Ditch Witch Z3500 / Z4500 Tractor Parts Manual PDF

Ditch Witch Z3500 / 24500 (TRACTOR)

ISSUE NO. 1/PL-08/97

Copyright 1997 The Charles Machine Works, Inc. Issue No. 1/PL-08/97, For Replacement Copy Order P/N 053-483 AutoCrowd, Jet Trac, Modularmatic, Roto Witch, Pro Tech, Perma Soil, Sidekick, Ditch Witch and

El are registered trademarks of The Charles Machine Works, INC.

FOREWORD This book 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.

There are several things to remember while using this book: ♦

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 book.

♦

Assembly instructions and Tech Bits articles referenced in footnotes are available through your local Ditch Witch dealer.

♦

Descriptions and specifications in this book were current at publication. However, The Charles Machine Works, Inc. reserves the right to improve equipment, so this book 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.

Ditch Witch® EQUIPMENT AND REPLACEMENT PARTS NORTH AMERICAN* LIMITED WARRANTY POLICY The following Major Component Limited Warranty covers . only Major Components listed under Major Component Limited Warranty that are manufactured and distributed by Charles Machine Works. Inc. ("CMW"). Replacement parts and other serial numbered Products ("Products") that are not listed under Major Component Limited Warranty, and non-major components are covered under Product Limited Warranty.

MAJOR COMPONENT LIMITED WARRANTY Major Components are warranted for a period of 1000 hours of use or one year, whichever occurs first, beginning on date of delivery of any such new Product to original purchaser.

Major Components are defined as:

Differentials and parts contained within.

Mechanical Transmissions.

Drive gear boxes and parts contained within.

Hydraulic, hydrostatic, and fluid pumps, motors and components that control or protect pumps and motors.

Auxiliary hydraulic control valves and electrical components used for controlling hydraulic components.

Hydraulic cylinders and components excluding repair kits.

Batteries, alternators, instruments, gauges, and protection components for electrical systems.

Pierce Airrow® bodies, strikers and tailpieces.

CMW will provide free replacement parts to original purchaser for any part of Major Components which Has a defect in material or workmanship within warranty period. Defects will be determined by an inspection of Major Component or part by CMW or its authorized dealer. Original purchaser of the Product containing a Major Component must present Major Component or part to CMW or its authorized dealer for inspection within 30 days of the date Major Component or parts fails. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts as it deems appropriate. *Equipment owners in countries other than U.S., Canada, Mexico and Puerto Rico should refer to Ditch Witch® International Warranty Policy.

PRODUCT LIMITED WARRANTY Products are warranted for *90 days from date of delivery of any new Product to original purchaser. CMW will provide free replacement parts to original purchaser for any Product which has a defect in material or workmanship. Replacement parts are warranted for 90 days from date of delivery of any such replacement part to original purchaser. Any part of a Product subject to ground contact is warranted only for defects in material or • workmanship and only for the period of operational life of such part, which period shall not in any event exceed the 90 day limited warranty above.

Defects will be determined by an inspection of the Product or part by CMW or its authorized dealer. Original purchaser of the Product must present Product or part to CMW or its authorized dealer for inspection within 30 days of the date of failure. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts as it deems appropriate. *180 days for Ditch Witch® DR52, DR65 and DP195.

EXCLUSIONS FROM PRODUCT AND MAJOR COMPONENT LIMITED WARRANTY SPECIFICALLY EXCLUDED FROM PRODUCT AND MAJOR COMPONENT LIMITED WARRANTY ARE: -Transportation and labor charges related to repair, replacement, or inspection of Products, Major Components or parts.

•Parts subject to ground contact.

-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 may be subject to another manufacturer's warranty (such warranty will be available to purchaser).

ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN. INCLUDING ANY WARRANTY OR 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 OR 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.

This limited warranty applies to original purchasers only. Some states do not allow exclusion or limitation of incidental or consequential damages. so 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 original purchaser specific legal rights and the original purchaser may also have other rights which vary from state to state.

For information regarding this limited warranty, contact CMW's Technical Service Department, P.O. Box 66, Perry, OK 73077-0066, or contact your local Ditch Witch® dealer.

First Printing 1/91 Revised 4/93

CONTENTS Decals Decal Location - Z3500 Decal Location - Z4500

8,11 12,14

Engine Components Air Cleaner - 195-816 Air Cleaner System Alternator Engine Cooling Hydraulics Engine - Deutz Diesel Engine Mount - Z3500 Engine Pump Mounting Fuel Line Muffler Secondary Muffler Throttle

24,25 22,23 20,21 32,33 18,19 16,17 30,31 34,35 26,27 28,29 36,37

Power Train Diff, Dana 44 Std - Z3500 52,53 Diff, Dana 44 LS - Z3500 54,55 Diff, Dana 70 HD - Z4500 60,61 Drive Line 42,43 Front Steer Diff, Dana 44 Std - Z3500 48,49 Front Diff Mount - Z3500 46,47 Front Diff Mount - Z4500 56,57 Gear Box HD, Dana 70 40,41 Parking Brake 44,45 Rear Rigid Diff, Dana 70 HD - Z4500 58,59 Rr Rigid Diff, Dana 44 Std/LS - Z3500 50,51 Rear Steer Diff, Dana 44 Std - Z3500 48,49 Tire - Tube - Wheel 62,63 Frame Components Backfill Blade - Z3500 Backfill Blade - Z4500 Console Dual Battery Kit - 190-472 Hood & Grille Left Fender Rear & Steps Frame Covers Continued

82,83 84,85 70,71 78,79 66,67 76,77 72,75

Seat - Belts - Covers Sound Insulation 4-Post ROPS - 190-449 4-Post ROPS Cover

68,69 80,81 86,87 88,89

Hydraulics Anti-Cav Hydraulics BFB Lift Hydraulics BFB Swing Hydaulics Charge Pressure Hydraulics Cyl, Front Steer - 151-038, Z3500 Cyl, Front Steer - 151-039, Z4500 Cyl, BFB Lift - 151-040, Z3500 Cyl, BFB Lift - 151-061, Z4500 Cyl, BFB Swing - 151-039, Z3500 Cyl, BFB Swing - 151-060, Z4500 Front Steering Hydraulics Ground Drive Hydraulics Hyd Motor - 158-794 Hyd Reservoir Hyd Schematic - Z3500 Hyd Schematic - Z4500 Manifold Hydraulics Oil Cooler Hydraulics Power Steering Valve - 158-506 ...

Power Steering Valve - 158-615 ...

Psi Relief Cartridge - 155-679 Pump & Filter Hydraulics Steering Motor Hydraulics Trick Quick Coupler - 155-958

108,109 114,115 116,117 106,107 126,127 128,129 132,133 134,135 128,129 130,131 104,105 102,103 118,119 98,99 92,93 94,95 110,111 96,97 120,121 120,121 122,123 100,101 112,113 124,125

Electrical Elect Schematics 4-Post ROPS Light Kit

138,139 140,141

Miscellaneous Bolt & Nut Torque Chart Filters Fluid & Lubrication Capacity Lubricant Abbreviations Chart Optional Kits 0-Ring Replacement Chart Related Publications Warranty Registration

144,145 146,147 149 150,151 146,147 148 146,147 152,153

DECALS

DECAL LOCATION Z3500 REF NO.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

PART NUMBER

QTY DESCRIPTION

275-737

DECAL KIT

274-220 1 274-247 AR 274-318 4 274-375 1 274-385 1 274-387 1 274-442 3 274-436 1 274-426 1 274-657 1 274-726 2 274-687 4 274-688 1 274-691 1 274-693 1 274-694 1 275-023 1 275-024 1 275-033 1 275-048 1 275-070 1 275-100 1 275-120 1 275-148 1 275-185 2 275-203 1 275-222 1 275-303 1 274-774 1 275-310 1 275-449 1 275-497 1 274-291 1 275-184 1

INTERLOCK DISPLAY ACCENT STRIPE TIE-DOWN LOCATIONS MASTER DISCONNECT SWITCH LEFT SEAT CONSOLE DECAL SECONDARY CONSOLE LIFT POINT LOCATIONS PRIMARY CONSOLE LUBRICATION SCHEDULE MAIN FUSE DECAL Z3500 MODEL-ID TYRE PRESSURE CONTROL VALVE DECAL RIGHT SEAT CONSOLE DECAL WORK LIGHTS FUSE BLOCK DECAL OIL LEVEL PARK BRAKE NOTICE. ALTERNATOR IMPORTANT SAFETY RULES WARNING RUNAWAY MANIFOLD (OPTION) RESERVOIR FUEL TANK (DIESEL) WARNING SINGLE OPERATOR BATTERY EMERGENCY ENGINE STOP WARNING ROLLOVER DITCH WITCH01-0 DITCH WITCH EMBLEM DITCH WITCH EMBLEM ENGINE OIL iiRAIN SOUND POWER RATING (102dB) WARNING MOVING PARTS

REMARKS

USE 84"

805-162

9

10

11

12

DECAL LOCATION Z4500 REF NO.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

PART NUMBER

QTY DESCRIPTION

275-731

DECAL KIT

274-220 1 274-247 AR 274-318 4 274 - 375 1 274-385 1 274-387 1 274-442 3 274-436 1 274-624 1 274-657 1 274-685 2 274-687 4 274-688 1 274-691 1 274-693 1 274-694 1 275-023 1 275-024 1 275-033 1 275-048 1 275-070 1 275-100 1 275-120 1 275-148 1 275-185 2 275-203 1 275-222 1 275-303 1 274-774 2 275-310 1 275-430 AR 275-449 1 275-497 1 274-291 1 275-184 1

INTERLOCK DISPLAY ACCENT STRIPE TIE-DOWN LOCATIONS MASTER DISCONNECT SWITCH LEFT SEAT CONSOLE DECAL SECONDARY CONSOLE LIFT POINT LOCATIONS PRIMARY CONSOLE LUBRICATION SCHEDULE MAIN FUSE DECAL Z4500 MODEL-ID TYRE PRESSURE CONTROL VALVE DECAL RIGHT SEAT CONSOLE DECAL WORK LIGHTS FUSE BLOCK DECAL OIL LEVEL PARK BRAKE NOTICE, ALTERNATOR IMPORTANT SAFETY RULES WARNING RUNAWAY MANIFOLD (OPTION) RESERVOIR FUEL TANK (DIESEL) WARNING SINGLE OPERATOR BATTERY EMERGENCY ENGINE STOP WARNING ROLLOVER DITCH WITCH® I-D DITCH WITCH EMBLEM ACCENT STRIPE DITCH WITCH ENGINE OIL DRAIN SOUND POWER RATING (102dB) WARNING MOVING PARTS

REMARKS

USE 84"

USE 10"

804-952

F 13

14

ENGINE COMPONENTS

ENGINE MOUNT Z3500

2

4/ SOO

U CM

17

17

CM

e ° CM

P

=

4

DETAIL A NOTE: POSITION BELLVILLE WASHER W/DISH SIDE TOWARD BOLT OR NUT FLG. AS SHOWN. B

805 638 -

16

ENGINE MOUNT Z3500 REF PART NO. NUMBER QTY DESCRIPTION 1. 106-598 8 WASHER (9/16". HARDENED) 2. 106-096 6 FLG LK BOLT (1/2-NC X 1-3/4") 3. 106-596 4 SCREW (M14-2 X 30MM) 4. 106-198 6 FLG LOCKNUT (1/2-NC. GR8) 5. 313-138 1 LEFT FRONT ENGINE MOUNT 6. 313-139 1 RIGHT FRONT ENGINE MOUNT 7. 313-140 1 LEFT REAR ENGINE MOUNT 8. 313-141 1 RIGHT REAR ENGINE MOUNT 9. 106-597 4 SCREW (M14-2 X 40MM) 10. 106-743 2 WASHER (1/2". HARDENED) 11. 106-116 10 BELLVILLE WASHER (1/2" X 1-1/2")

REMARKS SEE FOOTNOTE 4 SEE FOOTNOTE 384 EPDXY PATCH INCL; SEE FOOTNOTE 284 SEE FOOTNOTE 384 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 EPDXY PATCH INCL; SEE FOOTNOTE 284 SEE FOOTNOTE 4 SEE FOOTNOTE 4

FOOTNOTES 1. NO PAINT AREA; CLEAN PAINT OFF OF ENGINE BLOCK AND MOUNTS BEFORE BOLTING MOUNTS TO BLOCK. DRY WITH TAP OUT MOUNTING HOLES (M14 X 2.0) TO REMOVE PAINT; CLEAN WITH SAFETY SOLVENT; COMPRESSED AIR. 2. TORQUE M14 BOLTS (REF # 3 8 4) TO 100 FT LBS; USE EPDXY FULL LENGTH OF THREADS. 3. ALL 1/2-NC FLANGED FACE ENGINE MOUNTING BOLTS (6); LOCTITE (271 ) TORQUE 110-120 FOOT POUNDS. 4. CURRENT HARDWARE. USE FOR ALL REPLACEMENT.

805-638

17

18

DEUTZ ENGINE REF PART NO. NUMBER OTY DESCRIPTION 1. 195-609 DEUTZ DIESEL ENGINE 194-605 DEUTZ DIESEL ENGINE 2. 195-849 1 ENGINE OIL FILTER 3. 195-807 1 FUEL FILTER 4. 328-068 1 RIGHT REAR ENGINE MOUNT LEFT REAR ENGINE MOUNT 5. 328-067 1 6. 328-065 1 RIGHT FRONT ENGINE MOUNT LEFT FRONT ENGINE MOUNT 7. 328-064 1 8. 328-066 2 FRONT ENGINE SUPPORT 9. 116-414 2 SHOCK MOUNT KIT (3-PIECE) 10. 116-217 2 SHOCK MOUNT KIT (2-PIECE) 11. 106-596 4 SCREW (M14-2 X 30) 12. 106-597 4 SCREW (M14-2 X 40) 13. 106-598 8 WASHER (9/16"-M14, HARDENED) 14. 105-993 2 BOLT (5/8-NC X 4") 15. 105-964 4 WASHER (5/8") 16. 105-994 2 NUT (5/8-NC) 17. 105 - 136 2 BOLT (1/2-NC X 3-1/2") 18. 105-065 2 LOCKNUT (1/2-NC) 19. 105-827 4 BOLT (3/8-NC X 1-1/4") 20. 105-845 4 FLG LOCKNUT (3/8-NC) 1 BELT (ALTERNATOR/FAN) 21. 170-091 FAN (10-BLADE) 22. 195-858 1 194-607 1 FAN (10-BLADE) CONNECTOR (08J-1.5M90) 23. 154-305 1 HOSE (08JFX-20"-3500) 24. 154-620 1 BK CONNECTOR (08J90BK) 25. 154-148 1 JAM NUT (3/4-NF) 105-404 CAP (08JF) 26. 154-089 1 2 WASHER (1/2") 27. 105-071 28. 1105-8231 2 BOLT (5/16-NC X 3/4") FUEL FILTER MOUNT 29. 1363-0651 1 DRAIN BRACKET 30. 363-067 1 31. 106-162 6 FLG LK BOLT (M8-1.25 X 20MM) 32. 195-855 1 OIL FILL CAP

REMARKS Z4500 Z3500

SEE FOOTNOTE SEE FOOTNOTE SEE FOOTNOTE SEE FOOTNOTE SEE FOOTNOTE

1 1 1 1 1

Z4500 Z4500 Z4500 Z4500 Z4500

EPDXY PATCH INCL; SEE FOOTNOTE 2.

EPDXY PATCH INCL; SEE FOOTNOTE 2.

SEE FOOTNOTE 3

INCL HARDWARE Z4500 INCL HARDWARE Z3500

NOT SHOWN: 346-877 1 FAN SPACER FUEL LIFT PUMP 195-859 1 FUEL LIFT PUMP GASKET 165-744 1 195-861 4 INJECTOR PUMP 195-860 4 INJECTOR INJECTOR PUMP GASKET 165-745 1 ELBOW GASKET 165-746 1 FOOTNOTES 1. NO PAINT AREA; CLEAN PAINT OFF OF ENGINE BLOCK AND MOUNTS BEFORE BOLTING MOUNTS TO BLOCK. TAP OUT MOUNTING HOLES (M14 X 2.0) TO REMOVE PAINT; CLEAN THREADS WITH SAFETY SOLVENT; DRY WITH COMPRESSED AIR. 2. TORQUE M14 BOLTS (8) 100 FOOT POUNDS; USE EPDXY FULL LENGTH OF THREADS. 3. LOCTITE 4 MOUNT TO FRAME BOLTS.

805-607

19

20

ALTERNATOR REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

PART NUMBER OTY 215-159 1 170-266 1 106-602 1 105-095 AR 184-334 1 106-380 2 360-067 1 105-117 1 184-119 1 106-162 1 363-651 1

DESCRIPTION ALTERNATOR ALTERNATOR SHEAVE SCREW (M8-1.25 X 80MM) WASHER (1/4") SPACER (2.000") FLO LK SCREW (M8-1.25 X 16MM) ALTERNATOR STRAP (ADJUSTABLE) WASHER (5/16") SHEAVE SPACER FLO SCREW (M8-1.25 X 20MM) ALTERNATOR MOUNT

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 2

FOOTNOTES NEW STYLE SHEAVE (REF #2), WITH HUB. DOES NOT REQUIRE SPACER (REF #9).

1 ALTERNATOR MOUNT STYLE BEGINS WITH S/N 3N0610 2 ALTERNATOR MOUNT STYLE BEGINS WITH S/N 3N0610

805-157

C

21

AIR CLEANER SYSTEM

21

18 oss

19

22

20

6?

15

13

16 9

4 17 14

7

12

it

8

10

16 15

E

805-225

22

AIR CLEANER SYSTEM REF NO.

PART NUMBER OTY DESCRIPTION

1.

2.

195-816 1 346-930 1 346-445 1 116-416 1 328-185 1 110-576 1 110-169 1 115-250 1 115-399 AR 105-841 2 195-852 1 105-003 5 105-109 3 105-823 4 165-734 1 106-380 4 105-117 4 328-182 1 159-369 1 346-750 1 116-747 1 105-825 4 105-834 4

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

REMARKS

AIR CLEANER MOUNT BRACKET MOUNT BRACKET AIR INTAKE HOSE REAR MOUNTING PLATE T-BOLT CLAMP (2.25") WORM CLAMP (2-13/16" TO 3-3/4") CAP (02NF) WEATHER STRIP (1/4" X 3 /4") CLIP NUT (5/16-NC) AIR INLET TUBE PLO LOCKNUT (5/16-NC) BOLT (-5/16-NC X 1-1/2") BOLT (5/16-NC X 3/4") GASKET SCREW (M8-1.25 X 16MM) WASHER (5/16") AIR CLEANER MOUNT AIR PRE-CLEANER (2.5") AIR TUBE BULK HOSE (2.500") BOLT (3/8-NC X 3/4") LOCKNUT (3/8-NC)

Z4500 Z3500

USE TWO @ 5"

USE 16"

FOOTNOTES

805-225

E 23

24

AIR CLEANER REF NO. 1.

2.

3.

4.

5.

6.

PART NUMBER OTY 195-816 195-641 1 195-642 1 195-815 2 195-817 1 195-818 1 195-824 1

DESCRIPTION AIR CLEANER BAFFLE V-BAND CLAMP (6-1/2") WING NUT (7/16-NF) PRIMARY ELEMENT SAFETY ELEMENT BOTTOM CUP

REMARKS INCL REF 4'S 1 THPU 6

FOOTNOTES

802-359

A

25

26

MUFFLER REF NO. 1.

2.

3.

4.

5.

6.

7.

PART NUMBER QTY DESCRIPTION 196-149 1 MANIFOLD MUFFLER 106-175 8 NUT (M10-1.5) 105-158 18 CAM LOCK WASHER (3/8") 106 - 139 B STUD (M10 X 42mm) 165-727 4 MUFFLER GASKET 328-026 1 HEAD SHIELD 106-256 3 FLANGE BOLT (M6 X 15mm)

REMARKS

FOOTNOTES

INSTALLATION PROCEDURES: 1. INSTALL THREE METRIC BOLTS (REF #7) 3 OR 4 TURNS INTO ENGINE BLOCK. 2. INTALL MUFFLER TO ENGINE AND TIGHTEN NUTS (REF #2).

3. POP HEAT SHIELD INTO PLACE OVER THE HEAD OF BOLTS (REF #7) AND SLIDE HEAT SHIELD BACK INTO PLACE. 4. TIGHTEN HEAT SHIELD BOLTS USING A V DIRVE (10 mm) SOCKET, V DRIVE U-JOINT AND A LONG 1 /4" DRIVE EXTENSION BAR.

4

802-312

27

28

SECONDARY MUFFLER REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

PART NUMBER QTY DESCRIPTION 196-152 1 EXHAUST STACK 196-083 1 VERTICAL MUFFLER 196-157 1 SPARK ARRESTING MUFFLER 195-962 1 MUFFLER CLAMP (1-15/16") 195-847 1 EXHAUST GASKET 105-874 4 FLG LK BOLT (3/8-NC X 1-1/2") 105-845 8 FLO LOCKNUT (3/8-NC) 105-826 6 FLC LK BOLT (3/8-NC X 1.00") 116-063 4 ISOLATOR 105-003 8 FLO LOCKNUT (5/16-NC) 346-908 1 TAILPIPE BRACKET 346-997 1 MUFFLER SUPPORT 346-907 1 BOTTOM BRACKET 196-327 2 MUFFLER CLAMP (2") 196-312 1 UPPER TAILPIPE 196-313 1 LOWER TAILPIPE LOWER TAILPIPE 196-326 1 195-974 2 PERSONNEL PROTECTOR KIT 195-975 2 PERSONNEL PROTECTOR 105-003 8 FLC LOCKNUT (5/16-NC) 195-910 4 U-BOLT (5/16-NC X 2") 301-285 4 U-BOLT PLATE

REMARKS

Z4500 ONLY Z3500 ONLY

FOOTNOTES 1-BEGINS WITH S/N 3J0042

805-206

C

29

PUMP MOUNTING REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

PART NUMBER QTY 105-073 9 194-763 1 194-413 1 105-156 12 106-113 8 105-839 9 106-116 2 105-830 2 115-456 1 105-072 6 105-806 6

REMARKS

DESCRIPTION LOCK WASHER (7/16") PUMP MOUNTING PLATE FLYWHEEL COUPLING BOLT (3/8-NC X 1-1/2") SCREW (M10-1.0 X 70MM) SCREW (M10-1.5 X 55MM) WASHER (1/2" X 1-1/2") BOLT (1/2-NC X 1-1/4") INTERNAL SNAP RING (1-3/4") LOCK WASHER (3/8") SCREW (M8-1.25 X 25MM, GD8)

SEE FOOTNOTE 1

SEE FOOTNOTE 2 SEE FOOTNOTE 2 SEE FOOTNOTE 2 SEE FOOTNOTE 2

FOOTNOTES 1-THOROUGHLY PACK SPLINES WITH TEXACO #1912 COUPLING GREASE AT ASSEMBLY. 2-LOCTITE RC 271 (RED) OR 680 (GREEN)

805-208

31

ENGINE COOLING HYDRAULICS BEGINS WITH S/N

32

ENGINE COOLING HYDRAULICS BEGINS WITH S/N REF PART NO. NUMBER QTY DESCRIPTION 1. 360-342 1 ENGINE OIL COOLER 2. 116-142 2 SHOCK MOUNT 3. 105-886 2 WASHER (3/8") 4. 105-883 2 FLG LK BOLT (3/8-NC X 2") 5. 116-164 2 RUBBER MOUNT BLOCK 6. 505-114 4 WASHER (11/32") 7. 105-178 2 BOLT (5/16-NC X 2-1/2", GD 8) 8. 105-089 2 LOCKNUT (5/16-NC) 9. 154-026 2 UNION (12J-12JF90) 10. 154-174 2 S/0 COUPLER (12JF-12H) 11. 116-636 AR BULK HOSE (3/4") 12. 116-103 1 BULK STRIP (1/2" X 1") 13. 116-636 AR BULK HOSE (3/4") 14. 155-196 2 S/0 COUPLER (12S-12H45) 15. 110-332 1 CLAMP (1-5/8") 16. 106-380 1 SCREW (M8-1.25 X 16MM) 17. 110-353 2 WORM CLAMP (3/4" TO 1-1/2") 18. 111-011 2 WORM CLAMP (1" TO 1-3/4")

REMARKS

USE 35" USE 20-1/2" USE 30"

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

804-526

33

RETURN FUEL LINE CONNECT ION

34

FUEL LINES REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

PART NUMBER NY DESCRIPTION 346-009 1 RIGHT FUEL TANK STEP 346-563 1 RIGHT FUEL TANK STEP 346-015 1 LEFT FUEL TANK STEP 346-564 1 LEFT FUEL TANK STEP 154-270 2 CONNECTOR (120-12S90) 154-824 1 HOSE (120FX-27.5"-750) 217-517 1 FUEL SENDER 165-704 GASKET 105-214 SCREW (#10-24 X 1/2") 195-807 1 ENGINE FUEL FILTER 116-322 AR BULK HOSE (1/2") 364-080 1 FILLER NECK 363-139 1 FILLER NECK BRACKET 110-485 1 FUEL CAP 116-323 1 FILL HOSE (2" X 3") 110-134 2 WORM CLAMP (2.062" TO 2.750") 110-253 6 POP RIVET (3/16" X 1 /2") 105-826 2 FLO BOLT (3/8 - NC X 1") 105-845 2 FLO LOCKNUT (3/8-NC) 116-322 AR BULK HOSE (1/2") 116-322 AR BULK HOSE (1/2") 116-108 AR BULK HOSE (5/16") 110-217 6 CLAMP (7/16" TO 1") 116-108 AR BULK HOSE (5/16") 110-490 1 CLAMP (5/16") 110-249 4 CLAMP (1/4" TO 5/8") 156-239 2 SHUT-OFF VALVE (02N-05H90) 156-253 1 SLIP-ON COUPLER (03H-05H) 156-729 1 SLIP-ON TEE (08H)

REMARKS Z4500 Z3500 74500 Z3500

USE

5"

USE 43" USE 11" USE 10" USE 40"

FOOTNOTES

NOTES:

D

805-226

35

THROTTLE INSTALLATION

0

10

16

13

12

14

805-224

36

THROTTLE REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

INSTALLATION

PART NUMBER QTY DESCRIPTION 196-058 1 WIRE SWIVEL CONNECTOR WASHER (3/16) 106-205 1 THRUST WASHER 505-114 1 106-018 2 JAM NUT (3/8-NF) 106-379 4 FLO LK SCREW (M6-1.00 X 20MM) 106-385 6 FLO LOCKNUT (M6-1.0) THROTTLE HANDLE 365-296 1 196-130 1 FRICTION CONTROL 331-793 1 LEVER (THROTTLE) 110-519 1 KNOB (1/2-NC, ORANGE) 196-328 1 THROTTLE CABLE (64") 1 NUT (#10-32) 506-021 110-318 1 BALL JOINT (#10-32) 105-152 1 NUT (1/4-NF) 106-231 2 SCREW (M6 - 1.00 X 16MM) 346-983 1 THROTTLE BRACKET THROTTLE BRACKET 346-420 1

REMARKS

74500 ONLY Z3500 ONLY

FOOTNOTES

805-224

37

NOTES:

or

38

POWER TRAIN

GROUND DRIVE GEAR BOX DANA 70 HD OPTION

40

GROUND DRIVE GEAR BOX DANA 70 HD OPTION REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

PART NUMBER QTY 105-069 1 105-805 4 105-121 2 105-156 4 106-962 6 105-825 8 105-848 1 115-211 3 125-049 1 155-806 1 165-100 1 168-003 1 167-293 1 169-012 1 166-201 1 169-069 1 500-228 1 105-362 1 116-672 1 105-575 1 157-569 1

DESCRIPTION WASHER (3/8") SPRING WASHER (3/8") BOLT (1/2-NC X 1") BOLT (3/8-NC X 1-1/2") FLO BOLT (9/16-NC X 1.25",12 PT) FLO LK BOLT (3/8-NC X 3/4") BOLT (3/8-NC X 3/4 ", GD 8) PIPE PLUG (1/2-NPT, SO) BALL BEARING INTERNAL SEAL LARGE GEAR PINION GEAR OUTPUT SHAFT GEAR BOX COVER MOUNTING PLATE PINION ADAPTER EXTERNAL SNAP RING FLG NUT (7/8-NF) SNAP RING ROLL PIN (.500" X 1.25") INTERNAL SEAL

REMARKS

SEE FOOTNOTE 2

SEE FOOTNOTE 2 MAGNETIC SEE FOOTNOTE 2

SEE FOOTNOTE 1

SEE FOOTNOTE 2 SEE FOOTNOTE 3

FOOTNOTES 1. USE SILICONE (RTV) GASKET MATERIAL ON GEARBOX COVER, ON MOTOR MOUNTING FACES, & ON MOUNT PLATE WHEN MOUNTING TO DIFFERENTIAL HOUSING SURFACE. 2. LOCTITE 3. INSTALL SNAP RING (REF. NO. 19) IN GEAR BOX MOUNTING PLATE BEFORE PLATE IS BOLTED TO DIFFERENTIAL HOUSING.

B

805-228

41

42

DRIVE L INE REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

PART NUMBER OTY DESCRIPTION 165-432 1 DRIVE SHAFT 180-768 1 GEARBOX YOKE 180-711 1 REAR DRIVE SHAFT YOKE 180-729 1 FRONT DRIVE SHAFT YOKE 180-723 2 CROSS AND BEARING ZERK (02N, 22.5°) 115-010 105-714 2 SETSCREW (3/8-NC X 1") 105-031 1 BOLT (3/8-NC X 1") 105-072 1 LOCK WASHER (3/8") 105-118 1 WASHER (3/8") 105-053 1 NUT (3/8-NC)

REMARKS

SEE FOOTNOTE 1

FOOTNOTES 1- COAT INSIDE OF YOKE WITH ANTI-SIEZE BEFORE ASSEMBLY WITH DRIVE SHAFT.

805-209

B

43

44

PARK I NG BRAKE REF NO.

PART NUMBER OTY DESCRIPTION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

105-823 12 105-826 4 105-003 12 106-556 2 106-557 2 505-037 1 105-509 4 106-205 4 365-254 1 346-882 1 105-834 4 105-969 2 365-253 1 217-705 1 110-150 1 115-600 1 160-765 1 160-768 1 163-134 1 105-095 4 183-136 2 363-315 1 160-744 1 302-570 1 105-508 1 115-593 1

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

FLG LK BOLT (5/16 - NC X 3/4") FLG LK BOLT (3/8-NC X 1") FLG LOCKNUT (5/16-NC) BOLT (M4-0.7 X 20MM) NUT (M(-0.7) FRICTION PAD SET COTTER PIN (1/8" X 1") WASHER (.191) BELLCRANK (PARK BRAKE) BRAKE CABLE MOUNT FLG LOCKNUT (3/8-NC) FLG BOLT (5/8-NC X 1-1/2", GD 8) BELLCRANK PIVOT (PARK BRAKE) PLUNGER SWITCH CLEVIS PIN (5/16" X 1") EXTENSION SPRING BRAKE DISC CALIPER UNIT CONTROL CABLE WASHER (1/4") BRAKE PIN CABLE BRACKET (PARK BRAKE) PARK BRAKE LEVER CALIPER SUPPORT COTTER PIN (3/32 X 1.00") EXTENSION SPRING

REMARKS LOCTITE

FOOTNOTES

805-223

C

45

FRONT STEERING / DIFFERENTIAL MOUNT Z3500

10 17

21

,,.._„,, _ , ,,;--,-, N, c --,, —, , ,, -,,L, -i ,,,, , \ \ - ,,,,,,,---, _,„ / \ \ , , , ,,a% ,,, .,rn ,,---,; „,., .„, ) I \\r.._.,,,, /,`-' ----, 11 ! ! I ( /' , ,. . vi), , .-- -11\ .. 1

,---,,,,

23

-.'- 41f s, I I ■..) -- J<N)11,-,,,,j) ,-, / `.,22.7) _5-z // / / -----, ".

4

--__ _

a

1

(--_--- 12

.

1

,

2

A

805-640

46

FRONT STEERING / DIFFERENTIAL MOUNT Z3500 REF NO.

PART NUMBER

1.

2.

105-994 105-357 105-366 105-367 105-404 105-462 105-828 105-970 105-884 106-096 115-483 125-403 125-771 160-377 160-408 181-982 183-585 183-586 183-906 313-120 313-064 363-350 363-438 105-937 105-826 125-770 125-771

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

REMARKS

QTY DESCRIPTION 6 2 1 1 2 2 1 6 1 2 3 2 4 2 1 2 2

1 1 1

1 1 1 4 4 4 4

LOCKNUT (5/8-NC) LOCKNUT (5/8-NC) BOLT (1-NC X 4-1/2") LOCKNUT (1-NC) JAM NUT (3/4-NF) BOLT (5/8-NC X 2-1/4") FLO LK BOLT (1/2-NC X 3/4") FLG LK BOLT (5/8-NC X 1-3/4") WASHER (1/2") FLO BOLT (1/2-NC X 1 - 3/4") EXTERNAL CLIP RING BRONZE BUSHING FIBER BUSHING TIE ROD CLEVIS (3/4-NF) TIE ROD TAPERED INSERT TAPERED PIN PIN PIN DIFFERENTIAL MOUNT PIN RETAINER CYLINDER MOUNT BRACKET CYLINDER MOUNT BRACKET BOLT (3/8-NC X 1", ALN HD) FLG LK BOLT (3/8-NC X 1") BUSHING BUSHING

USE ON 363-350 (REF #21 ) CYL MOUNT BRKT ONLY SEE FOOTNOTE 1

SEE FOOTNOTE 1 SEE FOOTNOTE 1

FOOTNOTES 1-USE 363-438 CYL MOUNT BRKT, 186-906 PIN & 105-826 PLO BOLT TOGETHER.

805-640

A

47

48

STEERABLE AXLE Z3500 REF PART NO. NUMBER OTY DESCRIPTION

REMARKS

1. 105-114 10 LUG NUT (I/2-NF) 2. H05-123110 LUG BOLT (1/2-NF X 1-1/2") 105-230 10 LUG BOLT (1/2-NF X 1-1/2") 3. 105-364 4 BOLT (3/4-NF X 2", NYLOK) 4. 105-410 2 CASTLE NUT (3/4-NF) 5. 105-422 4 WASHER (3/4") 6. 105-518 2 COTTER PIN (1/8" X 1-1/2") 7. 125-260 4 BEARING 8. 125-261 4 RACE 9. 125-735 8 URETHANE FLANGE BUSHING 10. 155-808 4 INTERNAL SEAL 11. 160-117 2 SPINDLE FLANGE 12. 160-380 2 SPINDLE SHAFT 160-415 2 SPINDLE SHAFT 13. 160-402 1 RIGHT SPINDLE HOUSING 160-403 1 LEFT SPINDLE HOUSING 14. 1 61 -078 1 LEFT AXLE 161-135 1 LEFT AXLE 1 61 -079 1 RIGHT AXLE 161-136 1 RIGHT AXLE 15. 161-080 1 FRONT DIFFERENTIAL (STD) 161-198 1 REAR DIFFERENTIAL (STD) 161-137 1 FRONT DIFFERENTIAL (STD) 1 61 -081 1 FRONT DIFFERENTIAL (LIMITED SLIP) 161-199 1 REAR DIFFERENTIAL (LIMITED SLIP) 161-138 1 FRONT DIFFERENTIAL (LIMITED SLIP) 16. 180-279 2 WASHER (3/4") 17. 181-552 4 BUSHING 18. 182-084 2 AXLE YOKE (30S) 19. 182-087 2 CROSS AND BEARING 115-002 ZERK (02N90) 115-500 SNAP RING 20. 205-671 2 HUB CAP 21. 105-451 AR WAVE SPRING WASHER (3/4") 22. 157-503 2 INTERNAL SEAL

SEE FOOTNOTE 5 ENDS WITH S/N BEGINS WITH S/N

. SEE FOOTNOTE 6

INCL REF. # 2. SEE FOOTNOTE 4 SEE FOOTNOTE 1 SEE FOOTNOTE 2 SEE FOOTNOTE 1 SEE FOOTNOTE 2

SEE FOOTNOTE 1 SEE FOOTNOTE 2 SEE FOOTNOTE 1 SEE FOOTNOTE 2.

SEE FOOTNOTE 2.

SEE FOOTNOTE 1 SEE FOOTNOTE 2.

SEE FOOTNOTE 2.

INCLUDES REF. NO. 22 INCLUDES REF. NO. 22 INCLUDES REF. NO. 22 INCLUDES REF. NO. 22

SEE FOOTNOTE 3 NOT SHOWN

FOOTNOTES

1-DESIGNATED PARTS ARE NO LONGER AVAILABLE FOR THESE APPLICATIONS AND SHOULD IN ALL INSTANCES BE REPLACED BY CORRESPONDING PART THAT IS MARKED WITH FOOTNOTE 2. SEE FOOTNOTE 2.

2-THESE PARTS ARE PRESENT PRODUCTION, THEY ARE COMPLETELY INTERCHANGEABLE WITH EARLIER UNITS, AND SHOULD BE USED FOR ALL REPLACEMENTS. IF REPLACING THE DIFFERENTIAL REFER TO PAGE ENTITLED "FRONT STEERING" FOR INFORMATION CONCERNING MOUNTING. 3-KING PIN ASSEMBLY: INITIALLY INSTALL 4 WAVE WASHERS (PER JOINT), TORQUE THE KING PIN BOLT 220-250 FOOT POUNDS; CHECK GAP BETWEEN FLATWASHER AND FLANGED BUSHING= .005" TO .020"; REMOVE OR ADD WAVE WASHER(S) AS REQUIRED FOR GAP; REMOVE KING PIN BOLT, LOCTITE, AND TORQUE 220-250 FOOT POUNDS. 4 -BEFORE INSTALLING WHEELS ON TRACTOR, CLEAN LUG NUT CONICAL SEAT TO REMOVE PAINT; CLEAN WHEEL MOUNTING SURFACES (AXLE OR SPINDLE FLANGE AND WHEEL CENTER DISC) TO REMOVE PAINT. 5-TORQUE LUG NUTS (1/2-20 UNF) IN A CROSS PARTERN TO A FINAL TORQUE OF 150 FOOT POUNDS. 6-LUG BOLT 105-230 IS CURRENT PRODUCTION AND IS INTERCHANGEABLE WITH EARLIER UNITS. 105-230 SHOULD BE USED FOR ALL REPLACEMENTS IN SPINDLE 160-117.

A

805-641

49

50

REAR AXLE - DANA 44 Z3500 REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

PART NUMBER QTY DESCRIPTION 105-826 8 FLG LK BOLT (3/8-NC X 1") 105-114 10 LUC NUT (1/2-NF) 105-123 10 LUG BOLT (1/2-NF X 1-1/2") 105-230 10 LUG BOLT (1/2-NF X 1-1/2") 105-357 4 LOCKNUT (5/8-NC) 105-994 4 FLG LOCKNUT (5/8-NC, OR 8) 1105-3581 4 BOLT (5/8-NC X 1-1/2") 105-970 4 FLC BOLT (5/8-NC X 1-3/4",GR 8) 125-005 2 BALL BEARING 155-820 2 INTERNAL SEAL 160-022 2 AXLE RETAINER 160-164 1 LEFT REAR AXLE 160-165 1 RIGHT REAR AXLE 180-111 2 AXLE RING 161-110 1 REAR DIFFERENTIAL (STD) 161-111 1 REAR DIFFERENTIAL (LIMITED .SLIP)

REMARKS ENDS WITH S/N BEGINS WITH S/N

SEE FOOTNOTE 3 ; ; SEE FOOTNOTE 4

SEE FOOTNOTE 5 SEE FOOTNOTE 5

INCL REF #'S 2, 6, 8 & 10 INCL REF #'S 2, 6, 8 & 10 SEE FOOTNOTE 1 SEE FOOTNOTE 2

FOOTNOTES 1-REFER TO DIFFERENTIAL ASSEMBLY INSTRUCTIONS 052-182.

2-REFER TO DIFFERENTIAL ASSEMBLY INSTRUCTIONS 052-183.

3-105-123 LUG BOLT USED WITH .365" THICK AXLE FLANGE, (REF NO 9).

4-105-230 LUG BOLT USED WITH .440" THICK AXLE FLANGE, (REF NO 9).

5-CURRENT PRODUCTION, USE FLANGE-FACED HARDWARE FOR ALL REPLACEMENTS.

805-642

B 51

DIFFERENTIAL COMPONENTS Z3500 STANDARD FRONT - DANA

52

DIFFERENTIAL COMPONENTS Z3500 STANDARD FRONT - DANA REF PART NO. NUMBER OTY DESCRIPTION 1. 105-002 4 BOLT (1/2-NC X 2-1/2") 2. 105-362 1 FLO NUT (7/8-NF) 3.105-516 1 ROLL PIN (3/16" X 1-1/2") 4. 125-260 2 BEARING 5. 125-284 2 RACE 6.125-285 1 BEARING 7. 125-286 1 RACE 8. 125-295 1 BEARING 9. 125-296 1 RACE 10. 155-853 1 INTERNAL SEAL 11. 160-125 1 FRT DIFFERENTIAL HOUSING 12. 165-613 1 COVER GASKET 13. 501-142 AR SHIM (.003") 501-142 AR SHIM (.005") 501-144 AR SHIM (.010") 501-145 AR SHIM (.032") 14. 501-149 1 SLINGER 15. 501-150 12 BOLT (1/2-NF X 1-1/8") 16. 501-153 10 FLO LK BOLT (3/8-NC X 5/8") 17. 501-160 2 SPIDER GEAR 18. 501-161 1 SPIDER SHAFT 19. 501-162 2 SPIDER PINION GEAR SHIM 20. 501-163 AR SHIM (.003") 501-164 AR SHIM (.005") 501-165 AR SHIM (.010") 501-166 AR SHIM (.030") 21. 501-167 AR SHIM (.003") 501-168 AR SHIM (.005") 501-169 AR SHIM (.010") 22. 501-287 1 DIFFERENTIAL COVER 23. 501-340 2 AXLE GEAR CLUTCH PACK 24. 501-341 1 25. 501-359 1 RING GEAR AND PINION 26. 155-751 1 NEOPRENE WASHER 27. 105-284 1 WASHER (3/16") 28. 105-173 1 BOLT (1/4-NC X 3/8") DIFFERENTIAL CASE ASSEMBLY 29. 501-372 1 30. 501-425 1 OIL BAFFLE 31. 155-820 4 INTERNAL SEAL

REMARKS

LESS GEARS

INCL REF #'S 2,6-10,12,1315,20,21.

& 30

INCL REF #'S 3.17-19,23 & 24 FRONT ONLY

FOOTNOTES

NOTES: REFER TO ASSEMBLY INSTRUCTIONS 052-184 1.

802-363

A

53

DIFFERENTIAL DANA 44 - LIMITED SL IP Z3500

54

DIFFERENTIAL DANA 44 - LIMITED SLIP Z3500 REF PART NO. NUMBER OTY DESCRIPTION 1.

2.

3.

4.

5.

6.

7.

8.

161-081 9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

1

21.

22.

23.

24.

25.

26.

27.

28.

29.

M3500 & M3610. SEE FOOTNOTE 1 & 4 M3500. SEE FOOTNOTE 1 & 4 M3610. SEE FOOTNOTE 1 M3500. SEE FOOTNOTE 1 & 4 M2310. SEE FOOTNOTE 1 M2310. SEE FOOTNOTE 1

FT (STEERABLE) AXLE HOUSING

REAR (RIGID) AXLE HOUSING 161-093 1 CAP GASKET 165-618 1 501-126 2 PINION GEAR WASHER DIFFERENTIAL CASE ASSEMBLY 501-274 1 501-284 1 DIFFERENTIAL COVER RING GEAR AND PINION 501-286 1 501-294 1 OIL SLINGER FLG LOCKNUT (3/4-NE) 105-995 1 501-296 1 WASHER (3/4") 501-297 10 RING GEAR BOLT (3/4-NF X 3/4") 501-298 AR PINION SHIM (.003") 501-299 AR PINION SHIM (.005") 501-300 AR PINION SHIM (.010") 501-301 AR PINION SHIM (.030")

19. 501-302 AR

20.

REMARKS

125-251 1 PINION GEAR RACE 125-252 1 PINION RACE 125-266 2 CARRIER RACE PINION BEARING 125-289 1 PINION GEAR BEARING 125-291 1 125-293 2 CARRIER BEARING 155-851 1 INTERNAL SEAL FT (STEERABLE) AXLE HOUSING 161-138 1 161-111 1 REAR (RIGID) AXLE HOUSING REAR (RIGID) AXLE HOUSING 161-197 1 REAR (STEERABLE) AXLE HOUSING 161-199 1

INCL REF #'S 10 AND 25 - 29 INCL REF #15

PINION GEAR SHIM (.003")

501-303 AR PINION GEAR SHIM (.005") 501-304 AR PINION GEAR SHIM (.010") 501-305 AR CARRIER SHIM (.003") 501-306 AR CARRIER SHIM (.005") 501-307 AR CARRIER SHIM (.010") 501-308 AR CARRIER SHIM (.030") 501-325 10 FLG LK BOLT (5/16-NC X 5/8") 157-503 2 INTERNAL SEAL 501-569 1 OIL SLINGER 501-373 1 OIL SLINGER 501-592 2 CLUTCH PACK 501-593 2 RETAINER RING AXLE SHAFT 501-594 1 501-595 2 AXLE GEAR 501-596 2 AXLE GEAR

SEE FOOTNOTE 2

FOOTNOTES 1. INCLUDES: AXLE TUBES & DIFFERENTIAL CENTER CASTING, & ITEMS 1-7; 9-29; LESS AXLE SHAFTS. 2. USED IN STEERABLE AXLES ONLY. 3. MORE INFORMATION AT PARTS PAGES ENTITLED "STEERABLE AXLE" & "REAR AXLE".

4. M3700 SAME AS M3500

NOTES: REFER TO ASSEMBLY INSTRUCTION 052-183

805-643

A

55

FRONT DIFFERENTIAL MOUNT Z4500

5

9N 2

7

12 /

13

,

---S.

.5. --' _-v im ----_'<:

C-__--, - --\ II

/ \

/

\ \ I\

/

II

\ -

\• %‘— - --7 )'"

7\ N\ \N / " ' \\\ N / ,,,1 •<<.<<",

/6)/1 1'i '

,\ _.6/" . --- ---

' s ::: ' ' ir CH1 i/ ;//

''-• ( ,- A //

--s- - \ k.. '--1 .1 r --'-'-'1 ---

\( \'

A

:. Z>, ___:1

802

56

-

324

FRONT DIFFERENTIAL MOUNT Z4500 REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

PART NUMBER QTY DESCRIPTION 183-686 2 TAPERED PIN 105-975 4 WASHER (3/4") 125-771 4 COMPOSITION BUSHING 181-982 2 TAPERED INSERT 106-096 2 FLG BOLT (1/2-NC X 1-3/4", CD 8) 115-483 2 KLIP RING 1 DIFFERENTIAL MOUNT 328-001 328-003 2 SPACER BAR 105-464 4 BOLT (3/4-NC X 7", GD 8) 105-953 4 LOCK NUT (3/4-NC) 301-822 2 SADDLE CLAMP 105-502 2 COTTER PIN (3/16" X 2") 180-322 2 PIN

REMARKS

TORQUE TO 375 FT LBS

FOOTNOTES

A

802-324 57

58

RIGID REAR DIFFERENTIAL Z4500 REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

PART NUMBER

REMARKS

OTY DESCRIPTION

161-155 1 118-001 2 159-003 1 157-573 2 106-098 4 105-953 4 105-424 10 105-426 10 125-001 2 161-170 181-049 2 115-520 2 115-514 2

INCL REF #'S 1.3.4 & 13

RIGID REAR DIFFERENTIAL INTERNAL SNAP RING VENT PLUG (02N) INTERNAL SEAL FLG BOLT (3/4-NC X 2", GD 8) LOCKNUT (3/4-NC) LUG NUT (3/4-NF) LUG BOLT (3/4-NF X 1316") BALL BEARING REAR AXLE PARTS ASS'Y SHRINK RING EXTERNAL SNAP RING INTERNAL SNAP RING

ADD LOCTITE 680

INCL REF #'S 2 & 8 THRU 12

FOOTNOTES

802 - 325

A

59

DIFFERENTIAL COMPONENTS - DANA 70 HD (MODEL 4500 RIGID & STEERABLE - REAR) (MODEL 1025SK - FRONT)

13

802-364

C

60

DIFFERENTIAL COMPONENTS - DANA 70 HD ( MODEL 4500 RIGID & STEERABLE - REAR) ( MODEL 1025SK - FRONT) REF PART NO. NUMBER OTY DESCRIPTION 1. 105-002 4 BOLT (1/2-NC X 2-1/4") 2. 105-362 1 FLANGE NUT (7/8-NF) 3.125-285 1 BEARING 4. 125-287 1 BEARING 5. 125-102 2 BEARING 6.125-286 1 RACE 7. 125-288 1 RACE 8. 125-258 2 RACE 9. 501-163 AR SHIM (.003") 501-164 AR SHIM (.005") 501-165 AR SHIM (.010") 501-166 AR SHIM (.030") 10. 501-309 AR SHIM (.003") 501-310 AR SHIM (.005") 501-311 AR SHIM (.010") 11. 501-142 AR SHIM (.003") 501-143 AR SHIM (.005") 501-144 AR SHIM (.010") 501-145 AR SHIM (.032") 12. 501-632 1 RING GEAR AND PINION KIT 13. 501-662 8 FLG BOLT (7/16-NC X 3-1/2") 14. 501-150 12 BOLT (1/2-NF X 1-1/8") 15. 501-153 10 FLG LK BOLT (3/8-NC X 5/8") 16. 501-664 1 DIFFERENTIAL CASE 501-663 1 DIFFERENTIAL CASE ASSEMBLY 17. 501-282 1 CLUTCH PACK 18. 501-324 2 AXLE GEAR RING 19. 501-330 2 AXLE GEAR 20. 501-316 4 PINION GEAR 21. 501-317 2 PINION SHAFT COVER GASKET 22. 165-613 1 23. 501-287 1 DIFFERENTIAL COVER N.A. 1 DIFFERENTIAL HOUSING 24.

25. 155-853 1 PINION SEAL (1025 SKI SLINGER (1025 SK) 26. 501-149 1

REMARKS

INCL REF #'S 2. 3, 4, 6. 7. 9-11, 22. 25-27

INCL REF #'S 13 8 16-21 4 DISCS AND 6 PLATES

LESS GEARS SEE NOTE #2

FOOTNOTES

NOTES: 1. REFER TO ASSEMBLY INSTRUCTIONS 052-185.

2. MODEL 4500-FOR MORE INFORMATION SEE PARTS BOOK PAGE ENTITLED "GEAR BOX SHIFT ASSEMBLY".

802-364

C 61

62

T IRE-TUBE-WHEEL Z3500 / Z4500 REF NO. 1.

2.

3.

4.

5.

6.

7.

PART NUMBER QTY DESCRIPTION 205-880 4 TIRE AND WHEEL (26 X 12-12TL) 205-148 4 TIRE (26 X 12-12TL) INNER TUBE (26 X 12-15) 205-163 4 205-290 4 WHEEL 205-938 4 TIRE AND WHEEL (31 X 15.5-15) 205-160 4 INNER TUBE (31 X 15.5-15) 205-255 4 WHEEL (15 X 13WD W/5) 206-106 4 TIRE (31 X 15.5-15,4TL,F) 205-161 4 VALVE STEM (.625") 205-165 VALVE CAP 375-059 AR WHEEL WEIGHT (200 LB.) 105-340 AR FLANGE LOCKNUT (3/4-NC) 105-371 AR BOLT (3/4-NC X 6-1/2")

REMARKS Z3500 ONLY

Z4500 ONLY

FOOTNOTES

^

805-644

A

63

64

FRAME COMPONENTS

66

HOOD AND GRILLE REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

PART NUMBER OTY 346-895 1 346-831 1 105-841 8 346-753 1 346-551 1 105-834 4 105-826 14 346-912 1 362-651 1 106-039 2 106-205 3 362-650 1 346-416 1 110-253 7 105-823 8 110-502 1 110-598 110-580 3 346-932 1 105-825 2 346-909 2 106-265 4 105-085 4 346-990 1 346-841 1 116-495 4 105-095 16 105-117 13 105-260 10 105-089 8 110-071 1 105-836 1 106-076 4

DESCRIPTION CONSOLE CONSOLE CLIP NUT (5/16-NC) HOOD HOOD FLG LOCKNUT (3/8-NC) FLO LOCK BOLT (3/8-NC X 1") GRILLE AIR BARRIER (GRILLE) NUTSERT (3/8-NC) WASHER (3/16") FRAME COVER PLATE FRAME COVER PLATE POP RIVET (3/16" X 1 /2") FLG BOLT (5/16-NC X 3/4") CAM LOCK REPLACEMENT KEY HOOD HINGE (6") ENGINE ACCESS DOOR FLG LOCK BOLT (3/8-NC X 3 /4") GRILL MOUNT SCREW (1/4-NC X 3/4") LOCKNUT (1/4-NC) REAR ENGINE PANEL REAR ENGINE PANEL SHOCK MOUNT WASHER (1/4") WASHER (5/16"l CLIP NUT (3/8- NC) LOCKNUT (5/16- NC) KNOB FLO LOCK BOLT (1/4-NC X 1 /2") WASHER (1/4")

REMARKS

Z4500 Z3500

Z4500 Z3500

FOOTNOTES

E

805-212

67

68

SEAT - BELTS - COVERS REF PART

NO. NUMBER QTY DESCRIPTION 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.

REMARKS

110-704 1 SEAT BELT KIT 115-425 1 SEAT 184-252 2 BUSHING (SEAT BELT) 105-048 2 BOLT (1/2-NC X 1-1/4") 106-031 2 LOCKNUT (M12-1.75) 115-430 2 SEAT BELT TETHER 105-267 4 CUP WASHER (5/16") 362-906 1 RIGHT SEAT CONSOLE 331-065 1 SEAT MOUNT PLATE 105-273 2 SCREW (M12-1.5 X 30mm) LEFT SEAT CONSOLE 331-200 1 105-825 6 BOLT (3/8-NC X 3/4") 105-260 6 CLIP NUT (3/8-NC) 105-003 10 FLG LOCKNUT (5/16-NC) 331-063 6 CONTROLS COVER TAB 105-823 6 FLG BOLT (5/16-NC X 3/4") 105 - 095 8 WASHER (1/4") 105-089 4 LOCKNUT (5/16-NC) 105-117 6 WASHER (5/16") 110-348 4 POP RIVET (3/16" X .664") 105-071 2 WASHER (1/2") 105-814 4 FLG LOCKNUT (3/8-NC) 117-403 1 SEAT SWIVEL COMPONENTS 115-754 1 ABRASION SLEEVE 115-662 1 GROMMET (PLASTIC) 106-205 4 WASHER (.191") 105-835 6 CARRIAGE BOLT (3/8-NC) 105-834 6 FLG LOCKNUT (3/8-NC) 115-477 2 EXTERNAL GRIP RING (3/8") 346-830 1 SEAT BASE 346-435 1 SEAT BASE

SEE FOOTNOTE 1

24500 ONLY Z3500 ONLY

FOOTNOTES: 1. INCL SEAT TRACK SET 8 OPERATOR PRESENCE SWITCH

D

805-222

69

70

CONSOLE REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

PART NUMBER QTY DESCRIPTION 215-150 1 RESTRICTION INDICATOR (20", H20) 217-768 1 IGNITION SWITCH 106-521 1 BEZEL NUT (1-NS) 217-769 1 KEY (PAIR) 306-603 1 AUDIO ALARM 217-554 1 OIL PRESSURE GAUGE 306-607 1 HORN BUTTON 217-555 1 ENGINE OIL TEMP GAUGE 217-535 1 TACHOMETER 215-129 1 VOLT METER 215-133 1 FUEL GAUGE 217-020 2 PILOT LIGHT 217-029 1 INSERT (RED) 217-027 1 INSERT (RED) 217-021 1 INSERT (RED) 217-034 1 INSERT (RED) 306-608 1 COVER, HORN BUTTON 217-845 1 INTERLOCK MODULE 214-301 1 ACCESSORY SOCKET 274-436 1 PRIMARY CONSOLE DECAL 274-387 1 SECONDARY CONSOLE DECAL 110-110 1 PLUG (2-17/32")

REMARKS

PARK BRAKE HYD. OIL TEMP ENG. OIL PRESSURE ENGINE OIL TEMP

FOOTNOTES

805-227

71

O

LI)

O CO

O

cc CNI

STEPS AND REAR FRAME COVERS REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

PART NUMBER OTY DESCRIPTION 116-203 4 GROMMET (1-1/16") 328-009 1 COVER PLATE 110-253 8 POP RIVET (3/16" X I/2) 346-921 1 RIGHT REAR ENGINE PANEL 346-870 1 RIGHT REAR ENGINE PANEL 346-923 1 LEFT SIDE COVER 346-556 1 LEFT SIDE COVER 346-931 1 LEFT REAR ENGINE PANEL 346-840 1 LEFT REAR ENGINE PANEL 346-883 1 LEFT ENGINE PANEL DOOR 362-656 1 UPPER FAN SHROUD 105-260 10 CLIP NUT (3/8-NC) 105-825 11 FLG LK BOLT (3/8-NC X 3/") 116-107 AR WEATHER STRIP (1" X 1-1/4") 328-008 1 HOOD SUPPORT 105-834 3 FLANGE NUT (3/8-NC) 328-095 1 OIL COOLER MOUNT 362-655 1 LOWER FAN SHROUD 105-085 4 LOCKNUT (1/4-NC) 110-524 1 SPRING AND ROLLER 110-580 2 HINGE (6") 110-502 2 CAM LOCK (W/KEY) 110 - 598 CAM LOCK KEY 346-932 1 ENGINE ACCESS DOOR 328-020 1 ENGINE ACCESS DOOR 346-922 1 RIGHT SIDE COVER 346-555 1 RIGHT SIDE COVER 106-265 4 SCREW (1/4-NC X 3/4") 346-894 1 RIGHT REAR ROPS COVER 346-862 1 RIGHT REAR ROPS COVER 363-142 1 OIL VALVE MOUNT 363-140 1 FRONT BK MOUNT 346-418 1 FRONT BK MOUNT 105-845 6 FLG LOCKNUT (3/8-NC) 105-827 8 FLG LK BOLT (3/8-NC X 1-1/4") 105-826 2 FLG LK BOLT (3/8-NC X 1")

REMARKS

Z4500 Z3500 Z4500 Z3500 Z4500 Z3500

USE

Z4500 Z3500 Z4500 Z3500 Z4500 Z3500 Z4500 Z3500

FOOTNOTES

C

805-210

73

74

STEPS AND REAR FRAME COVER REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

PART NUMBER QTY DESCRIPTION 105-826 6 FLG LK BOLT (3/8-NC X 1") 346-947 1 RIGHT REAR FRAME COVER 346-419 1 RIGHT REAR FRAME COVER 328-102 1 LEFT REAR FRAME COVER 346-414 1 LEFT REAR FRAME COVER 346-896 1 RIGHT TUNNEL COVER 346-421 1 RIGHT TUNNEL COVER 105-260 13 CLIP NUT (3/8-NC) 105-825 4 FLG LK BOLT (3/8-NC X 3,4") 346-900 1 TUNNEL COVER 346-897 1 LEFT TUNNEL COVER 346-422 1 LEFT TUNNEL COVER 105-845 14 FLO LOCKNUT (3/8-NC) 105-827 12 FLG LK BOLT (3/8-NC X 1-1/4") 115-318 AR NON-SKID DECKING 364-069 1 LEFT FUEL STEP TANK LEFT FUEL STEP TANK 346-564 1 STEP 346-526 1 346-560 1 STEP 106-096 2 FLG LK BOLT (1/2-NC X 1-3/4") STONE SHIELD 362-588 1 RIGHT FUEL TANK STEP 346-009 1 RIGHT FUEL TANK STEP 346-563 1 106-039 4 NUTSERT (3/8-NC) 105-874 2 FLG LK BOLT (3/8-NC X 1-1/2") DECK SUPPORT PLATE 346-889 1 DECK SUPPORT PLATE 346-834 1 346-899 2 REAR TUNNEL COVER BRACKET 346-898 2 FRONT TUNNEL COVER BRACKET

REMARKS Z4500 Z3500 Z4500 Z3500 Z4500 Z3500

Z4500 Z3500

USE 4 @ 15.5"

Z4500 Z3500 Z3500 34500 Z3500 Z4500

FOOTNOTES

805-211

D 75

LEFT FENDER WITH DUAL BATTERY OPTION BEGINS WITH S/N 3J0042

76

LEFT FENDER WITH DUAL BATTERY OPTION BEGINS WITH S/N 3J0042 REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

PART NUMBER QTY DESCRIPTION 105-826 6 FLO BOLT (3/8-NC X 1") 328-104 1 LEFT REAR UPPER FENDER 328-105 1 LEFT REAR UPPER FENDER 115-563 1 COMPRESSION SPRING 115-477 2 EXTERNAL SNAP RING (3/8") 105-118 1 WASHER (3/8") 106-265 9 SCREW (1/4-NC X 3 4 '. BUT TORX) 363-141 1 FENDER SUPPORT 106-039 1 NUTSERT (3/8-NC) 110-582 1 HINGE (20-1/2") 110-222 2 HOOD LATCH 105-085 4 LOCKNUT (3/8-NC) 105-818 2 BOLT (1/4-NC X 1-1/2") 105-003 2 FLG LOCKNUT (5/16-NC X 3/4") 110-224 2 ANCHOR BRACKET 105-822 2 FLG LK BOLT (5/16-NC X 1/2") 110-502 1 CAM LOCK (W/KEYS) 110-598 CAM LOCK KEY LEFT REAR LOWER FENDER 328-106 1 365-179 1 FENDER SUPPORT ROD 328-155 1 LEFT INNER FENDER 105-845 9 FLG LOCKNUT (3/8-NC) 105-827 4 FLG LK BOLT (3/8-NC X 1-1/4") 105-223 1 WASHER (3/8") 105-841 1 CLIP NUT (5/16-NC) 106-624 1 BOLT (5/16-NC X 3/4") 105-260 2 CLIP NUT (3/8-NC) 363-114 1 LEFT INNER FENDER SUPPORT BATTERY HOLD DOWN 313-062 1 325-086 2 TIE DOWN ROD 110-223 2 LATCH BRACKET 110-253 4 POP RIVET (3/16" X 1/2") 105-832 9 FLG LOCKNUT (1/4-NC) 361-651 1 BRACKET FLO LK BOLT (3/8-NC X 3/4") 105-825 1

REMARKS

OPTIONAL

FOOTNOTES

802-187

A

77

NM fr) 1 CNJ 0 CO

\\

\\ \\ /

\\

\ \ /

\\

\\ \\

\\ \\ \\ \ \\

DU AL BA TTE RY KI T

\ \

OMMDD J

CO "it

141

DUAL BATTERY KIT REF NO.

PART NUMBER OTY DESCRIPTION 190-472 DUAL BATTERY KIT 1. 215-347 1 BATTERY CABLE (2GA X 11.5", POS) 116-193 TERMINAL COVER (RED) 105-109 BOLT (5/16-NC X 1-1/2") 105-092 NUT (5/16-NC) 2. 215-348 1 BATTERY CABLE (2CA X 11.5", NEC) 105-109 BOLT (5/16-NC X 1-1/2") 105-092 NUT (5/16-NC) 3.215-258 1 BATTERY (12V, 675 AMP) 4. 363-213 1 DUAL BATTERY RETAINER BAR 5. 106-384 2 BOLT (3/8-NC X 3/8") 6.325-086 2 TIE DOWN ROD 7. 105-095 2 WASHER (1/4") 8. 105-085 2 LOCKNUT (1/4-NC) 9. 116-051 AR BULK RUBBER (1/8" )

REMARKS INCL REF #'S 1-9

SEE FOOTNOTE 1

USE 2 @ 3"

FOOTNOTES 1-REFER TO INSTALLATION INSTRUCTIONS 050-205.

A

802-337 79

80

SOUND INSULATION REF PART NO. NUMBER OTY DESCRIPTION 1. 117-120 1 LEFT TUNNEL COVER INSULATION 2.

117-119 1 RIGHT TUNNEL COVER INSULATION 3.

117-125 TOP TUNNEL COVER INSULATION 4.

115-824 INJECTOR SHIELD INSULATION 5.

1 115-825 INJECTOR SHIELD INSULATION 1 6.

115-826 INJECTOR SHIELD INSULATION 7.

1 117-728 LEFT SIDE PANEL INSULATION 117-138 1 LEFT SIDE PANEL INSULATION ENGINE ACCESS DOOR INSULATION 8.

1 117-726 RIGHT SIDE PANEL INSULATION 117-137 1 RIGHT SIDE PANEL INSULATION ENGINE ACCESS DOOR INSULATION 9.

115-830 1 SEAT DECK INSULATION 117-139 1 SEAT DECK INSULATION 1 10.

117-724 CENTER HOOD INSULATION 1 117-135 HOOD INSULATION 117-117 1 KICKPANEL INSULATION 11.

12.

FIREWALL INSULATION 117-730 1 117-136 1 FIREWALL INSULATION 13.

117-725 1 RIGHT HOOD INSULATION 14.

117-723 1 LEFT HOOD INSULATION 1 15.

117-727 RIGHT REAR PANEL INSULATION 117-140 1 RIGHT REAR PANEL INSULATION 16.

117-729 1 LEFT REAR PANEL INSULATION XXX-XXX 1 LEFT REAR PANEL INSULATION

REMARKS

Z4500 Z4500 Z4500 74500 Z3500 Z4500 Z3500 Z4500 Z3500 74500 Z3500 Z4500 Z3500

Z4500 Z3500 Z4500 Z3500

INCLUDED WITH

117-135

FOOTNOTES

D

805-214

81

82

BACKF ILL BLADE Z3500 REF PART NO. NUMBER OTY DESCRIPTION 1. 106-516 8 FLG BOLT (5/8-NC X 1-1/2") 2. 105-940 1 WASHER (5/8") WASHER (1/2") 3. 105-859 1 4. 105-874 2 FLG LK BOLT (3/8-NC X 1-1/2") 5. 105-969 6 FLOE BOLT (5/8-NC X 1-1/2") 6. 106-096 5 FLG BOLT (1/2-NC X 1-3/4") 7. 115-002 1 ZERK (02N90) 8. 115-775 2 FRICTION WASHER (4.300") 9. 125-445 1 BRONZE BUSHING 2 COMPOSITION BUSHING (1.250") 10. 125-771 TAPERED INSERT (1.500") 11. 181-974 1 12. 181-981 2 TAPERED INSERT (1.000") 13. 181-982 4 TAPERED INSERT (1.250") TAPERED PIN (1.5" X 5.85") 14. 183-579 1 TAPERED PIN (1.25" X 11.59") 15. 183-583 1 16. 183-584 2 TAPERED PIN (1.00" X 2.44") 17. 183-587 2 TAPERED PIN 1.25" X 3.00") TAPERED PIN (1.25" X 3.94") 18. 183 - 588 1 BFB SWING POST 19. 328 -629 1 BLADE MOUNT 20. 313-027 1 BACKFILL BLADE (64") 21. 313-034 1 1 BFB SWING RETAINER 22. 328-611 FLG LK BOLT (5/8-NC X 1-1/4") 23. 105-400 1

REMARKS SEE FOOTNOTE 1

FOOTNOTES 1-LOCTITE & TORQUE TO 300 FT.LBS.

805-645

B 83

BACKF ILL BLADE 11 13 V --.,

11 N 13 ---_.

1

2 6 V

6 (

17

18

5/

8 10

19

/

12

0. 3

2

14

12 13

/ 11

, , 7 1 21 20 15

1

23

805 620 -

84

BACKFILL BLADE REF NO.

PART NUMBER OTY DESCRIPTION

1.

183-588 2.

105-400 3. 183-579 4.

328-087 183-583 5.

6. 183-687 7.

328-077 8.

125-450 9. 328-083 10.

115-815 11.

106-096 12.

125-771 13.

181-982 14.

105-940 15.

181-974 106-098 16.

17.

115-816 18.

105 - 831 19.

105-088 20.

105-969 115-002 21.

346-017 22.

23.

105-969

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

REMARKS

TAPERED PIN (1.25" X 3.94") FLG LK BOLT (5/8-NC X 1-1/4") TAPERED PIN (1.5" X 5.85") BACKFILL BLADE MOUNT TAPERED PIN (1.25" X 11.59") TAPERED PIN (1.25" X 2.69") BACKFILL BLADE SWING POST BRONZE BUSHING SWING RETAINER FRICTION WASHER (5.100") FLG LK BOLT (1/2-NC X 1-3/4") COMPOSITION BUSHING TAPERED INSERT (1.250") WASHER (5/8"ID) TAPERED INSERT(1.500") FLG BOLT (3/4 - NC X 2", GD 8) FRICTION WASHER (6.500") FLG LK BOLT (1/2-NC X 1-1/2") WASHER (9/16") FLG BOLT (5/8-NC X 1-1/2") ZERK (02N90) 72" BACKFILL BLADE FLG BOLT (5/8-NC X 1-1/2")

LOCTITE AND TORQUE TO 550 FT LBS

TURF EDGE

FOOTNOTES

805-620

B 85

86

4 POST ROPS REF NO. .

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

PART NUMBER OTY DESCRIPTION 190-449 4-POST REPS CONVERSION KIT 306-274 2 REAR LEG 346-449 1 LEFT REAR ROPS LEG 346-443 1 RIGHT REAR ROPS LEG 346-917 1 RIGHT FRONT LEG 1 06-1 90 2 BOLT (3/4-NC X 6- 1 /2", GD 8) 105 - 340 4 FLG LOCKNUT (3/4 - NC) 105-384 4 WASHER (3/4") 105-831 10 FLG LK BOLT (1/2-NC X 1-1/2") 105-833 14 FLG LOCKNUT (1/2-NC) 105-969 6 FLG LK BOLT (5/8-NC X 1-1/2") 105-994 6 FLG LOCKNUT (5/8-NC) 105-383 2 BOLT (3/4-NC X 6") 306-276 1 TOP FRAME 346-916 1 LEFT FRONT LEG 346-903 2 BRAKE LIGHT MOUNT 110-348 8 POP RIVET (3/16" X .664") 107-171 2 CARRIAGE BOLT (1/2-NC X 1 - 1/4") 346-905 1 SPRAY BOX 346-904 1 SPRAY BOX ARM 105-833 2 FLG LOCKNUT (1/2-NC) 107-087 2 U-BOLT (3/8-NC X 5.0") 346-885 1 VALVE MOUNT 346-827 1 VALVE MOUNT 116-157 1 HEADLINER INSULATION 346-485 1 CANOPY 106-243 4 SCREW (5/16-NC X 1-1/2") 105-285 4 BOLT (5/16-NC X 1-3/4 7r ) 105-117 8 WASHER (5/16") 105-826 2 FLO LK BOLT (3/8-NC) 346-490 2 MOUNT BRACKET 105-83 4 2 FLG LOCKNUT (3/8-NC) 258-009 2 MIRROR

REMARKS Z4500 Z3500 Z3500

TORQUE TO 150 FT LBS TORQUE TO 150 FT LBS TORQUE TO 220 FT LBS TORQUE TO 375 FT LBS

INCLUDES NUTS 8.

Z4500 Z3500

1 NCL

WASHERS

NUT 8 WASHER

FOOTNOTES

805-213

E

87

88

4 POST ROPS COVER REF NO.

PART NUMBER

1.

2.

3.

4.

5.

6.

346-485 1 306-282 1 306-283 1 116-413 1 306-284 1 306-286 1 306-285 1 110-348 26 105-089 4 105-117 13 106-243 5 105-285 4

7.

8.

9.

10.

11.

OTY DESCRIPTION

REMARKS

CANOPY CANOPY REAR PLATE CANOPY FRONT PLATE CANOPY HEADLINER REAR HEADLINER SUPPORT R FRT HEADLINER SUPPORT L FRT HEADLINER SUPPORT POP RIVET (3/16" X .664") LOCKNUT (5/16-NC) WASHER (5/16") SCREW (5/16-NC X 1-1/2", SLF TAP) BOLT (5/16-NC X 1-3/4")

FOOTNOTES 1-REFER TO INSTALLATION INSTRUCTIONS. "4-POST ROPE"

ADDITIONAL PARTS TO THIS KIT ARE SHOWN ON PAGE TITLED

NOTES: CANOPY AND HEADLINER ASSEMBLY: 1. POP RIVET REAR PLATE (REF 4 2) TO CANOPY PLATE. 2. POP RIVET FRONT PLATE (REF # 3) TO CANOPY PLATE. 3. INSTALL HEADLINER FLUSH AGAINST FRONT PLATE (REF # 3).

4. POP RIVET REAR. RIGHT SIDE AND LEFT SIDE SUPPORTS, FOR HEADLINER, TO CANOPY PLATE.

805-619

B 89

90

HYDRAULICS

YDRA_ L IC SC

A

IC

Z3500

FROM POWER BEYOND

FILTER FILTER

2

E""

-IN`CH

I OIL COOLER

I

IREVOROUND DRIVE

SI 15 PSI BYPASS

FWD _J

225 PSI

2 PSI P

FWD

PB

REV

2 PSI I__

1 ATTACHMENT REV

ATTP,,CWHDMENT

TO STEERING MOTOR

I_ 1_

r

SIGHT GLASS

g'ELAE,4.

NBINOM.

FILL SCREEN

RESERVOIR

4'

DRAIN

ATTACHMENT FLUSHING

BOOM LIFT

ATTACHMENT DRAIN

—ININNH

BOOM SLIDE ,

SWING

rA•1

1

L

2

LYS

A

•

• BLADE LIFT

805-646

92

93

YDRA_L IC SC F

ATIC

24500

POWER STEERING VALVE

FROM POWER BEYOND

FILTER F IL 7EP PLEINENI)

• N.L

DOUBLEACTING CYLINDER

ti 111=1111 OIL COOLER

REvGROUND DRIVE

es

Qj \ 15 PSI BYPASS

FWD

TWO

REV

•

P

225 PSI

PB

2 PSI P AL

FWD

PB

REV

2 PSI

ATTACHMENT

TO STEERING MOTOR

•

r aRea,,

SIGHT GLASS

ATTACHMENT REV

• LIFT —PBOOM M*

RESERVOIR --GRAM

ATTACHMENT FLUSHING

ATTACHMENT DRAIN

—11111111til 1.1111

4

BOOM SLIDE

M■ IM

BLADE LIFT

A

805-234

94

NOTES:

I

M

95

OIL COOLER HYDRAULICS

FROM SWING CONTROL VALVE

32 -------- 33

IN

D

805-219

96

OIL COOLER HYDRAUL ICS REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

PART NUMBER QTY 360-339 1 106-252 4 106-253 4 116-164 4 505-114 4 105-089 4 159-073 1 159-074 363-214 1 346-832 1 105-825 4 105-827 2

DESCRIPTION OIL COOLER JAM NUT (5/16-NC) STUD (5/16-NC X 2-3/4") SHOCK MOUNT WASHER (5/16") LOCKNUT (5/16-NC) HYD OIL FILTER (16S-16S) ELEMENT (1-3/8-UNF) FILTER MOUNT FILTER MOUNT FLG LOCK BOLT (3/8-NC X 3/4") FLC LOCK BOLT (3/8-NC X 1- 1 /4")

115-754 154-479 155-146 116-094 116-460 154-192 115-399 110-353 105-834

2 2 2 AR AR 1 AR 14 2

ABRASION SLEEVE (1.59" X 30") S-0 COUPLER (16S-16H90-08SF) S/O COUPLER (12S-16H90) BULK HOSE (1") BULK HOSE (1") S/O TEE (16H-16H-16H) WEATHER STRIP (1/4" X 3/4") WORM CLAMP (2-1/16" TO 2-3/4") FLG LOCKNUT (38-NC)

155-195 154-845 154-310 154-302 154-412 158-576

1 1 1 1 2 2

S/O COUPLER (20S-16H90) HOSE (060FX45-26"-3000) REDUCER NUT (100F) S/O BR TEE (100-16H-16H) S/O RUN TEE (12S-16H-16H)" CHECK VALVE (12SF-123F)

154-451 514-062 154-226 154-256 154-930 154-223 154-672

1 1 1 1 1 1 1

REDUCER STEM (060) BRANCH "T" CONNECTOR ((04 - 06S90) UNION (080-080FX90) HOSE (080FX45-36"-3000) CONNECTOR (040-08S45) HOSE (040FX-15"-3000)

REMARKS

INCL REF NO 8 Z4500 Z3500

USE USE USE

/I /I

If

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805 - 219

D

97

HYDRAULIC RESERVOIR

15

to

17

FROM ATTACHMENT CASE DRAIN 13

10

E

805-218

98

HYDRAULIC RESERVOIR REF NO.

PART NUMBER

1.

346-007 346-565 110-010 110-132 165-626 105-214 116-316 110-336 157-001 155-074 155-953 154-720 154-266 155-195 154-272 154-248 154-265 154-702 154-235 105-826 110-353 215-148 364-171

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

(NY DESCRIPTION 1 1 1 1 1 6 1 2

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

REMARKS

HYDRAULIC RESERVOIR HYDRAULIC RESERVOIR FILLER CAP FILLER NECK GASKET FLO BOLT (#10-24 X 1/2") SUCTION HOSE STRAINER (24S-20SF) 0-RING (924 090) PLUG (085, ALN) AIR VENT (06N) HOSE (080FX-20"-3000) UN RUN TEE (080FX-080-080) S/0 COUPLER (20S-16H90) REDUCER NUT (080F) REDUCER STEM (040) UN RUN TEE (040FX-040-040) HOSE (040EX-30"-3000) CONNECTOR (08S - 08090) FLG LK BOLT (3/8-NC X 1") WORM CLAMP (2-1/16" TO 2-3/4") TEMPERATURE SWITCH SIGHT GAUGE

Z4500 Z3500

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR 0-RING REPLACEMENT.

E

805-218

99

PUMP AND FILTER HYDRAULICS

z77

TO STEERING & AUX. CIRCUIT 1PRIORITY FLOW)

19

FROM SUCTION STRAINER ON HYD.TANK 11

D

805-215 100

PUMP AND FILTER HYDRAULICS REF NO.

PART NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

155-298 154-246 154-240 154-296 346-524 158-410 154-226 154-710 115-754 155-230 106-004 105-072 106-255 154-311 105-886 116-142 500-003 105-814 346-525 107-224

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

363-635 363-634 105-825 105-834

1 1 4 4

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

QTY DESCRIPTION

REMARKS

RUN TEE (10S-100-040) CONNECTOR (080-06S) CONNECTOR (08J — M18 - 1.50) CAP (040) RIGHT PUMP MOUNT TRIPLE HYD PUMP CONNECTOR (040-06S90) HOSE (100FX-54"-2750) ABRASION SLEEVE (1.59" X 30") S/O COUPLER (16S-16H45) BOLT (3/8—NC X 1-3/8") LOCKWASHER (3/8") WASHER (3/8") REDUCER STEM (040) WASHER (3/8") SHOCK MOUNT BOLT (3/8—NC X 2-3/4") FLU LOCKNUI (3/8—NC) LEFT PUMP MOUNT BOLT (3/8-16NC X 4-1/8". CD8) BOLT c /8-18NC X 3-3/4 GD81 PUMP SUPPORT PLATE PUMP SUPPORT BRACKET FLG LK BOLT (3/8-16NC X3/4") LOCKNUT (3/8-16NC)

SEE FOOTNOTE 1

Z3500 Z3500 Z3500 Z3500

FOOTNOTES: 1. USE SEAL REPAIR KIT 190-767

NOTES: REFER TO 0—RING CHART (800-301 ) IN BACK OF THE BOOK FOR REPLACEMENT OF 0 — RINGS.

D

805-215

101

102

GROUND DRIVE HYDRAULICS REF NO.

PART NUMBER

1.

158-794

1

HYDRAULIC MOTOR

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

515-004 159-381 154-273 105-048 105-070 154-247 110-030 159-388 155-486 154-288 154-411 154-384 154-737

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

HOSE (120FX45-26"-4000) HYD CHECK VALVE (80PM.2PSI) CONNECTOR (120-100S90) BOLT (1/2-NC X 1-1/2") LOCK WASHER (1/2") CONNECTOR (10S-120) CABLE TIE (1/16" - 4") HYD CHECK VALVE (06S-060) HOSE (060FX90-31" - 3000) CONNECTOR (10S-10090) CONNECTOR (04S-060) PLUG (06S) HOSE (060FX90-17"-3000)

15.

16.

17.

154-346 154-845 155-129

1 1 1

BRANCH TEE (06S-060-060) HOSE (060FX45-26" - 3000) REDUCER (125-06SF)

QTY DESCRIPTION

REMARKS

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805-216

B

103

104

FRONT STEERING HYDRAULICS REF PART NO. NUMBER OTY DESCRIPTION 1.

154-220 2 CONNECTOR (040-06S) 2.

154-840 1 HOSE (040FX90-66"-3000) 3. 154-705 1 HOSE (040FX90-60"-3000) 4.

154 - 255 2 UNION (040-040FX90) 5.

105-075 2 BOLT (3/8-NC X 2") 6.

105-072 2 LOCK WASHER (3/8") 7.

305-256 2 BACKUP SPACER 8.

110 - 270 4 BOLT-ON CLAMP (9/16") 9.

125-770 2 COMPOSITION BUSHING (1.250") 10.

125-771 2 COMPOSITION BUSHING (1.000") 11.

151-039 2 HYD CYL (2.0" X 1.0" X 5.0") 151-038 1 HYD CYL (2.0" X 1.0" X 4.0") 12.

154-293 2 BRANCH TEE (040-040-04S) 13.

154-252 2 CONNECTOR (04S-04090) 14.

154-706 2 HOSE (040FX90-40"-3000) 15.

110-030 2 CABLE TIE (1/16" TO 4") 16.

115-713 3 ABRASION SLEEVE (1.59" X 24") 17.

105-834 1 FLG LOCKNUT (3/8-NC) 18.

110-333 1 BOLT-ON CLAMP (1") 19.

105-825 1 FLG LOCK BOLT (3/8-NC X 3/")

REMARKS

74500 Z3500

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-3011 IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

D

805-217

105

CHARGE PRESSURE HYDRAULICS

h

,,..\

1

1

, I f -\ 1 ci ` il

41

d [1( —

/ /

[r II

■, /- ,

,j i '—

\

\\

1

805-232

C 106

CHARGE PRESSURE HYDRAULICS NO.

PART NUMBER OTY DESCRIPTION

1.

2.

3.

4.

154-227 154-483 154-296 515-377

1 1 1 1

REMARKS

CONNECTOR (060-08S90) BRANCH TEE (08S-060-060) CAP (040F) HOSE (0160FX90-9"-3000)

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301 ) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

-

C

805-232

107

108

ANT I -CAV HYDRAUL ICS REF NO. 1.

2.

3.

4.

5.

PART NUMBER OTY DESCRIPTION 158-811 1 ANTI-CAV VALVE 154-220 3 CONNECTOR (040-06S) 155-130 2 PLUG (06S) 154-963 2 HOSE (040FX45 - 24"-3000) 105-198 2 BOLT (1/4-NC X 1-3/4")

6.

7.

8.

9.

10.

105-832 2 FLC LOCKNUT (1/4-NC) 154-265 1 UN RUN TEE (0040FX040-040) 154-743 1 HOSE (040FX90 - 23"-3000) 154-252 1 CONNECTOR (04S-04090) 154-715 1 HOSE (040FX90 - 18"-3000) 154-255 1 UNION (040-040FX90)

11.

REMARKS

FOOTNOTES

NOTES: REFER TO 0-RING (800-301) CHART IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805-229

B 109

MANIFOLD HYDRAULICS

D

805 220 -

110

MANIFOLD HYDRAULICS REF NO.

PART NUMBER

OTY DESCRIPTION

1.

155-959 1 2. 155-679 1 155-750 157-508 3. 105-071 2 4.

106-118 2 5.

154-300 2 6.

155-933 2 190-184 7.

155-935 2 8.

155-958 1 9.

155-936 1 10.

155 - 709 3 11.

110-126 1 12.

105-834 2 13.

105 - 098 2 14.

105-118 2 15. 346-928 1 346-411 1 16. 154-835 1 17.

154-236 1 18.

154-928 1 19.

154-470 1 154-902 1 20.

115-754 AR 21.

REMARKS

HYD MANIFOLD BLOCK RELIEF VALVE (2500PSI) 0-RING (022 D90) BACKUP RING (022 D90) WASHER (1/2") SCREW (M14-2 X 25mm) CONNECTOR (100-12590) QDC ADAPTER (12-12S/J) SEAL REPAIR KIT DUST CAP (1/2" - 3/4") TRICK ODC BODY (12-14S) DUST PLUG (1/2" - 3/") 0-RING (912 D90) CLAMP (7/16") FLG LOCKNUT (3/8-NC) BOLT (3/8-NC X 3") WASHER (3/8") MANIFOLD MOUNT MANIFOLD MOUNT HOSE (100FX45-26"-2750) CONNECTOR (080-12S90) HOSE (080FX45-38"-3000) CONNECTOR (100-1245) HOSE (080FX90 -66" - 3000) ABRASION SLEEVE (1.59" X 30")

Z4500 Z3500

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805-220

D 111

STEERING MOTOR HYDRAULICS

FROM MANIFOLD

4

6

TO HYDRAULIC TANK

TO AUXILIARY HYDRAULIC CIRCUIT CONTROL VALVE "IN" FORT

C

805-207

112

STEERING MOTOR HYDRAULICS REF NO. 1.

2.

PART NUMBER QTY DESCRIPTION 154-283 1 CONNECTOR (080-06545) 158-506 1 POWER STEERING VALVE 158-615 1 POWER STEERING VALVE 3. 154 - 221 CONNECTOR (06S - 060) 1 4. 154-266 1 UNION RUN TEE (080FX-080-080) 5. 154-246 1 CONNECTOR (080-06S) 6. 156-438 1 HYD LINE (080EX-10.1 7. 154-253 1 CONNECTOR (080-06S90)

REMARKS

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805-207

113

114

BLADE LIFT NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

PART NUMBER OTY DESCRIPTION 158-830 154-233 151-061 151-040 154-256 106-330 154-226 154-285 363-140 125-771 115-713 115-817 154-704 154-702 154-276 154-727 105-095 154-220 106-093 106-385 155-623

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

REMARKS

HYDRAULIC VALVE CONNECTOR (08S-800) CYL. (2.5" X 1.25" X 6.0") CYL. (2.5" X 1.25" X 5.0") 080-080FX90) SCREW (M8-1.25 X 70MM) CONNECTOR (040-06590) BK CONNECTOR (040-040458K) FRONT BULKHEAD MOUNT COMPOSITION BUSHING (1.250") ABRASION SLEEVE (1.59" X 24") ABRASION SLEEVE (1.59" X 84") HOSE (040FX45-86"-3000) HOSE (040FX45-30"-3000) CONNECTOR (040-08590) HOSE (040FX90-30"-3000) WASHER (1/4") CONNECTOR (040-06S) SCREW (M6-1.00 X 45mm) FLG LOCKNUT (M6-1.00) HYD CHECK VALVE

Z4500 Z3500

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

D

805-230

115

116

BLADE SWING REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

PART NUMBER OTY DESCRIPTION 158-830 1 HYDRAULIC VALVE 154-233 2 CONNECTOR (08S-080) 154-265 2 UN RUN TEE (040FX-040-040) 154-252 2 CONNECTOR (04S-04090) 154-278 2 CONNECTOR (040-04S) 154-418 1 UNION (085-080FX90) 151-060 2 HYD CYL (2.0" X 1.25" X 5.0") 151-039 2 HYD CYL (2.0" X 1.00" X 5.0") 154-701 2 HOSE (040FX-14"-3000) 125-771 4 COMPOSITION BUSHING (1.250") 110-169 1 CLAMP (2-13/16" TO 3-3/4") 115-776 1 ABRASION SLEEVE (1.59 X 7") 115-817 1 ABRASION SLEEVE (1.59" X 84") 154-841 1 HOSE (040FX45-94"-3000) 154-704 1 HOSE (040FX45-86"-3000) 106-330 4 SCREW (M8-1.25 X 70m) 105-095 4 WASHER (1/4") 106-386 4 FLG LOCKNUT (M8-1.25) 154-276 2 CONNECTOR (040-08590)

REMARKS

Z4500 Z3500

FOOTNOTES

NOTES: REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

805-231

D 117

118

HYDRAULIC MOTOR REF PART

NO. NUMBER OTY DESCRIPTION 1.

158-794 500-347

1

HYDRAULIC MOTOR SEAL REPAIR KIT

REMARKS INCL REF NO. 1

FOOTNOTES

805-221

A

119

POWER STEERING VALVE REF NO.

PART NUMBER QTY DESCRIPTION 158-506 POWER STEERING VALVE 158-615 POWER STEERING VALVE 1. 105-361 JAM NUT (13/16-NEF) 1 2. 158-507 1 ORBITROL VALVE 158-617 1 ORBITROL VALVE 155-790 0-RING (032 090) 3. 155-696 1 ORBTROL COLUMN 158-623 1 ORBITROL COLUMN 4. 500-424 1 SEAL REPAIR KIT 5. 500-459 SEAL 6. 118-007 1 INTERNAL SNAP RING

REMARKS INC REF #'S 1-5 & SEE FOOTNOTE 1 SEE FOOTNOTE 2 - ALL PORTS ARE (06S) SEE FOOTNOTE 1 SEE FOOTNOTE 2 FOR UPPER COVER SEE FOOTNOTE 1 SEE FOOTNOTE 2 EITHER STEERING VALVE

FOOTNOTES 1-ENDS 1/11/93 2-BEGINS 1/11/93

NOTES: 1-REFER TO 0-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS 0-RINGS. 2-ORDER 158-615 (POWER STEERING VALVE ASS'Y) IF REPLACING 158-507 (REF #2) OR 155-696 (REF #3).

801-806

E

121

122

PRESSURE RELIEF CARTRIDGE REF NO.

PART NUMBER QTY DESCRIPTION 155-679 RELIEF CARTRIDGE (2500PSI) 1. 155-707 1 0-RING (910 D90) 2. 155-749 1 0-RING (023 070) 3. 155-750 1 0-RING (022 D90) 4. 500-025 AR SHIM (.010" THK) 5. 500-318 1 COMPRESSION SPRING 6. 157-508 1 BACKUP RING (022)

REMARKS SEE FOOTNOTE 1;

INCL REF #'S 1 THRU 6

FOOTNOTES 1-REFER TO INSTALLATION DIAGRAM 052-139 FOR REPLACEMENT PROCEDURES.

NOTES: REFER TO 0 - RING CHART (800-3011 IN BACK OF THE BOOK FOR REPLACEMENT OF 0-RINGS.

801-427

123

124

TRICK QUICK COUPLER REF NO. 1.

2.

3.

4.

5.

6.

7.

8.

PART NUMBER QTY DESCRIPTION TRICK QUICK COUPLER 155-958 155-728 1 BACKUP RING (213 090) 155-745 1 0-RING (213 D70) 155-747 1 0-RING (914 D90) 500-358 1 VALVE STEM REPAIR KIT 155-747 1 0-RING (914 D90) 155-777 1 0-RING (119 090) 157-016 1 BACKUP RING (-119) 500-493 1 VALVE STEM REPAIR KIT

REMARKS SEE FOOTNOTE 2 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 2 SEE FOOTNOTE 2 SEE FOOTNOTE 2 SEE FOOTNOTE 2

FOOTNOTES 1 THESE PARTS ARE ASSOCIATED WITH "SNAPTITE" COUPLERS, WHICH ARE NO LONGER AVAILABLE. 2 THESE PARTS ARE ASSOCIATED WITH "FASTER" COUPLERS, WHICH ARE USED IN PRESENT PRODUCTION AND ALL REPLACEMENTS.

801-457

125

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.00" OD ROD X 4.0" STROKE

126

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.00" OD ROD X 4.0 STROKE REF NO.

PART NUMBER

151-038 1. 190-165 2.150-778 3. 150-290 4. 106-096 5. 150-775 6. 150-772 7. 150-421

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

REMARKS

QTY DESCRIPTION 1 1 1 1 1 1 1

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

INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1

ROD U-SEAL INSTALLER ROD WIPER INSTALLER

ROD WIPER/PISTON SEAL INSTALLER PISTON INSTALLER CYLINDER HEAD SPANNER WRENCH

FOOTNOTES 1-CLEAN A DRY THREADS. APPLY RED LOCTITE (RC 271 OR RC 2721.

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

801-096

A

127

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.00" OD ROD X 5.0" STROKE

128

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.00" OD ROD X 5.0 STROKE REF NO.

PART NUMBER QTY DESCRIPTION HYDRAULIC CYLINDER 151-039 1. 190-165 1 SEAL REPAIR KIT

2.

150-778

1

LOCK RING

3. 150-291 4. 106-096

1 1

CYLINDER BARREL FLG BOLT (1/2-NC X 1-3/4",GD 8)

5.

150-775

1

PISTON

6. 150-772 7. 150-422

1 1

CYLINDER HEAD CYLINDER ROD

REMARKS INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1

NOT SHOWN:

259-100 259-235

ROD U-SEAL INSTALLER ROD WIPER INSTALLER

259-239

ROD WIPER/PISTON SEAL INSTALLER

259-241 259-188

PISTON INSTALLER CYLINDER HEAD SPANNER WRENCH

FOOTNOTES

1-CLEAN & DRY THREADS.

APPLY RED LOCTITE (RC 271 OR RC 272).

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

801-097

A

129

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.25" OD ROD X 5.0" STROKE

130

HYDRAULIC CYLINDER 2.0" ID BARREL X 1.25" OD ROD X 5.0 STROKE REF NO.

PART NUMBER QTY DESCRIPTION 151-060 HYDRAULIC CYLINDER 1. 190-169 SEAL REPAIR KIT 2.150-778 LOCK RING 3. 150-291 1 CYLINDER BARREL 4. 106-097 1 FLG BOLT (5/8-NC X 1-3/4",CD 8) 5.150-771 PISTON 6. 150-770 1 CYLINDER HEAD 7. 150-423 1 CYLINDER ROD

NOT SHOWN: 259-100 259-236 259-239 259-241 259-188

REMARKS INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1 INCLUDES MOLDED - ON WEAR RING

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

FOOTNOTES 1-LUBRICATE WITH WD-40 OR EQUAL.TOROUE TO 180-200 FT-LBS (245-270 N.M)

801-099

131

HYDRAULIC CYLINDER 2.5" ID BARREL X 1.25" OD ROD X 5.0" STROKE

132

HYDRAULIC CYLINDER 2.5" ID BARREL X 1.25" OD ROD X 5.0" STROKE REF NO.

PART NUMBER OTY DESCRIPTION 151-040 HYDRAULIC CYLINDER 1. 190-166 1 SEAL REPAIR KIT

2.

150-779

1

LOCK RING

3.

4.

150-292 106-097

1 1

CYLINDER BARREL FLG BOLT (5/8-NC X 1-3/4",GD 8)

5.

150-776

1

PISTON

6.

7.

150-773 150-423

1 1

CYLINDER HEAD CYLINDER ROD

REMARKS INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1

NOT SHOWN:

259-100 259-236

ROD U-SEAL INSTALLER ROD WIPER INSTALLER

259-242

PISTON SEAL INSTALLER

259-243 259-188

PISTON INSTALLER CYLINDER HEAD SPANNER WRENCH

FOOTNOTES

1-CLEAN W DRY THREADS.

APPLY RED LOCTITE (RC 271 OR RC 272).

A

TORQUE TO 180-200 FT-LBS (245-270 N.M)

801 -1 05

133

HYDRAULIC CYLINDER 2.5" ID BARREL X 1.25" OD ROD X 6.0" STROKE

134

HYDRAULIC CYLINDER 2.5" ID BARREL X 1.25" OD ROD X 6.0" STROKE REF NO.

PART NUMBER OTY DESCRIPTION 151-061 HYDRAULIC CYLINDER 1. 190-166 1 SEAL REPAIR KIT 2. 150-779 1 LOCK RING 3. 152-010 1 CYLINDER BARREL 4. 106-097 1 FLO BOLT (5/8-NC X 1-3/4",CD 8) 5.150-776 1 PISTON 6. 150-773 1 CYLINDER HEAD 7. 150-438 1 CYLINDER ROD

NOT SHOWN: 259-100 259-236 259-242 259-243 259-188

REMARKS INCLUDES REF NO.'S 1 THRU 7

SEE FOOTNOTE 1

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

FOOTNOTES 1-LUBRICATE WITH WD-40 OR EOUAL.TOROUE TO 180-200 FT-LBS (245-270 N.M)

801 -1 06

135

136

ELECTRICAL

-

ELECTRICAL SCHEMATIC Z3500 / Z4500

INTERLOCK

START RELAY TO BAT)-2

TO BAT FUSED}-2A POWER CIRCUIT

9

MASTER DISCONNECT SWITCH

I- 1 A

9A -

17

START TO ST).- 4A

FUSE 4; 2

BAT

2A -BAT FUSED FUSE 14 r-C1\_,- 3A ---> ACC ACC FUSE 24 ST 3 4 4A 4 ST 5 Fr _r_ 3E1 1GN 54-4 4 IGO

FUSE 1A 2A

TO 1GN

TO I GN>---1 SA

11B -j 1

i

ENGINE

STOP

IGNITION SWITCH

FUSE 2A

FUEL SOLENOID

ENGINE STOP RELAY 11A

12

T

0 0

SWITCH - 19 ATTACHMENT NEUTRAL SWITCH

-_(\j__ 6 Lopillo-N K IT NEUTRAL

FUSE 1A B. 2A LOCATED IN ENGINE ENCLOSURE FUSEL.] B • 2B. 3136 4B LOCATED BELOIL ICIIINSOLE _ J

SEAT SWITCH

RELAY

4 A2

F ALTERNATOR

14 H

0

0

21 --> GROUND 1 DRIVE ENGAGED GROUND DR IVE

3 c."--. 5

22 -I

1

RELAY

GROUND DRIVE - NEUTRAL

A3

15

4

o./1115

17 GROUND DRIVE NEUTRAL SWITCH

❑ OVER I DE

16

1

--------------------------

-

STATUSIND ICATOR HORN BUTTON

GROUND DRIVE ENGAGED

• o-- 23

TO ION

-

-

-

7GAUGES

HORN

I

TO ION

21 PARK BRAKE SWITCH

TACH/HOUR METER

I

5A

I > TACH

40

FUEL SOLENOID

- - - - - - - - - - -- - - - - - - WATER PUMP OPTION

TO ACC)- 3A -0-'1'......- 20 WATER PUMP SWITCH

FUEL SOLENOID / (: WATER ) PUMP

OIL PRESS SENDER

114

1

L--L_

FUSE #1

4-POST OPTION

o---111O--- 41

UP

TO ACC

-r\j-- 42

►

52 53 ANGLE 3A SWITCH

-

43

FUSE #2

WORK LIGHT SWITCH

FUSE #3

FLASHER

DOWN GROUND DRIVE NEUTRAL

22

REAR BRAKE LIGHTS

36

-2_

36

46

*CC,

47

0G

4R -0-1-

-

REAR

BLINKER LEFT

LIGHT KIT OPTION 6 TO ACC ›- 3A

FRONT SWIT50 CH

A

RIGHT BLINKER LIGHTS

RIGHT

LEFT BLINKER LIGHTS

805-233 138

ELECTRICAL SCHEMATIC Z3500 / Z4500 CKT WIRE

Nn. (-n um

-

FUNCTIrIN

1.

BLK 1A. BLK 2.

RED T2A. i-(Eu 3.

ORG/RED 3A. ORG

SYSTEM GROUND BATTERY GROUND TO DISCONNECT SWITCH BATTERY CIRCUIT -FUSED - BATTERY OIRCEFITT ACCESSORY CIRCUIT FUSED ACCESSORY CIRCUIT

4A. WHT 5.

ORG/BLU 5A. ORG/GRN HEL)7BEK 7.

ORG/BLU 8.

YEL

FUSED START CIRCUIT IGNITION CIRCUIT FUSED IGNITION CIRCUIT -FITSEDTCRUITIT -TOT4=Pusi DIODE CATHODE TO ALTERNATOR TACHOMETER TO ALTERNATOR

RFMARKS

_9BA. PUR 10.

WHT/BLK 11.

ORG/BLK

START RELAY (Al) TO COLD START OPTION START INTERLOCK TO START RELAY (A1) START INTERLOCK TO FUEL SOLENOID FUSE

71Y. - 014G-7EEK

TLTEE - SDEENCIITYTOSE - TO-EN-GTRE - STOP- =U

11B. ORG/BLK 12. WHT _13 14.

TAN/GRN 15.

WHT/BLU 16.

WHT/RED - 1;IT/WHT

ENGINE STOP RELAY TO FUEL SOLENOID 5 VOLT START INTERLOCK POWER

- -

18.

19.

BLU/ORG - -241.---8LULGRN 21.

22.

23.

24.

25.

26.

ATTACHMENT NEUTRAL SWITCH TO START INTERLOCK GROUND DRIVE RELAY (A3) TO START INTERLOCK SEAT SWITCH TO START INTERLOCK

611-GGRO - DR1W--NTECTRAL--WITCR - TO- NrUTAL - REE -AY (A2F ENGINE STOP SWITCH TO ENGINE STOP RELAY -WATER-RUMP--S4C-TCH-TO--WA,T-E-R-RUMP

YEL/BLK GRA/BLU TAN/BLU YEL/BLU

NEUTRAL RELAY (A2) TO NEUTRAL PARK BRAKE SWITCH NEUTRAL RELAY TO STOP LIGHTS HORN BUTTON TO HORN NEUTRAL RELAY TO GROUND DRIVE RELAY

TAN/BLK

PARK BRAKE SWITCH TO PARK BRAKE LIGHT AND RELAY (A4) 40,R4ING-L4-G.HAARA4110--4-OF-C-C(N6-0E-P400E--K-0QK ENGINE OIL TEMP LIGHT TO TEMPERATURE SENDER ENGINE OIL PRESSURE LIGHT TO PRESSURE SENDER HYDRAULIC OIL TEMPERATURE LIGHT TO SENDER

- 28. WHT/GRN 29.

WHT/BLU 30.

GRA/BLK 31.

32.

YEL/RED 33.

BRN -34, -GR-NL 35.

BLU 36.

RED/BLU 37.

BLU/YEL 38.

RED/ORG 39.

ORG/RED 40.

ORG/WHT 42.

43.

44.

45.

46.

47.

ORG/BLK BLU/BRN BRN/ORG BLK BLU/ORG YEL/RED

CATHODE OF CONSOLE DIODE BLOCK TO LIGHT TEST RELAY FUEL GAUGE TO FUEL SENDER -ENGINE-C4L--TMR GAUGE--T-0--ENGINE-04-L- T&MR-SENDERENGINE OIL PRESSURE GAUGE TO ENGINE OIL PRESSURE SENDER LIGHT KIT RELAY TO LIGHT FUSES TOW VALVE SWITCH TO TOW VALVE SOLENOID STOP SWITCH TO STOP LATCH RELAY STOP LATCH RELAY TO FUEL SOLENOID FUSE BLOCK TO FRONT WORK LIGHT SWITCH if6RK --161-15-5C-F6H-TO-FRON-F-WORK-t-I-e-FFS FUSE BLOCK TO REAR WORK LIGHT SWITCH WORK LIGHT SWITCH TO REAR WORK LIGHTS COLD START SWITCH TO COLD START SOLENOID COLD START SOLENOID TO TEMP SWITCH FUSE BLOCK TO FLASHER FLASHER TO BLINKER SWITCH

49.

50.

51.

52.

53.

54.

GRA/RED GRA/GRN GRA/ORG PUR/ORG PUR/YEL PUR/GRN

BLINKER SWITCH TO RIGHT BLINKER LIGHTS BLINKER SWITCH TO LEFT BLINKER LIGHTS FUSE BLOCK TO BEACON ANGLE SWITCH TO BFB UP SOLENOID ANGLE SWITCH TO BFB DOWN SOLENOID SWING SWITCH TO BFB RIGHT SOLENOID

- 41: -BLH}fYEt

A

805-233

139

140

4-POST ROPS LIGHT KIT REF NO.

PART NUMBER

1.

2.

6.

7.

8.

217-110 217-108 217-402 215-839 215-181 105-214 217-109 217-007 110-259

2 1 1 1 1 2 2 2 2

STOP/ TURN/ TAIL LIGHT STROBE LIGHT W/AMBER LENS GUARD (400 STROBE) LIGHT HARNESS (4-POST ROPS) FLASHER SCREW (# 10-24 X 1 /2. SLF TAP) PEDESTAL TURN SIGNAL. AMBER WORKING LIGHT (CLEAR/RECT) CLAMP (.63")

9.

10.

11.

105-825 105-834 105-231 105-823 217-889

2 2 2 2 1

FLO LK BOLT (3/8-NC X 3/4") FLO LOCKNUT (3/8-NC) SCREW (1/4"-NC X 3 /4", SLF TAP) FLG LK BOLT (5/16"-NC X 3/4") TURN SIGNAL/HAZARD LIGHT SWITCH

3.

4.

5.

QTY DESCRIPTION

REMARKS W/ REAR REFLECTOR

ON EARLY MODELS

FOOTNOTES 1-REFER TO INSTALLATION INSTRUCTIONS.

B

805-618

141

142

MISCELLANEOUS

SAE BOLT AND NUT Torque Value Chart GRADE 5: UNC or UNF THREAD

Size

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Hex Nut or Hex bolt tapped into hex nut, or drilled and tapped hole

ft•lb 12 25 40 65 100 150 200 350 560 840 1030 1460

N•m 16 34 54 90 135 200 270 475 760 1140 1400 1980

Hex Top Deformed Locknut

ft•lb 8 15 25 40 60 90 120 210 340 500 620 880

N•m 11 20 34 55 80 125 165 285 460 680 840 1195

Flange Nut or Flange Locknut or Flange bolt tapped into flange nut, or drilled and tapped hole

ft•lb 20 45 75 125 190 270 370 650 1250 1580 1950 2760

N•m 27 60 100 170 260 370 500 880 1425 2145 2645 3745

GRADE 8: UNC or UNF THREADS

Size

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Hex Nut or Hex bolt tapped into hex nut, or drilled and tapped hole Grade "C" 1

ft•lb 14 30 55 85 130 190 260 450 730 1090 1550 2180

N•m 19 40 73 115 175 260 355 610 990 1480 2100 2955

Hex Top Deformed Locknut Grade "C"

ft•lb 10 18 35 50 80 110 160 270 440 650 930 1310

N•rn 14 25 50 70 110 150 245 365 600 880 1260 1780

1 - For nuts that are NOT Grade "C", use torque values for grade 5.

052-201

144

Flange Nut or Flange Locknut or Flange bolt tapped into flange nut, or drilled and tapped hole Grade "C"

ft•lb 24 50 90 140 220 310 430 750 1210 1820 2580 3640

N•m 33 70 125 190 300 420 585 1015 1640 2465 3500 4935

METRIC BOLT and CAP SCREW TORQUE VALUES

Size

Class 4.8 Lubricated I

Class 8.8 & 9.8 Lubricated

Drys

Class 10.9

Dry

Lubricated

Class 12.9 Dry

Lubricated

Dry

N•rn

ft•lb

N•in

ft•lb

N•rn

ft•lb

141•m

ft•lb

N•rn

ft•lb

N•m

ft•lb

N•rn

ft•lb

!ki•i

ft•lb

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

6505 950 1600

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 1000 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

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 percent of the dry torque indicated on the chart. Apply torque to the nut - not the bolt head. Tighten toothed or serrated type lock nuts to the full torque value.

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 the strength of the original.

1 - LUBRICATED means coated with a lubricant such as engine oil, WD-40, anti-seize compond or phophate and oil coatings.

2 - DRY means plain or zinc plated without any other type of lubricant.

145

Z3500-Z4500 Related Publications Component

Ass'y

I

P/N

Model:

Z3500 - Z4500 .... Parts Manual Z3500 - Z4500 .... Operators Manual Z3500 - Z4500 .... Repair Guide (Service Manual) Z3500 - Z4500 .... Supplementary Maint Guide - Trencher Z3500 - Z4500 .... Special Tools Guide Ermine: Z3500 Deutz Parts Manual - F3M1011F Deutz Operators Manual - F3M1011F Deutz Service (Shop) Manual - F3M1011F Deutz Problem Diagnosis Guide Deutz Sales & Service Directory Z4500 Deutz Parts Manual - F4M1011F Deutz Operators Manual - F4M1011F Deutz Service (Shop) Manual - F4M1011F Deutz Problem Diagnosis Guide Deutz Sales & Service Directory Differential: Z3500 Dana Service (Shop) Manual - 44 LS Front/Rear Dana Service (Shop) Manual - 44 LS Front/Rear Dana Service (Shop) Manual - 44 LS Front/Rear Dana Service (Shop) Manual - 44 LS Front/Rear Z4500 Dana Service (Shop) Manual - 60 LS Front/Rear Dana Service (Shop) Manual - 70 LS Front/Rear Dana Service (Shop) Manual - 70 LS Front/Rear

053-483 054-511 N/A 050-633 052-901

_ _ _

194-605 .... 053-0 054-0 055-0 050-555 050-556 194-609 .... 053-053 054-047 055-049 050-555 050-556 161-081 .... 055-021 161-138 .... 055-021 161-111 .... 055-021 161-199 .... 055-021 161-168 .... 055-022 161-155 .... 055-023 161-173 .... 055-023

Filters Engine:

Air Cleaner Parts Ass'y Filter Element (primary) Filter Element (secondary) Air Pre-Cleaner (2.500") Oil Filter Element (spin-on) - Deutz Fuel Filter Element (spin-on) - Deutz

195-816 195-817 195-818 159-369 195-849 195-807

Hydraulic:

Oil Filter Element (1-3/8-UNF, spin-on) Oil Strainer (24S-20SF)

146

159-074 110-336

Z3500-Z4500 Optional Kits 0-ring Repair Kit - FLG, ORS & SAE (15 different 0-rings) 0-ring Repair Kit - Field Service (46 different 0-rings)

147

I 190-051 190-052

SAE, ORS, and 4-BOLT FLANGE HYDRAULIC FITTING REPLACEMENT 0-RING CHART Dash Size

Fraction Size

NPT & NPTF

JIC Thread

SAE (Port Seal 0-Ring) oThread

1/8-27

ORS or ORFS (Face Seal 0-Ring)

Flange 0-Ring

Size

0-Ring P/N

@Thread Size

0-Ring P/N

©NA

(AA

©NA

NA

NA

NA

01

1/16

02

1/8

5/16-24

5/16-24

NA

NA

NA

NA

03

3/16

3/8-24

3/8-24

NA

NA

NA

NA

04

1/4

7/16-20

7/16-20

155-760

9/16-18

157-037

NA

05

5/16

1/2-20

1/2-20

155-717

NA

NA

NA

06

3/8

9/16-18

9/16-18

155-705

11/16-16

157-038

NA

08

1/2

3/4-16

3/4-16

155-706

13/16-16

157-039

NA

10

5/8

7/8-14

7/8-14

155-707

1-14

157-040

NA

12

3/4

1-1/16-12

1-1/16-12

155-709

1-3/16-12

157-017

155-723

14

7/8

1-3/16-12

1-3/16-12

155-747

NA

NA

NA

16

1

1-5/16-12

1-5/16-12

155-748

1-7/16-12

155-714

157-029

20

1-1/4

1-5/8-12

1-5/8-12

155-702

1-11/16-12

NA

157-078

24

1-1/2

1-7/8-12

1-7/8-12

157-001

2/12

NA

157-128

32

2

2-1/2-12

2-1/2-12

NA

NA

NA

500-031

40

2-1/2

3/12

3/12

NA

NA

NA

NA

48

3

3-1/2-12

3-1/2-12

NA

NA

NA

NA

56

3-1/2

NA

NA

NA

NA

NA

NA

= Diameter of threads in fractions of an inch and number of threads per inch O = NA - Not a current CMW p/n'ed o-ring or the dash size not used in current CMW applications.

SAE: A 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: "0-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 the other plain to act as the sealing surface.

Flange: A fitting type that seals by compressing a hard o-ring between a grooved flange and a mating flat surface. The flange is held against the flat surface by four bolts and a semi-circular retainer.

Classified as Code 61 or Code 62 depending upon the pressure in the system.

0-Ring

148

800-301

Z3500 - 24500 Fluid & Lubrication Capacities Components

U.S. Metric Z3500 10.5 qt 9.9 L 11.0 qt 10.4 L Z4500 10.5 qt 9.9 L 11.0 qt 10.4 L

Engine Oil:

Deutz - F3M1011F W/ Filter Deutz - F4M1011F W/ Filter

I

Code

P/N

DE010W40 DE010W40

194-605

DE010W40 DE010W40

194-609

MPL80W90

N/A

MPL80W90 MPL80W90 MPL80W90 MPL80W90

161-080 161-081 161-137 161-138

MPL80W90

161-168

MPL80W90 MPL80W90 MPL80W90 MPL80W90

161-110 161-111 161-198 161-199

MPL80W90 MPL80W90

161-155 161-173

THF THE

346-565

THF THF

346-007

D D

346-563 346-564

D D

346-009 346-015

Gear Box:

3.21:1 - Cmw Ground Drive Differential:

Front - Dana 44 STD Front - Dana 44 LS Front - Dana 44 STD Front - Dana 44 LS Front - Dana 60 LS Differential:

Rear - Dana 44 STD Rear - Dana 44 LS Rear - Dana 44 STD Rear - Dana 44 LS Rear - Dana 70 LS Rear - Dana 70 LS Hydraulic Oil:

Hyd Reservoir - Cmw Hyd System Hyd Reservoir - Cmw Hyd System

2.0 qt

1.8 L

Front

Z3500 (Steer) 5.0 pt 2.3 L (Steer) 5.0 pt 2.3 L (Steer) 5.0 pt 2.3 L (Steer) 5.0 pt 2.3 L Z4500 (Steer) 5.9 pt 2.8 L Rear Z3500 (Rigid) 5.5 pt 2.6 L (Rigid) 5.5 pt 2.6 L (Steer) 5.5 pt 2.6 L (Steer) 5.5 pt 2.6 L Z4500 (Rigid) 5.7 pt 2.7 L (Steer) 5.7 pt 2.7 L

Z3500 11.0 gal 41.6 L _ gal _L Z4500 12.7 gal 48.0 L _ gal _L

Fuel Capacity:

Z3500 Fuel Tank - Cmw Right Step 6.5 gal 24.6 L Fuel Tank - Cmw Left Step (Fill) ••• 6.5 gal 24.6 L Z4500 Fuel Tank - Cmw Right Step 8.0 gal 30.2 L Fuel Tank - Cmw Left Step (Fill) 8.0 gal 30.2 L

149

LUBRICANT ABBREVIATIONS AGMA-7

Worm gear lubricant matching American Gear Manufacturer's Association compound #7

ATF-F BF CG

Automatic Transmission Fluid, Type "F"

CMW P/N 256-627 (qt) Brake Fluid, DOT 3, meeting Motor Vehicle Safety Standard #16 Splined Coupling Grease, Texaco Code 1912

CMW P/N 256-648 (14 oz cartridge) 256-661 (4 oz squeeze tube)

CL DEO

DEXRON II or DX2 (ATF-A) EO EPG GEO HYDO H2 O MPG MPL M-W N-S

THE TJC

Chain Lubricant Diesel Engine Oil (SAE 10W40) meeting API (American Petroleum Intitute) engine service classification SF/CD or CE. (The following is for Detroit Diesel engines, but the same oil may be used in other engines as well.)

Should meet Detroit Diesel spec 7SE270 (low ash - less than 1%).

Automatic transmission fluid meeting Allison classification C3 and GM service classification (GM6432-M) (Automatic Transmission Fluid, Type „A„) Engine Oil, DEO or GEO, of the appropriate SAE weight listed under GEO (API: CC or SD). EO is not intended for engine lubrication.

Extreme Pressure Grease lubricant. Generally regarded as a molybdenum base. If lithium or another base lube is required, it must be specified by name.

Gasoline Engine Oil (refer to engine Operator's Manual for SAE weights) meeting API service classification SE-CC Hydraulic Oil, SAE 10W or 10W40, engine oil, meeting API service classification SE Water Coolant: 50-50 mix of water and anti-freeze Battery: Fresh distilled water Multi Purpose Grease. Generally regarded as a molybdenum base. If lithium or another base lube is required, it must be specified by name.

Multi Purpose Gear Oil Lubricant (SAE 80W90) meeting API service classification GL5 PhilLube non-lead grease or equivalent Never Seize. Grease based lubricant with high metallic zinc content used to facilitate assembly and prevent galling of threads. Generally used on threads subject to high heat, or frequent assembly and disassembly.

(Typical Mil Spec: S46163) Tractor Hydraulic Fluid, similar to Texaco TDH oil, Phillips HG, Mobil Fluid 423, Chevron Tractor Hydraulic Fluid, or equivalent Tool Joint Compound. High concentration metallic zinc in grease

CMW P/N 256-653 (2.5 gal bucket)

10W40 GA

Engine oil, SAE 10W40, meeting API service classification SE/CC (See also HYDO, EO or GEO) Gasoline Additive. Sta-Bil (brand) 4 oz. can. Used to maintain volatility of gasoline over an extended storage period. (Not for use with diesel fuel.)

CMW P/N 256-632 NOTE: Lubricants and other products available from CMW have CMW part numbers listed. Other products available-locally.

150

151

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However, if you purchased from any other source, please fill out the form on the reverse side and return it to us.

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The Charles Machine Works, Inc. P.O. Box 66 Perry, Oklahoma 73077-9989

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The Charles Machine Works, Inc. Box 66 Perry, OK 73077-9989