Ditch Witch R150 R150E Parts Manual 053-1171 - PDF DOWNLOAD

R150/R150E

Parts Manual

CMW

®

Issue 10

053-1171

1

R150/R150E ISSUE NO. 10PL-08/17 For Replacement Copy Order P/N 053-1171

This product and its use may be covered by one or more patents at http://patents.charlesmachine.works.

This manual contains information concerning the following models:

R150 R150E

Copyright 2007, 2008, 2011, 2017 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.

ID0194353

2

3

FOREWORD_________________________________________ This manual contains illustrated parts lists to help you select quality Ditch Witch® replacement parts for your Ditch Witch equipment. Using other replacement parts will lessen the productivity of your equipment.

•

Descriptions 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.

•

Part numbers enclosed in a box or marked as “obsolete” in the remarks column 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 referenced in footnotes are available through your local Ditch Witch dealer.

•

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 Ditch Witch 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 replacement parts.

Ver. 04

ID0128552

4

WARRANTY _________________________ DW WARRANTY Policy August, 2016

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 Ditch Witch factory that fail due to a defect in material or workmanship within one (1) year of first commercial use. 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 Ditch Witch Product Support (DWPS) or its authorized dealer. DWPS will provide the location of its inspection facilities or it’s nearest authorized dealer upon inquiry. DWPS 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 the Ditch Witch factory.

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 the DWPS, P.O. Box 66, Perry, OK 73077-0066, or contact your local dealer.

Ver. 05

ID0134872

5

CONTENTS______________________ Decals

Decal Location ........................................... 8

Engine Components

Air Filter ................................................... 18 Engine & Muffler ................................ 12, 14 Engine Electronics ................................... 16 Hydraulic Pump & Mounting ..................... 20

Power Train

Brake Hub & Motors ................................. 24 Tires & Wheels......................................... 26

Frame Components

Articulation Joint....................................... 30 Battery Installation – Electric Start Only ........ 54 Brake ....................................................... 32 Console ................................................... 58 Controls ................................................... 52 Foot Control ............................................. 34 Frame Tower Mounting ............................ 42 Fuel Tank ................................................. 50 Grille ........................................................ 56 Hydrualic Cooler Mounting ....................... 46 Manifold Assembly ................................... 36 Manual Compartment............................... 48 Operator’s Cushion .................................. 60 Operator’s Platform ............................ 38, 40 Valve/Filter Mounting ............................... 44

Accessories

Dual Wheel Kit ......................................... 98 EC Kit .......................................................96 Hour Meter Kit .......................................... 94 Rear Tie Down ....................................... 102 Single Point Lift ...................................... 104 Wheel Weight ......................................... 100 Miscellaneous Bolt/Nut Torque Chart ............................ 108 Filters ..................................................... 112 Optional Kits ........................................... 112 Parts Manual Change Request .............. 113 Related Publications............................... 112 Replacement O-Ring Chart .................... 111 Warranty Registration............................. 116

Hydraulics

Divider/Combiner Manifold ....................... 66 Divider/Combiner Manifold – Service Parts .. 78 Drive Hydrualics ....................................... 64 Control Valve – 1-Spool ............................. 80 Control Valve – 2-Spool ............................. 82 Cooler ...................................................... 72 Cylinder – 2.5” x 1.0” x 4.0”........................... 88 Pump – Service Parts ............................ 84, 86 Tank......................................................... 70 Pump Hydraulics ...................................... 76 Steering Cylinder ..................................... 68 Valve Hydraulics ...................................... 74

Electrical *See technical supplement for further electrical information

ID0196193

6

7

DECALS

ID0135069

8

DECAL LOCATION R150 / R150E

3 4 17 5

16

2 6

1

18

20

11 3

19

12

10 8

13

9 14 7

15

15

ID0190071

9

DECAL LOCATION R150 / R150E REF PART NO. NUMBER

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

270-4839 270-4838 274-318 270-1996 274-442 700-063 270-2000 270-1895 275-371 274-854 275-355 270-6773 270-1986 275-173 270-2001 270-1894 274-291 273-475 270-2040 270-1023 270-2339 270-2338

QTY

DESCRIPTION

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

R150 SERVICE DECAL KIT R150E SERVICE DECAL KIT TIE DOWN LOCATION PARKING BRAKE LIFT LOCATION HYDRAULIC OIL CAP RT LOGOTYPE R150 RT MODEL ID STEERING FRAME LOCK LOGO PLACARD CAUTION HOT PARTS PATENT CONTROL PANEL FUEL TANK (GASOLINE) LT LOGOTYPE R150 LT MODEL ID SOUND POWER 10 WARNING READ OPERATOR MANUAL OPERATORS MANUAL NOTICE HYDRAULIC OIL LEVEL ZAHN R150 TOP CONTROL PATCH ZAHN BOTTOM CONTROL PATCH

REMARKS

USED IN DECAL KIT 270-4838 AND 270-4839

USED IN DECAL KIT 270-4838 AND 270-4839 SEE FOOTNOTE 1 MACHINES WITHOUT REAR PANEL, INSTALL DECAL ABOVE MANUAL TUBE

FOOTNOTES:

1 . NOT PART OF KIT.

15

ID0190071

10

NOTES:

ID0134963

11

ENGINE COMPONENTS

ID0134845

12

ENGINE & MUFFLER

R150E ENDS WITH S/N CMWR150EL80000137 R150

4

6

6

7 ENGINE HARDWARE 5 12

9 9 3 8 8

SEE FOOTNOTE 1

7 25

13 (9")

14

15

2 15 31

8

10

17

29 22

25 32

30

13 (18") 16 13 (4") 11

10

SEE FOOTNOTE 2 27 26 23 24

21

20

27 26

19 18

24 1

28 28 05

ID0172888

13

ENGINE & MUFFLER

R150E ENDS WITH S/N CMWR150EL80000137 R150 REF PART NO. NUMBER

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 ENGINE (15 HP HONDA, MANUAL) 1 ENGINE (15 HP HONDA, ELECTRIC) 1 MUFFLER MOUNT 1 MUFFLER 1 MOUNT 3 FLG LK BOLT (5/16-NC X 3/4") 3 FLG LOCKNUT (5/16-NC) 4 FLG LOCKNUT (1/4-NC) 2 FLG LK BOLT (1/4-NC X 1") 3 FLG SCREW (M6-1.00 X 15MM, SELF TAP) 4 SNAP-ON CLAMP (.468" TO .531") 1 MUFFLER GASKET 31 BULK HOSE (1/4", SOLD PER 1") 1 CABLE TIE (1/16" TO 11/4") 2 WORM CLAMP (1/4" TO 5/8") 1 FUEL FILTER (04H-04H, IN-LINE) 2 FLG BOLT (3/8-NC X 1-1/4") 1 CAP (06J) 1 DRAIN HOSE (06JM-06JFX90M-16"-1000) 1 CONNECTOR (06J-M20) 1 GASKET, OIL PLUG 1 FUEL PUMP W/CONNECTOR 1 HONDA ENGINE SUBPLATE 4 FLG LK BOLT (3/8-NC X 2") 4 FLG LOCKNUT (3/8-NC) 4 WASHER (.531", HARDENED) 4 BOLT (1/2-NC X 2") 4 FLG LOCKNUT (1/2-NC) 1 MOUNT 2 FLG LK BOLT (1/4-NC X 1/2") 1 S/O COUPLER (02N-04H90) 1 COUPLER (1/8NPTX1/4OD,STR)

195-1143 195-1168 300-4499 195-1184 300-4218 105-823 105-003 105-832 105-819 105-1217 110-628 195-1304 115-381 110-248 110-249 195-1140 105-677 154-054 150-2031 150-1968 500-1470 300-6963 300-3480 105-883 105-834 106-743 105-229 105-833 300-4391 105-836 155-158 155-107

DESCRIPTION

REMARKS

SEE NOT SHOWN FOR OPTIONS.

SUPPLIED WITH ENGINE, SERVICE PART USE 1 AT 4" , 1 AT 9" & 1 AT 18" LONG ELECTRIC START ENGINES REQUIRE 2 CABLE TIES.

SUPPLIED WITH ENGINE, SERVICE PART

NOT SHOWN:

195-1264 SPARK ARRESTER SERVICE PARTS: 195-1301 STARTER, RECOIL (RED) 195-1302 AIR FILTER ELEMENT 195-1303 STARTER, ELECTRIC 195-1305 SPARK PLUG 195-1308 CARBURETOR ASSEMBLY 215-1401 KEY SWITCH 215-020 KEY 215-1402 KEY SWITCH 215-1403 KEY

OPTIONAL FOR MUFFLER

FOR MANUAL START (195-1143) FOR MANUAL START (195-1143) FOR ELECTRIC START (195-1168) FOR ELECTRIC START (195-1168)

FOOTNOTES:

1. REGULATOR / RECTIFIER 215-1328 COMES WITH ENGINE 195-1168, ELECTRIC START. MUST BE ORDERED SEPARATELY AS SERVICE PART. SEE PARTS PAGE ID0196025 FOR MANUAL START REGULATOR AND RECTIFIER. 2. USE THIS BOLT TO GROUND ELECTRICAL HARNESSES. NOTE:

05

ID0172888

14

ENGINE & MUFFLER

R150E BEGINS WITH S/N CMWR150EL80000138 R150

4

6

6

7 ENGINE HARDWARE 5 12

9 9 3

SEE FOOTNOTE 1 13 (9")

8

8

7 25

14

15

10

2 15 31

8

17

29 22

25 32

30

13 (18") 16 13 (4") 11

10

SEE FOOTNOTE 2 27 26 23 24

21

20

27 26

19 18

24 1

28 28 02

ID0201339

15

ENGINE & MUFFLER

R150E BEGINS WITH S/N CMWR150EL80000138 R150 REF PART NO. NUMBER

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 ENGINE (15 HP HONDA, MANUAL) 1 ENGINE (15 HP HONDA, ELECTRIC) 1 MUFFLER MOUNT 1 MUFFLER 1 MOUNT 3 FLG LK BOLT (5/16-NC X 3/4") 3 FLG LOCKNUT (5/16-NC) 4 FLG LOCKNUT (1/4-NC) 2 FLG LK BOLT (1/4-NC X 1") 3 FLG SCREW (M6-1.00 X 15MM, SELF TAP) 4 SNAP-ON CLAMP (.468" TO .531") 1 MUFFLER GASKET 31 BULK HOSE 1/4" (50 PSI) 1 CABLE TIE (1/16" TO 11/4") 2 WORM CLAMP (1/4" TO 5/8") 1 FUEL FILTER (04H-04H, IN-LINE) 2 FLG BOLT (3/8-NC X 1-1/4") 1 CAP (06J) 1 DRAIN HOSE (06JM-06JFX90M-16"-1000) 1 CONNECTOR (06J-M20) 1 GASKET, OIL PLUG 1 FUEL PUMP W/CONNECTOR 1 HONDA ENGINE SUBPLATE 4 FLG LK BOLT (3/8-NC X 2") 4 FLG LOCKNUT (3/8-NC) 4 WASHER (.531", HARDENED) 4 BOLT (1/2-NC X 2") 4 FLG LOCKNUT (1/2-NC) 1 MOUNT 2 FLG LK BOLT (1/4-NC X 1/2") 1 S/O COUPLER (02N-04H90) 1 COUPLER (1/8NPTX1/4OD,STR)

195-1143 195-1354 300-4499 195-1184 300-4218 105-823 105-003 105-832 105-819 105-1217 110-628 195-1304 105-1437 110-248 110-249 195-1140 105-677 154-054 150-2031 150-1968 500-1470 300-6963 300-3480 105-883 105-834 106-743 105-229 105-833 300-4391 105-836 155-158 155-107

DESCRIPTION

REMARKS

SEE NOT SHOWN FOR OPTIONS.

SUPPLIED WITH ENGINE, SERVICE PART USE 1 AT 4" , 1 AT 9" & 1 AT 18" LONG ELECTRIC START ENGINES REQUIRE 2 CABLE TIES.

SUPPLIED WITH ENGINE, SERVICE PART

NOT SHOWN:

195-1264 SPARK ARRESTER SERVICE PARTS: 195-1301 STARTER, RECOIL (RED) 195-1352 STARTER, RECOIL (BLACK) 195-1302 AIR FILTER ELEMENT 195-1303 STARTER, ELECTRIC 195-1305 SPARK PLUG 195-1308 CARBURETOR ASSEMBLY 215-1401 KEY SWITCH 215-020 KEY 215-1402 KEY SWITCH 215-1403 KEY

OPTIONAL FOR MUFFLER FOR USE WITH 195-1143 FOR USE WITH 195-1354

FOR MANUAL START (195-1143) FOR MANUAL START (195-1143) FOR ELECTRIC START (195-1354) FOR ELECTRIC START (195-1354)

FOOTNOTES:

1. REGULATOR / RECTIFIER 215-1328 COMES WITH ENGINE 195-1168, ELECTRIC START. MUST BE ORDERED SEPARATELY AS SERVICE PART. SEE PARTS PAGE ID0196025 FOR MANUAL START REGULATOR AND RECTIFIER. 2. USE THIS BOLT TO GROUND ELECTRICAL HARNESSES. NOTE:

02

ID0201339

16

ENGINE ELECTRONICS R150

5 5 2 8 9 4 11

4

6 1 11

3 3

03

11 3

7

10

ID0202810

17

ENGINE ELECTRONICS R150

REF PART NO. NUMBER

QTY

1 215-1380 2 215-1381 3 105-819 4 105-085 5 105-1218 6 300-7460 7 501-325 8 105-873 9 105-003 10 300-7572 11 155-751

1 1 3 3 2 1 2 1 1 1 3

DESCRIPTION

REMARKS

REGULATOR CAPACITOR FLG LK BOLT (1/4-NC X 1") LOCKNUT (1/4"-NC) POP RIVET (5/32 X .525, BLACK) MOUNT FLG LK BOLT (5/16-NC X 5/8") FLG LK BOLT (5/16-NC X 1") FLG LOCKNUT (5/16-NC) COVER WASHER (1/4", NEOPRENE)

NOT SHOWN:

FOOTNOTES:

NOTE:

03

ID0202810

18

AIR FILTER

R150E BEGINS WITH S/N CMWR150EL80000138

3

8 6

6

4

SEE FOOTNOTE 1

1

5 2 1

7

01

ID0201300

19

AIR FILTER

R150E BEGINS WITH S/N CMWR150EL80000138 REF PART NO. NUMBER

1 2 3 4 5 6 7 8

195-1157 195-280 195-1130 105-866 194-339 110-134 105-003 195-1267

QTY

1 1 1 2 1 2 2 1

DESCRIPTION

AIR FILTER PARTS ASSY. ELEMENT (PRIMARY) AIR FILTER INLET HOSE FLG LK BOLT (5/16-NC X 1.250") MOUNTING CLAMP (4.800") WORM CLAMP (2.062" TO 2.750") FLG LOCKNUT (5/16-NC) HOSE

REMARKS

INCLUDES REF NO. 2

SUPPLIED WITH ENGINE, SERVICE PART

NOT SHOWN:

FOOTNOTES:

1. CLAMP SUPPLIED WITH ENGINE, USE 110-134 FOR SERVICE PARTS.

NOTE:

01

ID0201300

20

HYDRAULIC PUMP & MOUNTING R150 / R150E

3 8

3 2

10

4 1

11

8 16

7

3

12

5 6

10 14

9 10

11

13 15

10 14

03

ID0173181

21

HYDRAULIC PUMP & MOUNTING R150 / R150E REF PART NO. NUMBER

QTY

160-1100 160-1101 500-1445 105-677 160-1111 160-1090 160-1091 300-4492 500-1593 150-1541 105-158 105-052 500-1476 500-1500 105-031 150-1653 110-031

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

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

DESCRIPTION

PUMP MOUNTING KIT HYD. PUMP MOUNT HOUSING (5.625") COVER FLG BOLT (3/8-NC X 1-1/4") ROTEX 24 GREEN SPIDER INSERT FLANGE COUPLER (1.000") FLANGE COUPLER (9T .625") CALIPER MOUNT COVERS (METAL) GROUND DRIVE PUMP CAM WASHER (3/8") BOLT (3/8-NC X 1-1/4") COUPLER O-RING BOLT (3/8-NC X 1") SINGLE GEAR PUMP CABLE TIE (1/2") 20" LG

REMARKS

INCL'S REF. NO.'S 1, 2, 4, 5 & 6 INCL'S COVERS, REF NO. 2 SERVICE PART, OLD STYLE SEE FOOTNOTE 1 SEE FOOTNOTE 1 SERVICE PART, INCLUDES 4 MOUNTING SCREWS AND 2 COVERS. INCL'S REF NO.'S 12 & 13 SERVICE PART SERVICE PART

ONLY USED WITH OLD STYLE COVERS

NOT SHOWN:

FOOTNOTES:

1. APPLY 242 LOCTITE TO SET SCREWS ON COUPLER.

NOTE:

1. KEY, SUPPLIED WITH ENGINE, IS .25" SQ. X 1.7" LG.

03

ID0173181

22

NOTES:

ID0134963

23

POWER TRAIN

ID0135064

24

BRAKE HUB & MOTORS

10

6

2 8

1

9

5 3 4

7

7 2

9

3

4

5 10

6 8 04

1 ID0171430

25

BRAKE HUB & MOTORS REF PART NO. NUMBER

QTY

1 300-4341 2 301-1290 3 300-5985 4 105-286 5 105-1192 6 105-054 7 105-833 8 105-082 9 155-572 10 105-418

2 HUB (MACHINED) 2 BRAKE ROTOR 10 SPACER (.75 X .375 X 1.00) 10 BOLT (3/8-NC X 1-3/4") 10 LUG BOLT (7/16-NF X 2 1/4") 10 LUG NUT (7/16-NF) 6 FLG LOCKNUT (1/2-NC) 8 BOLT (1/2-NC X 2-1/2") 2 HYD MTR (GEROLER) 20.6 CID 1 LOCKNUT (1-20 NEF)

DESCRIPTION

REMARKS

SEE FOOTNOTE 3

SEE FOOTNOTE 3

SEE FOOTNOTE 1 SERVICE PART, SEE FOOTNOTE 2

NOT SHOWN:

260-1061

HUB PULLER

SERVICE PART

FOOTNOTES:

1. REMOVE ALL PAINT, RUST, GREASE AND OIL FROM TAPERED BORE IN HUB AND ON THE TAPERED MOTOR SHAFT. USE A CLEAN WHITE RAG OR PAPER TOWEL WITH ALCOHOL TO WIPE CLEAN THE TAPERED BORE IN HUB AND THE TAPERED MOTOR SHAFT. ALLOW HUB AND MOTOR SHAFT TO DRY BEFORE ASSEMBLING. TORQUE NUT, 105-418, OF HYD. MOTOR TO 325-375 FT-LBS, DRY. NOTE : DO NOT USE ABRASIVE MATERIAL, SUCH AS SANDPAPER OR ABRASION WHEELTO REMOVE CONTAMINATES FROM HUB BORE OR ON MOTOR SHAFT. 2. IF REUSING EXISTING NUT, CLEAN THREADS AND APPLY 242 LOCTITE OR EQUIVALENT BEFORE REINSTALLING. 3. FOR REPLACEMENT HUB, ORDER THE HUB AND LUG BOLT ASSEMBLY 650-1103. HUB 300-4341 IS NOT AVAILABLE AS A STAND ALONE ITEM. NOTE:

04

ID0171430

26

TIRES & WHEELS R150 / R150E

10 8

7 9 10 11

12 2

6 1

5

4

3

03

ID0194482

27

TIRES & WHEELS R150 / R150E REF PART NO. NUMBER

QTY

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

1 TIRE (18 X 9.5 X 8 B/L, 4PLY TL) 1 WHEEL (8.00 X 6.937, W.5) 1 TIRE (18 X 8.50-8, B4TL, NHS) 1 WHEEL (8 X 5.375 WD, W15) 1 VALVE STEM (.453", SNAP-IN) 1 VALVE CAP (.305"-32) 10 LUG NUT (7/16-NF) 1 TIRE & WHEEL (RIGHT) 1 TIRE & WHEEL (LEFT) 2 TIRE & WHEEL (18 X 8.5 X 8, TURF TAMER) 1 POLYURETHANE FILL 18 X 9.5-8 BL RIGHT 1 POLYURETHANE FILL 18 X 9.5-8 BL LEFT 2 SPACER (.75 X .375 X 1.00)

205-477 205-476 205-144 205-227 205-164 205-165 105-054 205-479 205-480 205-861 205-1156 205-1157 300-5985

DESCRIPTION

REMARKS

REQUIRES 5 PER HUB INCLUDES REF NO.'S 1, 2, 5 & 6 INCLUDES REF NO.'S 1, 2, 5 & 6 INCLUDES REF NO.'S 3 THRU 6 SEE DEALER FOR REQUIRED USE. SEE FOOTNOTE 1 SEE DEALER FOR REQUIRED USE. SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. THERE ARE NO SERVICE PARTS AVAILABLE FOR URETHANE FILLED TIRE ASSEMBLIES. THESE MUST BE PURCHASED AS DIRECTIONAL ASSEMBLIES ONLY.

NOTE:

03

ID0194482

28

NOTES:

ID0134963

29

FRAME COMPONENTS

ID0135068

30

ARTICULATION JOINT

SEAL DIRECTION

7 6 5

2 3

1 PIN STORAGE POSITION PIN LOCK POSITION 3

4

2 8

02

ID0172197

31

ARTICULATION JOINT REF PART NO. NUMBER

QTY

1 300-4074 2 157-539 3 125-538 4 300-4329 5 181-1000 6 105-969 7 105-1263 8 125-572

1 2 2 1 1 1 1 1

DESCRIPTION

ARTICULATION JOINT (MACHINING) WIPER SEAL (1.500") COMPOSITION BUSHING (1.5") TAPERED PIN (1.500 X 8.25, SPECIAL) TAPERED INSERT (1.625") FLG BOLT (5/8-NC X 1-1/2",GD8) PIN (.625 X 2.5) THRUST WASHER (1.50")

REMARKS

NOTE SEAL DIRECTION WHEN INSTALLING

USE LOCKTITE 242 OR EQUIVALENT ARTICULATION JOINT LOCK PIN

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0172197

32

BRAKE

4 5

6

10

9

8 3 7

11

4

5

2

7 8

6

1

8

8

8

5

3

8

4

4

6 01

DI AU REC XIL TIO IAR N O YV F IEW

5

6

ID0170521

33

BRAKE REF PART NO. NUMBER

QTY

1 300-3506 2 110-022 3 300-3507 4 300-3511 5 300-3512 6 117-053 7 105-047 8 105-510 9 105-031 10 105-150 11 125-402

1 1 1 2 2 2 4 4 2 2 1

DESCRIPTION

REMARKS

BRAKE LEVER KNOB (1/2-NC, BLACK) BRAKE CAM PIN (1.0 X 6.6) BRAKE LINK COMPRESSION SPRING LOCKNUT (3/8-NC) ROLL PIN (1/4" X 1-1/2") BOLT (3/8-NC X 1") BOLT (3/8-NC X 1-3/4") BRONZE BUSHING

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0170521

34

FOOT CONTROL

5 3 5 3

2 4

2 1 4

01

ID0170522

35

FOOT CONTROL REF PART NO. NUMBER

QTY

1 300-3509 2 110-411 3 322-289 4 105-284 5 105-198

1 2 2 8 4

DESCRIPTION

REMARKS

FOOT CONTROL BOLT-ON CLAMP (3/4", SET) BACKUP (BOLT-ON) WASHER (3/16") BOLT (1/4-NC X 1-3/4")

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0170522

36

MANIFOLD ASSEMBLY R150/R150E

2

1 3

01

ID0188328

37

MANIFOLD ASSEMBLY R150/R150E REF PART NO. NUMBER

QTY

1 2 3

1 DIVIDER/COMBINER MANIFOLD 2 BOLT (5/16-NC X 3-1/4") 2 FLG LOCKNUT (5/16-NC)

150-1187 105-129 105-003

DESCRIPTION

REMARKS

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0188328

38

OPERATORS PLATFORM

ENDS WITH S/N CMWR300XVA0001047 ENDS WITH S/N CMWR230XVA0000355

2 3

9

12 10

4 12

11

9

6 11 10

9 7

12

2 1

3 5

12 10

9

11 11 8

7 8 11 8 05

11

4 ID0171935

39

OPERATORS PLATFORM

ENDS WITH S/N CMWR300XVA0001047 ENDS WITH S/N CMWR230XVA0000355

REF PART NO. NUMBER

QTY

1 375-1011 2 105-1132 3 105-827 4 105-814 5 300-4213 6 300-4214 7 106-499 8 105-065 9 105-858 10 105-1199 11 106-743 12 181-635

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

DESCRIPTION

REMARKS

OPERATORS PLATFORM COMPRESSION SPRING GBR-8 63D FLG LK BOLT (3/8-NC X 1-1/4") FLG LOCKNUT (3/8-NC) PLATFORM MOUNT LEFT PLATFORM MOUNT RIGHT FLG BOLT (1/2-NC X 1-1/2",GD8) LOCKNUT (1/2-NC) BOLT (1/2-NC X 1-1/4") JAM LOCKNUT (1/2 - NC) WASHER (.531", HARDENED) SPACER

NOT SHOWN:

FOOTNOTES:

NOTE:

05

ID0171935

40

OPERATOR'S PLATFORM

BEGINS WITH S/N CMWR300XAA0001051 BEGINS WITH S/N CMWR230XAA0000356

1 13

10

9

5

7 12

4

11

6

13

1 10

2

7

6

8

3 03

7 8

9 ID0255133

41

OPERATOR'S PLATFORM

BEGINS WITH S/N CMWR300XAA0001051 BEGINS WITH S/N CMWR230XAA0000356 REF PART NO. NUMBER

QTY

1 105-1132 2 375-1011 3 301-0002 4 301-0003 5 105-1199 6 106-499 7 106-743 8 105-065 9 105-098 10 105-814 11 105-858 12 181-635 13 301-0001

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

DESCRIPTION

REMARKS

COMPRESSION SPRING GBR-8 63D OPERATORS PLATFORM PLATFORM MOUNT LEFT PLATFORM MOUNT RIGHT JAM LOCKNUT (1/2 - NC) FLG BOLT (1/2-NC X 1-1/2",GD8) WASHER (.531", HARDENED) LOCKNUT (1/2-NC) BOLT (3/8-NC X 3") FLG LOCKNUT (3/8-NC) BOLT (1/2-NC X 1-1/4") SPACER SPACER

NOT SHOWN:

FOOTNOTES:

NOTE:

03

ID0255133

42

FRAME TOWER MOUNTING

1 12 13 10 2

11 8

8

6

5

6

10

11

12

9

9

14

7

3

6

10 7 11 14 5

01

10

4

ID0172788

43

FRAME TOWER MOUNTING REF PART NO. NUMBER

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

QTY

DESCRIPTION

300-3529 1 RIGHT FRAME TOWER 300-3525 1 LEFT FRAME TOWER 300-4631 1 INNER FENDER RIGHT 300-4632 1 INNER FENDER LEFT 105-052 2 BOLT (3/8-NC X 1-1/4") 105-047 4 LOCKNUT (3/8-NC) 105-858 2 BOLT (1/2-NC X 1-1/4") 105-065 4 LOCKNUT (1/2-NC) 105-1200 2 BOLT (1/2-NC X 1-1/2", GD 8) 107-594 4 WASHER (.406", HARDENED) 106-743 4 WASHER (.531", HARDENED) 362-1170 2 THERMAL BARRIER 118-388 72 3MIL FLEXIBLE SILVER TAPE 107-595 2 BOLT (3/8-NC X 1", GD8)

REMARKS

TORQUE TO 85 FT. LBS. TORQUE TO 85 FT. LBS.

USE 8 @ 9"

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0172788

44

VALVE/FILTER MOUNTING R150 / R150E

9 3

4

7

7

7 6 1 7 9

8

5 2 8 10 6 11

02

ID0172509

45

VALVE/FILTER MOUNTING R150 / R150E REF PART NO. NUMBER

QTY

1 150-1378 2 150-1252 3 300-4292 4 300-3504 5 300-3503 6 105-873 7 105-003 8 105-178 9 105-823 10 150-3111 11 149-939

1 HYDRAULIC CONTROL VALVE (2-SPOOL) 1 HYD CONTROL VALVE (1-SPOOL) 1 ATTACHMENT LOCK MOUNT 1 FILTER MOUNT 1 VALVE MOUNT 4 FLG LK BOLT (5/16-NC X 1") 10 FLG LOCKNUT (5/16-NC) 5 BOLT (5/16-NC X 2-1/2", GD8) 5 FLG LK BOLT (5/16-NC X 3/4") 1 FILTER HEAD, 50 PSI BYPASS 1 FILTER ELEMENT

DESCRIPTION

REMARKS

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0172509

46

HYDRAULIC COOLER MOUNTING

1

2

3

3 7

7 6 TO FILTER

5

2

7 TO TANK

2

2

4 4

02

ID0172791

47

HYDRAULIC COOLER MOUNTING REF PART NO. NUMBER

QTY

1 2 3 4 5 6 7

1 COOLER MOUNT 4 CLIP NUT (5/16-NC) 2 FLG LK BOLT (5/16-NC X 1") 2 FLG LK BOLT (5/16-NC X 1") 9 BULK HOSE (3/4", SOLD PER FT) 8 BULK HOSE (3/4", SOLD PER FT) 4 WORM CLAMP (1" TO 1-3/4")

300-3781 105-841 105-873 105-873 116-636 116-636 111-011

DESCRIPTION

REMARKS

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0172791

48

MANUAL COMPARTMENT

5 4 2

1 3

1

01

3

2

5

4

ID0188412

49

MANUAL COMPARTMENT REF PART NO. NUMBER

QTY

1 2 3 4 5

1 1 2 2 2

362-1227 300-4185 110-367 105-873 105-003

DESCRIPTION

REMARKS

MANUAL COMPARTMENT MANUAL MOUNT WORM CLAMP (3-1/4" TO 4-1/8"") FLG LK BOLT (5/16-NC X 1") FLG LOCKNUT (5/16-NC)

ORIENTATION MUST BE AS SHOWN.

15/16" COMBINATION WRENCH

USED WITH R230 & R300 ONLY

NOT SHOWN:

260-1051

FOOTNOTES:

NOTE:

01

ID0188412

50

FUEL TANK

ENDS WITH S/N:

2

1

3

SEE FOOT NOTE 1

4

6

6 5 6

5

08

7

5

ID0171933

51

FUEL TANK

ENDS WITH S/N: REF PART NO. NUMBER

1 2 3 4 5 6 7

362-1159 364-698 156-064 115-153 107-248 501-325 105-117

QTY

1 1 1 1 6 4 1

DESCRIPTION

FUEL TANK FUEL CAP S/O SHUT-OFF (02N-03H90) PLUG (04N, SQ) FLG LK BOLT (5/16-NCX3/4",NLK) FLG LK BOLT (5/16-NC X 5/8") WASHER (5/16")

REMARKS

SEE NOTE 1 REGARDING OBSOLETE TANK. SEE FOOTNOTE 1 FOR FITTINGS. SEE FOOTNOTE 2 SEE FOOTNOTE 2 TORQUE TO 13 FT-LB TORQUE TO 27 FT-LB R150 REQUIRES 5 WASHERS

NOT SHOWN:

FOOTNOTES:

1. REPLACEABLE BULKHEAD FITTINGS: 500-1584 BULKHEAD FITTING (04NPT-F) 1/4 NPT 500-1585 BULKHEAD FITTING (02NPT-F) 1/8 NPT 2. APPLY 567 LOCTITE AND USE BACKUP WRENCH ON BULKHEADS WHEN TIGHTENING FITTINGS.

NOTE:

FUEL TANK 362-1159 IS OBSOLETE AND HAS BEEN REPLACED BY 362-1870. THIS REPLACEMENT WILL NOT FIT THE R150 AND THERE IS NO REPLACEMENT FOR THE R150.

08

ID0171933

52

CONTROLS R150 / R150E

12

13

11

15

9

10

KOHLER

HONDA

16 21

5

15

5

20

17 19

14 5 1

23 26

6

24

18

2

1 2

4

3

7 33

8 4 3

25

24 FOOT CONTROL

CORRECT ORDER FOR CONNECTING CONTROL LINK

22

34 36

27 30

31 32 28 29

35

37

7 8 38 39 BRAKE ENGAGED BRAKE DISENGAGED 02

ID0161039

53

CONTROLS R150 / R150E REF PART NO. NUMBER

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

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

300-3788 115-809 106-743 105-834 106-078 105-806 105-071 107-360 365-478 300-999 362-1247 362-1135 362-1132 106-380 107-669 362-1133 300-3762 107-519 105-117 125-811 115-780 105-213 110-508 107-110 300-3769 105-803 110-507 300-3523 105-130 105-285 300-4259 300-5985 105-003 110-082 105-512 160-1097 105-1189 110-297 110-067

DESCRIPTION

CONTROL LINK CRUMBER SPRING WASHER (.531", HARDENED) FLG LOCKNUT (3/8-NC) NUT (M8-1.25) SCREW (M8-1.25 X 25MM) WASHER (1/2") SHLD BLT (1/2" X 5/8"", 3/8-NC) LEVER (5.88") LEVER LEVER RELEASE LONG KNOB KNOB FLG LK SCREW (M8-1.25 X 16MM) JAM NUT (M12-1.75) KNOB CONTROL LEVER SCREW (M8-1.25 X 12MM) WASHER (5/16") BEARING BUSHING KLIP RING (.625") NUT (5/16-NF) BALL JOINT (5/16-NF), LH LOCKNUT (5/16-NF, NYL INSERT) ROD (5/16 X 22.5) NUT (5/16-NF, LH) BALL JOINT 5/16 (RH) CONTROL LEVER/ROTOR BOLT (5/16-NC X 2-1/4") BOLT (5/16-NC X 1-3/4") SPACER (.625 X .385 X 1.4) SPACER (.75 X .375 X 1.00) FLG LOCKNUT (5/16-NC) CLEVIS PIN (1/4 X 11/16) COTTER PIN (.094 X .750) CALIPER DISC BRAKE CLEVIS MALE THREAD (1/4 NF) SPG CLEVIS PIN (1/4" X 11/16"") CLEVIS (1/4-NF)

REMARKS

REFER TO FOOTNOTE 1

SEE FOOTNOTE 2

FOOTNOTES:

1. HONDA CONTROL ROD (REF #17) BOLTS TO OUTSIDE HOLE ON HANDLE ASSEMBLY. 2. REFER TO OPERATORS MANUAL FOR CALIPER AND LINKAGE ADJUSTMENTS.

NOTE:

02

ID0161039

54

BATTERY INSTALLATION ELECTRIC START ONLY

4 TO STARTER 3 2 1

7

3

8 6 5 9

9 GRD TO MOTOR

02

ID0175843

55

BATTERY INSTALLATION ELECTRIC START ONLY REF PART NO. NUMBER

QTY

1 215-256 2 105-832 3 105-820 4 215-1198 5 215-1199 6 300-4262 7 195-339 8 105-095 9 300-4334

1 2 2 1 1 1 2 2 2

DESCRIPTION

REMARKS

BATTERY (12V, 200 AMP) FLG LOCKNUT (1/4-NC) FLG LK BOLT (1/4-NC X 3/4") POSTIVE BATT. CABLE (6 GA. X 12', RED) BAT CABLE (6GA X 22", BLACK) BATTERY HOLD DOWN WING NUT (1/4-NC) WASHER (1/4") J-HOOK (PLATED)

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0175843

56

GRILLE

9 6 3 5

8

7

2

1

02

ID0172789

57

GRILLE REF PART NO. NUMBER

QTY

1 2 3 5 6 7 8 9

1 6 6 2 2 2 2 1

300-4157 105-873 105-841 211-282 105-1218 105-820 105-832 214-301

DESCRIPTION

GRILL FLG LK BOLT (5/16-NC X 1") CLIP NUT (5/16-NC) ATC FUSE COVER POP RIVET (5/32 X .525, BLACK) FLG LK BOLT (1/4-NC X 3/4") FLG LOCKNUT (1/4-NC) ACCESSORY SOCKET

REMARKS

SERVICE PARTS / COMES WITH HARNESS

SEE FOOTNOTE 1 - NOT AVAILABLE ON R150

NOT SHOWN:

FOOTNOTES:

1. ACCESSORY SOCKET 214-301 INCLUDES: (2-WAY) MALE CONNECTOR 214-103, PACKARD MALE TERMINAL 214-104, ACCESSORY SOCKET 214-253 AND WEATHER-PAC SEAL (2.80mm) 157-645.

NOTE:

02

ID0172789

58

CONSOLE

11

1

10 4

9 13

12

11 6 5

8

16 7

18 15

5 17 3

15 9

14

18

14

11 2

10

10 11

03

ID0172790

59

CONSOLE REF PART NO. NUMBER

QTY

1 362-1171 2 362-1136 3 362-1137 4 217-762 5 105-1233 6 362-1167 7 362-1166 8 362-1165 9 362-1148 10 105-834 11 105-835 12 362-823 13 217-854 14 105-137 15 106-389 16 110-854 17 105-117 18 362-1269

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

DESCRIPTION

FRONT HANDLE BAR ASSEMBLY REAR HANDLE BAR ASSEMBLY CONSOLE ROCKER SWITCH (SPDT) SMOOTH FLG LK BOLT (5/16-NC X 1.0") PUSH-IN FASTENER PUSH-IN FASTENER PUSH-IN FASTENER BOOT FLG LOCKNUT (3/8-NC) CARRIAGE BOLT (3/8-NC X 3/4") COVER SWITCH CLIP NUT (5/16-NC) WASHER (M8) SWITCH ACTUATOR GUARD WASHER (5/16") U-CLIP

REMARKS

SEE NOT SHOWN FOR OPTIONS. TORQUE TO 108 IN-LBS

USED ON R230 & R300 USED ON R150 & R150E

NOT SHOWN:

362-1174

BLACK CONSOLE (SPECIAL PAINT)

FOOTNOTES:

NOTE:

03

ID0172790

60

OPERATORS CUSHION R150 / R150E

3

4 2

1 2 4

01

3

ID0180150

61

OPERATORS CUSHION R150 / R150E REF PART NO. NUMBER

QTY

DESCRIPTION

1 2 3 4

1 2 2 2

CUSHION CLAMPING KNOB PUSH NUT (1/4) WASHER (5/16")

362-1142 362-1151 105-1219 105-117

REMARKS

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0180150

62

NOTES:

ID0134963

63

HYDRAULICS

ID0135071

64

DRIVE HYDRAULICS R150/R150E

1

2

15

4 14

3

11

11

6 5

4 9

13 8

13

10

5 7

11

01

11

12

ID0173134

65

DRIVE HYDRAULICS R150/R150E REF PART NO. NUMBER

QTY

1 150-1187 2 150-2021 3 150-2020 4 155-572 5 154-284 6 150-1931 7 515-212 8 150-1402 9 150-1403 10 150-1404 11 154-421 12 157-331 13 150-2019 14 150-2044 15 159-156

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

DESCRIPTION

DIVIDER/COMBINER MANIFOLD QDC ADAPTER (02-04S, VITON O-RING) CONNECTOR (08S-08O90, VITON O-RING) HYD MTR (GEROLER) 20.6 CID CONNECTOR (08S-08O45) HOSE (08OFX45-12"-3000) HOSE (08OFX45-15"-3000) HYDRAULIC LINE (-06) HYDRAULIC LINE (-06) HYDRAULIC LINE (-06) CONNECTOR (06O-10S90) UN RUN TEE (06OFX-06O-08O) CONNECTOR (06O-08S90, VITON O-RING) CONNECTOR (04S-04O90, VITON O-RING) QDC ADAPTER (02-040F)

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 1

SEE FOOTNOTE 1 SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. FITTINGS HAVE VITON O-RINGS. REFER TO PARTS PAGE IDO194243 FOR SERVICE PARTS.

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

01

ID0173134

66

DIVIDER/COMBINER MANIFOLD

3

2 4

5

1

01

ID0194243

67

DIVIDER/COMBINER MANIFOLD REF PART NO. NUMBER

QTY

1 2 3 4 5

2 1 1 1 1

150-2019 150-1187 150-2021 150-2020 150-2044

DESCRIPTION

CONNECTOR (06O-08S90, VITON O-RING) DIVIDER/COMBINER MANIFOLD QDC ADAPTER (02-04S, VITON O-RING) CONNECTOR (08S-08O90, VITON O-RING) CONNECTOR (04S-04O90, VITON O-RING)

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. FOR REPLACEMENT VITON ORINGS: -04 SAE 155-0001 -08 SAE 155-0002 -04 ORFS 155-0003 -06 ORFS 155-0004 -08 ORFS 155-0005 NOTE:

01

ID0194243

68

STEERING CYLINDER

11

5 4 2 3 12 1

6 10

7 9 6

02

8

ID0172889

69

STEERING CYLINDER REF PART NO. NUMBER

QTY

1 150-1883 2 125-771 3 125-538 4 300-3608 5 105-823 6 154-226 7 105-223 8 107-244 9 153-365 10 515-010 11 110-333 12 115-777

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

DESCRIPTION

CYL (2.5 X 1.00 X 4.0) COMPOSITION BUSHING (1.25") COMPOSITION BUSHING (1.5") TAB PIN(1.25 X 2.85) FLG LK BOLT (5/16-NC X 3/4") CONNECTOR (04O-06S90) WASHER (3/8") FLG LK BOLT (3/8-NC X 1") HOSE (04OFX90S-34"-3000) HOSE (04OFX90-32"-3000) BOLT-ON CLAMP (1") ABRASION SLEEVE (1.59" X 15"")

REMARKS

USE HARDWARE FROM FUEL TANK ASSEMBLY

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART 800-301 IN THE BACK OF THE BOOK FOR O-RING REPLACEMENT

02

ID0172889

70

HYDRAULIC TANK 11

13

11

12 15 14 15

1

9

3 SEE FOOTNOTE 1

2

4

5

6

2

7

8 10

16

10

10

03

ID0171934

71

HYDRAULIC TANK REF PART NO. NUMBER

QTY

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

1 5 1 1 1 1 1 1 1 3 6 1 1 1 2 1

362-1158 501-325 154-227 150-1542 150-1595 159-154 500-302 155-197 121-040 107-248 105-1247 150-1063 150-1958 150-1062 153-607 105-117

DESCRIPTION

HYDRAULIC RESERVOIR FLG LK BOLT (5/16-NC X 5/8") CONNECTOR (06O-08S90) CHECK VALVE (-08M, 65PSI) S/O COUPLER (16S-12H-06O-04SF) QDC ADAPTER (02-04S) PLUG (-12 S) REDUCER (12S-16H45) SIGHT GLASS FLG LK BOLT (5/16-NCX3/4",NLK) FLG BOLT (#10-24 X .5") FILLER NECK W/ SCREEN CAP AND BASE (MATCH PAIR) FILLER NECK FLANGE GASKET WASHER (5/16")

REMARKS

TORQUE TO 27 FT-LBS SEE FOOTNOTE 1

TORQUE TO 13 FT-LBS

INCL. REF NO.'S 13, 14 & 15

R150 REQUIRES 3 WASHERS

FOOTNOTES:

1. BEFORE INSTALLATION OF CHECK VALVE (150-1542) REMOVED O-RING FROM ORFS, MALE END.

NOTE:

1. REFER TO "PUMP HYDRAULICS" PAGE ID0175841 FOR DESTINATION OF THESE CONNECTORS. 2. REFER TO O-RING CHART 800-301 IN THE BACK OF THE BOOK FOR O-RING REPLACEMENT

03

ID0171934

72

HYDRAULIC COOLER

3

2 4 8 7

3

6 7 4

TO HYD. TANK

1

TO FILTER OUTLET 4 7 5

7 9

03

ID0156614

73

HYDRAULIC COOLER REF PART NO. NUMBER

QTY

1 2 3 4 5 6 7 8 9

1 OIL COOLER W/FAN 1 COOLER MOUNT 6 FLG LK BOLT (5/16-NC X 3/4") 6 FLG LOCKNUT (5/16-NC) 8 BULK HOSE (3/4", SOLD PER FT) 9 BULK HOSE (3/4", SOLD PER FT) 4 WORM CLAMP (1" TO 1-3/4") 1 S/O COUPLER (12S-12H45) 1 S/O COUPLER (12S-12H90)

195-1051 300-3781 105-823 105-003 116-636 116-636 111-011 155-196 155-174

DESCRIPTION

REMARKS

INCLUDES REF NO.'S 8 & 9, SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. INCLUDES SERVICE PART 500-1156 (FAN ONLY).

2. APPLY 567 LOCTITE TO NPT PLUG ON COOLER IF REMOVED (NOT SHOWN).

NOTE:

REFER TO O-RING CHART 800-301 IN THE BACK OF THE BOOK FOR O-RING REPLACEMENT

03

ID0156614

74

VALVE HYDRAULICS R150 / R150E

12 5 3 1 4

11

2 15

8

6 5

AUX. TO ATTACHMENT 7 13 5

03

10

ATTACHMENT LIFT

ID0175842

75

VALVE HYDRAULICS R150 / R150E REF PART NO. NUMBER

QTY

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

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

150-3111 149-939 150-2028 154-226 154-235 154-236 515-255 154-220 154-246 150-1589 150-1378 150-1252 154-296 154-327 154-387

DESCRIPTION

FILTER HEAD, 50 PSI BYPASS FILTER ELEMENT S/O COUPLER (12S-12H) CONNECTOR (04O-06S90) CONNECTOR (08S-08O90) CONNECTOR (08O-12S90) HOSE (08OFX-18"-3000) CONNECTOR (04O-06S) CONNECTOR (06S-08O) HYDRAULIC LINE (-08) HYDRAULIC CONTROL VALVE (2-SPOOL) HYD CONTROL VALVE (1-SPOOL) CAP (04OF) CAP (08OF) CONNECTOR (04O-06S90, ORF)

REMARKS

USE ONLY FOR SHIPPING AND WHEN MACHINE HAS NO ATTACHMENT. USE ONLY FOR SHIPPING AND WHEN MACHINE HAS NO ATTACHMENT.

NOT SHOWN:

FOOTNOTES:

NOTE:

03

ID0175842

76

PUMP HYDRAULICS R150 / R150E

10

13

12 11 REFER TO NOTE #1

3

14

4 16

5 15 16

1 6 2

7 8 9

02

ID0175841

77

PUMP HYDRAULICS R150 / R150E REF PART NO. NUMBER

QTY

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

1 GROUND DRIVE PUMP 1 SINGLE GEAR PUMP 1 QDC ADAPTER (02-08OFX) 1 UNION RUN TEE (08OFX-08O-08O) 1 CONNECTOR (08S-08O) 1 CONNECTOR (06S-06O45) 1 CONNECTOR (04S-04O90) 1 S/O COUPLER (10S-16H90-08SF) 1 PLUG (08S, SOC, FM) 1 CONNECTOR (08S-08O90) 1 HOSE (08OFX45-26"-3000) 1 HOSE (04OFX90S-26"-3000) 1 REDUCER (04O-06OF) 1 HOSE (06OFX-11"-3000) 9 BULK HOSE (1", SOLD PER FT) 2 WORM CLAMP (1" TO 1-3/4")

150-1541 150-1653 159-158 154-266 154-233 154-224 154-252 155-225 155-074 154-235 515-402 154-802 154-373 150-1684 116-460 111-011

DESCRIPTION

REMARKS

NOT SHOWN:

FOOTNOTES:

NOTE:

1. REFER TO "HYDRAULIC TANK" PAGE ID0171934 FOR CONNECTOR INFORMATION.

02

ID0175841

78

DIVIDER / COMBINER MANIFOLD SERVICE PARTS

2

1

1

3

01

2

ID0179484

79

DIVIDER / COMBINER MANIFOLD SERVICE PARTS REF PART NO. NUMBER

QTY

DESCRIPTION

REMARKS

150-1187 1. 500-1162 2. 500-1330 3. 500-1161

-

SOLENOID VALVE SOLENOID VALVE SOLENOID COIL, 12VDC W/ ZENER DIODE FLOW CONTROL CARTRIDGE

INCLUDES 1-3.

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0179484

80

HYDRAULIC CONTROL VALVE (1-SPOOL) SERVICE PARTS

5

1

2 4 3

2

06

ID0183877

81

HYDRAULIC CONTROL VALVE (1-SPOOL) SERVICE PARTS REF PART NO. NUMBER

1.

2.

3.

4.

5.

150-4195 500-1165 500-1438 500-2550 499-143 500-2711

QTY

DESCRIPTION

REMARKS

HYD CONTROL VALVE (1-SPOOL) SPRING RETURN KIT (SD4) VALVE BODY SPOOL (1CPS[XS]/SD4) VALVE LEVER RELIEF VALVE KIT

SEAL KIT 500-1163

NOT SHOWN:

FOOTNOTES:

NOTE:

06

ID0183877

82

HYDRAULIC VALVE (2-SPOOL) SERVICE PARTS

9 3 8

1

5 2

3 5

4

01

7

6

ID0183815

83

HYDRAULIC VALVE (2-SPOOL) SERVICE PARTS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

150-1378 153-063 500-1434 500-1435 153-065 500-1166 499-143 157-218 500-736 500-1167

QTY

DESCRIPTION

REMARKS

SEAL KIT 190-736

1 1 1 1 1 1 1 1 1

HYDRAULIC CONTROL VALVE (2-SPOOL) VALVE SPRING KIT VALVE BODY PLUG (SD5 THD) RELIEF VALVE KIT SPOOL (1CS/SD5) VALVE LEVER O-RING (D70) PLUG (SD5 THD) 8D3ME SPRING RETURN KIT W/ EXT

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0183815

84

HYDRAULIC PUMP SERVICE PARTS

2 3 1

1 1

1 1

02

ID0184038

85

HYDRAULIC PUMP SERVICE PARTS REF PART NO. NUMBER

150-1541 1. 191-413 2. 500-405 3. 500-1557

QTY

DESCRIPTION

REMARKS

GROUND DRIVE PUMP SEAL KIT PISTON KIT SHOCK VALVE

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0184038

86

HYDRAULIC PUMP SERVICE PARTS

1 1

1 1

01

1

1 1

ID0196108

87

HYDRAULIC PUMP SERVICE PARTS REF PART NO. NUMBER

1.

150-1653 500-1158

QTY

1

DESCRIPTION

REMARKS

HYDRAULIC PUMP SEAL KIT

INCLUDES REF. NO. 1

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0196108

88

HYDRAULIC CYLINDER (2.5" X 1.0" X 4.0")

1

4

11

13 3

12

5 10 9 8 7 6

2

01

ID0194142

89

HYDRAULIC CYLINDER (2.5" X 1.0" X 4.0") REF PART NO. NUMBER

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

150-283 150-1880 150-1881 106-096 150-1882 157-537 157-540 150-779 157-021 500-031 125-775 157-019 157-535

QTY

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

DESCRIPTION

CYLINDER BARREL (2.5 X 4.0) CYLINDER ROD (1.00 X 4.0) CYLINDER PISTON (2.5" X 1.00") FLG BOLT (1/2-NC X 1-3/4",GD8) CYLINDER HEAD (2.5" X 1.00") WIPER SEAL (1.000") U-SEAL (1.000") LOCK RING (2.5") BACKUP RING (228 D90) O-RING (228 D90) WEAR RING O-RING (139 D90) BACKUP RING (139 D90)

REMARKS

SEE FOOTNOTE 2 SEE FOOTNOTE1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1

NOT SHOWN:

259-100 259-235 259-242 259-243 259-188

U-SEAL INSTALLER (1"-1.499") 1.00 ROD WIPER TOOL WIPER SEAL INSTALLER (2.5") PISTON INSTALLER (2.5") CYL HEAD SPANNER - TWO PIN

FOOTNOTES:

1- SEAL REPAIR KIT P/N 190-1237 2- APPLY LOCTITE 277 OR EQUIVALENT, TORQUE TO 90-100 FT/LBS

NOTE:

01

ID0194142

90

NOTES:

ID0134963

91

ELECTRICAL SEE TECHNICAL SUPPLEMENT FOR FURTHER ELECTRICAL INFORMATION

ID0134878

92

NOTES:

ID0134963

93

ACCESSORIES

94

HOUR METER KIT

3 4 4 3

2

1

ASSEMBLED VIEW

04

ID0173661

95

HOUR METER KIT REF PART NO. NUMBER

1 2 3 4

190-1173 215-2594 300-3789 105-819 105-832

QTY

1 1 2 2

DESCRIPTION

HOUR METER KIT HOUR METER HOUR METER MOUNT FLG LK BOLT (1/4-NC X 1") FLG LOCKNUT (1/4-NC)

REMARKS

INCLUDES REF NO'S: 1 THRU 4 SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. ELECTRICAL CONNECTORS: ORG/GRN=POSITIVE & BLACK=NEGATIVE

NOTE:

04

ID0173661

96

EC KIT

R150/R150E

2 1 3

12

8

11

9

10 12

4 5

7

01

6

ID0194496

97

EC KIT

R150/R150E REF PART NO. NUMBER

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

190-1297 364-698 362-1175 362-1176 300-4372 300-4373 105-823 105-089 217-874 105-197 105-095 105-865 105-832

QTY

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

DESCRIPTION

EC KIT (R150/R150E) FUEL CAP FUEL CAP COVER FUEL CAP COVER BASE MOUNT COVER FLG LK BOLT (5/16-NC X 3/4") LOCKNUT (5/16-NC) BATTERY DISCONNECT BOLT (1/4-NC X 1") WASHER (1/4") BOLT (1/4-NC X 3/4", GD8) FLG LOCKNUT (1/4-NC)

REMARKS

INCLUDES REF NO.'S 2-12

ATTACH WITH EXISTING HARDWARE FROM COOLER.

REINSTALL NEGATIVE BATTERY CABLE TO THIS BOLT.

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0194496

98

DUAL WHEEL KIT

6 7 1

1

7 6

SEE FOOTNOTE 1 5

3

4

05

2

ID0178735

99

DUAL WHEEL KIT REF PART NO. NUMBER

QTY

190-1210 205-1050 105-1212 105-385 105-054 105-171 205-1045 205-1107

2 2 1 8 8 2 2

1 2 3 4 5 6 7

DESCRIPTION

DUAL WHEEL KIT INSIDE HUB BOLT (5/8-NC X 13.00") GD8 LOCK WASHER (5/8") LUG NUT (7/16-NF) LUG BOLT OUTSIDE HUB SPACER RING

REMARKS

INCL. REF. NO'S. 1 THRU 7

NOT SHOWN:

FOOTNOTES:

1. USE EXISTING HARDWARE TO MOUNT DUAL WHEEL KIT TO MACHINE.

NOTE:

05

ID0178735

100

WHEEL WEIGHT

3

2

1 SEE FOOTNOTE 2

3

1

2

02

ID0185095

101

WHEEL WEIGHT REF PART NO. NUMBER

1 2 3

190-1258 205-1050 375-1017 106-012

QTY

DESCRIPTION

WHEEL WEIGHT KIT 2 INSIDE HUB 2 WHEEL WEIGHT 2 FLANGE BOLT (5/8-NC X 3")

REMARKS

INCL. REF #'S 1-3 SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. ORIENTATION OF P/N 205-1050 REQUIRED FOR PROPER ALIGNMENT OF WEIGHT CUTOUT WITH VALVE STEM. 2. USE EXISTING HARDWARE TO MOUT TO MACHINE.

NOTE:

02

ID0185095

102

REAR TIE DOWN 7

8

6 6

5 9 10 4

1

3

2

01

ID0188623

103

REAR TIE DOWN REF PART NO. NUMBER

QTY

323-0002 300-5056 105-357 300-5055 118-193 110-033 313-759 118-194 180-544 118-1006 105-376

1 2 1 1 1 2 1 1 1 2

1 2 3 4 5 6 7 8 9 10

DESCRIPTION

REAR TIE DOWN REAR TIE DOWN LOCKNUT (5/8-NC) MOUNT PLATE A-336 LOK-A-LOY CONNECTING LINK HAIR CLIP PIN (1/8" X 1/2") LANYARD DOUBLE CLEVIS LINK REAR STAND PIN CHAIN (3/8" ) BOLT (5/8-NC X 3", GD8)

REMARKS

INCLUDES REF. NO'S 1-10

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0188623

104

SINGLE POINT LIFT

1

2

01

ID0199157

105

SINGLE POINT LIFT REF PART NO. NUMBER

QTY

190-1265 1 300-5004 2 105-866

- SINGLE POINT LIFT KIT 1 LIFT PLATE 4 FLG LK BOLT (5/16-NC X 1.250")

DESCRIPTION

REMARKS

INCLUDES REF #'S 1 AND 2

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0199157

106

NOTES:

ID0134963

107

MISCELLANEOUS

ID0135063

108

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

109

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.

110

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

111

112

R150/R150E Related Publications Component

Ass’y

P/N

Model: R150/R150E .......... Parts Manual ................................................................... ............. 053-1171 R150/R150E .......... Operators Manual ............................................................ ............. 053-1173 R150/R150E .......... Special Tools Guide ........................................................ ............. 052- 901 R150/R150E .......... ZAHN Front End’s ............................................................ ............. 053-1169 R150/R230/R300 ... Tech Supplement ............................................................. ............. 053-1168 R150/R230/R300 ... Repair Guide (Service Manual) ....................................... ............. 053-1323 Engine: HONDA ................. Parts Manual…IGX440…. 195-1168, 195-1143 .............. ............. 053-1175 HONDA ................. Service (Shop) Manual – GX390QA ............................... ............. 053-1174

Filters Engine: Air Filter .......................................................................................................................... 195-1302 Fuel Filter ........................................................................................................................ 195-1140

Hydraulic: Oil Filter Element ............................................................................................................. 149-939

Optional Kits O-ring Repair Kit - FLG, ORS & SAE (15 different O-rings) ............................................ 190-051 O-ring Repair Kit - Field Service (46 different O-rings) .................................................... 190-052

VER.03

ID0194444

113

Parts Manual Change Request (Please print clearly)

Date: _______________________

Dealer No. (required): _____________________________

Your Name: _____________________________ Phone: _________________

Position: _____________________________

Fax: _________________

E-mail: __________________

Publication Information: Parts Manual No.: _____-_____

Model: __________

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.

ID0135001

114

115

ID0040564

116

ID0135281