Ditch Witch 6520 Trencher Parts Manual 053-420 - PDF

6520

Parts Manual

CMW

®

Issue 4

053-420

1

6520 ISSUE NO. 04PL-08/14 For Replacement Copy Order P/N 053-420

This manual contains information concerning the following models: 6520 Trencher

Copyright 1993, 1994, 2012, 2014 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Arrow, The Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.

2

3

This manual contains illustrated parts lists to help you select quality ProTech ® Replacement parts for your Ditch Witch ® equipment. Using other replacement parts will lessen the productivity of your equipment. ♦ Part numbers enclosed in a box are no longer available from The Charles Machine Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you. ♦ Footnotes provide more information to help you identify parts shown in the manual. ♦ Assembly instructions and Tech Bits articles referenced in footnotes are available through your local Ditch Witch dealer. ♦ Description and specifications in this book were current at publication. However, The Charles Machine Works, Inc. reserves the right to improve equipment, so this manual might not reflect the most current improvements. ♦ Instructions on recommended equipment use and maintenance are in the Operator’s Manual that was shipped with your equipment.

Keep the following in mind when ordering ProTech replacement parts: ♦ Specify parts you need by part number and description, not by illustration reference numbers. ♦ Have equipment model and serial number on hand to help ensure you get the right parts for your machine whether it’s old or new.

Thank you for buying and using Ditch Witch equipment and ProTech replacement parts.

4

DW WARRANTY Policy July, 2005

POLICY 1: DITCH WITCH® EQUIPMENT AND REPLACEMENT PARTS LIMITED WARRANTY POLICY

Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK500 Attachments). Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial” use of the serial numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work.

EXCLUSIONS FROM PRODUCT WARRANTY •

All incidental or consequential damages.

•

All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for which products were intended.

•

All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer’s recommendations.

•

All engines and engine accessories (these are covered by original manufacturer’s warranty).

•

Tires, belts, and other parts which are subject to another manufacturer’s warranty. (Such warranty will be available to purchaser.)

•

ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.

IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED. Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase.

Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part

by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or it’s nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts under this warranty as it deems appropriate.

Extended warranties are available upon request from your local Ditch Witch dealer or CMW. Some states do not allow exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary from state to state.

For information regarding this limited warranty, contact CMW’s Product Support Department, P.O. Box 66, Perry, OK 73077-0066, or contact your local Ditch Witch dealer.

5

Decals Decal Location – 6520 Cab ........................ 12 Decal Location .......................................... 8

Engine Components Air Filter System ...................................... 24 Air Filter ................................................... 16 Alternator ................................................ 22 Engine Mounts – After .............................. 20 Engine Mounts ........................................ 18 Fuel Line ................................................. 26 Fuel Line ................................................. 28 Radiator .................................................. 30

Power Train Brake Calipers ........................................ 76 Brake System ......................................... 74 Differential Components ......................... 48 Differential Components ......................... 54 Drive Line ................................................ 42 Front Differential ..................................... 52 Front Steering Differential & Mount ......... 68 Ground Drive Transmission – Installation ... 40 Ground Drive Transmission – Mount ......... 34 Ground Drive Transmission – Shifter ........ 38 Ground Drive Transmission .................... 36 Park Brake Installation ............................ 78 Rear Steer Indicator ................................ 62 Rear Steer .............................................. 60 Rear Steering Planetary Differential ........ 50 Rear Steering Tilt Frame Diff. Mount ...... 66 Rigid Rear Differential ............................. 46 Rigid Rear Frame Differential Mount ....... 64 Rigid Rear Planetary Differential ............. 44 Tire & Wheel – Optional ............................ 72 Tire & Wheel ........................................... 70 Wheel End – Heavy Duty ........................... 58 Wheel End – Standard Duty ........................ 56

Frame Components 2-Post ROPS Installation ...................... 108 4-Post ROPS ........................................ 110 4-Post Working Lights ........................... 112 Backfill Blade ........................................ 104 Battery Mount ......................................... 90 Cab Heater ........................................... 118 Cab Installation ..................................... 116 Cab ........................................................ 114 Console ................................................... 86

Doors ......................................................82 Enclosure ................................................ 84 Fenders & Covers ................................... 88 Fuel Tank .............................................. 100 Hydraulic Reservoir ............................... 102 Operator Station Installation .................... 92 Seat – Belts – Covers ............................. 98 Seat Deck Installation ............................. 94 Suspension Seat Deck ............................ 96 Tilt Backfill Blade ................................... 106

Control Components Attachment Control ............................... 124 Ground Speed & Direction Control ........ 122 Throttle Installation ................................ 126

Hydraulics Auxiliary Manifold Hydraulics ................. 134 Backfill Blade Manifold Hydraulics ......... 160 Backfill Blade Manifold .......................... 162 Backhoe Crowd Control ........................ 180 Backhoe Crowd Control ........................ 182 Cold Start Kit ......................................... 130 Control Valve ......................................... 176 Diagnostic Ports .................................... 138 Frame Tilt Hydraulics ............................ 172 Front Steering Hydraulics ...................... 142 Ground Drive ......................................... 166 Hydraulic Cylinder - (2 x 1 x 5) ................. 144 Hydraulic Cylinder - (2 x 1 x 6) ................. 158 Hydraulic Cylinder - (2 x 1 x 8) ................. 154 Hydraulic Cylinder - (3 x 1.75 x 8) .............. 150 Hydraulic Schematic .............................. 178 Lift Cylinder Hydraulics .......................... 148 Oil Cooler Hydraulics ............................. 140 Power Steering Valve ............................ 146 Pump Hydraulics ................................... 132 Relief Cartridge ..................................... 164 Shift Manifold Hydraulics ....................... 168 Shift Manifold ........................................ 170 Swing Cylinder Hydraulics ..................... 152 Tilt Cylinder Hydraulics .......................... 156 Tow & Flush Manifold Hydraulics .......... 172 Trick Quick Coupler ............................... 136

6

Electrical Electrical Diagram – Console Harness ....... 190 Electrical Diagram – Engine Harness ........ 194 Electrical Diagram – Frame Harness ......... 192 Electrical Diagram – Seat Harness ........... 196 Electrical Schematic .............................. 186

Miscellaneous Bolt/Nut Torque Chart ........................... 200 Replacement O-Ring Chart ................... 203 Parts Manual Change Request ............. 205 Warranty Registration ........................... 208

7

DECALS

8

DECAL LOCATION 6520

4

30

24

2

6

19

33

5 4

1 3 12 13

25 35 18

20

23

7 10

11

32 27

9

21

15

36

22

4

31

16

34

28 17

8

29

04

14 20

16

26

ID0125537

9

DECAL LOCATION 6520

REF PART NO. 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

04

275-637 274-087 274-220 274-233 274-247 274-273 274-274 274-275 274-276 274-277 274-279 274-282 274-758 274-283 274-284 274-289 274-291 274-318 274-351 274-375 274-387 274-442 275-023 275-024 275-033 275-048 275-070 275-100 275-120 275-131 275-148 275-149 275-172 275-185 275-303 275-449 275-497 274-758

QTY

DESCRIPTION

DECAL KIT 1 REAR STEER INDICATOR DECAL 1 INTERLOCK DISPLAY DECAL 1 REAR STEER DISPLAY DECAL AR ACCENT STRIP ( 2-1/4” ) 2 6520 MODEL - ID DECAL 1 PRIMARY CONSOLE DECAL 1 LEFT SEAT CONSOLE DECAL 1 RIGHT SEAT CONSOLE DECAL 1 REAR STEER CONTROLS DECAL 1 ATTACHMENT SPEED DECAL 1 BACKFILL BLADE FUNCTIONS DECAL 1 BACKFILL BLADE FUNCTIONS DECAL 1 FRAME TILT CONTROL DECAL 1 ATTACHMENT SPEED CONTROL DECAL 1 TEST PORTS DECAL 1 SOUND POWER RATING ( 106 db ) 4 TIE DOWN LOCATIONS 1 LUBRICATION CHART 1 MASTER DISCONNECT SWITCH 1 SECONDARY CONSOLE DECAL 4 LIFT LOCATION DECAL 1 OIL LEVEL DECAL 1 PARKING BRAKE DECAL 1 NOTICE ALTERNATOR DECAL 1 IMPORTANT SAFETY RULES DECAL 1 WARNING RUNAWAY DECAL 1 MANIFOLD DECAL 1 RESERVOIR DECAL (THF) 1 MODULARMATIC - ID DECAL 1 FUEL TANK ( DIESEL ) DECAL 1 RADIATOR ( COOLANT ) DECAL 2 DITCH WITCH - ID DECAL 2 WARNING SINGLE OPERATOR DECAL 1 WARNING ROLLOVER DECAL 1 DITCH WITCH EMBLEM PLAQUE 1 ENGINE OIL DRAIN DECAL 1 ATTACHMENT SPD HI / LO

REMARKS

INC REF #’S 1 THRU 35

USE 120”

ID0125537

10

DECAL LOCATION 6520

9.00" 4.69”

.50” .809

32

8.5”

32

8.5”

4.0”

4.0”

33

25

2.0"

04

1.5”

1.5”

2.0"

ID0125537

11

12

DECAL LOCATION 6520 CAB

5

9

7

6 3

8

1

01

2 4

ID0140832

13

DECAL LOCATION 6520 CAB REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

275-636 275-131 275-172 275-449 274-247 274-240 274-241 274-242 274-243 274-470

QTY

1 2 1 2 1 1 1 1 1

DESCRIPTION

REMARKS

DECAL KIT MODULARMATIC-ID DECAL DITCH WITCH LOGOTYPE DITCH WITCH EMBLEM PLAQUE ACCENT STRIPPING (2-1/4' X 20") CAB LIGHT CONTROLS CAB WIPER CONTROLS CAB ACCESSORIES SEE-THRU-LOGOTYPE FUSE BLOCK DECAL

INC. REF #"S 1 THRU 7

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0140832

14

NOTES:

15

ENGINE COMPONENTS

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

NOTES:

33

POWER TRAIN

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

FRONT DIFFERENTIAL

6520, 7020, 7520, 8020 PLANETARY STANDARD DUTY

34 7

35 13

3

14

10

1 2

29

9 10

33 28

30

36

31 6

27 26

8

5 4 32

11

31

12

13 14 18 17

21

15 16

20

22 23 24 25

02

19

ID0138176

53

FRONT DIFFERENTIAL

6520, 7020, 7520, 8020 PLANETARY STANDARD DUTY REF PART NO. 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.

QTY

161-188 1 106-549 2 161-203 1 161-205 1 161-267 1 106-419 12 106-035 12 161-202 2 106-383 14 181-981 2 183-771 4 125-453 4 155-874 2 125-809 2 106-469 6 181-982 6 125-771 2 183-765 2 151-044 2 125-770 2 160-420 1 105-378 2 160-413 2 125-432 2 183-764 2 110-078 2 115-524 2 115-165 2 106-164 2 105-491 4 106-654 4 181-208 4 125-473 8 184-721 4 315-038 4 155-912 1 115-127 1 181-253 4

DESCRIPTION

REMARKS

AXLE HOUSING DOWEL PIN (1/2" X 1", HARDENED) DIFFERENTIAL (STANDARD) DIFFERENTIAL (LIMIT SLIP) DIFFERENTIAL (LIMIT SLIP) STUD BOLT (M18-1.5 X 80mm) LUG NUT (M18-1.50) WHEEL END FLG LK SCREW (M10-1.50 X 30mm) TAPERED INSERT (1.00") TAPERED PIN (31.75mm x 52mm) BRONZE BUSHING INTERNAL SEAL (3.005") COMPOSITION BUSHING (2.250") FLG SCREW (M12-1.75 X 30mm) TAPERED INSERT (1.250") COMPOSITION BUSHING (1.250") TAPERED PIN (31.7mm x 110mm) CYL (2" X 1" X 6") COMPOSITION BUSHING (1.00") TIE ROD JAM NUT (1-NF) ROD END (1"-NF) BRONZE BUSHING (1.00") TAPERED PIN (25.4mm) MACHINERY BUSHING (1") EXTERNAL SNAP RING (1.00") PLUG (08N, ALN) FLG LK SCREW (M10-1.50 X 30mm) BOLT (1-UNS X 3") FLG LK SCREW (M10-1.50 X 16mm) SPINDLE WASHER (1") BRONZE BUSHING BUSHING (25.4mm) SPINDLE BOLT LOCK AIR VENT (O2N) REDUCER (O8N-O2NF) MACHINERY BUSHING (1", 18GA)

SEE FOOTNOTE 1 6520,7020 W/L35R YOKE 6520,7020 W/L35R YOKE 7520,8020 W/410 SERIES YOKE

STANDARD DUTY

ENDS WITH S/N _______ ENDS WITH S/N _______ ENDS WITH S/N _______ ENDS WITH S/N _______

BEGINS WITH S/N _______ BEGINS WITH S/N _______ BEGINS WITH S/N _______ BEGINS WITH S/N _______ BEGINS WITH S/N _______ BEGINS WITH S/N _______

NOT SHOWN:

FOOTNOTES:

1. AXLE HOUSING REQUIRES THREE GALLONS HG OIL ON ORIGINAL FILL (FRONT AND REAR).

NOTE:

8020 USE BEGINS WITH S/N________

02

ID0138176

54

55

56

57

58

WHEEL END HEAVY DUTY 6520,7020,7520,8020 25 30

23

22 24

31

16

30 19

22 11

12 13

20 15

13

26

29 5

12

21

10

8 17

30

9

7 14

8 7

18

6 33

2 32 4 3 1

28

03

27

ID0138185

59

WHEEL END HEAVY DUTY 6520,7020,7520,8020 REF PART NO. 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.

QTY

161-225 191-246 166-484 167-268 1 169-054 1 155-830 1 125-433 1 126-060 1 157-608 1 126-064 2 126-063 2 169-036 1 107-206 6 165-150 1 126-059 6 126-031 6 118-020 1 165-148 3 157-086 1 115-496 1 106-419 6 165-151 1 183-746 3 165-766 AR 165-768 AR 106-549 5 106-660 4 115-025 2 169-037 1 118-021 1 167-269 1 182-190 1 184-297 1 501-599 6 106-886 3 126-083 1 157-213 1

DESCRIPTION

WHEEL END ASS'Y (HEAVY DUTY) WHEEL END REPAIR KIT (HEAVY DUTY) WHEEL END REPAIR KIT SHORT SHAFT SPINDLE HOUSING INTERNAL SEAL (2.750") BRONZE BUSHING (1-1/2") THRUST WASHER RACE (1.500") INTERNAL SEAL (7.881") TAPERED BEARING (4.330") TAPERED RACE (6.496") PLANETARY HOUSING SCREW (M12-1.75 X 35mm) RING GEAR THRUST WASHER RACE (1.375") NEEDLE BEARING (1.375") INTERNAL SNAP RING PLANET GEAR O-RING (272 D70) INTERNAL SNAP RING STUD BOLT (M18-1.5 X 80mm) SUN GEAR PLANET PIN SHIM (.05mm) SHIM (.254mm) DOWEL PIN (1/2" X 1", HARDENED) SCREW (M12-1.75 X 30mm, 10.9) PLUG (08N, SQ FM, MAG) PLANETARY CAGE EXTERNAL SNAP RING (1.500") LONG SHAFT CROSS AND BEARING KIT HUB DETENT BALL (.375") SCREW (M12-1.75 X 40mm, ALN) BEARING RACE SEAL, V-RING

REMARKS

FOOTNOTE 1 FOOTNOTE 2

RED BROWN

NOT SHOWN:

FOOTNOTES:

1. INCLUDES REFERENCE NUMBERS 3, 4, 6-8, 11, 30, 32, 33, 105-965, 164-627, 166-330, AND 178-611 2. INCLUDES REFERENCE NUMBER 12, 13, 15, 16, 20, 22, 23, 25, AND 30

NOTE:

WHEEL AND ASSEMBLY REQUIRES USE OF 1-1/4 QT . OF 90W LUBRICANT.

03

ID0138185

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

NOTES:

81

FRAME COMPONENTS

82

83

84

85

86

CONSOLE

20

3

4

20

5

2

6 18

1 2 3

7

1

8 10

9

11

17 11 13 11 15

19

12

1

14 16

SEE FOOTNOTE

04

ID0123147

87

CONSOLE REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

QTY

215-150 214-852 214-961 214-962 360-603 217-552 217-551 306-607 217-531 214-378 215-129 215-133 217-020 217-029 217-036 217-027 217-021 217-051 217-028 306-608 110-208 154-339

DESCRIPTION

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

FILTER MINDER IGNITION SWITCH KEY, PAIR (BASE CODE) SWITCH MOUNTING NUT AUDIO ALARM HYD. GRD. DRIVE PRESS GAUGE HYD. SYSTEMS PRESSURE GAUGE HORN BUTTON WATER TEMP GAUGE TACHOMETER BATT/AMP GAUGE FUEL GAUGE PILOT LIGHT INSERT (RED) INSERT (YEL) INSERT (RED) INSERT (RED) INSERT INSERT (BLANK) COVER LEVEL INDICATOR ADAPTER CONN (04O-04N)

REMARKS

CALIBRATION NEEDED

PARK BRAKE HYD. OIL FILTER RESTRICTION HYD. OIL TEMP ENG. OIL PRESSURE WATER TEMP

TILT FRAME ONLY

NOT SHOWN:

FOOTNOTES:

1-THESE SLOTS ARE RESERVED FOR ROCKER SWITCHES FOR THE FOLLOWING OPTIONS: ROTO-WITCH REEL CARRIER COLD START NOTE:

04

ID0123147

88

89

90

91

92

93

94

95

96

97

98

SEAT - BELTS - COVERS

6520 - HT150 - RT150 HT185 - HT185T2 - RT185 - RT185T2 2 1

3 1 21

27

4 6

7 18

5 24

25

8 20

11 9 26

19

18

12

14

13 17

16

15

23 10 22

06

ID0031526

99

SEAT - BELTS - COVERS

6520 - HT150 - RT150 HT185 - HT185T2 - RT185 - RT185T2 REF PART NO. NUMBER

QTY

DESCRIPTION

1. 110-704 1 SEAT BELT SET 2. 115-425 1 SEAT 115-445 1 REPLACEMENT SEAT 3. 184-252 2 BUSHING (.563" X 1" X .590") 4. 105-048 2 BOLT (1/2-NC X 1-1/2") 5. 106-031 2 LOCKNUT (M12-1.75) 6. 115-430 2 SEAT BELT TETHER 7. 105-267 4 CUP WASHER (5/16") 8. 331-201 1 RIGHT SEAT CONSOLE 331-188 1 RIGHT SEAT CONSOLE 9. 331-065 1 SEAT MOUNT 10. 105-273 2 SCREW (M12-1.75 X 30mm) 11. 331-200 1 LEFT SEAT CONSOLE 332-020 1 LEFT SEAT CONSOLE 331-187 1 LEFT SEAT CONSOLE 12. 106-264 6 BOLT (5/16-NC X ƒ", BUT SOC) 13. 105-841 6 CLIP NUT (5/16-NC) 14. 106-386 6 FLG LOCKNUT (M8-1.25) 15. 331-063 6 MOUNT TAB 16. 106-162 6 FLG SCREW (M8-1.25 X 20mm) 17. 184-253 2 SPACER (SEAT MOUNT) 18. 105-089 4 LOCKNUT (5/16-NC) 19. 105-866 6 FLG LK BOLT (5/16-NC X 1-1/4") 20. 215-1107 1 SEAT SWITCH 21. 105-071 2 WASHER (1/2") 22. 331-155 2 SUPPORT SPACER 23. 331-156 1 TETHER SUPPORT 24. 115-754 1 ABRASION SLEEVE (1.59" X 30") 25. 115-662 1 GROMMET EDGE (3/16" X 12.7") 26. 115-663 1 GROMMET EDGE (1/4" X 12.7") 115-662 1 GROMMET EDGE (3/16" X 12.7") 27. 362-823 2 COVER

REMARKS

INCLUDES SEAT TRACK SET AND OPERATOR PRESENCE SWITCH

OPERATOR MODULE CAB MODULE

RT150/RT185/7020 OPERATOR MODULE HT150/HT185 OPERATOR MODULE RT150/RT185/6520/7020 CAB

CAB MODULE OPERATOR MODULE

NOT SHOWN:

FOOTNOTES:

NOTE:

06

ID0031526

100

101

102

103

104

105

106

TILT BACKFILL BLADE 6520 7020

1 8 10 6 5

11

7 9

2 3 4

02

ID0108655

107

TILT BACKFILL BLADE 6520 7020 REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

QTY

106-469 1 106-012 6 314-104 1 125-770 1 125-771 1 300-4338 1 181-981 1 181-982 1 183-767 1 183-766 1 106-164 1

DESCRIPTION

REMARKS

SCREW (M12 -1.75 X 30mm) FLANGE BOLT (5/8-NC X 3") TILT BLADE RETAINER COMPOSITION BUSHING COMPOSITION BUSHING BACKFILL BLADE TAPERED INSERT (1") TAPERED INSERT (1.250") TAPERED PIN (60mm) TAPERED PIN (90mm) FLG SCREW (M10-1.50 X 30mm)

SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. BACKFILL BLADE 314-081 IS SUPERSEDED BY BACKFILL BLADE 300-4338.

NOTE:

02

ID0108655

108

109

110

111

112

113

114

115

116

117

118

119

120

NOTES:

121

CONTROL COMPONENTS

122

123

124

125

126

127

128

NOTES:

129

HYDRAULICS

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

HYDRAULIC CYLINDER (3" X 1.75" X 8")

2

1 3 4 5 6

7

8

07

ID0125475

151

HYDRAULIC CYLINDER 3" X 1.75" X 8" REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

151-070 190-172 150-911 152-014 106-122 105-363 150-765 150-763 150-436

QTY

1 1 1 1 1 1 1 1

DESCRIPTION

REMARKS

CYL (3.0" X 1.75" X 8.0") SEAL REPAIR KIT (3.0" X 1.75") LOCK RING (3") CYLINDER BARREL (3") BOLT (7/8-NC X 2-1/4", GD8) WASHER (7/8") CYLINDER PISTON (3" X 1.75") CYLINDER HEAD (3" X 1.75") CYLINDER ROD (1.75")

INCL REF NO.'S 1 THRU 7 INCL REF NO.'S 4 THRU 5

SEE FOOTNOTE 1 INCL MOLDED-ON WEAR RING

NOT SHOWN:

259-040 259-238 259-065 259-066 259-188

U-SEAL INSTALLER (1.5" - UP) WIPER INSTALLER (1.75") PISTON SEAL INSTALLER (3") PISTON INSTALLER (3") CYL HEAD SPANNER - TWO PIN

FOOTNOTES:

1. CLEAN & DRY THREADS.

APPLY RED LOCTITE (RC 271 OR RC 272).

TORQUE TO 410-460 FT-LBS (560-625 N.M.)

NOTE:

07

ID0125475

152

153

154

HYDRAULIC CYLINDER (2.0" X 1.00" X 8.0")

2

1 3 4 5

6

7

05

ID0129120

155

HYDRAULIC CYLINDER REF PART NO. NUMBER 1.

2.

3.

4.

5.

6.

7.

151-031 190-165 150-778 150-285 106-096 150-775 150-772 150-417

QTY 1 1 1 1 1 1 1

DESCRIPTION

REMARKS

8.0") CYL (2.0" X 1.0" X SEAL REPAIR KIT (2" X 1") LOCK RING (2") CYLINDER BARREL (2") FLG BOLT (1/2-NC X 1-3/4", GD8) CYLINDER PISTON (2.0" X 1.0") CYLINDER HEAD (2" X 1") CYLINDER ROD

INCL. REF. NO.'S 1 THRU 7

SEE FOOTNOTE 1

NOT SHOWN: 259-100 259-235 259-239 259-241 259-188

U-SEAL INSTALLER (1" - 1.499") 1.00 ROD WIPER TOOL WIPER/SEAL INSTALLER (2") PISTON INSTALLER (2") CYL HEAD SPANNER - TWO PIN

FOOTNOTES: 1 -TORQUE TO 90-100 FT-LBS (120-135 N.M).

NOTE:

05

ID0129120

156

157

158

HYDRAULIC CYLINDER 2.0" X 1.0" X 6.0"

2

1 3 4 5

6

7

03

ID0022902

159

HYDRAULIC CYLINDER 2.0" X 1.0" X 6.0" REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

151-044 190-165 150-778 150-294 106-096 150-775 150-772 150-424

QTY

1 1 1 1 1 1 1

DESCRIPTION

REMARKS

HYDRAULIC CYLINDER SEAL REPAIR KIT LOCK RING CYLINDER BARREL FLG BOLT (1/2-NC X 1-3/4",GD 8) PISTON CYLINDER HEAD CYLINDER ROD

INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1

NOT SHOWN:

259-100 259-235 259-239 259-241 259-188

ROD U-SEAL INSTALLER ROD WIPER INSTALLER PISTON SEAL INSTALLER PISTON INSTALLER CYLINDER HEAD SPANNER WRENCH

FOOTNOTES:

1-LUBRICATE WITH WD-40 OR EQUAL TO 90-100 FT-LBS (120-135 N.M)

NOTE:

03

ID0022902

160

161

162

163

164

RELIEF CARTRIDGE

3 6

2

4 5 1

7

PSI

02

ID0139037

165

RELIEF CARTRIDGE REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

QTY

DESCRIPTION

155-687 RELIEF CARTRIDGE KIT (160 PSI) 155-681 WH RELIEF CARTRIDGE KIT (500 PSI) 158-512 WH RELIEF CARTRIDGE KIT (1350 PSI) 155-679 WH RELIEF CARTRIDGE KIT (2500 PSI) 158-553 WH RELIEF CARTRIDGE KIT (3000 PSI) 500-956 WH RELIEF CARTRIDGE KIT (3000 PSI) 157-365 RP51N RELIEF CARTRIDGE (4500 PSI) 155-707 1 O-RING (910 D90) 155-749 1 O-RING (023 D70) 155-750 1 O-RING (022 D90) 500-025 AR SHIM (.010" THK) 500-318 1 COMPRESSION SPRING 157-508 1 BACKUP RING (022 D90) 500-957 1 SEAL REPAIR KIT

REMARKS

INCL REF NO'S 1 THRU 7, OBSOLETE INCL REF NO'S 1 THRU 7 INCL REF NO'S 1 THRU 7 INCL REF NO'S 1 THRU 7 INCL REF NO'S 1 THRU 7 INCL REF NO'S 1 THRU 7

SEE FOOTNOTE 1 SEE FOOTNOTE 2 INCL REF NO'S 1 THRU 3 & 6

NOT SHOWN:

FOOTNOTES:

1. REFER TO INSTALLATION DIAGRAM 052-139 FOR REPLACEMENT PROCEDURES. 2. OLD STYLE .556" OD X 1.286" LG, .120" DIA PIANO WIRE. NEW STYLE .605" OD X 1.296" LG .125" DIA STAINLESS STEEL WIRE.

NOTE:

02

ID0139037

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

NOTES:

185

ELECTRICAL

186

187

188

189

190

ELECTRICAL DIAGRAM CONSOLE HARNESS 6520

GRN WHT/BLU TAN/BLK BRN/ORG WHT/GRN

TO ENGINE HARNESS

ORG/BLU YEL BLK WHT/BLK RED

1

ORG WHT/BLU ORG/BLU YEL/BLU BLU/ORG BLU/YEL

3

ORG LO OIL PRESS

WHT/BLU ORG/GRN

HYD OIL FILTER

TO ENGINE HARNESS

TO ENGINE HARNESS

ORG/BLK

ORG

1 PARK BRAKE

TAN/BLK

HYD OIL TEMP WHT/BLK

WHT/GRN ORG/GRN WHT/BLK TAN/BLK BRN BLU/ORG

TO FRAME HARNESS

WHT/RED WHT ORG ORG/BLU

TO FRAME HARNESS

BLK BLK WHT/BLK WHT

HYD OIL LIGHT TEST RELAY

BLK ORG/GRN WHT BLK

HYD FLUID LIGHT TEST RELAY

ORG

HI ENG TEMP

4 WHT WHT/BLK ORG/BLK BLK ORG

WHT/GRN

1

WHT WHT/BLK ORG/BLK BLK ORG

WHT WHT/BLK WHT/GRN WHT/BLU WHT/RED

WHT WHT/BLK WHT/GRN WHT/BLU WHT/RED

2

OPERATOR GND DRIVE DIG CHAIN

WHT/GRN BLK WHT BLK

INTERLOCK DISPLAY/MODULE

ORG

WHT WHT RED

4 GRD DRIVE INT RELAY

TAN/BLK TAN/BLK BLK TAN/BLK

PARK BRAKE RELAY

4

4

BLK TAN/BLK TAN/BLK

I

4 ENG TEMP LIGHT TEST RELAY

WHT KTAN/BL WHT/BLU BLK

ORG

B

4

GRD DRIVE RELAY

12

S

IGNITION SWITCH TAN/BLK WHT/BLK WHT/BLU ORG/GRN WHT/GRN BLU BLU BLU BLU BLU 12 3

456 789

10 11 12

6

ORG YEL BLK

DIODE BLOCK

ORG

GRN

5

BLK ORG BLK

BLU

BLK

AUDIO ALARM

ORG

9 BRN

S

G

I

WATER TEMP

10 S

G

I

FUEL GAUGE

8 TI

11

TACHOMETER

START RELAY

7 G

I

VOLTMETER

87 85

86

30

RED

WHT/BLK BLK WHT/BLK

03

BRN/ORG WHT/BLK BRN/ORG

COLD START OPTION

BLU/YEL ORG BLU/ORG

ROTO WITCH OPTION

YEL/BLU ORG WHT/BLU

REEL CARRIER OPTION

ID0105627

191

ELECTRICAL DIAGRAM CONSOLE HARNESS 6520 REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

217-020 217-046 217-051 217-021 217-027 217-036 217-029 217-028 217-756 214-006 217-710 306-603 216-521 215-129 215-415 217-535 215-415 217-531 215-415 215-133 215-415 217-701 105-820 105-832 214-852 214-961 214-962

QTY

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

DESCRIPTION

PILOT LIGHT BULB RED INSERT RED INSERT RED INSERT RED INSERT RED INSERT RED INSERT INTERLOCK/DISPLAY MODULE CONSOLE HARNESS RELAY (SPDT) AUDIO ALARM DIODE BLOCK VOLTMETER LIGHT KIT (OPTIONAL) TACHOMETER LIGHT KIT (OPTIONAL) WATER TEMP GAUGE LIGHT KIT (OPTIONAL) FUEL GAUGE LIGHT KIT (OPTIONAL) POWER RELAY (SPDT) FLG LK BOLT (1/4-NC X 3/4 ") FLG LOCKNUT (1/4-NC) IGNITION SWITCH KEY, PAIR SWITCH MOUNTING NUT

REMARKS

REPLACEMENT ENG OIL TEMP ENG OIL PRESS HYD OIL HI TEMP HYD FILTER PRESS PARK BRAKE BLANK

NOT SHOWN:

FOOTNOTES:

NOTE:

03

ID0105627

192

193

194

195

196

197

198

NOTES:

199

MISCELLANEOUS

200

SAE Bolt and Nut Torque Value Chart Grade 5: UNC or UNF Thread Size

Hex nut, or bolt tapped into hex nut, or d&t hole

Hex top deformed locknut

Flange nut, locknut, or bolt tapped into flange nut or d&t* hole

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

1/4

12

16

8

11

20

27

5/16

25

34

15

20

45

60

3/8

40

54

25

34

75

100

7/16

65

90

40

55

125

170

1/2

100

135

60

80

190

260

9/16

150

200

90

125

270

370

5/8

200

270

120

165

370

500

3/4

350

475

210

285

650

880

7/8

560

760

340

460

1250

1425

1

840

1140

500

680

1580

2145

1-1/8

1030

1400

320

840

1950

3645

1-1/4

1460

1980

880

1195

2760

3475

Grade 8: UNC or UNF Thread Size

Hex nut, or bolt tapped into hex nut, or d&t hole

Hex top deformed locknut

Flange nut, locknut, or bolt tapped into flange nut or d&t* hole

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

1/4

14

19

10

14

24

33

5/16

30

40

18

25

50

70

3/8

55

73

35

50

90

125

7/16

85

115

50

70

140

190

1/2

130

175

80

110

220

300

9/16

190

260

110

150

310

420

5/8

260

355

160

245

430

585

3/4

450

610

270

365

750

1015

7/8

730

990

440

600

1210

1640

1

1090

1480

650

880

1320

2465

1-1/8

1550

2100

930

1260

2580

3500

1-1/4

2180

2955

1310

1780

3640

4935

*drilled and tapped

201

Metric Bolt and Cap Screw Torque Values Size

Class 4.8

Class 8.8 and 9.8

Class 10.9

Class 12.9

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

N•m

ft•lb

M6

4.8

3.5

6

4.5

9

6.5

11

8.5

13

9.5

17

12

15

11.5

19

14.5

M8

12

8.5

15

11

22

16

28

20

32

24

40

30

37

28

47

35

M10

23

17

29

21

43

32

55

40

63

47

80

60

75

55

95

70

M12

40

29

50

37

75

55

95

70

110

80

140

105

130

95

165

120

M14

63

47

80

60

120

88

150

110

175

130

225

165

205

150

260

190

M16

100

73

125

92

190

140

240

175

275

200

350

225

320

240

400

300

M18

135

100

175

125

260

195

330

250

375

275

475

350

440

325

560

410

M20

190

140

240

180

375

275

475

350

530

400

675

500

625

460

800

580

M22

260

190

330

250

510

375

650

475

725

540

925

675

850

625

1075

800

M24

330

250

425

310

650

475

825

600

925

675

1150

850

1075

800

1350

1000

M27

490

360

625

450

950

700

1200

875

1350

1000

1700

1250

1600

1150

2000

1500

M30

675

490

850

625

1600

950

1650

1200

1850

1350

2300

1700

2150

1600

2700

2000

M33

900

675

1150

850

1750

1300

2200

1650

2500

1850

3150

2350

2900

2150

3700

2750

M36

1150

850

1450

1075

2250

1650

2850

2100

3200

2350

4050

3000

3750

2750

4750

3500

Do not use these values if a different torque value or tightening procedure is given for specific application.

Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class fasteners.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to strength of original.

Make sure fastener threads are clean and that the threads are properly started. This will prevent them from cross threading or galling when tightened.

Tighten plastic insert or crimped type steel locknuts to approximately 50% of dry torque indicated on chart.

Apply torque to the nut - not the bolt head. Tighten toothed or serrated type locknuts to full torque value.

LUBRICATED means coated with lubricant. DRY means plain or zinc plated without any type of lubricant.

202

Hydraulic Cylinder Bolt Torque Chart Bolt Size (inch)

Bolt Part No.

Cylinder Repair Kit Part No.

Torque (ft•lb)

Torque (N•m)

1/2

106-096

190-165

90-100

120-135

5/8

106-097

190-166 & 190-169

180-200

245-270

3/4

106-098

190-167 & 190-170

290-325

395-440

7/8

106-122

190-172 & 190-174

410-640

550-625

1

106-145

190-175 & 190-189

630-700

855-950

1-1/8

106-146

190-177

770-850

1045-1170

As a general rule: •

1/2-inch bolts are used in cylinders with 1-inch rods

•

5/8-inch bolts are used in cylinders with 1 1/4-inch rods

•

3/4-inch bolts are used in cylinders with 1 1/2-inch rods

•

7/8-inch bolts are used in cylinders with 1 3/4-inch rods

•

1-inch bolts are used in cylinders with 2-inch rods (one with 1 3/4-inch)

•

1-1/8-inch bolts are used in cylinders with 2-1/4-inch rods

IMPORTANT: Do not reuse cylinder piston bolts when rebuilding a hydraulic cylinder. Each cylinder repair kit contains a new bolt. Use it. Lubricate lightly and torque to value shown on chart.

SAE & ORS Hydraulic Fitting Replacement O-Ring Chart Fraction Size

Dash Size

SAE (Port Seal O-Ring)

ORS (Face Seal O-Ring)

Thread Size

O-Ring P/N

Thread Size

O-Ring P/N

1/16

1

NA

NA

NA

NA

1/8

2

5/16 - 24

NA

NA

NA

3/16

3

3/8 - 24

NA

NA

NA

1/4

4

7/16 - 20

155-760

9/16 - 18

157-037

5/16

5

1/2 - 20

NA

NA

NA

3/8

6

9/16 - 18

155-705

11/16 - 16

157-038

1/2

8

3/4 -16

155-706

13/16 - 16

157-039

5/8

10

7/8 - 14

155-707

1 - 14

157-040

3/4

12

1-1/16 - 12

155-709

1-3/16 - 12

157-017

7/8

14

1-3/16 - 12

155-747

NA

NA

1

16

1-5/16 - 12

155-748

1-7/16 - 12

155-714

1-1/4

20

1-5/8 - 12

155-702

1-11/16 - 12

NA

1-1/2

24

1-7/8 - 12

157-001

2 -12

NA

2

32

2-1/2 - 12

NA

NA

NA

2-1/2

40

3 - 12

NA

NA

NA

3

48

3-1/2 - 12

NA

NA

NA

Thread size indicates the diameter of the threaded area in fractions of an inch and number of threads per inch.

NA = not a current CMW part numbered o-ring, or dash size does not occur in current CMW applications SAE = straight thread fitting that seals by sandwiching a hard o-ring between a shoulder on the male part and an angular surface at the mouth of the female port.

ORS = o-ring face seal; a type of fitting that seals by compressing a hard, captive o-ring between two flat parallel faces, one grooved for the o-ring and the other plain to act as the sealing surface

203

204

205

Parts Manual Change Request (Please print clearly)

Date: _______________________

Dealer No. (required): _____________________________

Your Name: _____________________________ Phone: _________________

Position: _____________________________

Fax: _________________

E-mail: __________________

Publication Information: Model: __________

Parts Manual No.: _____-_____

Illustration Part No.: Manual Page No.: 1. _____-_____ .......................................................... 1. __________ 2. _____-_____ .......................................................... 2. __________ 3. _____-_____ .......................................................... 3. __________ Nature of Change Request:

/ Text

/ Graphics

/ Missing Information

Describe change requested (if possible, include copy of publication page with changes marked.): ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Please fax completed form to Parts Manual Department (580) 572-3525 Thank you for taking the time to submit this request. We will contact you if further information is needed to process your request.

206

207

208