-7377 298-0546 333-2416 332-3846 299-0369 350-2519 298-1643 297-7016 297-7018 297-7021 298-6833 298-1738 298-1359 6V-7978 298-7880 299-0395 298-8041 298-8761 297-7010 364-5684 298-1772 344-7161 307-9601 297-7032 298-7364 298-0552 298-7363 297-7008

Qty. Ref Ref Ref Ref 7 6 7 5 2 Ref 1 1 1 8 7 6 1 2 2 2 2 1 AR 1 1 4 1 1 1 AR 1 2 Ref 12 22 2 2 1 4 1 8 1 Ref 3 Ref 4 4 6 4

Description

Rev.

CAB WELDMENT, (see Figure 6-2 for details) ACCELERATOR PEDAL ASSY, (see Figure 7-1 for details) BRAKE PEDAL ASSY, (see Figure 7-3 for details) STEERING CONTROL ASSY, (see Figure 7-2 for details) WASHER, 5/16 LOCKWASHER, 5/16 HEX HD CAPSCREW, 5/1618X1, GR5 LOCK WASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1 STEERING WHEEL, (see Figure 7-2 for details) FNR SHIFTER SHIFTER DECAL MANUAL STORAGE BOX WASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1, GR5 HEX HD CAPSCREW, 1/4-20X1, GR5 CUP HOLDER MOUNT WASHER LOCKWASHER HEX NUT, 10-24, GR2 FLAT HD SOCKET SCREW, 10-24X1 CUP HOLDER TRAY TRIM-LOK OPEN CAB DASH PANEL ENCLOSED CAB DASH PANEL FENDER WASHER, 11/32X1.25 HEX HD CAPSCREW, 5/16-18X.75, GR5 HEX HD CAPSCREW, 5/16-18X1.25, GR5 HEX HD CAPSCREW, 5/16-18X1.75, GR5 GASKA-TAPE DASH CLAMP SCREW, 3/8-16X1 INSTRUMENT PANEL, (see Figure 6-4 for details) PAN HD SCREW, #10 TINNERMAN NUT, #10-24 LOAD CHART BRACKET ROUND HD MACHINE SCREW, 1/4-20X0.625 DASH BRACE HEX HD CAPSCREW, 1/4-20X.0625, GR5 RIGHT SIDE CONSOLE PANEL FENDER WASHER, 1/4 SEAT RISER ACCESS PANEL FUEL TANK ASSY, (see Figure 4-5 for details) HEX HD CAPSCREW, 3/8-16X1.25, GR5 SUSPENSION SEAT, (see Figure 6-3 for details) WASHER, 5/16 HEX LOCK NUT, 5/16-18, GR2 WASHER, 1/4 BUTTON HD SCREW, 1/4-20X5/8

TL642

6-7


CAB Figure 6-1 Cab Assembly Item 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 67 69 70 101 112 113 118 120 132 133 142 143 144 145 146 147 148 155 160 164 169 180 185 192 193 200 203 209 301 302 303 304 305

6-8

Part Number 298-1770 298-8069 298-8068 299-0370 298-1362 299-0310 298-1695 298-1370 298-8378 298-8673 364-5693 370-1094 344-3273 298-7374 350-2526

297-7099 297-7100 298-0544 298-0547 8T-4138 299-0341 299-0346 298-7282 298-7283 298-7285 298-7292 298-7977 298-6843 298-7013 298-8590 298-8426 350-2506 350-2517 349-6874 346-9672 299-1352 298-7319 350-2518 297-7013 298-0548 298-7371 325-1066 359-8938

Qty. Ref 4 2 1 7 AR 1 Ref 1 1 1 1 1 1 1 1 3 1 Ref Ref 2 4 2 4 1 2 1 2 2 1 1 AR 4 1 1 1 1 2 2 1 1 1 1 2 4 4 4 1 1

Description

Rev.

IGNITION SWITCH, (see Figure 6-4 for details) SELF TAPPING SCREW, #6X0.5 HOSE GUARD STOVER LOCK NUT, 5/16-18 STOVER LOCK NUT, 1/4-20 TRIM-LOK FLOORMAT L.H. CAB MIRROR INSTALL, (see Figure 1-1 for details) AIR BREATHER ADAPTER, 12-12 HOSE ASSY ACCELERATOR BRAKET RH INSTRUMENT PANEL ELECTRICAL OPTIONS ASSY, (includes items 301 thru 306) DASH HARNESS, (not shown) TRANSMISSION RELAY HARNESS WASHER, 3/8 SEAT RISER SIDE PANEL KEY, (see Figure 6-4 for details) CAT THREADLOCK FLAT HD SOCKET SCREW, 6-32X0.62 FLAT HD SOCKET SCREW, 10-24X0.75 HEX NUT, 6-32, GR2 HEX LOCK NUT, 10-24, GR2 STAR WASHER, 1/4 HEX HD CAPSCREW, M6X20, GR8.8 WEATHERPACK SHROUD WEATHERPACK CABLE SEAL PIN WIPER SWITCH BLOWER SWITCH WASHER FLUID HOSE HOSE CLAMP RUBBER GROMMET FAN BASE PLATE DEFROSTER FAN ENCLOSED CAB OPTIONS HARNESS ROUND VENT CONDUIT WINDOW WASHER FLUID TANK ACCESSORY MODULE HARNESS POTENTIOMETER TUBING CLIP CONDUIT HEX HD CAPSCREW, 1/4-20X1.5, GR5 HEX NUT, 1/4-20, GR2 WASHER VEC OPTION BOX VEC OPTIONS HARNESS

TL642

31200255



Item

Part Number

Qty.

306 404 409 410 411 412 413 414 415 416 417 418 419 420 421 423 424 501 502 504 505 506 507 508 510 511 512 513 614 635 636 637 638 639 654 656 666 667

300-6101 298-7379

4 6 Ref 4 4 4 1 3 1 2 2 1 1 4 1 10 1 1 1 2 2 2 2 2 2 1 AR 1 6 6 1 Ref 4 4 1 10 1 1

298-7372 298-7378 297-7012 299-6693 297-7017 298-7367 297-7039 328-7822 298-8043 298-7105 6V-7978 323-3877 334-3559 334-3558 297-7009 297-7012 298-7363 298-7372 298-7378

299-6623 334-3560 298-7364 297-7017 303-4866 298-7363 298-0549 6V-7978 360-7793

Description

Rev.

WIRE TIE LOCKWASHER, 5/16 JOYSTICK, (see Figure 7-4 for details) WASHER, 1/4 LOCKWASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1, GR5 SINGLE CONTROL VALVE HEX HD CAPSCREW, 5/16-18X1, GR5 LH VERTICAL CONTROLLER WASHER, 1/2 HEX HD CAPSCREW, 1/2-13X1, GR5 TILT RHEOSTAT DECAL TILT RHEOSTAT SELF TAP PAN HD SCREW, #6-32X0.5 SWAY CONTROLLER HAN HD SCREW, #10 LH PANEL LOWER RIGHT HAND CONSOLE CONSOLE MOUNT BRACKET BUTTON HD SCREW, 1/4-20X1 HEX HD CAPSCREW, 1/4-20X1, GR5 WASHER, 1/4 WASHER, 1/4 LOCKWASHER, 1/4 PANEL RETAINER CLIP RIGHT HAND DASH COVER TRIM LOC, 3/16 NUT, 0.25-20 WASHER, 5/16 HEX HD CAPSCREW, 5/16-18X1, GR5 BRACKET CONTROLLER, (see Figure 7-5 for details) WASHER, 1/4 HEX LOCK NUT, 1/4-20, GR2 CONTROL PANEL (with outriggers) PAN HD SCREW, #10 SWAY DECAL OUTRIGGER DECAL


31200255

TL642

6-9

CAB Figure 6-2 Cab

NOTE: APPLY LOCTITE, ITEM 68, TO ALL HARDWARE THAT REQUIRE LOCKNUTS.

6-10

TL642

31200255

CAB Figure 6-2 Cab (Continued)

NOTE: APPLY LOCTITE, ITEM 68, TO ALL HARDWARE THAT REQUIRE LOCKNUTS.

31200255

TL642

6-11

CAB Figure 6-2 Cab Item

1 2 3 4 5 6 8 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 45

6-12

Part Number

Qty.

299-7148 298-7225 308-6651 303-8618 320-0534 304-2656 303-8579 N/S N/S 303-8619 303-8612 304-3181 303-8615 303-8585 303-8592 303-8591 303-8596 304-3799 303-8593 303-8594 303-8595 303-8625 303-8628

1 1 1 1 AR AR 13 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 2 AR 1 1 3 1 1 1 1 1 2 3 1 1 1 1 2 1 1 11’ 2 2 1 1 1 2 1

303-8624 303-8627 303-8630 303-8632 303-8631 303-4978 303-8626 303-8634 303-8590 303-8635 304-2638 304-2639 303-8597 303-8613 303-8629 303-8582 303-8633 303-8581 304-2301 303-8614 303-8649 303-8667 303-8648 304-2300 303-8642

Description

Rev.

OPEN CAB, (includes items 1 thru 11) ENCLOSED CAB, (includes items 1 thru 66) CAB ENCLOSURE, (includes items 14, 16 thru 18, 24 thru 26, 31 & 32) RH WINDOW w/ BORDER URETHANE ACTIVATOR SETTING BLOCK SERIAL TAG, (open cab) SERIAL TAG, (enclosed cab) REAR WINDOW ROPS WARNING DECAL PLUG, (open cab) SPACER, (enclosed cab) PLUG, (open cab) SCREW, 1/4-28X3/4, (enclosed cab) WET ARM ADAPTER ADAPTER KIT WIPER SYSTEM ASSY WET ARM KIT WIPER ARM WIPER BLADE, 28” FRONT WINDOW PLUG, 1-1/4 CLEAR SEALANT SKY LIGHT WINDOW HEADLINER RIVET, 1/8 EXIT HAMMER w/ CABLE EMERGENCY EXIT DECAL LH SIDE REAR WINDOW FOAM, LH SIDE PANEL HEX BOLT, 3/8-16X6-1/2 HEX BOLT, 3/8-16X4-1/2 HEX NUT, 3/8-16 LOWER DOOR ASSY, (includes items 44 thru 66 & items 68 and 69) UPPER DOOR ASSY, (includes items 2, 3, 38 thru 43 & item 68) DOOR STRAP HEX BOLT, 3/8-16X7/8 WASHER STRIKER DOOR HOLD-OPEN, FEMALE BULB SEAL HEX BOLT, 5/16-18X5/8 WASHER SLAM LATCH DOOR HOLD-OPEN, MALE UPPER DOOR GLASS FLAT HD SCREW, 1/4-20X1-1/4 GRAB HANDLE

TL642

31200255

CAB Figure 6-2 Cab (Continued) Item

Part Number

Qty.

Description

46 47 48 49 50 51 52 53 54 55 56 57 58 59

303-8578 303-8638 303-8587 303-8588 303-8641 303-8643 303-8644 303-8640 303-8646 303-8645 331-6125 303-8647 304-2649 363-7725 5P-8500 303-8581 303-8583 303-8636 303-8586 303-8637 303-8639 304-4580

3 1 6 1 1 1 1 6 1 1 2 1 4 1 1 8’ 1 1 3 1 1 1 AR AR 1 4 4 4 1 1

SCREW, M6X1X12 PLASTIC DOOR COVER WHIZ-LOCK SCREW, #10-24X0.5 INSIDE HANDLE ASSY, LH RELEASE LEVER, RH WINDOW/LH DOOR SOCKET HD SCREW, #8-32X1.12 NUT, #8-32 LOCKNUT, #10-24 SLAM LATCH STIFFENER SLAM LATCH, LH RIVNUT, 1/4-20 LOWER DOOR DRIVE BAR WELDMENT HEX SCREW, 1/4-20X3/4 PADDLE LATCH, LH KEY BULB SEAL CAM LATCH, RH EXTERIOR RELEASE DOOR ROD ROD END RETAINER CLIP INTERIOR RELEASE DOOR ROD FOAM, LOWER DOOR SERIAL TAG, (cab enclosure kit) LOCTITE BLACK VINYL TAPE, 2” SEAT RISER WELDMENT FLAT WASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1, GR5 LOCKWASHER, 3/8 WIPER ARM DRIVE WIPER PIVOT SHAFT, 2”

60 61 62 63 64 65 67 68 69 70 71 72 73 74 75

304-2640 304-3798 304-2648 304-2636 304-2637 303-8589 303-8611

Rev.


31200255

TL642

6-13

CAB Figure 6-3 Suspension Seat

5

1 2

3

4

6 7

8

9

10

6-14

TL642

PAL0700

31200255

CAB Figure 6-3 Suspension Seat Item 1 2 3 4 5 6 7 8 9 10

31200255

Part Number

Qty.

298-8722 299-0927

1 1 1 1 1 1 1 1 1 1 1 1

304-2626 299-0925 299-0928 298-8669 299-6637 299-0924 299-0922 299-0921

Description SUSPENSION SEAT, (includes all items) ARMREST ASSY RH KIT, (includes items 2 & 3) ARMREST, MOLDED KIT ARMREST STOP ASSY BACK CUSHION KIT BACK PANEL KIT SEAT BELT KIT SEAT BELT, 3 IN., (California Only), (not included with 298-8722) TETHER KIT SEAT CUSHION KIT KNOB KIT SLIDE KIT

TL642

Rev. C

6-15


CAB

BAT-1

2

HR MTR

3

HORN

4

FUL GAG

5

ST RLY

6

BAT-2

7

SP-1

8

SP-2

9

ALT EXC

10

SP-3

11

STR AW

12

STR CRB

13

TRANS-B

14

TRANS-A

15

TRANS-C

16

TRANS-D

17

TRANS-E

18

REV AL

7 18

6

8

15 17

9 18

11 18

1

DEUTSCH 8 PIN RECEPTACLE

KEY WIRE DESIGNATION

KEY

WIRE COLOR/STRIPE KEY

WIRE GAGE 16

ALT EXC BACK LT BRK SOL BRK SW BAT-1 BAT-2 BR SW PWR

VIOLET/RED YELLOW/ORANGE BLUE/TAN RED/TAN RED RED ORANGE/BLUE

16 16 14 8 12 16

CLT TMP FUL GAG GND-1 GND-2 GAG PWR

BLUE/VIOLET BLUE/BLACK BLACK BLACK ORANGE/TAN

16 16 8 12 16

HMTR GND HR MTR HORN HRN PWR

BLACK BLUE/RED ORANGE/YELLOW ORANGE/VIOLET

16 16 16 16

WIRE DESIGNATION

PIN DESIGNATION

WIRING SPECIFICATIONS KEY

WIRE COLOR/STRIPE

WIRE GAGE

SHFT PWR 1 SHFT PWR 2 GP SW SHIFT-B GP SIG

16 16

INST GND KEY ACC

BLACK ORANGE/GRAY

KEY STRT

RED/BROWN

16

KEY PWR OIL GAG PS IGN PB LT GND REV AL

RED BLUE/BROWN ORANGE/DK GREEN BLACK BLUE

12 16 16 16 16

STOP LT

YELLOW/RED

12

ST RLY SP-1 SP-2

VIOLET/ORANGE GRAY/ORANGE GRAY/YELLOW

16 12 12

SP-3 STR AW STR CRB

GRAY/BLUE VIOLET/LT GREEN VIOLET/YELLOW

16 16 16

STR PWR

ORANGE/WHITE

16

WIRE COLOR/STRIPE

WIRE DESIGNATION

SHIFT STRT TR LT TR LT SW TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E WORK LT

WIRE GAGE

ORANGE/RED ORANGE/BLACK WHITE/BLUE

16 16 16

VIOLET/TAN WHITE/GREEN RED/WHITE BLUE/WHITE BLUE/WHITE VIOLET/WHITE

16 16 16 16 16 16 16 16 16 16 12

VIOLET/TAN VIOLET/GRAY VIOLET/DK GREEN VIOLET/BLUE YELLOW/BLUE

1

13 14 16

1

SHFT PWR 1

2

TRANS-A

3

SHIFT-B

4 SHIFT STRT 5

TRANS-C

6

TRANS-E

7

TRANS-D

8

SHFT PWR 2

WIRE DESIGNATION

1

WIRE DESIGNATION

PIN DESIGNATION

Figure 6-4 Instrument Panel

1

WARN_LT_CK

REV_ALARM

ACC

AUX_ELEC1 SW1-86

SW2-87A

SW2-86

AUX_ELEC2 SW1-87A

GND85

OPT SPARE_COIL

WIRE DESIGNATION

LIGHTS

12

10 BA T

4

6-16

ST

3

CO N

3 AC C

2

RE L

PLUG

W/W

PLUG

18

FAN/HTR

PIN DESIGNATION

SPARE_BAT

PLUG

17

SL_SWA

16

WL_SWA

GP SIG

W/W_SW

GP SW

15

SL_SWB

14

WL_SWB

TR LT SW

WL2

PRK SOL

13

HTR_SW

12

FAN_SW

CLT TMP

FAN/HTR 25A

11

W/W 25A

PS IGN OIL GAG

LIGHTS 25A

9 10

RELAYS 10A GAUGES 10A STEER 10A

STOP LT

SPARE_BAT 25A

GND-2

8

OPT3 15A

WORK LT

7

5

OPT1 10A OPT2 15A

6

OPT3

PLUG

OPT2

5

OPT1

PLUG

GND3

PLUG

4

GND2

3

GND1

BACK LT

KEY 15A HORN 10A

GND-1

2

OPT_PWR 30A

1

NOTE: BLACK PLASTIC PANEL NOT AVAILABLE FOR SERVICE. MUST ORDER COMPLETE INSTRUMENT PANEL, 298-7222, FOR REPLACEMENT. PAL2240

TL642

31200255


CAB Figure 6-4 Instrument Panel

Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10

298-7222 298-6907 299-7132 298-7091 299-0325 299-0363 303-8662 320-8390 304-2613 333-2415 5P-8500 298-7048 346-2984 298-7093 298-7092 304-2641 299-0860 304-2642 304-2612

1 1 2 1 AR 1 1 1 1 1 1 1 1 1 1 1 4 1 3

11 12 13 14 15 16 17 18

31200255

Description

Rev.

INSTRUMENT PANEL, (includes all items) CONNECTOR STRAIN RELIEF, 90 DEGREES CONNECTOR RELAY HOURMETER PARK BRAKE SWITCH, (includes item 18) 4 IN 1 GAUGE HORN SWITCH, (includes item 18) IGNITION SWITCH KEY STEER SELECT SWITCH, (includes item 18) RECEPTACLE SMALL GAUGE BRACKET LARGE GAUGE BRACKET PRE HEAT SWITCH, (includes item 17) BULB ACTUATOR ACTUATOR

TL642

6-17



4

3

2

1 7 286 5 287

CONN POS

1 2 3 4 5 6

C

6

4

3

1

H-WIRE DESIGNATION 1 WAIT TO START LT 2 GAUGE PWR 6

H CONN POS

1 2

G-WIRE DESIGNATION ENG WARN LT GAUGE PWR 5

WIRE GA & TYPE

18 GXL 18 GXL

113 114 115

WIRE GA & TYPE

18 GXL 18 GXL

1 2

TRANS TEMP WARN

F-WIRE DESIGNATION TRANS TEMP SW GAUGE PWR 4

WIRE GA & TYPE

18 GXL 18 GXL

ENG. STOP

E CONN POS

1 2

CONN POS

E-WIRE DESIGNATION ENG STOP LT GAUGE PWR 3

1 2 3 4 5 6 7 8

WIRE GA & TYPE

18 GXL 18 GXL

105 106 107

C B A

B

6-18

A

G ENG. WARN. F

CONN POS

101 102 103 104

6

WAIT TO START

WIRE GA & TYPE

18 GXL 18 STP 18 STP ----

108 109 110 111 112

WIRE LOADING VIEW

CONN POS

WIRE DESIGNATION GAUGE PWR 2 YEL/CAN HI GRN/CAN LO DASH GND FUL LVL PLUGGED

TL642

CONN POS

A B C

WIRE DESIGNATION FUL LVL DASH GND GAUGE PWR 1 ENG STOP LT TRANS TMP SW ENG WARN LT WAIT TO START LT PLUGGED

WIRE DESIGNATION YEL CAN H GRN CAN L SHIELD

WIRE GA & TYPE

18 GXL 18 GXL 18 GXL ---18 GXL --

WIRE GA & TYPE

18 STP 18 STP 18 STP

PAL5010

31200255



Item 1 2 3 4 5 6 7 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 286 287

31200255

Part Number

Qty.

333-1338

1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 1 1

298-8147 303-8662 304-2613 334-0787 334-0789 334-0788 346-2984 334-5962 298-7268

356-2911

305-5448 333-2415 5P-8500

Description INSTRUMENT PANEL, (includes items 1 thru 7) BULB HOUSING STEER SELECT SWITCH PARK BRAKE SWITCH HORN SWITCH 3-IN-1 GAUGE INSTRUMENT PANEL HARNESS, (includes items 101 thru 115) DASH PANEL 8 PIN RECEPTACLE WEDGELOCK TERMINAL PLUG CONNECTOR WEDGE LOCK CONTACT CONNECTOR DOUBLE LOCK PLATE SOCKET WIRE SEAL PLUG BULB BASE TERMINAL BULB IGNITION SWITCH KEY

TL642

Rev. G

B

6-19

CAB Figure 6-5 Heating Components

LOW HSW

BAT HSW

MED HSW HIG HSW

NOT USED

31 32 33 34 39 35 40 423

5 36

18 20 7 19

20 524 38 15 16 21

11

13

12

19 6

14

RETURN SUPPLY

VIEW OF RH CONSOLE TO SHOW HEATER VALVE MTG

17

HOSE VIEW

3 25 26 27 601 602

22 23 17 24 21 RETURN SUPPLY

201 203

208 207 202 201 17

PAL2112

6-20

TL642

31200255

CAB Figure 6-5 Heating Components (Continued)

SW1-86

SW2-87A

SW2-86

SW1-87A

GND85

SPARE_COIL

WARN_LT_CK

AUX_ELEC1

AUX_ELEC2

FAN/HTR

W/W

LIGHTS

ACC

OPT

F

REV_ALARM

WL_SWA

SL_SWA

OPT3 15A OPT3 GND3

OPT1 10A OPT2 15A OPT1

OPT2

GND1

KEY 15A HORN 10A OPT_PWR 30A

SPARE_BAT 25A

LIGHTS 25A


W/W 25A

FAN/HTR 25A W/W_SW

GND2

WL_SWB

SL_SWB

A

WL2

D C B

HTR_SW

E

328

SPARE_BAT

111

OIL

LT

12+

FUEL

GND

TEMP

104

GND HSW BAT HSW F

BAT WSW

E D C B

HIG WSW LOW WSW

A

WAS WSW PAR WSW BAT WSW

BAT HSW GND HSW PAR WSW WAS WSW LOW WSW HIG WSW

102

FAN WIRING HIG HWS MED HWS LOW HWS GND HWS

HIG HWS MED HSW

BAT FAN

LOW HWS

PAR WSW LOW WSW BAT WSW

3 2

1 B

GND HWS

HIGH WSW W

103

WAS WSW

GND FAN

WEATHER PACK CONNECTOR WIRING CHART GND FAN "A" "B" BAT FAN

GND HSW BAT HSW

BAT HSW GND HSW PAR WSW WAS WSW LOW WSW HIG WSW

B

GND FAN BAT FAN

101

A

PAR WSW HIG WSW LOW WSW

WAS WSW

31200255

109 112 113

PAL2101

TL642

6-21

CAB Figure 6-5 Heating Components Item

Part Number

Qty.

3 5 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 36 38 39 40 101 102 103 104 109 111 112 113

298-7041 299-0333 298-7102 298-7077 298-7098 298-8584 298-7285 299-0331 298-7277 298-7296 298-7290 298-7262 298-7263 298-7931 298-7977 298-7834 299-0949 297-7021 298-8032 298-7372 298-7378 298-8590 298-7013 298-6843 298-8022 298-7844 298-8589 299-6646 298-7102 298-1770 298-7051 298-7052 298-7053 298-7283 299-0341 298-7896 298-7282 299-0346

1 2 1 2 1 1 1 1 1 1 2 AR AR 18 4 1 1 1 4 4 4 1 1 1 4 4 2 1 2 2 1 1 1 1 1 2 2 2

HEATER UNIT, (includes items 601 & 602) AIR DIFFUSER VENT RECTANGULAR VENT 3-WAY CONNECTOR HEATER CONTROL CABLE HEATER CONTROL PANEL HEATER SWITCH ROTARY CONTROL KNOB HOT WATER VALVE HEATER HOSE DUCT HOSE, 2” AIR HOSE, 2-1/2” HOSE CLAMP HOSE CLAMP CLAMP HALVES SET COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 SOCKET BUTTON HD CAPSCREW, 1/4-20X5/8 FLAT WASHER, 1/4 LOCKWASHER, 1/4 DEFROST FAN FAN BASE PLATE RUBBER GROMMET SOCKET HD CAPSCREW, #10-24X3/4, GR8 WHIZ-LOCK NUT, 10-24 VENT REDUCER KNOB RECTANGULAR VENT SELF TAP SCREW, #6 WIPER/HEATER HARNESS WIPER/WASHER HARNESS HEATER HARNESS WIPER/WASHER SWITCH SHROUD CONN FUSE MALE PIN TERMINAL CABLE SEAL

304-2565 303-8599 303-8600 299-0328 298-7290

1 2 1 1 1 AR 1 1 1 AR

HEATER ENGINE PARTS, (includes items 201 thru 208) GEAR CLAMP HOSE BARB COOLANT RESTRICTER ORAFICE HOSE, 5/8 LOCTITE, #567 LOOP CLAMP ELBOW, 90 DEGREES RELAY WEATHER STRIP TAPE

201 202 203 205 206 207 208 328 423

6-22

298-1633 303-8601 299-0325 298-6833

Description

TL642

Rev.

E

31200255

CAB Figure 6-5 Heating Components (Continued) Item

Part Number

Qty.

524 601

303-4807

2 1

602

299-0972

2

299-6616

1

Description

Rev.

VENT WELDMENT HEATER FAN MOTOR, (Before S/N TBK01121), (no longer available, order 355-4772 for initial replacement) HEATER FAN WHEEL

OPEN CAB HEATER, (includes items 3, 6, 11 thru 17, 19 thru 27, 38, 101 thru 103, 111, 201 thru 208, 328 & 524)


31200255

TL642

6-23

CAB Figure 6-6 Cab Air Conditioning

STARTER

110 113 114 GROUND

TO CIRCUIT BOARD ON DASH

COMPRESSOR

111 112

C A/ E D SI E AT HE E D SI

R

105 106 107 108 109

104 3 4 14 19 2

21

7

18

201 202 203 204

22 27

11

6 3 4 14

3 4 14

24

1

3 5 14

25 26 PAL3434

6-24

TL642

31200255

CAB Figure 6-6 Cab Air Conditioning Item

Part Number

Qty.

303-4893 313-5257 305-2023 298-0555 298-0573 7X-3359 355-5429 322-9668 298-1633 298-7365 325-1433 298-7374 314-2893 309-6819

1 1 1 8 7 1 1 1 1 14 1 2 1 A/R

AIR CONDITIONING ASSY, ENGINE PARTS, (includes items 1 thru 22) A/C COMPRESSOR BRACKET ADJUSTMENT BRACKET NUT, 3/8-16 GR2 SOCKET HEAD CAP SCREW, 3/8-16X1-1/2 SOCKET HEAD CAP SCREW, 3/8-16X1-1/4 A/C DRIVE PULLEY BRACKET, FRONT ADJUST P-CLAMP, 1-3/4” ID WASHER, 3/8 A/C BELT SHIELD WASHER, 3/8 A/C REFRIGERANT DECAL A/C SHIM

H

1 2 3 4 5 6 7 11 14 18 19 21 22

304-3171

AIR CONDITIONING ASSY, (includes items 101 thru 114) AIR CONDINTIONING KIT, , (see Figure 6-7 for details) HALF CLAMP SET CLAMP HALVES STACK BOLT SAFETY WASHER COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 A/C WIRE HARNESS, (see Figure 10-7 for details) RELAY HEX HD CAPSCREW, 5/16-18X1/2, GR5 SCREW, 3/8-16X1 WHIZ-LOCK NUT, 3/8-16

F

299-0327 300-6074 298-1359 303-4795

1 Ref 1 1 1 1 1 1 Ref 1 1 1 1

331-0101 311-0660 297-7030 298-7374 298-7380

1 1 3 3 3

FAN GUARD INSTALLATION, W/ A/C, (includes items 201 thru 204) FAN GUARD HEX HD CAPSCREW, 3/8-16X7/8, GR 5 FLAT WASHER, 3/8 LOCK WASHER, 3/8

A

101 104 105 106 107 108 109 110 111 112 113 114

201 202 203 204

298-7846 298-7834 298-7835 298-7837 299-0949 297-7021

Description

Rev.


31200255

TL642

6-25

CAB Figure 6-7 Air Conditioning Components 215 214

201

216

204 203

218

206 207

217

213

204

205

209

211 212

208 210

104 103

112 202

104

102 114 113

107

106

108

110

105 101

110

111

109

6-26

TL642

PAL3650

31200255

CAB Figure 6-7 Air Conditioning Components (Continued)

302

2 STARTER

GROUND

3 TO CIRCUIT BOARD ON DASH

303

4 COMPRESSOR

6 5 C A/ E D SI ER AT HE E D SI

301 1

401

402

31200255

PAL3660

TL642

6-27

CAB Figure 6-7 Air Conditioning Components Item 1 2 3 4 5 6 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220

6-28

Part Number

Qty.

313-5260 318-9229 299-7178 318-9231 318-9230 318-9232

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 4 1 1 1 3’ 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 3 1 2 1 1 2’ 4 8

298-7095 299-0972 299-7182 318-9246

299-7179 318-9233

298-8317 318-9234

298-7278 318-9237 318-9238 298-8313 299-7180

318-9239 318-9240

299-7184 318-9241

318-9242

Description AIR CONDITIONING KIT, (includes items 1 thru 6) EVAPORATOR/HEATER UNIT, (includes items 101 thru 121 POWER HEAD ONLY, (includes items 101 thru 105, 109 and 110) CONDENSOR, (includes items 201 thru 225) HOSE KIT, (includes items 301 thru 303) COMPRESSOR KIT, (includes items 401 thru 405) THERMOSTAT SWITCH A/C SWITCH CASE TOP CASE BOTTOM BLOWER MOTOR BLOWER WHEEL HEATER/COOLER COIL VALVE BULB CLAMP O-RING, #8 3 HOLE TOP LEG THERMOSTAT HEATER HOSE HEATER SPLICE WORM GEAR CLAMP AIR RESTRICTER, (not illustrated) METRO SWITCH, (not illustrated) 12 VOLT RELAY, (not illustrated) DRAIN HOSE, 3/8, (not illustrated) DRAIN ELBOW, 3/8, (not illustrated) DRAIN TEE, 3/8, (not illustrated) PRESSURE SWITCH, (not illustrated) CASE TOP CASE BOTTOM OVERHEAD CONDENSER COIL MOUNTING BRACKET TUBE ASSY DRIER DRIER MOUNT O-RING HOSE CLAMP TUBE ASSY TUBE ASSY HOSE CLAMP CUSHION CLAMP HOLE PLUG CONDENSER FAN HARNESS PIGTAIL O-RING, #8 CLOSED CELL FOAM WELL NUT, (not illustrated) NYLON INSERT NUT, 1/4-20, (not illustrated)

TL642

Rev. D

31200255

CAB Figure 6-7 Air Conditioning Components Item

Part Number

Qty.

221 222 223 224 225 301 302 303 401 402 403 404 405

318-9243

1 4 1 4 4 1 1 1 1 1 2 2 2

318-9244

318-9235 298-8314 318-9236 318-9228 299-7181 318-9245 318-9246 318-9247

Description

Rev.

RELAY, (not illustrated) HEX HD CAPSCREW, 3/8-16X3, (not illustrated) HARNESS, (not illustrated) FLAT WASHER, 3/8, (not illustrated) LOCKWASHER, 3/8, (not illustrated) HOSE ASSY HOSE ASSY HOSE ASSY COMPRESSOR BELT O-RING, #6, (not illustrated) O-RING, #8, (not illustrated) O-RING, #10, (not illustrated)


31200255

TL642

6-29

CAB


6-30

TL642

31200255

SECTION 7 CONTROLS

31200255

TL642

CONTROLS Figure 7-1 Accelerator Pedal Assembly

11

6

1

201 121 119

18 19

114

14

202

16 1

203

3

9 10

7

17

8

12

22

21 20

23

4 5 2 15 13 PAL0520

7-2

TL642

31200255

CONTROLS Figure 7-1 Accelerator Pedal Assembly Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 114 119 121 201 202 203

299-6669 298-8790 298-8593 298-8592 298-7010 298-7275 298-7064 298-1753 298-7250 298-7065 298-7071 298-8031 298-8774 297-7012 298-8164 298-1581 298-8049 298-8024 298-1634 298-7365 298-7991 298-1586 298-7364 298-6852 298-7993 298-1586 298-7373 304-2297 304-4572 304-2298

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 2

Description ACCELERATOR PEDAL ASSY, (includes items 1 thru 23) ACCELERATOR PEDAL BRACKET ACCELERATOR PEDAL ARM ACCELERATOR BELL CRANK PEDAL PEDAL PAD FLANGE BUSHING FLAT WASHER EXTENSION SPRING STUD, #10-32X1-1/4 BALL JOINT, 1/4-28 SOCKET HD SHOULDER SCREW, 3/8X5/8 PIVOT PIN HEX HD CAPSCREW, 5/16-18X1, GR5 ACCELERATOR CABLE, (includes items 201 thru 203) LOCKNUT, 1/4-20 HEX NUT, 3/8-16 SOCKET HD CAPSCREW, 3/8-16X1-1/2 WAVE WASHER FLAT WASHER, 3/8 HEX HD CAPSCREW, 5/16-18X3/4, GR5 LOCKWASHER, 5/16 FLAT WASHER, 5/16 BUSHING HEX HD CAPSCREW, 5/16-18X1, GR5 LOCKWASHER, 5/16 FLAT WASHER, 5/16 U-BOLT SADDLE HEX NUT

Rev. C


31200255

TL642

7-3

CONTROLS Figure 7-2 Steering Column & Attaching Parts

401

402

305 201

304

801

502

501 2

601 111

6 5 120

735

1

3

4 PAL0601

7-4

TL642

31200255

CONTROLS Figure 7-2 Steering Column & Attaching Parts Item 1 2 3 4 5 6 111 120 201 304 305 401 402 501 502 601 735 801

Part Number

Qty.

299-1339 298-8745 303-8610 298-8637 298-0471 298-0463 298-7380 297-7029 297-7031 298-7380 298-1683 299-0562 299-0560 299-0913 299-6632

1 1 1 1 1 4 2 2 2 2 1 1 1 1 1 2 1 1 Ref Ref

298-0403

Description STEERING CONTROL ASSY, (includes items 1 thru 6) STEERING CONTROL UNIT STEERING CONTROL UNIT SEAL KIT STEERING COLUMN, (includes item 201) ELBOW, 90 DEGREES, (includes o-ring) CONNECTOR, (includes o-ring) LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X3/4, GR5 HEX HD CAPSCREW, 3/8-16X1, GR5 LOCKWASHER, 3/8 STEERING WHEEL NUT, (torque to 29-34 lb-ft) SHIFTER, 4-SPEED, (includes items 501 & 502) STEERING WHEEL, (includes items 401 & 402) CENTER CAP SPINNER KNOB, (includes items 6 & 7) HEX HD CAPSCREW, (torque to 30-35 lb-ft) CLAMP SET SHIFTER ADAPTER HARNESS INSTRUMENT PANEL HARNESS, (see Figure 10-3 for details) SHIFTER DECAL, (see Figure 11-1 for details)

Rev. A, 1


31200255

TL642

7-5

CONTROLS Figure 7-3 Brake Pedal Assembly

13 17

1

13 17

17

11

15 10 14

16

2

8 7

4 19 5

6 121 119

3 114

PAL3032

7-6

TL642

31200255

CONTROLS Figure 7-3 Brake Pedal Assembly Item 1 2 3 4 5 6 7 8 10 11 13 14 15 16 17 19 114 119 121

Part Number

Qty.

307-9870

1 Ref 1 1 1 1 1 4 4 1 1 2 1 2 1 3 AR 4 4 4

305-2026 305-2025 299-0208 297-7031 303-4798 303-4745 298-7388 298-0522 300-6104 298-0507 300-6099 298-8280 298-8244 298-1610 298-7993 298-1586 298-7373

Description POWER BRAKE ASSY, (includes items 1 thru 19) POWER BRAKE VALVE, (see Figure 9-9 for details) BRAKE BRACKET BRAKE PEDAL PIVOT PIN HEX HD CAPSCREW, 3/8-16X1, GR5 LOCKWASHER, 3/8 HEX HD CAPSCREW,10-1.50X30mm, GR8.8 SPRING LOCKWASHER, 10mm CONNECTOR CONNECTOR ELBOW, 90 DEGREES, (swivel nut) FITTING REDUCER ACTUATOR TIE BAR CONNECTOR MOLY PASTE HEX HD CAPSCREW, 5/16-8X1, GR5 LOCKWASHER, 5/16 FLAT WASHER, 5/16

Rev. C


31200255

TL642

7-7

CONTROLS Figure 7-4 Boom Joystick w/Tilt

8

1

16

2 3

17

18

18

5

2&4 1&3

4

19

2

3

1

4

9

6 13

11

12 7

10

15 14 PAL1080

NOTE: THE BOSCH REXROTH CORPORATION JOYSTICK HANDLE SWITCH IS NOT A FIELD SERVICEABLE COMPONENT. ANY ATTEMPT BY NON-FACTORY AUTHORIZED PERSONNEL TO REPAIR OR REPLACE THE SWITCH WILL VOID THE WARRANTY AND CAN RESULT IN A JOYSTICK MALFUNCTION.

7-8

TL642

31200255

CONTROLS Figure 7-4 Boom Joystick w/Tilt Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

31200255

Part Number

Qty.

Description

298-8585 299-0970 299-0966

299-0960 299-7122 299-0209 299-0210 299-0834

1 1 1 1 1 1 1 AR 1 1 1 1 2 1 1 1 4 4 1 1 1

BOOM JOYSTICK W/TILT, (includes all items) HANDLE W/ WIRE & CONNECTOR BENT LEVER KIT, (includes items 3 & 4) SPRING PIN HEX NUT BOOT CARDAN KIT, (includes item 7) SHIM RETAINING PLATE UPPER BODY, (includes item 10) LOWER BODY O-RING DOWEL PIN O-RING SCREW ASSY O-RING PLUNGER & GUIDE KIT REGULATING UNIT SPRING, (ports 1 & 3), (pack of two) SPRING, (ports 2 & 4), (pack of two) GROMMET W/CABLE TIE KIT

299-0498

AR

SEAL KIT, (includes items 11 thru 15)

299-0954 299-0953 298-7082 299-0967

TL642

Rev. A

7-9

CONTROLS Figure 7-5 Hydraulic Controller - Outrigger, (if equipped)

3

3

4

4

5

5

6 7 6 8 7 8 10 9 1 2

10 PAL2020

7-10

TL642

31200255

CONTROLS Figure 7-5 Hydraulic Controller - Outrigger, (if equipped) Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10

299-0558 299-0559 299-0917 299-7144 299-0976 299-0915 299-0960 299-0916 299-0210 299-0635 299-0636

2 1 1 2 2 2 2 2 2 2 1

31200255

Description HYDRAULIC CONTROLLER - OUTRIGGER, (includes all items) HYDRAULIC CONTROLLER, (includes one each of items 3 thru 8) HYDRAULIC CONTROLLER, (includes one each of items 3 thru 8) GRIP RUBBER BOOT LEVER OPERATION KIT PLUNGER KIT REGULATING UNIT KIT RETURN SPRING O-RING BOLT & NUT KIT

TL642

Rev. A

7-11

CONTROLS


7-12

TL642

31200255

SECTION 8 HYDRAULIC CIRCUITS

31200255

TL642


HYDRAULIC CIRCUITS Figure 8-1 Priority Valve

4

25

20 6

5

28

27

7

1

29 15

26

30

16

9

4 19

13 TO HYDRAULIC TANK

31

4

8

TO JOYSTICK ASSY, (see Figure 8-5)

11

21

2 FROM HYDRAULIC PUMP

23

24

17

18

22 20

PAL0680

8-2

TL642

31200255



Item 1 2 4 5 6 7 8 9 11 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Part Number 298-1384 298-6868 298-7926 298-7356 298-0473 298-1599 298-0469 298-0468 298-0463 298-1378 298-1404 298-0410 298-1403 298-1379 298-0468 298-1405 304-2600 298-1606 298-7983 298-7310 297-7013 298-0496 303-4770 298-0489

Qty. Ref 1 3 1 1 1 1 1 1 1 1 1 1 Ref 1 1 1 1 1 Ref 1 1 1 2 1 1 1

Description

Rev.

PRIORITY VALVE, (see Figure 9-10 for details) HOSE ASSY TEST COUPLING CONNECTOR CONNECTOR, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) CONNECTOR, (includes o-ring) CONNECTOR, (includes o-ring) CONNECTOR, (includes o-ring) CONNECTOR, (includes o-ring) HOSE ASSY TUBE ASSY HOSE ASSY STEERING CONTROL ASSY, (see Figure 7-2 for details) TUBE ASSY HOSE ASSY CONNECTOR, (includes o-ring) TUBE ASSY ELBOW, 90 DEGREES, (swivel nut) MAIN CONTROL VALVE, (see Figure 9-6 for details) ELBOW, 90 DEGREES, (swivel nut) CLAMP SET COVER PLATE HEX HD CAPSCREW, 1/4-20X1-1/2, GR5 SWIVEL NUT RUN TEE CONNECTOR ELBOW, 90 DEGREES


31200255

TL642

8-3



103

127

202

17

17

26

155

26 8 9 10

144 149

19 3 4

19 20 21 22 23

14 15 16

423 11

5

1 2 12 13

424 301

8-4

TL642

PAL5640

31200255



Item 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 26 103 127 144 145 155 202 301 423 424

Part Number 298-7380 297-7032

298-7360 299-0355 298-7381 297-7076

298-8023 298-7378 298-8047 298-7068

Qty. Ref 3 3 1 1 1 2 4 4 Ref 2 2 2 2 1 2 1 Ref 1 1 1 Ref Ref 1 1

Description

Rev.

PRIORITY VALVE, (see Figure 9-10 for details) LOCKWASHER, 3/8 HEX HD CAPSCREW, 3/8-16X1.25, GR5 HOSE ASSY ADAPTER TUBE O-RING FLANGE HALF LOCK WASHER, 7/16 HEX HD CAPSCREW, 7/16-14X1.5, GR8 HOSE ASSY, (see Figure 8-2 for details) ADAPTER, 90 DEGREES, (includes o-ring) SOCKET HD CAPSCREW, 1/4-20X2.5 LOCKWASHER, 1/2 NUT, 1/4-20 SOLENOID VALVE HOSE ASSY PIPE ASSY HYDRAULIC TANK, (see Figure 9-8 for details) SUCTION HOSE HEAVY DUTY BAND CLAMP HEAVY DUTY BAND CLAMP MAIN CONTROL VALVE, (see Figure 9-6 for details) STEERING CONTROL, (see Figure 7-2 for details) HOSE ASSY HOSE ASSY


31200255

TL642

8-5

Before S/N TBK00795

HYDRAULIC CIRCUITS Figure 8-2 Dump Circuit

16 2 17

8

15 12 13

20

1

25 17

29

14

18

1 TO TRANSMISSION

5

FROM PRIORITY VALVE

4

19

2

3

23

22

21 6

7

28

9

11 26 FROM BOOM JOYSTICK

10

27

PAL1350

8-6

TL642

31200255

Before S/N TBK00795

HYDRAULIC CIRCUITS Figure 8-2 Dump Circuit Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 29

298-0411 298-0412 299-0355 297-7076 298-7381 298-7360 298-0409

1 1 2 4 4 1 1 Ref Ref 1 1 3 3 3 1 Ref Ref Ref 1 1 Ref 1 1 Ref Ref Ref Ref

298-1381 298-1367 297-7022 299-0947 298-7435 304-2576

304-2575 298-1411 304-2600 298-0468

Description

Rev.

HOSE ASSY HOSE ASSY SPLIT CLAMP HALF HEX HD CAPSCREW, 7/16-14X1-1/2 LOCKWASHER, 7/16 O-RING HOSE ASSY OIL COOLER, (see Figure 4-6 for details) HYDRAULIC RESERVOIR ASSY, (see Figure 9-8 for details) HOSE ASSY HOSE ASSY HEX HD CAPSCREW, 5/16-18X2, GR5 PLATE COVER CLAMP SET HOSE ASSY ELBOW, (see Figure 4-6 for details) ELBOW, (see Figure 4-6 for details) CONNECTOR, (see Figure 4-6 for details) HOSE ASSY TUBE ASSY MAIN CONTROL VALVE, (see Figure 9-6 for details) ELBOW, 90 DEGREE, (swivel nut) CONNECTOR, (includes o-ring) STEERING CONTROL ASSY, (see Figure 7-2 for details) BRAKE ASSY, (see Figure 7-3 for details) HOSE ASSY, (see Figure 8-5 for details) HOSE ASSY, (see Figure 8-1 for details)


31200255

TL642

8-7

S/N TBK00795 thru TBK01166 excluding TBK01162

HYDRAULIC CIRCUITS

Figure 8-2 Dump Circuit

16 17 34

8

12

25

15

20

18

13

35

14

18

33

32 TO TRANSMISSION

5 3

4

30

1

30

29

FROM PRIORITY VALVE

23

2

6

7

19 22

21 9

11 26

28 FROM BOOM JOYSTICK

10 27

PAL4740

8-8

TL642

31200255


HYDRAULIC CIRCUITS

Figure 8-2 Dump Circuit Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 29 30 32 33 34 35

324-7404 324-7403 299-0355 297-7076 298-7381 298-7360 298-0409

1 1 2 4 4 1 1 Ref Ref 1 1 2 2 2 1 Ref Ref Ref 1 1 Ref 1 1 Ref Ref Ref Ref 2 1 1 1 1

298-1381 298-1367 297-7021 299-0949 298-7436 304-2576

304-2575 298-1411 304-2600 298-0468

298-0467 324-7385 324-7388 324-7389 324-7390

Description

Rev.

HOSE ASSY HOSE ASSY SPLIT CLAMP HALF HEX HD CAPSCREW, 7/16-14X1-1/2 LOCKWASHER, 7/16 O-RING HOSE ASSY OIL COOLER, (see Figure 4-6 for details) HYDRAULIC RESERVOIR ASSY, (see Figure 9-8 for details) HOSE ASSY HOSE ASSY HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 TWIN PLATE COVER TWIN CLAMP HOSE ASSY ELBOW, (see Figure 4-6 for details) ELBOW, (see Figure 4-6 for details) CONNECTOR, (see Figure 4-6 for details) HOSE ASSY TUBE ASSY MAIN CONTROL VALVE, (see Figure 9-6 for details) ELBOW, 90 DEGREE, (swivel nut) CONNECTOR, (includes o-ring), STEERING CONTROL ASSY, (see Figure 7-2 for details) BRAKE ASSY, (see Figure 7-3 for details) HOSE ASSY, (see Figure 8-5 for details) HOSE ASSY, (see Figure 8-1 for details) ADAPTER,(includes o-ring) TUBE TUBE TUBE TUBE


31200255

TL642

8-9



305

342

71 70

337 344 345

70 66

72

324 74 319

325

6

73 342

345 337 344

39

63 324 319 59

37 38

609 57 58 60

40

611

601

33 34 FROM PRIORITY VALVE

27

FROM BOOM JOYSTICK

217

5 108 421 510 514 701

501

8-10

TL642

PAL5650

31200255



Item 5 6 27 33 34 37 38 39 40 57 58 59 60 63 66 70 71 72 73 74 108 217 305 319 324 325 337 342 344 345 421 501 510 514 601 609 611 701

Part Number

298-0473 298-0474 331-2387 310-8507 303-8599 341-1835

361-2845 309-6321 361-2844 303-4762 368-0506

360-6620 303-4758 298-0541 367-3289 367-3290

298-0522 300-6099 298-0468 304-2600

Qty. 1 1 Ref 3 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 Ref 2 2 2 8 2 4 2 1 Ref 1 1 Ref 1 2 Ref

Description

Rev.

HOSE ASSY HYDRAULIC PIPE HYDRAULIC TANK, (see Figure 9-8 for details) ADAPTER, 90 DEGREES, (includes o-ring) ADAPTER, 90 DEGREES, (includes o-ring) ADAPTER, STRAIGHT, (includes o-ring) OIL DRAIN VALVE GEAR CLAMP FUEL HOSE COVER PLATE CLAMP SET PIPE ASSY HEX HD CAPSCREW, 1/4-20X2.5, GR5 CAP CHECK VALVE ADAPTER, TEE, (includes o-ring) ADAPTER, STRAIGHT, (includes o-ring) HOSE ASSY PIPE ASSY HOSE ASSY HOSE ASSY HOSE ASSY RADIATOR, (see Figure 4-6 for details) ADAPTER, 90 DEGREES, (includes o-ring) FITTING ADAPTER, 90 DEGREES, (includes o-ring) LOCKNUT, 3/8-16 FITTING HOSE CLAMP HOSE ASSY HOSE ASSY BRAKE ASSY, (see Figure 7-3 for details) ADAPTER, STRAIGHT, (includes o-ring) ADAPTER, STRAIGHT, (includes o-ring) MAIN CONTROL VALVE, (see Figure 9-6 for details) ADAPTER, STRAIGHT, (includes o-ring) ADAPTER, SWIVEL NUT ELBOW, (includes o-ring) STEERING CONTROL ASSY, (see Figure 7-2 for details)


31200255

TL642

8-11

HYDRAULIC CIRCUITS Figure 8-3 Steer Select Valve

11 2 REAR AXLE

11 2 9

10

20

5 6

21

13 6

5

3

13

17

6

16

15

13

2

8

1 4 2 FRONT AXLE

19

1

20

22

7

14

21 18 12

PAL0511

8-12

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-3 Steer Select Valve Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part Number 298-0502 324-7401 324-7402 303-4804 303-4802 303-4803 324-7398 324-7399 298-1371 298-1596 303-8602 297-7016 298-7379 298-7364 298-7834 299-0949 297-7021 298-7892

Qty. Ref 4 1 1 4 4 2 Ref 1 1 Ref 2 4 2 4 4 4 Ref 1 2 2 1

Description

Rev.

HOSE ASSY, (see Figure 5-1 for details) BULKHEAD UNION, 3/4-16X1/2, TUBE HOSE ASSY HOSE ASSY ELBOW, 90 DEGREES, (swivel nut) CONNECTOR, (includes item 13) CONNECTOR, (includes item 14) STEER SELECT VALVE, (see Figure 9-11 for details) HOSE ASSY HOSE ASSY HOSE ASSY, (see Figure 5-11 for details) HOSE ASSY O-RING O-RING HEX HD CAPSCREW, 5/16-18X3/4, GR5 LOCKWASHER, 5/16 FLAT WASHER, 5/16 STEERING CONTROL ASSY, (see Figure 7-2 for details) CLAMP COVER HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 CLAMP


31200255

TL642

8-13

HYDRAULIC CIRCUITS Figure 8-4 Service/Parking

21

24

22

19

18 23

17

15 9

14

2

10 11 10

4

13

11

7 8

6

1

3

5 12

2

8-14

3

16

4

PAL0430

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-4 Service/Parking Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24

Part Number 298-7839 299-6645 297-7013 298-1398 298-7833 298-7372 297-7012 298-7838 299-6644 298-7439 298-1395 298-1378 298-1406 315-6549

298-0492 298-0498 298-6868 298-0473 298-0525

Qty. Ref 2 2 4 1 1 1 1 4 4 4 1 1 1 1 Ref Ref Ref 1 1 1 1 1

Description

Rev.

FRONT AXLE ASSY, (see Figure 5-1 for details) CLAMP COVER PLATE HEX HD CAPSCREW, 1/4-20X1-1/2, GR5 HOSE ASSY CLAMP SET FLAT WASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1, GR5 CLAMP SET COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/8 HOSE ASSY HOSE ASSY PARK BRAKE TUBE SERVICE BRAKE TUBE, (supply) BRAKE ASSY, (see Figure 7-3 for details) REAR AXLE ASSY, (see Figure 5-11 for details) PRIORITY VALVE, (see Figure 9-10 for details) RUN TEE, (includes o-ring) SWIVEL NUT BRANCH TEE TEST COUPLING ELBOW, 90 DEGREES, (includes o-ring) HYDRAULIC FITTING


31200255

TL642

8-15

HYDRAULIC CIRCUITS Figure 8-5 Joystick Circuit

WITH OUTRIGGERS

TO OUTRIGGER CONTROLLER, (see Figure 8-11)

16

1 2

7

15

6

9

11

2

12

2

13 14

WITHOUT OUTRIGGERS

TO HYDRAULIC RESERVOIR, (see Figure 8-2)

4 9 10

5

10

FROM OUTRIGGER CONTROLLER, (see Figure 8-11)

6 FROM PRIORITY VALVE, (see Figure 8-1)

4 7

17

8 9

WITHOUT OUTRIGGERS

PAL2491

WITH OUTRIGGERS

8-16

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-5 Joystick Circuit Item 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Number 298-0473 298-1373 298-1372 298-1374 298-1375 298-1387 298-1366 303-4880 298-7358 297-7012 298-7378 298-7372 298-0489

Qty. Ref 3 1 1 1 1 1 1 2 6 Ref 4 4 4 1 Ref Ref

Description

Rev.

MAIN CONTROL VALVE, (see Figure 9-6 for details) ELBOW, 90 DEGREES, (includes o-ring) HOSE ASSY HOSE ASSY HOSE ASSY HOSE ASSY HOSE ASSY HOSE ASSY, (no outriggers) HOSE ASSY, (with outriggers) CONNECTOR, (includes o-ring) BOOM JOYSTICK, (see Figure 7-4 for details) HEX HD CAPSCREW, 1/4-20X1, GR5 LOCKWASHER, 1/4 FLATWASHER, 1/4 ELBOW, 90 DEGREE, LONG SWIVEL NUT RUN TEE, (with outriggers), (see Figure 8-11 for details) RUN TEE, (with outriggers), (see Figure 8-11 for details)


8-17

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-6 Lift Cylinder

15

14

16

1 13

12

2

2 3

3

11 10

9 19 20 7

17 19

4

7 6

8-18

18

5

PAL0410

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-6 Lift Cylinder Item 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20

Part Number 298-1423 298-1389 325-8144 324-7406 298-0466 298-7437 299-6644 298-7439 298-7298 298-7305 298-1597 298-1612 298-1792 297-7014 298-7372 298-1581

Qty. Ref 2 2 1 1 Ref 2 1 1 1 Ref 2 AR 2 2 1 3 6 3

Description

Rev.

LIFT CYLINDER, (see Figure 9-1 for details) HYDRAULIC SWIVEL HOSE ASSY TUBE ASSY TUBE ASSY MAIN CONTROL VALVE, (see Figure 9-6 for details) CONNECTOR, (includes o-ring) CLAMP SET COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/8 MALE ELBOW, (see Figure 9-1 for details) HOSE ASSY TY-WRAP MALE CONNECTOR, 1/8X3/16 TUBE LUBE FITTING, STRAIGHT 1/8 SPECIAL TUBE CLAMP HEX HD CAPSCREW, 1/2-20X2 FLAT WASHER, 1/4 HEX LOCKNUT, 1/4-20


8-19

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-7 Extend/Retract

8

2

10

2 7

6

9 11

10

9 11

SEE FIGURE 8-6 FOR CLAMP DETAILS

1

12

2 5 2

8-20

4

PAL0420

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-7 Extend/Retract Item 1 2 4 5 6 7 8 9 10 11 12

Part Number 298-0466 323-4208 298-1400 325-8140 298-1469 324-7383 298-1470 324-7384 298-1388 298-1657 298-7249

Qty. Ref 4 1 1 1 Ref 1 1 1 1 2 2 36” Ref

Description

Rev.

MAIN CONTROL VALVE, (see Figure 9-6 for details) CONNECTOR, (includes o-ring) TUBE ASSY TUBE ASSY, (Before S/N TBK000797) TUBE ASSY, (S/N TBK000797 & After) EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details) TUBE ASSY, (Before S/N TBK000797) TUBE ASSY, (S/N TBK000797 & After) TUBE ASSY, (Before S/N TBK000797) TUBE ASSY, (S/N TBK000797 & After) HOSE ASSY CLAMP NYLON SLEEVE TUBE CLAMP, (see Figure 8-6 for details)


8-21

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-8 Tilt & Tilt Compensating Cylinder

26

16 27 30

22

15

23

31

19

25

28 29

17

15

18

24

20

31

21

32 10

32

14

221 121 33

120

11

125

13 119

125

229 118

8

128

34 117 123

7

9

125

8 6

122 5

4

313

123

8-22

312

2 1

PAL1140

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-8 Tilt & Tilt Compensating Cylinder Item 1 2 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 117 118 119 120 121 122 123 125 128 221 229 312 313

Part Number 298-0464 298-1414 325-8141 298-1386 298-1385 298-0497 298-0490 298-0474 298-1369 298-1368 298-1656 298-1472 298-1471 299-6644 298-7438 298-7439 298-0519 298-0504 303-4912 297-7030 298-7365 298-1465 298-8716 298-7380 298-8049 298-0501 298-1466 299-0471 298-0463 298-7068 299-0780 298-8023 298-7378 298-8047 298-1418 298-1380 298-1398 298-7357 298-0507

298-0489 298-7358

Qty. Ref 2 1 1 1 1 2 1 Ref 1 1 1 2 1 1 3 3 3 2 2 1 2 2 2 1 2 2 2 2 2 Ref 1 1 2 2 2 2 1 1 2 4 1 Ref Ref 1 1

Description

Rev.

MAIN CONTROL VALVE, (see Figure 9-6 for details) CONNECTOR, (includes o-ring) TUBE ASSY TUBE ASSY HOSE ASSY HOSE ASSY SWIVEL NUT RUN TEE, 1/2 TUBE ELBOW, 90 DEGREES, (swivel nut) COMPENSATING CYLINDER, (see Figure 9-4 for details) ELBOW, 90 DEGREES, (includes o-ring) HOSE ASSY HOSE ASSY CLAMP TUBE ASSY TUBE ASSY COVER PLATE CLAMP SET HEX HD CAPSCREW, 5/16X1-3/8 FITTING, 90 DEGREES BULKHEAD FITTING, 90 DEGREES HOSE BRACKET HEX HD CAPSCREW, 3/8-16X7/8, GR5 FLAT WASHER, 3/8 HOSE ASSY HOSE RETAINER LOCKWASHER, 3/8 HEX NUT, 3/8-16 BULKHEAD UNION, 9/16-18X3/8, TUBE HOSE ASSY ELBOW, 90 DEGREES TILT CYLINDER, (see Figure 9-3 for details) CONNECTOR, (includes o-ring) SOLENOID VALVE SOLENOID SOCKET HD CAPSCREW, 1/4-20X2-1/2, GR8 WASHER, 1/4 HEAVY HEX NUT, 1/4-20 HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY CONNECTOR ELBOW, 90 DEGREES SWIVEL NUT BRANCH TEE, (see Figure 8-5 for details) SWIVEL NUT RUN TEE, (see Figure 8-1 for details) ELBOW, 90 DEGREES CONNECTOR


31200255

TL642

8-23

HYDRAULIC CIRCUITS Figure 8-9 Auxiliary Hydraulics 302 105

104 102 129

114

103 112 115

110 124

201

127

125

106

113

202

127

123 107

101

126 111

410 412 119

411

413 116 48 414

414 130

47

49

130

46

45

44

1 8

8-24

43 42

TL642

PAL0441

31200255

HYDRAULIC CIRCUITS Figure 8-9 Auxiliary Hydraulics Item

Part Number

Qty.

1 8 42 43 44 45 46 47 48 49

298-0464 298-1407 298-1408 324-7391 324-7392 298-7438 299-6644 298-7439 324-7405

Ref 2 1 1 1 1 1 1 1 2

MAIN CONTROL VALVE, (see Figure 9-6 for details) STRAIGHT THREAD CONNECTOR, (includes o-ring) TUBE ASSY TUBE ASSY TUBE ASSY TUBE ASSY CLAMP COVER PLATE HEX BOLT, 5/16X1-3/8 HOSE ASSY

1 1 1 1 1 1 1 1 4 4 2 2 2 2 1 2 1 2 1 1 1 3 3 3 2 1 2 1 1 Ref 1 1 1 1 2

AUX HYDRAULICS ASSY, (includes items 101 thru 202) RETRACT SHEAVE PIN THRUST WASHER RETAINING RING HOSE SHEAVE PULLY HOSE RETAINER ASSY, (includes the following items) HOSE RETAINER, R.H. PAD SOCKET FLAT HD CAPSCREW, #10-24X5/8 HEX NUT, #10-24 HEX HD CAPSCREW, 3/8-16X7/8, GR5 FLAT WASHER, 3/8 BULKHEAD FITTING, 90 DEGREES, (includes o-ring) ELBOW, 90 DEGREES HOSE RETAINER HEX NUT, 3/8-16 HOSE ASSY BULKHEAD UNION HOSE ASSY HOSE ASSY HOSE BRACKET CLAMP COVER PLATE HEX BOLT, 5/16X1-3/8 HOSE CLAMP THRUST WASHER BULKHEAD FITTING HYDRAULIC TUBE HYDRAULIC TUBE PIN, (see Figure 2-3 for details) DUST CAP FEMALE QUICK DISCONNECT DUST PLUG MALE QUICK DISCONNECT ELBOW, 90 DEGREES

101 102 103 104 105

106 107 110 111 112 113 114 115 116 119 123 124 125 126 127 129 130 201 202 302 410 411 412 413 414

299-1286 298-7024 298-1742 298-6830 298-7246 299-6659 298-7012 298-7067 298-8030 298-8067 297-7030 298-7365 298-0504 298-0519 298-8760 298-8049 298-1465 298-0501 298-1467 298-1468 300-6094 298-7438 299-6644 298-7439 298-1656 298-1741 298-0506 298-1473 298-1474 300-6103 300-6078 300-6084 300-6079 300-6095

Description

Rev.

D, 8


31200255

TL642

8-25

HYDRAULIC CIRCUITS Figure 8-10 Sway Cylinder

3

2 16

8

5

17

6

1

10 14 15

7

13 121 202

9

12

PAL1331

8-26

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-10 Sway Cylinder Item 1 2 3 5 6 7 8 9 10 12 13 14 15 16 17 121 202

Part Number 298-8157 298-7358 298-1383 298-1415 298-1416 303-4754 298-0462 298-0507 298-7833 298-7372 297-7012 298-7988 298-7378 299-0383

Qty. Ref 1 2 2 1 1 Ref 1 1 1 3 3 3 3 3 1 Ref

Description

Rev.

SWAY CYLINDER, (see Figure 9-5 for details) SWAY CYLINDER VALVE CONNECTOR, (includes o-ring) HOSE ASSY TUBE ASSY TUBE ASSY MAIN CONTROL VALVE, (see Figure 9-6 for details) ELBOW, 90 DEGREES CONNECTOR, (includes o-ring) ELBOW, 90 DEGREES, (swivel nut) CLAMP SET FLAT WASHER, 1/4 HEX HD CAPSCREW, 1/4-20X1, GR5 HEX HD CAPSCREW, 1/4-20X1-3/4, GR5, (torque to 9-12 lb-ft) LOCKWASHER, 1/4 ADAPTER BONNET CABLE, (see Figure 6-1 for details)


31200255

TL642

8-27

HYDRAULIC CIRCUITS Figure 8-11 Outrigger Controller, (if equipped)

6 FROM JOYSTICK, (see Figure 8-5)

TO JOYSTICK, ( see Figure 8-5)

4

7

4 5

3 2

15

14

TO HYDRAULIC RESERVOIR, (see Figure 8-2) FROM PRIORITY VALVE, (see Figure 8-1)

1 18 11

11

11 8 9

13 12

10

16

13

16

17

PAL3330

8-28

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-11 Outrigger Controller, (if equipped) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

31200255

Part Number 298-0498 298-0489 298-0507 298-0493 297-7012 303-4866 298-7363 298-0549 298-7356 297-7017 298-7364

303-4879 297-7025

Qty. Ref 1 1 2 1 Ref 4 1 4 4 8 3 6 Ref Ref 4 Ref 3

Description

Rev.

HOSE ASSEMBLY, (see Figure 8-5 for details) SWIVEL NUT BRACH TEE, (includes o-ring) ELBOW, 90 DEGREES, (long) ELBOW, 90 DEGREES, (includes o-ring) RUN TEE, (includes o-ring) OUTRIGGER CONTROLLER, (see Figure 7-5 for details) HEX HD CAPSCREW, 1/4-20X1-1/8, GR5 CONTROLLER BRACKET FLAT WASHER, 1/4 HEX LOCKNUT, 1/4-20 CONNECTOR, (includes o-ring) HEX HD CAPSCREW, 5/16-18X1, GR5 FLAT WASHER, 5/16 HOSE ASSEMBLY, (see Figure 8-1 for details) HOSE ASSEMBLY, (see Figure 8-2 for details) HOSE ASSEMBLY OUTRIGGER CONTROL VALVE, (see Figure 9-14 for details) HEX HD CAPSCREW, 5/16-18X3-1/4, GR5

TL642

8-29

HYDRAULIC CIRCUITS Figure 8-12 Outrigger Cylinders, (if equipped)

128 147 TO FIGURE 8-2 185 186 2

1

102 143 144

3

4

10 8 FROM FIGURE 8-1

18 17 19

13 9 16 11

22

12

7 6

10

24

15

20

17

23

7

5 6

16

18

14

21

19

20

21

PAL3350

8-30

TL642

31200255

HYDRAULIC CIRCUITS Figure 8-12 Outrigger Cylinders, (if equipped) Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 102 128 143 144 147 185

310-8452 310-8451 323-5627 310-8453 310-8454 304-2600 298-0468 298-1403 310-8455 298-0469

1 1 1 1 1 3 3 1 1 2 Ref 2 2 1 1 4 4 4 4 4 Ref 1 1 Ref 1 2 1 1 2 1

31200255

298-0465 303-4756 303-4877 303-4876 298-7438 299-6644 297-7019 298-1499 298-7358 303-4875 303-4878 298-7436 297-7017 297-7021 299-0949 315-6551

Description

Rev.

HYDRAULIC TUBE HYDRAULIC TUBE UNION TEE HYDRAULIC TUBE HYDRAULIC TUBE ELBOW, 90 DEGREES, (includes o-ring) CONNECTOR, (includes o-ring) HYDRAULIC TUBE HYDRAULIC TUBE CONNECTOR, (includes o-ring) OUTRIGGER CONTROL VALVE, (see Figure 8-12 for details) CONNECTOR ELBOW, 90 DEGREES, (includes o-ring) HYDRAULIC TUBE HYDRAULIC TUBE CLAMP SET COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/8, GR5 HOSE ASSEMBLY CONNECTOR, (includes o-ring) OUTRIGGER CYLINDER, (see Figure 9-13 for details) HYDRAULIC TUBE HYDRAULIC TUBE MAIN CONTROL VALVE, (see Figure 9-6 for details) CLAMP SET HEX HD CAPSCREW, 5/16-18X1, GR5 HEX HD CAPSCREW, 0.315-18X1.75, GR5 COVER PLATE LOCKNUT, 5/16-18 TUBE BRACE

TL642

8-31

HYDRAULIC CIRCUITS


8-32

TL642

31200255

SECTION 9 HYDRAULIC COMPONENTS

31200255

TL642

S/N TBK00100 thru TBK00774

HYDRAULIC COMPONENTS Figure 9-1 Lift Cylinder

24

4 5

2 3 1

23 25

6

26

9

10

9 7 8

27

28

1

11 19 18

17

16

15 13 14 20

21 22 22

12

29

23

27

9-2

TL642

30

28 PAL0450

31200255


HYDRAULIC COMPONENTS Figure 9-1 Lift Cylinder Item 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

31200255

Part Number

Qty.

298-8115 303-8620 303-8621 354-5048 299-0499 304-2281 304-2283 298-1646 299-0863 299-0864

298-7407 299-0188 304-2299 298-1682 298-8167 298-8131 297-7077 298-7392 337-7993 298-1598

1 1 1 1 1 4 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 2 2 1 2

LIFT CYLINDER, (includes items 1 thru 24) CASE ASSY VALVE BLOCK ASSY, (includes item 3) VALVE, (torque to 44 lb-ft) SEAL KIT CAPSCREW, (torque to 10-12 lb-ft) LOCKWASHER LOCKNUT PISTON ASSY, (includes items 8 thru 11) PISTON WEAR RING CAP SEAL O-RING SET SCREW HEAD ASSY, (includes items 14 thru 20) HEAD O-RING ROD SEAL STEP SEAL WEAR RING U-CUP CANNED WIPER O-RING SHAFT ASSY BUSHING GREASE FITTING LOWER LIFT CYLINDER PIN KEEPER PLATE HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 100-110 lb-ft) HARD WASHER, 1/2 UPPER LIFT CYLINDER PIN MALE ELBOW, 90 DEGREES, 3/6X1/8 TUBE

299-0501

1

SEAL KIT, (includes items 9 thru 11 & 15 thru 20)

298-1663 299-0187 304-2282

Description

TL642

Rev. B

9-3


HYDRAULIC COMPONENTS Figure 9-1 Lift Cylinder

17 14

18

14 15

18

115

113 111

19

110

13 9

7

8

9 3

22 21

10

9

10

4

2

1

2

6

20

18

18

14

208

205

9-4

TL642

207 PW0070

31200255


HYDRAULIC COMPONENTS Figure 9-1 Lift Cylinder Item

1 2 3 4 5 6 7 8 9 10 12 13 14 15 17 18 19

20 21

22 110 111 113 115 205 207 208

Part Number

Qty.

Description

Rev.

325-0035 331-3800

1 1 1 2 1 1 1 1 1 1 2 2 2 1 4 1 1 4 1

B A

341-4081 341-4074

1 1 1

341-4082 341-4079 298-8131 297-7077 298-7392 298-8167 297-7077 298-7392 337-7993

1 1 1 1 1 1 1 1 1

LIFT CYLINDER, (includes items 1 thru 22), (S/N TBK00775 thru TBK00984) LIFT CYLINDER, (includes items 1 thru 22), (S/N TBK00985 & After) O-RING BACK-UP O-RING SEAL SEAL WIPER SEAL SEAL WEAR RING WEAR RING SET SCREW SELF TAPPING SCREW LUBE FITTING PORT PLUG VALVE BUSHING TUBE ASSY, (no longer available; replace with both 341-4082 head and 3414081 tube assy), (S/N TBK00775 thru TBK00984) TUBE ASSY, (S/N TBK00985 & After) ROD ASSY HEAD, (no longer available; replace with both 341-4082 head and 341-4081 tube assy), (S/N TBK00775 thru TBK00984) HEAD, (S/N TBK00985 & After) PISTON KEEPER PLATE HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 100-110 lb-ft) HARD WASHER, 1/2 LIFT CYLINDER PIN HEX HD CAPSCREW, 1/2-13X1-1/4, GR8 HARD WASHER, 1/2 LIFT CYLINDER PIN

341-4080

1


341-4075 341-4076

354-5048 341-4078


31200255

TL642

9-5


HYDRAULIC COMPONENTS Figure 9-2 Extend/Retract Cylinder

1

2

21

3 4 5 20

1

4 19

6 18

17 16

7 8 15 14

13 12 11

10

9

PAL1530

9-6

TL642

31200255


HYDRAULIC COMPONENTS Figure 9-2 Extend/Retract Cylinder Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

31200255

Part Number

Qty.

298-7018 299-0855 354-5048 299-0499 298-1647

303-8655 298-7314 298-7026

1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1

EXTEND/RETRACT CYLINDER, (includes all items except item 20 & 21) CASE ASSY VALVE, (torque to 40-45 lb-ft) SEAL KIT LOCK NUT, (torque to 600-650 lb-ft) WEAR RING PISTON SEAL PISTON ASSY, (includes items 4, 5 and 7) O-RING SPACER SHAFT SET SCREW, (torque to 11 lb-ft) CANNED WIPER HEAD ASSY, (includes items 11, 13 thru 18), (torque to 100 lb-ft) O-RING U-CUP STEP SEAL WEAR RING BACKUP O-RING WEAR BAND RETAINING RING EXTEND/RETRACT CYLINDER PIN

313-2471

1

SEAL KIT, (includes items 4, 5, 7, 11 & 13 thru 18)

313-2472 304-2272 304-2273 298-1766 313-2473

Description

TL642

Rev. G

9-7


HYDRAULIC COMPONENTS Figure 9-2 Extend/Retract Cylinder

15

16

18

105 136 106 12

9 6

9 21

23 2

3

4

1

20 10 8

5 7

17 22

13

19 PW0090

9-8

TL642

31200255


HYDRAULIC COMPONENTS Figure 9-2 Extend/Retract Cylinder Item 1 2 3 4 5 6 7 8 9 10 12 13 15 16 17 18 19 20 21 22 23 105 106 136

Part Number

Qty.

325-0033

1 1 1 1 1 1 1 1 1 2 2 1 2 3 1 1 1 1 1 1 1 1 1 2 AR

341-4085 341-4086 341-4087 354-5048 341-4088 341-4083 341-4084 341-4091 341-4092 341-4089 341-4090 298-7026 298-7314

341-4093

1

Description CROWD CYLINDER, (includes items 1 thru 23) O-RING O-RING BACK-UP RING O-RING SEAL SEAL WIPER SEAL WEAR RING WEAR RING LOCKNUT SET SCREW PORT PLUG COUNTERBALANCE VALVE WEAR PAD TUBE ASSY ROD HEAD PISTON COLLAR SPACER CYLINDER PIN RETAINING RING MOLY PASTE

Rev. B



31200255

TL642

9-9


HYDRAULIC COMPONENTS Figure 9-3 Tilt Cylinder

1

25 7

2

103

117

3 4

19

3

105 5

6

19

18

17 15 14 13

16

12 11

10

8 8

9

26

PAL1160

9-10

7

TL642

31200255


HYDRAULIC COMPONENTS Figure 9-3 Tilt Cylinder Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 103 105 117

Part Number

Qty.

298-7019 354-5048 299-0499 298-1647

299-0851 299-0857 299-0861 299-0859 298-8782 297-7077 298-7392

1 1 1 1 2 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

TILT CYLINDER, (includes items 1 thru 21) VALVE, (torque to 45-50 lb-ft) SEAL KIT LOCK NUT, (torque to 1250-1300 lb-ft) WEAR RING PISTON SEAL PISTON O-RING GREASE FITTING SHAFT ASSY SET SCREW, (torque to 11 lb-ft) CANNED WIPER HEAD, (torque to 200 lb-ft) O-RING U-CUP SEAL STEP SEAL WEAR RING BACKUP U-CUP RETAINING RING CASE ASSY BUSHING, (manganese phosphate coating) BUSHING, (manganese phosphate coating) TILT CYLINDER PIN HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 100-110 lb-ft) WASHER, 1/2

299-0495

1

SEAL KIT, (includes items 3, 4, 6, 10 & 12 thru 17)

304-2284 298-1682 299-0858 298-1663 299-0856

Description

Rev. J


31200255

TL642

9-11


HYDRAULIC COMPONENTS Figure 9-3 Tilt Cylinder

16

17

14 17 19

13

11

403

9 4 9

405

22

417

1

12

7 2 21

8

6

3

5 13 20

18

9-12

TL642

PAL4780

31200255


HYDRAULIC COMPONENTS Figure 9-3 Tilt Cylinder Item 1 2 3 4 5 6 7 8 9 11 12 13 14 16 17 18 19 20 21 22 403 405 417

Part Number

Qty.

325-0034

341-4077 354-5048 341-4096 341-4097 341-4094 341-4095 341-4098 341-4099 298-8782 297-7077 298-7392

1 1 1 1 1 1 1 1 1 2 1 1 3 1 1 2 1 1 1 1 1 1 1 1

TILT CYLINDER, (includes items 1 thru 22) O-RING O-RING SEAL SEAL WIPER SEAL SEAL WEAR RING WEAR RING LOCKNUT SELF TAPPING SCREW LUBE FITTING PORT PLUG COUNTERBALANCE VALVE BUSHING BUSHING TUBE ASSY ROD ASSY HEAD PISTON CYLINDER PIN HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 100-110 lb-ft) WASHER, 1/2

341-4100

1


341-4085 341-4076

Description

Rev. A


31200255

TL642

9-13

HYDRAULIC COMPONENTS Figure 9-4 Compensating Cylinder

9

1

23 22

2 3 4 3

21

20

5

1

6

16 15 14

13

17 12

11 25

7

10

24

8

18

21

9-14

TL642

20

19 PAL1360

31200255

HYDRAULIC COMPONENTS Figure 9-4 Compensating Cylinder Item 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

Part Number

Qty.

298-8114 304-2251 305-5459

1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1

COMPENSATING CYLINDER, (includes items 1 thru 17) CASE ASSY LOCK NUT, (torque to 1250-1300 lb-ft) WEAR RING PISTON SEAL PISTON ASSY O-RING SHAFT ASSY GREASE FITTING GREASE FITTING SET SCREW CANNED WIPER HEAD, (torque to 200 lb-ft) U-CUP SEAL STEP SEAL WEAR RING U-CUP O-RING PIN KEEPER PLATE HARD WASHER, 1/2 HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 100-110 lb-ft) PIN BUSHING, (manganese phosphate coating) BUSHING, (manganese phosphate coating) SQUARE RING

1 1 1

SEAL KIT SEAL KIT, PISTON END, (includes items 3, 4 & 6) SEAL KIT, ROD END, (includes items 11, 13 thru 17)

304-2253

304-2254

298-8287 298-8131 298-7392 297-7077 298-8782 304-2255 304-2256

304-2627 304-2257 304-2258

31200255

Description

TL642

Rev.

9-15


HYDRAULIC COMPONENTS Figure 9-5 Sway Cylinder

7

16

19 1 2 3 4

107 105

3 5 1 6

15 14 13

12 11

9 10

8

7

16 106

9-16

TL642

107

31200255


HYDRAULIC COMPONENTS Figure 9-5 Sway Cylinder Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 105 106 107

Part Number

Qty.

298-8137 298-8201 298-1675

299-0861 298-7035 298-7034 298-6831

1 1 1 2 1 1 1 3 1 1 1 1 1 1 1 1 3 1 1 4

SWAY CYLINDER, (includes items 1 thru 16) CASE ASSY LOCK NUT, (torque to 550-600 lb-ft) WEAR RING PISTON SEAL PISTON O-RING GREASE FITTING SHAFT ASSY SET SCREW CANNED WIPER HEAD, (torque to 100 lb-ft) O-RING U-CUP SEAL STEP SEAL U-CUP SEAL BUSHING SWAY CYLINDER PIN SWAY PIN RETAINING RING

299-0496

1

SEAL KIT (includes items 3, 4, 6, 10 & 12 thru 15)

304-2292 298-1682 304-3227 298-1663 304-3820

Description

Rev. D


31200255

TL642

9-17


HYDRAULIC COMPONENTS Figure 9-5 Sway Cylinder

15 14

11 15

105 13 107

16

12 9 4 9 18

1

5 2 19 8 6 8 3 7 14

17

106 15

107

9-18

TL642

PY2041

31200255


HYDRAULIC COMPONENTS Figure 9-5 Sway Cylinder Item 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 105 106 107

Part Number

Qty.

325-0036

1 1 1 1 1 1 1 1 2 2 2 1 1 3 3 1 1 1 1 1 1 4

SWAY CYLINDER, (includes items 1 thru 19) O-RING O-RING SEAL SEAL SEAL SEAL WIPER WEAR RING WEAR RING O-RING LOCKNUT SELF TAPPING SCREW LUBE FITTING BUSHING TUBE ASSY ROD ASSY PISTON HEAD CYLINDER PIN CYLINDER PIN RETAINING RING

1


341-4085 341-4076

298-7035 298-7034 298-6831

Description

Rev. A


31200255

TL642

9-19

HYDRAULIC COMPONENTS Figure 9-6 Main Control Valve

9-20

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-6 Main Control Valve Item

1 2 3 4 5 6

Part Number

Qty.

Description

Rev.

298-1365 310-8321 304-2270 329-9751

1 1 1 1 1 1 1 1

MAIN CONTROL VALVE, (no outrigger), (includes items 1 thru 51 & 56) MAIN CONTROL VALVE, (with outrigger), (includes items 1 thru 51 & item 56) INLET COVER ASSY, (includes item 2) MAIN RELIEF, 4000PSI, (includes items 3, 4 & 5) O-RING BACKUP RING O-RING VALVE SECTION ASSY, (Lift), (includes one each of items 13 & 25 and two of item 7) LOAD CHECK PLUG, (includes items 8 thru 12) O-RING BACKUP RING O-RING BACKUP RING O-RING HYDRAULIC REMOTE POSITIONER, (includes items 14 thru 24) HEX HD CAPSCREW, 1/4-20X3 LOCKWASHER, 1/4 BEARING PLATE BONNET SEAL SPOOL POSITIONER WASHER SPRING, (large) SPRING, (small) STOP SLEEVE STOP COLLAR HYDRAULIC REMOTE POSITIONER, (includes items 14 thru 18) VALVE SECTION ASSY, (Crowd), (includes one each of items 7, 13, 25 & 56) RELIEF CARTRIDGE, 4300 PSI, (includes items 8 thru 12) VALVE SECTION ASSY, (Tilt), (includes one each of items 13 & 25 and two of item 27) VALVE SECTION ASSY, (Sway), (includes one each of items 30 & 41 and two each of 7 & 37) SPOOL POSITIONER ASSY, (includes items 31 thru 36) SCREW WASHER BONNET SPOOL COLLAR SPRING COLLAR SPRING SPOOL SEAL KIT, (includes items 38 thru 40) RETAINER WASHER SEAL SPOOL RETAINER, (includes items 42 & 43) WASHER SCREW

C A

304-2294

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

316-9020 304-2295 329-9754 304-3228

5 10 10 10 10 10 3 24 24 6 6 6 3 3 3 3 3 3 3 1 2 1

29

303-8623

1

30 31 32 33 34 35 36 37 38 39 40 41 42 43

303-8605

2 4 4 2 2 4 2 4 4 4 4 2 4 4

31200255

303-8609

304-4564

303-8606

303-8607

TL642

9-21

HYDRAULIC COMPONENTS Figure 9-6 Main Control Valve (Continued) Item

Part Number

Qty.

44

304-2247

1

45 46

329-9755 304-2271

47

304-3813

2 1 1 1 2 3 3 7 17 3 3 3 1 1

VALVE SECTION ASSY, (Aux), (includes one each of items 30 & 41 and two each of 37 & 45) RELIEF CARTRIDGE, 3000 PSI, (includes items 8 thru 12) OUTLET COVER ASSY, (no outrigger), (includes item 47) OUTLET COVER ASSY, (with outrigger), (includes items 47 & 55) PLUG, (no outrigger) PLUG, (with outrigger) HEX HD CAPSCREW HEX NUT O-RING O-RING CARRIAGE BOLT, 5/16-18X3 FLAT WASHER, 5/16 HEX LOCKNUT, 5/16-18 PLUG RELIEF CARTRIDGE, 3800 PSI, (includes items 8 thru 12)

1 1 1 1 5

VALVE SECTION SEAL KIT, (includes items 50 & 51) STUD KIT, (no outrigger, (includes items 48 & 49) STUD KIT, (with outrigger), (includes items 48 & 49) MAIN RELIEF SEAL KIT, (includes items 3, 4 & 5) PLUG SEAL KIT, (includes items 8 thru 12)

48 49 50 51 52 53 54 55 56

298-7373

329-9753

304-2248 304-2249 304-2269 304-2250

9-22

Description

TL642

Rev.

31200255

HYDRAULIC COMPONENTS Figure 9-6 Main Control Valve (Continued) Item

9-23

Part Number

Qty.

Description

TL642

Rev.

31200255

HYDRAULIC COMPONENTS Figure 9-7 Implement Pump

15 5 7

10 9

12

13

4

2 6 8

13

14

9-24

12

9

10

7

3

11 1

PAL1460

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-7 Implement Pump Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

31200255

Part Number

Qty.

Description

298-7247 304-2630 304-3205 304-3206 304-2629 304-2335 304-2246 304-2651 304-2628 298-7294

304-3807 304-3806

1 1 1 1 1 4 2 4 1 2 2 1 2 2 1 4

IMPLEMENT PUMP, (includes all items) SHAFT END COVER ASSY PORT END COVER ASSY GEAR HOUSING GEAR SHAFT SET CAPSCREW DRIVE SCREW DOWEL PIN NAME PLATE THRUST PLATE O-RING LIP SEAL CHANNEL SEAL BACK-UP SEAL SPLINE ADAPTER WASHER

304-2339

1


TL642

Rev. B

9-25

HYDRAULIC COMPONENTS Figure 9-8 Hydraulic Tank Assembly

509

510

26 28 29 30

21

516

16 1

17 10

118

3

9 8

134 119

13 12 2 24 25

9-26

7

TL642

27

609

23 PAL0401

31200255

HYDRAULIC COMPONENTS Figure 9-8 Hydraulic Tank Assembly Item 1 2 3

7 8 9 10 12 13 16 17 21 23 24 25 26 27 28 29 30 118 119 134 509 510 516 609

Part Number

Qty.

299-6615 303-4808 299-0376 108-1153 108-1153 303-8617 298-8588 298-8135 329-3482 298-8587 298-0515 299-0379 305-2033 298-0486 305-2032 298-0473 298-7358 298-0474 331-2386 298-0518 310-8507 341-2967 303-8599 297-7039 298-7367 298-7382 299-0310 298-1695 298-1370 304-2601

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 3 3 3 1 1 1 1

Description HYDRAULIC TANK ASSY, (includes items 1 thru 30) HYDRAULIC RESERVOIR FLUID LEVEL GAUGE, (includes mounting hardware) OIL FILTER FILTER ELEMENT (PTI TECH. #FSE-070-KC-B) BAR GAUGE FILLER CAP FILL TUBE CONNECTOR TANK FILTER CONNECTOR TANK FILTER CONNECTOR ELBOW, 90 DEGREES, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) CONNECTOR, (includes o-ring) ELBOW, 90 DEGREES, (includes o-ring) ADAPTER MALE PIPE FITTING OIL DRAIN VALVE HOSE CLAMP HEX HD CAPSCREW, 1/2-13X1, GR5 FLAT WASHER, 1/2 LOCKWASHER, 1/2 BREATHER BULKHEAD BREATHER HOSE ELBOW, 45 DEGREES

Rev. E, 7


31200255

TL642

9-27

HYDRAULIC COMPONENTS Figure 9-8 Hydraulic Tank Assembly

258

259 3

151

1

260 2

128

143

126

124 125

9-28

PAL5590

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-8 Hydraulic Tank Assembly Item 1 2 3 124 125 126 128 143 151 258 259 260

31200255

Part Number

Qty.

361-2832

Ref 1 1 1 3 3 3 1 Ref 1 1 1 1

298-8668 298-7367 298-7382 297-7039 298-8588 305-2032 299-0310 298-1695 298-1370

Description HYDRAULIC TANK ASSY, (includes items 1 & 2) FILTER FLUID LEVEL GAUGE ELBOW, 90 DEGREES WASHER, 1/2 LOCKWASHER, 1/2 HEX HD CAPSCREW, 1/2-13X1, GR5 BREATHER CAP HYDRAULIC FITTINGS, (see Figure 8-2 for details) ADAPTER, 90 DEGREES AIR BREATHER BULKHEAD CONNECTOR, FEMALE HOSE ASSY

TL642

Rev. J

9-29

HYDRAULIC COMPONENTS Figure 9-9 Brake Valve

21 22

20

19

18 17

16

23 24

14

13 25 26

15

49 50 14 15

17 27

28

16 22

51 46

48 47

32

52

41 45

34

43

30

31 32 33

29

35

44

40

39

38 37

1

2

3

4 5

6 7

8 9 10

9-30

36

TL642

11

12 53

PAL3591

31200255

HYDRAULIC COMPONENTS Figure 9-9 Brake Valve Item 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 43 44 45 46 47 48 49

31200255

Part Number

Qty.

344-1586 304-3213 299-0192 317-0601 299-7131 317-0602 299-7130 317-0603 299-0191 317-0604 317-0605

1 1 2 2 2 1 2 1 2 2 2 2 2 1 4 4 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1

304-3211 298-8175 304-3212 298-1796 298-1797 299-0985 304-3214 304-3215 317-0607 304-3216 298-8303 317-0608 317-0609 317-0610 317-0611 299-0194 299-0193 317-0612 317-0613 317-0614 298-8302 317-0615 317-0616 317-0617 304-3209 298-1794 317-0618 317-0619 317-0620 317-0621 317-0622 317-0623 317-0624 317-0625 317-0626 317-0627 317-0628

Description POWER BRAKE VALVE, (includes items 1 thru 52) SCREW PIN SPRING WIPER COVER WIPER COVER QUAD RING PISTON PISTON RING PIN SPRING BALL PLUG O-RING O-RING BACKUP RING DUMP PISTON DUMP SPOOL SPRING PLUG O-RING INLET SEAT O-RING RETAINER SPRING PISTON SEAT BALL SPRING SPRING O-RING PLUG NEEDLE ROLLER MAKE-UP CHECK PLUG O-RING SPRING SPRING GUIDE SPRING ORIFICE SPRING PLUG O-RING PLUG O-RING ORIFICE PLUG

TL642

Rev. B

9-31

HYDRAULIC COMPONENTS Figure 9-9 Brake Valve (Continued) Item

Part Number

Qty.

50 51 52 53

317-0629

1 1 2 2

Description

Rev.

PLUG HOUSING SPOOL POPPET


9-32

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-9 Brake Valve (Continued) Item

31200255

Part Number

Qty.

Description

TL642

Rev.

9-33

HYDRAULIC COMPONENTS Figure 9-10 Priority Valve

2

3 4

1

5

9

8 7

6

9-34

PAL2320

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-10 Priority Valve Item

Part Number

Qty.

299-0322

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3

1 2

298-8170

3 4

304-2260 304-2259

5

304-2263 299-0505 304-3218 304-2262 299-0505 303-8666

6 7 8 9 104 107

304-2261 299-0506 297-7032 298-7380

Description PRIORITY VALVE ASSY, (includes items 1 thru 9) VALVE BODY CHECK VALVE CARTRIDGE SEAL KIT COIL ASSY SOLENOID VALVE SEAL KIT RELIEF VALVE CARTRIDGE SEAL KIT ORIFICE PLUG RELIEF VALVE CARTRIDGE SEAL KIT COMPENSATOR CARTRIDGE SEAL KIT REDUCING VALVE CARTRIDGE SEAL KIT HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 LOCKWASHER, 3/8

Rev. C


31200255

TL642

9-35

HYDRAULIC COMPONENTS Figure 9-11 Steer Select Valve

9 7

8

2 3

7 5 4 7

6 1

PAL1310

9-36

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-11 Steer Select Valve Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9

303-5004 304-4579 303-8566 304-2657 304-3207 304-3208 304-3818 303-8565 303-8658 304-2646

1 1 4 1 1 4 2 1 2 2

31200255

Description

Rev.

STEER SELECT VALVE, (includes all items) STEERING MANIFOLD CAPSCREW STEERING CONTROL, (includes items 7 thru 9) COVER PLATE CAPSCREW O-RING SEAL KIT SOLENOID HAND NUT

TL642

9-37

HYDRAULIC COMPONENTS Figure 9-12 Quick Coupler Cylinder

1

6 11

13 14 12 10 8

9

6

PAL2840

9-38

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-12 Quick Coupler Cylinder Item 1 6 8 9 10 11 12 13 14

Part Number

Qty.

295-3419 315-3678 315-3680 315-3679

1 1 2 2 2 2 2 2 2 2

305-6015

1

Description

Rev.

QUICK COUPLER CYLINDER, (includes all items) CASE ASSEMBLY ROD ASSEMBLY HEAD ASSEMBLY WIPER RING SEAL PISTON SEAL O-RING O-RING BACKRING



31200255

TL642

9-39

HYDRAULIC COMPONENTS Figure 9-13 Outrigger Cylinder, (if equipped)

24

23

26 25

27 22 19 28

22

17

20

21

20 1 2

3 4

18

5 6

4 7

2 9 10

8 11 12 13

14 15

16

18

9-40

TL642

17

PAL0850

31200255

HYDRAULIC COMPONENTS Figure 9-13 Outrigger Cylinder, (if equipped) Item 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

31200255

Part Number

Qty.

299-1323 298-6909 305-2106 305-5459

305-2087 305-5460 305-2090 298-6906 298-1645 298-6844 299-7116 299-0852 298-7358 305-6020 298-8002 298-7380 299-0396

1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 2 1 2 2 3 3 1

OUTRIGGER CYLINDER ASSY, (includes all items) OUTRIGGER CYLINDER, (includes items 2 thru 18) BARREL, (includes item 18) LOCKNUT, (torque to 1300-1350 lb-ft) WEAR RING PISTON SEAL PISTON O-RING O-RING BACK-UP RING CAPSCREW HEAD WEAR RING STEP SEAL U-CUP CANNED WIPER SHAFT ASSY, (includes item 18) GREASE FITTING BUSHING OUTRIGGER CYLINDER VALVE, (includes items 20 thru 23) O-RING THERMAL RELIEF VALVE VALVE SEAL KIT CHECK CARTRIDGE CONNECTOR, (includes item 25) O-RING HEX HD CAPSCREW, 3/8-16X2-1/4, GR5, (torque to 30-35 lb-ft) LOCKWASHER, 3/8 ORIFICE, (C2 port)

315-1126

1

SEAL KIT, (includes items 4, 5, 6, 8, 9, 10, 13, 14 & 15)

305-2088

305-5431 305-2089

Description

TL642

Rev. A

9-41

HYDRAULIC COMPONENTS Figure 9-14 Outrigger Control Valve, (if equipped)

18 17

15

5 14

21

24

20

11 10

6

6 8

9

13

15

12 16 11

4

5 2

7 15 16

9

8

28 19

15 18

9-42

20

27

3

26 25

23 1

17

PAL3490

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-14 Outrigger Control Valve, (if equipped) Item

Part Number

Qty.

304-2573 1 2 3 4 5 6

1 1 1 3 9 2 2

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

2 4 4 2 4 2 2 2 8 4 4 8 2 4 1 4 8 4 1 1 1 1 1

299-0523

31200255

1 1 1 1

Description OUTRIGGER CONTROL VALVE INLET COVER ASSY, (includes items 2 thru 5) PLUG SQUARE SEAL O-RING PLUG VALVE SECTION ASSY, (Outriggers), (includes two of item 3, six of item 4 and items 7 thru 20) SPOOL O-RING SEAL RETAINER STRIPPER BOLT WASHER TUBE SPRING SPRING O-RING TUBE END CAP SOCKET HD CAPSCREW, 4-1/2 PLUG PLUG OUTLET COVER ASSY, (includes one of item 5) STUD ASSY, (includes items 23 & 24) HEX NUT STUD O-RING BACK-UP RING GASKET O-RING O-RING

Rev. B

VALVE SECTION SEAL KIT, (includes items 3 & 4) R/V SEAL KIT, (includes items 25 thru 27) REMOTE SEAL KIT, (includes two of item 8 and four of item 15) WORK VALVE SEAL KIT, (includes three of item 3, two of item 8, four of item 15, item 28 and 29)

TL642

9-43

HYDRAULIC COMPONENTS Figure 9-15 Swing Carriage Cylinder

9-44

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-15 Swing Carriage Cylinder Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

31200255

Part Number

Qty.

Description

327-6331 327-6316 327-6307 327-6313 327-6310 327-6309 327-6312 See Kit See Kit See Kit 327-6308 See Kit See Kit See Kit See Kit See Kit 327-6311

2 2 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1

SWING CARRIAGE CYLINDER, (includes all items) VALVE CARTRIDGE, COUNTERBALANCE GREASE FITTING BARREL, (valve block included) HEX NUT, (torque to 311-338 Nm) PISTON GLAND ROD BUSHING O-RING PISTON RING O-RING WASHER O-RING BACK-UP RING SEAL O-RING ROD WIPER BUSHING

327-6314

1

SEAL KIT

TL642

Rev.

9-45

HYDRAULIC COMPONENTS Figure 9-16 Side Shift Carriage Cylinder

9-46

TL642

31200255

HYDRAULIC COMPONENTS Figure 9-16 Side Shift Carriage Cylinder Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

362-2120 362-2121 327-6312 327-6307 Use kit K1 Use kit K1 327-6313 Use kit K1 327-6308 Use kit K1 Use kit K1 Use kit K1 327-6310 Use kit K1 Use kit K1 327-6309 327-6311 327-6331

1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SIDE SHIFT CYLINDER ASSY, (includes items 1 thru 17) BARREL BUSHING HEX NUT PISTON RING O-RING PISTON O-RING WASHER O-RING BACKUP RING O-RING CYLINDER GLAND POLY-PAK SEAL ROD WASHER PISTON ROD BUSHING GREASE ZERK

K1

327-6314

1

SEAL KIT, (includes items 4, 5, 7, 9 thru 11, 13 & 14)

31200255

Description

TL642

Rev.

9-47

HYDRAULIC COMPONENTS


9-48

TL642

31200255

SECTION 10 ELECTRICAL

31200255

TL642

ELECTRICAL Figure 10-1 Battery & Cables

157 156

6 7 10

157 174

156

173

6

155 174 7

8

PAL1450

10-2

TL642

31200255

ELECTRICAL Figure 10-1 Battery & Cables Item

Part Number

Qty.

6 7 8

298-7841 298-6850 175-4390

2 2 1

10 155 156 157 173 174

298-6925 298-0404 298-0405 298-0406 303-4795 298-7853

1 1 1 1 1 2

Description

Rev.

WHIZ-LOK NUT, 5/16-18 HOLD DOWN STUD, 5/16-18 BATTERY, (12 volt, 1000 amps), TOP STUD, 3/8-16 UNC THREAD, BCI GROUP 31 BATTERY HOLD DOWN NEGATIVE BATTERY CABLE, (battery to frame) NEGATIVE BATTERY CABLE, (frame to starter) POSITIVE BATTERY CABLE WHIZ-LOK NUT, 3/8-16 TERMINAL NUT


31200255

TL642

10-3

ELECTRICAL Figure 10-2 Battery Disconnect Option

EXISTING NUT, WASHER, AND GROUND STUD.

155

156 1 3 2 4 5

6

PAL1490

10-4

TL642

31200255

ELECTRICAL Figure 10-2 Battery Disconnect Option Item 1 2 3 4 5 6 155 156

Part Number

Qty.

304-2592 303-4749 298-0549 298-7363 303-4828 304-4563 303-4829 303-4831

1 2 2 2 1 1 1 1 Ref Ref

Description BATTERY DISCONNECT OPTION, (includes all items) SCREW, 1/4-20X3/4 HEX LOCKNUT, 1/4-20 FLAT WASHER, 1/4 BATTERY DISCONNECT SWITCH BATTERY DISCONNECT KEY BATTERY DISCONNECT BAR BATTERY DISCONNECT MOUNT NEGATIVE BATTERY CABLE, (see Figure 10-1 for details) NEGATIVE BATTERY CABLE, (see Figure 10-1 for details)

Rev. A


31200255

TL642

10-5

ELECTRICAL Figure 10-3 Engine Harness

X16 B A

"PS IGN" TO X2

16 AWG

"PS IGN" TO X8

SP1

"PS IGN" TO X21

16 AWG

"PS IGN" TO X25

16 AWG

SP2 16 AWG

"BRK SOL" TO X2

"BRK SOL" TO X5

16 AWG

"BRK SOL" TO X12

16 AWG

15 16 17 C

16 AWG

16 20 21 22

B A

SPLICE INFORMATION X15 X14

18 19

X5 X12 B A

X1

14 15 16

14 15 16 A B

1 2 3 4

DIODE

X13 X2 SP1

SP2

2 3 4 5 6 CONN POS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CONN POS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

WIRE DESIGNATION BAT-1 HR MTR HORN FUL GAG ST RLY BAT-2 SP-1 SP-2 ALT EXC SP-3 STR AW STR CRB TRANS-B TRANS-A TRANS-C TRANS-D TRANS-E REV AL

WIRE DESIGNATION GND-1 BACK LT PLUG PLUG PLUG WORK LT GND-2 STOP LT PS IGN OIL GAG CLT TMP BRK SOL TR LT SW GP SW GP SIG PLUG PLUG PLUG

CONN WIRE POS DESIGNATION 1 STR CRB 2 GND-7

CONN WIRE POS DESIGNATION 1 STR AW 2 GND-8

10-6

DIODE

X1 COLOR RED BLU/RED ORA/YEL BLU/BLK VIL/ORA RED GRY/ORA GRY/YEL VIL/RED GRY/BLU VIL/GRN VIL/YEL VIL/TAN VIL/WHT VIL/GRY VIL/DGN VIL/BLU BLUE

GAUGE TYPE

TO

8 AWG 16 AWG 16 AWG 16 AWG 16 AWG 12 AWG 12 AWG 12 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG

X19 X21 X6 X13 X9 X19 X14 X14 X27 X14 X4 X3 X5 X5 X5 X5 X5 X16

GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL

X2 COLOR BLACK YRL/ORN YEL/BLU BLACK YEL/RED ORN/DGN BLU/BRN BLU/VIL BLU/TAN BLU/WHT WHT/BLU WHT/GRN -

GAUGE TYPE

TO

8 AWG 16 AWG 16 AWG 12 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG -

X17 X15 X15 X17 X15 SP1 X20 X26 SP2 X5 X21 X10 -

GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL -

X3 COLOR VIL/YEL BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X1 X17

GXL GXL

X4 COLOR VIL/GRN BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X1 X17

GXL GXL

X3

X6

X4

7 8 28

7 8 28

9 10 11 10 12 13

X7 X8 CONN POS 1 2 3 4 5 6 7 8 9 10 11 12

WIRE DESIGNATION TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E BRK SOL TR LT SW GND-9 GND-10 GND-11 GND-12 GND-13

TERM WIRE # DESIGNATION 1 HORN

CONN WIRE POS DESIGNATION A FP PWR B FP RLY

CONN POS 1 (30) 2 (85) 3 (87A) 4 (87) 5 (86)

WIRE DESIGNATION FP RLY GND-6 FUEL PUMP PS IGN

X5 COLOR VIL/WHT VIL/TAN VIL/GRY VIL/DGN VIL/BLU BLU/TAN BLU/WHT BLACK BLACK BLACK BLACK BLACK

GAUGE TYPE

TO

16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG

X1 X1 X1 X1 X1 SP2 X2 X17 X17 X17 X17 X17

GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL

X6 COLOR ORA/YEL

GAUGE TYPE

TO

16 AWG

GXL

X1

GAUGE TYPE

TO

X7 COLOR

RED/GRN 16 AWG WHT/GRN 16 AWG

GXL GXL

X11 X8

X8 COLOR WHT/GRN BLACK WHT/VIL ORN/DGN

GAUGE TYPE

TO

16 AWG 16 AWG 16 AWG 16 AWG

X7 X9 X22 SP1

GXL GXL GXL GXL

TERM WIRE # DESIGNATION 1 ST RLY GND-6 2 GND-6 3 START SOL 4 ST RLY PWR

TERM WIRE # DESIGNATION 1 GP SIG GND-6 2 GND-6 3 GLOW PLG 4 GP RLY

TERM WIRE # DESIGNATION GP PWR 1 FP PWR 2 GP RLY

CONN WIRE POS DESIGNATION A BRK SOL B GND-3

TL642

X10

X9

X11

X9 COLOR VIL/ORA BLACK BLACK RED/VIL ORANGE

GAUGE TYPE

TO

16 AWG 16 AWG 16 AWG 10 AWG 10 AWG

GXL GXL GXL GXL GXL

X1 X10 X8 X18 X19

GAUGE TYPE

TO

X10 COLOR

WHT/GRN 16 AWG BLACK 16 AWG BLACK 16 AWG ORN/RED 8 AWG ORN/BLU 8 AWG

GXL GXL GXL GXL GXL

X2 X17 X9 X24 X11

X11 COLOR

GAUGE TYPE

RED/GRN 8 AWG RED/GRN 16 AWG ORN/BLU 8 AWG

GXL GXL GXL

TO X19 X7 X10

X12 COLOR BLU/TAN BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

SP2 X17

GXL GXL

CONN WIRE POS DESIGNATION A FUL GAG B GND-4

CONN POS -

WIRE DESIGNATION SP-1 SP-2 SP-3

CONN POS A B C D

WIRE DESIGNATION BACK LT STOP LT WORK LT GND-16

CONN WIRE POS DESIGNATION A REV AL B GND-5

X13 COLOR BLU/BLK BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X1 X17

GXL GXL

X14 COLOR

GAUGE TYPE

GRY/ORA 12 AWG GRY/YEL 12 AWG GRY/BLU 16 AWG

TO

GXL GXL GXL

X1 X1 X1

GAUGE TYPE

TO

X15 COLOR

YRL/ORN 16 AWG YEL/RED 16 AWG YEL/BLU 16 AWG BLK 16AWG

X16

GXL X2 GXL X2 GXL X2 GXL X17

COLOR

GAUGE TYPE

TO

BLUE BLACK

16 AWG 16 AWG

X1 X17

GXL GXL

PAL1031

31200255

ELECTRICAL Figure 10-3 Engine Harness (Continued)

POWER

GND

MOLDED TWO POSITION CONNECTOR

TIE WRAP

16 22 24 25

X21

X20

MOLDED DIODE DIODE INSTALLATION (TYP) 3-PLCS

32

29

X24

X26

X27

X28

X17

30 31

X22

X23 7 8 28

X25

X18 X19 CONN POS A B C

TERM WIRE # DESIGNATION 1 GND-1 GND-3 2 GND-4 GND-5 3 GND-6 GND-7 4 GND-8 GND-9 5 GND-10 GND-11 6 GND-12 GND-13 7 GND-14 GND-15 8 GND-2 9 GND-16

TERM WIRE # DESIGNATION 1 START SOL

TERM WIRE # DESIGNATION ALT BAT 1 1 ALT BAT 2 BAT-1 2 BAT-2 ST RLY PWR 3 GP PWR

TERM WIRE # DESIGNATION 1 OIL GAG

31200255

X17 COLOR BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK

GAUGE TYPE 8 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 12 AWG 16AWG

TO

GXL X2 GXL X12 GXL X13 GXL X16 GXL X10 GXL X3 GXL X4 GXL X5 GXL X5 GXL X5 GXL X5 GXL X5 GXL X23 GXL X22 GXL X2 GXL X15

X18 COLOR RED/VIL

GAUGE TYPE

TO

10 AWG

X9

GXL

X19 COLOR

GAUGE TYPE

RED/WHT 8 AWG RED/WHT 8 AWG RED 8 AWG RED 12 AWG ORANGE 10 AWG RED/GRN 8 AWG

GXL GXL GXL GXL GXL GXL

TO X28 X28 X1 X1 X9 X11

X20 COLOR BLU/BRN

GAUGE TYPE

TO

16 AWG

X2

GXL

WIRE DESIGNATION HR MTR PS IGN GP SW

CONN WIRE POS DESIGNATION 1 FUEL PUMP 2 GND-15

CONN WIRE POS DESIGNATION 1 PS IGN 2 GND-14

CONN WIRE POS DESIGNATION 1 GLOW PLG

X21 COLOR

GAUGE TYPE

BLU/RED 16 AWG ORN/DGN 16 AWG WHT/BLU 16 AWG

COLOR

GAUGE TYPE

TO

16 AWG 16 AWG

X8 X17

COLOR

GAUGE TYPE

ORN/DGN 16 AWG BLACK 16 AWG

GXL GXL

TO X25 X17

X24 COLOR ORN/RED

GAUGE TYPE

TO

8 AWG

X10

GXL

X25

TERM WIRE # DESIGNATION 1 CLT TMP

BLU/VIL

TL642

GXL GXL

X23

ORN/DGN 16 AWG ORN/DGN 16 AWG

TERM WIRE # DESIGNATION ALT BAT 1 1 ALT BAT 2

TO X1 SP1 X2

X22 WHT/VIL BLACK

TERM WIRE # DESIGNATION PS IGN 1 PS IGN

TERM WIRE # DESIGNATION 1 ALT EXC

SXL SXL SXL

COLOR

GAUGE TYPE GXL GXL

TO SP1 X23

X26 COLOR

GAUGE TYPE

TO

16 AWG

X2

GXL

X27 COLOR VIL/RED

GAUGE TYPE

TO

16 AWG

X1

GXL

X28 COLOR RED/WHT RED/WHT

GAUGE TYPE

TO

8 AWG 8 AWG

X19 X19

GXL GXL

PAL1041

10-7

ELECTRICAL Figure 10-3 Engine Harness Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 28 29 30 31 32

Part Number

Qty.

298-0400

1 1 2 2 2 1 1 3 3 1 1 2 1 1 1 2 3 5 1 1 1 1 1 2 1 1 3 1 1 1 1

303-4983 303-4982 303-8663

176-1477

362-6358 196-2413 299-0944 362-7670 299-0312 299-0340 299-0349 299-0346 305-2115 299-0908 299-7106 362-6360 304-2623 196-2412 362-6359 299-7096 362-3261 362-4916 304-2606 305-5449 303-4997

Description PERKINS ENGINE HARNESS, (includes all items) CONNECTOR NUT LOCKWASHER STRAIN RELIEF CONNECTOR PLUG CONNECTOR TERMINAL CONNECTOR ASSY, (includes 7.5 amp fuse) CONNECTOR TERMINAL COVER CONNECTOR RELAY, (Fuel Pump) CONNECTOR TERMINAL SEAL CONNECTOR CONNECTOR LOCK CONNECTOR CONNECTOR TPA TERMINAL CONNECTOR TPA SEAL CONNECTOR CONNECTOR WEDGE DIODE

Rev. D


10-8

TL642

31200255

ELECTRICAL Figure 10-3 Engine Harness (Continued) Item

31200255

Part Number

Qty.

Description

TL642

Rev.

10-9

ELECTRICAL Figure 10-4 Transmission Harness

SP3 16 AWG

"GND-9" TO X5

"GND-9" TO Y1

16 AWG

"GND-9" TO Y2

16 AWG

8 "GND-11" TO X5

16 AWG

"GND-11" TO Y5

16 AWG

3 4

Y4

16 AWG

"GND-11" TO Y4

Y5

SP4

Y6

3 4 3 4

8 1 2

3 4

8

Y2

X5 SP4 X29

SP3

3 4 3 4

Y3

Y1

8

5 6 7

8

CONN WIRE POS DESIGNATION A TRANS-D B GND-11

Y4 COLOR VIL/DGN BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X5 SP4

GXL GXL

POWER

GND

CONN WIRE POS DESIGNATION A TRANS-E B GND-11

CONN WIRE POS DESIGNATION A BRK SOL B GND-12

CONN WIRE POS DESIGNATION A TR LT SW B GND-13

Y5 COLOR VIL/BLU BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X5 SP4

GXL GXL

CONN WIRE POS DESIGNATION A TRANS-A B GND-9

Y6 COLOR BLU/TAN BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

GXL GXL

X5 X5

GAUGE TYPE

TO

16 AWG 16 AWG

X5 X5

CONN WIRE POS DESIGNATION A TRANS-B B GND-9

X29 COLOR BLU/WHT BLACK

GXL GXL

CONN WIRE POS DESIGNATION A TRANS-C B GND-10

Y1 COLOR VIL/WHT BLACK

TIE WRAP GAUGE TYPE

TO

16 AWG 16 AWG

X5 SP3

GXL GXL

Y2 COLOR VIL/TAN BLACK

GAUGE TYPE

TO

16 AWG 16 AWG

X5 SP3

GXL GXL

Y3 COLOR VIL/GRY BLACK

MOLDED TWO POSITION CONNECTOR

GAUGE TYPE

TO

16 AWG 16 AWG

X5 X5

GXL GXL

DIODE INSTALLATION (TYP) 6-PLCS

CONN POS 1 2 3 4 5 6 7 8 9 10 11 12

WIRE DESIGNATION TRANS-A TRANS-B TRANS-C TRANS-D TRANS-E BRK SOL TR LT SW GND-9 GND-10 GND-11 GND-12 GND-13

X5 COLOR VIL/WHT VIL/TAN VIL/GRY VIL/DGN VIL/BLU BLU/TAN BLU/WHT BLACK BLACK BLACK BLACK BLACK

GAUGE TYPE

TO

16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG

Y1 Y2 Y3 Y4 Y5 Y6 X29 SP3 Y3 SP4 Y6 X29

GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL GXL

PAL1050

10-10

TL642

31200255

ELECTRICAL Figure 10-4 Transmission Harness Item 1 2 3 4 5 6 7 8

31200255

Part Number

Qty.

303-4752 344-7163 304-2647

1 1 1 5 5 1 1 1 6

362-6743

303-4997

Description TRANSMISSION HARNESS, (includes all items) CONNECTOR CONNECTOR LOCK CONNECTOR TERMINAL CONNECTOR TERMINAL SEAL MOLDED DIODE

TL642

Rev. A

10-11

ELECTRICAL Figure 10-5 Auxiliary Electrics

A

211 212 213

B

A

** unknown ** ** unknown ** 4 YES GROUND(YELLOW) 3 9112-5077 12-5077 0

218 219 220

C

217

C

B

202

202 204 205

VIEW C-C QC VALVE HARNESS WIRE COLOR

YELLOW BROWN

WIRE COLOR BLACK RED YELLOW BLUE ORANGE

211 212 213

201

QC VALVE HARN. TO BOOM HARN

WIRE DESIGNATION QC PWR QC PWR NO CONN QC GND QC GND

QC PWR YELLOW

QC PWR YELLOW EXTRA BLACK

PLUG F E

B A D

C

PLUG

202

QC GND BROWN

101

105 W/W_SW

WL_SWA

W/W

25A

25A

SL_SWA

SPARE_BAT OPT1

HTR_SW

WL2

SL_SWB

WL_SWB

15A

OPT1

15A OPT3

10A OPT2

ACC

OPT2

LIGHTS

OPT3

W/W

GND1

FAN/HTR

GND2

FAN_SW

GND3

1

2 B+

12+

OIL

FUEL

D GR

LT

GND

G

+

TEMP

3

4

REV_ALARM

WARN_LT_CK SW1-86

AC C

25A

FAN/HTR

10A STEER

LIGHTS

RELAYS

10A GAUGES

10A SPARE_BAT

KEY

25A

30A

15A HORN

10A OPT_PWR

104

QC GND BROWN

AUX_ELEC1 SW2-87A

SW2-86

AUX_ELEC2

SW1-87A

GND85

OPT SPARE_COIL

BAT ST

BAT

IGN

IGN

IGN

QA VALVE

202

103

VIEW A-A

VIEW D-D PACKARD METRI-PAK CONNECTION #1

TERMINAL # DESIGNATION

8

NO CONN.

7

GND

6

QC GND

5

GND

4

QC GND

3

QC PWR

2

PWR

1

QC PWR

WIRE DESIGNATION

TIE WRAP TO EXSISTING DASH HARNESS

1 202

D

D

** unknown ** ** unknown ** 4 YES

VIEW B-B

1 9112-5077 0

PAL1481

10-12

TL642

31200255

ELECTRICAL Figure 10-5 Auxiliary Electrics Item

Part Number

Qty.

1 101 103 104 105 201 202 204 205 211 212 213 217 218 219 220

299-1297 298-7047 300-6092 298-7221 299-0325 298-7848 298-7070 298-7072 297-7030 298-7374 298-7839 299-6645 298-7440 298-0434 298-7437 299-6644 298-7439

1 1 1 1 1 1 1 1 1 1 3 3 6 1 1 1 1

Description

Rev.

AUXILIARY ELECTRICS, (includes all items) AUXILIARY FRAME WIRING HARNESS DASH HARNESS CONDURA SWITCH RELAY FUSE, 10A TUBE WELD AUXILIARY WIRING HARNESS HEX HD CAPSCREW, 3/8-16X7/8, GR5 FLAT WASHER, 3/8 CLAMP COVER PLATE HEX HD CAPSCREW, 1/4-20X1-3/8 QUICK CHANGE HARNESS CLAMP COVER PLATE HEX HD CAPSCREW, 5/16-18X1-3/8, GR5

E, 6


31200255

TL642

10-13

ELECTRICAL Figure 10-6 Tilt Electronics

TILT CYLINDER

14 5000 PSI

SW1-86

REV_ALARM

COMPENSATING CYLINDER

SW2-87A

SW2-86

SW1-87A

AUX_ELEC1

WARN_LT_CK

GND85

203

SPARE_COIL

AUX_ELEC2

OPT

OPT1 GND1 WL_SWA

SL_SWA

KEY

15A HORN 10A OPT_PWR 30A

10A GAUGES 10A STEER 10A SPARE_BAT 25A

25A

LIGHTS

W/W_SW

RELAYS

W/W

25A

25A

FAN/HTR

4300 PSI

OPT3

WL2 FAN_SW

4300 PSI

GND3

OPT1

ACC

10A OPT2 15A OPT3 15A

LIGHTS

OPT2

W/W

GND2

FAN/HTR

HTR_SW

SL_SWB

WL_SWB

15

-TILT PWR-

CONNECT TO OPT-2 YELLOW WIRE

SPARE_BAT

B

16

A

MAIN CONTROL VALVE TILT SECTION

CROWD

RHEOSTAT

TILT UP TILT DWN

RED WIRE

7

8

-TILT PWR 1-

-TILT PWR-

-TILT PWR 2-

A

B

SOLENOID VALVE

13

201

T B

-TILT UP-

P

TO 'BV' ON PRIORITY BLOCK

ROCKER SWITCH ON JOYSTICK

-TILT DWN-

105 106 GND 15

12

GND 16

RHEOSTAT

OPT-2

A

+ 12 VOLTS

ELECTRIC/HYDRAULIC SCHEMATIC

CONNECT TO EXISTING CAB GND. LOCATION TILT UP GND 16

"T"

TILT DWN GND 15

"P"

202

10-14

TL642

PAL2230

31200255

ELECTRICAL Figure 10-6 Tilt Electronics Item

Part Number

Qty.

7 8 12 13 14 15 16 105 106 201 202 203

298-7308 299-0324 298-8152 298-7079 299-0325 298-7849 298-7850 300-6074 298-7385

1 1 1 1 1 1 1 1 1 Ref Ref Ref

Description

Rev.

BULLET TRMINAL FULLY INSULATED BULLET RECEPTACLE HARNESS ASSEMBLY TILT HARNESS BOSCH RELAY FUSE, 15 AMP FUSE, 30 AMP HEX HD CAPSCREW, 3/8-16X7/8, GR5 STAR LOCK WASHER BOOM JOYSTICK w/TILT, (see Figure 7-4 for details) SOLENOID VALVE, (see Figure 8-8 for details) INSTRUMENT PANEL, (see Figure 6-4 for details)


31200255

TL642

10-15

ELECTRICAL Figure 10-7 A/C Harness

GND

G

1 3 5

GND RLY 87

H

A GND

GND AC SW

RLY 85

GND

RLY 85

B

E

RLY 87

RLY 30

4 5 6

FAN SW C FAN SW C

RLY 30

F

PRS SW

D

AC SW

C PRS SW

PAL3461

RLY 85

WIRE CHART WIRE DESIGNATION

WIRE COLOR/STRIPE

WIRE GAGE

RLY 87 RLY 30

AC SW

ORANGE RED BLUE VIOLET YELLOW

16 16 16 16 16

FAN SW C

GREEN

16

GND

BLACK

16

RLY 85 PRS SW

10-16

WIRE END A WEATHER PACK

WIRE END B

WIRE END C

1/4 FEMALE SPADE 1/4 FEMALE SPADE 1/4 FEMALE SPADE 1/4 FEMALE SPADE 1/4 FEMALE SPADE WEATHER PACK

1/4 FEMALE SPADE

WIRE END D

WIRE END E 1/4 FEMALE SPADE 1/4 FEMALE SPADE 1/4 FEMALE SPADE

WIRE END F

WIRE END G

WIRE END H

1/4 FEMALE SPADE WEATHER PACK

1/4 FEMALE SPADE 1/4 FEMALE SPADE

REMARKS CONDENSOR TO RELAY DASH CIRCUIT BOARD TO RELAY RELAY TO PRESSURE SWITCH TO COMP. CLUTCH PRESSURE SWITCH TO THERMOSTATIC SWITCH AC SWITCH TO THERMOSTATIC SWITCH AC SWITCH TO FAN C

1/4 FEMALE SPADE

TL642

RING 3/8 SCREW

RING 3/8 SCREW

GROUND

31200255

ELECTRICAL Figure 10-7 A/C Harness Item

Part Number

Qty.

1 3 4 5 6

298-8285 299-0339 299-0346 299-0341 298-7282 299-0347

1 1 1 1 2 1

Description A/C HARNESS, (includes items 1 thru 6) SHROUD CABLE SEAL SHROUD TERMINAL CABLE SEAL

Rev. F


31200255

TL642

10-17

ELECTRICAL Figure 10-8 Cab Work Light Harness

1 4

5

2 3

PY1770

10-18

TL642

31200255

ELECTRICAL Figure 10-8 Cab Work Light Harness Item

Part Number

Qty.

1 2 3 4 5

328-1548 303-4969 303-4970 334-5871 323-7236 298-7252

1 2 2 1 1 2

31200255

Description

Rev.

CAB WORK LIGHT HARNESS, (includes all items) TERMINAL TERMINAL TERMINAL TERMINAL WIRE, 16 GA, BLACK

TL642

10-19

ELECTRICAL Figure 10-9 Chassis Harness

3 6 36 37

15 38 39 40

3 34 35

A

17 41 42 43 45

3 34 35

B

A

B

8 9 33

17 42 44

30 31 32

30 31 32

3 6 29 PT -31 36-24 HD

6 24 27 HD36-24-31ST

7 8 9

10 11 12

13 14 15 16 17 18

10-20

14 15 16 17 18 21

15 16 17 18 19

14 15 16 17 18 20

HD 36-24 -19 SE

1 2 3 4 5 6

2 6 22 23 24 25 26

PAL5490

TL642

31200255

ELECTRICAL Figure 10-9 Chassis Harness Item 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 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Part Number

Qty.

344-3254 362-4934 303-4983 298-7268

1 1 2 5 1 1 5 1 2 2 1 1 1 1 3 5 4 6 4 1 1 1 1 1 2 1 1 1 1 2 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1

305-5438 299-0312 362-7670 196-2413 299-0339 298-7282 299-0346 299-0959 299-6629 196-2412 267-9572 299-0346 299-0348 299-0958 299-0957 299-0956 305-2039 303-4982 298-7269 305-5437 356-2912 305-5423 176-1477 362-3261 299-0312 305-5449 304-2606 305-2038 362-6360 304-2623 305-2115 299-0349 299-0350 299-0340 299-0343

Description CHASSIS HARNESS, (includes items 1 thru 44) CONNECTOR NUT CONTACT CONTACT PLUG PLUG RELAY CONNECTOR TERMINAL CONNECTOR TERMINAL SEAL CONNECTOR CONNECTOR LOCK TERMINAL TERMINAL SEAL SEAL CONNECTOR CONNECTOR CONNECTOR CONNECTOR WASHER CONTACT CONTACT CAP CONNECTOR CONNECTOR HOUSING TERMINAL SEAL RELAY LOCK CONNECTOR CONNECTOR CAP CONNECTOR SECONDARY LOCK SEAL CONNECTOR TERMINAL PLUG CONNECTOR CONNECTOR

Rev. E


31200255

TL642

10-21

ELECTRICAL


10-22

TL642

31200255

SECTION 11 DECALS

31200255

TL642

DECALS Figure 11-1 Cab & Frame Decals

23 7 19

1 2 3 4 5 6

39

17

7

18

8

4

VIEW D-D

5 VIEW E-E

VIEW F-F

16

E VIEW B-B

E

13

24

8

A

B

14

VIEW A-A

A

B

46 101

G

D

34 D G

42

F VIEW G-G C

3

F

16

VIEW C-C

C

31

20 20

33

28 32 30 PAL2314

OPEN CAB

11-2

TL642

ENCLOSED CAB

31200255

DECALS Figure 11-1 Cab & Frame Decals Item

3 4

Part Number

Qty.

Description

Rev.

305-3767

Ref

10

314-5304

Ref

314-2351

Ref

313-6241

1 1

DECAL INSTALLATION, ENGLISH, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) DECAL INSTALLATION, ISO, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) DECAL INSTALLATION, FRENCH, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) SERIAL NO. NAME PLATE LUBRICATION CHART DECAL, (Before S/N TBK01167 excluding TBK01162) LUBRICATION CHART DECAL, (S/N TBK01167 & After including TBK01162) MAINTENANCE CHART DECAL, (Before S/N TBK01167 excluding TBK01162) MAINTENANCE CHART DECAL, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/O OUTRIGGERS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/O OUTRIGGERS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) COVER, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE-SWING, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE-SWING, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) LIFTING HOOK, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LIFTING HOOK, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162)

1 5

313-6242

1

7

314-6696

1 1

314-6032 344-7172

1 1 1 1

315-8700 314-6031

1 1 1 1

314-6697

1 1

312-2615

1 1

313-4359

1 1

314-6030

1 1

339-9620

1 1

31200255

TL642

5 5

H B F A B A B A B B C A B A B A B A B A

11-3

DECALS Figure 11-1 Cab & Frame Decals (Continued) Item

Part Number

Qty.

339-9609

1 1

314-5306 314-5307

1 1 1 1

314-5308 314-5309

1 1 1 1

314-5310

1 1

314-5311

1 1

314-5312

1 1

359-9448

1 1

339-9595

1 1

315-4601

1 1

315-4603 315-4605

1 1 1 1

315-4606 315-4607

1 1 1 1

11-4

Description

Rev.

LOAD CHART BOOKLET, W/O OUTRIGGERS, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/O OUTRIGGERS, METRIC UNIT, (S/N TBK01167 & After including TBK01162) COVER, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SWING, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SWING, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKET, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKET, METRIC UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) LIFTING HOOK, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LIFTING HOOK, METRIC UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) COVER, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE-SWING, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE-SWING, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162)

TL642

D B C A B A B A C B C A B A B A C A B A C C B A B A B B B B

31200255


Part Number

Qty.

Description

Rev.

315-4609

1

SIDE SHIFT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) LIFTING HOOK, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LIFTING HOOK, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, METRIC UNIT (S/N TBK01167 & After including TBK01162) COVER, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SWING, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SWING, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKET, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKET, METRIC UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, METRIC UNIT, (S/N TBK01167 & After including TBK01162)

B

1 315-4610

1 1

315-4611

1 1

339-9603

1 1

339-9594

1 1

315-4615

1 1

315-4617 315-4618

1 1 1 1

315-4619 315-4621

1 1 1 1

315-4622

1 1

315-4623

1 1

315-4625

1 1

339-9604

1 1

31200255

TL642

A B A B A B A B A C B B A B A B B B A B A B A B A B A

11-5


Part Number

Qty.

Description

Rev.

339-9596

1

LIFTING HOOK, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LIFTING HOOK, METRIC UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/WINCH, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/WINCH, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) COVER, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE-SWING, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE-SWING, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) WINCH, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) WINCH, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/WINCH, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/WINCH, METRIC UNIT, (S/N TBK01167 & After including TBK01162) COVER, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, METRIC UNIT, (S/N TBK01167 & After including TBK01162)

B

1 321-2484

1 1

321-2485 321-2485

1 1 1 1

321-2487

1 1

321-2488

1 1

321-2489

1 1

321-2490

1 1

321-2491

1 1

321-2492

1 1

321-2493 321-2504

1 1 1 1

321-2505

1 1

321-2506

1 1

11-6

TL642

A B B B A B A B A B B B A B A B A B A B A B B B A B A

31200255


Part Number

Qty.

Description

Rev.

321-2507

1 1 1

SIDE TILT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SWING, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SWING, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKET, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKET, METRIC UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) WINCH, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) WINCH, METRIC UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) COVER, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE-SWING, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE-SWING, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162)

B A B

321-2508

1 321-2509

1 1

321-2510

1 1

321-2511

1 1

321-2512

1 1

321-2513 321-2494

1 1 1 1

321-2495 321-2496

1 1 1 1

321-2497

1 1

321-2498

1 1

321-2499

1 1

321-2500

1 1

31200255

TL642

B B A B A B A B A B A B B B A B A B B A B B A B A

11-7


Part Number

Qty.

Description

Rev.

321-2501

1

STANDARD BUCKETS, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKETS, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) WINCH, ENGLISH UNIT, (Before S/N TBK01167 excluding TBK01162) WINCH, ENGLISH UNIT, (S/N TBK01167 & After including TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, METRIC UNIT, (S/N TBK01167 & After including TBK01162) COVER, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) COVER, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD CARRIAGE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD CARRIAGE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE TILT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE TILT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SWING, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SWING, METRIC UNIT, (S/N TBK01167 & After including TBK01162) SIDE SHIFT, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) SIDE SHIFT, METRIC UNIT, (S/N TBK01167 & After including TBK01162) TRUSS BOOM, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) TRUSS BOOM, METRIC UNIT, (S/N TBK01167 & After including TBK01162) STANDARD BUCKET, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) STANDARD BUCKET, METRIC UNIT, (S/N TBK01167 & After including TBK01162) MULTI-PURPOSE, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) MULTI-PURPOSE, METRIC UNIT, (S/N TBK01167 & After including TBK01162) WINCH, METRIC UNIT, (Before S/N TBK01167 excluding TBK01162) WINCH, METRIC UNIT, (S/N TBK01167 & After including TBK01162) REAR PANEL CAT DECAL OIL LEVEL DEAL HYDRAULIC OIL DECAL TIE-DOWN DECAL TIP OVER DECAL, ENGLISH TIP OVER DECAL, ISO

B

1 321-2502

1 1

321-2503 321-2514

1 1 1 1

321-2515 321-2516

1 1 1 1

321-2517

1 1

321-2518

1 1

321-2519

1 1

321-2520

1 1 1 1

321-2522

1 1

321-2523 8 13 14 16 17

11-8

303-4906 298-8438 303-4962 303-4963 303-4946 314-5324

1 1 1 1 1 4 1 1

TL642

A B A B A B B B A B

B B B B B A B A B A B A A A

31200255

DECALS Figure 11-1 Cab & Frame Decals (Continued) Item 18

19

20

23

24

27

28

30

31

32

33 34 39 42 46 101

Part Number

Qty.

314-2338 303-4941 314-5321 314-2339 303-4949 314-5315 314-2340 303-4948 314-5316 314-2341 303-4939 314-5318 314-2343 303-4942 314-5322 314-2344 305-3791 314-5317 314-2350 303-4950 314-5320 314-2345 303-4945 314-5327 314-2346 303-4944 314-5323 314-2347 303-4947 314-5325 314-2348 298-1844 303-4909 299-0354 303-4819 330-4923 323-5609 298-1694

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description

Rev.

TIP OVER DECAL, FRENCH ELECTROCUTION HAZARD DECAL, ENGLISH ELECTROCUTION HAZARD DECAL, ISO ELECTROCUTION HAZARD DECAL, FRENCH CRUSH HAZARD WARNING DECAL, ENGLISH CRUSH HAZARD WARNING DECAL, ISO CRUSH HAZARD WARNING DECAL, FRENCH NO RIDERS DECAL, ENGLISH NO RIDERS DECAL, ISO NO RIDERS DECAL, FRENCH BATTERY DECAL, ENGLISH BATTERY DECAL, ISO BATTERY DECAL, FRENCH ROTATING PARTS DECAL, ENGLISH ROTATING PARTS DECAL, ISO ROTATING PARTS DECAL, FRENCH DASH DECAL KIT, RH, (includes items 28 thru 33), ENGLISH DASH DECAL KIT, RH, (includes items 28 thru 33), ISO DASH DECAL KIT, RH, (includes items 28 thru 33), FRENCH TIP OVER DECAL, ENGLISH TIP OVER DECAL, ISO TIP OVER DECAL, FRENCH RUN OVER DECAL, ENGLISH RUN OVER DECAL, ISO RUN OVER DECAL, FRENCH READ MANUAL DECAL, ENGLISH READ MANUAL DECAL, ISO READ MANUAL DECAL, FRENCH MACHINE ROLL DECAL, ENGLISH MACHINE ROLL DECAL, ISO MACHINE ROLL DECAL, FRENCH BOOM OPERATION DECAL CAT IGNITION SWITCH DECAL TILT ANGLE GAUGE CAT LOGO DECAL ETHER START WARNING DECAL, ENGLISH ETHER START WARNING DECAL, ISO & FRENCH SHIFTER DECAL


31200255

TL642

11-9

DECALS Figure 11-2 Boom Decals

29 2 E

E

36

29

50 °

60°

70°

80°

47

° 40

30°

-10°

0°

10°

20°

12

1

VIEW E-E

38

37

45

46

22 29

47

47

29

-10°

9

PAL2301

11-10

TL642

31200255

DECALS Figure 11-2 Boom Decals Item

Part Number

Qty.

305-3767

Ref

314-5304

Ref

314-2351

Ref

303-4883 303-4884 303-4964 298-0576 303-4940 314-5319 314-2342 303-4943 314-5326 314-2349 298-8743

1 1 1 1 1 1 1 5 5 5 1

320-7883

1

37

298-7901

1

38

298-7902

1

43

320-7882

1

44

298-7365

1

45

309-6301

1

47

330-5286

2

1 2 9 12 22

29

36

Description DECAL INSTALLATION, ENGLISH, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) DECAL INSTALLATION, ISO, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) DECAL INSTALLATION, FRENCH, (not available to order, see items 1 thru 47 on Figure 11-1 and all items on Figure 11-2 for service) TL642 CAT LH BOOM DECAL TL642 CAT RH BOOM DECAL BOOM EXTEND DECAL BOOM ANGLE DECAL CARRY PERSONNEL DECAL, ENGLISH CARRY PERSONNEL DECAL, ISO CARRY PERSONNEL DECAL, FRENCH PINCH POINT DECAL, ENGLISH PINCH POINT DECAL, ISO PINCH POINT DECAL, FRENCH PENDULUM, (Before S/N TBK00798 excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) PENDULUM, (S/N TBK00798 & After excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) HEX NUT, (Before S/N TBK00798 excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) WASHER, (Before S/N TBK00798 excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) SPACER, (S/N TBK00798 & After excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) WASHER, 3/8, (S/N TBK00798 & After excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) HEX LOCKNUT, 3/8-16, (S/N TBK00798 & After excluding TBK00804, TBK00805, TBK00806, TBK00807 & TBK00808) GOOSENECK 6 DECAL

Rev. 10 5 5


31200255

TL642

11-11

DECALS


11-12

TL642

31200255

SECTION 12 OPTIONS

31200255

TL642

OPTIONS Figure 12-1 Block Heater Installation

1

PAL1260

12-2

TL642

31200255

OPTIONS Figure 12-1 Block Heater Installation Item

Part Number

Qty.

1

299-6648 303-4841

1 1

31200255

Description BLOCK HEATER INSTALLATION, (includes item 1) BLOCK HEATER

TL642

Rev. A

12-3

OPTIONS Figure 12-2 8” Winch

12-4

TL642

31200255

OPTIONS Figure 12-2 8” Winch Item 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 42 43 44 45 46 47 48 49

31200255

Part Number

Qty.

298-8596 304-2302 304-4573 304-3182 304-4577

1 1 1 1 1 1 1 1 1 1 1 6 1 2 4 2 1 1 1 1 1 1 1 2 1 2 1 1 1 2 1 1 2 1 2 2 1 1 1 1 1 2 2 1 1 1 2 2 8

304-2304 304-4578 304-2305 304-2306 304-4575 304-3183 304-2307 304-2308 304-2309

304-2318 304-2319 303-8650 304-2320 304-2322 304-2323 304-2324 304-2325

304-2266 304-3812 303-8651 304-2328 304-2329 304-2267 303-8652 303-8653

Description

Rev.

WINCH, 8” DRUM, (includes all items) GEAR CASE LOCK SET A LOCK SET B CABLE DRUM, 8” BRAKE DRUM GEAR CASE COVER CABLE DRUM SHAFT, 8” WORM SHAFT, (includes item 10) WORM GEAR WORM CABLE DRUM SHAFT KEY LOCK SEAT A BUSHING BUSHING STUD BOLT, 1/2X1-1/2 COLLAR BRAKE PLATE BRAKE HOUSING BRAKE DRUM ADJUSTING BOLT ADJUSTING NUT SPRING SEAT ROLLER BRAKE LINING BRAKE PLATE A BRAKE PLATE B FIXING PLATE OIL FILL PLUG BEARING SHIM BEARING HUB GASKET GEAR CASE GASKET O-RING WASHER BUSHING SEAL WORM SHAFT KEY WORM SHAFT KEY SPRING BRAKE DRUM SPRING MOTOR MOUNT ADAPTER COUPLER, WINCH SHAFT BEARING V.C. TYPE LOCK RING OIL LEVEL PLUG OIL DRAIN PLUG COUPLER SPACER BEARING HUB OIL SEAL CAP SCREW, 3/8X1-1/2

TL642

12-5

OPTIONS Figure 12-2 8” Winch (Continued) Item 50 51 52 53 54 55 56 57 58

Part Number

Qty.

304-2334 304-3817

8 1 5 1 1 1 1 2 1

320-4875

1

304-2332 304-3184 304-3185 304-3186

Description

Rev.

LOCK WASHER GREASE FITTING NUT HEX HD CAPSCREW, 3/8X1 LOCK WASHER HEX HD CAPSCREW, 3/8X1 BRAKE COVER GASKET OIL SEAL LOCK SEAT GASKET

BRAKE LINING ASSY, (includes items 5, 16 thru 26, 31, 34, 37, 38, 43, 49, 50, 52 & 56)


12-6

TL642

31200255

OPTIONS Figure 12-2 8” Winch (Continued) Item

31200255

Part Number

Qty.

Description

TL642

Rev.

12-7

OPTIONS Figure 12-3 Winch Motor

12-8

TL642

31200255

OPTIONS Figure 12-3 Winch Motor Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

31200255

Part Number

Qty.

303-8656 304-3192

304-3194 304-3195 304-3196 304-3197 304-3198 304-3199 304-3200 304-3201 304-3202 304-3203 304-3204

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

WINCH MOTOR, (includes all items) DUST SEAL SPLIT WIRE RING METAL BACKUP SHIM HIGH PRESSURE SEAL METAL BACKUP SHIM TEFLON BACKUP SHIM SHAFT SEAL BODY SEAL KIT SEAL CARRIER THRUST WASHER THRUST BEARING DRIVE LINK MID MOUNT WEAR PLATE ROTOR KIT DRIVE LINK PIN END COVER BOLT SET HOUSING COOLING PLUG SHAFT, (includes item 21) KEY

304-3190 304-3191 304-2268

1 1 1

SEAL KIT, (includes items 1 thru 10) SEAL KIT, (includes items 1 thru 8) SEAL KIT, (includes items 9 & 10)

304-3193

Description

TL642

Rev.

12-9

OPTIONS Figure 12-4 Pressure Reducer Valve - 1360 PSI

1

3 4 5

2

PAL1220

12-10

TL642

31200255

OPTIONS Figure 12-4 Pressure Reducer Valve - 1360 PSI Item 1 2 3 4 5

31200255

Part Number

Qty.

Description

298-7099 304-3189 304-3188

1 1 1 1 1 1

PRESSURE REDUCER VALVE, 1360 PSI, (includes all items) PRESSURE REDUCING CARTRIDGE CHECK CARTRIDGE O-RING O-RING O-RING

304-3187

1

SEAL KIT, (includes items 3, 4 & 5)

TL642

Rev.

12-11

OPTIONS Figure 12-5 Pintle Hook Installation

1 2 3 4

PAL2170

12-12

TL642

31200255

OPTIONS Figure 12-5 Pintle Hook Installation Item 1 2 3 4

31200255

Part Number

Qty.

304-2660

1 Ref 1 4 4

299-0361 298-7922 298-7382

Description PINTLE HOOK INSTALLATION, (includes items 1 thru 4) COUNTERWEIGHT, (see Figure 1-1 for details) PINTLE HOOK HEX HD CAPSCREW, 1/2-13X1-3/4 LOCKWASHER, 1/2

TL642

Rev. B

12-13

OPTIONS Figure 12-6 Fender Option

10 12

10 11

10 11 14

9 13

1 2 4

6 7 8

1 3 5

6 7 8

PAL0090

12-14

TL642

31200255

OPTIONS Figure 12-6 Fender Option Item

Part Number

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

299-6673 298-8604 298-8791 298-8792 299-0544 299-0546 298-8290 298-1849 298-7382 298-7373 298-7364 297-7026 297-7024 298-1578 298-0565

1 4 1 1 1 1 16 16 16 24 24 16 8 24 8

31200255

Description FENDER OPTION, (includes all items) FENDER RIGHT REAR FENDER MOUNT LEFT REAR FENDER MOUNT LEFT FRONT FENDER MOUNT RIGHT FRONT FENDER MOUNT FENDER STUD HEX NUT, M12X1.25 LOCKWASHER, 1/2 FLAT WASHER, 5/16 FLAT WASHER, 5/16 HEX HD CAPSCREW, 5/16-18X3-1/2, GR5 HEX HD CAPSCREW, 5/16-18X3, GR5 HEX LOCKNUT, 5/16-18 PLUG

TL642

Rev. A

12-15

Before S/N TBK00706

OPTIONS Figure 12-7 Work Light Package VIEW A-A

7 9 10 16

5 11 3 GND DL

1 4 11 15

2 8 11 13 14

LIGHT-1 GND L

A B

GND L GND L1 STOP SW DOME LT STOP LT WORK LT LIGHT-1 LIGHT SW

A

A

6 9 10

B

1 4 11 15

DOME LT

A

17

LIGHT-2 GND L

WORK LT LIGHT SW GND LT IND LT

17 17

12

STOP LT STOP SW

A B C

BACK-LT STOP-LT WORK-LT/TAIL-LT MIRROR-LT GND

A B

GND 2 B A

111

C

108 109 110

101 102 103 104 105 106 111 401 402 403 404 405 406 407

STOP SW

STOP LT

B

107

A

GND 1

TERMINAL A TERMINAL B TERMINAL C A B C

12-16

114

STOPLIGHT SWITCH MTG. ON BRAKE ASSEMBLY

GREEN RED BLACK

BACK-LT STOP-LT TAIL-LT

PAL3080

TL642

31200255

Before S/N TBK00706

OPTIONS Figure 12-7 Work Light Package (Continued)

BACK-LT STOP-LT TAIL-LT GND-1

201

GND-2

202

B C

A

B C

A

C

B

A

204 205 206

BACK-LT STOP-LT WORK-LT/TAIL-LT

A B C

LIGHT SW

WORK LT

REF: LIGHT HARNESS (9140-3305) LIGHT-2 GND L

LIGHT-1 GND L

B A

302

GND L1 IND LT

B A

301

203 208 209 210

DOME LT

12+

OIL

R

FUEL D GR

W/W

FAN/HTR

LIGHTS

WARN_LT_CK

REV_ALARM

ACC

RUN

ST

AUX_ELEC1 SW2-87A

SW2-86

OPT

AUX_ELEC2 SW1-87A

GND85

SPARE_COIL

STOP SW

REF: ENGINE HARNESS (G6-42A 9147-3101) (TF6-42 9150-3060)

A B C

LIGHT SW

DEUTSCH P/N HD-36-24-18-PN

4

2

5 6

18

REV AL

17

TRANS-E

TRANS-D

16

TRANS-D

TRANS-C

15

TRANS-C

REV AL TRANS-E

14

TRANS-A

TRANS-B

13

TRANS-B

STR CRB

12

STR CRB

TRANS-A

TRANS TEMP WARN LIGHT

STR AW

11

STR AW

SP-3

10

SP-3

ALT EXC

9

ALT EXC

SP-2

8

SP-2

SP-1

7

SP-1

6

BAT-2 ST RLY

5

FUL GAG

4

HORN

3

HR MTR

2

BAT-1

1

FRONT WORK LIGHT

BAT-2 ST RLY FUL GAG HORN HR MTR BAT-1

GND

7

1

3

MIRROR-LT

8

ACC

STRT

IGN

DEUTSCH P/N HD-34-24-18-SN

WORK LT

B

GND L

BAT

STEER SELECT CARLING SWITCH P/N VJD1S00BAZC00-000

7 4 5 6

LIGHT-2

GND L

LIGHT-1

1

A

8

2 3

B

A STEER LIGHT HORN LIGHT

HORN CARLING SWITCH P/N VJD1S00BAZC00-000

C

12V

6

B

IGNITION SWITCH POLLACK P/N 31-610

A

A

B

5 6

C

2 3

GND

4 5

2

4 3

3

REF: TAIL LIGHT HARNESS (9140-3306)

7

1

7

1

TEMP

A

8

G

B

8

PARK BRAKE CARLING SWITCH P/N VDD1B6ABARC00-000

B+

GND

4 IN 1 GAGE BEEDE

BACK-LT STOP-LT TAIL-LT

HOUR METER DATCON P/N 56458-10

WORK LIGHT CARLING SWITCH P/N V1D1S00BAZC00-000

2

MIRROR-LT GND

A B C

FRONT WORK LIGHT (ON CAB)

GND L1 IND LT

WORK LIGHT INDICATOR

FUEL 12 UDC

1

A B

B A

BACK-LT STOP-LT WORK-LT/TAIL-LT

C

DASH PANEL

OIL

N

STOP LT

SW1-86

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START

OTHER CONNECTORS REMOVED FOR CLARITY

PARK BRAKE LIGHT

IG

IGN

IGNITION

4X2

FRONT WORK LIGHT (ON CAB)

C

BAT

OPT3 15A

IG N

OPT1 10A OPT2 15A

START

FAN/HTR 25A

W/W 25A

303 304

4X4 OFF

WL_SWA

SL_SWA

+

LIGHTS 25A

-

ACC

W/W_SW

SPARE_BAT

VOLTS


10

SPARE_BAT 25A

0 16

100

TEMP

LT

KEY 15A HORN 10A

E 240 TEMP

+

GND

AC

OI

30A OPT_PWR

0 0 0 0 0 0

GND DL

80

F

FUEL

T BA

WORK LIGHTS

QUARTZ

GND L

LIGHT-2

D1

87a

85 30

86

87a

86

85 30

WARN LT CK

87a

85 30

AUX ELEC1

86

AUX ELEC2

87a

85 30

OPT

G

GND1 GND2 GND3

LIGHT-1

WL2

WL SWB

87

HTR SW

FAN SW

86

D8

D7

D6

87

87a

85 30

86

87

87a

85 30

86

85 30

86

LIGHTS

W/W

FAN/HTR

87

87a

WORK LT

87a

85 30

C

STOP LT

BACK LT

2

BACK LT

B

BACK LT

A

GND-1

1

GND-1

GND

B

C

STOP LIGHT (RED)

TAIL LIGHT (BLACK)

REAR TAIL LIGHT ASSEMBLY

(25A) W/W

(25A) LIGHTS

(10A) RELAYS

(10A) GAGES

(10A) STEER

(25A) SPARE BAT

(15A) KEY

(10A) HORN

(30A) OPT_PWR

GND AA BAT

SL_SWA

IND LT

(25A) FAN/HTR

GND DL

SPARE_BAT

W/W_SW

DOME LT

DOME LT

WORK LT

STOP LT

A

Y MOTOROLA MR 752 OR EQUIV

WL_SWA

DOME LIGHT SWITCH

STOP SW

ELECTRICAL SCHEMATIC

STOPLT SW

31200255

GROUND (AT STARTER MOTOR)

BACK-UP LIGHT (GREEN)

W X

I

STOP SW

GND-5

ACC

J K L

N

BACK-UP ALARM

GND 1

GND 2

WORK LT

H

M D10

REV AL

PS IGN

GND L

U V

D9

GND-2

6

GND DL

STOP LT

SL SWB

STOP LT

7

DEUTSCH P/N HD-36-24-18-SN

86

(15A) OPT-3

87

GND L

REV ALARM

(15A) OPT-2

OIL GAG

8

3

GND L

85 30

(10A) OPT-1

CLT TMP

9

GND-2

5

GND L1

87a

87

11 10

PS IGN STOP LT

4

OPT-3

86

F

D5

D4

D3 87

87

OPT-2

D2 87

OPT-1

10 OHM 30W R1

CLT TMP OIL GAG

WORK LT

TAIL LT

O P Q R S T

BRK SOL

STOP LT

SPARE_COIL

TR LT SW

12

BACK LT

SW1-87a GND 85

SW2-87a SW2-86

13

BRK SOL

MIRROR-LT

14 TR LT SW

DEUTSCH P/N HD-34-24-18-PN

SWI-86

B

16 15

IND LT

A B C D E

A

18 17

GND L1

WORK LT

LIGHT SW

LIGHT SW

GND L

CAB FIREWALL

TL642

DOME LIGHT

PAL3090

12-17

Before S/N TBK00706

OPTIONS Figure 12-7 Work Light Package Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 101 102 103 104 105 106 107 108 109 110 111 114 115 201 202 203 204 205 206 208 209 210 301 302 303 304 401 402 403

12-18

Part Number

Qty.

299-6670 299-0338 299-0849 298-0528 298-6911 298-1773 298-8045 299-0341 299-0339 298-7376 298-7282 299-0347

1 2 2 1 1 2 2 2 1 3 5 5 AR 1 3 3 2 1 3 AR 1 1 1 1 1 1 1 3 3 1 1 1 AR 1 1 AR 1 2 2 2 2 2 1 1 1 1 1 38” 38”

298-7044 298-1627 298-8066 298-1755 299-0850 298-8744 298-6857 298-6858 299-6654 297-7052 298-7369 298-7383 298-8614 298-7282 299-0347 299-0342 298-7045 298-6866 299-0338 298-8128 299-0341 299-0349 299-0347 298-8001 298-8049 298-8766 298-1761 298-7896 299-0325 298-6860 298-7302 298-7303

Description WORK LIGHT PACKAGE, (includes items 1 thru 304) UTILITY FLOOD LIGHT BULB INTERIOR LIGHT MOUNTING UNIT MOUNTING BOLT SELF TAPPING SCREW, #8-32X3/8 WEATHER PACK SHROUD WEATHER PACK SHROUD LOCKWASHER, #8 MALE PIN TERMINAL CABLE SEAL LOCTITE, #242 LIGHT HARNESS PAN HD SCREW, #8-32X3/8 HEX NUT, #8 SPACER GROMMET, RUBBER ECONOMY WIRING DUCT SILICONE SEALANT, (not shown) TAIL LIGHT HOUSING TAIL LIGHT BRACKET TAIL LIGHT ASSY, (includes items 401 thru 407) HEX HD CAPSCREW, 3/4-10X1-1/4, GR5 FLAT WASHER, 3/4 LOCKWASHER, 3/4 STOPLIGHT MOUNTING TAB MALE PIN TERMINAL CABLE SEAL WEATHER PACK SHROUD TAIL LIGHT HARNESS STOPLIGHT SWITCH LOCTITE, #242 UTILITY FLOOD LIGHT FLOOD LIGHT BRACKET LOCTITE, #242 WEATHER PACK SHROUD FEMALE PIN TERMINAL CABLE SEAL HEX HD CAPSCREW, 3/8-16X2, GR5 HEX NUT, 3/8-16 LOCKWASHER, 3/8 TOGGLE SWITCH WORK LIGHTS DECAL FUSE, 25 AMP RELAY TAIL LIGHT BLACK WIRE, 16 GA. GREEN WIRE, 16 GA.

TL642

Rev. E

31200255

Before S/N TBK00706

OPTIONS Figure 12-7 Work Light Package (Continued) Item

Part Number

Qty.

404 405 406 407

298-7304 298-7306 298-7291 298-6860

38” 3 45” 1

Description

Rev.

RED WIRE, 16 GA. BUTT CONNECTOR WIRE LOOM TAIL LIGHT


31200255

TL642

12-19


OPTIONS Figure 12-7 Work Light Package

15

301 302 303 305 306

11

1 6

12 23

201 202 203 204 205

15

304

15

A

4 14 23

A

17 16

FAN/HTR 25A

W/W 25A

LIGHTS 25A

SL_SWA

SPARE_BAT

FAN_SW HTR_SW

WL2

SL_SWB

WL_SWB

WARN_LT_CK

REV_ALARM

LIGHTS

ACC

OPT3 15A

OPT1 10A OPT2 15A

W/W

OPT3

OPT2

OPT1

GND3

GND2

GND1

FAN/HTR

+


-

4X4

SPARE_BAT 25A

10

WL_SWA

0 16 VOLTS

KEY 15A HORN 10A

100

OPT_PWR 30A

E 240 TEMP

0 0 0 0 0 0

5 7 28

80 OI W/W_SW

F

8

27

26 FUEL

QUARTZ

13

15

307 308 309 310

4X2

2 7

AUX_ELEC1 SW1-86

SW2-87A

SW2-86

AUX_ELEC2 SW1-87A

GND85

OPT SPARE_COIL

VIEW A-A

3

VIEW B-B

18

101 102 103

8 21 22 20

9 25 19 VIEW OF R.H. CONSOLE

10 B

B

12-20

TL642

24 1 4 6 9 14

PAL2714

31200255


OPTIONS Figure 12-7 Work Light Package (Continued)

EMPTY BCN PWR BEACON EMPTY EMPTY EMPTY EMPTY EMPTY

X7 BEACON

1 2

BEACON BCN GND

1 2

CAB LT CAB LT GND

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

X3

WORK LIGHT SWITCH

X2

EMPTY CAB LT PWR CAB LT EMPTY WORK LT PWR WORK LT EMPTY EMPTY

BEACON SWITCH

X5 REAR CAB WORK LIGHT

CAB LT CAB LT GND

1 2

CAB LT CAB LT GND

1 2

FRONT CAB WORK LIGHTS

X6

X4

"SL_SWA" ON CIRCUIT BOARD G6/G9

WORK LT PWR

"OPT1" ON CIRCUIT BOARD G6/G9

BCN PWR

"GND1" ON CIRCUIT BOARD G6/G9

BCN GND

"WL_SWA" ON CIRCUIT BOARD G6/G9

CAB LT PWR

"GND3" ON CIRCUIT BOARD G6/G9

CAB LT GND

"WL_SWB" ON CIRCUIT BOARD G6/G9

PLUG WORK LT PWR BCN PWR PLUG BCN GND CAB LT PWR CAB LT GND WORK LT

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

PLUG WORK LT PWR BCN PWR PLUG BCN GND CAB LT PWR CAB LT GND WORK LT

WORK LT

X2

(6 PLACES)

X1

X1

19

18

REAR WORK LIGHT

X3

17

X1 1 2

WORK LT LT GND

WORK LT LT GND

1 2

WORK LT LT GND

1 2

BOOM WORK LIGHTS

X2

REVERSE STOP LT WORK LT LT GND

A B C D

PLUG PLUG WORK LT LT GND

X4

CURRENT

PAL2720

ENGINE HARNESS G6/G9

31200255

TL642

12-21


OPTIONS Figure 12-7 Work Light Package Item 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 28 101 102 103 201 202 203 204 205 301 302 303 304 305 306 307

12-22

Part Number

Qty.

305-3789 303-4735 08T-8919 304-2569 298-0548 298-0557 298-7363 298-7367 315-2027 299-0849 298-7971 303-4914 303-4924 303-4961 303-4925 298-7378 298-7281 304-4551 304-4552 303-4915 303-4916 303-4923 297-7052 298-7369

1 5 2 1 5 2 8 4 3 3 4 1 2 2 1 5 AR 1 1 1 1 1 1 1 AR 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 4 2 1 1 1 1 1 3

317-5987 297-7031 299-0325 80694009 298-7382 303-4969 323-7236 299-0338 299-0849 303-4969 323-7236 299-0338 299-0849 298-1755 298-1773 304-2571 303-4971 303-4972 299-0338 299-0849 299-0398 298-6910 303-4927 332-1348

Description WORK LIGHT PACKAGE, (includes items 1 thru 28) HEX HD CAPSCREW, 1/4-20X7/8, GR5 HEX HD CAPSCREW, 1/2-13X1-3/4, GR5 BOOM LIGHT MOUNTING BRACKET HEX NUT, 1/4-20 HEX NUT, 1/2-13 FLAT WASHER, 1/4 FLAT WASHER, 1/2 UTILITY FLOOD LIGHT, (includes items 101 thru 103) BULB CLAMP BOOM WORK LIGHTS HARNESS FLOOD LIGHT ASSEMBLY, (includes items 201 thru 205) KEEPER BEACON/FLOODLIGHT INSTALLATION, (includes items 301 thru 310) LOCKWASHER, 1/4 WIRING DUCT WORK LIGHTS SWITCH BEACON SWITCH WORK LIGHTS CAB HARNESS WORK LIGHTS HARNESS BACKUP LIGHT MOUNTING BRACKET HEX HD CAPSCREW, 3/4-10X1-1/4, GR5 WASHER, 3/4 SILICON SEALANT CLIP HEX HD CAPSCREW, 3/8-16X1, GR5 RELAY FUSE LOCKWASHER, 1/2 PIN TERMINAL 2 POSITION TERMINAL UTILITY FLOOD LIGHT BULB PIN TERMINAL 2 POSITION TERMINAL UTILITY FLOOD LIGHT BULB SPACER WORK LIGHT MOUNTING BOLT BEACON BRACKET PIN TERMINAL 2 POSITION TERMINAL UTILITY FLOOD LIGHT BULB ROTATING BEACON BULB GROMMET INDENTED HEX HEAD MACHINE SCREW, #10-24X0.75

TL642

Rev. E

B

B C

A, 1

A, 1

A, 1

31200255


OPTIONS Figure 12-7 Work Light Package (Continued) Item

Part Number

Qty.

308 309 310

298-0546 5W-8686 298-7377

3 3 3

Description

Rev.

NUT, #10-24 GR2 WASHER, #10 LOCKWASHER, #10


31200255

TL642

12-23

OPTIONS Figure 12-8 Beacon Light Package

12 13 14

15

15

4 5 6 11 7

15 15

1 2 3 4 5 6

TO BEACON SWITCH IN DASH

TO CIRCUIT BOARD

16

104

101

BEACON

FUEL

QUARTZ

F

80 OIL

E 240 TEMP

0 0 0 0 0 0

0 16 VOLTS 10

100

-

+

ALT

4X4

START

ACC

RUN

OFF

LOW BRAKE FLUID

4X2

IGNITION

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START

87 TERM 3 BEACON SW

GND L1

TERM 2 BEACON-1

IND LT

86 BEACON 10 AMP FUSE

12+

BATT 85

LIGHT AT SWITCH

30 AMP FUSE

LT

D

+

IND LT

GR

GND TEMP

GND L

AC C

T BA

ST

BAT

ELECTRICAL SCHEMATIC (299-6617)

IG N

N IG

GND L1

FUEL

BEACON-1

OIL

30

87A

RELAY PWR

BEACON SWITCH 2

3

BEACON SW

BEACON (ON CAB)

IGN

OPT1 10A OPT2 15A

ACC

WL2

OPT1

KEY 15A HORN 10A


SPARE_BAT 25A

W/W 25A

LIGHTS 25A

GND1

12-24

SL_SWA

GND L

SPARE_BAT

BEACON-1

PAL3100

A

106 B

TO BEACON

WL_SWA

OPT3 15A

OPT

FAN_SW

FAN/HTR 25A W/W_SW

103 105

SPARE_COIL

OPT3

LIGHTS

W/W

GND85

AUX_ELEC2

OPT2

SW1-87A

GND2

SW2-86

GND3

WL_SWB

SW2-87A

AUX_ELEC1

HTR_SW

SL_SWB

FAN/HTR

WARN_LT_CK

OPT_PWR 30A

SW1-86

REV_ALARM

TL642

31200255

OPTIONS Figure 12-8 Beacon Light Package Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 101 103 104 105 106

Part Number

Qty.

299-6617 299-0398 298-6910 298-8248 299-0360 298-8039 298-7377 298-8067 297-7012 298-7372 298-7378 298-8047 299-0850 299-0341 298-7282 299-0346 298-7281 298-7100 298-8766 299-0325 298-1771 298-7848 298-7850

1 1 1 1 1 3 3 3 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1

Description BEACON LIGHT PACKAGE, (includes all items) ROTATING BEACON BULB BEACON BRACKET RUBBER GROMMET ROUND HD MACHINE SCREW, #10-24X3/4 LOCKWASHER, #10 HEX NUT, #10-24 HEX HD CAPSCREW, 1/4-20X1, GR5 FLAT WASHER, 1/4 LOCKWASHER, 1/4 HEX NUT, 1/4-20 RUBBER GROMMET WEATHER PACK, (shroud) WEATHER PACK, (male pin terminal) WEATHER PACK, (cable seal) ECONOMY WIRING DUCT, 79” BEACON HARNESS TOGGLE SWITCH RELAY DECAL BEACON 10 AMP FUSE 30 AMP FUSE

Rev. A, 2


31200255

TL642

12-25

OPTIONS Figure 12-9 Road Lights Installation

24 9 4 8 10 14 16

9 4 8 10 14 16

23

25

VIEW A-A

1 4 8 10 16

4 8 10 14 16

A

2 5 9 1 USE EXISTING HARDWARE TO MOUNT CLAMP ON FAR SIDE OF FRAME. ROUTE HARNESS THRU THIS CLAMP

A

4 8 10 16 27

4 8 10 13 16

4 8 10 16 26

3 9 28

4 8 10 16

29

PAL3240

TAIL LIGHT VIEW

12-26

TL642

31200255

OPTIONS Figure 12-9 Road Lights Installation (Continued)

12

VIEW OF STEERING COLUMN

22 15 7 11 21 20

LOWER DASH

HAZARD LIGHTS

19

BEACON LIGHT WORK LIGHTS

FUEL

QUARTZ

F

80 OI

E 240 TEMP

0 0 0 0 0 0

0 16 VOLTS 10

100

-

+

4X4

4X2

30

31

OPT SPARE_COIL

ACC

LIGHTS

AUX_ELEC2 GND85

SW1-87A

W/W

WARN_LT_CK

AUX_ELEC1 SW2-86

SW2-87A

FAN/HTR

SL_SWB

WL2

HTR_SW

FAN_SW

25A W/W

25A FAN/HTR

W/W_SW

25A LIGHTS

WL_SWA

10A STEER 10A GAUGES 10A RELAYS

25A SPARE_BAT

SL_SWA

WL_SWB

GND3

GND2

GND1

OPT3

OPT2

15A OPT2 10A OPT1

15A OPT3

OPT1

30A OPT_PWR 10A HORN 15A KEY

SPARE_BAT

REV_ALARM

SW1-86

CONNECT TO CURRENT CHASSIS/BOOM HARNESS CONNECT TO WORK LIGHT BOOM HARNESS

1 6 17

18 USE BRAKE VALVE TO ATTACH TAB MOUNTING SCREW PAL3250

31200255

TL642

12-27

OPTIONS Figure 12-9 Road Lights Installation (Continued)

A B C D

X7

PLUG PLUG WORK LT LT GND

REVERSE PLUG WORK LT LT GND

X6

A B C D

REVERSE STOP LT WORK LT LT GND

CURRENT ENGINE HARNESS TL6/TL9

20

X4

X2 LOW

TAIL 1 2 3 4 5 6

BACK LEFT TAIL LIGHT TURN

GND2 LO BEAM HI BEAM PARK LT LT TURN PLUG

GND1 PARK LT REVERSE LT TURN STOP LT PLUG

1 2 3 4 5 6

HIGH LEFT HEAD LIGHT SIDE

LOW

1 2 3 4 5 6 7 8

X1

GND1 GND2 STOP LT RT TURN LT TURN PARK LT LO BEAM HI BEAM

TURN STOP

1 2 3 4 5 6

BACK RIGHT TAIL LIGHT TURN

STOP

GND1 PARK LT REVERSE RT TURN STOP LT PLUG

X1

GND2 LO BEAM HI BEAM PARK LT RT TURN PLUG

GND1 GND2 STOP LT RT TURN LT TURN PARK LT LO BEAM HI BEAM

TAIL

X5 15A BAT PWR PLUG HI BEAM PLUG LO BEAM PARK LT PLUG 15A OPT 2 LT TURN RT TURN FLASHER OUT PLUG

X5

21

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6

HIGH RIGHT HEAD LIGHT SIDE

X3

FLASH PWR NC

TURN

HIGH HD NC LOW HD SIDE LT

HEADLIGHT/TURN SIGNAL SWITCH

NC LIGHT PWR LEFT RIGHT TURN PWR NC

P EMPTY FLASHER PWR EMPTY FLASHER OUT EMPTY

X P L

15A OPT 2 FLASHER PWR 15A BAT PWR EMPTY FLASHER OUT EMPTY LT TURN RT TURN EMPTY GND1

1 2 3 4 5 6 7 8 9 10

FLASHER

FLASHER

X3 BRAKE PEDAL SWITCH

STOP LT 15A BAT PWR

X8

L

X

FLASHER

HAZARD SWITCH

X6 15A FUSE "GND2" ON CIRCUIT BOARD TL6/TL9

15A OPT 2

"OPT2" ON CIRCUIT BOARD TL6/TL9

15A OPT 2 GND

X2

15A OPT 2 15A OPT 2 GND

A B

15A OPT 2 GND2

X1 (2 PLACES)

X4 15A BAT PWR

SP BAT PWR

X2 GND1

X7

12-28

TL642

(2 PLACES)

"SPARE_BAT" ON CIRCUIT BOARD TL6/TL9;

"GND1" ON CIRCUIT BOARD TL6/TL9;

PAL3260

31200255

OPTIONS Figure 12-9 Road Lights Installation Item 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

31200255

Part Number

Qty.

305-3790 324-9527 297-7044 303-4740 298-0546 298-0559 324-9528 303-4973 298-7362 298-7375 298-7377 303-4979 303-4980 324-9529 324-9530 298-7289 324-9531 298-6866 298-8614 304-2594 303-4917 303-4918 303-4922 315-5795 315-5797 346-2985 305-5467 315-5798 346-2985 305-5467 315-5799 346-2985 305-5467 315-5800 346-2985 305-5467 315-5802 315-5806 299-0325 298-7896

1 4 2 1 27 2 2 1 30 7 27 1 1 2 4 1 27 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1

Description ROAD LIGHTS INSTALLATION, (includes all tiems) CLAMP, 1/2 HEX HD CAPSCREW, 1/2-13X2-1/4, GR5, (torque to 75 lb-ft) HEX HD CAPSCREW, 1/2-13X2-3/4, GR5, (torque to 80 lb-ft) HEX NUT, 10-24 HEX LOCKNUT, 1/2-13 TAP SCREW FASTON TERMINAL FLAT WASHER, #10 FLAT WASHER, 1/2 LOCKWASHER, #10 CONNECT TERMINAL, MALE TURN SIGNAL SELECTOR REFLECTOR, RED REFLECTOR, YELLOW VARIABLE LOAD FLASHER SOCKET BUTTON HD CAPSCREW, #10-24X3/4 STOPLIGHT SWITCH MOUNTING TAB SWITCH ROAD LIGHTS FRAME HARNESS ROAD LIGHTS CAB HARNESS ROAD LIGHTS HARNESS FRONT ROAD LIGHTS BRACKET FRONT ROAD LIGHTS, RH, (torque to 50 lb-ft) CONNECTOR LOCK CONNECTOR FRONT ROAD LIGHTS, LH, (torque to 50 lb-ft) CONNECTOR LOCK CONNECTOR TAIL LIGHT, RH CONNECTOR LOCK CONNECTOR TAIL LIGHT, LH CONNECTOR LOCK CONNECTOR TAIL LIGHT BRACKET TAIL LIGHT COVER RELAY FUSE, 25A

TL642

Rev. B

12-29

Before S/N TBK00706

OPTIONS Figure 12-10 Boom Lights Installation

A

6

6

VIEW A-A A

4 5 9

2 5

3

1 4 5 7

8

1 4 5 7

7 11

REPLACE EXISTING SCREW AND USE EXISTING WASHER TO MOUNT CLAMP

10 1 4 5 7

ROUTE WIRE HARNESS

THRU EXISTING CLAMPS AS SHOWN PAL3271

BOOM HARNESS ROUTING

12-30

TL642

31200255

Before S/N TBK00706

OPTIONS Figure 12-10 Boom Lights Installation Item 1 2 3 4 5 6

7 8

9

10 11

Part Number

Qty.

315-2025 303-4735 297-7033 315-2026 298-8049 298-7365 315-2027 303-4969 323-7236 299-0338 299-0849 298-7971 315-2024 299-0343

1 3 2 1 5 10 2 2 1 1 1 4 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1

299-0348 299-0350 304-2606 305-5449 315-2023 357-6165 299-0349 299-0342 298-7282 305-2115 299-0346 317-5987 297-7031

Description BOOM LIGHTS INSTALLATION, (Includes all items) HEX HD CAPSCREW, 1/4-20X7/8, GR5 HEX HD CAPSCREW, 3/8-16X1.5, GR5 BOOM LIGHT MOUNTING BRACKET HEX NUT, 3/8-16 GR5 FLAT WASHER, 1/4 UTILITY FLOOD LIGHT TERMINAL TERMINAL, RECEPTACLE FLOOD LIGHT BULB CLAMP, 1/2 WIRE, BOOM LIGHTS CONNECTOR TERMINAL SEAL PLUG CONNECTOR LOCK WIRE, JUMPER HARNESS CONNECTOR TERMINAL SEAL SHROUD TERMINAL CONNECTOR SEAL CLIP TUBE .75” HEX HD CAPSCREW, 3/8-16X1, GR5

Rev. A


31200255

TL642

12-31

OPTIONS Figure 12-11 Skylight Wiper Assembly

104

107 105

103 101

109 108 102 106 107

2 3 4 5

PAL3330

12-32

TL642

31200255

OPTIONS Figure 12-11 Skylight Wiper Assembly Item 1 2 3 4 5

101 102 103 104 105 106 107 108 109

Part Number

Qty.

314-8489

1 A/R 1 A/R 53” 1 1 1 1 1 1 1 1 1 1 1 1

343-7820 298-7281 314-7754 304-2606 305-5449 339-0837 339-1711 339-1712 320-0525 320-0529 339-1713 339-1714 343-7819 325-1068

Description SKYLIGHT WIPER ASSY, (includes items 1 thru 5) LOCTITE, #242 SKYLIGHT WIPER MOTOR ASSY, (includes items 101 thru 109) SEALANT WIRING DUCT WIPER MOTOR JUMPER HARNESS HOUSING LOCK FLAT WASHER, 1/4 FLAT WASHER, 1/4 NUT, #10-24 WIPER ARM WIPER BLADE HEX BOLT, #10-24X3/4 WIPER COVER WIPER MOTOR HARNESS

Rev. B


31200255

TL642

12-33

Before S/N TBK00854

OPTIONS Figure 12-12 Cold Weather Package

POWER CORD FROM ENGINE BLOCK HEATER

ATTACH TO ENGINE POD FRAME (NOT SHOWN FOR CLARITY)

5 6

1

4

PLUG END CONNECTS TO OPERATOR SUPPLIED 120V POWER SOURCE

3 2

115

201

107

PLUG FROM ENGINE BLOCK HEATER PLUG FROM BATTERY HEATER PAL3400

12-34

TL642

31200255

Before S/N TBK00854

OPTIONS Figure 12-12 Cold Weather Package Item 1 2 3 4 5 6 107 115

201 301

Part Number

Qty.

311-0680

1 1 1 1 1 A/R 6 2 1

COLD WEATHER PACKAGE, (includes items 1 thru 6) 3-WAY EXTENSION CORD BATTERY HEATER DECAL ENGINE BLOCK HEATER DECAL HEATER CORD DECAL 11” WIRE TIE CABLE TIE MOUNT TERMINAL HOLD DOWN STUD, 11-1/2 BATTERY INSULATE

A

1 1 Ref

BATTERY HEATER INSTALLATION, (includes item 201) BATTERY HEATER BLOCK HEATER INSTALLATION, (not shown), (see Figure 12-1 for details)

A

345-1922 344-7176 344-7179 346-2986 335-8093 346-4742 311-0684 311-0685 311-0679

Description

Rev.


31200255

TL642

12-35


OPTIONS

Figure 12-13 Arctic Package 107

102

5 6

101

104 106

103 105

2 1

3

4 PAL5320

12-36

TL642

31200255


OPTIONS

Figure 12-13 Arctic Package Item 1 2 3 4 5 6 101 102 103 104 105 106 107 201

Part Number

Qty.

331-4682 331-4674 331-4665

Ref 1 1 1 2 1 2 2 1 1 1 1 2 2 Ref

331-4659 331-4658 324-7945 300-6103 300-6078 300-6079 300-6084 298-0496 299-0471

Description ARTIC PACKAGE, (includes items 1 thru 6) STARTER MOTOR, 2400 AMP, 4.2kw HEATER, SILICONE LAMINATE OIL PAN HEATER EXTENSION CORD, 3 WAY TILT RECIRCULATION INSTALLATION, (includes items 101 thru 107) HOSE ADAPTER, 90 DEG. ADAPTER QUICK DISCONNECT COUPLING, FEMALE QUICK DISCONNECT COUPLING, MALE DUST PLUG ADAPTER DUST CAP BLOCK HEATER INSTALLATION, (not shown), (see Figure 12-1 for details)

Rev. A

B

D


31200255

TL642

12-37


OPTIONS Figure 12-13 Arctic Package

5

2 9 10 11 7 1

201 204 207

6

202 203

104 105 106

201 205 206 101

208

102

103

PAL5630

12-38

TL642

31200255


OPTIONS Figure 12-13 Arctic Package

Item

Part Number

Qty. 1

1 2 3 4 5 6 7 8 9 10 11 101 102 103 104 105 106 201 202 203 204 205 206 207 208

1 331-4674 331-4665

359-9986

8T-4196 8T-4133 331-4656 311-0679 298-6925 331-7310 298-0553 299-0471 298-0496 324-7945 300-6078 300-6079 300-6103 300-6084 331-4658

1 1 1 1 1 1 2 2 2 2 2 2 2 1 2 2 2 2 2 1 1 1 1 2

Description ARTIC PACKAGE INSTALL, (not available to order, see items 1 thru 11 for service) ARTIC BATTERIES INSTALL, (not available to order, see items 101 thru 106 for service) STARTER MOTER, 2400AMP 4.2KW ARCTIC TILT RECIRCULATION INSTALL HEATER OIL PAN HEATER POSITIVE CABLE NEGATIVE CABLE 3 WAY EXTENSION CORD, (not shown) STARTER ADAPTER PLATE HEX HD CAPSCREW, M10X1.5X35 HEX NUT, M10X1.5 BATTERY BATTERY HEATER BATTERY BASE INSULATION BATTERY HOLD DOWN BRACKET HOLD DOWN STUD HEX NUT, 5/16-18, GR2 ADAPTER, 90 DEGREES, (includes o-ring) ADAPTER, TEE, (includes 0-ring) ADAPTER, (includes o-ring) FEMALE COUPLING MALE COUPLING DUST CAP DUST PLUG HOSE ASSY

Rev. A


31200255

TL642

12-39

OPTIONS Figure 12-14 Top Cab Glass Shield

11

3 6 8

3 7 9 10

12

1 2 4 5

PY1270

12-40

TL642

31200255

OPTIONS Figure 12-14 Top Cab Glass Shield Item 1 2 3 4 5 6 7 8 9 10 11 12

31200255

Part Number

Qty.

328-1546 297-7031 303-4774 303-4961 298-7365 298-7380 298-7382

1 2 2 4 4 2 2 A/R 2 2 2 1 Ref

298-8050 298-1755 315-3424 328-1545

Description TOP CAB GLASS SHIELD, (includes all items) HEX HD CAPSCREW, 3/8-16X1 HEX NUT, 3/8-16 GR8 SHIM WASHER, 3/8 LOCK WASHER, 3/8 LOCK WASHER, 1/2 SILICONE SEALANT HEX NUT, 1/2-13 SPACER BOLT, 1/2-13 HOLLOW SHIELD HARNESS, CAB WORK LIGHT, (see Figure 10-8 for details)

TL642

Rev. A

12-41

OPTIONS Figure 12-15 Front Cab Glass Shield

8

2

4

1 3 5 9 1 6 7 10

PY1280

12-42

TL642

31200255

OPTIONS Figure 12-15 Front Cab Glass Shield Item 1 2 3 4 5 6 7 8 9 10

31200255

Part Number

Qty.

328-1547 303-4961 317-0090 298-7382 298-7840 298-8050 298-1755 315-3424 328-1544

1 4 1 2 4 2 2 2 1 Ref A/R

Description FRONT CAB GLASS SHIELD, (includes all items) SHIM TAPE LOCK WASHER, 1/2 WHIZ LOCK SCREW, 5/16-18X.625 HEX NUT, 1/2-13 SPACER BOLT, 1/2-13 HOLLOW SHIELD HARNESS, CAB WORK LIGHT, (see Figure 10-8 for details) SILICONE SEALANT

TL642

Rev. A

12-43

OPTIONS Figure 12-16 Hydraulic Cooler Bypass Install

8 11 10 5

7

6

9 5

PAL5020

12-44

TL642

31200255

OPTIONS Figure 12-16 Hydraulic Cooler Bypass Install Item

Part Number

Qty.

5 6 7 8 9 10 11

340-0961 298-0476 309-6332 340-0977 340-0978 340-0979 340-0985 340-0986

1 2 1 1 1 1 1 1

31200255

Description HYDRAULIC COOLER BYPASS INSTALL, (includes all items) FITTING, 90 DEGREE, (includes o-ring) CHECK VALVE HYDRAULIC COOLER HOSE ASSY TANK RETURN HOSE ASSY HYDRAULIC BYPASS COOLER INLET TUBE BYPASS HOSE ASSY HYDRAULIC BYPASS COOLER OUTLET TUBE

TL642

Rev. A

12-45

OPTIONS Figure 12-17 Beacon Light Mount w/AC

1

5 3 4

2

PAL5200

12-46

TL642

31200255

OPTIONS Figure 12-17 Beacon Light Mount w/AC Item

Part Number

Qty.

1 2 3 4 5

323-0971 332-1348 298-0546 5W-8686 298-7377 323-0972

1 3 3 3 3 1

31200255

Description BEACON LIGHT MOUNT W/AC, (includes items 1 thru 5) INDENTED MACHINE HD CAPSCREW, #10-24X3/4 HEX NUT, #10-24 WASHER, #10 LOCKWASHER, #10 BEACON MOUNT PLATE

TL642

Rev. A

12-47

OPTIONS


12-48

TL642

31200255

SECTION 13 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. Part Number

Description

298-1466 298-1465 298-7246 298-7073 298-7074 298-7075 298-7076 298-8208 298-8209 298-1787 298-1788 298-1726 298-1727 298-1789 298-1790 298-1734 298-1735 298-1736 298-1737 299-0493 298-1728 298-1729 298-1730 298-1731 298-1732 298-1733 298-8579 298-8724 299-0305

BOOM ASSEMBLY Tilt Cyl Hose, (see Figure 8-8) Boom Hose, (see Figure 8-8) Hose Sheave, (see Figure 2-3) Bearing Pad, (see Section 2) Bearing Pad, (see Section 2) Bearing Pad, (see Section 2) Bearing Pad, (see Section 2) Bearing Pad, (see Section 2) Bearing Pad, (see Section 2) Shim, .0598, (see Section 2) Shim, .0359, (see Section 2) Shim, .0598, (see Section 2) Shim, .0359, (see Section 2) Shim, .0598, (see Section 2) Shim, .0359, (see Section 2) Shim, .0598, (see Section 2) Shim, .0359, (see Section 2) Shim, .0598, (see Section 2) Shim, .0359, (see Section 2) Spacer, .1875, (see Section 2) Spacer, .0598, (see Section 2) Spacer, .0598, (see Section 2) Spacer, .0598, (see Section 2) Spacer, .0598, (see Section 2) Spacer, .0598, (see Section 2) Spacer, .0598, (see Section 2) Bearing Pad, Push Beam, (see Figure 2-5) Quick Coupler Pin, (see Figure 2-8) Quick Release Pin, (see Figure 2-8)

298-7224 103-5916 9L0895 130-1161

ENGINE Fuel Tank Cap, (see Figure 4-5) Fan, (see Figure 4-4) Alternator Belt, (see Section 4) Dipstick, (see Section 4)

299-0562 298-8164 303-8573 299-0227 303-8574 303-8584

DRIVE TRAIN FNR Shifter, 4-Speed, (see Figure 7-2) Accelerator Cable, (see Figure 7-1) Wheel End Seal, (see Section 5) Wheel End Bushing, (see Section 5) Wheel Hub Seal, (see Section 5) Universal Joint Kit, (see Figure 5-21)

31200255

Qty./Machine 2 2 1 10 4 4 2 4 4 AR AR AR AR AR AR AR AR AR AR 2 10 4 4 2 4 2 1 1 1

1 1 1 1

1 1 4 4 2 4

TL642

13-1

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

Description

298-8585 299-0970 299-0501 313-2471 299-0495 304-2627 299-0496 108-1153 299-0379 298-8587 299-0310 299-0376 303-8617

HYDRAULIC SYSTEMS Boom Joystick Assy w/Tilt, (see Figure 7-4) Boom Joystick Handle Assy, (see Figure 7-4) Lift Cyl Seal Kit, (see Figure 9-1) Extend/Retract Cyl Seal Kit, (see Figure 9-2) Tilt Cyl Seal Kit, (see Figure 9-3) Comp Cyl Seal Kit, (see Figure 9-4) Sway Cyl Seal Kit, (see Figure 9-5) Hydraulic Filter Element, (see Figure 9-8) Tank Filter, (see Figure 9-8) Tank Filter, (see Figure 9-8) Breather, (see Figure 9-8) Fluid Level Gauge, (see Figure 9-8) Bar Gauge, (see Figure 9-8)

303-4827 298-8412 299-0390 310-7936 299-0326 298-7293 333-2415 303-4891 268-3633 298-6870 268-3633 329-0290 303-4891 339-7766

ELECTRICAL Engine Temp. Sensor, (see Figure 4-2) Transmission Temp Switch, (see Figure 4-2) Oil Press Sender, (see Figure 4-1) Fuel Level Sender, (see Figure 4-5) Starter Relay, (see Figure 4-1) Backup Alarm, (see Figure 1-1) Ignition Switch, (see Figure 6-4) Alternator, (see Figure 4-4) Starter, (see Figure 4-4) Horn, (see Figure 1-1) Starter, (see Figure 4-4), (Before S/N TBK01051) Starter, (see Figure 4-4), (S/N TBK01051 & After) Alternator, (see Figure 4-4), (Before S/N TBK01051) Alternator, (see Figure 4-4), (S/N TBK01051 & After)

1001008686 304-4563 31200247 31200292 31200255

13-2

MISC Key Battery Disconnect Key Owner/Operator Manual Service Manual Parts Manual

Qty./Machine 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

1 1 1 1 1

TL642

31200255


31200255

Description

TL642

Qty./Machine

13-3


13-4

Description

TL642

Qty./Machine

31200255

SECTION 14 PART NUMBER INDEX PART NUMBER INDEX Part Number

Page

1001100284 ................... 5-50 1001100323 ................... 5-49 1001120963CP .............. 5-49 1001121519CP .............. 5-49 103 ................................. 4-15 103-5916 ........................ 4-13 108-1153 ........................ 9-27 108-1153 ........................ 9-27 124-7702 ........................ 4-13 130-1161 ........................ 4-13 175-4390 ........................ 10-3 176-1477 .............10-8, 10-21 196-2412 .............10-8, 10-21 196-2413 .............10-8, 10-21 1R1804........................... 4-13 206-5234 ........................ 4-23 206-5234 ........................ 4-23 206-5235 ........................ 4-23 206-5235 ........................ 4-23 230 ................................. 4-15 254-2267 ........................ 4-13 267-9572 ...................... 10-21 268-0867 ........................ 4-13 268-3633 ........................ 4-13 284-4636 ........................ 4-13 285 ................................. 4-15 295-3419 ........................ 9-39 297-7008 ...................6-4, 6-7 297-7009 ...................6-4, 6-9 297-7010 ...................6-3, 6-7 297-7010 ........................ 3-13 297-7011 .......................... 4-3 297-7011 .......................... 1-9 297-7012 ... 6-3, 6-4, 6-7, 6-9, 8-15, 8-17, 8-27, 8-29, 12-25 297-7012 .......................... 7-3 297-7013 .................6-8, 8-15 297-7013 .......................... 8-3 297-7014 .................6-3, 8-19 297-7016 4-21, 6-3, 6-7, 8-13 297-7017 . 6-4, 6-7, 6-9, 8-29, 8-31 297-7018 ..........4-23, 6-4, 6-7 297-7019 ........................ 8-31 297-7020 ........................ 2-21 297-7021 4-19, 6-3, 6-7, 6-22, 6-25, 8-9, 8-13, 8-31 297-7022 .......................... 8-7 297-7024 ...................... 12-15 297-7025 ........................ 8-29 297-7026 ...................... 12-15 297-7029 ........................ 4-23 297-7029 ..........2-3, 2-13, 7-5 297-7030 .....4-19, 6-25, 8-23, 8-25, 10-13 297-7030 .................2-5, 2-13 297-7031 .....4-17, 6-7, 12-22,

31200255

Part Number

Page

12-31, 12-41 297-7031............ 1-8, 7-5, 7-7 297-7032 4-10, 4-17, 6-7, 8-5, 9-35 297-7032................... 1-4, 1-9 297-7033...................... 12-31 297-7033.......................... 3-9 297-7036........................ 1-13 297-7038.......................... 2-9 297-7039. 6-4, 6-9, 9-27, 9-29 297-7039....... 1-13, 2-5, 2-17, 2-19, 2-21 297-7040.......................... 1-5 297-7041.......................... 2-3 297-7044...................... 12-29 297-7045........................ 4-21 297-7047.......................... 2-7 297-7048.......................... 4-4 297-7052........... 12-18, 12-22 297-7056.......... 2-5, 2-9, 2-15 297-7057................... 2-5, 2-9 297-7060................. 2-9, 2-13 297-7061.......................... 2-9 297-7066.......................... 2-9 297-7067.......................... 2-9 297-7068.......................... 2-9 297-7069........ 2-5, 2-10, 2-15 297-7070................. 2-5, 2-10 297-7076............ 8-5, 8-7, 8-9 297-7077 9-3, 9-5, 9-11, 9-13, 9-15 297-7077.......................... 3-9 297-7084.......................... 1-5 297-7088.......................... 1-8 297-7097........................ 4-10 297-7098.......................... 4-3 297-7099.......................... 6-8 297-7100.......................... 6-8 298 .......................... 2-5, 4-15 298-0400........................ 10-8 298-0402.......................... 4-4 298-0403.......................... 7-5 298-0404........................ 10-3 298-0405........................ 10-3 298-0406........................ 10-3 298-0407........................ 2-21 298-0409................... 8-7, 8-9 298-0410.......................... 8-3 298-0411.......................... 8-7 298-0412.......................... 8-7 298-0413........................ 2-21 298-0414........................ 2-21 298-0416........................ 2-21 298-0418........................ 4-23 298-0419.......................... 4-4 298-0421........................ 4-19 298-0422........................ 4-27 298-0423........................ 4-19 298-0425.......................... 4-4

Part Number

Page

298-0426 ........................ 4-27 298-0434 ...................... 10-13 298-0435 ........................ 4-23 298-0439 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-0440 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-0441 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-0442 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-0443 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-0444 ...............4-37, 4-39 298-0445 ...............4-37, 4-39 298-0446 ...............4-37, 4-39 298-0447 ...............4-37, 4-39 298-0448 ...............4-37, 4-39 298-0449 ...............4-37, 4-39 298-0450 ...............4-37, 4-39 298-0451 ........................ 4-53 298-0452 ........................ 4-53 298-0453 ........................ 4-53 298-0454 ........................ 4-53 298-0455 ........................ 4-53 298-0456 ........................ 4-53 298-0462 ........................ 8-27 298-0463 ........................ 8-23 298-0463 ...................7-5, 8-3 298-0464 ...............8-23, 8-25 298-0465 ........................ 8-31 298-0466 ...............8-19, 8-21 298-0466 ........................ 2-21 298-0467 ...................4-4, 8-9 298-0468 4-19, 4-21, 8-7, 8-9, 8-11, 8-31 298-0468 .......................... 8-3 298-0469 ........................ 8-31 298-0469 .......................... 8-3 298-0471 .................2-21, 7-5 298-0473 .... 8-11, 8-15, 8-17, 9-27 298-0473 .......................... 8-3 298-0474 5-3, 5-5, 5-25, 8-11, 8-23, 9-27 298-0474 .......................... 3-7 298-0475 .......................... 3-7 298-0476 .............4-19, 12-45 298-0477 ........................ 4-19 298-0486 ........................ 9-27 298-0489 ..... 8-17, 8-23, 8-29 298-0489 .......................... 8-3 298-0490 ........................ 8-23 298-0492 ........................ 8-15 298-0493 ........................ 8-29 298-0496 ...... 5-3, 5-5, 12-37, 12-39 298-0496 .......................... 8-3 298-0497 ........................ 8-23

TL642

Part Number

Page

298-0497 .......................... 3-7 298-0498 5-3, 5-5, 5-25, 8-15, 8-29 298-0501 ............... 8-23, 8-25 298-0502 ........................ 8-13 298-0504 ............... 8-23, 8-25 298-0506 ........................ 8-25 298-05075-3, 8-23, 8-27, 8-29 298-0507 ................... 3-9, 7-7 298-0515 ........................ 9-27 298-0516 .......................... 4-3 298-0517 .......................... 4-3 298-0518 ........................ 9-27 298-0519 ............... 8-23, 8-25 298-0522 ........................ 8-11 298-0522 .......................... 7-7 298-0525 ........................ 8-15 298-0526 ..........4-4, 4-7, 4-19 298-0528 ...................... 12-18 298-0529 .......................... 6-4 298-0530 ......4-23, 4-27, 4-29 298-0532 ................... 4-3, 4-9 298-0541 ............... 4-19, 8-11 298-0541 ........................ 1-13 298-0544 .......................... 6-8 298-0546 ...6-7, 12-23, 12-29, 12-47 298-0547 .......................... 6-8 298-0548 ............... 6-8, 12-22 298-0548 ........................ 3-13 298-0549 ........ 6-9, 8-29, 10-5 298-0549 .......................... 1-9 298-0551 ................... 1-4, 1-5 298-0552 ................... 6-3, 6-7 298-0553 ...................... 12-39 298-0555 ........................ 6-25 298-0557 ............. 4-21, 12-22 298-0559 ............... 4-4, 12-29 298-0565 ...................... 12-15 298-0565 .......................... 1-9 298-0570 .......................... 1-9 298-0573 ........................ 6-25 298-0574 ........................ 1-13 298-0576 ...................... 11-11 298-1358 ........................ 2-21 298-1359 ..........6-3, 6-7, 6-25 298-1360 ................... 1-5, 1-8 298-1362 ................... 6-4, 6-8 298-1365 ........................ 9-21 298-1366 ........................ 8-17 298-1367 ................... 8-7, 8-9 298-1368 ........................ 8-23 298-1369 ........................ 8-23 298-1370 ........ 6-8, 9-27, 9-29 298-1371 ........................ 8-13 298-1372 ........................ 8-17 298-1373 ........................ 8-17 298-1374 ........................ 8-17 298-1375 ........................ 8-17

14-1

PART NUMBER INDEX Part Number

Page

298-1378 ........................ 8-15 298-1378 .......................... 8-3 298-1379 .......................... 8-3 298-1380 ........................ 8-23 298-1381 ................... 8-7, 8-9 298-1383 ........................ 8-27 298-1384 .......................... 8-3 298-1385 ........................ 8-23 298-1386 ........................ 8-23 298-1387 ........................ 8-17 298-1388 ........................ 8-21 298-1389 ........................ 8-19 298-1393 .......................... 5-5 298-1394 ..........5-3, 5-5, 5-25 298-1395 ........................ 8-15 298-1397 .......................... 5-3 298-1398 ............... 8-15, 8-23 298-1400 ........................ 8-21 298-1403 ........................ 8-31 298-1403 .......................... 8-3 298-1404 .......................... 8-3 298-1405 .......................... 8-3 298-1406 ........................ 8-15 298-1407 ........................ 8-25 298-1408 ........................ 8-25 298-1411 ................... 8-7, 8-9 298-1414 ........................ 8-23 298-1415 ........................ 8-27 298-1416 ........................ 8-27 298-1418 ........................ 8-23 298-1423 ........................ 8-19 298-1465 ............... 8-23, 8-25 298-1466 ........................ 8-23 298-1467 ........................ 8-25 298-1468 ........................ 8-25 298-1469 ........................ 8-21 298-1470 ........................ 8-21 298-1471 ........................ 8-23 298-1472 ........................ 8-23 298-1473 ........................ 8-25 298-1474 ........................ 8-25 298-1499 ........................ 8-31 298-1540 ........................ 4-17 298-1541 ........................ 4-13 298-1578 ...................... 12-15 298-1579 .......................... 1-4 298-1581 ........................ 8-19 298-1581 .......................... 7-3 298-1586 ............1-4, 7-3, 7-7 298-1596 ........................ 8-13 298-1597 ........................ 8-19 298-1598 .......................... 9-3 298-1599 .......................... 8-3 298-1606 .......................... 8-3 298-1609 ................... 1-5, 1-9 298-1610 ..........5-3, 5-5, 5-25 298-1610 .......................... 7-7 298-1612 ........................ 8-19 298-1612 1-13, 2-3, 2-7, 2-17,

14-2

Part Number

Page

2-19, 2-21, 3-9 298-1615 ................ 2-9, 2-15 298-1626 ......... 2-5, 2-9, 2-15 298-1627 ......................12-18 298-1628 .. 1-4, 2-5, 2-9, 2-15 298-1629 ......... 2-5, 2-9, 2-15 298-1630 ..........................3-7 298-1631 ................ 1-8, 1-11 298-1632 ......... 5-3, 5-5, 5-25 298-1633 ....... 4-3, 6-22, 6-25 298-1634 ..........................7-3 298-1643 .................. 6-3, 6-7 298-1645 ........................9-41 298-1646 ..........................9-3 298-1647 ................ 9-7, 9-11 298-1650 ........................2-17 298-1651 ........................2-17 298-1656 .............. 8-23, 8-25 298-1657 ........................8-21 298-1660 ..........................3-7 298-1663 ....... 9-3, 9-11, 9-17 298-1666 ..........................4-3 298-1674 ........................4-19 298-1675 ........................9-17 298-1682 ....... 9-3, 9-11, 9-17 298-1683 ..........................7-5 298-1684 ........................4-23 298-1689 ......... 2-5, 2-9, 2-15 298-1694 ..........................6-7 298-1694 ........................11-9 298-1695 ....... 6-8, 9-27, 9-29 298-1696 ........................4-23 298-1697 ........................4-23 298-1726 .................. 2-5, 2-9 298-1727 .................. 2-5, 2-9 298-1728 .................. 2-5, 2-9 298-1729 ................ 2-5, 2-10 298-1730 ................ 2-9, 2-15 298-1731 ........................2-15 298-1732 .................. 2-5, 2-9 298-1733 ................ 2-9, 2-15 298-1734 ........................2-15 298-1735 ................ 2-9, 2-15 298-1736 ..........................2-5 298-1737 ..........................2-5 298-1738 .................. 6-3, 6-7 298-1739 ........................2-17 298-1740 .................. 1-4, 1-8 298-1741 ........................8-25 298-1741 ..........................2-7 298-1742 ........................8-25 298-1742 ..........................2-7 298-1744 ........................5-49 298-1746 .................. 1-4, 1-8 298-1750 ..........................1-4 298-1751 ........................1-11 298-1753 ..........................7-3 298-1754 ..........................2-3 298-175512-18, 12-22, 12-41,

Part Number

Page

12-43 298-1755 .......................... 1-5 298-1758 ........................ 4-27 298-1761 ...................... 12-18 298-1766 .......................... 9-7 298-1770 .. 6-3, 6-4, 6-8, 6-22 298-1771 ...................... 12-25 298-1772 ................... 6-3, 6-7 298-1773 ........... 12-18, 12-22 298-1781 .......................... 2-3 298-1786 .......................... 2-3 298-1787 ................... 2-5, 2-9 298-1788 ................... 2-5, 2-9 298-1789 ................. 2-9, 2-15 298-1790 .......................... 2-9 298-1791 ........................ 5-47 298-1792 ........................ 8-19 298-1793 ..........5-3, 5-5, 5-25 298-1794 ........................ 9-31 298-1796 ........................ 9-31 298-1797 ........................ 9-31 298-1799 ................. 5-9, 5-29 298-1800 ............... 5-11, 5-31 298-1801 ............... 5-13, 5-33 298-1802 ............... 5-13, 5-33 298-1803 ............... 5-13, 5-33 298-1804 ............... 5-13, 5-33 298-1805 ............... 5-13, 5-33 298-1806 ............... 5-13, 5-33 298-1807 ............... 5-13, 5-33 298-1808 ............... 5-13, 5-33 298-1809 ............... 5-13, 5-33 298-1810 ............... 5-13, 5-33 298-1811 ............... 5-13, 5-33 298-1812 ............... 5-13, 5-33 298-1813 ............... 5-15, 5-35 298-1814 ........................ 5-15 298-1815 ........................ 5-19 298-1816 ........................ 5-19 298-1817 ............... 5-19, 5-39 298-1819 ............... 5-19, 5-39 298-1820 ........................ 5-19 298-1821 ........................ 5-19 298-1822 ........................ 5-19 298-1825 ............... 5-21, 5-43 298-1844 ........................ 11-9 298-1849 ...................... 12-15 298-1853 ................. 5-9, 5-29 298-1854 ................. 5-9, 5-29 298-18575-9, 5-11, 5-29, 5-31 298-1860 ............... 5-11, 5-31 298-1861 ............... 5-11, 5-31 298-1862 ............... 5-11, 5-31 298-1863 ........................ 5-31 298-1865 .....5-11, 5-15, 5-31, 5-35 298-1877 ............... 5-17, 5-37 298-1878 ......5-19, 5-39, 5-41 298-1879 ......5-19, 5-39, 5-41

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298-1881...... 5-19, 5-39, 5-41 298-1883............... 5-19, 5-39 298-6830........................ 8-25 298-6830.......................... 2-7 298-6831............... 9-17, 9-19 298-6832.......................... 3-7 298-6833........ 4-19, 6-7, 6-22 298-6843................. 6-8, 6-22 298-6844........................ 9-41 298-6849........................ 1-13 298-6850........................ 10-3 298-6852.......................... 7-3 298-6857...................... 12-18 298-6858...................... 12-18 298-6860........... 12-18, 12-19 298-6862.......................... 2-7 298-6865................... 5-3, 5-5 298-6866........... 12-18, 12-29 298-6868........................ 8-15 298-6868.......................... 8-3 298-6870................... 1-4, 1-9 298-6891........................ 1-13 298-6906........................ 9-41 298-6907........................ 6-17 298-6909........................ 9-41 298-6910........... 12-22, 12-25 298-6911...................... 12-18 298-6920........................ 2-17 298-6921........................ 2-17 298-6922.......................... 2-3 298-6924.......................... 2-9 298-6925............. 10-3, 12-39 298-7010.......................... 7-3 298-7011.......................... 2-7 298-7012........................ 8-25 298-7013................. 6-8, 6-22 298-7014.......................... 2-5 298-7015.......................... 2-5 298-7016........................ 2-13 298-7017.......................... 6-4 298-7018.......................... 9-7 298-7019........................ 9-11 298-7022........................ 2-17 298-7023.......................... 2-7 298-7024........................ 8-25 298-7026................... 9-7, 9-9 298-7027.......................... 2-3 298-7028........................ 2-17 298-7030................... 1-4, 1-8 298-7031.......................... 2-3 298-7032........................ 2-17 298-7034............... 9-17, 9-19 298-7035............... 9-17, 9-19 298-7036.......................... 6-7 298-7037........................ 4-23 298-7039.......................... 6-3 298-7041........................ 6-22 298-7044...................... 12-18 298-7045...................... 12-18

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298-7047 ...................... 10-13 298-7048 ........................ 6-17 298-7050 .......................... 6-4 298-7051 ........................ 6-22 298-7052 ........................ 6-22 298-7053 ........................ 6-22 298-7055 .......................... 3-7 298-7057 ...............2-19, 2-21 298-7063 ........................ 2-13 298-7064 .......................... 7-3 298-7065 .......................... 7-3 298-7066 ...............4-27, 4-29 298-7067 ........................ 8-25 298-7067 .......................... 2-7 298-7068 .................8-5, 8-23 298-7069 .......................... 2-7 298-7070 ...................... 10-13 298-7071 .......................... 7-3 298-7072 ...................... 10-13 298-7073 .......................... 2-9 298-7074 .................2-9, 2-15 298-7075 ...................2-5, 2-9 298-7076 ........................ 2-15 298-7077 ........................ 6-22 298-7079 ...............6-3, 10-15 298-7082 .......................... 7-9 298-7091 ........................ 6-17 298-7092 ........................ 6-17 298-7093 ........................ 6-17 298-7095 ........................ 6-28 298-7098 ........................ 6-22 298-7099 ...................... 12-11 298-7100 ...................... 12-25 298-7101 .......................... 6-4 298-7102 ........................ 6-22 298-7105 ...................6-3, 6-9 298-7106 ........................ 2-17 298-7107 ........................ 2-17 298-7108 .......................... 2-7 298-7221 ...................... 10-13 298-7222 ...............6-16, 6-17 298-7224 ........................ 4-17 298-7225 ........................ 6-12 298-7228 ........................ 2-21 298-7229 ........................ 4-23 298-7233 ......4-41, 4-43, 4-47 298-7234 ........................ 4-53 298-7235 ......4-35, 4-49, 4-57 298-7237 ........................ 4-35 298-7238 ........................ 4-41 298-7239 ......4-35, 4-53, 4-55 298-7240 ........................ 4-53 298-7241 ........................ 4-53 298-7243 ........................ 4-17 298-7246 ........................ 8-25 298-7246 .......................... 2-7 298-7247 ........................ 9-25 298-7249 .................5-3, 8-21 298-7250 .......................... 7-3

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298-7251........................ 4-17 298-7252...................... 10-19 298-7254........................ 4-17 298-7256........................ 4-35 298-7257........................ 4-35 298-7258........................ 4-35 298-7259........................ 4-35 298-7260........................ 4-35 298-7261........................ 4-55 298-7262........................ 6-22 298-7263........................ 6-22 298-7268............. 6-19, 10-21 298-7269...................... 10-21 298-7274............... 5-21, 5-43 298-7275.......................... 7-3 298-7277........................ 6-22 298-7278........................ 6-28 298-7281 12-22, 12-25, 12-33 298-7282..... 6-8, 6-22, 10-17, 10-21, 12-18, 12-25, 12-31 298-7283................. 6-8, 6-22 298-7285................. 6-8, 6-22 298-7286.......................... 6-4 298-7289...................... 12-29 298-7290........................ 6-22 298-7291...................... 12-19 298-7292................... 6-4, 6-8 298-7293................... 1-4, 1-9 298-7294........................ 9-25 298-7296........................ 6-22 298-7297........................ 4-19 298-7298........................ 8-19 298-7302...................... 12-18 298-7303...................... 12-18 298-7304...................... 12-19 298-7305........................ 8-19 298-7306...................... 12-19 298-7308...................... 10-15 298-7310.......................... 8-3 298-7311........................ 5-49 298-7312........................ 2-17 298-7314................... 9-7, 9-9 298-7318.......................... 2-7 298-7319.......................... 6-8 298-7342........................ 4-21 298-7343........................ 4-23 298-7344........................ 4-51 298-7345........................ 4-57 298-7346............... 4-35, 4-55 298-7347............... 4-35, 4-55 298-7348...... 4-41, 4-43, 4-47 298-7349........................ 4-35 298-7350........................ 4-57 298-7351........................ 4-53 298-7352........................ 4-55 298-7354........................ 4-53 298-7355........................ 2-21 298-7356........................ 8-29

Part Number

Page

298-7356 .................2-21, 8-3 298-7357 ........................ 8-23 298-7358 .... 8-17, 8-23, 8-27, 8-31, 9-27, 9-41 298-7358 .......................... 3-9 298-7360 ........... 8-5, 8-7, 8-9 298-7362 ....... 6-4, 6-7, 12-29 298-7363 . 6-4, 6-7, 6-9, 8-29, 10-5, 12-22 298-7363 ......... 1-5, 1-9, 3-13 298-7364 ...... 4-3, 4-19, 4-21, 4-23, 6-4, 6-7, 6-9, 8-13, 8-29, 12-15 298-7364 .......................... 7-3 298-7365 4-7, 4-9, 6-25, 8-23, 8-25, 12-31, 12-41 298-7365 . 1-8, 1-9, 2-13, 3-7, 7-3, 11-11 298-7367 6-4, 6-9, 9-27, 9-29, 12-22 298-7367 ...................2-3, 2-9 298-7368 .......................... 4-3 298-7368 .......................... 2-3 298-7369 ...........12-18, 12-22 298-7371 .......................... 6-8 298-7372 ... 6-3, 6-4, 6-7, 6-9, 6-22, 8-15, 8-17, 8-19, 8-27, 12-25 298-7372 .................1-9, 3-13 298-7373 4-19, 6-4, 6-7, 9-22, 12-15 298-7373 ........... 1-5, 7-3, 7-7 298-7374 .... 4-17, 4-19, 4-23, 4-27, 6-8, 6-25, 10-13 298-7374 .... 1-4, 1-8, 1-9, 2-3 298-7375 ..... 4-4, 4-21, 12-29 298-7375 ...................1-5, 2-7 298-7376 ...................... 12-18 298-7377 .. 6-7, 12-23, 12-25, 12-29, 12-47 298-7378 ... 4-3, 6-3, 6-4, 6-9, 6-22, 8-5, 8-17, 8-23, 8-27, 12-22, 12-25 298-7378 .......................... 1-8 298-7379 . 4-23, 6-4, 6-7, 6-9, 8-13 298-7379 ...................1-9, 3-7 298-7380 .... 4-10, 4-17, 4-19, 4-23, 6-7, 6-25, 8-5, 8-23, 9-35, 9-41, 12-41 298-7380 . 1-9, 2-3, 2-7, 2-13, 7-5 298-7381 ........... 8-5, 8-7, 8-9

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298-7382 ...9-27, 9-29, 12-13, 12-15, 12-22, 12-41, 12-43 298-7382 .1-5, 1-13, 2-7, 2-17 298-7383 ...................... 12-18 298-7385 ...................... 10-15 298-7387 ................... 4-3, 4-7 298-7388 ..........4-3, 4-7, 4-27 298-7388 .......................... 7-7 298-7389 ................... 4-3, 4-7 298-7392 ..4-4, 4-10, 9-3, 9-5, 9-11, 9-13, 9-15 298-7392 .......................... 3-9 298-7395 .......................... 1-9 298-7407 .......................... 9-3 298-7410 ........................ 4-33 298-7411 ........................ 4-33 298-7412 .....4-37, 4-39, 4-41, 4-43, 4-45, 4-47 298-7413 ........................ 4-45 298-7414 ........................ 4-49 298-7415 ........................ 4-51 298-7416 ........................ 4-51 298-7417 ........................ 4-53 298-7418 ........................ 4-55 298-7419 ........................ 4-55 298-7430 ............... 5-19, 5-39 298-7435 .......................... 8-7 298-7436 ................. 8-9, 8-31 298-7437 ............. 8-19, 10-13 298-7437 ........................ 2-21 298-74386-4, 8-23, 8-25, 8-31 298-7439 .....8-15, 8-19, 8-23, 8-25, 10-13 298-7440 ...................... 10-13 298-7833 ............... 8-15, 8-27 298-7834 ......6-22, 6-25, 8-13 298-7835 ........................ 6-25 298-7837 ........................ 6-25 298-7838 ........................ 8-15 298-7839 ............. 8-15, 10-13 298-7840 ............. 4-19, 12-43 298-7840 ................... 1-4, 1-9 298-7841 .....4-19, 4-21, 4-23, 10-3 2987-8429...................... 1-13 298-7844 ........................ 6-22 298-7845 .......................... 1-4 298-7846 ........................ 6-25 298-7848 ........... 10-13, 12-25 298-7849 ...................... 10-15 298-7850 ........... 10-15, 12-25 298-7853 ........................ 10-3 298-7854 ........................ 4-23 298-7855 ........................ 4-25 298-7867 ........................ 5-19 298-7868 ........................ 5-31 298-7870 ........................ 5-19 298-7873 ......5-19, 5-39, 5-41

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298-7875 ................... 1-4, 1-9 298-7876 ......4-35, 4-53, 4-55 298-7877 ......4-35, 4-49, 4-55 298-7880 ................... 6-3, 6-7 298-7881 ........................ 4-35 298-7884 ........................ 4-21 298-7890 .......................... 4-4 298-7892 ........................ 8-13 298-7896 ..6-22, 12-18, 12-29 298-7897 .......................... 1-4 298-7900 .......................... 1-9 298-7901 ...................... 11-11 298-7902 ...................... 11-11 298-7913 ................... 1-4, 1-9 298-7916 .......................... 3-7 298-7918 .......................... 3-7 298-7919 .......................... 3-7 298-7922 ...................... 12-13 298-7922 .......................... 1-8 298-7925 .......................... 2-3 298-7926 .......................... 8-3 298-7931 ........................ 6-22 298-7971 ........... 12-22, 12-31 298-7974 .......................... 4-4 298-7976 ................... 1-4, 1-5 298-7977 ................. 6-8, 6-22 298-7980 ................. 4-9, 4-17 298-7981 ........................ 4-19 298-7983 .......................... 8-3 298-7988 ........................ 8-27 298-7990 .......................... 1-4 298-7991 ................... 1-4, 7-3 298-7992 ........................ 4-19 298-7993 ................... 7-3, 7-7 298-7995 .......................... 3-7 298-8001 ...................... 12-18 298-8002 ........................ 9-41 298-8003 .......................... 2-7 298-8009 .......................... 2-3 298-8011 .......................... 1-5 298-8012 .......................... 2-9 298-8013 ................. 2-9, 2-15 298-8014 ........................ 2-15 298-8015 ................... 2-5, 2-9 298-8016 .......................... 2-5 298-8019 .......................... 2-9 298-8020 .......................... 2-9 298-8021 ........................ 2-15 298-8022 ........................ 6-22 298-8023 ................. 8-5, 8-23 298-8024 .......................... 7-3 298-8030 ........................ 8-25 298-8030 .......................... 2-7 298-8031 .......................... 7-3 298-8032 ........................ 6-22 298-8034 ................... 1-5, 1-9 298-8037 ........................ 2-15 298-8038 ........................ 2-15 298-8039 ...................... 12-25

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Page

298-8041 .................. 6-3, 6-7 298-8042 ........................4-17 298-8043 .................. 6-3, 6-9 298-8045 ......................12-18 298-8047 . 6-3, 6-4, 8-5, 8-23, 12-25 298-8048 ..........................1-4 298-8049 .. 8-23, 8-25, 12-18, 12-31 298-8049 .... 1-4, 1-8, 3-7, 7-3 298-8050 .......... 12-41, 12-43 298-8050 ..........................1-5 298-8051 ..........................3-7 298-8052 .. 1-4, 1-5, 1-8, 1-11 298-8053 .................. 1-4, 1-8 298-8059 ..........................2-3 298-8062 ........................2-17 298-8063 ..........................2-3 298-8066 ......................12-18 298-8067 ............ 8-25, 12-25 298-8067 ..........................2-7 298-8068 ..........................6-8 298-8069 ..........................6-8 298-8070 ..........................2-3 298-8114 ........................9-15 298-8115 ..........................9-3 298-8118 ........................4-19 298-8119 ..........................1-4 298-8121 ........................4-19 298-8122 ........................4-23 298-8124 ..........................1-4 298-8126 ..........................1-4 298-8127 ......... 5-3, 5-5, 5-25 298-8128 ......................12-18 298-8131 ......... 9-3, 9-5, 9-15 298-8133 ..........................6-4 298-8135 ........................9-27 298-8137 ........................9-17 298-8138 ..........................5-7 298-8139 ........................5-27 298-8140 .................. 1-5, 1-9 298-8141 ..........................6-3 298-8143 ........................4-23 298-8145 ........................4-27 298-8147 ........................6-19 298-8149 ..........................6-3 298-8152 .............. 6-3, 10-15 298-8156 ........................4-27 298-8157 ........................8-27 298-8164 ..........................7-3 298-8167 .................. 9-3, 9-5 298-8170 ........................9-35 298-8175 ........................9-31 298-8178 ................ 5-9, 5-29 298-8179 ................ 5-9, 5-29 298-8181 ........................5-13 298-8182 .............. 5-15, 5-35 298-8186 ........................5-19 298-8187 ........................5-19

Part Number

Page

298-8188 ........................ 5-19 298-8189 ............... 5-19, 5-39 298-8191 ......5-19, 5-39, 5-41 298-8192 ......5-19, 5-39, 5-41 298-8193 ............... 5-21, 5-43 298-8194 ............... 5-21, 5-43 298-8195 ............... 5-21, 5-43 298-8196 ............... 5-21, 5-43 298-8197 ............... 5-21, 5-43 298-8198 ............... 5-21, 5-43 298-8200 ........................ 5-33 298-8201 ........................ 9-17 298-8205 .......................... 1-4 298-8208 ................... 2-5, 2-9 298-8209 ................. 2-9, 2-15 298-8243 ........................ 4-23 298-8244 .......................... 7-7 298-8248 ...................... 12-25 298-8250 ........................ 4-17 298-8257 ........................ 2-17 298-8267 .......................... 1-5 298-8280 .......................... 7-7 298-8285 ...................... 10-17 298-8287 ........................ 9-15 298-8290 ...................... 12-15 298-8297 ............... 5-21, 5-43 298-8300 ............... 5-23, 5-45 298-8302 ........................ 9-31 298-8303 ........................ 9-31 298-8313 ........................ 6-28 298-8314 ........................ 6-29 298-8317 ........................ 6-28 298-8378 .......................... 6-8 298-8379 .......................... 4-4 298-8380 .......................... 4-4 298-8410 ................... 4-3, 4-9 298-8412 ................... 4-3, 4-9 298-8426 .......................... 6-8 298-8430 ........................ 1-13 298-8431 ........................ 1-13 298-8435 .......................... 4-4 298-8438 ........................ 11-8 298-8576 .......................... 2-7 298-8578 .......................... 2-3 298-8579 ........................ 2-13 298-8580 ........................ 4-19 298-8581 ................... 1-4, 1-8 298-8583 ........................ 2-17 298-8584 ........................ 6-22 298-8585 .......................... 7-9 298-8587 ........................ 9-27 298-8588 ............... 9-27, 9-29 298-8589 ........................ 6-22 298-8590 ................. 6-8, 6-22 298-8592 .......................... 7-3 298-8593 .......................... 7-3 298-8596 ........................ 12-5 298-8598 ........................ 4-19 298-8599 ........................ 5-47

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298-8603........................ 4-19 298-8604...................... 12-15 298-8605........................ 4-19 298-8608.......................... 6-3 298-8609.......................... 6-3 298-8612.......................... 1-4 298-8614........... 12-18, 12-29 298-8637.......................... 7-5 298-8644.......................... 6-3 298-8668........................ 9-29 298-8669........................ 6-15 298-8673.......................... 6-8 298-8716........................ 8-23 298-8722........................ 6-15 298-8724........................ 2-19 298-8728........................ 4-23 298-8729........................ 4-23 298-8732.......................... 4-4 298-8733.......................... 4-4 298-8734............... 2-19, 2-21 298-8737.......................... 4-7 298-8738.......................... 4-7 298-8739........................ 4-19 298-8740.......................... 4-7 298-8743...................... 11-11 298-8744...................... 12-18 298-8745.......................... 7-5 298-8760........................ 8-25 298-8761................... 6-3, 6-7 298-8766........... 12-18, 12-25 298-8767........................ 2-17 298-8774.......................... 7-3 298-8777.......................... 1-4 298-8780........................ 5-49 298-8781........................ 5-50 298-8782...... 9-11, 9-13, 9-15 298-8783................... 5-3, 5-5 298-8789........................ 4-27 298-8790.......................... 7-3 298-8791...................... 12-15 298-8792...................... 12-15 299........................ 4-15, 4-25 299-0187.......................... 9-3 299-0188.......................... 9-3 299-0191........................ 9-31 299-0192........................ 9-31 299-0193........................ 9-31 299-0194........................ 9-31 299-0195........................ 5-29 299-0196................. 5-9, 5-29 299-0197................. 5-9, 5-29 299-0199................. 5-9, 5-29 299-0201........................ 5-11 299-0202........................ 5-11 299-0205............... 5-23, 5-45 299-0206............... 5-23, 5-45 299-0207............... 5-23, 5-45 299-0208.......................... 7-7 299-0209.......................... 7-9

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299-0210 .................7-9, 7-11 299-0223 ...............5-11, 5-31 299-0227 ......5-17, 5-31, 5-37 299-0228 ...............5-11, 5-31 299-0235 ...............5-17, 5-37 299-0236 ...............5-17, 5-37 299-0240 ......5-19, 5-39, 5-41 299-0241 ......5-19, 5-39, 5-41 299-0253 ........................ 5-11 299-0271 .......................... 4-3 299-0277 ........................ 1-13 299-0278 ........................ 1-13 299-0285 ........................ 2-21 299-0303 .......................... 4-7 299-0304 ........................ 4-27 299-0305 ........................ 2-19 299-0308 ........................ 2-21 299-0309 .......................... 4-3 299-0310 ........6-8, 9-27, 9-29 299-0312 .............10-8, 10-21 299-0316 ........................ 5-47 299-0317 ........................ 5-47 299-0321 ........................ 4-31 299-0322 ........................ 9-35 299-0324 ...................... 10-15 299-0325 ...6-17, 6-22, 10-13, 10-15, 12-18, 12-22, 12-25, 12-29 299-0326 .......................... 4-3 299-0327 ........................ 6-25 299-0328 ........................ 6-22 299-0330 .......................... 1-4 299-0331 ........................ 6-22 299-0333 ........................ 6-22 299-0338 12-18, 12-22, 12-31 299-0339 10-17, 10-21, 12-18 299-0340 .............10-8, 10-21 299-0341 .....6-8, 6-22, 10-17, 12-18, 12-25 299-0342 ...........12-18, 12-31 299-0343 ...........10-21, 12-31 299-0346 .......6-8, 6-22, 10-8, 10-17, 10-21, 12-25, 12-31 299-0347 ...........10-17, 12-18 299-0348 ...........10-21, 12-31 299-0349 .10-8, 10-21, 12-18, 12-31 299-0350 ...........10-21, 12-31 299-0352 ........................ 4-23 299-0353 ........................ 4-19 299-0354 ........................ 11-9 299-0355 ............8-5, 8-7, 8-9 299-0359 ........................ 4-55 299-0360 ...................... 12-25 299-0361 ...................... 12-13 299-0361 .......................... 1-8 299-0362 .......................... 3-7

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Part Number

Page

299-0363........................ 6-17 299-0369................... 6-3, 6-7 299-0370.......................... 6-8 299-0373............... 4-19, 4-21 299-0376........................ 9-27 299-0378.......................... 4-3 299-0379........................ 9-27 299-0383........................ 8-27 299-0387.......................... 1-5 299-0390.......................... 4-4 299-0392............... 4-27, 4-29 299-0395................... 6-3, 6-7 299-0396........................ 9-41 299-0398........... 12-22, 12-25 299-0400........................ 4-17 299-0401........................ 2-13 299-0402................... 1-4, 1-9 299-0468........................ 4-49 299-0469........................ 4-35 299-0470........................ 4-57 299-0471.. 8-23, 12-37, 12-39 299-0479........................ 4-31 299-0493.......................... 2-9 299-0495........................ 9-11 299-0496........................ 9-17 299-0498.......................... 7-9 299-0499.......... 9-3, 9-7, 9-11 299-0501.......................... 9-3 299-0505........................ 9-35 299-0506........................ 9-35 299-0508............... 5-13, 5-33 299-0511........................ 5-15 299-0520............... 5-17, 5-37 299-0523........................ 9-43 299-0544...................... 12-15 299-0546...................... 12-15 299-0557........................ 4-25 299-0558........................ 7-11 299-0559........................ 7-11 299-0560.......................... 7-5 299-0562.......................... 6-7 299-0562.......................... 7-5 299-0591........................ 4-57 299-0592........................ 4-33 299-0593........................ 4-33 299-0594..... 4-37, 4-39, 4-41, 4-43, 4-47 299-0595........................ 4-41 299-0596............... 4-41, 4-49 299-0597........................ 4-43 299-0598..... 4-37, 4-39, 4-43, 4-47 299-0599............... 4-37, 4-39 299-0600............... 4-37, 4-39 299-0601........................ 4-45 299-0602............... 4-37, 4-39 299-0603........................ 4-47 299-0604...... 4-37, 4-39, 4-47 299-0605............... 4-37, 4-39

Part Number

Page

299-0606 ........................ 4-53 299-0635 ........................ 7-11 299-0636 ........................ 7-11 299-0637 ........................ 4-33 299-0638 ........................ 4-33 299-0639 ........................ 4-33 299-0640 ........................ 4-37 299-0641 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 299-0642 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 299-0643 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 299-0644 ........................ 4-39 299-0645 ........................ 4-43 299-0646 ........................ 4-45 299-0647 ........................ 4-45 299-0650 ..... 4-45, 4-49, 4-57 299-0651 ........................ 4-47 299-0652 ........................ 4-49 299-0653 ........................ 4-49 299-0654 ........................ 4-49 299-0655 ........................ 4-49 299-0656 ........................ 4-51 299-0657 ........................ 4-51 299-0658 ........................ 4-51 299-0659 ........................ 4-51 299-0660 ........................ 4-51 299-0661 ........................ 4-53 299-0662 ........................ 4-53 299-0663 ........................ 4-53 299-0780 ........................ 8-23 299-0788 ........................ 5-15 299-0789 ........................ 5-15 299-0790 .................5-9, 5-29 299-0793 .................5-9, 5-29 299-0794 .................5-9, 5-29 299-0795 ...............5-11, 5-31 299-0796 ...............5-11, 5-31 299-0797 ...............5-23, 5-45 299-0808 ...............5-11, 5-31 299-0813 ...............5-23, 5-45 299-08215-9, 5-17, 5-29, 5-37 299-0827 ...............5-17, 5-37 299-0834 .......................... 7-9 299-0835 ........................ 4-45 299-0836 ........................ 4-33 299-0839 ...............4-51, 4-53 299-0840 ........................ 4-51 299-0841 .... 4-37, 4-39, 4-41, 4-43, 4-45, 4-47 299-0842 ........................ 4-23 299-0849 12-18, 12-22, 12-31 299-0850 ...........12-18, 12-25 299-0851 ........................ 9-11 299-0852 ........................ 9-41 299-0853 .......................... 2-7 299-0855 .......................... 9-7 299-0856 ........................ 9-11

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Page

299-0857 ........................ 9-11 299-0858 ........................ 9-11 299-0859 ........................ 9-11 299-0860 ........................ 6-17 299-0861 ............... 9-11, 9-17 299-0863 .......................... 9-3 299-0864 .......................... 9-3 299-0896 ........................ 4-35 299-0897 ........................ 4-51 299-0898 ........................ 4-53 299-0899 ........................ 4-33 299-0900 ........................ 4-55 299-0908 ........................ 10-8 299-0912 ........................ 4-19 299-0913 .......................... 7-5 299-0915 ........................ 7-11 299-0916 ........................ 7-11 299-0917 ........................ 7-11 299-0918 ........................ 4-33 299-0919 ........................ 4-53 299-0920 ........................ 4-55 299-0921 ........................ 6-15 299-0922 ........................ 6-15 299-0924 ........................ 6-15 299-0925 ........................ 6-15 299-0927 ........................ 6-15 299-0928 ........................ 6-15 299-0944 ........................ 10-8 299-0947 .......................... 8-7 299-0949 ....... 6-22, 6-25, 8-9, 8-13, 8-31 299-0953 .......................... 7-9 299-0954 .......................... 7-9 299-0956 ...................... 10-21 299-0957 ...................... 10-21 299-0958 ...................... 10-21 299-0959 ...................... 10-21 299-0960 ................. 7-9, 7-11 299-0966 .......................... 7-9 299-0967 .......................... 7-9 299-0970 .......................... 7-9 299-0972 ............... 6-23, 6-28 299-0976 ........................ 7-11 299-0985 ........................ 9-31 299-1286 ........................ 8-25 299-1297 ...................... 10-13 299-1323 ........................ 9-41 299-1337 ........................ 5-25 299-1338 .......................... 5-3 299-1339 .......................... 7-5 299-1340 ........................ 4-17 299-1344 ........................ 4-23 299-1345 ........................ 4-23 299-1349 ........................ 2-21 299-1350 ........................ 4-19 299-1351 ........................ 2-21 299-1352 .......................... 6-8 299-6615 ........................ 9-27 299-6616 ........................ 6-23

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299-6617 ........... 12-24, 12-25 299-6620 ......4-41, 4-43, 4-47 299-6621 ........................ 4-53 299-6623 ................... 6-4, 6-9 299-6623 ........................ 2-21 299-6624 ........................ 2-21 299-6629 ...................... 10-21 299-6632 .......................... 7-5 299-6633 ........................ 4-25 299-6634 ........................ 4-25 299-6635 ........................ 4-51 299-6636 ........................ 4-53 299-6637 ........................ 6-15 299-6639 ............... 5-21, 5-43 299-6644 .......6-4, 8-15, 8-19, 8-23, 8-25, 8-31, 10-13 299-6644 ........................ 2-21 299-6645 ............. 8-15, 10-13 299-6646 ........................ 6-22 299-6648 ........................ 12-3 299-6654 ...................... 12-18 299-6659 ........................ 8-25 299-6669 .......................... 7-3 299-6670 ...................... 12-18 299-6673 ...................... 12-15 299-6693 .......................... 6-9 299-7086 ........................ 4-57 299-7090 ........................ 4-35 299-7091 ........................ 4-35 299-7092 ........................ 4-51 299-7096 ........................ 10-8 299-7099 ........................ 4-23 299-7103 .......5-9, 5-11, 5-19, 5-29, 5-31, 5-39, 5-41 299-7106 ........................ 10-8 299-7116 ........................ 9-41 299-7118 .......................... 2-9 299-7122 .......................... 7-9 299-7130 ........................ 9-31 299-7131 ........................ 9-31 299-7132 ........................ 6-17 299-7134 ................. 5-9, 5-29 299-7136 ............... 5-11, 5-31 299-7137 ............... 5-11, 5-31 299-7138 ............... 5-13, 5-33 299-7139 ............... 5-13, 5-33 299-7140 ............... 5-17, 5-37 299-7141 ............... 5-19, 5-39 299-7142 ........................ 5-19 299-7144 ........................ 7-11 299-7148 ........................ 6-12 299-7161 ................. 5-9, 5-29 299-7165 ............... 5-19, 5-39 299-71705-9, 5-23, 5-29, 5-45 299-7178 ........................ 6-28 299-7179 ........................ 6-28 299-7180 ........................ 6-28

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Part Number

Page

299-7181 ........................6-29 299-7182 ........................6-28 299-7184 ........................6-28 2Y-6141 .................... 1-5, 1-8 300....................................2-7 300-6073 ........................2-17 300-6074 ............ 6-25, 10-15 300-6074 ..........................1-9 300-6078 . 8-25, 12-37, 12-39 300-6078 2-19, 2-21, 3-7, 3-9 300-6079 . 8-25, 12-37, 12-39 300-6079 2-19, 2-21, 3-7, 3-9 300-6082 .................. 4-3, 4-7 300-6084 . 8-25, 12-37, 12-39 300-6084 .............. 2-19, 2-21 300-6092 ......................10-13 300-6094 ........................8-25 300-6095 ........................8-25 300-6095 .............. 2-19, 2-21 300-6099 ........................8-11 300-6099 ..........................7-7 300-6101 ..........................6-9 300-6103 . 8-25, 12-37, 12-39 300-6103 .............. 2-19, 2-21 300-6104 ..........................7-7 300-6114 ..........................1-4 301-9752 ..........................3-5 301-9753 ..........................3-5 301-9754 ..........................3-5 301-9755 ..........................3-5 301-9756 ..........................3-5 301-9757 ..........................3-3 301-9758 ..........................3-3 302-0581 ..........................4-7 303-4735 .......... 12-22, 12-31 303-4737 ..........................3-7 303-4740 ......................12-29 303-4741 .................. 3-3, 3-9 303-4742 ..........................4-3 303-4743 ..........................4-3 303-4743 ........................2-13 303-4744 .................. 1-4, 1-8 303-4745 ..........................7-7 303-4749 ........................10-5 303-4751 ..........................1-8 303-4752 ......................10-11 303-4753 ..........................4-3 303-4754 ........................8-27 303-4755 ..........................3-7 303-4756 ........................8-31 303-4757 ..........................4-9 303-4758 ................ 4-4, 8-11 303-4759 ........................4-21 303-4761 ........................4-21 303-4762 ........................8-11 303-4769 ..........................4-3 303-4770 ..........................8-3 303-4774 .............. 4-3, 12-41 303-4776 ..........................4-3

Part Number

Page

303-4777 .......................... 4-7 303-4779 ................... 1-5, 1-9 303-4782 ................... 3-3, 3-9 303-4785 .......................... 4-3 303-4787 .......................... 4-7 303-4789 .......................... 4-3 303-4790 .......................... 4-3 303-4792 .......................... 4-4 303-4795 ............... 6-25, 10-3 303-4798 ................... 1-4, 7-7 303-4799 .......................... 1-8 303-4802 ........................ 8-13 303-4803 ........................ 8-13 303-4804 ........................ 8-13 303-4805 ........................ 4-17 303-4807 ........................ 6-23 303-4808 ........................ 9-27 303-4819 ........................ 11-9 303-4821 .......................... 4-4 303-4826 .......................... 4-4 303-4827 .......................... 4-7 303-4828 ........................ 10-5 303-4829 ........................ 10-5 303-4831 ........................ 10-5 303-4836 ................... 1-5, 1-9 303-4841 ........................ 12-3 303-4864 ................... 1-5, 1-9 303-4865 .......................... 6-3 303-4866 ................. 6-9, 8-29 303-4875 ........................ 8-31 303-4876 ........................ 8-31 303-4877 ........................ 8-31 303-4878 ........................ 8-31 303-4879 ........................ 8-29 303-4880 ........................ 8-17 303-4883 ...................... 11-11 303-4884 ...................... 11-11 303-4890 .......................... 1-5 303-4891 ........................ 4-13 303-4893 ........................ 6-25 303-4898 .......................... 3-7 303-4906 ........................ 11-8 303-4909 ........................ 11-9 303-4912 ........................ 8-23 303-4914 ...................... 12-22 303-4915 ...................... 12-22 303-4916 ...................... 12-22 303-4917 ...................... 12-29 303-4918 ...................... 12-29 303-4922 ...................... 12-29 303-4923 ...................... 12-22 303-4924 ...................... 12-22 303-4925 ...................... 12-22 303-4926 ............... 2-19, 2-21 303-4927 ...................... 12-22 303-4929 .......................... 2-7 303-4935 ........................ 2-17 303-4939 ........................ 11-9 303-4940 ...................... 11-11

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Part Number

Page

303-4941........................ 11-9 303-4942........................ 11-9 303-4943...................... 11-11 303-4944........................ 11-9 303-4945........................ 11-9 303-4946........................ 11-8 303-4947........................ 11-9 303-4948........................ 11-9 303-4949........................ 11-9 303-4950........................ 11-9 303-4951.......................... 4-3 303-4952.......................... 4-3 303-4953.......................... 4-3 303-4957................... 3-3, 3-9 303-4958................... 3-3, 3-9 303-4961 12-22, 12-41, 12-43 303-4962........................ 11-8 303-4963........................ 11-8 303-4964...................... 11-11 303-4966.......................... 1-5 303-4969 10-19, 12-22, 12-31 303-4970...................... 10-19 303-4971...................... 12-22 303-4972...................... 12-22 303-4973...................... 12-29 303-4978........................ 6-12 303-4979...................... 12-29 303-4980...................... 12-29 303-4981.......................... 1-4 303-4982............. 10-8, 10-21 303-4983............. 10-8, 10-21 303-4988................... 3-3, 3-9 303-4989................... 1-4, 1-8 303-4997............. 10-8, 10-11 303-4999.......................... 3-7 303-5000........................ 2-17 303-5001.......................... 2-7 303-5003.......................... 1-4 303-5004........................ 9-37 303-8559.......................... 4-3 303-8561........................ 4-57 303-8562............... 4-37, 4-39 303-8563............... 4-37, 4-39 303-8565........................ 9-37 303-8566........................ 9-37 303-8567.......................... 1-4 303-8568........................ 4-57 303-8570............... 5-11, 5-31 303-8571............... 5-11, 5-31 303-8572............... 5-11, 5-31 303-8573............... 5-17, 5-37 303-8574............... 5-21, 5-43 303-8578........................ 6-13 303-8579........................ 6-12 303-8581............... 6-12, 6-13 303-8582........................ 6-12 303-8583........................ 6-13 303-8584........................ 5-47 303-8585........................ 6-12

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Page

303-8586 ........................ 6-13 303-8587 ........................ 6-13 303-8588 ........................ 6-13 303-8589 ........................ 6-13 303-8590 ........................ 6-12 303-8591 ........................ 6-12 303-8592 ........................ 6-12 303-8593 ........................ 6-12 303-8594 ........................ 6-12 303-8595 ........................ 6-12 303-8596 ........................ 6-12 303-8597 ........................ 6-12 303-8599 . 4-3, 4-4, 4-9, 6-22, 8-11, 9-27 303-8600 ........................ 6-22 303-8601 ........................ 6-22 303-8602 ........................ 8-13 303-8605 ........................ 9-21 303-8606 ........................ 9-21 303-8607 ........................ 9-21 303-8609 ........................ 9-21 303-8610 .......................... 7-5 303-8611 ........................ 6-13 303-8612 ........................ 6-12 303-8613 ........................ 6-12 303-8614 ........................ 6-12 303-8615 ........................ 6-12 303-8617 ........................ 9-27 303-8618 ........................ 6-12 303-8619 ........................ 6-12 303-8620 .......................... 9-3 303-8621 .......................... 9-3 303-8623 ........................ 9-21 303-8624 ........................ 6-12 303-8625 ........................ 6-12 303-8626 ........................ 6-12 303-8627 ........................ 6-12 303-8628 ........................ 6-12 303-8629 ........................ 6-12 303-8630 ........................ 6-12 303-8631 ........................ 6-12 303-8632 ........................ 6-12 303-8633 ........................ 6-12 303-8634 ........................ 6-12 303-8635 ........................ 6-12 303-8636 ........................ 6-13 303-8637 ........................ 6-13 303-8638 ........................ 6-13 303-8639 ........................ 6-13 303-8640 ........................ 6-13 303-8641 ........................ 6-13 303-8642 ........................ 6-12 303-8643 ........................ 6-13 303-8644 ........................ 6-13 303-8645 ........................ 6-13 303-8646 ........................ 6-13 303-8647 ........................ 6-13 303-8648 ........................ 6-12 303-8649 ........................ 6-12

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Part Number

Page

303-8650........................ 12-5 303-8651........................ 12-5 303-8652........................ 12-5 303-8653........................ 12-5 303-8654.......................... 1-5 303-8655.......................... 9-7 303-8656........................ 12-9 303-8658........................ 9-37 303-8659.......................... 1-4 303-8660.......................... 1-4 303-8661.......................... 1-4 303-8662............... 6-17, 6-19 303-8663........................ 10-8 303-8666........................ 9-35 303-8667........................ 6-12 303-8668.......................... 2-7 304-2241................. 5-9, 5-29 304-2243........................ 5-15 304-2244........................ 5-19 304-2246........................ 9-25 304-2247........................ 9-22 304-2248........................ 9-22 304-2249........................ 9-22 304-2250........................ 9-22 304-2251........................ 9-15 304-2253........................ 9-15 304-2254........................ 9-15 304-2255........................ 9-15 304-2256........................ 9-15 304-2257........................ 9-15 304-2258........................ 9-15 304-2259........................ 9-35 304-2260........................ 9-35 304-2261........................ 9-35 304-2262........................ 9-35 304-2263........................ 9-35 304-2264........................ 5-15 304-2265........................ 5-15 304-2266........................ 12-5 304-2267........................ 12-5 304-2268........................ 12-9 304-2269........................ 9-22 304-2270........................ 9-21 304-2271........................ 9-22 304-2272.......................... 9-7 304-2273.......................... 9-7 304-2281.......................... 9-3 304-2282.......................... 9-3 304-2283.......................... 9-3 304-2284........................ 9-11 304-2292........................ 9-17 304-2294........................ 9-21 304-2295........................ 9-21 304-2297.......................... 7-3 304-2298.......................... 7-3 304-2299.......................... 9-3 304-2300........................ 6-12 304-2301........................ 6-12 304-2302........................ 12-5

Part Number

Page

304-2304 ........................ 12-5 304-2305 ........................ 12-5 304-2306 ........................ 12-5 304-2307 ........................ 12-5 304-2308 ........................ 12-5 304-2309 ........................ 12-5 304-2318 ........................ 12-5 304-2319 ........................ 12-5 304-2320 ........................ 12-5 304-2322 ........................ 12-5 304-2323 ........................ 12-5 304-2324 ........................ 12-5 304-2325 ........................ 12-5 304-2328 ........................ 12-5 304-2329 ........................ 12-5 304-2332 ........................ 12-6 304-2334 ........................ 12-6 304-2335 ........................ 9-25 304-2339 ........................ 9-25 304-2565 ........................ 6-22 304-2566 .......................... 6-3 304-2566 ........................ 3-13 304-2567 .......................... 4-3 304-2569 ...................... 12-22 304-2571 ...................... 12-22 304-2573 ........................ 9-43 304-2575 ...................8-7, 8-9 304-2576 ...................8-7, 8-9 304-2581 .......................... 3-7 304-2582 .......................... 3-7 304-2592 ........................ 10-5 304-2594 ...................... 12-29 304-2595 ........................ 2-21 304-2596 ........................ 4-57 304-2597 ...............4-37, 4-39 304-2598 ...............4-37, 4-39 304-2599 ...............4-37, 4-39 304-2600 8-7, 8-9, 8-11, 8-31 304-2600 .......................... 8-3 304-2601 ........................ 9-27 304-2603 ...............5-13, 5-33 304-2604 .......................... 4-7 304-2605 ........................ 4-53 304-2606 10-8, 10-21, 12-31, 12-33 304-2612 ........................ 6-17 304-2613 ...............6-17, 6-19 304-2614 ........................ 4-57 304-2615 ........................ 4-57 304-2617 ........................ 4-57 304-2618 .......................... 1-5 304-2620 ...............5-11, 5-31 304-2621 ...............4-41, 4-43 304-2622 ...............4-41, 4-43 304-2623 .............10-8, 10-21 304-2626 ........................ 6-15 304-2627 ........................ 9-15 304-2628 ........................ 9-25 304-2629 ........................ 9-25

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Part Number

Page

304-2630 ........................ 9-25 304-2631 ........................ 4-57 304-2632 .....4-37, 4-39, 4-41, 4-43, 4-45, 4-47 304-2633 .....4-37, 4-39, 4-41, 4-43, 4-45, 4-47 304-2634 .....4-37, 4-39, 4-41, 4-43, 4-45, 4-47 304-2635 .....4-37, 4-39, 4-41, 4-43, 4-45, 4-47 304-2636 ........................ 6-13 304-2637 ........................ 6-13 304-2638 ........................ 6-12 304-2639 ........................ 6-12 304-2640 ........................ 6-13 304-2641 ........................ 6-17 304-2642 ........................ 6-17 304-2646 ........................ 9-37 304-2647 ...................... 10-11 304-2648 ........................ 6-13 304-2649 ........................ 6-13 304-2651 ........................ 9-25 304-2652 ........................ 4-17 304-2656 ........................ 6-12 304-2657 ........................ 9-37 304-2658 .......................... 2-3 304-2660 ...................... 12-13 304-2660 .......................... 1-8 304-3165 ........................ 2-17 304-3171 ........................ 6-25 304-3176 ........................ 2-19 304-3177 .......................... 1-5 304-3181 ........................ 6-12 304-3182 ........................ 12-5 304-3183 ........................ 12-5 304-3184 ........................ 12-6 304-3185 ........................ 12-6 304-3186 ........................ 12-6 304-3187 ...................... 12-11 304-3188 ...................... 12-11 304-3189 ...................... 12-11 304-3190 ........................ 12-9 304-3191 ........................ 12-9 304-3192 ........................ 12-9 304-3193 ........................ 12-9 304-3194 ........................ 12-9 304-3195 ........................ 12-9 304-3196 ........................ 12-9 304-3197 ........................ 12-9 304-3198 ........................ 12-9 304-3199 ........................ 12-9 304-3200 ........................ 12-9 304-3201 ........................ 12-9 304-3202 ........................ 12-9 304-3203 ........................ 12-9 304-3204 ........................ 12-9 304-3205 ........................ 9-25 304-3206 ........................ 9-25 304-3207 ........................ 9-37

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304-3208 ........................ 9-37 304-3209 ........................ 9-31 304-3211 ........................ 9-31 304-3212 ........................ 9-31 304-3213 ........................ 9-31 304-3214 ........................ 9-31 304-3215 ........................ 9-31 304-3216 ........................ 9-31 304-3218 ........................ 9-35 304-3220 ........................ 5-15 304-3221 ............... 5-15, 5-35 304-3222 ............... 5-15, 5-35 304-3225 ........................ 5-39 304-3226 ........................ 5-39 304-3227 ........................ 9-17 304-3228 ........................ 9-21 304-3230 ................. 5-9, 5-29 304-3231 ................. 5-9, 5-29 304-3232 ............... 5-15, 5-35 304-3798 ........................ 6-13 304-3799 ........................ 6-12 304-3805 .......................... 1-5 304-3806 ........................ 9-25 304-3807 ........................ 9-25 304-3810 ........................ 4-17 304-3812 ........................ 12-5 304-3813 ........................ 9-22 304-3817 ........................ 12-6 304-3818 ........................ 9-37 304-3819 ........................ 5-39 304-3820 ........................ 9-17 304-4551 ...................... 12-22 304-4552 ...................... 12-22 304-4563 ........................ 10-5 304-4564 ........................ 9-21 304-4572 .......................... 7-3 304-4573 ........................ 12-5 304-4575 ........................ 12-5 304-4577 ........................ 12-5 304-4578 ........................ 12-5 304-4579 ........................ 9-37 304-4580 ........................ 6-13 304-4581 ................. 5-9, 5-29 305 ............................... 10-21 305-2023 ........................ 6-25 305-2025 .......................... 7-7 305-2026 .......................... 7-7 305-2028 .......................... 6-3 305-2032 ............... 9-27, 9-29 305-2033 ........................ 9-27 305-2038 ...................... 10-21 305-2039 ...................... 10-21 305-2087 ........................ 9-41 305-2088 ........................ 9-41 305-2089 ........................ 9-41 305-2090 ........................ 9-41 305-2106 ........................ 9-41 305-2115 ..10-8, 10-21, 12-31 305-3763 ........................ 2-17

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Part Number

Page

305-3767 ............ 11-3, 11-11 305-3768 ..........................3-7 305-3783 ..........................3-3 305-3784 ..........................3-3 305-3785 ..........................3-3 305-3786 ..........................3-3 305-3789 ......................12-22 305-3790 ......................12-29 305-3791 ........................11-9 305-5423 ......................10-21 305-5426 .............. 5-11, 5-31 305-5431 ........................9-41 305-5437 ......................10-21 305-5438 ......................10-21 305-5448 ........................6-19 305-5449 10-8, 10-21, 12-31, 12-33 305-5459 .............. 9-15, 9-41 305-5460 ........................9-41 305-5467 ......................12-29 305-6015 ........................9-39 305-6020 ........................9-41 307-9601 ..........................6-7 307-9602 ..........................4-9 307-9603 ..........................4-9 307-9870 ..........................7-7 308-0608 ........................2-21 308-6651 ........................6-12 308-7035 ..........................1-8 309-2991 ..........................1-9 309-4311 ..........................3-9 309-4312 ..........................3-9 309-4313 ..........................3-9 309-4315 ..........................3-9 309-4316 ..........................3-9 309-4317 ..........................3-9 309-4318 ..........................3-9 309-4319 ..........................3-9 309-4320 ..........................3-9 309-4321 ..........................3-9 309-4322 ..........................3-9 309-4323 ..........................3-9 309-6238 ..........................4-9 309-6238 ..........................1-8 309-6301 ......................11-11 309-6321 ......... 6-3, 6-4, 8-11 309-6332 ......................12-45 309-6353 ........................2-21 309-6819 ........................6-25 310-6250 ........................3-11 310-6251 ........................3-11 310-7936 ........................4-17 310-8321 ........................9-21 310-8451 ........................8-31 310-8452 ........................8-31 310-8453 ........................8-31 310-8454 ........................8-31 310-8455 ........................8-31 310-8507 ....... 4-4, 8-11, 9-27

Part Number

Page

310-8508 .......................... 4-4 311 ................................. 4-15 311-0660 ........................ 6-25 311-0679 ........... 12-35, 12-39 311-0680 ...................... 12-35 311-0684 ...................... 12-35 311-0685 ...................... 12-35 311-2854 .......................... 3-5 311-9612 ........................ 4-57 311-9613 ........................ 4-57 312-2615 ........................ 11-3 313-2471 .......................... 9-7 313-2472 .......................... 9-7 313-2473 .......................... 9-7 313-3349 .......................... 3-9 313-4359 ........................ 11-3 313-5257 ........................ 6-25 313-5260 ........................ 6-28 313-6241 ........................ 11-3 313-6242 ........................ 11-3 314-2338 ........................ 11-9 314-2339 ........................ 11-9 314-2340 ........................ 11-9 314-2341 ........................ 11-9 314-2342 ...................... 11-11 314-2343 ........................ 11-9 314-2344 ........................ 11-9 314-2345 ........................ 11-9 314-2346 ........................ 11-9 314-2347 ........................ 11-9 314-2348 ........................ 11-9 314-2349 ...................... 11-11 314-2350 ........................ 11-9 314-2351 ............. 11-3, 11-11 314-2893 ........................ 6-25 314-5304 ............. 11-3, 11-11 314-5306 ........................ 11-4 314-5307 ........................ 11-4 314-5308 ........................ 11-4 314-5309 ........................ 11-4 314-5310 ........................ 11-4 314-5311 ........................ 11-4 314-5312 ........................ 11-4 314-5315 ........................ 11-9 314-5316 ........................ 11-9 314-5317 ........................ 11-9 314-5318 ........................ 11-9 314-5319 ...................... 11-11 314-5320 ........................ 11-9 314-5321 ........................ 11-9 314-5322 ........................ 11-9 314-5323 ........................ 11-9 314-5324 ........................ 11-8 314-5325 ........................ 11-9 314-5326 ...................... 11-11 314-5327 ........................ 11-9 314-6030 ........................ 11-3 314-6031 ........................ 11-3 314-6032 ........................ 11-3

TL642

Part Number

Page

314-6130.......................... 6-4 314-6696........................ 11-3 314-6697........................ 11-3 314-7754...................... 12-33 314-7795........................ 4-57 314-7798........................ 4-57 314-8479........................ 3-19 314-8489...................... 12-33 315-1126........................ 9-41 315-2004........................ 4-57 315-2023...................... 12-31 315-2024...................... 12-31 315-2025...................... 12-31 315-2026...................... 12-31 315-2027........... 12-22, 12-31 315-3422.......................... 1-5 315-3423.......................... 1-5 315-3424........... 12-41, 12-43 315-3424.......................... 1-5 315-3678........................ 9-39 315-3679........................ 9-39 315-3680........................ 9-39 315-4601........................ 11-4 315-4603........................ 11-4 315-4605........................ 11-4 315-4606........................ 11-4 315-4607........................ 11-4 315-4609........................ 11-5 315-4610........................ 11-5 315-4611........................ 11-5 315-4615........................ 11-5 315-4617........................ 11-5 315-4618........................ 11-5 315-4619........................ 11-5 315-4621........................ 11-5 315-4622........................ 11-5 315-4623........................ 11-5 315-4625........................ 11-5 315-5502.......................... 6-3 315-5795...................... 12-29 315-5797...................... 12-29 315-5798...................... 12-29 315-5799...................... 12-29 315-5800...................... 12-29 315-5802...................... 12-29 315-5806...................... 12-29 315-6549........................ 8-15 315-6551........................ 8-31 315-8700........................ 11-3 316-9020........................ 9-21 317-0088.......................... 1-5 317-0089.......................... 1-5 317-0090...................... 12-43 317-0090.......................... 1-5 317-0601........................ 9-31 317-0602........................ 9-31 317-0603........................ 9-31 317-0604........................ 9-31 317-0605........................ 9-31

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317-0607 ........................ 9-31 317-0608 ........................ 9-31 317-0609 ........................ 9-31 317-0610 ........................ 9-31 317-0611 ........................ 9-31 317-0612 ........................ 9-31 317-0613 ........................ 9-31 317-0614 ........................ 9-31 317-0615 ........................ 9-31 317-0616 ........................ 9-31 317-0617 ........................ 9-31 317-0618 ........................ 9-31 317-0619 ........................ 9-31 317-0620 ........................ 9-31 317-0621 ........................ 9-31 317-0622 ........................ 9-31 317-0623 ........................ 9-31 317-0624 ........................ 9-31 317-0625 ........................ 9-31 317-0626 ........................ 9-31 317-0627 ........................ 9-31 317-0628 ........................ 9-31 317-0629 ........................ 9-32 317-5987 ...........12-22, 12-31 318-9222 ........................ 3-17 318-9228 ........................ 6-29 318-9229 ........................ 6-28 318-9230 ........................ 6-28 318-9231 ........................ 6-28 318-9232 ........................ 6-28 318-9233 ........................ 6-28 318-9234 ........................ 6-28 318-9235 ........................ 6-29 318-9236 ........................ 6-29 318-9237 ........................ 6-28 318-9238 ........................ 6-28 318-9239 ........................ 6-28 318-9240 ........................ 6-28 318-9241 ........................ 6-28 318-9242 ........................ 6-28 318-9243 ........................ 6-29 318-9244 ........................ 6-29 318-9245 ........................ 6-29 318-9246 ...............6-28, 6-29 318-9247 ........................ 6-29 320-0525 ...................... 12-33 320-0529 ...................... 12-33 320-0534 ........................ 6-12 320-4875 ........................ 12-6 320-7882 ...................... 11-11 320-7883 ...................... 11-11 320-8390 ........................ 6-17 321-0556 ........................ 3-15 321-2484 ........................ 11-6 321-2485 ........................ 11-6 321-2487 ........................ 11-6 321-2488 ........................ 11-6 321-2489 ........................ 11-6 321-2490 ........................ 11-6

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Part Number

Page

321-2491........................ 11-6 321-2492........................ 11-6 321-2493........................ 11-6 321-2494........................ 11-7 321-2495........................ 11-7 321-2496........................ 11-7 321-2497........................ 11-7 321-2498........................ 11-7 321-2499........................ 11-7 321-2500........................ 11-7 321-2501........................ 11-8 321-2502........................ 11-8 321-2503........................ 11-8 321-2504........................ 11-6 321-2505........................ 11-6 321-2506........................ 11-6 321-2507........................ 11-7 321-2508........................ 11-7 321-2509........................ 11-7 321-2510........................ 11-7 321-2511........................ 11-7 321-2512........................ 11-7 321-2513........................ 11-7 321-2514........................ 11-8 321-2515........................ 11-8 321-2516........................ 11-8 321-2517........................ 11-8 321-2518........................ 11-8 321-2519........................ 11-8 321-2520........................ 11-8 321-2522........................ 11-8 321-2523........................ 11-8 321-5021........................ 4-45 321-5022........................ 4-45 321-5023........................ 4-45 321-5024........................ 4-45 322-9668........................ 6-25 323-0971...................... 12-47 323-0972...................... 12-47 323-1647.......................... 1-5 323-3877.......................... 6-9 323-4208........................ 8-21 323-5609........................ 11-9 323-5627........................ 8-31 323-7236 10-19, 12-22, 12-31 324-5262.......................... 3-5 324-7383........................ 8-21 324-7384........................ 8-21 324-7385.......................... 8-9 324-7388.......................... 8-9 324-7389.......................... 8-9 324-7390.......................... 8-9 324-7391........................ 8-25 324-7392........................ 8-25 324-7398........................ 8-13 324-7399........................ 8-13 324-7401........................ 8-13 324-7402........................ 8-13 324-7403.......................... 8-9

Part Number

Page

324-7404 .......................... 8-9 324-7405 ........................ 8-25 324-7406 ........................ 8-19 324-7945 ...........12-37, 12-39 324-9527 ...................... 12-29 324-9528 ...................... 12-29 324-9529 ...................... 12-29 324-9530 ...................... 12-29 324-9531 ...................... 12-29 325-0033 .......................... 9-9 325-0034 ........................ 9-13 325-0035 .......................... 9-5 325-0036 ........................ 9-19 325-1066 .......................... 6-8 325-1068 ...................... 12-33 325-1345 ...............4-27, 4-29 325-1351 ...............4-27, 4-29 325-1352 ...............4-27, 4-29 325-1433 ........................ 6-25 325-8140 ........................ 8-21 325-8141 ........................ 8-23 325-8143 .......................... 5-3 325-8144 ........................ 8-19 327-6270 ........................ 3-15 327-6271 ...............3-13, 3-15 327-6272 ........................ 3-15 327-6273 ........................ 3-17 327-6274 ........................ 3-17 327-6277 ........................ 3-19 327-6287 ........................ 3-19 327-6305 ........................ 3-19 327-6307 ...............9-45, 9-47 327-6308 ...............9-45, 9-47 327-6309 ...............9-45, 9-47 327-6310 ...............9-45, 9-47 327-6311 ...............9-45, 9-47 327-6312 ...............9-45, 9-47 327-6313 ...............9-45, 9-47 327-6314 ...............9-45, 9-47 327-6316 ........................ 9-45 327-6317 ........................ 3-15 327-6318 ........................ 3-15 327-6320 ........................ 3-17 327-6321 ........................ 3-17 327-6323 ........................ 3-17 327-6324 ........................ 3-17 327-6325 ...............3-17, 3-19 327-6326 ........................ 3-17 327-6327 ........................ 3-17 327-6328 ...............3-17, 3-19 327-6329 ...............3-17, 3-19 327-6330 ........................ 3-17 327-6331 ...............9-45, 9-47 327-6333 ...............3-17, 3-19 327-6335 ........................ 3-15 328 ............................... 12-41 328-1544 ...................... 12-43 328-1545 ...................... 12-41 328-1546 ...................... 12-41

TL642

Part Number

Page

328-1547 ...................... 12-43 328-1548 ...................... 10-19 328-7288 ........................ 3-13 328-7289 ........................ 3-13 328-7290 ........................ 3-13 328-7291 ........................ 3-13 328-7292 ........................ 3-13 328-7293 ........................ 3-13 328-7822 .......................... 6-9 329 ................................. 4-15 329-0046 .......................... 1-8 329-0290 ........................ 4-13 329-3482 ........................ 9-27 329-9751 ........................ 9-21 329-9753 ........................ 9-22 329-9754 ........................ 9-21 329-9755 ........................ 9-22 330-3035 ........................ 4-13 330-4923 ........................ 11-9 330-5286 ...................... 11-11 330-8325 .......................... 3-9 331-0101 ........................ 6-25 331-0104 ........................ 4-49 331-0795 ........................ 4-19 331-0803 ..........5-3, 5-5, 5-25 331-0804 ..........5-3, 5-5, 5-25 331-1596 .......................... 2-3 331-2385 ................... 4-3, 4-9 331-2386 ........................ 9-27 331-2387 ........................ 8-11 331-2460 .......................... 4-3 331-3800 .......................... 9-5 331-3810 .......................... 2-3 331-3989 ........................ 5-27 331-4656 ...................... 12-39 331-4658 ........... 12-37, 12-39 331-4659 ...................... 12-37 331-4665 ........... 12-37, 12-39 331-4674 ........... 12-37, 12-39 331-4682 ...................... 12-37 331-6125 ........................ 6-13 331-7310 ...................... 12-39 332-1348 ........... 12-22, 12-47 332-3846 .......................... 6-7 332-3847 .......................... 6-7 333-1338 ........................ 6-19 333-2415 ............... 6-17, 6-19 333-2416 .......................... 6-7 334-0787 ........................ 6-19 334-0788 ........................ 6-19 334-0789 ........................ 6-19 334-3558 ................... 6-4, 6-9 334-3559 ................... 6-4, 6-9 334-3560 ................... 6-4, 6-9 334-3738 ........................ 2-21 334-5871 ...................... 10-19 334-5962 ........................ 6-19 335 ................................. 4-15 335-3833 ........................ 4-55

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Page

335-8059 ........................ 3-13 335-8066 ........................ 3-13 335-8077 ........................ 3-13 335-8078 ........................ 3-13 335-8080 ........................ 3-13 335-8093 ...................... 12-35 335-8098 ........................ 3-13 336-2804 ........................ 3-13 337-7993 ................... 9-3, 9-5 338-9996 ........................ 3-13 338-9997 ........................ 3-13 338-9999 ........................ 3-13 339-0000 ........................ 3-13 339-0003 ........................ 3-13 339-0004 ........................ 3-13 339-0837 ...................... 12-33 339-1711 ...................... 12-33 339-1712 ...................... 12-33 339-1713 ...................... 12-33 339-1714 ...................... 12-33 339-7766 ........................ 4-13 339-9594 ........................ 11-5 339-9595 ........................ 11-4 339-9596 ........................ 11-6 339-9603 ........................ 11-5 339-9604 ........................ 11-5 339-9609 ........................ 11-4 339-9620 ........................ 11-3 340-0961 ...................... 12-45 340-0977 ...................... 12-45 340-0978 ...................... 12-45 340-0979 ...................... 12-45 340-0985 ...................... 12-45 340-0986 ...................... 12-45 340-3225 .......................... 4-9 340-4180 ........................ 2-13 340-4182 ........................ 2-13 340-4184 ........................ 2-13 340-8974 ........................ 3-13 340-8975 ........................ 3-13 340-8976 ........................ 3-13 340-8977 ........................ 3-13 340-8978 ........................ 3-13 340-8979 ........................ 3-13 341-1835 ................. 4-4, 8-11 341-2966 ................. 4-3, 4-10 341-2967 ........................ 9-27 341-4074 .......................... 9-5 341-4075 .......................... 9-5 341-4076 ........9-5, 9-13, 9-19 341-4077 ........................ 9-13 341-4078 .......................... 9-5 341-4079 .......................... 9-5 341-4080 .......................... 9-5 341-4081 .......................... 9-5 341-4082 .......................... 9-5 341-4083 .......................... 9-9 341-4084 .......................... 9-9 341-4085 ........9-9, 9-13, 9-19

14-10

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Page

341-4086 ..........................9-9 341-4087 ..........................9-9 341-4088 ..........................9-9 341-4089 ..........................9-9 341-4090 ..........................9-9 341-4091 ..........................9-9 341-4092 ..........................9-9 341-4093 ..........................9-9 341-4094 ........................9-13 341-4095 ........................9-13 341-4096 ........................9-13 341-4097 ........................9-13 341-4098 ........................9-13 341-4099 ........................9-13 341-4100 ........................9-13 343-7819 ......................12-33 343-7820 ......................12-33 343-9736 ........................3-13 343-9737 ........................3-13 343-9738 ........................3-13 344-1586 ........................9-31 344-3254 ......................10-21 344-3273 ..........................6-8 344-7016 ........................4-55 344-7161 .................. 6-3, 6-7 344-7163 ......................10-11 344-7172 ........................11-3 344-7176 ......................12-35 344-7179 ......................12-35 345-1922 ......................12-35 345-2161 ........................1-13 346..................................4-15 346-2984 .............. 6-17, 6-19 346-2985 ......................12-29 346-2986 ......................12-35 346-4742 ......................12-35 346-9672 ..........................6-8 348-2862 ........................4-53 349-6874 .................. 6-4, 6-8 350-0995 ..........................3-7 350-2506 ..........................6-8 350-2517 ..........................6-8 350-2518 ..........................6-8 350-2519 ..........................6-7 350-2520 ..........................6-3 350-2524 ........................5-41 350-2526 ..........................6-8 350-8568 ........................5-29 350-8569 ........................5-29 350-8570 ........................5-33 350-8571 ........................5-35 350-8572 ........................5-37 350-8573 ........................5-41 350-8574 ........................5-41 350-8575 ........................5-41 350-8576 ........................5-41 350-8577 ........................5-41 350-8578 ........................5-41 350-8579 ........................5-41

Part Number

Page

350-8580 ............... 5-23, 5-45 352-4588 .......................... 1-8 354-5048 ... 9-3, 9-5, 9-7, 9-9, 9-11, 9-13 355-5429 ........................ 6-25 356-2911 ........................ 6-19 356-2912 ...................... 10-21 357-6165 ...................... 12-31 359-8938 .......................... 6-8 359-9448 ........................ 11-4 359-9986 ...................... 12-39 360 ................................... 4-9 360-6606 ........................ 4-25 360-6607 ........................ 4-25 360-6608 ........................ 4-25 360-6609 ........................ 4-25 360-6610 .......................... 4-9 360-6611 ........................ 4-25 360-6612 .......................... 4-9 360-6613 .......................... 4-9 360-6614 .......................... 4-9 360-6616 .......................... 4-9 360-6617 ........................ 4-21 360-6620 ........................ 8-11 360-6624 .......................... 1-9 360-6625 .......................... 4-9 360-7793 .......................... 6-9 360-7796 .......................... 1-9 361-2832 ........................ 9-29 361-2844 ........................ 8-11 361-2845 ........................ 8-11 361-2859 ........................ 4-29 361-2861 ........................ 4-21 361-2863 ........................ 4-21 361-2868 .......................... 4-9 362-2100 ........................ 3-19 362-2101 ........................ 3-19 362-2102 ........................ 3-19 362-2103 ........................ 3-19 362-2104 ........................ 3-19 362-2106 ............... 3-17, 3-19 362-2107 ........................ 3-19 362-2108 ........................ 3-19 362-2109 ............... 3-17, 3-19 362-2110 ............... 3-17, 3-19 362-2111 ............... 3-17, 3-19 362-2112 ........................ 3-19 362-2113 ........................ 3-19 362-2114 ........................ 3-19 362-2115 ........................ 3-19 362-2116 ........................ 3-19 362-2117 ........................ 3-19 362-2118 ........................ 3-19 362-2119 ........................ 3-19 362-2120 ........................ 9-47 362-2121 ........................ 9-47 362-2122 ........................ 3-19 362-3261 ............. 10-8, 10-21 362-4916 ........................ 10-8

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Part Number

Page

362-4934...................... 10-21 362-6358........................ 10-8 362-6359........................ 10-8 362-6360............. 10-8, 10-21 362-6743...................... 10-11 362-7670............. 10-8, 10-21 363-7725........................ 6-13 364-5667........................ 4-21 364-5671.......................... 1-8 364-5674.......................... 1-8 364-5675........................ 4-25 364-5676........................ 4-25 364-5678.......................... 1-8 364-5679.......................... 1-8 364-5684.......................... 6-7 364-5685.......................... 1-9 364-5686.......................... 1-9 364-5687.......................... 1-9 364-5688.......................... 1-9 364-5689........................ 4-21 364-5690........................ 4-21 364-5693.......................... 6-8 364-5694........................ 4-21 364-5695........................ 4-21 364-5697.......................... 1-9 364-5698.......................... 1-8 364-5699.......................... 4-9 364-5700........................ 4-21 364-5702.......................... 4-9 364-5703.......................... 1-8 365................................. 2-21 365-9207........................ 2-21 365-9208............... 2-19, 2-21 365-9211........................ 2-21 367-3289........................ 8-11 367-3290........................ 8-11 367-3291.......................... 1-8 367-4055........................ 4-21 367-4056........................ 4-21 367-4087........................ 4-21 367-4967.......................... 1-9 368-0506........................ 8-11 368-0510........................ 4-21 368-0511........................ 4-21 370-1094.......................... 6-8 370-7770........................ 5-49 3P-8517 ......................... 4-19 4520368......................... 5-49 4520369......................... 5-49 4520370......................... 5-49 4520371......................... 5-49 4520374......................... 5-49 4520375......................... 5-49 4520449......................... 5-49 4520450......................... 5-49 4520451......................... 5-49 4520453......................... 5-49 4520455......................... 5-49 4520456......................... 5-49

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4520458 ......................... 5-49 4520459 ......................... 5-49 4520461 ......................... 5-49 4520462 ......................... 5-49 4520645 ......................... 5-49 4520646 ......................... 5-50 4520647 ......................... 5-50 4L-6459 ............................ 4-9 5C-2890 ........................... 4-7 5C-9553 ......................... 4-25 5P-8500........6-13, 6-17, 6-19 5W-8686............12-23, 12-47 6V-7978..............6-3, 6-7, 6-9 6V-8776............................ 4-9 7W2326 .......................... 4-13 7X-3359.......................... 6-25 80694009 ..................... 12-22 8780031 ......................... 5-49 8780036 ......................... 5-49 8780045 ......................... 5-49 8780048 ......................... 5-50 8780050 ......................... 5-49 8780264 ......................... 5-49 8T-4121 ..............4-3, 4-7, 4-9 8T-4133 ..........4-7, 4-9, 12-39 8T-4136 .. 4-3, 4-7, 4-10, 4-27 8T-4138 ............................ 6-8 8T-4186 ............................ 4-7 8T-4189 ............................ 4-4 8T-4196 ................. 4-7, 12-39 8T-4200 ............................ 4-4 8T-4205 .......................... 4-25 8T-4205 ............................ 1-9 8T-4223 ............................ 4-9 8T-4908 ............................ 4-7 8T-4956 ..... 4-3, 4-4, 4-7, 4-9, 4-10 8T-4970 ............................ 1-5 8T-7008 ............................ 1-5 8T-8919 ........................ 12-22 91405035 ....................... 5-49 91405036 ....................... 5-49 91475031 ....................... 5-49 91475032 ....................... 5-49 91475054 ....................... 5-49 91475055 ....................... 5-49 91475093 ....................... 5-49 91475105 ....................... 5-49 91515056 ....................... 5-49 91515066 ....................... 5-49 91535017 ....................... 5-49 91535019 ....................... 5-49 9L0895 ........................... 4-13 KENR6216 ..................... 4-15 RENR9961 ..................... 4-15 RENR9965 ..................... 4-15 SEBU8180 ..................... 4-15

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Telehander TL642 CAT Parts

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