manual partes montcargas mc

CONTENTS

SECTION DESCRIPTION

1 FRAME & BODY PANELS

2 PEDALS & CONTROLS

3 STEER AXLE

4 DRIVE AXLES

5 WHEELS & TIRES

6 ENGINE

7 TRANSMISSION

8 COOLING SYSTEM

9 AIR, FUEL & EXHAUST

10 HYDRAULICS

11 ELECTRICAL

PM1802JUNE 2008 CONTENTS

CONTENTS PM1802 JUNE 2008 ii

Section 1: Frame, Body & Rollcage

Page No.

1-2

1-3

1-4

1-6

1-7

1-8

1-9

1-10

1-12

1-14

Description

Frame & Counterweight

Rollcage Assembly

Cab Assembly

Hood & Rear Fenders: 14,000 - 16,000 Lb.

Hood & Rear Fenders: 18,000 - 20,000 Lb.

Transmission Tunnel & Seat

Front Floorboard

Decals -Caution, Danger & Warning

Decals - Operational

Decals - Identification

PM1801 AUG 2007 FRAME , BODY & ROLLCAGE 1 ·1

Frame & Counterweight

Ref. Part No. Description Qty. 1 500-000 Frame Assembl , 14,000 -16,000 lb. Unit

510-000 Frame Assembl , 18,000 - 20,000 lb. Unit 2 011-203 Bolt , 3/4-10 x 8-1/2 " 8 3 011-335 Washer, Flat 3/4 Grade 8" 16 4 011-111 Nut , lock 3/4-10 8 5 500-000l Mast Trunnion Block Cap 2 6 011-276 Bolt , SHCS 7/8-9 x 3" 4 7 N/A Counterweight Assembly, Contact Your Master

Dealer To Order 8 011-065 Bolt, 1"-8 x 3-1/2" 4 9 011-040 Washer, lock 1" 4 10 011-031 Washer, Flat 1" 4

FRAME, BODY & ROllCAGE PM1801 AUG 2007 1-2

Rollcage Assembly

Ref. Part No. Qt 503-050 513-050

2 011-411 4 3 011-040 6 4 011-031 6 5 011-019 2

PM1801AUG 2007 FRAME , BODY & ROLLCAGE 1 - 3

2

10

8 ,9

12 I »<: 14 r<;

5 r : 4

11

16

1 - 4 FRAME , BODY &ROLLCAGE PM1801 AUG 2007

c

Cab Assembly

Ref. Part No. Description Qty. 1 010-810 Cab Assembly 1 2 010-817A Glass , Front 1

011-519 Weather Strip (Specify l.enqth) AR 3 011-147 Bolt, 5/16-18 x 1" 22 4 011-028 Washer, Flat 5/16" 70 5 011-033 Washer, Lock 5/16" 48 6 011-021 Nut, 5/16-18 17 7 210-550Z Bracket, Windshield Mount, Top 1 8 010-813 Door & Panel Assembly, RH 1

010-813A Door Panel Assembly, RH 1 010-810C Door Assembly with Hinqes, RH 1 010-810H Hinge , Door 3 010-8101 Handle, Inside 1

j 010-810J Handle, Outside 1 9 010-812 Door & Panel Assembly, LH 1

010-812A Door Panel Assembly, LH 1 010-8100 Door Assembly with Hinqes, LH 1 010-810H Hinqe , Door 3 010-8101 Handle, Inside 1 010-810J Handle, Outside 1

10 210-550K2 Door Stop 2 11 215-027 Bracket, Door Mount, Front 2 12 215-028 Bracket, Door Mount, Rear Lower 2 13 215-029 Bracket, Door Mount, Rear Upper 2 14 011-006 Bolt, 5/16-18 x 3/4" 26 15 010-817B Glass, Rear 1 16 010-818 Gasket, Locking (Specify Length) AR 17 010-804* Wiper Motor, Front 1 18 010-801* Wiper Arm , Front 1 19 010-801A* Wiper Blade , Front 1 20 010-710* Wiper Motor, Rear 1 21 010-808* Wiper Arm , Rear 1 22 010-808A* Wiper Blade, Rear 1 23 010-599* Floor Mat 1

* Not Shown

\.)

PM1801 AUG 2007 FRAME, BODY &ROLLCAGE 1 - 5

Hood & Rear Fenders, 14,000 - 16,000 Lb. Unit

Ref. Part No. Descri tion Qt . 1 503-001A Tilt Back Assembl 2 011-009 Bolt , 3/8-16 x 1" 10 3 011-091 Washer, Flat 3/8" 20 4 011-034 Washer, Lock 3/8" 10 5 011-023 Nut , 3/8-16 10 6 500-001GR Door Assembl , RH 7 500-001GL Door Assembl , LH 1 8 011-059 Hin e, Door 4 9 011-005 Bolt, 5/16-18 x 1/2" 16 10 011-028 Washer, Flat 5/16 " 18 11 011-021 Nut , 5/16-18 10 12 13 14

215-117 010-570 011-533

Door Pro Rod Door Latch Assembl Screw, Round Head 10-32 x 1/2"

2 4 16

15 011-466 Nut, 10-32 16 16 503-001 K En ine Access Cover, Rear 17 500-001 FR Fender Assembl ,RH 18 500-001 FL Fender Assembl , LH 19 011-013 Bolt , 1/2-13 x 1" 4 20 011-029 Washer, Flat 1/2" 6 21 011-061 Bolt , 1/2-13 x 2-1/4 " 2 22 011-230A Rubber Bum er 8

7

FRAME, BODY & ROLLCAGE PM1801 AUG 2007 1 - 6

Hood & Rear Fenders, 18,000 - 20,000 Lb. Unit

Ref. Part No. Descri tion Qt . 513-001A Tilt Back Assembl 1

2 011-009 Bolt , 3/8-16 x 1" 10 3 011-091 Washer, Flat 3/8" 20 4 011-034 Washer, Lock 3/8" 10 5 011-023 Nut, 3/8-16 10 6 500-001GR Door Assembl , RH 7 500-001GL Door Assembl , LH 8 011-059 Hin e, Door 4 9 011-005 Bolt , 5/16-18 x 1/2" 16 10 011-028 Washer, Flat 5/16" 18 11 011-021 Nut, 5/16-18 10 12 215-117 Door Pro Rod 2 13 010-570 Door Latch Assembl 4 14 011-533 Screw, Round Head 10-32 x 1/2" 16 15 011-466 Nut, 10-32 16 16 503-001 K En ine Access Cover, Rear 17 510-001FR Fender Assembl ,RH 1 18 510-001 FL Fender Assembl ,LH 19 011-013 Bolt, 1/2-13 x 1" 4 20 011-029 Washer, Flat 1/2" 6 21 011-061 Bolt, 1/2-13 x 2-1/4" 2 22 011-230A Rubber Bum er 8

16

6

7 11

I 10

,-( 12

-""'-

PM1801 AUG 2007 FRAME, BODY & ROLLCAGE 1 - 7

Transmission Tunnel &Seat

Ref. Part No. 503-006

2 011-013 3 011-029 4 011-180

011-180A 011-500 011-500A

5 011-284 6 100-128C 7 011-401 8 011-162 9 011-035 10 011-114 11 011-507

Qt

6 6

4

4 4 4 4

2

3~> <,

7~>--, 8

11

FRAME, BODY & ROLLCAGE PM1801 AUG 2007 1 - 8

Front Floorboard

Ref. Part No. Description Qt . 500-053 Floorboard (with Electronically Controlled

Accelerator Pedal 1

2 011-013 Bolt , 1/2-13 x 1" 6 3 011-029 Washer, Flat 1/2" 6

PM1801 AUG 2007 FRAME, BODY & ROLLCAGE 1 ·9

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J. CGUt ct 'fWD tAll I lR liA: l'm I'P fll 1M. nt:lt lit 100m.

tAl''''''• . ' ,If. . lUl Ctlftt( l . P UIB!Wa &l;t., $1IlJ,t) Wf.ctt. q At UlC*14ft[lh' · sn,.lfJl(l

)~~~J.~IlJ=:=:==:::'-:.~:: WWDQt:O.MllthNi MIFDual.lI

I I(RWQIU' ••'Wt1!StCiil'fi1t. ~,"*.

WHEN RAIS ING REAR TILT DEC K. USE TILT DECK PIN AND "HAIR PIN"

LOCK PROVIDED BY MANUFACTURER.

FAILURE TO LOCKREAR TILT DECK

COULD RESULT IN SEVERE INJURY.

LOAD AND MAST MUST BE CENTERED AND

SIDE SHIFT MUST NOT BE USED AT LIFT HEIGHTS

ABOVE 15 FEET OR MACHINE MAY OVERTURN.

TRUCK RATING IS BASED WITH MAST VERTICAL TO GROUN D LEVEL AND RATEDLOAOTO 12 FEET LI FT HEIGHT. FOR LI FTS ABOVE 12 FEET. REFER TO MAST RATING FOR LOAD CA PACITY AND LI MIT MASTTILT TO 3' FORWARO AND 8' REARWARD . EXCE EDING THESE CAPACITIES WILL ADVERSELY AFFECT TRUCK STABILITY.

DO NOT PERMIT RIDERSON FORKS.

DO NOT STAND UNDER FORKS.

t]Ci)

(1) ~ DO NOT PERId'T

.' RIOERSONFORKS.

OONOT STAAD UNDERFORKS.

t]Ci) t l t ·I H

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) .u~, Dt$JIOU'IfiHt:;

PARKING BRAKE t o UlGAG£ Mdt PUSH aonilltld(

_ t'{D.&.\ S 00_ "0 P1Jl. l ifl(A, 'lfU4$t ....H

00 NOT UAVEKEYIN ACCESSORIES PO SITION.

DEAf) 8ATT£RY Will RESULT.

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Decals - Caution, Danger & Warning

A DANGER DEATH OR INJURY CAN RESULT FROMCONTACTING ELECTRIC POWER LINES.

ALWAYSCONTACT THE ELECTRIC POWERLINE OWNER. THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE POWER LINES MOVED OR INSULATED BEFORE MACHINE OPERAn ONS BEGIN.

NEVER OPERATE THIS MACHINEWITHIN 10 FEET OF ELECTRIC POWER LINES.

ROLLCAGE FRONT INNER PANEL PIN: 010-292

TO PROTECT ENGINE AND HYDRAU LIC COMPONENTS

• DO NOT EXCEED 1/2 THROTTLE FOR FIRST 5 MINUTES OF OPERAT ION .

• IDLE ENGINE FOR 1 MINUTE BEFORE SHUTDOWN AFTER FULL LOAD OPERATION.

INSTRUMENT PANEL-RH SIDE PIN: 010-121

A WARNING

NO RIDERS

BOTH FRONT FENDERS PIN: 010-404

A WARNING DO NOT USE FULL FORWARD

MASTTILT UNLESSMAST IS FULLYCOLLAPSED.

FAILURE0 FOLLOWTHIS WARNING WILL CAUSE MACHINE

TO OVERTURN. 010.298

FRONT ROLLCAGE PANEL PIN: 010-121

A \. '.'f\KNI~JG

• Starteng;ne only from operators seat. If safety startswitchISbypassed engInecanstartwrtn trarlSmlSsionlflgear

• Donotconnect orshort across terminals on starter ~ellid

• Attach booster cables as shown onbatte'Y decal

Staftmgingearcau~og

run3illay canresIJ/t in senoustnjlJry.

A WARNING ~ ALWA.YS ENGAGE PARKING BRAKE

IlalASE ['''-: BEFORE DI$ MOUNn NG

PARKING BRAKE TO ENGAGE BRAKEPUSHBOTH PEDALS DOWN AND PULL LEVER J

RH FENDER SIDE PANEL PIN: 010-404

KEEP HMOS

ANDCLOTH ING

AWAYFROM

ROTATING FAN

AND BEL1STO

PREVENT

SERiOUS INJURY.

FAN SHROUD THIS VEHICLE is EQUIPPED

WITH A BACK-UP ALARM. FRONT ROLLCAGE PANEL PIN: 010-413

WHEN BACKING . THE PIN: 010-121 ALARM

MUST SOUND THE OPERATOR IS

RESPON ISBLE FOR THE SAFE USE OF THIS VEHICLE

DECAL, BACK-UP ALARM (INCLUDED WITH BACK-UPALARM)

PM1801 AUG 2007 FRAME, BODY & ROLLCAGE 1 - 11


DECAL SET - OPERATIONAL: PIN 010-450

DOWN LEFTFORW

HYDRAULIC " ~o o " ~ :; :;OIL

-~-010-212

\ , \ J\' TRANS.

UP BACK RIG HT DIESEL OIL

FUEL -G)010-282 010-279

~ ~ TRANSMISSION ; ~ TEMPERATURE

4 2 HYDRAULIC U 0

-~-N r~ CLUTCH DISENG. - OIL ~ BUTTON 0 10-255 --G)

l~ U TRANSMISSION r... DEPRESS BUTTON TO3 1 0 10-299 010-261 ",,'" CHANGE GEARS

010-254

LEFT TILT SIDE SH~~:J

1 -12 FRAME , BODY & ROLLCAGE PM1801 AUG 2007


INSTRUMENT PANEL NEXT TO AUX. LEVER

PIN: 010-297

BA EM AB CE

R 0 N

010 ·136

PIN: 010-136

.....

..... PIN: 010-298

RELEASE

CLAMP

PIN: 010-416

LIGH TS 0: 010 -133 .........

PIN: 010-133

WIPERS <S;) 010 ·131

PIN: 010-137

PULL 13- ~

ENGAGE

I 4WD I

DISENGAGE

oPUSH

TRANS TUNNEL NEXT TO LEVER

PIN: 010-256

DRIV E

NEUT.

PIN: 010-134

~ PIN: 010-128

PM1801 AUG 2007 FRAME, BODY & ROLLCAGE 1 -13

Decals - Identification

TURBO DECAL , TURBO

PIN: 010-454

DECAL, MASTER CRAFT PIN: 010-453MC

4X4 DECAL, 4 X 4 PIN: 010-452

MC-20-374 DECAL, MODEL NUMBER(SPECIFYYOUR MODEL NUMBER)

PIN: 010-449

.---MADE IN USA

DECAL, MADE IN USA PIN: 010-381

1 - 14 FRAME, BODY & ROLLCAGE PM1801 AUG 2007

Section 2: Pedals & Controls

Page No. Description

2-2 Control Valve Levers, 3-Spool (Standard)

2-4 Control Valve Levers, 4-Spool (Optional)

2-6 Brake Assembly & Accelerator Pedal

2-7 Forward/Reverse Shifter

2-8 Parking Brake Handle & Cable

2-9 Differential Lock Pedal

2-10 Steering Wheel Components

PM1802 JUNE 2008 PEDALS &CONTROLS 2-1

r::r--- 7

5

10

~2

4

14

11

10

18

1"', 12

'1II ~

I '~, 13 I

I <, I '~I19 l '~

8

PEDALS &CONTROLS PM1802 JUNE 2008 2-2

Control Valve Levers 3-Spool (Standard)

Ref. Part No. Description Qty. 1 050-024 Control Lever 2 2 011-168 Bushing 6 3 050-079 Knob 2 4 050-401 Control Lever, Mast Lift Selection 1 5 050-400 Knob, Mast Lift Selection Control Lever 1 6 110-102 Switch, De-Clutch 1 7 110-093A Boot 1 8 050-024A Pivot Tube , 15/16"00 x 9" 1 9 011-042F Cotter Pin, 7/64" x 1-1/2" 2 10 050-0240 Bracket 2 11 011-006 Bolt, 5/16-18 x 3/4" 4 12 011-033 Washer, Lock 5/16" 4 13 011-021 Nut, 5/16-18 4 14 050-021 Clevis, 3/8-24 x 3/8" 3 15 011-084 Clevis Pin, 3/8" x 1-1/4" 3 16 011-042E Cotter Pin, 5/32" x 3/4" 3 17 050-020 Connectino Rod 3 18 011-024 Nut, Lock 3/8-24 6 19 050-021A Clevis, 3/8-24 x 3/8" Round 3 20 050-080 Clevis Pin, 3/16" x 1-1/4" 3 21 011-267 Cotter Pin, 5/64" x 1/2" 3

PM1802 JUNE 2008 PEDALS & CONTROLS 2-3

0- 3 I

14

18

10

~2

19 "',I ~

I I

l

5

12

4

11

10

8

PEDALS &CONTROLS PM1802 JUNE 2008 2-4

0

c

Q

Control Valve Levers 4-Spool (Optional)

Ref. Part No. Description 1 050-024 Control Lever 2 011-168 Bushing 3 050-079 Knob 4 050-401 Control Lever, Mast Lift Selection 5 050-400 Knob, Mast Lift Selection Control Lever 6 110-102 Switch, De-Clutch 7 110-093A Boot 8 050-024PY Pivot Tube, 15/16"00 x 11-3/8" 9 011-042F Cotter Pin, 7/64" x 1-1/2" 10 050-0240 Bracket 11 011-006 Bolt, 5/16-18 x 3/4" 12 011-033 Washer, Lock 5/16" 13 011-021 Nut, 5/16-1 8 14 050-021 Clevis, 3/8-24 x 3/8" 15 011-084 Clevis Pin, 3/8" x 1-1/4" 16 011-042E Cotter Pin, 5/32" x 3/4" 17 050-020 Connectino Rod

050-020A Connecting Rod, Tilt Lever 050-020B Connectino Rod, Mast Lift Lever

18 011-024 Nut, Lock 3/8-24 19 050-021A Clevis, 3/8-24 x 3/8" Round 20 050-080 Clevis Pin, 3/16" x 1-1/4" 21 011-267 Cotter Pin, 5/64" x 1/2"

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

PM1802 JUNE 2008 PEDALS & CONTROLS 2-5

Brake Assembly &Accelerator Pedal

Ref. Part No. 1 500-054 2 011-072 3 011-075 4 020-140 5 011-007 6 011-090 7 090-182 8 011-004 9 011-032 10 020-143 11 011-390 12 020-142

Description Qty. Bracket, Brake Pedal & Accelerator Pedal Mounting 1 Bolt, 5/8-11 x 1-1/2" 4 Washer, Flat 5/8" 4 Brake Pedal 1 Bolt, 5/16-18 x 1-1/2" 3 Washer, Lock 5/16" 3 Accelerator Pedal 1 Bolt, 1/4-20 x 3/4" 2 Washer, Lock 1/4" 2 Accumulator 2 Clamp, 3-1/2" U-Bolt 4 Switch, Low Pressure Warning (Mounted inside of 1 frame on ri ht hand side

13 020-141 Valve, Brake Char e 1 14 011-010 Bolt, 3/8-16 x 1-1/2" 2 15 020-148 Filter Assembly , Steering & Brake Circuit (Not 1

Shown 16 020-148A Element, Filter Replacement Not Shown 1 17 500-000VC Bracket, Low Pressure Warning Switch (Not 1

Shown

13

10

PEDALS & CONTROLS PM1802JUNE 2008 2-6

Forward/Reverse Shifter

Ref. Part No. Qt 115-026

2 115-020A 3 110-1220 2

2

3


Park Brake Handle &Cable

Ref. Part No. Description Qty. 027-091 Park Brake Handle Assembl Includes 1-7

1 027-091A Park Brake Handle, without Ball Switch 2 027-091C Clamp Kit 2 3 050-021 Clevis, Cable End 4 011-084 Pin, Clevis 5 011-041 Cotter Pin, 1/8" x 1" 1 6 020-076 Cable, Park Brake 1 7 110-170 Switch, Ball

5

~4

PEDALS & CONTROLS PM1802 JUNE 2008 2-8

Differential Lock Pedal

Ref. Part No. Description Qt 050-060 Differential Lock Pedal Assembly

2 011-121 Grease Fittin 3 025-001 Bushin 4 011-031 Washer, Flat 1" 1 5 011-042 Cotter Pin, 5/32" x 2" 6 9R-0872 Cylinder Assembl , Includes Clevis & Nut 7 011-148 Clevis Pin, 0 5/16" x 1-1/4" 2 8 011-141 Cotter Pin, 0 1/8" x 1" 2

7~ ...

ACCELERATOR PEDAL ~

BRAKE PEDAL BRACKET


Steering Wheel Components

Ref. Part No. Description Qt . 030-011 Steer Motor

2 030-178 Steerin Column 3 011-010 Bolt, 3/8-16 x 1-1/2" 4 4 011-034 Washer, Lock 3/8" 4 5 030-177 Steer in Wheel 6 030-001 Nut 7 030-177A Center Cap

4

3

2

5

6

7

2 -10 PEDALS & CONTROLS PM1802 JUNE 2008

Section 3: 4WO ITL S080 Steer Axle


3-2 Steer Drive Assembly

3-4 Knuckle

3-6 Hub Components

3-8 Differential Assembly

3-10 Brake

3-12 Steer Axle Ram

3-14 Drive Shaft

PM1802 JUNE 2008 4WD ITL SD80 STEERAXLE 3-1

252290

4WD ITL SD80 STEERAXLE PM1802 JUNE 2008 3-2

F2-7-1 Axle, Steer Drive, Assembly, 24.975:1 Ratio, Pivot Mount, 461/22080

Ref. Part No. Description Qty. 1 461-22080 Axle , SD80 Steering Assy , 24.975:1 Pivot Moun t 1 2 453-30551 ,/ Casing, Axle 1 3 453-07301 Differential Housinq Assembly 1 4 826-01452 Bolt , Verbus Ripp, M12 x 35mm 14 5 453-05800 Rod, Track 1 6 808-00253 Bush inq, 3000 x 25 10 x 33mm 2 7 904-09300 Seal , Oil 4 8 1450-0001 Nipple , Grease, Stra iqht , 1/8 BSP 2 9 911-22800 Pin, Pivot , 0 25 x 105mm 6 10 1321-0405Z Bolt 6 11 F2-7-10 Steer Knuckle 1 12 816-80037 Pluq, Filler 1 13 1406-0021 Seal , Bonded 3/4" BSP 1 14 816-80012 Plug, Magnetic, 3/4" BSP 1 15 1406-0021 Seal, Bonded 3/4" BSP 1

0

16 17 18 19 20 21

808-00252 907-08400 ,/ /' 2203-1082 ,r 904-50040 .: 4102-1212 826-00439

Bushing Bearinq Curcl ip Seal Gasket Dowel

2 2 2 2

AR 2

., I

PM1802JUNE 2008 4WD ITL SD80 STEERAXLE

0

3-3

252330

4WD ITLSD80 STEER AXLE PM1802 JUNE 2008 3-4

0

0

~

"

Ref. 1 1A 2 r 4 /

5 / 6 7 8 /'

Part No. 453-08403 453-08503 458-20060 ..907-08300 " 904-06700 _ 1315-3509Z 816-60056 914-84700 -

/'

8A 8B

8C 80 9 11 13 15 16 17 18 19

914-87500 -914-87401 914-84104 914-84202 914-86403 914-84203 914-84204 .,

911-22800 1315-0405Z 917-50200 904-50009 453-11701 816-60040 835-00017

th ~

F2-7-10 Knuckle, Steer Axle, 461/22080

Description Qty. Joint, Knuckle Swive l, Splined, RH 1 Joint , Knuckle Swive l, Splined, LH 1 Trunnion 4 Bear inq, Taper Roller 4 Seal 4 Bolt 16 Nipple , Grease 4 Shaft , Drive, RH - '" te.s. ~ '"" 1

/Shaft, Drive , LH -- 1 Shaft , Hub Side 1 Shaft , Differential Side , RH 1 Shaft , Different ial Side , LH 1 Yoke , Double 1 Circlip 4' \ Kit, Spider , 96mm Over Caps, 35nim Cap Diameter 2

<:.Pin, Pivot, 0 25 x 105mm 2 Screw , M10 x 20mm 4 Bearinq 4 Seal 2 Cap, Breather , 2mm Hole 2 Nipple, Bleed 2 Cap, Grease Nipple 2

PM1802JUNE 2008 4WD ITL SD80 STEER AXLE

0

3-5

13

12

20 26

252321

4WO ITL S080 STEERAXLE PM1802JUNE 2008 3-6

F2-7-20 Hub &Components, Steer Axle, 461/22080

0 Ref. Part No. Description Qty. 1 453-04209 Carrier, Planetary Hub 2 2 816-82010 Pluq, Maqnetic, M22 2 3 450-10208 Pad, Thrust 2 4 821-00494 Circlip , External 2 5 828-00196 O-Rinq 2 6 454-07401 Gear, Sun, 45mm Long 2 7 821-00209 Circlip 12 8 907-50200 Bearinq , Roller , Double Row 6 9 450-10206 Gear, Planet 6 10 2203-0054 Circlip 6 11 453-07802 Gear , Brake Plate Carrier 2 12 453-01803 Gear , Annulus Ring 2 13 448-54602 Carrier, Annulus , Internal Spline 2 14 826-01435 Bolt, Verbus Ripp M12 x 55mm Long 8 15 821-00210 Circlip , Internal , Square Section 2 16 907-52200 Bearing 4 17 453-30305 Plate, Retaining 2 17A 453-08602 Pipe, Hub Breather 1 18 458-20447 Hub, Without Studs, 10 Stud 1

c

458-20403 Cover, Plate, Hub Seal 1 19 826-00923 Stud, Wheel 20 20 904-50033 Seal, Oil 2 22 1315-0407Z Bolt, M10 x 25mm 4 23 828-00249 a-Ring 2 24 826-01065 Screw , Grub 2 25 828-00248 a-Ring 4 26 458-20403 Cover , Plate, Hub Seal 2

PM1802JUNE 2008 4WD ITL SD80 STEER AXLE

0

3-7

15

157230

4WO ITL S080 STEER AXLE PM1802 JUNE 2008 3-8

c

0

F2·7·30 Differential Assembly, 24.975:1 Ratio, Steer Axle, 461/22080

Ref. Part No. Description Qty. 1 453-31050 Differential , Assembly 1 2 453-07301 Casing, Drive Head 1 3 450-10900 Differential , Assembly 1 4 450-10800 Cas ino, Assembly, Differential 1 5 1315-3418Z Bolt , M10 x 80mm 8 6 450-11000 Gear, Set , 33 Spline 6 Gears, 2 Pins c/w Washers 1 7 808-00209 Washer, Thrust, Side Gear 2 8 808-00210 Was her, Thrust, Pin ion 2 9 450-10903 Pin, Trunn ion 2 10 NSP Non Serviced Part 2 11 NSP Non Serv iced Part 2 12 907-50100 Bearinq, Taper Roller 2 13 453-0 1702 Nut , Adjus ting 2 14 826-01080 Bolt 12 15 458-70039 Gear, Crown Wheel & Pinion , 8T/37T (Pink) 1 16 907-09000 Bearinq 1 17 921-01900 Kit, Shim AR 18 921-53400 Kit, Spacer 1 19 907-08300 Bearinq, Taper Roller 1 20 904-50023 Seal 1 21 450-27200 Yoke 1 22 Was her (Not Requ ired with Nut 826-01483) 1 23 826-01483 Nut, Stake & Washer, M24 1 24 826-00818 Pin, Tension 2

PM1802 JUNE 2008 4WD ITLSD80 STEER AXLE

0

3-9

3 -10 4WO ITL 5080 5TEERAXLE PM1802 JUNE 2008

F2-7-50 Brakes, Steering Axle, 461/22080

c Ref. Part No. 1 1A 2 3 4 5 6 7

458-20214 448-54602 813-50015 813-50014 453-01807 458-20289 458-20353 453-15500

8 9 10 11 12 14 20

2203-1145 814-00367 440-08902 816-60040 835-00017 826-01343

~

Description Qty. Piston, Brake, 3 Plate PRB 2 Carrier, Annulus, Internal Spline 2 Seal 2 Seal 2 Plate, Pressu re 2 Plate , Brake Counter 8 Plate, Brake Friction 6 Plate, Retain inc 2 Circl ip 2 Spring 6 Pin, Hexaqon Head 6 Nipple, Bleedinq 2 Cap, Grease Nipple 2 Screw, Grub , Nylon Coated 4 Not Fitted 0

PM1802JUNE 2008 4WO ITL S080 STEER AXLE 3 - 11

0

.4

142121

3 -12 4WD ITLSD80 STEERAXLE PM1802 JUNE 2008

0

Cl

E4-4-1, Ram, Steer Axle 5080, 553/13800

Ref. Part No. Description Qty. 1 553-13800 Ram, Steer 30mm Rod x 60mm Cylinder 1 2 553-13900 Cylinder 1 2A 655-00393 Pipe, Piston Side 1 2B 553-08200 Pipe, Rod Side 1 3 808-00246 Bushinc , 3500 x 25 10 x 27mm Lonq 1 4 590-34000 Rod, Piston 1 5 1450-1007 Nipple, Grease , 45° Angle 1

816-60065 Adapter ,4-Way 1 6 594-00015 Cap, End 1 7 808-00246 Bushing, 3500 x 25 10 x 27mm Long 1 8 595-10032 Piston, Head 1 9 816-60056 Nipple, Grease 1 10 1403-0001 Washer , Aluminum 1 11 904-09300 ' Seal, Oil 4 12 991-00098 , Kit, Seal, 30mm Rod x 60mm Cylinder 1 13 826-01182 Dowel 1

PM1802JUNE 2008 4WO ITL S080 STEER AXLE 3 -13

0

Drive Shaft 070-201 5080 Steer Axle to ITL Transmission

Ref. Part No. Description Qt 070-201 Drive Shaft Assembly

2 075-077 Slip Yoke 3 070-078 Shaft Yoke Assembl 4 070-079 Flan e Yoke 5 070-081 Universal Joint 1 6 011-546 Bolt , 1/2-20 x 1-3/4" Grade 8 4 7 011-548 Washer, Lock 1/2" Grade 8 4 8 011-547 Nut , 1/2-20 Grade 8 4 9 075-005S Strap Kit

4

3

5

3 -14 4WD ITLSD80 STEER AXLE PM1802 JUNE 2008

Section 4: NH 063 Drive Axle


4-2 Trumpet Housing Assembly

4-6 Axle Center Housing, with Differential & Related Parts

4-8 Drive Shaft

PM1802 JUNE 2008 NEW HOLLAND D63 DRIVE AXLE 4 -1

4

~ 47 /:

2

5

17

46

41

NEW HOLLAND 063 DRIVE AXLE PM1802 JUNE 2008 4-2

c

Q Trumpet Housing Assembly

Ref. Part No. Description Qty. 1 E4NN2N099AA Housinq , RH Inner Brake (Used on left side of axle) 1

E4NN2N100CA Housing, LH Inner Brake (Used on right side of axle) 1 2 86539262 Nut, G5, 1/2"-20 2 3 C5NN2N333A Pin 2 4 83959626 Disc, SM17WP 4 5 83956598 Disc, Intermediate 2 6 93956597 Disc , Assembly, Actuatinc , 180 (Includes 7-11) 1 7 81818828 Pin, Pivot 2 8 C7NN2N325A Link, Plain 2 9 80087309 Nut, Jam, 1/2"-20 2 10 82979987 Ball 6 11 84814903 Spr ing 4 12 83964342 Housinq , Outer Brake 1 13 81823522 Gear , Planetary Sun 1 14 E7NN4010AA Housing, RH (Includes 15, 16 & 18) 1

83959622 Housinq, LH (Includes 15, 16 & 18) 1 15 C5NN4075A Gear, Planetary Ring 1 16 86516474 CuP, Roller Bearinq , Outer 1 17 377525S Stud 2 18 272684 Cup, Bearing , Inner 1 19 304842S36 Screw , Cap, HH, G5, 7/8 "-9 x 2" 1 20 D9NN4N029AA Carrie r Assembly (Includes 21-27) 1 21 81802412 Cone, Bearinq, Inner 1 22 DONN4048A Shaft, Planet Gear 3 23 DAPN4013A Kit, Needle Bearing, 58 Bearings = 1 Kit 3 24 C5NN4A007A Washer, Thrust 6 25 C5NN4A008A Spacer 3 26 81823520 Gear, Planetary, 20 Teeth 3 27 81820847 Retainer 1 28 DONN4N237A Washer, Retainer 1 29 81803491 Spacer, 1.245/1 .321 mm AR

81803502 Spacer, 1.361/1 .422mm AR 81803503 Spacer , 1.448/1.524mm AR 81803504 Spacer, 1.549/1 .626mm AR 81803505 Spacer, 1.651/1.727mm AR 81803506 Spacer, 1.753/1.829mm AR 81803507 Spacer, 1.854/1 .930mm AR 81803508 Spacer, 1.956/2 .032mm AR 81803509 Spacer,2.057/2.134mm AR 81803510 Spacer, 2 .159/2.235mm AR 81803511 Spacer, 2.261/2 .337mm AR

30 DONN4N240A Bolt, Lock 1 35 82037652 Seal Assembly, Boot 1 36 81877008 Rod, Brake Control, 7.03" x 12mm x 1.75mm 1 39 011-041 Pin, Cotter, 1/8" x 1" 1 40 76260S36 Pin, Clevis, 5/8 " x 1-3/8" 1 41 87753 Bolt, 5/8 "-11 x 2" 11 42 86568108 Shaft 1 43 E3NN1N118AB Stud , 3/4 "-16 x 2-5 /8" 12 44 83958913 Seal 1

PM1802JUNE 2008 NEW HOLLAND D63 DRIVE AXLE

0

4-3

4

~ 47/ 2

4

17

46

41

NEW HOLLAND D63 DRIVE AXLE PM1802 JUNE 2008 4-4

c

Q

Ref. 45 86516475 46 83417133

Trumpet Housing Assembly

Part No. Description Qty. Cone, Roller Bearinq , Outer 1 Seal 1 Cap, HH, G5, 5/16"-18 x 1/2" 6 Block, Thrust (3.500, 4.111 & 4.625 Ratio) 1 Block, Thrust (5.286 & 6.667 Ratio) 1 Washer, Lock , 3/8" 2 Cap, HH, G5, 3/8"-16 x 1" 2

47 88574 48 83959624

C5NN4194B 49 80680 50 88206

PM1802JUNE 2008 NEW HOLLAND D63 DRIVE AXLE

0

4-5

23

1

9 12

13 STANDARD DIFFERENTIAL

c---~~. ~1 Jl0 15 1916 14/ /J " <- , fA\! ~-:-J- //~ 148 15 16

60 59 r --0-- -~dUJ~~7 18 s-t ,9 <~----- -_._ ---_ __ '-W-' 17 -- _>

<. / i--~~it--------------- ---- t>: 8 6 44 45464748

NEW HaLLANO 063 ORIVEAXLE PM1802 JUNE 2008 4-6

0

e

Axle Center Housing, with Differential & Related Parts

Ref. Part No. Description Qty. 1 82959782 Housinq Assembly, Differential , CW (Includes 2-6) 1 2 263136 Plug, Pipe, Magnetic, Square Socket , 3/4"-14 1 3 87811S36 Pluq, Standard Drain, 3/4"-14 2 4 21T4022 Pluq, Differential Housinc Vent 1 5 DONN4N206A Plug, Center Housing, No Spin 1 6 81803420 CuP, Differential, RH 1 7 510884 Bearinq , Cone & Roller , Differential , LH 1 8 81803413 Bearing Assembly, Cone & Roller, Rear Axle , 1

Different ial, RH 9 81816246 Case Assy , Differential , Gear Ratio 3.500 - 4.625 1

81816247 Case Assy, Differential, Gear Ratio 5.286 - 6.667 1 10 83957533 Bolt, 1/2"-20 x 1.62" 12 11 83417169 Nut, Lock , G2, 1/2"-20 12 12 43104S Screw, Cap, HH, G8, Self-Locking, 1/2"-13 x 2-7/8" 8 13 81847145 Gear Set, Matched , 3.500 1

83958890 Gear Set, Matched, 4.111 1 E2NN4209DA Gear Set, Matched, 4.625 (Standard with Axle) 1 81834053 Gear Set, Matched, 5.286 1 E2NN4209CA Gear Set , Matched, 6.667 1

14 81803445 Gear, Differential Side 1 14B 81803451 Gear, Differential Lock Slide, Diff Lock Models Only 1 15 81803424 Washer, Thrust Gear, Differential , RH 2 16 81800471 Bushinq, Gear Case, Differential, RH 2 17 81728114 Pinion, Differential 4 18 83989915 Washer, Thrust, Axle Pinion , Differential 4 19 81876885 Spider, Axle, Differential 1 20 81824478 Bearing Assembly, Pinion Pilot 1 21 81803542 Rinq, Drive, Pinion Pilot Bearinq 1 22 83992835 Bearing , Cone 1 23 D8NN4614CA Retainer Assernblv (Includes 24 & 25) 1 24 86017029 Bearing , Cup, Drive Pinion, Rear, Standard 1 25 81812385 Cup, Tapered Roller Bearinq, Front, Standard 1 26 83914106 Spacer, Pinion Bearing , 1.3281/1 .3286 (Replaces AR

D8NN4662FA) D8NN4662GA Spacer, Pinion Bearing, 1.3289/1 .3294 AR D8NN4662HA Spacer, Pinion Bearinq , 1.3297/1 .3302 AR D8NN4662JA Spacer , Pinion Bearinq , 1.3305/1.3310 AR D8NN4662KA Spacer, Pinion Bearing , 1.3313/1.3318 AR D8NN4662LA Spacer, Pinion Bearinq, 1.3321/1.3326 AR D8NN4662MA Spacer , Pinion Bearing , 1.3329/1.3340 AR D8NN4662NA Spacer , Pinion Bearinq , 1.3337/1 .3342 AR D8NN4662PA Spacer , Pinion Bearing , 1.3345/1.3350 AR D8NN4662SA Spacer, Pinion Bearinq. 1.3353/1 .3358 AR D8NN4662TA Spacer, Pinion Bearing, 1.3361/1 .3366 AR D8NN4662UA Spacer, Pinion Bearinq , 1.3369/1 .3374 AR D8NN4662VA Spacer, Pinion Bearing , 1.3377/1.3382 AR D8NN4662XA Spacer , Pinion Bearinq , 1.3385/1 .3390 AR

27 81827354 O-Ring , 4.625" 10 x 0.139 " W 1 28 81845711 Cone & Roller, Pinion, Standard, Front 1 29 81845713 Seal, Pinion Bearing Retainer, Standard 1

PM1802 JUNE 2008 NEW HOLLAND 063 DRIVE AXLE

0

4-7

23

1

9~2 13 STANDARD DIFFERENTIAL

11 10 -----------...J~~@~~r- ~ 'J 16 15 14 19/ /J " ~ -~--J-!J_ J l<-; r. 14815 16 60 59 7 .-___ __ 18 ~~dbI~

9<f1JJ'-~~?f---'!----~------- v> 8 6 44 45464748

HANICAL ~~~ERE NTIAL LOCK

NEW HOllAND D63 DRIVE AXLE PM1802JUNE 2008 4-8

0

c

Axle Center Housing, with Differential & Related Parts

Ref. Part No. 30 83912246 31 81834073 32 E7NN4858AA

83949810 85805307 E9NN4858AA E6NN4858AA E3NN4858AA

33 81845714 34 D1NN4N118A 35 83949812 36 37 88702 38 80280248 44 81800472 45 81800474 46 81812261 47 81800475 48 81803474 49 E6NN4N050AA 50 80087308 51 81804978 52 390791S36

53 E6NN4N079AA 54 C5NN4N095A 55 C5NN4N090A 56 137286 57 C7NN2N059A 58 81802560 59 510892 60 81803515

81803516 81803517 81803518 81803519 81803520 81803521

Description Qty. Retainer Assembly, Drive Pinion, Standa rd 1 Seal Assembly , Drive Pinion Oil, Standard 1 Flange, U-Joint, with Handbrake , 1480 (Standard 1 with Axle) Flange, U-Joint, 1410, with Tapped Holes 1 Flange, U-Joint, 1410, with Brake Flange 1 Flanqe, U-Joint, 1480 1 Flange, U-Joint , 1550 1 Flange, U-Joint , EG2150 (4C) 1 Seal, Drive Pinion, Standard 1 Washer, Pinion, Flange, Standard 1 Nut, Slotted , Standard , 1-1/4"-18 1 Pin, Cotter, Standard (Procure Locally) 1 Screw, Cap, HH, G5, 9/16"-12 x 1-1/2" 6 Washer , Lock, 9/16" 6 Adapter , Differential Lock Gear Case 1 Spring, Different ial Lock Coupler 1 Coupler, Axle, Differential Lock 1 Washe r, Differential Lock, Coupler Stop 1 Rinq, Lock, Bull Pinion Bearinq 1 Fork, Axle, Differential Lock 1 Nut, Jam, G5, 3/8"-24 1 Screw, Set, 3/8"-24 x 7/16" 1 Washer , Flat, Steel , HD, 0.95 x 1.44 x 0.13 (Older 2 axles use 3 washers) Shaft, Rear Axle Differential Lock Lever 1 Seal Assembly, Differential Lock Shaft Oil 1 Shield, Differential Lock Shaft Seal 1 Rinq, Snap, #87, Ext 1 Pin, Shackle , Differential Lock 1 Lever, Differentia l Lock 1 Cup, Bearing , Different ial, LH 1 Shim, Differential Gear Bearing, 0.038" 1.016mm AR Shim, Differential Gear Bearinq, 0.044" 1.118mm AR Shim, Differential Gear Bearing, 0.050" 1.270mm AR Shim, Differential Gear Bearinq, 0.056" 1.422mm AR Shim, Differential Gear Bearinq, 0.062" 1.575mm AR Shim, Differential Gear Bearing, 0.068" 1.727mm AR Shim, Different ial Gear Bearinc, 0.074" 1.880mm AR

81803522 Shim, Different ial Gear Bearing, 0.080" 2.032mm AR

o PM1802JUNE 2008 NEW HOLLAND D63 DRIVE AXLE 4-9

Drive Shaft 070-200 NH D63 Drive Axle to ITl Transmission

Ref. Part No. Description Qt 070-200 Drive Shaft Assembl

2 077-580B Slip Yoke 3 077-580A Shaft Yoke Assembl 4 077-580e Flan e Yoke 5 075-005 Universal Joint 6 011-546 Bolt, 1/2-20 x 1-3/4 " Grade 8 4 7 011-548 Washer, Lock 1/2" Grade 8 4 8 011-547 Nut , 1/2-20 Grade 8 4 9 065-062 Strap Kit

8~ 7

6

4

1

3

5

9

2

5

4 -10 NEW HOLLAND D63 DRIVE AXLE PM1802 JUNE 2008

Section 5: Wheels &Tires


5-2 Drive Wheels & Tires

5-3 Steer Wheels & Tires

5-4 Notes

PM1802JUNE 2008 WHEELS & TIRES 5-1

Drive Wheels & Tires

Ref. Part No. Description Qt 1 010-003 Drive Wheel Asse mbl 1A 010-003A Wheel

2 2

1B 010-003B Side Rin 2 1C 010-003C Lock Ring 2 1D 010-003E O-R in 2 2 010-003F Valve Stem 2 3 067-096 Nut, 3/4-16 UNF Standard , Grade 8 SAE 24 4 067-097 Washer, Flat 3/4", Hardened, Grade 8 24 5 010-003-1 Tire, 20.5 x 25, 16 PI 2

2

3~--jfl-tt+- I

/4

WHEELS & TIRES PM1802JUNE 2008 5-2

Steer Wheels & Tires

Ref. Part No. Description Qt . 010-034A Steer Wheel 2

2 010-005 Valve Stem 2 3 011-612 Nut, Flan e 3/4-16 UNF, Grade 8 SAE 16 4 010-034 Tire, 15-19.5 SC Load SS F TL 2

PM1802JUNE 2008 WHEELS &TIRES 5-3

Notes

WHEELS & TIRES PM1802 JUNE 2008 5-4

Section 6: CAT C4.4 Tier3 Engine

Page No.

6-3

6-4

6-5

6-6

6-7

6-10

6-12

6-14

6-15

6-16

6-17

6-18

6-20

6-22

6-23

6-24

6-25

6-26

6-27

6-28

6-29

6-30

Description

305-0489 Engine AR-Primary

301-8245 Balancer GP

298-5892 Camshaft GP

298-5111 Cover GP-Engine

301-8240 Cover GP-Valve Mechanism

298-5888 Crankshaft GP

298-5887 Cylinder Block GP

298-4526 Cylinder Head AS

298-5890 Cylinder Head GP

311-4644 Drive GP-Fan

301-8237 Flywheel GP

298-5110 Gear GP-Front

301-8239 Pan GP-Oil

301-8236 Housing GP-Flywheel

299-5033 Lifting GP-Engine

311-4641 Mounting GP-Engine

298-5889 Piston GP

298-5129 Plug GP-Cylinder Head

298-5098 Plug GP-Engine


308-4160 Pulley GP-Crankshaft

298-5891 Valve Mechanism GP

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6-1

Section 6: CAT C4.4 Tier3 Engine

Page No.

6-31

6-32

6-33

6-34

6-36

6-37

6-38

6-42

6-43

6-44

6-48

6-49

6-52

6-53

6-54

6-55

6-56

6-60

6-61

6-62

6-63

6-64

6-65

Description

298-5100 Filter GP-Engine Oil

298 -5128 Plug GP-Engine Oil Manifold

301-8243 Connection GP-Water

301-8241 Cooler GP-Engine Oil

311-4640 Fan GP

298-5105 Pump GP-Water

312-1672 Radiator GP

301-8248 Connection GP-Air Inlet

307-8762 Filter Element AS-Air

311-7456 Turbocharger GP

304-8762 Pipe GP-Exhaust

311-2271 Filter GP-Fuel

298-5123 Filter GP-Primary Fuel

263-7148 Filter GP-Water Sep & Fuel

301-8251 Filter GP-Water Sep & Fuel

292-3780 Injection GP-Fuel

305-6701 Pump GP-Fuellnjection

283-2271 Pump GP-Fuel Injection

311-7455 Alternator GP-Charging

304-6436 Control & Mtg GP-Engine Elek

298-5125 Glow Plug GP

298-5130 Harness GP-Wiring

303-4619 Starting Motor GP-Electric

CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008 6-2

0

C)

305-0489 Engine AR-Primary

Part No. Description Qty. 311-7455 Alternator GP-Charqing 1 301-8245 Balancer GP 1 298-5892 Camshaft GP 1 301-8248 Connection GP-Inlet 1 301-8243 Connection GP-Water 1 304-6436 Control & Mtq GP-Enqine Electric 1 301-8241 Cooler GP-Oil 1 301-8240 Cover GP-Valve Mechanism 1 298-5111 Cover GP-Engine 1 298-5888 Crankshaft GP 1 298-5887 Cylinder Block GP 1 298-5890 Cylinder Head GP 1 311-4644 Drive GP-Fan 1 311-4640 Fan GP 1 298-5100 Filter GP-Engine Oil 1 311-2271 Filter GP-Fuel 1 298-5123 Filter GP-Primary Fuel 1 301-8251 Filter GP-Water Sep & Fuel 1 301-8237 Flywheel GP 1 298-5110 Gear GP-Front 1 298-5125 Glow Plug GP 1 298-5130 Harness GP-Wiring 1 301-8236 Housing GP-Flywheel 1 299-5033 Lifting GP-Engine 1 311-4641 Mounting GP-Engine 1 301-8239 Pan GP-Oil 1 304-8762 Pipe GP-Exhaust 1 298-5889 Piston GP 1 298-5129 Plug GP-Cylinder Head 1 298-5098 Plug GP-Engine 1 298-5131 Plug GP-Engine 1 298-5128 Plug GP-Engine Oil Manifold 1 308-4160 Pulley GP-Crankshaft 1 305-6701 Pump GP-Fuel Injection 1 298-5105 Pump GP-Water 1 312-1672 Radiator GP 1 303-4619 Startinq Motor GP-Electric 1 311-7456 Turbocharger GP 1 298-5891 Valve Mechanism GP 1 298-5894 Cylinder Block AS-Short 1 305-8454 Electronics GP-Engine Ratings 1

PM1802JUNE 2008 CAT C4.4 TIER 3 ENGINE

0

6-3

301-8245 Balancer GP

Ref. Part No. Descri tion Qt 61-0454 Bolt , M10 x 1.5 x 70mm 6

2 234-0615 Balancer Assembl 3 8N-7998 Dowel 4 195-2221 Nut, M12 x 1.75 THO 5 234-0189 Bolt 6 234-0198 Shaft, Gear 7 234-0201 Washer, Thrust 8 234-0204 Gear, Balancer, 17 Teeth 9 234-0205 Gear Assem bl , 44 Teeth 11 234-0212 Bolt 5 12 234-0220 Cover 1 13 234-0223 Rotor Assembl 14 234-0614 Dowel 15 16 17 18

234-0616 234-0590 234-0591 234-0613

Valve, Relief, En ine Oil Pressure Plun er S rin Plu ,Retainer

1

15

8 '---3

~ 1

@

2

CAT C4.4 TIER 3 ENGINE PM1802JUNE 2008 6-4

Ref. 1 2 3 3A

Qt . 8 8 1

2

PM1802JUNE 2008 CAT C4.4 TIER 3 ENGINE 6-5

298-5111 Cover GP-Engine

Ref. Part No. Description Qty. 1 61-0646 Bolt, M10 x 1.5 x 14mm 2 100-4830 Bolt , M10 x 1.5 x 20mm 3 111-8222 Bolt 5 4 209-5502 Cover Assembly, Power Take-Off 4A 209-5503 Seal, Cover 5 214-3203 Washer, Sealinq

CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008 6-6

1E

1A

4A

4

3

{1t~ / ~

4C 40

1F

18

-- -' f"'-.._---

1C

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6-7

11

~ 9

CAT C4.4 TIER 3 ENGINE PM1802JUNE 2008 6-8

0

0

301-8240 Cover GP-Valve Mechanism

Ref. Part No. 1 301-8253 1A 298-4546 1B 298-4547 1C 295-1042 10 298-4548 1E 298-4549 1F 136-3608 1G 124-0506 2 277-5031 3 298-4550 4 298-4551 4A 298-4552 4B 285-1973 4C 277-5064 40 277-5065 5 277-5067 6 198-8645 7 162-1562 8 50-1026 9 7C-1281 10 277-5094 10A 277-5096 11 61-0217

Description Qty. Cover Assembly, Cylinder Head 1

Gasket, Valve Cover 1 Valve, Breather, Crankcase 1 Screw, Taoo ino 4 Separator, Oil 1 Seal, a-Ring 1 Cap Assembly, Enqine Oil Filler 1

Seal 1 Bolt, Special , Shoulder 7 Bolt, Special, Shoulder 4 Base GP-Valve Cover & Inj Harness 1

Gasket, Valve Mechanism Base 1 Harness Assembly, Enqine 2 Seal, a-Ring 2 Clip 2

Sleeve 4 Hose, Crankcase Breather 1 Sprinq , Crankcase Breather Hose 1 Clamp, Hose 1 Bracket 1 Cover Assem blv 1

Seal, a-Ring 1 Bolt, M8 x 1.25 x 20mm 1

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE

0

6-9

9

6 - 10 CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008

0

0

Ref. 1 2

3

Part No. 1B-8736 032-9090 067-6873 032-9091 067-6874 067-6873 067-6874

4 5

216-8314 225-7772 233-3784

6

233-3785 233-3786 225-8839

7 8

276-7394 298-4524

9 298-4525

298-5888 Crankshaft GP

Description Qty. Key, Woodruff 1 Washer, Thrust, Standard-Upper 2

Washer, Thrust , 0.18mm OS Washer, Thrust, Standard-Lower 2

Washer, Thrust, 0.18mm OS Washer, Thrust, 0.18mm OS Washer, Thrust, 0.18mm OS Gear, Crankshaft, 34 Teeth 1 Bearinq Set, Main, Standard 1 Kit, Crankshaft Bearing, 0.25mm OS Kit, Crankshaft Bearing, 0.50mm OS Kit, Crankshaft Bearlnq, 0.75mm OS Dowel 1 Bolt 3 Kit, Bearinq 1 Ring, Timing , Cranksahft 1

PM1802JUNE 2008 CAT C4,4 TIER 3 ENGINE 6·11

0

5---e ··4 ~~

4--11 J

6 -12 CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008

298-5887 Cylinder Block GP

0 Ref. Part No. Description Qty. 1 61-0645 Bolt, M8 x 1.25 x 25mm 4 2 61-0646 Bolt, M10 x 1.5 x 14mm 1 3 035-8063 Plug 1 4 035-8068 Bolt, 5/8-18 x 3.75in 10 5 067-6002 Dowel 10 6 067-6006 Plug 1 7 067-6043 Plug, Side 1 8 100-484 1 Bolt, M6 x 1 x 10mm 4 9 185-0884 Dowel 2 10 209-9219 Bolt, M8 x 1.25 x 16mm 10 11 214-3203 Washer, Sealing 1 12 225-8858 Plug 1 13 232-7440 Bearing 1 14 232-7449 Housing Assembly 1 15 232-7596 Plug 1 16 232-7597 Plug 2 17 232-7599 Plug 1 18 233-9408 Gasket 1 19 252-6318 Plate 1 20 276-5605 Jet Assembly, Piston Cooling 4

c

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6 -13

0

298-4526 Cylinder Head AS

, Pipe Seal ,O-Rin

Ref. Part No. Description

94

8

8

Qt 1 28 -0858 Plu 2

199-9751 232-1322 Plu 1 276-8116 Plu , Core

5 276-8117 Plu , Core 309-6678 Valve , Inlet 276-8123 Retainer 32 276-8124 Valve , Exhaust

9 299-5511 Seal , Valve Stem 16 10 276-8133 Cap, Valve 16 11 295-6661 Plu 1 12 298-4527 Plu , Core 13 298-4528 Plu , Core 14 298-4530 S ring, Valve 16

32

6 7

4

8

68

6 -14 CATC4.4 TIER 3 ENGINE PM1802JUNE 2008

298-5890 Cylinder Head GP

Ref. Part No. Description Qt . 225-5501 Bolt, M15 x 1.5 x 137mm 10

2 298-4526 C linder Head Assembl 1 3 304-7278 Gasket, C linder Head


311-4644 Drive GP-Fan

Ref. Part No. Qt . 1 111-0859 4 2 128-5247 3 130-3879 4 230-8065

2


311-8237 Flywheel GP

Ref. Part No. Qt . 103-6131

1A 033-7687 2 103-6132 4 3 0$-1603 6 4 5P-8245 6 5 149-5599


6 -18 CATC4.4 TIER 3 ENGINE PM1802 JUNE 2008

c

0

0

298-5110 Gear GP-Front

Ref. Part No. Description Qty. 1 61-0217 Bolt, M8 x 1.25 x 20mm 6 2 61-0645 Bolt, M8 x 1.25 x 25mm 4 3 61-0650 Bolt, M10 x 1.5 x 65mm 3 4 7C-4616 Bolt, M12 x 1.75 x 45mm 1 5 067-6179 Dowel 1 6 100-3751 Bolt, M8 x 1.25 x 65mm 5 7 100-4830 Bolt, M10 x 1.5 x 20mm 1 8 101-3895 Bolt, M8 x 1.25 x 35mm 2 9 124-3815 Bolt, M8 x 16 x 1.25mm 9 10 133-1011 Washer 1 11 216-8634 Gear, Camshaft, 68 Teeth 1 12 226-8767 Cover Assembly, Front 1 12A 226-8766 Gasket, Cover 1 13 232-3666 Washer, Thrust 1 14 251-4336 Gear Assembly, Idler, 73 Teeth 1 15 277-3012 Gasket, Cover, Housing 1 16 282-9861 Hub, Idler Gear 1 17 288-0422 Seal, Oil 1 18 294-0298 Housing, Front 1 19 295-1711 Plate, Retaininq 1


17

18

I

11 ~ 3

15

4

6·20 CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008

0

C)

Ref. Part No. 1 2B-0858 2 61-0217 3 61-0289 4 61-0291 5 61-0292 6 61-0293 7 61-0363 8 61-1497 9 7C-0351 10 067-6213 11 101-3895 12 124-7702 12A 61-4079 13 131-4291 14 155-4828 15 220-8311 16 225-6005 17 230-8094 18 230-8251 19 233-8148 20 275-9883

301-8239 Pan GP-Oil

Description Qty. Pluq, Pipe 2 Bolt, M8 x 1.25 x 20mm 8 Plug 1 Nut, M8 x 1.25 thd 2 Bolt 2 Bolt, M8 x 1.25 x 80mm 4 Bolt, M6 x 1 x 20mm 2 Seal 1 Plug, Drain, Engine Oil 2 Gasket 1 Bolt, M8 x 1.25 x 35mm 2 Tube Assembly 1

Nut 1 Gauge Assembly, Oil Level, Engine Dipstick 1 Stud 2 Bolt, M8 x 1.25mm 4 Gasket 1 Bridqe 1 Pan, Oil 1 Strainer, Enqine Oil 1 Seal 2

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6 - 21

c

Housin , FI Dowel

301-8236 Housing GP-Flywheel

Ref. Part No. Description Qt . 23 2

2

2

1 61-0423 Bolt , M12 x 1.75 x 30mm 61-0593 Bolt , M10 x 1.5 x 30mm 61-0847 Plu 7W-1176 Plate , Cover

5 114-4363 Bolt , M8 x 1.25 x 12mm 6 121-0883 Bolt , M10 x 1.5 x 30mm 6

199-3109 Plu 220-8632 heel 1

9 287-8597

4

{2

7

32

7

4

8

</ / /

6 - 22 CAT C4.4 T IER 3 ENGINE PM1802 JUN E 2008

299-5033 Lifting GP-Engine

Ref. Part No. Description Qt 41 61-0654 Bolt , M10 x 1.5 x 25mm

2 299-5024 Bracket 1 3 299-5026 Bracket

3 ~ \ \

\-,

1

~

~ 1

2

PM1802JUNE 2008 CAT C4.4 TIER 3 ENGINE 6·23

311-4641 Mounting GP-Engine

Ref. Part No. Description Qt . 6H-3616 Plu , Protection 4

2 61-0423 Bolt , M12 x 1.75 x 30mm 6 3 101-7185 Bracket 4 101-7186 Bracket

4

3

1

6·24 CAT C4.4 TIER 3 ENGINE PM1802 JUNE 2008

2

298-5889 Piston GP

Ref. 1

Part No. 225-5441

Qt 4

225-5451 4

225-5453 4

225-5454 4

225-5458 4

225-5459 4

225-5438 225-5439 310-9269

1 2 4

124-3536 276-7476

2 4


298-5129 Plug GP-Cylinder Head

Ref. Part No. Description Qty. 232-1322 Plug

2 199-9751 Seal , O-Ring

2


Q Ref.

I----- -


Description - - - - - - -

Qty. -----I

225-6522 Pluq 1

o PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6·27


Ref. Part No. Description Qty. 28 -0858 PluQ 3


308-4160 Pulley GP-Crankshaft

Ref. Part No. Description Qt . 61-0501 Block 1

2 111-3297 Pulle 1 3 7W-4634 Bolt , 7/16-20 x 1.5in 3

2


298-5891 Valve Mechanism GP

Ref. Part No. Description Qty. 1 276-9227 Link 8 2 298-4533 Shaft Assembly 1 3 276-9200 Plug , Shaft End 2 4 276-9201 Clip 1 5 276-9206 Spring , Shaft 3 6 276-9207 Spring , Shaft 1 7 278-5111 Rocker Arm Assembly 4 7A 276-9230 Nut 1 7B 278-5113 Adjusting Screw, Torx 1 8 278-5112 Rocker Arm Assem bly 4 8A 276-9230 Nut 1 8B 278-5113 Adjusting Screw, Torx 1 9 280-1912 Bracket 4 10 280-1913 Retainer 4 11 280-1914 Bolt, M8 x 1.25 x 55mm 8

9 ~ 10~ 2


298-5100 Filter GP-Engine Oil

Ref. Part No. Description Qt 7W -2326 Filter Assembly, Eng ine Oil

\ , "'-- -

PM1802 JUNE 2008 CAT C4.4 TIER 3 ENGINE 6·31

298-5128 Plug GP-Engine Oil Manifold

Ref. Part No. Description Qty. 1 225-7941 PluQ 2 8T-7876 Seal, O-RinQ 1 3 035-8063 Plug


301-8243 Connection GP-Water

Ref. Part No. Description Qt 1 132-2899 Bolt, M10 x 1.5 x 40mm 2 2 277-2974 Re ulator Assembl ,Water Temperature 1

(Connector Included) 3 281-8744 Gasket, Water Re ulator, Housin 1

rt-' 2

3

PM1802JUNE 2008 CAT C4.4 TIER 3 ENGINE 6 - 33

1G

1E

f ' 1F-':0

10

6

5

1C

6 - 34 CATC4. 4 TIER 3 ENGINE PM1802 JUNE 2008

0

0

301-8241 Cooler GP-Engine Oil

Ref. Part No. 1 298-4553 1A 298-4558 1B 298-4559 1C 298-4560 1D 61-1090 1E 101-3771 1F 61-0217 1G 61-0260 2 249-0974 3 225-7944 4 61-0645 5 252-6318 6 233-9408

Description Cooler Assembly, Engine Oil

Cooler, Engine Oil Gasket Gasket Bolt, M8 x 1.25 x 40mm Bolt Bolt, M8 x 1.25 x 20mm Bolt, M8 x 1.25 x 25mm

Head Assembly, Oil Filter Gasket Bolt, M8 x 1.25 x 25mm Plate Gasket

Qty. 1 1 1 2 5 2 1 8 1 1 8 1 1


0

311-4640 Fan GP

Ref. Part No. Description Qty. 111-5767 Fan

2 135-6363 Extens ion, Fan 1 3 135-6362 Stud 4 4 113-6349 Nut. M12 x 1.75 x 93mm 4

-----._.


298-5105 Pump GP-Water

Ref. Part No. Descri tion Qt 61-0217 Bolt, M8 x 1.25 x 20mm 2

2 61-0254 Bolt, M8 x 1.25 x 30mm 2 3 113-8129 Bolt, M8 x 75mm 7 4 307-9843 Pump GP-Water 1 4A 278-3242 Bolt, Flan e Head 2 4B 287-7430 Gasket, Cover 1 4C 225-8019 Gasket 5 277-2925 Connection Assembl SA 225-7738 Seal, O-Ring 5B 277-2923 Gasket


3


21

23


19B

/~~ 19E

190 19


0

0

312-1672 Radiator GP

Ref. Part No. Description Qty. 1 5P-0597 Clamp , Hose 3 2 5P-0598 Clamp 6 3 61-0260 Bolt, M8 x 1.25 x 25mm 1 4 61-0291 Nut, M8 x 1.25 thd 1 5 61-0594 Nut, M10 x 1.15 thd 2 6 7W-2601 Spacer 2 7 100-4458 Bolt, M8 x 1.25 x 14mm 4 8 100-4461 Bolt, M10 x 1.5 x 50mm 2 9 100-4830 Bolt, M10 x 1.5 x 20mm 2 10 101-7537 Bolt, M12 x 35mm 8 11 101-7538 Mount 2 12 101-7540 Washer 2 13 101-7541 Bolt 4 14 101-7546 Mount 1 15 103-6714 Clip 3 16 236-7722 Hose, Radiator, Upper 1 17 236-7734 Hose, Aftercooler 1 18 236-7735 Hose, Aftercooler 2 19 236-7766 Radiator Assembly 1 19A 114-4363 Bolt, M8 x 1.25 x 12mm 12 19B 236-7760 Guard , Radiator 1 19C 236-7763 Bracket, Mounting 1 19D 236-7764 Cap, Radiator 1 19E 236-7765 Plug, Drain, Radiator 1 20 236-8773 Bracket, Mounting 1 21 236-8777 Hose, Air Inlet 1 22 236-8780 Tube 1 23 236-8781 Hose, Radiator, Lower 1 24 236-8782 Guard 1 25 236-8783 Guard 1 26 236-8784 Guard , Fan 1 27 299-1601 Cover 1 28 303-2160 Stud 3 29 311-4621 Bracket 1 30 311-4623 Bracket 1 31 311-4624 Tube, Air 1 32 311-4631 Stud 1


C

301-8248 Connection GP-Air Inlet

Ref. Part No. Description Qty. 61-0260 Bolt, M8 x 1.25 x 25mm 4

2 111-8222 Bolt 4 3 114-2579 Gasket 2 4 124-3815 Bolt , M8 x 1.25 x 16mm 4 5 185-6627 Plate 2 6 238-8289 Pipe Assem bl 6A 238-8288 Gasket, Inlet

6 - 42 CAT C4.4 TIER 3 ENGINE · PM1802 JUNE 2008

307-2807 Filter Element AS-Air

Ref. Part No. Description Qt 104-2083 Cap , Air Cleaner

2 133-7403 Valve, Air Cleaner Dust 3 206-5234 Filter Element Assembly, Air, Primary 4 206-5235 Filter Element Assembly, Air, Seconda 5 206-5237 Cover Assembl 6 252-9208 Indicator, Air Filter Chan e 7 307-2808 Bracket

~~) '

5


26A

26B~ 26B~

I B

26

B 37

26A , /

26B ~ 26B~

3

19

REFER TO ALL ILLUSTRATIONS OF THIS GROUP FOR AUXILIARY VIEWS

24

6 - 44 CAT C4A TIER 3 ENGINE PM1802 JUNE 2008

./I

30

25~~"'.

(J'_/-~~)~_/

11

30C~ 13

308 -8

36E

8

~ <,

I

360

~ 3J6/ / C 36 E ~

//

k7~36A 368


36

35

34


Q

0

c

311-7456 Turbocharger GP

Ref. Part No. Description Qty. 1 61-0217 Bolt, M8 x 1.25 x 20mm 2 2 61-0254 Bolt, M8 x 1.25 x 30mm 2 3 61-0563 Nut, M10 x 1.5 thd 7 4 61-0593 Bolt, M10 x 1.5 x 30mm 2 5 61-0654 Bolt, M10 x 1.5 x 25mm 3 6 61-0789 Bolt, M10 x 1.5 x 60mm 4 7 61-0817 Adapter 1 8 61-4200 Bolt, M10 x 1.5 x 16mm 2 9 6M-7959 Clamp, Hose 1 10 9Y-9381 Washer, Hard 1 11 100-4830 Bolt, M10 x 1.5 x 20mm 1 12 106-8916 Bolt, M6 x 16mm 2 13 127-8165 Spacer 1 14 147-5553 Stud 7 15 194-5390 Gasket, Manifold 1 16 225-8530 Gasket 1 17 225-8533 Gasket 1 18 225-8534 Gasket 1 19 227-4562 Elbow, Exhaust 1 20 232-6189 Tube Assembly 1 21 278-0361 Bolt, M10x 1.5x45mm 8 22 293-0598 Clip 1 23 294-7375 Solenoid, Air Fuel Ratio Control 1 24 298-4570 Gasket, Exhaust Manifold 1 25 298-4576 Clip 1 26 301-8255 Tube Assembly 1 26A 225-8524 Bolt, M10 x 1 x 23mm 2 26B 225-8526 Washer, M10.4 x 13.75 x 1.37mm thk 4 27 301-8256 Manifold, Exhaust 1 28 302-0581 Adapter, Exhaust 1 29 303-2116 Clip 4 30 303-5791 Tube Assembly 1 30A 4B-8774 Nut, Flared 1 30B 032-8047 Ferrule 30C 035-8014 Nut, 7/16in 1 31 303-5792 Bracket 1 32 307-2805 Bracket 1 33 307-2807 Filter, Element AS-Air 1 34 307-2831 Bracket 1 35 307-2832 Hose, Air 1 36 311-7458 Tube Assembly 1 36A 032-8047 Ferrule 1 36B 032-8191 Nut 1 36C 298-4576 Clip 2 360 300-6520 Hose Assembly 1 36E 107-2348 Clip 2 37 316-0514 Turbocharger 1


304-8762 Pipe GP-Exhaust

Ref. Part No. Description Qty. 61-4013 Flanqe

2 61-4039 Gasket, Exhaust 1 3 61-4012 Stud 3 4 61 -0563 Nut , M10 x 1.5 thd 3


"'K11B

~1 1 A

11


10

4

FUEL

/ FILTER

6 - 50 CATC4 . 4 TIER 3 ENGINE PM1802 JUNE 2008

311-2271 Filter GP-Fuel ev ~ Ref. Part No. Description Qty.

1 61-0254 Bolt, M8 x 1.25 x 30mm 1 2 61-4709 Bolt, M8 x 1.25 x 100mm 1 3 215-9509 Fitting Assembly, Quick Disconnect 1 4 232-1115 Clip, Pipe 3 5 234-3063 Clip 2 6 277-6165 Connection , Fuel 1 7 298-4592 Tube Assembly 1 8 298-4595 Tube Assembly 1 9 298-4597 Tube Assembly 1 10 308-7487 Tube Assembly 1 11 308-7571 Tube Assembly 1 11A 295-4670 Bolt, Special, Banjo 2 11B 308-7577 Washer 4 12 311-2270 Spacer 1

278-4138 Protection GP-Fuel System (Not Shown) 5

C

0


298-5123 Filter GP-Primary Fuel

Ref. Part No. Description Qt . 298-4603 Filter AS-Fuel , Primar 1

1A 298-0600 Filter AS-Fuel , Ultra High Efficiency 278-4138 Protection GP-Fuel System

-----

1A --_.

..... »>-_._---


263-7148 Filter GP-Water Separator & Fuel

Ref. Part No. Descri tion Qt . 271-5076 Filter AS-Water Se arator & Fuel

2 307-3526 Kit, Bowl 2A 277-4993 Seal , O-Ring 2B 313-1670 Seal ,O-Rin 1 2C 313-1671 Washer 3 313-1663 Sensor, Pressure, Fuel 1

2 3


301-8251 Filter GP-Water Separator & Fuel

Ref. Part No. Description Qt 1 263-7148 Filter GP-Water Separator & Fuel 1 2 277-4990 Elbow 1 3 277-4991 Connection 1 4 277-4993 Seal , O-Ring 1

FUEL INJECTOR PUMP


292-3780 Injector GP-Fuel

Ref. Part No. Description Qt . 1 287-7637 Washer

12 274-1639 Seal

l~, 2


27

19 ) 32

18

28

35

I I

/ '---- 36

/

37

31


17 16

~'7A

PM1802 JUNE 2008 CAT C4,4 TIER 3 ENGINE 6 - 57

21

23

C~~.4TIER~3~E;N;G;I~N;E-----------------------6 - 58 PM1802 JUNE 2008

C

C

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

16A 17

17A 18 19 20 21 21A 22

22A 23 23A 24 24A 25 25A 26 26A 27 28 29 30 31 32 33 34 35 36 37 38


Part No. Description Qty. 61-0260 Bolt, M8 x 1.25 x 25mm 3 61-0455 Bolt, M8 x 1.25 x 55mm 3 61-0572 Bolt, M8 x 1.25 x 20mm 4 7W-2632 Washer, 8.5 x 16.8 x 1.6mm thk 1 100-4830 Bolt, M10 x 1.5 x 20mm 1 101-3895 Bolt, M8 x 1.25 x 35mm 4 124-3815 Bolt, M8 x 1.25 x 16mm 4 141-8584 Bolt, M8 x 1.25 x 50mm 4 300-6714 Mount 8 160-0162 Washer 2 217-0099 Spacer, 8.2 x 25 x 2mm thk 4 217-8477 Clip 1 230-8989 Gear, Fuel Pump , 68 Teeth 1 232-3149 Washer, 8.35 x 16.85 x 1.55mm thk 6 308-8425 Rail Assembly, Fuel 1 268-6677 Bracket Assembly 1 260-3718 Bracket 1 260-3939 Screw, Hex Head 1 268-6678 Bracket Assem bly 1 260-3719 Bracket 1 260-3939 Screw, Hex Head 1 278-5168 Clamp, Injector 4 278-5170 Bolt 4 278-5203 Spacer 4 278-5225 Kit, Sensor, Enqine Oil Pressure 1 199-9267 Seal , O-Ring 1 311-3858 Kit, Sensor, Engine Speed 1 238-0120 Sensor GP-Speed 1 274-1639 Seal 1 278-5272 Kit, Sensor, Intake Air Temperature 1 278-5226 Seal, O-Rinq 1 278-5273 Kit, Sensor, Air Pressure 1 199-9252 Seal, O-Rinq 1 278-5307 Kit, Sensor , Coolant Temperature 1 199-9267 Seal, O-Rinq 1 311-6342 Kit, Sensor, Fuel Rail Pressure 1 309-8006 Seal , O-Ring 1 283-2271 ' Pump GP-Fuel Injection 1 292-3780 Injector GP-Fuel 4 298-4535 Bracket, Support 1 298-4536 Bracket, Mountinq 1 298-4537 Tube Assembly 1 298-4538 Tube Assembly Cyl No 1 1 298-4539 Tube Assembly Cyl No 2 1 298-4540 Tube Assembly Cyl No 3 1 298-4541 Tube Assembly Cyl No 4 1 298-4542 Tube Assembly 1 298-4543 Bolt 1 308-3395 Bracket, Mountinq 1 278-4138 Protection GP-Fuel System 4

~


--.


Ref. Part No. Descri tion Qt . 5A-3604 Bolt, Socket Head, M8 x 1.25 x 25mm 5

2 238-0120 Sensor GP-S eed, Fuel Pum 3 117-1385 Seal,O-Rin 4 60-7889 Seal,O-Rin 1 5 277-1950 Nut 6 277-1949 Washer 7 228-7100 Seal,O-Rin 8 248-1066 Fittin ,Fuel 9 293-0249 Pump GP-Fuel Transfer 10 247-6019 Seal 11 8T-4200 Bolt, M8 x 1.25 x 16mm


311-7455 Alternator GP-Charging

Ref. Part No. Description Qt 1 6B-0923 Spacer, 10.3 x 19.05 x 6.35mm thk 1 2 61-0260 Bolt, M8 x 1.25 x 25mm 1 3 61-0454 Bolt, M10 x 1.5 x 70mm 1 4 61-0594 Nut. M10 x 1.5 thd 1 5 067-6366 Washer, M8 x 1.25 thd 1 6 100-8451 Bolt, M8 x 1.25 x 130mm 1 7 113-6349 Nut, M12 x 1.75 x 93mm 8 140-8783 Bolt, M10 x 45 thd 2 9 225-3141 -Alternator GP-Charging, 12 Volt 1 10 233-9530 Bracket 11 233-9531 Lever, Adlustin 1 12 228-7391 Pulley, Alternator

12

9

6

I I-:

11

10


304-6436 Control & Mtg GP-Engine Electric

Ref. Part No. Description Qt 286-3683 Control GP-Un ro rammed

2 278-5201 Connection 2 3 278-5202 Seal, O-Ring 2


298-5125 Glow Plug GP

Ref. Part No. Description Qt 1 292-9880 Glow Plu ,12 Volt 4 2 298-5772 Bar 1

2


298-5130 Harness GP-Wiring

Ref. Part No. Descri tion Qt 288-0514 Harness Assembl , En ine

2 236-5539 Clip 3 278-5209 Bracket 4 278-5210 Bolt 1 5 298-4605 Bracket 6 124-3815 Bolt , M8 x 1.25 x 16mm 3 7 217-8477 Clip 8 298-4606 Bracket 9 298-4607 Bracket 1 10 217-9039 Strap, Cable 3

8.: I

~~. 6 "{ ())


303-4619 Starting Motor GP-Electric

Ref. Part No. Description Qt . 1 61-0364 Stud, M10 x 1.5 x 30mm 3 2 61-0594 Nut, M10 x 1.5 thd 3 3 225-3148 Starting Motor GP-Electric, 12 Volt

2~l I


Notes

6 - 66 CAT C4.4 TIER 3 ENGINE PM1802JUNE 2008

Section 7: PS750 4WD Transmission with elW PTa


7-2 G2-13-1 Transmission

7-4 G2-13-10 Transmission Assembly

7-6 G2-13-20 Clutch, Input

7-8 G2-13-30 Pump, Torque Converter

7-10 G2-13-40 Clutch, Reverse

7-12 G2-13-50 Mainshaft Components

7-14 G2-13-60 Layshaft Components

7-16 G2-13-70 Switch, Solenoid

7-18 G2-13-80 Pipework

7-19 G2-13-90 Shaft, PTO

7-20 Z1-3-5 Torque Converter, 2.1:1 Ratio

7-21 P1-1-90 Dipstick, Tube

7-22 Notes

PM1802 JUNE 2008 ITL PS750 4WD TRANSMISSION WITH elW PTO 7-1

235561

7-2 ITL PS750 4WD TRANSMISSION WITH e/W PTO PM1802 JUNE 2008

C)

C)

G2-13-1 Transmission, PS750 4WD Powershift, 460/81160

Ref. Part No. Description Qty. 1 459/30173 Housinc , Flywheel , 5 Speed , SAE3 1 2 459/30465 Casing, Front, PS750 5 Speed 1 3 459/10015 Casing, Rear 1 4 826/0 1417 Bolt 19 4A 826/01580 Bolt 2 5 445/14001 Dowel 4 6 1315/3418Z Bolt, M10 x 80 7 6A 1315/0408Z Bolt, M10 x 30 2 6B 826/01417 Bolt 4 7 1606/0017 Adapter, 5/8" x 1/2" M/M 2 8 1406/0018 Seal , Bonded , 1/2" BSP 3 9 816/80041 PluQ 1 10 814/00222 Sprinq 1 11 916/00008 Bearing, 0 14 Ball 1 12 816/80053 PluQ, 3/8" Tapered 7 13 813/50027 Gasket 1 14 32/902200 Strainer, Suction 1 15 1321/0303Z Screw, M8 x 16 2 16 816/15184 Adapter, 1/2" BSP x 1" UNF 1 17 Transit Pluq, Replaced By Item 34 1 18 828/10222 a -Ring 5 20 1406/0015 Washer, Seal 3 21 1321/3420Z Bolt 2 24 816/80051 Pluq, 1/8" Tapered 7 25 1 30 816/80047 Plug 1 31 1406/0026 Washer. Seal 1 32 45/908300 Connector, Pressure Test 1 33 816/80005 Plug 1 34 581/18062 Filter, Oil, Transmission 1

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTa

C

7-3

26 25

2

235612 31

ITL PS750 4WD TRANSMISSION WITH CIWPTO PM1802 JUNE 2008 7-4

0 G2-13-10 Transmission, Assembly, Powershift, 460/81160

~ Ref. Part No. Description Qty. 1 460/81160 Gearbox, PS750 4WD L, Powershift 1 2 459/10119 Clutch Assembly 4WD 1 20 445/37100 Gear, Output, 41T , Plate Carrier 1 21 445/04700 Kit, Shim 1 24 904 /50023 Seal 1 25 813/50054 Gasket 1 26 449/10014 Cover , 4WD Output 1 27 826/01417 Bolt 10 28 331/12043 Flanqe, Output , 4WD Gearbox 1 31 445/33701 Gear, Input 25T 1 32 826/01553 Bolt, Setscrew 1

Q

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH C/w PTO

C

7-5

310740

7·6 ITL PS750 4WD TRANSMISSION WITH elW PTO PM1802 JUNE 2008

0

0

G2-13-20 Clutch, Input, 4WD CIW PTO, Powershift Transmission, 460/81160

Ref. Part No. Description Qty. OA 459/10004 Clutch, Input 1 1 460/80300 Housing, Clutch 1 2 904/50020 Seal, Rinq 1 3 907/10000 Bearing 2 4 460/35602 Gear, Plate Carrier, 31T 1 5 2203/1115 Circlip 2 6 449/10001 Gear,48T 1 7 449/10501 Disc , Sprmq, Splined 2 8 828/00414 O-Rinq 2 9 814/00345 Spring 2 10 821/00523 Circlio 2 11 445/12303 Washer, Thrust 2 12 449/10003 Hous inq, Plate Carrier Assembly, 22T & 45T 1 13 445/40203 Sprinq, Retaininq 2 14 445/40204 Baffle, Oil 2 15 449/11370 Piston, Assembly 2 16 445/30011 Plate, Friction 12 17 445/12307 Plate , Counter 12 18 828/00224 O-Rinq 2 19 917/02700 Bearing 1 20 445/12314 Shim, Plate , Toothed AR 22 459/10171 Kit, Pressure Plate, 6mm & 6.5mm 1 23 445/26108 Washer, Thrust 2 24 921/52400 Kit, Shim 1 25 917/02800 Bearing, Thrust 2 26 907/52800 Bearinq, 35 x 65 x 18 1 27 921/02000 Kit, Shim 1 28 907/52800 Bearinq, 35 x 65 x 18 1

PM1802 JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTO

C

7-7

ITL PS750 4WD TRANSMISSION WITH elW PTO PM1802JUNE 2008 7-8

c

Q

G2-13-30 Pump, Torque Converter, 4WD CIW PTO, Powershift Transmission, 460/81160

Ref. Part No. 1 20/925000 2 813/50041 3 1315/3311Z 4 904150028 5 460/35608 6 828/00275 7 904/50031 8 916/10001 9 459/50209

Description Qty. Pump, Assembly, Transmission 1 Seal, Rear 1 Bolt, M8 x 45 4 Seal, Rinq 1 Washer 1 O-Ring 1 Seal, Sinqle Lip 1 Bearing, Ball , 60 x 95 x 18 1 Gear, Enqine Driven , Bearinq Support 1

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH elW PTO

0

7-9

290901

7 -10 ITL PS750 4WD TRANSMISSION WITH elW PTO PM1802 JUNE 2008

c

e

C)

G2-13-40 Clutch, Reverse, 4WD CIW PTO, Powershift Transmission, 460/81160

Ref. Part No. 1 459/10003 2 449/11510 3 828/00224 4 449/11370 5 828/00414 7 445/40204 8 814/00345 9 445/40203 10 821/00523 11 449/10501 12 459/10171 13 445/30011 14 445/12307 15 2203/1115 16 445/12314 17 445/13203 18 917/02800 19 445/26108 20 449/10002 21 449/10003 22 917/02700 23 445/03209 24 907/52800 24A 907/52800 25 904/50020 27 449/10001 28 921/53600 29 816/80041 30 1406/0018

Description Qty. Clutch, Reverse , Powershift 1 Housing, Reverse Gear 1 O-Rinq 2 Piston, Assembly 2 a-Ring 2 Baffle, Oil 2 Spring 2 Sprinq, Retaining 2 Circlip 2 Disc, Spring , Splined 2 Kit, Pressure Plate, 6mm & 6.5mm 2 Plate, Friction 12 Plate, Counter 12 Circlip 2 Shim, Plate, Toothed AR Washer, Thrust 2 Bearing, Thrust 4 Washer , Thrust 4 Housing , Plate Carrier Assembly, 31T & 45T 1 Housing, Plate Carrier Assembly, 22T & 45T 1 Bearinq 2 Washer, Thrust 2 Bearinq, 35 x 65 x 18 1 Bearing, 35 x 65 x 18 1 Seal, Ring 3 Gear,48T 1 Kit, Shim, 0 65mm (55 Various Shims) 1 Plug 1 Seal, Bonded, 1/2" BSP 1

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTa 7·11

7 -12 ITL PS750 4WD TRANSMISSION WITH CIWPTO PM1802 JUNE 2008

0 G2-13-50 Mainshaft Components, Powershift

Transmission, 460/81160

Ref. Part No. Description Qty.

C>

1 826/01551 Nut, Stake M30 (46mm Head) 1 2 823/00331 Washer 1 3 449/01602 Flanqe, Output 1 4 904/05100 Seal 1 5 907/53800 Bearinq 1 6 921/53400 Kit, Spacer 1 7 907/53700 Bearing 1 8 459/50762 Gear, Transfer, 46T 1 9 459/10259 Clutch, Assembly, Mainshaft 1 10 445/12314 Shim , Plate, Toothed 1 11 459/10171 Kit, Pressure Plate, 6mm & 6.5mm 1 12 445/03205 Plate, Friction 9 13 445/12307 Plate, Counter 9 14 821/00523 Circlip 1 15 445/12304 Retainer, Sprinq 1 16 814/00297 Spring 1 17 331/38655 Baffle, Oil 1 18 2203/1115 Circlip 1 19 449/10900 Piston, Assembly 1 20 828/00224 O-Rinq 1 21 828/00414 O-RinQ 1 22 449/10300 Gear, Mainshaft 1 23 904/50020 Seal, Rinq 2 24 907/52800 Bearing, 35 x 65 x 18 1 24A 907/52800 Bearino, 35 x 65 x 18 1 25 445/04700 Kit, Shim 1 26 449/10009 Spacer, Mainshaft 1 27 828/00412 O-Rlnq 2

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTO 7 -13

C

n

31

235523

7 -14 ITL PS750 4WD TRANSMISSION WITH CIWPTO PM1802 JUNE 2008

C

o

G2-13-60 Layshaft Components, 4WD CIW PTO, Powershift Transmission, 460/81160

Ref. Part No. 1 826/01361 2 459/30266 3 813/10171 4 921/53700 5 449/11340 6 907/09600 7 449/10021 8 917/50300 9 831/00113 10 449/10812 11 917/50400 12 445/30007 13 821/00523 14 445/12304 15 814/00297 16 445/13205 17 2203/1115 18 445/12314 19 449/10602

449/10603 20 445/30011 21 445/12307 22 449/10900 23 904/50020 24 828/00224 25 828/00231 26 828/00414 27 459/50411 28 907/09600 29 30 828/10222 31 449/10601

Description Bolt Cover, Layshaft, PS750 5 Speed Gasket, l.avshaft, PS750 5 Speed Kit, Shim Clutch, Layshaft Assembly, Low Ratio Beartnq, 35 x 73 x 24 Gear, Layshaft Bearing, Needle, 70 x 50 x 3mm Washer, Thrust, 50 x 70 x 1mm Gear,40T Bearinq, Needle Roller Washer Circlip Retainer, Sprlnq Spring Baffle, Oil Circlip Shim, Plate, Toothed Plate, Pressure, 6mm thick Plate, Pressure, 6.5mm Plate , Friction Plate, Counter Piston, Assembly Seal, Rinq a-Ring O-Rinq a-Ring Housing, Clutch, Layshaft Bearinq, 35 x 73 x 24 Input Gear (See G2-13-1) O-Rinq Plate, Pressure, 4mm

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

AR 1 1 7 6 1 2 1 1 1 1 1 1 1 1

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTa 7 -15

C

10r--'---,

fQ~

O..:l!~~ ~o

235481

7 -16 ITL PS750 4WD TRANSMISSION WITH elW PTO PM1802 JUNE 2008

G2-13-70 Switch, Solenoid, 4WD elW PTO, Powershift

c Transmission, 460/81160

Ref. Part No. Description Qty. 1 813 /50055 Gasket 1 2 459 /10090 Adapter , Block Assembly, Std Pressure 4WD 1 2A 459/70168 Spool , Adapte r Solenoid 1 3 814/00407 Sprinq 1 4 816/80061 Pluq 1 5 1315/0308Z Screw , M8 x 30 14 7 1315/3311Z Bolt, M8 x 45 2 8 25/105100 Valve , Soleno id, c/w AMP Connectors 1 8A 25/104001 Coil, Solenoid 1 9 25/104700 Valve , Solenoid 3 9A 477 /00824 Coil 1 10 35/100801 Kit, Seal, Solenoid Valve 1 12 1391/3108Z Capscrew 12 13 1391/3201 Capscrew, M6 x 10mm x 12.9 1 14 704 /30500 Sensor, Speed 1 15 828/00376 a-Ring, 0 5mm Section 1 16 25/102700 Cartridqe , Blank 1

0

PM1802JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTa 7 -17

C

G2-13-80 Pipework, 4WD elW PTO, Powershift Transmission, 460/81160

Ref. Part No. Description Qty. 1 449/52700 Pipe, 4WD Feed 1 2 816/15178 Ada ter 1 3 1406/0008 Seal, Washer 1 4 1603/0001 Ada ter, Bund Pipe 1 5 1406/0011 Seal, Bonded 1 7 449151500 Pi e, Mainshaft 1 9 1406/0018 Seal, Bonded, 1/2" BSP 2 10 1603/0003 Adapter 2

5

b~ 4

10

~~ 9

252240

7-18 ITL PS750 4WD TRANSMISSION WITH elW PTO PM1802 JUNE 2008

G2-13-90 Shaft, PTO, 4WD, Powershift Transmission, 460/81160

Ref. Part No. Description Qty. 1 460/32301 Shaft , PTa 2 904/50020 Seal , Rin 2 3 907/52800 Bearin ,35 x 65 x 18 2 4 445/04012 Spacer 5 921/53600 Kit, Shim , 0 65mm 55 Various Shims 6 826/01813 Circli 7 460/35606 Gear, Transfer, 37T 8 826/01553 Bolt, Setscrew

PM1802 JUNE 2008 ITL PS750 4WD TRANSMISSION WITH CIW PTa 7 -19

Z1·3·5 Torque Converter, 2.1:1 Ratio, Drive Plate

Ref. Part No. Description Qt 475/01000 Converter, 2.1:1 Ratio, 1 Pur Ie, 1 Black S at

2 041500300 Kit, Drive Plate 3 04/500303 Bolt 6 4 04/500304 Bolt 6 5 04/500305 Washer, Plain 12

248321

7 - 20 ITL PS750 4WD TRANSMISSION WITH CIW PTO PM1802JUNE 2008

P1·1·90 Dipstick, Tube

Ref. Part No. Description Qt 475/26200 Tube, Dipstick, White

2 475/26100 Dipstick, White 3 155/10600 Nut, Sealastic 3A 904/20334 Kit, Seal, and Ferrule 4 475/31201 Bracket 1

1

2

248370

PM1802 JUNE 2008 ITL PS750 4WD TRANSMISSION WITH elW PTa 7 - 21

Notes

7 - 22 ITLPS750 4WD TRANSMISSION WITH elW PTO PM1802JUNE 2008

Section 8: Cooling System


8-2 Radiator & Cowling

8-3 Radiator Bracket & Fixings

8-4 Radiator Bracket & Fixings

8-5 Guards

8-6 Radiator & Hoses

8-7 Coolant Recovery Reservoir

8-8 Hydraulic Oil Cooler

PM1802 JUNE 2008 COOLING SYSTEM 8-1

Radiator & Cowling

Ref. Part No. Description Qt 1 2486F103 Radiator 1 2 Radiator 1 3 24850075 Cowl 1 4 24850076 Mount in Bracket 1 5 24850073 Radiator Cap 1 6 24850077 Drain Plug 1 7 2314H102 Screw 6 8 2314H102 Screw 6

b I

2 '", I

7

COOLING SYSTEM PM1802 JUNE 2008 8-2

Radiator Bracket & Fixings

Ref. Part No. Description Qt 3823A056 Mountin Bracket

2 33546 Rubber 2 3 2311F055 Screw 4 4 2314J008 Screw 2 5 0920471 Washer 2 6 33115117 Spacer 2 7 2314C369 Screw 8

~4

~7

I

PM1802 JUNE 2008 COOLING SYSTEM 8-3

Radiator Bracket & Fixings

Ref. Part No. Description Qty. 1 3651A021 Bracket 1 2 2314J003 Screw 2 3 2634A115 Mount ing 1 4 2318A209 Nut 2 5 2131A010 Washer 2 6 2134A010 Washer 2 7 500-056 Bracket 1 8 2314H004 Screw 1

8 ~:(~ ~6 I

~~ $-37

I J:

- 1

~2v /~

-.


Guards

Ref. Part No. Description Qt . 3756V087 Radiator Guard 1

2 3756V088 Radiator Guard 3 2314H001 Screw 2 4 2314H001 Screw 3

4

~ ~3

PM1802JUNE 2008 COOLING SYSTEM 8-5

Radiator & Hoses

Ref. Part No. Description Qty. 3483H045 Hose

2 24810075 Hose Clip 3 24810076 Hose Clip 4 3383A029 Hose 5 24810074 Hose Clip 6 3483H047 Hose 7 24810074 Hose Clip 2 8 3476A001 Air Pipe 9 3383A032 Hose 1 10 24810074 Hose Clip 11 24810074 Hose Clip 12 3383A034 Hose 13 24810075 Hose Clip 14 24810075 Hose Clip 1

(

6

8


Coolant Recovery Reservoir

Ref. Part No. Description Qty. 067-020 Reservoir

2 067-020A Cap 3 011-051 Clamp , 1/2" Hose 2 4 010-905 Hose, 5/16" ID (Bulk-Specify Len th) AR 5 011-147 Bolt, 5/16-18 x 1" 2 6 011-033 Washer, 5/16" Lock 2 7 011-021 Nut, 5/16-18 2

7

From Radiator 4 Overflow

3 J2 ~ \ 1

~ ../' 3

../'

PM1802JUNE 2008 COOLING SYSTEM 8-7

Hydraulic Oil Cooler

tion Cooler Assembl Fittin ,900 Elbow

Ref. Part No. Descri Qt . 077-025 , H draulic Oil

2 050-104 2 3 040-363 Hose, 3/4" x 104" 1 4 040-364 Hose, 3/4" x 122" 1 5 040-098 Hose, 3/8" x 114" Cooler to Steer Motor 1 6 040-188 Hose, 1/2" x 80" Cooler to H draul ic Tank 7 050-353 Fittin , Elbow SAE 12 to 1/2" JIC 2 8 050-136 Reducer, 1/2" to 3/8" 9 011-330 Bolt, 3/8-16 x 3/4" 4 10 011-334 Washer , 3/8" Lock 4 11 500-057 Bracket , Cooler to Radiator 4

fROM MOTOR

TO TRANSMI SSION

6

TO HYDRAULIC TANK

STEER

fROM TRANSMISSION

COOLING SYSTEM PM1802JUNE 2008 8-8

Section 9: Air, Fuel & Exhaust


9-2 Fuel Tank

9-4 Air Cleaner & Hoses

9-5 Air Cleaner Assembly

9-6 Exhaust System

9-8 Notes

PM1802 JUNE 2008 AIR, FUEL & EXHAUST 9-1

13~14/15

12 C+Y )

8

7

4

('

3

1 2

AIR, FUEL & EXHAUST PM1802 JUNE 2008 9-2

0

0

Ref. 1

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

-4 16 17

Part No. 500-026 510-026 050-246 090-117 090-022 011-051 090-082 011-129 011-029 011-025 011-036 090-107A 090-107B 011-350 011-033 500-026D 090-107 090-181

Fuel Tank

Description Qty. Fuel Tank , 14,000 - 16,000 Lb. Units 1 Fuel Tank , 18,000 - 20,000 Lb. Units 1 Fitting, 1/2" NPT Plug 1 Fitting, 900

, Brass Pipe to Barb 1 Fuel Petcock 1 Clamp , 1/2" Hose 1 Hose, 5/16" (Specify l.enqth) AR Bolt, 1/2-13 x 1-1/2" 8 Washer, Flat 1/2" 16 Nut, 1/2-13 8 Washer, Lock 1/2" 8 Gasket, Fuel Sender 1 Screw, 10-32 x 15/32" (Included with Sender) 5 Bolt, 5/8-18 x 5/8" 4 Washer, Lock 5/16" 4 Cover Plate, Sender Unit 1 Sender Unit 1 Cap, Fuel 1

~~

PM1802JUNE 2008 AIR, FUEL &EXHAUST 9-3

Air Cleaner & Hoses

Ref. Part No. Description Qt 060-103 Air Cleaner Assembly

2 060-1038 Clam , 6" Hose 1 3 060-103C Elbow, 5-1/2" 00 to 4-1/2" 00, Rubber 4 060-103F Clamp, 5" Hose 3 5 060-1030 Tube, 4" 00 x 13" x 30° 6 060-103E Elbow, 4-1/2" 00 7 500-055 Bracket, Air Cleaner Mount, 14,000-16,000 LB Cap.

510-055 Bracket, Air Cleaner Mount, 18,000-20,000 LB Cap. 1 8 011-147 Bolt, 5/16-18 x 1" 8 9 011-028 Washer, Flat 5/16" 16 10 011-033 Washer, Lock 5/16" 8

Nut, 5/16-18 011-02111 8

HOOD

7

BACK OF CAB

11~>, 9

3

5

44I

~~"TO TURBO CHARGER 4

44,

AIR, FUEL & EXHAUST PM1802 JUNE 2008 9-4

Air Cleaner Assembly

Ref.

2 3

Part No. 060-103 060-1038 060-103A

I

I /[,../

Description Air Cleaner Assembl Includes 1-3 Element , Inner Element, Outer

Qt 1

PM1802JUNE 2008 AIR, FUEL & EXHAUST 9-5

9-6 AIR, FUEL &EXHAUST PM1802 JUNE 2008

2

,

~lO I I

I I

Il.., I

"' I '''' , I

"' I''''-,J

1

3

11

I

I I

I BOLTS TO EXHAUS T

OUTE R FLANGE

-: , '/'

,/ ,'/'

,/ ,/'

,/'

, '/'

8

0

0

Ref. Part No. 1 060-062 2 060-062B 3 210-518A 4 011-023 5 011-091 6 011-009 7 2314J005 8 500-009A

500-009B 9 011-345 10 011-283 11 060-062A

Exhaust System

Description Qty. Muffler 1 Tail Pipe 1 Bracket, Wrap Around Muffler 1 Nut, 3/8-16 2 Washer, Flat 3/8" 2 Bolt, 3/8-16 x 1" 2 Nut, Exhaust Flange 3 Support, Muffler 1 Bracket , Muffler Support to Wrap Around Bracket 1 Bolt, 10 x 1.50 x 30mm 2 Clamp, 3" Muffler 1 Pipe, Manifold to Muffler 1

PM1802 JUNE 2008 AIR, FUEL &EXHAUST

0

9-7

Notes

AIR , FUEL & EXHAUST PM1802 JUNE 2008 9-8

Section 10: Hydraulic System


10-2 Hydraulic Tank & Fittings

10-4 Hydraulic Oil Filter

10-5 Hydraulic Pump

10-6 Hydraulic Steering Circuit

10-7 Variable Relief Valve

10-8 Hydraulic Circuit-Tilt & Side Shift

10-10 Tilt Cylinder 050-490

10-12 Side Shift Cylinder 050-470

PM1802 JUNE 2008 HYDRAULIC SYSTEM 10 -1

10 - 2 HYDRAULIC SYSTEM PM1802 JUNE 2008

C

Hydraulic Tank &Fittings (J

Ref. 1

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

Part No. 500-025 510-025 500-025F 055-011 055-078E-1 055-121 011-010 011-034 011-129 011-029 011-036 011-025 050-412 040-075 040-384 040-377 040-374 050-014A 050-097 040-376 050-246

~

PM1802 JUNE 2008

Description Qty. I Hydraulic Tank Assembly, 14,000-16 ,000 Lb Units 1 I Hydraulic Tank Assembly, 18,000-20,000 Lb Units 1 I Dipstick Gasket Plate , Access Hole Cover, with Breather Cap Breather Cap Bolt 3/8-16 x 1-1/2" Washer, Lock 3/8" Bolt, 1/2-13 x 1-1/2" Washer, Flat 1/2" Washer, Lock 1/2" Nut, 1/2-13 Fittinq, 900

, 1-1/4" AORB x 1-1/2" Barb

1 1 1 1 6 6 8 16 8 8 1

Hose, 1-1/2" Suction (Bulk-Specify Length) AR I Hose, 1" x 30", Control Valve to Tank 1 Hose, 1/2" x 86", Variable Relief Valve to Tank 1 Hose, 1/2" x 92", Brake Return to Tank 1 Fitting, 900 Elbow, 1/2" JIC x 1/2" NPT 3 Fitting, 900 Elbow, 3/4" JIC x 1" NPT 1 Hose, 1/2" x 92", Tank to Oil Cooler 1 Plug, 1/2" NPT 1

.

,

" HYDRAULIC SYSTEM 10·3

Hydraulic Oil Filter

Ref. Part No. Description Qt . 050-075 Head , Filter

2 050-074 Filter 3 050-074A Gasket, Filter 4 100-144 Bracket 5 011-006 Bolt , 5/16-18 x 3/4" 2 6 011-033 Washer, Lock 5/16" 2 7 050-068 Fittin , 1-1/4" Pipe to Barb 2 8 050-010D Clam 2 9 040-075 Hose, 1-1/2 " Suction S ecifi AR

TO HYDRAULIC

....

3

2

TANK

9

TO HYDRAULIC PUMP

PM1802JUNE 200810·4

Hydraulic Pump

Ref. Part No. Description Qt . 050-419 Pump, 2-Sta e

2 011-702 O-Rin , 4-1/4" 00 x 4" 10 3 011-426 Bolt, M12x1.5 x 35MM GR-10.9 2 4 050-068 Fittin , 1-1/4" Pi e to Barb 5 050-0100 Clamp 6 040-075 Hose , 1-1/2" Suction Specif Len th AR 7 050-568 Fittin , 3/4" JIC x 3/4" Tube 90° 1 8 050-007A Kit, Tube Assembl 9 040-383 Hose , 1" x 134" , To Control Valve 1 10 030-008 Fittin ,3/8" BSP to 1/2" JIC ST THO Adapter 1 11 040-373 Hose , 1/2" x 125", To Steer Motor

PM1802 JUNE 2008 HYDRAULIC SYSTEM 10 - 5

Steering Hydraulic Circuit

Ref. Part No. Description Qt . 030-011 Steer Motor

2 030-008 Fitting, Strai ht, 3/8" SSP to 1/2" JIC 4 3 040-375 Hose, 1/2" x 45", Steer Motor to Trans . Pump 4 040-380 Hose, 1/2" x 188", Steer Motor to Trans . Oil Cooler 5 040-382 Hose, 1/2" x 151", Steer Motor to LH Steer C Iinder 1 6 040-381 Hose, 1/2" x 152", Steer Motor to RH Steer C Iinder 1

10 - 6 HYDRAULIC SYSTEM PM1802JUNE 2008

Variable Relief Valve

Ref.

2 3 4 5 6

Part No. 050-255 050-255A 050-104 050-151 040-384 040-385

2

Description Valve, Variable Relief Cartrid e, Relief Valve Fittin ,90 De Adiustable Elbow Fittin ,Strai ht, 1/2" ORB x 3/4" JIC Hose, 3/4" x 30", Relief Valve to Mast Hose, 3/4" x 19", Relief Valve to Control Valve

Qty.

1 3 1 1

3

-~,

TO MAST

TO CONTROL VALVE

3

4

PM1802JUNE 2008 HYDRAULIC SYSTEM 10 -7

1 'fliT

C. It""'~ (tv OJ1>-4qo raj 10- ,0

9

10 t'S,J. Sh,ff c'd rwtJi"f ~, 10 -' Z..

10 - 8 HYDRAULIC SYSTEM PM1802 JUNE 2008

Hydraulic Circuit - Tilt & Side Shift

C Ref. 1

2 3 4

5

6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part No. 050-325 050-565 050-326 050-104 050-132 050-303 050-141 056-302 040-129 050-199 050-141 050-470 040-350 040-351 050-126 050-126A 040-352 040-353 050-490 011-177 120-121 120-160

Description Control Valve, 3-Spool Control Valve, 4-Spool Fitting, 1" Barb x 3/4"ORB, Control Valve Return Fittinq, Inlet, 90° Adjustable Fitting, 90°, 3/8"ORB x 1/2"JIC, 3-Spool Valve Fitting, 90°, 5/8"ORB x 1/2"JIC, 4-Spool Valve Fittinq, 90°, 3/8"ORB x 3/8"JIC, 3-Spool Valve Fitting, 90°, 5/8"ORB x 3/8"JIC, 4-Spool Valve Hose, 3/8" x 18", Upper Port to Rod End Fittinq, 45°, 3/8"STR x 3/8"JIC Fitting, 90°, 3/8"STR x 3/8"JIC Cylinder, Side Shift Hose, 1/2" x 13", Lower Port to Lower Tee Hose, 1/2" x 29", Upper Port to Upper Tee Flttinq, Bulkhead Branch Tee 3/8"JIC Nut, Lock, Bulkhead Tee Hose, 1/2" x 34", Bulkhead Tee to RH Cylinder Hose, 1/2" x 40", Bulkhead Tee to LH Cylinder Cylinder , Tilt Fittinq, Grease 1/8" Straiqht Kit, Control Valve Seal, 3-Spool (Not Shown) Kit, Control Valve Seal, 4-Spool (Not Shown)

Qty. 1 1 1 1 2 2 4 6 1 1 5 1 1 1 2 2 1 1 2 4

AR AR

0

PM1802JUNE 2008 HYDRAULIC SYSTEM 10 - 9

C

10 -10 HYDRAULIC SYSTEM PM1802 JUNE 2008

c

0.....,.. Ref. Part No. 1 050-430 2 050-430A 3 050-430B 4 050-430C 5 050-4300 6 050-430E 7 050-446 8 050-446A 9 011-555 10 NSS 11 NSS 12 NSS 13 NSS 14 NSS 15 NSS 16 NSS 17 NSS 18 NSS 19 500-015 20 011-042C 21 120-430

Tilt Cylinder 050-490

Description Qty. Cylinder Assembly 2 Tube Assembly 1 Rod 1 Head 1 Piston 1 Lock Nut 1 Rod End 1 Jam Nut 1 Grease Fitting , Press In 2 Wear Ring 1 Seal 1 O-Ring 1 O-Ring 1 Back-Up 1 Retaining Ring 1 Wear Ring 1 Seal 1 Wiper 1 Clevis Pin, 1-3/4" x 7" 2 Cotter Pin, 1/4" x 3" 2 Seal Kit (Includes 10-14 & 16-18) 1

PM1802 JUNE 2008 HYDRAULIC SYSTEM 10 -11

C

Side Shift Cylinder 050-470

Ref. Part No. Description Qt 050-470 C Iinder Assembly

2 050-470A Tube 3 050-470B Piston 4 050-470C Rod 5 050-4700 Gland 1 6 7 8 9

050-470E NSS NSS NSS

Nut, Piston Retainin Wear Rin O-Rin Seal

1

10 NSS O-Ring 11 NSS Back-Up 12 NSS Retain in Rin 1 13 NSS Wear Rin 14 NSS Seal 15 NSS Wi er 16 011-157 Clevis Pin, 1" x 2-1/2" 2 17 011-042 Cotter Pin, 5/32" x 2" 2 18 120-470 Seal Kit Includes 7-15)

A 16~~ 17

4 0

15 14

13

5

12 11

10

( /" I /"

I /" I /"

V

7 8

9

10 -12 HYDRAULIC SYSTEM PM1802JUNE 2008

Section 11: Electrical


11-2 Instrument Panel

11-4 Battery Box

11-5 Turn Signals

11-6 Rear Lights & Side Marker Lights

11-7 Accessories

11-8 K-5-86 Transmission Electronic Control Unit

Fold-Out Wiring Harness Drawing 115-075

PM1802 JUNE 2008 ELECTRICAL 11 -1

ELECTRICAL PM1802 JUNE 2008 11 - 2

0 Ref. Part No.

c

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17

18 19 20 21 22

100-744 110-011 110-195 110-195G 011-540 110-195C 110-1950 110-195A 110-195B 110-195F

110-195E NSS NSS NSS NSS NSS 110-151 C 110-151G 110-151 B 110-151 F 110-151 112-201 110-190 110-190A

"'" ~

Instrument Panel

Description Qty. Instrument Panel 1 Gauge, Hour Meter 1 Cluster Assembly (Includes 4 & 6-16) 1 Lens & Cover Assembly 1 Screw, 10-32 x 1/2" 8 Gauqe, Fuel 1 Gauge, Voltmeter 1 Gauqe, Water Temperature 1 Gauqe, Oil Pressure 1 Lens, Air Filter Restriction, Park Brake Warning, Oil 1 Filter Restriction & Trans Oil Filter Restriction Lens, Water Temp. & Oil Pressure Warning Lamp 1 Housinq, Cluster 1 Bulb, Small 6 Socket, Small Bulb 6 Socket, Large Bulb 2 Bulb, l.arqe 2 Switch, Work Lamps 1 Switch , 4WD Engage 1 Switch, Pre-Heat 1 Cover, Blank 1 Switch, Mountinq 1 Switch, Drive/Neutral 1 Switch, Ignition 1 Key, lenition Switch 1

PM1802 JUNE 2008 ELECTRICAL 11·3

Battery Box

Ref. Part No. Descri tion Qt . 500-003 Batter Box Assembl

2 011-014 Bolt, 5/8-11 x 1" 2 3 011-090 Washer, Flat 5/8" 2 4 110-128 Battery, Series 31H, with Screw-In Top Post 2 5 100-634A Strap 2 6 011-256 J-Bolt 4 7 011-023 Nut, 3/8-16 4

6

11 - 4 ELECTRICAL PM1802 JUNE 2008

Turn Signals

Ref. Part No. Descri tion Qt 010-502 Kit, Turn Si nal 1

1 010-502A Switch 1 2 010-502B Flasher 1 3 110-151C Switch , Li hts 1 4 110-502R Lam , RH 1 5 110-502L Lamp, LH 1 6 110-091 Circuit Breaker, 20 Amp 1

4 5

3

6

2

PM1802 JUNE 2008 ELECTRICAL 11 - 5

Rear Lights &Side Marker Lights

Part No. Ref.

482

2

Qt 1 210-550G 2 210-550F 2

010-577 011-000

5 010-576A 6 010-5768 2

010-576C

3

7

4

2

1

4

/'=~- 6

5

7

11 ·6 ELECTRICAL PM1802 JUNE 2008

Accessories

Q BACK-UP ALARM

PIN 010-556

STARTER RELA Y PIN 112-102

CAB FAN PIN 010-730

S'WITCH) STROBE LIG HT PIN 010-501DRec t . 'Work Ligh t s

PIN 110-260 Rep lo.cef"len t Bulb

PIN 110-260A

CAB DOME LIGHT PIN 010-731

HORN PIN 110-005

m~~ ABC

FIRE EXTINGUISHER

STROBE LIGHT PIN 010-533 PIN 010-825 REPLA CEMENT BULB PIN 010- 53 3A

FIRE EXTINGUISHER COVER PIN 010- 5 33B PIN 010-537 GASKET PIN 010-5 33 C

FIRST AID KIT

PM1802 JUNE2008 ELECTRICAL 11·7

K1-5-86 Electronic, Control Unit, Transmission 475/56250

Ref.

2 3 6 7 8

Part No. 460/36705 475/50712 475/48900 460/34500 460/38200 460/34900

Qt

1

11 ·8 ELECTRICAL PM1802 JUNE 2008

713450

4

~

manual partes montcargas mc

Documents

rollcage panel pin

lever pin

c g n o o o

inner panel pin

frame body panels

frame assembl

o z qo

flat14 frame