Manitou MT6642T MT6642XT MT8044XT Parts Manual - PDF DOWNLOAD

TABLE OF CONTENTS

MANITOU NORTH AMERICA, INC. 6401 IMPERIAL DRIVE Waco, TX 76712-6803

MT6642T MT6642XT MT8044XT PARTS MANUAL MT6642T/XT S/N: 17173 and below MT8044XT S/N: 18177 and below

For Parts Orders contact your Manitou North America Dealer or call: Manitou North America, Parts Dept.

800-425-3727 or (254) 799-0232Parts Dept. Fax: (254) 867-6504 Email: parts.mna@manitou.com CATALOG 805931 R05-05

TABLE OF CONTENTS

Introduction The Table of Contents pages list the page locations of various component groups on the machine.

When ordering service parts, specify the part number, full description, quantity required, and the unit model and serial number.

Model and serial numbers for this unit are stamped on a plate located inside the operator’s station. The serial number is also stamped on the top front of the frame. The following reference shows the breakdown of the serial number: Unit Number

Model Engine

6642 J V 12 13201 Month Year (V=04, W=05, etc.)

“Right” and “left” are determined from a position standing behind the unit and facing the direction of travel.

Manitou North America Inc., reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any unit previously delivered.

Grease fittings and common attaching hardware, such as cotter pins, set screws, woodruff keys, screws and nuts are included in the parts list, indented below the part they are associated with, but NOT illustrated, except where a particular routing or special fastening arrangement must be maintained. The hardware listed is for mounting purposes and is NOT included when the part is ordered for replacement.

Standard attaching hardware torque values are provided on the inside back cover. Unless otherwise specified, all capscrews are Grade 5, cadmium or zinc plated; hexagon nuts for Grade 5 capscrews or bolts are Grade A.

TABLE OF CONTENTS

Introduction FILTER REFERENCE

List of Abbreviations Used in this Manual AN AR ASY BHB CB CN CYL CS DIA FHMS FLN FLS FT GR HLN HYD JN L LH LT N NA NIN NPTF NSS P PB PHS RH RHMS RHSMS RNF RT SHCS SHSS SFN SHSS STS THMS TRS W/ WN

TYPE Engine Oil Note c

Acorn Nut As Required Assembly Button Head Bolt Carriage Bolt Castellated Nut Cylinder Capscrew (Hexagon Head) Diameter Flat Head Machine Flanged Flexlock Nut Flanged Lock Screw Foot or Feet Grade Hexlock Nut Hydraulic Jam Nut Lock (Washer) Left Hand Left Nut (Plain Hex) Not Applicable Nylon Insert Lock Nut National Pipe Threaded Fitting Not Sold Separately Plain (Washer) Plow Bolt Pan Head Screw Right Hand Round Head Machine Screw Round Head Sheet Metal Screw Retained Nut Fastener Right Socket Head Caps crew Socket Head Set Screw Serrated Flange Nut Square Head Set Screw Self-Thread Screw Hex. Washer Head Truss-Head Machine Screw Thread Roll Screw With Wing Nut

PART NUMBER 808000

Engine Fuel Note a Note b

808002 808003

Engine Air Transmission Oil Hydraulic Oil

see pgs. 54 & 56 808004 808005

Notes: a

Used with 99 hp John Deere TIER II engine. (Units equipped with this engine use the manual accelerator pedal.)

b

Used with 115 hp John Deere TIER II engine. (Units equipped with this engine use the electronic accelerator pedal.)

c Use Dust Seal P/N 809290 as needed.

TABLE OF STANDARD WASHERS, NUTS Size & Description

Part No.

Size & Description

Part No.

#10-32 N

808544

1/4 L 1/4-20 NIN 1/4 P 1/4-20 SFN

808589 808661 808588 808545

7/16 L 7/16-14 NIN 7/16 P

808594 808625 809287

1/2-13 NIN 1/2 P

808665 808595

5/16 L 5/16-18 5/16-18 5/16 P 5/16-18 5/16-18

808591 808603 808662 808590 808671 808555

5/8 L 5/8-11 N

808597 809288

3/4-10 N 3/4-10 NIN 3/4 P

809289 808626 808593

808593 809286 808663 808592 808559 808670

1-8 JN

808592

3/8-16 3/8-16 3/8-16 3/8-16 3/8-16 3/8-16

1

N NIN RNF SFN

L N NIN P SFN WN

TABLE OF CONTENTS

Table of Contents Page Introduction Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Cab Standard Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Front and Rear Window Group (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Wiper (Option) / Front and Rear Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Top and Left Window (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Cab Door (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Instrument Panel, Switches and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Heater (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Steering Column and Shifter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Brake Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Brake and Accelerator Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Cab Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Chassis, Covers and Tanks Outrigger (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Frame Level Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Frame Stabilizing Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Chassis Hoods and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Front and Rear Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Fuel Tank/ Battery Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Hydraulic Tank Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 WPS Work Platform System Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Engine Engine - External Components/Fuel Lines Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Air Intake Group (1st Mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Air Intake Group (2nd Mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Exhaust Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Radiator/Coolers Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Transmission External Components Group (including Drive Shafts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Converter Housing Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Case and Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Torque Converter Grouup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Pump Drive Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

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Table of Contents Page Transmission (continued) Charge Pump Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Reverse Idler Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Forward and Reverse Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Third Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 First and Second Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Output Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Drive Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Modulation Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Axles External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Brake and Steering Lines Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Steering and Center Housing / Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Differential / Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Outer End / Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Brakes - Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Brakes - Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Boom Coponents Outer Boom - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Outer Boom - Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Outer Boom - Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Intermediate Boom - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Intermediate Boom - Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Intermediate Boom - Hose Tray Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Intermediate Boom - Chain Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Inner Boom - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Inner Boom - Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Quickattach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Boom Hydraulics Extend Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Tilt Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Slave Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Lift Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 Auxiliary Hydraulics Group (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Attachments Standard Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Fork Shift Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Rotate Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Swing Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Truss Boom Attachment Group (including Hydraulic Winch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Bucket Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

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Table of Contents Page Hydraulics Hydraulic Pump Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Steer Motor and Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Main Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 Main Valve / Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 Hydraulic Controls - No Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 Hydraulic Controls - Auxiliary Hydraulic Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Hydraulic Controls - Outrigger Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 Hydraulic Controls - WPS Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156 Hydraulic Controls - WPS and Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 Hydraulic Controls - WPS and Auxiliary Hydraulic Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Hydraulic Controls - All Options with WPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 Hydraulic Controls - All Options without WPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 Outrigger Main Valve / Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166 Hydraulic Components Breakdown Frame Level Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 Stabilizing Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 Lift Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 Boom Extend Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174 Slave Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176 Tilt Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 Outrigger Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 Fork Shift Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 Rotate Carriage Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 Swing Carriage Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 Hydraulic Pump - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 Master Cylinder Brake Valve - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 Power Steer Motor - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 Steer Select Valve - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189 Priority Flow Divider - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 Flow Divider - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 Stabilizing Valve - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 Main Valve - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 Main Valve - Auxiliary Hydraulics Work Section - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 Outrigger Control Valve - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 Controller - Tilt/Frame Level Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 Controller - Lift/Extend - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 Controller - Outrigger (Option) - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 Controller - Auxiliary Hydraulics (Option) - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 Steer Cylinder - Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 PWP Manifold Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209 Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 Torque Specification

4

TABLE OF CONTENTS

Decals

NEW DECAL APPLICATION

GENERAL INFORMATION

Before applying the new decals, surfaces must be free from dirt, dust, grease and other foreign material. To apply a solid-formed decal, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Slowly peel off the other portion of the backing paper while applying hand pressure to smooth out decal surface. To apply a die-cut decal, first remove the backing paper.

Then, properly orient and position the decal onto the clean mounting surface. After the decal is firmly applied and smoothly pressed down, remove the front covering paper.

CAUTION ALWAYS read and follow the safety precautions on decals. Replace decals if they are damaged, or if the unit is repainted. If repainting, BE SURE that all applicable decals are affixed in their proper locations.

Decal locations information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted.

For correct replacement of decals, compare the location illustrations to your machine before starting to refinish the unit. Check off each required decal using the illustration reference number to find the part number, description and quantity in the list. Refer to the appropriate illustrations for replacement locations.

5

TABLE OF CONTENTS

DECALS 808026

808025

808026 808025 808027 808029

808029 808028

808030

808027

808060 - MADE IN USA

808027 - F-N-R SHIFT

808031

808035

808032 808028

6

808030

TABLE OF CONTENTS

DECALS (cont.)

808036 808033

808034

808033 808036

808033 808033

808035

808061 - ATTACHMENT TILT/FRAME LEVEL 808062 - BOOM CONTROL

MT8044 808013 808012 808011 808010 808009 808008 808007

MT6642 808019 808018 808017 808016 808015 N/A 808014

LOAD CHARTS STANDARD CARRIAGE ROTATING CARRIAGE BUCKET TRUSS BOOM WINCH SWING CARRIAGE PWP EQUIPPED UNITS

808063 - OUTRIGGER CONTROL 808064 - AUXILIARY CONTROL

7

TABLE OF CONTENTS

DECALS (cont.)

808031 808037

808035

808032

808036 808033

808034

RED 808038

8

TABLE OF CONTENTS

DECALS (cont.)

808037 808031

808033

808033 808038

9

TABLE OF CONTENTS

DECALS (cont.)

806319

804768

MT6642T - 805814 MT6642XT - 805815 MT8044XT - 805816

804768

806320

804768

MT6642T - 805814 MT6642XT - 805815 MT8044XT - 805816

10

TABLE OF CONTENTS

DECALS (cont.)

PWP Safety Decals 808040

808039

808041

808040

808042

808039

808039

808041

808042

11

TABLE OF CONTENTS

Cab Standard Cab and Covers

3 2 25

26

4

27 1

4

29 24 5

9

INSTRUMENT PANEL AND LOAD CHARTS

5

23 22

6

10

7

29 8

11

12

15 14

16

5 8 13

21

20

7

28 DASH ACCESS PANELS

15 19

FRONT

18

30 17 15

12

6 11

TABLE OF CONTENTS

Cab Standard Cab and Covers Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17a 18a 19

20 21 22

Part No. 809176 808248 808241 808493 808492 808545 808484 808482 808483 808306 808667 808666 808242 808307 808589 808600 808249 808258 808257 808260 808471 808497 808498 808261 808236 808090 808802 809177

Description

Qty. Req.

CAB WELDMENT . . . . . . . . . . . . . . 1 BULB SEAL, RIGHT WINDOW . . . . 1 GLASS, RIGHT HAND . . . . . . . . . . 1 CLIP, WINDOW . . . . . . . . . . . . . . . . 3 SCREW, FLANGE . . . . . . . . . . . . . 6 1/4”-20 WHIZ LOCK NUT. . . . . . . AR WASHER, FLAT (BLACK) . . . . . . . . 3 BUSHING, NYLON . . . . . . . . . . . . . 3 GROMMET, 1/2”ID X 1/4”GROOVE 3 MOUNT, REAR GLASS UPPER . . . 2 5/16”-18X3/4” BUTT. HD BOLT . . . . 4 1/4”-20X1” BUTT. HD BOLT . . . . . . 3 GLASS, REAR. . . . . . . . . . . . . . . . . 1 MOUNT, REAR GLASS LOWER . . 1 1/4” LOCK WASHER . . . . . . . . . . . . 2 1/4”-20X5/8” BUTT. HD BOLT . . . AR BULB SEAL, REAR WINDOW . . . . 1 PANEL, HEATER. . . . . . . . . . . . . . . 1 PANEL, DASH COVER . . . . . . . . . . 1 COVER, BOTTOM. . . . . . . . . . . . . . 1 3/8 WHIZ LOCK NUT . . . . . . . . . . . 1 5/16” LOCK WASHER . . . . . . . . . . 1 5/16”-18X3/4” BUTT. HD BOLT . . . 4 WLDMNT, BRAKE CYL COVER . . . 1 COVER, HYD. CONTROLLERS . . . 1 1/4”-20X3/4” SCREW, PHILP HD. . 5 INDICATOR/FRAME LEVEL . . . . . . 1 #8-32X1” SCREW . . . . . . . . . . . . . 2

Ref. No.

Part No.

23

25b 26c 27 28 29

808862 808667 808245 808090 808308 808723 808734 809178 809179

30

808470

00 00a

808231 808733

00

808672

a

Use when not equipped with a heater.

b

Refer to Instrument Panel and Switches section on the next page for information regarding switches and gauges.

c

Refer to Decal Section for Load Chart Decals.

24

13

Description

Qty. Req.

PLATE, INCLMT MOUNT . . . . . . . . 1 5/16”-18X3/4” BUTT. HD BOLT . . . 4 COVER, FUSE PANEL . . . . . . . . . . 1 1/4”-20X3/4” SCREW, PHILP HD. . 4 PANEL, DASH . . . . . . . . . . . . . . . . . 1 LOAD CHART PLATE . . . . . . . . . . . 2 1/4”-20 U-BOLT . . . . . . . . . . . . . . . . 1 ACCESS STEP (weld on) . . . . . . . 1 GROMMET, 5/8” . . . . . . . . . . . . . . AR (not shown) BRACKET . . . . . . . . . . . . . . . . . . . . 1 -- ITEMS NOT SHOWN-HARNESS, CANOPY . . . . . . . . . . . 1 HOLE PLUG, 2-1/2” DIA . . . . . . . . . 1 (defroster hole in dash) TREAD STRIP, 6” WIDE (4 FT.) . . . 1

TABLE OF CONTENTS

Cab Front and Rear Window Group (Option)

3 REAR WINDOW HINGE

1

2

FRONT WINDOW HINGE

7

6

1

5

5

4

1

2 4

6

3

12

9

11

10

13

18

14

17

14 16 15

16 16 19

20

FRONT

14

8

TABLE OF CONTENTS

Cab Front and Rear Window Group (Option) Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14

Part No. 808490 808420 808421 808491 808483 808422 808495 808485 808242 808249 808247 808240 808095 808486

Description

Qty. Req.

Ref. No.

Part No.

5/16”-18 ACCORN NUT . . . . . . . . AR 5/16”-18X1” BUTTN HD BOLT . . . . 4 5/16”-18X3/4” BUTTN HD BOLT . . . 8 BUSHING, STEEL . . . . . . . . . . . . . . 4 GROMMET, 1/2”IDX1/4”GROOVE . 6 5/16” FLAT WASHER (BLACK) . . . . 4 HINGE, FRONT WINDOW . . . . . . . 2 HINGE, PLASTIC (rear window) . . . 1 GLASS, REAR. . . . . . . . . . . . . . . . . 1 BULB SEAL, REAR GLASS . . . . . . 1 BULB SEAL, FRONT GLASS . . . . . 1 GLASS, FRONT . . . . . . . . . . . . . . . 1 HOLD OPEN, T-STYLE. . . . . . . . . . 1 PIN, QUICK DETATCH . . . . . . . . . . 4

15a 16 17 18 19a 20a

808096 808481 808488 808487 808254 808255

MOUNT, REAR WINDOW LATCH . 1 PIN, ROLL - 3/16”x1/2” . . . . . . . . . . 3 HOLD OPEN, L-STYLE. . . . . . . . . . 1 HOLD OPEN, L-STYLE. . . . . . . . . . 1 MOUNT, WIND. HOLD OPEN (RH) 1 MOUNT, WIND. HOLD OPEN (LH). 1

a 00 00 00

Use the parts 809180 809181 808600

listed below to fasten mount to frame: 1/4” FLAT WASHER . . . . . . . . . . AR 1/4” LOCK WASHER. . . . . . . . . . AR 1/4”-20X5/8” BUTTN HD BOLT . . AR

15

Description

Qty. Req.

TABLE OF CONTENTS

Cab Wiper (Option) / Front and Top Glass

10 9

3 4

5

8

6

11

7 15 1

14 2 19

12 17

17 18

16

13

FRONT (FRONT WINDOW) UP (TOP WINDOW)

16

TABLE OF CONTENTS

Cab Wiper (Option) / Front and Top Glass ALL PARTS ARE USED ON BOTH FRONT AND TOP GLASS - EXCEPT NOTED

Ref. No. 01 02 03 04 05c 06 07 08 09 10 11

12 13 14 15 16 17 18

Part No. 808573 808479 808562 808561 808570 808565 808574 808494 808320 808569 808566 808319 808564 808568 808571 808563 808572 808093 808480

Description

Qty. Req.

Ref. No.

Part No.

BOLT / 10-24x1.25 HEX GR5 . . . . . 1 WASHER/BLK NYLON . . . . . . . . . . 1 COVER WIPER MOTOR. . . . . . . . . 1 WIPER MOTOR / TRICO . . . . . . . . 1 TOWER SEAL / TRICO WIPER . . . 1 GASKET / PANTO ADAPTER . . . . . 1 PANTO ADAPTER PLATE. . . . . . . . 1 ADAPTOR/WET ARM . . . . . . . . . . . 1 WIPER BLADE (16”) . . . . . . . . . . . . 1 ADAPTER / PIN LOCK . . . . . . . . . . 1 WIPER ARM . . . . . . . . . . . . . . . . . . 1 Note a (15-12/”) Note b (18-1/2”) M8 / ACORN NUT . . . . . . . . . . . . . . 1 M5 / ACORN NUT . . . . . . . . . . . . . . 1 RAIN SHIELD . . . . . . . . . . . . . . . . . 1 M18 / NUT . . . . . . . . . . . . . . . . . . . . 1 SCREW / M5 16mm . . . . . . . . . . . . 1 WASHER, #10 WEATHERTITE . . . 2 NUT/ACORN #10-24 BLK . . . . . . . . 1

19c 20

808560 808089

00 00

-- ITEMS NOT SHOWN -(Windshield Wiper Harness) 809182 HARNESS, TOP WIPER . . . . . . . . . 1 809183 HARNESS, FRONT WIPER . . . . . . 1

00 00

(Windshield Washer System) 808321 HARNESS, WASHER BOTTLE . . . 1 808347 TUBING, WASHER (15-1/2’) . . . . . . 1

a b c

Used for front window Used for top window Not used on top window

WASHER SYSTEM RESERVOIR LOCATED OUTSIDE CAB

-

UNDER RIGHT SIDE WINDOW

20

17

Description

Qty. Req.

BUSHING / NYLON. . . . . . . . . . . . . 2 BOTTLE, DUAL -PUMP WASHER . 1

TABLE OF CONTENTS

Cab Top and Left Window (Option)

1

5

2

6 7

3 8

4

9

2 10

4 5

8

FRONT

18

9

TABLE OF CONTENTS

Cab Top and Left Windows (Option) Ref. No. 01a 02 03 04 05 06

Part No. 808244 808490 808252 808483 808491 808250

Description

Qty. Req.

GLASS, TOP . . . . . . . . . . . . . . . . . . 1 5/16”-18 ACCORN NUT . . . . . . . . AR WINDOW MOUNT, UPPER. . . . . . . 1 GROMMET, 1/2”IDX1/4”GROOVE . 3 BUSHING, STEEL . . . . . . . . . . . . . . 4 BULB SEAL, LEFT GLASS . . . . . . . 1

19

Ref. No.

Part No.

Description

07 08 09 10

808243 808422 808420 808253

a

Use P/N 808934 Adhesive / Sealant to attach top glass to cab.

Qty. Req.

GLASS, LEFT REAR. . . . . . . . . . . . 1 5/16” FLAT WASHER (BLACK) . . . . 4 5/16”-18X1” BUTTN HD BOLT . . . . 4 WINDOW MOUNT, LOWER . . . . . . 2

TABLE OF CONTENTS

Cab Cab Door (Option)

1 2 5 3 11 8 9

7 12

8

10

7 6

15

13 14

22

21

16

9

20

19

18

4

17 8

FRONT

20

7

6

5

TABLE OF CONTENTS

Cab Cab Door (Option) Ref. No.

Part No.

Description

Qty. Req.

00

808348

CAB DOOR . . . . . . . . . . . . . . . . . . 1 (includes items 1-10, 12 and 15)

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

808303 808246 808238 808239 808419 808422 808491 808483 808490 809184 808417 808317 808145 808662 808323

WELDMENT, CAB DOOR FRAME . 1 BULB SEAL, DOOR FRAME . . . . . 1 GLASS, UPPER DOOR . . . . . . . . . 1 GLASS, LOWER DOOR . . . . . . . . . 1 5/16”-18X1-3/4” BUTTN HD BOLT . 5 5/16” FLAT WASHER (BLACK) . . . . 5 BUSHING, STEEL . . . . . . . . . . . . . . 8 GROMMET, 1/2”IDX1/4”GROOVE . 8 5/16”-18 ACCORN NUT (BLACK) . . 8 5/16”-18X2” BUTTN HD BOLT . . . . 3 1/4”-20X4-1/2” BOLT . . . . . . . . . . . . 3 WELDMENT, DOOR HINGE . . . . . . 3 HINGE BEARING (washer) . . . . . . . 3 5/16”-18 NYLON INSERT NUT . . . . 3 BUMPER, DOOR . . . . . . . . . . . . . . 1

Ref. No.

Part No.

16

808489

17 18

808413 NSS

19 20

808094 808327 808097 808310 809185 808600 809186 808484 808661 808891 808086 809187 809188 809189

21

22

21

Description

Qty. Req.

HOLD OPEN/DOOR (SET) . . . . . . . 1 (includes item #18) [mounts to cab] 1/4”-20x1-1/2” BOLT . . . . . . . . . . . . 1 HOLD OPEN/DOOR STUD. . . . . . . 1 (included with item #16 as a set) GLASS MOUNT . . . . . . . . . . . . . . . 1 HANDLE, EXT. DOOR LOCKING . . 1 KEY ONLY . . . . . . . . . . . . . . . . . . . 1 LATCH RELEASE, INTERIOR . . . . 1 1/4-20X1-1/4” FLAT HD SCREW . . 2 1/4-20X5/8” BUTTN HD BOLT . . . . 1 M6-1X12 8.8 BOLT. . . . . . . . . . . . . 2 FLAT WASHER (BLACK) . . . . . . . . 1 1/4”-20 NYLON INSERT NUT . . . . 2 1/2” HOLE PLUG . . . . . . . . . . . . . . 2 STRIKER . . . . . . . . . . . . . . . . . . . . . 1 7/16” LOCK WASHER . . . . . . . . . . 1 7/16” FLAT WASHER . . . . . . . . . . . 1 7/16”-14 NUT . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Cab Instrument Panel, Switches and Fuses REFER TO

“NOTE”

ON FACING PAGE

1

2

3

4

5

6

FRONT

7 8 9

10

16

15

14

13

12

11

17 FUSES AND RELAYS LOCATED UNDER LOAD CHARTS ON SIDE DASH

25

26 27

24

28

23 29 SWITCHES LOCATED

30

ON LOWER DASH

31

22 21

18 19

32 20

22

TABLE OF CONTENTS

Cab Instrument Panel, Switches and Fuses Ref. No.

Part No.

Description

01 02 03 04 05 06 07 08 09 10 11a 12 13 14 15 16 17

808724 808809 808922 808083 808928 808921 808926 808927 808924 808938 NA 808925 808923 808923 808069 808721 808308

18 19

808438 808073 808074 808231

20b

Qty. Req.

GAUGE, FUEL . . . . . . . . . . . . . . . . 1 GAUGE, WATER TEMP. . . . . . . . . . 1 SWITCH, STEER MODE. . . . . . . . . 1 SWITCH, ENGINE FAULT. . . . . . . . 1 SWITCH, CLUTCH CUT OUT. . . . . 1 SWITCH, PARK BRAKE . . . . . . . . . 1 SWITCH, LIGHTS . . . . . . . . . . . . . . 1 SWITCH, TURN SIGNALS . . . . . . . 1 SWITCH, HAZARD LIGHTS . . . . . . 1 SWITCH, WPS . . . . . . . . . . . . . . . . 1 OPTIONAL SWITCH . . . . . . . . . . . . 1 SWITCH, ETHER . . . . . . . . . . . . . . 1 SWITCH, WIPER/WASHER . . . . . . 1 SWITCH, WIPER/WASHER . . . . . . 1 GAUGE, HOUR METER . . . . . . . . . 1 GAUGE, LIGHT CLUSTER . . . . . . . 1 PANEL, DASH . . . . . . . . . . . . . . . . . 1 (does not include switches or gauges) SWITCH, PUSH BUTTON. . . . . . . . 2 SWITCH, IGNITION w/KEY. . . . . . . 1 KEY ONLY . . . . . . . . . . . . . . . . . . . 1 HARNESS, CANOPY . . . . . . . . . . . 1

Ref. No.

Part No.

Description

21 22 23 24 25 26 27 28 29 30 31 32

808892 808892 808394 809190 809190 809190 808394 808394 808395 808395 808395 808395

a

Use P/N 809191 Switch Hole Plug to cover hole when switches are not present.

b

Not all connections or terminals are shown in this illustration. The fuse and relay blocks as shown are located under the load chart panel on the side dash.

CHANGE OVER RELAY 20 AMP . . 1 CHANGE OVER RELAY 20 AMP . . 1 FUSE, MINI 15 AMP . . . . . . . . . . . . 1 FUSE, MINI 25 AMP . . . . . . . . . . . . 1 FUSE, MINI 25 AMP . . . . . . . . . . . . 1 FUSE, MINI 25 AMP . . . . . . . . . . . . 1 FUSE, MINI 15 AMP . . . . . . . . . . . . 1 FUSE, MINI 15 AMP . . . . . . . . . . . . 1 MICRO RELAY, 20 AMP . . . . . . . . . 1 MICRO RELAY, 20 AMP . . . . . . . . . 1 MICRO RELAY, 20 AMP . . . . . . . . . 1 MICRO RELAY, 20 AMP . . . . . . . . . 1

Note: Switches shown in the llustration or listed on this page are for reference purposes only. Your machine might be configured differently or might not include all of the options shown.

FUSE AND RELAY REFERENCE 21 22

(Relay #2) - 20 AMP change-over relay - PARK BRAKE (Relay #1) - 20 AMP change-over relay - IGNITION

23 24 25 26 27 28

(Fuse (Fuse (Fuse (Fuse (Fuse (Fuse

29 30 31 32

(Relay) (Relay) (Relay) (Relay)

#2) #4) #6) #5) #3) #1) -

-

15 AMP fuse 25 AMP fuse 25 AMP fuse 25 AMP fuse 15 AMP fuse 15 AMP fuse

20 AMP micro 20 AMP micro 20 AMP micro 20 AMP micro

-

(IGNITION) - transmission, park brake, WPS, steer select, injector (IGNITION) - heater, gauges (IGNITION) - front wiper motor (IGNITION) - top wiper motor (IGNITION) - lights, ether, clutch cutout (BATTERY) - ignition switch, horn, brake lights, backup alarm

relay relay relay relay

-

Qty. Req.

top wiper lights bulb check front wiper

23

TABLE OF CONTENTS

Cab Heater (Option)

2

FRONT

3

4

5

1 6 7

8 2

7

9

24

TABLE OF CONTENTS

Cab Heater (Option) Ref. No.

Part No.

01

808318

02 03 04 05

808351 809192 808324 808325 808352 809165

Description

Qty. Req.

HEATER ASSEMBLY . . . . . . . . . . . 1 (Includes items 1-9) BLOWER MOTOR (only). . . . . . . . . 1 GRILL, DEFROSTER . . . . . . . . . . . 2 INSTRUMENT PANEL. . . . . . . . . . . 1 DECAL, HEAT CONTROL. . . . . . . . 1 CONTROL, TEMPERATURE . . . . . 1 KNOB ONLY . . . . . . . . . . . . . . . . AR

25

Ref. No.

Part No.

Description

Qty. Req.

06 07 08 09

808411 808600 808496 808412

SWITCH, VARIABLE SPEED . . . . . 1 1/4”-20X5/8” BUTTN HD BOLT . . . 10 VAVLE, WATER . . . . . . . . . . . . . . . . 1 LOUVER . . . . . . . . . . . . . . . . . . . . . 1

00 00

NSS 809193

-- ITEMS NOT SHOWN-5/8” HEATER HOSE (10’) . . . . . . . . 1 HEATER HOSE CLAMP. . . . . . . . AR

TABLE OF CONTENTS

Cab Steering Column and Shifter Group

1

FRONT

2 3

6

12 7

4

5 11

8 T 9 L P 10

26

9

R

STEER MOTOR PORTS

TABLE OF CONTENTS

Cab Steering Column and Shifter Group Ref. No. 01 02 03 04 05 06 07 08

Part No. 808432 808435 808436 808586 808830 808849 809130 808833 808668

Description

Qty. Req.

STEERING WHEEL (15”) . . . . . . . . 1 CAP, STEERING WHEEL . . . . . . . . 1 NUT, STEERING WHEEL . . . . . . . . 1 M5X.8X35mm HX SKTHD BOLT . . 2 RUBBER GROMMET . . . . . . . . . . . 1 F-N-R/1-2-3 SHIFTER (includes #7) 1 BOOT . . . . . . . . . . . . . . . . . . . . . . 1 CLAMP, SHIFTER(included w/ #6) . 1 3/8”-16X1-1/4” BUTTN HD BOLT . . 4

27

Ref. No.

Part No.

Description

Qty. Req.

09 10 11 12

808445 808763 808101 808262

ADAP, -8ORM -8JICM STR. . . . . . . 3 CHECK VALVE . . . . . . . . . . . . . . . . 1 MOTOR, STEER . . . . . . . . . . . . . . . 1 COLUMN, STEERING. . . . . . . . . . . 1

00 00

808234 808099

-- ITEMS NOT SHOWN-WIRE HARNESS, FNR SHIFTER. . 1 MODULE, F-N-R SHIFTER . . . . . . . 1

TABLE OF CONTENTS

Cab Seat

1

2

4

7

5

3

8

2

3 9

4

3 5

6

2

10

4 5 5

11

3

3 8

4 4

2

5

3

9 6

12 13

FRONT

SUSPENSION SEAT

(OPTION)

28

TABLE OF CONTENTS

Cab Seat Ref. No. 01

Part No.

02

808079 809194 808914

03 04 05 06 07a 08 09

808654 808598 808625 808899 808898 808590 808555

Description

Qty. Req.

Ref. No.

Part No.

SEAT, OPERATOR’S. . . . . . . . . . . . 1 ARM REST (only) . . . . . . . . . . . . . 1 SEAT BELT . . . . . . . . . . . . . . . . . . . 1 (includes tethers) 7/16”-20X1” BOLT . . . . . . . . . . . . AR 7/16” FLAT WASHER . . . . . . . . . . AR 7/16”-20 NYLON INSERT NUT . . AR BRACKET, TETHER . . . . . . . . . . . . 2 MOUNT, SEAT BELT . . . . . . . . . . . . 1 5/16” FLAT WASHER . . . . . . . . . . AR 5/6”-18 NYLON INSERT NUT . . . AR

10a 11 12b

809195 808640 808835

13

808343

a

Used for standard seat only. Not used with suspension seat option.

b

Used for suspension seat option only.

29

Description

Qty. Req.

SEAT RISER . . . . . . . . . . . . . . . . . . 1 5/16”-18X1” BOLT . . . . . . . . . . . . AR BELLOWS, SUSPENSION SEAT . . 1 (includes seatbelt / tether bracket) PEDESTAL . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Cab Brake Valve Group

FRONT

CLUTCH CUT-OUT

(OPTION)

2 3

BRAKE LIGHT PRESSURE

Front Axle Service Brake (right side tee)

SWITCH

4 5

1

6 8 7 19 17

18

15

20 16

12

11

8

5 12

15 9

13

14

10 11

10 9

Rear Axle Service Brake (left side tee)

30

TABLE OF CONTENTS

Cab Brake Valve Group Ref. No. 01 02a 03b 04 05 06 07 08 09 10 11 12 13 14 15 16 17

Part No. 808299 808299 808681 808905 808656 808446 808281 808280 808725 808725 808342 808703 808279 808643 808663 808608 808662

Description

Qty. Req.

SWITCH, PRESSURE 150 PSI. . . . 1 SWITCH, PRESSURE 150 PSI. . . . 1 PLUG, -4ORM SAE . . . . . . . . . . . . . 1 MANIFOLD, BRAKE LINE. . . . . . . . 1 ADAP, -40RM -4JICM 90 DEG . . . . 3 ADAP, -4ORM -4JICM STR. . . . . . . 1 HOSE, -4 A4/A6 66” . . . . . . . . . . . . 1 HOSE, -4 A4/A4 38” . . . . . . . . . . . . 1 HOSE, -4 A4/DM4 17” . . . . . . . . . . . 1 HOSE, -4 A4/DM4 17” . . . . . . . . . . . 1 ADAP, -4 SWIVEL TEE . . . . . . . . . . 2 ADAP, HYDROMAX -4JICM STR . . 2 HOSE, -4 A4/A6 90” . . . . . . . . . . . . 1 3/8”-16X1-3/4” BOLT . . . . . . . . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . . 6 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 2 5/16”-18 NYLON INSERT NUT . . . . 2

31

Ref. No.

Part No.

Description

Qty. Req.

18 19 20

808642 808719 808714

5/16”-18X2” BOLT . . . . . . . . . . . . . . 2 SWITCH, DIFF. PRESSURE . . . . . . 1 VALVE, MASTER CYLINDER . . . . . 2

00

808805

-- ITEMS NOT SHOWN-WIRE, 16ga. 6” . . . . . . . . . . . . . . . . 1 (ground wire for item #20)

a

Used when unit is equipped with Clutch Cut-Out option.

b

Used when unit is not equippped with Clutch Cut-Out option.

TABLE OF CONTENTS

Cab Brake and Accelerator Pedals

FRONT

28

29

27 26 ELECTRONIC THROTTLE USED WITH

25

115

24

1

MANUAL THROTTLE USED WITH

99HP TIER

II

22 23 3 2 22

21

5 4

9

7

6 20

8

19 18 10

17 11

16

11 12 13 14

12

15 14 13

32

HP TIER II

TABLE OF CONTENTS

Cab Brake and Accelerator Pedals Ref. No.

Part No.

01 02 03 04

808711 808604 808555 808264

05 06 07

808155 808595 808474

08 09 10 11 12 13 14 15 16 17 18 19 20 21 22a 23a

808154 808632 808424 808466 808630 808675 808575 808156 808608 808592 808663 808594 808654 808714 808722 808705

Description

Qty. Req.

Ref. No.

Part No.

PAD, BRAKE PEDAL . . . . . . . . . . . 1 5/16”-18X1-1/4” BOLT . . . . . . . . . . . 2 5/16”-18 FLANGE NUT . . . . . . . . . . 2 BRAKE LEVER ASSEMBLY . . . . . . 1 (includes item 7) BRAKE LINKAGE, WLDMNT . . . . . 1 1/2” FLAT WASHER . . . . . . . . . . . . 1 BRONZE BUSHING . . . . . . . . . . . . 2 (included with item 4) PIN, BRAKE LEVER PIVOT . . . . . . 1 ROLL PIN, .19X1 . . . . . . . . . . . . . . . 1 ZERK, GREASE 1/4”-28 . . . . . . . . . 1 PIN, CLEVIS 1/2”X27/64” . . . . . . . . 2 1/8”X1” COTTER PIN . . . . . . . . . . . 2 YOKE, CLEVIS 1/2”-13 . . . . . . . . . . 2 1/2”-13 NUT. . . . . . . . . . . . . . . . . . . 2 ROD, BRAKE VALVE . . . . . . . . . . . 1 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 6 3/8” FLAT WASHER . . . . . . . . . . . . 6 3/8”-16 NYLON INSERT NUT . . . . . 6 7/16” LOCK WASHER . . . . . . . . . . . 2 7/16”-20X1” BOLT . . . . . . . . . . . . . . 2 VALVE, BRAKE MASTER CYL. . . . 2 BRACKET, THROTTLE RETRN . . . 2 SPRING, CABLE TENSION . . . . . . 1

24a

808848 808666 808545 809073 808084 808301 808667 808671 808602 808590

25b 26b 27b 28b 29b

33

Description

Qty. Req.

PEDAL, ACCELERATOR . . . . . . . . 1 1/4”-20X1” BUTTN HD BOLT . . . . . 3 1/4”-20 FLANGE NUT . . . . . . . . . . 3 BOOT . . . . . . . . . . . . . . . . . . . . . . . 1 THROTTLE PEDAL, ELECTRONIC 1 COVER, ELEC. THROTTLE . . . . . . 1 5/16”-18X3/4” BUTTN HD BOLT . . . 2 5/16”-18 RETAIN/CLIP NUT. . . . . . 2 5/16”-18X3/4” BOLT . . . . . . . . . . . . 2 5/16” FLAT WASHER . . . . . . . . . . . 2

00a

-- ITEMS NOT SHOWN-(Throttle) 808717 THROTTLE CABLE. . . . . . . . . . . . . 1 808772 COUPLER (John Deere) . . . . . . . . 1 808771 THROTTLE ROD (John Deere) . . . 1

00

808674

a b

Used when equipped with a 99 hp TIER II engine.

Used when equipped with a 115 hp TIER II engine.

(Brake) RETURN SPRING (Brake lever) . . . 1 (attaches to item 4)

TABLE OF CONTENTS

Cab Cab Mounts

4 2 7

1 2 4 3

5

6

7 2

4 7 2

4

FRONT

34

TABLE OF CONTENTS

Cab Cab Mounts Ref. No. 01 02 03 04 05 06

Part No. 809196 809197 808259 809198 808092 808621

Description

Qty. Req.

1”-8X5-1/2” GR8 BOLT . . . . . . . . . . 1 1” SAE FLAT WASHER . . . . . . . . . . 7 RETAINER, CANOPY NUT . . . . . . . 1 1”-8 CLASS C LOCK NUT . . . . . . . 4 WASHER, CANOPY NUT . . . . . . . 1 3/8”-16X1-1/4” BOLT . . . . . . . . . . . . 2

35

Ref. No.

Part No.

07

808309

00

808733

Description

Qty. Req.

1”-8X3-3/4” GR8 BOLT . . . . . . . . . . 3 -- ITEMS NOT SHOWN-HOLE PLUG, 2-1/2” DIA . . . . . . . . . 1 (plugs hole in cab where side bolt attaches)

TABLE OF CONTENTS

Chassis Outrigger (Option)

RIGHT 8

7 1

6

2

7 6

3 4 5

14

1 9 10 13

11 12

1 2

15 17

16

3 20

21

5

1 18

4

LEFT

19

FRONT

36

TABLE OF CONTENTS

Chassis Outrigger (Option) Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14a 15 16 17 18

Part No. 808603 808874 808912 808858 808873 808620 808583 808164 808851 808851 808851 808851 808445 808910 808911 808909 808908 808784

Description

Qty. Req.

5/16”-18x3/4” BOLT . . . . . . . . . . . . 16 CAP, PIN LOCK. . . . . . . . . . . . . . . . 4 PIN, PIVOT . . . . . . . . . . . . . . . . . . . 4 BUSHING . . . . . . . . . . . . . . . . . . . . 6 CAP, PIVOT PIN . . . . . . . . . . . . . . . 4 3/4”-10X3” BOLT GR8 . . . . . . . . . . . 8 3/4”-10 STOVER LOCK NUT “C” . . 8 WLDMNT, OUTRIGGER MNT. . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM STR. . . . . . . 4 CYLINDER, OUTRIGGER. . . . . . . . 2 BUSHING . . . . . . . . . . . . . . . . . . . . 2 WLDMNT, OUTRIGGER LEG . . . . . 2 BUSHING . . . . . . . . . . . . . . . . . . . . 2 PIN, PIVOT . . . . . . . . . . . . . . . . . . . 2

Ref. No.

Part No.

Description

19 20 21

808783 808663 808610

WLDMNT, OUTRIGGER PAD . . . . . 2 3/8”-16 CNTR LOCK NUT. . . . . . . . 2 3/8”-16X3” BOLT . . . . . . . . . . . . . . . 2

00 00

808063 808424

-- ITEMS NOT SHOWN -DECAL, OUTRIGGER CONTROL . 1 ZERK, GREASE 1/4-28 STR . . . . AR

a

Refer to Hydraulic Breakdown section for a listing of individual components.

Note: Refer to Hydraulic Section for more information regarding the Outrigger control valve, hydraulic contoller and components.

HOSE LOCATOR 09 10 11 12

OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER

CYLINDER CYLINDER CYLINDER CYLINDER

“LEFT SIDE” (extend) “LEFT SIDE” (retract) “RIGHT SIDE” (extend) “RIGHT SIDE” (retract)

OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER

Note:

For more information on hose routing for the Outrigger Option, refer to the Outigger Main Valve / Controller pages located in the Hydraulic Section of this manual.

37

VAVLE VAVLE VAVLE VAVLE

LEFT SECTION (extend) LEFT SECTION (retract) RIGHT SECTION (extend) RIGHT SECTION (retract)

Qty. Req.

TABLE OF CONTENTS

Chassis Frame Level Cylinder Group 3 1

2 4 5

7 6 RETRACT EXTEND

8 9

10

11

RIGHT 12 13 17 14

FRON

T AXL

16

15

FRONT

38

E

LEFT

TABLE OF CONTENTS

Chassis Frame Level Cylinder Group Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808304 808756 808611 808663 808712 808803 808454 808297 808302

Description

Qty. Req.

LEVEL CYLINDER . . . . . . . . . . . . . 1 BRONZE BEARING . . . . . . . . . . . . 1 3/8”-16X3-1/2” BOLT . . . . . . . . . . . . 1 3/8”-16 NYLON INSERT NUT . . . . . 1 PIN, CYLINDER (base end) . . . . . . 1 ADAP, W/ORIFICE -8ORM -8JICM . 1 ADAP, -8ORM -8JICM 90 DEG . . . . 1 HOSE, -8 A8/A8 168” . . . . . . . . . . . 1 HOSE, -8 A8/A8 190” . . . . . . . . . . . 1

Ref. No.

Part No.

10 11 12 13 14 15 16 17

808708 808855 808621 808856 808109 809199 808583 808634

Description

BRONZE BEARING . . . . . . . . . . . . 1 LOCK, PIVOT PIN . . . . . . . . . . . . . . 1 3/8”-16X1-1/4” BOLT . . . . . . . . . . . . 1 PIVOT PIN (rod end) . . . . . . . . . . . . 1 FRAME LEVEL MOUNT . . . . . . . . . 1 PLATE, FRAME LEVEL. . . . . . . . . . 1 3/4”-10 STOVER NUT . . . . . . . . . . . 4 3/4”-10X9” GR8 BOLT . . . . . . . . . . . 4

HOSE LOCATOR 08

FRAME LEVEL CYLINDER “OUTSIDE” (retract)

09

FRAME LEVEL CYLINDER “INSIDE” (extend)

STABLIZING CYL MANIFOLD “TOP PORT” (located on left inside rear of frame) MAIN VALVE (1st section - right side)

39

Qty. Req.

TABLE OF CONTENTS

Chassis Frame Stabilizing Cylinder Group

TO FRAME LEVEL CYLINDER (EXTEND)

1

2 3 4

5

6 7

8 Retract

10 Main Valve Extend

10

9 8

7

1st Section (Frame Level)

9 5

28

TO FRAME LEVEL CYLINDER (RETRACT)

11 22

27

23

29

14

12

6 25

26 13 15

24 23

16 17

11

18

21

RIGHT 22 2

REAR A

XLE

20

19

LEFT FRONT

40

TABLE OF CONTENTS

Chassis Frame Stabilizing Cylinder Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 14 15

Part No. 808302 809200 808458 808117 808445 808295 808603 808591 808879 808878 808295 808621 808855 808856

Description

Qty. Req.

HOSE, -8 A8/A8 190” . . . . . . . . . . . 1 HOSE, -8 A8/A8 26” . . . . . . . . . . . . 1 ADAP, -12ORM -8JICM 90 . . . . . . . 2 FRAME STABILIZER CYLINDER . . 1 ADAP, -8ORM -8JICM STR. . . . . . . 2 HOSE, -8 A8/DS8 46” . . . . . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 4 5/16” LOCK WASHER . . . . . . . . . . . 4 TRUNNION PIVOT PIN. . . . . . . . . . 2 BUSHING . . . . . . . . . . . . . . . . . . . . 2 HOSE, -8 A8/DS8 46” . . . . . . . . . . . 1 3/8”-16x1-1/4” BOLT . . . . . . . . . . . . 1 LOCK, PIVOT PIN . . . . . . . . . . . . . . 1 LEVEL CYL. PIN (rod end) . . . . . . . 1

Ref. No.

Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28 29

808423 808858 808118 809199 808583 808634 808660 808454 809201 808589 808588 808297 808424 808305

Description

Qty. Req.

1/4”-28 GREASE ZERK 90 DEG. . . 1 BUSHING (rod end). . . . . . . . . . . . . 1 STABILIZER CYL MOUNT . . . . . . . 1 MOUNT PLATE . . . . . . . . . . . . . . . . 1 3/4-10 NUT GR8 . . . . . . . . . . . . . . . 4 3/4-10X9” GR8 BOLT . . . . . . . . . . . 4 ADAP, -6ORM -8JICM 90 DEG . . . . 2 ADAP, -8ORM -8JICM 90 DEG . . . . 2 1/4”-20X4” BOLT GR5 . . . . . . . . . . . 1 1/4” LOCK WASHER . . . . . . . . . . . . 1 1/4” FLAT WASHER . . . . . . . . . . . . 1 HOSE, -8 A8/A8 168” . . . . . . . . . . . 1 1/4”-28 GREASE ZERK STR . . . . . 1 MANIFOLD, STABLIZING CYL. . . . 1

Hose Locator Ref No.

From Port

To Port

01 02 06 11 27

MAIN VALVE, 1ST SECTION (extend) MAIN VALVE, 1ST SECTION (retract) STABILIZING CYL. MANIFOLD “REAR” STABILIZING CYL. MANIFOLD “FRONT” STABILIZING CYL. MANIFOLD “TOP”

FRAME LEVEL CYLINDER “INSIDE” (extend) STABILIZING CYL. MANIFOLD “BOTTOM” (retract) STABLILIZING CYLINDER “TOP PORT” STABLILIZING CYLINDER “BOTTOM PORT” FRAME LEVEL CYLINDER “OUTSIDE” (retract)

41

TABLE OF CONTENTS

Chassis Chassis Hoods, Covers and Frame

6

16

1

17

3 4

2

FRONT

5 13

3

14

6 4 3

7

16

2

15

3

14

25

3

18

24

9

10

19

16

8 2

11

23 24 23

12 22

22 2 21

13

3

4

17 18 3

2

16

20 27 4

4 3

2

26

42

TABLE OF CONTENTS

Chassis Chassis Hoods, Covers and Frame Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20

Part No. 808814 808603 808590 808671 808640 808801 808237 808662 808132 808671 808602 808680 808847 808774 808682 808601 808545 808775 808776 808136

Description

Qty. Req.

HOOD, TOP. . . . . . . . . . . . . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . AR 5/16” FLAT WASHER . . . . . . . . . . AR 5/16” RETAINED NUT CLIP . . . . . AR 5/16”-18X1” BOLT . . . . . . . . . . . . AR GUIDE, NYLATRON 28” . . . . . . . . . 2 BULKHEAD PLATE WELDMENT . . 1 5/16” NYLON INSERT NUT . . . . . AR SUPPORT, BULKHEAD PANEL . . . 1 5/16” RETAINED NUT CLIP . . . . . AR 5/16”-18X1/2” BOLT . . . . . . . . . . . AR PANEL, RADIATOR (left side) . . . . . 1 PANEL, ENGINE . . . . . . . . . . . . . . . 2 HANDLE, HOOD . . . . . . . . . . . . . . . 2 PANEL, RADIATOR (right side). . . . 1 1/4”-20X1” BOLT . . . . . . . . . . . . . AR 1/4”-20 WHIZ LOCK NUT. . . . . . . AR GUIDE, NYLATRON 4” . . . . . . . . . . 4 MID HOOD WELDMENT. . . . . . . . . 1 FRONT HOOD WELDMENT. . . . . . 1

Ref. No.

Part No.

21 22 23 24 25 26 27

808135 808699 808698 808697 808816 808683 808950

00

808230 808808

808500 00 00

808437 808707

Description

FRONT FRAME COVER. . . . . . . . . 1 FASTENER RECEPTACALE . . . . AR FASTENER RETAINER . . . . . . . . AR FASTENER STUD . . . . . . . . . . . . AR COVER, ACCESS . . . . . . . . . . . . . . 2 FRAME . . . . . . . . . . . . . . . . . . . . . . 1 BEARING, SELF ALIGNING . . . . . . 2

-- ITEMS NOT SHOWN -WIRE HARNESS, FRAME . . . . . . . 1 (includes the following diode and fuse): DIODE PACK, 4 DIODES. . . . . . . . 1 (located under chassis cover just in front of transmission) 60 AMP MAXI FUSE . . . . . . . . . . . 1 (located near engine starter) HORN . . . . . . . . . . . . . . . . . . . . . . . 1 GROUND STRAP . . . . . . . . . . . . . . 1

808808 DIODE PACK LOCATED UNDER TRANS. HOOD

43

Qty. Req.

TABLE OF CONTENTS

Chassis Front and Rear Lights

1 2

3 4 FRONT OF CAB

FRONT

REAR COVER

7

9

5 8 7

FRONT

10

6 8

44

TABLE OF CONTENTS

Chassis Front and Rear Lights Ref. No. 01 02 03 04 05 06

Part No.

07

808889 808592 808663 808341 808137 808897 808600 808545 808505

08

808919

09

808558

10

808936 808078

Description

Qty. Req.

HEAD LIGHT . . . . . . . . . . . . . . . . . . 2 3/8” FLAT WASHER . . . . . . . . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . . 2 GROMMET . . . . . . . . . . . . . . . . . . . 2 COVER, REAR . . . . . . . . . . . . . . . . 1 BACKUP ALARM. . . . . . . . . . . . . . . 1 1/4”-20X5/8” BOLT, BTNHEAD . . . . 2 1/4”-20 FLANGE NUT . . . . . . . . . . . 2 BEZEL, RUBBER . . . . . . . . . . . . . . 2 (included with item #04) LIGHT, BRAKE/TURN . . . . . . . . . . . 2 (includes item #03 bezel) . . . . . . . . .

BEZEL, RUBBER . . . . . . . . . . . . . . 1 (included with item #06) LIGHT, HALOGEN BACKUP . . . . . . 1 (includes item #05 bezel) JUMPER WIRE, BACKUP LIGHT . 1

Ref. No.

Part No.

Description

00

808735

00

808901

00

808344

a

Standard wire harness, used when not equipped with turn signals.

b

Used with optional light package for units equipped with turn signals. Wire harness 808232 is not used when unit is equipped with turn signals.

TURN SIGNAL FLASHER . . . . . . . . 1 (located under dash through joystick access cover) HARNESS, HEAD LIGHT . . . . . . . . 2 (dash to head lights) GROMMET . . . . . . . . . . . . . . . . . . . 2 (under dash for head light harness)

Note: Refer to the Outer Boom - Front Section for the work lights and wire harness associated with the boom.

-- ITEMS NOT SHOWN -00a 00b

808232 808166

808396 808577 808576

Qty. Req.

WIRE HARNESS, REAR LIGHTS. . 1 HARNESS, LIGHT PACKAGE . . . . 1 (dash to rear lights - includes the following diodes:) DIODE PACK (see below). . . . . . . 1 DIODE PACK (see below). . . . . . . 1 CLEAR COVER, DIODE PACK . . . 2

808396

808577

DIODE PACK

DIODE PACK

LOCATED NEAR

LOCATED UNDER DASH

REAR LIGHTS

NEAR SWITCHES

45

TABLE OF CONTENTS

Chassis Fuel Tank / Battery Group

FRONT

8 7

19 9 10

18 16

20

17

6 11

12

14 15

21

5 3

4 13

2

22 23 24

1

25 26 34

33

31 30

Fuel Lines (back side of tank)

26 32 29

46

27

28

TABLE OF CONTENTS

Chassis Fuel Tank / Battery Group Ref. No. 01 02 03 04 05 06

Part No.

12 13 14 15 16

808147 808091 808612 808665 808088 808148 808507 808900 809106 808774 809108 808544 808637 808773 808697 808698 808699 808718 808439 NSS 808694

17 18 19 20 21

808732 808731 808736 808661 808072

07 08

09 10 11

Description

Qty. Req.

Ref. No.

Part No.

22

WELDMENT, FUEL TANK . . . . . . . . 1 GROMMET, FUEL TANK. . . . . . . . . 1 1/2”-13X1-3/4” BOLT . . . . . . . . . . . . 6 1/2”-13 NYLON INSERT NUT . . . . . 6 PLATE, TOOLBOX BOTTOM . . . . . 1 TOOLBOX COVER, WELDMENT. . 1 GASKET, 1/8”X1/2”X60” . . . . . . . . . 1 CAMLOCK . . . . . . . . . . . . . . . . . . . . 1 KEY ONLY (stamped CH751) . . . . 1 HANDLE, HOOD . . . . . . . . . . . . . . . 1 #10-32X1/2” RND HD SCREW . . . . 2 #10-32 NUT . . . . . . . . . . . . . . . . . . 2 5/16”-18 ACORN NUT . . . . . . . . . AR STUD, HINGE . . . . . . . . . . . . . . . . . 2 FASTNER, STUD . . . . . . . . . . . . . . 2 FASTENER, RETAINER. . . . . . . . . 2 FASTENER, RECEPTACLE . . . . . . 2 GROMMET . . . . . . . . . . . . . . . . . . . 1 GASKET, SENDER . . . . . . . . . . . . . 1 GASKET, FUEL CAP ASSEMBLY . . 1 SENDER/FUEL LEVEL . . . . . . . . . . 1 (includes #14 Gasket) CAP/FUEL ASSEMBLY . . . . . . . . . . 1 MIRROR, 6.5X10 CONVEX . . . . . . 1 MIRROR BRACKET . . . . . . . . . . . . 1 1/4” NYLON INSERT NUT . . . . . . . 1 5/16”x1/2 FLAT LOCK BOLT . . . . . . 4

Qty. Req.

24 25 26 27 28 29 30 31 32 33 34

808105 808755 808670 808686 808896 808087 808667 808559 NSS 808462 808457 809109 808298

CABLE, NEG BATTERY . . . . . . . . . 1 Note a Note b CABLE, POS BATTERY . . . . . . . . . 1 Note a Note b 3/8”-16 WINGNUT . . . . . . . . . . . . . . 2 BATTERY HOLDDOWN BAR . . . . . 1 ROD, BATTERY HOLDDOWN . . . . 2 PLATE, BATTERY ACCESS . . . . . . 1 5/16”-18X3/4” BHSCS . . . . . . . . . . . 4 3/8”-16 FLANGE NUT . . . . . . . . . . . 4 12VDC BC1 4DLT BATTERY . . . . . 1 ADAP, PLUG -8 ORING SAE . . . . . 1 ADAP, -8ORM -6JICM 90 . . . . . . . . 2 HOSE, 3/8” X 73” (supply). . . . . . . . 1 HOSE, 1/4” X 73” (return) . . . . . . . . 1

00

808707

-- ITEMS NOT SHOWN -GROUND STRAP . . . . . . . . . . . . . . 1

a

When equipped with a 115 HP Tier II engine. (equipped with an electronic throttle pedal)

b

When equipped with a 99 HP Tier II engine. (equipped with a manual throttle pedal)

808104 808706 23

47

Description

TABLE OF CONTENTS

Chassis Hydraulic Tank Group

2 3

FRONT

1 4

30

5 6 7 33 8

29 9

Hydraulic Filter Assembly (Item #27)

28 10 27

11 12

34

26 35

13

14

25

24

23 22 36

21

14 19

31

20

19

32

15 Return Hose (Outrigger Option)

18 Hydraulic Tank (Rear Side)

48

17 16 13

TABLE OF CONTENTS

Chassis Hydraulic Tank Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25a 26 27

Part No. 808768 809110 809111 809112 808153 808152 809170 808640 808590 808788 808789 808110 808440 808713 808326 808853 808282 808716 808455 808443 808608 808592 808793 808462 809113 808410 808100

Description

Qty. Req.

TUBE ASSEMBLY . . . . . . . . . . . . . . 1 HOSE, -16 A16/A16 20” . . . . . . . . . 1 ADAP, -16JICM BLKHEAD 90. . . . . 1 1/4”-20X1-1/2” BOLT . . . . . . . . . . . . 2 PLATE, TOP CUSHION. . . . . . . . . . 1 CLAMP, CUSHION TUBE . . . . . . . . 1 FILL CAP ASSEMBLY . . . . . . . . . . . 1 5/16”-18X1” BOLT . . . . . . . . . . . . . 10 5/16” FLAT WASHER . . . . . . . . . . 10 ACCESS COVER . . . . . . . . . . . . . . 1 GASKET . . . . . . . . . . . . . . . . . . . . . 1 HYDRAULIC TANK.. . . . . . . . . . . . . 1 ADAP, -24JICM 24NPTM 90 . . . . . . 1 HOSE, -24 A24/A24 35” . . . . . . . . . 1 HOSE, -4 A6/DS6 18” . . . . . . . . . . . 1 HOSE, 4 A6/DS6 20”. . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 HOSE, -6 A6/DS8 52” . . . . . . . . . . . 1 ADAP, -6ORM -6JICM 90 DEG . . . . 2 ADAP, -6ORM -6JICM STR. . . . . . . 2 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 2 3/8” FLAT WASHER . . . . . . . . . . . . 2 3/8”-16 RETAINED NUT . . . . . . . . . 2 PLUG, -8 ORING SAE. . . . . . . . . . . 1 PLUG, -12 ORING SAE. . . . . . . . . . 1 SIGHT GLASS. . . . . . . . . . . . . . . . . 1 FILTER ASY. . . . . . . . . . . . . . . . . . . 1

Ref. No.

Part No.

28 29 30 31b 32b 33 34 35

808621 809175 808780 808453 808267 808339 808005 808340

36

808679

Description

(Includes items 33-35) 3/8”-16X1-1/4” BOLT . . . . . . . . . . . 4 ADAP, -20ORM -16JICM STR. . . . . 1 ADAP, -16JICM -16JICFS 90 . . . . . 1 ADAP, -12ORM -12JICM 90 . . . . . . 1 HOSE, -12 A12/DS12 30” . . . . . . . . 1 O-RING, FILTER . . . . . . . . . . . . . . . 1 HYDRAULIC FILTER ELEMENT. . . 1 SEAL KIT (three o-rings) . . . . . . . . . 1 (includes item 33) ADAP, -6JICM -6JICFS 90 . . . . . . . 1

-- ITEMS NOT SHOWN --

00 00 00

(located inside hydraulic tank) 809202 ADAP, 1-1/2” NPT 90 ELBOW . . . . 1 808690 ADAP, 1-1/2” PIPE NIPPLE. . . . . . . 1 808006 STRAINER, HYD. OIL . . . . . . . . . . . 1

a b

Not used when equipped with outriggers.

Used when equipped with outriggers.

HOSE LOCATOR 02 14 15 16 17 18 32

HYDRAULIC TUBE (from hyd. tank) HYDRAULIC TANK (bottom) HYDRAULIC TANK RETURN (return HYDRAULIC TANK RETURN (return HYDRAULIC TANK RETURN (return HYDRAULIC TANK RETURN (return HYDRAULIC TANK RETURN (front)

Qty. Req.

BULKHEAD then HYD. COOLER “UPPER” HYDRAULIC PUMP “IN” FLOW DIVIDER “T” PRIORITY VALVE “T” JOYSTICK (lift/extend controller) “T” STEER MOTOR “T” OUTRIGGER VALVE “OUT” (return to tank)

manifold) manifold) manifold) manifold)

49

TABLE OF CONTENTS

WPS Work Platform System Group

2

1 3

(Attached to Personnel Work Platform)

4

110 “

5 612”

Ref. No.

Part No.

00

808942

01 02 03

808131 808941 808940

Description

Qty. Req.

REMOTE SWITCH W/CABLE. . . . . 1 (Includes item 1-4) CABLE ASSEMBLY . . . . . . . . . . . . . 1 REMOTE STOP SWITCH . . . . . . . . 1 REMOTE SWITCH ENCLOSURE. . 1

50

Ref. No.

Part No.

04 05

808944 808943

Description

Qty. Req.

REMOTE SWITCH POUCH . . . . . . 1 REMOTE SWITCH HARNESS . . . . 1 (Consists of two cables)

TABLE OF CONTENTS

WPS Work Platform System Group

Located under tank/engine cover attached to inner frame

1 2

5 4 Located under dash in Joystick Access Cover

3

Chain and Shackle (Used to secure Personnel Work Platform)

Ref. No. 01 02 03 04a 05a

Part No. 808935 808127 808939 808946 808945

Description

Qty. Req.

LEVEL SENSOR . . . . . . . . . . . . . . . 1 MANIFOLD, WPS JOYSTICK . . . . . 1 WPS CONTROL MODULE . . . . . . . 1 5/16” CHAIN SHACKLE . . . . . . . . . 1 5/16” CHAIN GR40 16 LINKS . . . . 1

51

Ref. No.

Part No.

Description

Qty. Req.

00 00

808938 808233

a

Chain shackle and chain are used to secure the Personnel Work Platform.

-- ITEMS NOT SHOWN -WPS SWITCH (located on dash) . . 1 WPS WIRE HARNESS . . . . . . . . . . 1

TABLE OF CONTENTS

Engine Engine - External Components

1

19

4

2 3

5

18

17

20

16

15

14

09

08 21 22 23 07

6

10

FRONT

11 12 13

52

TABLE OF CONTENTS

Engine Engine - External Components Ref. No. 01 02 03

04 05 06 07 08 09 10 11 12 13 14 15 16 17

18c 19 20be 21b 22b 23b

Part No. NSS 808434 808102 809203 808758 808861 808103 808112 808113 808613 808615 808744 808749 808664 808872 808844 808843 808557 808845 808465 808846 808813 808772 808544 808771 808676 808544

Description

Qty. Req.

ENGINE, JD 4045T . . . . . . . . . . . . 1 RELAY, ENGINE STARTER . . . . . . 1 MOUNT, RELAY . . . . . . . . . . . . . . . 1 Note a Note b SENDER, WATER TEMP . . . . . . . . 1 FUEL LINE TUBE . . . . . . . . . . . . . . 1 SENDER, OIL PRESSURE . . . . . . . 1 ENGINE MOUNT (right) . . . . . . . . . 1 ENGINE MOUNT (left) . . . . . . . . . . 1 M16-2X35M BOLT GR8.8 . . . . . . . . 4 5/8”-11X3-1/2” BOLT . . . . . . . . . . . . 2 MOUNT, VIBRATION ISOLATOR . . 2 WASHER, ISOLATOR MOUNT. . . . 2 5/8”-11 NYLON INSERT NUT . . . . . 2 ADAP, M18 -6NPTF STR . . . . . . . . 2 SHUTOFF, MANUAL/WATER . . . . . 1 STEM, HOSE . . . . . . . . . . . . . . . . . 1 FAN BELT . . . . . . . . . . . . . . . . . . . . 1 Note a Note b ADAP, M18 10 BEAD STR . . . . . . . 1 BRACKET, ALTERNATOR. . . . . . . . 1 BRACKET, THROTTLE . . . . . . . . . 1 COUPLER, ROD TO CABLE . . . . . 1 #10-32 NUT . . . . . . . . . . . . . . . . . . 2 ROD, THROTTLE EXTEND . . . . . . 1 BALL JOINT #10-32 . . . . . . . . . . . . 1 #10-32 NUT . . . . . . . . . . . . . . . . . . 1

ETHER KIT

--

CLAMP

OPTIONAL

--

Ref. No.

Part No.

00

808798

-- ITEMS NOT SHOWN -ENGINE BLOCK HEATER (opt.). . . 1

00b

808717

(Throttle Cable) CABLE, THROTTLE . . . . . . . . . . . . 1

00a

808098

(Electrical) HARNESS, TIER II . . . . . . . . . . . . . 1

00

808322

00d

808913

00

808925

00 00 00

809204 809109 808298

a

When equipped with a 115 HP Tier II engine. (equipped with an electronic throttle pedal)

b

When equipped with a 99 HP Tier II engine. (equipped with a manual throttle pedal)

c

Replaces item 16 and (1) of item 14.

d

Ether cannister assembly is located on the rightrear side of machine. Thermostat is located on engine block, and switch is located on dash.

e

Used with 99 hp TIER II engine with a manual throttle pedal. For 115 TIER II engine with electronic throttle pedal subsititue Harness mount bracket P/N 808144.

ATOMIZER

THERMOSTAT

VALVE

-

BRACKET

TUBING

FITTING

53

Description

Qty. Req.

(Ether - Optional) HARNESS, ETHER KIT . . . . . . . . . 1 (includes 21” BLU/WHT jumper wire) ETHER KIT (otional) . . . . . . . . . . . . 1 (includes: thermostat, atomizer, valve bracket, fitting, clamp and tubing. Does not include ether canister.)

SWITCH, ROCKER (ether) . . . . . . . 1 (located in dash panel) (Fuel Line) HOSE END, -5 JICF . . . . . . . . . . . . 1 HOSE, 3/8” X 73” (supply). . . . . . . . 1 HOSE, 1/4” X 73” (return) . . . . . . . . 1

TABLE OF CONTENTS

Engine Air Intake Group (1ST MOUNTING) MT6642 - SERIAL NO. 17113 & BELOW MT8044 - SERIAL NO. 18115 & BELOW 5

FRONT

3 1

4

2

6

10 12 13 7 8 16 11 14 10

15

13

9

17

54

TABLE OF CONTENTS

Engine Air Intake Group (1ST MOUNTING) Ref. No.

Part No.

00

808425

01 02

808001 809205 809206 809069 809070 NSS NSS 808952 808426 808603 808555 808781 808782

03 04 05 06 07

08 09

Description

Qty. Req.

Ref. No.

AIR CLEANER ASY. . . . . . . . . . . . .1 (Includes 1-6 & 11) ELEMENT . . . . . . . . . . . . . . . . . . . .1 WINGBOLT . . . . . . . . . . . . . . . . . . .1 RUBBER/STEEL GASKET . . . . . . .1 CLAMP . . . . . . . . . . . . . . . . . . . . . .1 THRUMBSCREW . . . . . . . . . . . . . .1 END CAP . . . . . . . . . . . . . . . . . . . . .1 GASKET . . . . . . . . . . . . . . . . . . . . .1 EVACUATOR . . . . . . . . . . . . . . . . . .1 MOUNTING BAND . . . . . . . . . . . . .2 5/16”-18X3/4” BOLT . . . . . . . . . . .4 5/16”-18 WHIZ LOCK NUT . . . . . .4 INLET HOOD/CAP . . . . . . . . . . . . .1 90o RUBBER ELBOW, 4” DIA. . . . .1

55

Part No.

10 11

808659 NSS

12 13 14 15 16 17

808473 808655 809207 808157 808840 808427

00 00

808836 808837

Description

Qty. Req.

ADJUST. CLAMP, #72 . . . . . . . . . . .3 HOUSING . . . . . . . . . . . . . . . . . . . .1 (Included with item 00) STR. RUBR. ADAPTER 4” TO 3” . .1 ADJUST. CLAMP, #52 . . . . . . . . . . .3 ADJUST. CLAMP, #44 . . . . . . . . . . .1 BRACKET . . . . . . . . . . . . . . . . . . . .1 INTAKE TUBE . . . . . . . . . . . . . . . . .1 90o RUBBER ELBOW, 3” DIA. . . . .1

-- ITEMS NOT SHOWN -PRE-CLEANER (opt.) . . . . . . . . . . . 1 REDUCER 4”-3” (opt.). . . . . . . . . . . 1 (used with pre-cleaner 808836)

TABLE OF CONTENTS

Engine Air Intake Group (2ND MOUNTING) MT6642 - SERIAL NO. 17114 & UP MT8044 - SERIAL NO. 18116 & UP

56

TABLE OF CONTENTS

Engine Air Intake Group (2ND MOUNTING) Ref. No.

Part No.

00

809278

01 02 03 04 05 06 07 08 09

NSS 809279 808066 808067 NSS 809282 808781 808659 809280

Description

Qty. Req.

AIR CLEANER ASSEMBLY. . . . . . .1 (Includes 1-5) END CAP. . . . . . . . . . . . . . . . . . . .1 EJECTOR/DUST . . . . . . . . . . . . . .1 ELEMENT, PRIMARY . . . . . . . . . . .1 ELEMENT, SECONDARY . . . . . . . .1 HOUSING, AIR CLEANER . . . . . . .1 CLAMP, AIR CLEANER MOUNT . .1 INLET HOOD/CAP . . . . . . . . . . . . .1 ADJUST. CLAMP, #72 . . . . . . . . .AR REDUCER, 3.84” - 3.25” . . . . . . . .1

Ref. No.

Part No.

10 11 12 13 14

808655 809281 809283 808840 808157

15

808427

16 17 18

57

Description

Qty. Req.

CLAMP, #52 SAE . . . . . . . . . . . . AR INDICATOR, RESTRICTION 30in. .1 ADAPTER, RUBBER W/TAP . . . . 1 INTAKE TUBE . . . . . . . . . . . . . . . 1 BRACKET . . . . . . . . . . . . . . . . . . 1 90o RUBBER ELBOW, 3” DIA. . . . 1

-- OPTIONAL PRECLEANER -809284 REDUCER, 4” - 3” . . . . . . . . . . . . 1 808782 90o RUBBER ELBOW, 4” DIA. . . . 1 809285 PRECLEANER . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Engine Exhaust Group

FRONT 2 1 3

4 5

11 11

9

6 8

10 7

58

TABLE OF CONTENTS

Engine Exhaust Group Ref. No. 01 02 03 04 05 06

Part No. 808839 809131 808785 808777 808428 808765

Description

Qty. Req.

EXHAUST PIPE WELDMENT . . . .1 TURBO CLAMP . . . . . . . . . . . . . . . .1 TAIL PIPE . . . . . . . . . . . . . . . . . . . .1 HANGER . . . . . . . . . . . . . . . . . . . . .1 CLAMP, 2-1/2” . . . . . . . . . . . . . . . . .1 BRACKET . . . . . . . . . . . . . . . . . . . .1

Ref. No.

Part No.

07

808684 808617 808592 808663 808595 809208 808778 808678

08 09 10 11

59

Description

Qty. Req.

STRAP . . . . . . . . . . . . . . . . . . . . . . .1 3/8”-16X1” BOLT . . . . . . . . . . . . . .1 3/8” FLAT WASHER . . . . . . . . . . . .1 3/8”-16 NYLON INSERT NUT . . . .1 3/8” FLAT WASHER . . . . . . . . . . . .2 M12-1.75X30 C8 BOLT . . . . . . . . . .2 MUFFLER . . . . . . . . . . . . . . . . . . . .1 CLAMP 3” . . . . . . . . . . . . . . . . . . . .2

TABLE OF CONTENTS

Engine Radiator/Coolers Group

FRONT

LEFT 9

8

4 1

7

6

5

13

10

2 14

11

30

12

3

2

15 22 24 29

28

16 10

17 18

19 26

27 20 21

23

10 25

24

22

60

2

RIGHT

TABLE OF CONTENTS

Engine Radiator/Coolers Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

Part No. 808640 808590 808467 808256 808671 808468 808106 808948 808838 808947 808806 808815 808726 808603 809209 808602 809210 808841

Description

Qty. Req.

Ref. No.

5/16”-18X1” BOLT . . . . . . . . . . . .AR 5/16” FLAT WASHER . . . . . . . . . .AR OIL COOLER . . . . . . . . . . . . . . . . . .2 MOUNT, TOP HOOD . . . . . . . . . . . .1 5/16” NUT RETAINING CLIP . . . .AR RADIATOR . . . . . . . . . . . . . . . . . . .1 CAP, RADIATOR 10LB. . . . . . . . . . .1 HOSE CLAMP #24 SAE . . . . . . . . . 1 UPPER HOSE . . . . . . . . . . . . . . . . .1 HOSE CLAMP #32 SAE . . . . . . . . .3 FAN . . . . . . . . . . . . . . . . . . . . . . . . .1 FAN SPACER . . . . . . . . . . . . . . . . .1 FAN GUARD (Half) . . . . . . . . . . . . .2 5/16”-18X3/4” BOLT . . . . . . . . . . .AR M8-1.25X45M BOLT . . . . . . . . . . . . 4 5/16”-18X1/2” BOLT . . . . . . . . . . .AR VINYL CLAMP 3/8” HOSE . . . . . . . 2 LOWER HOSE . . . . . . . . . . . . . . . .1

19 20 21 22 23 24 25 26 27 28 29 30

Part No. 808595 808665 809211 808685 808289 808658 808288 808663 808592 809110 808289 808812

Description

Qty. Req.

1/2” FLAT WASHER . . . . . . . . . . . .2 1/2”-13 NYLON INSERT NUT . . . . .2 ADAP, -12JICFS -12JICM 90 DEG .1 ADAP, -16ORM -12JICM . . . . . . . . .2 HOSE -12 A12/DM12 102” . . . . . . .1 ADAP, -16ORM -16JICM 90 DEG . .2 HOSE -16 A16/A16 42” . . . . . . . . . .1 3/8”-16 NYLON INSERT NUT . . . . .2 3/8” FLAT WASHER . . . . . . . . . . . .2 HOSE, -16 A16/A16 20” . . . . . . . . .1 HOSE, -12 A12/DM12 102” . . . . . . .1 FAN SHROUD . . . . . . . . . . . . . . . . .1

-- ITEMS NOT SHOWN -00

808433

RADIATOR DRAIN VALVE . . . . . . . 1

HOSE LOCATOR 23 25 28 29

TRANSMISSION COOLER “LOWER” HYDRAULIC COOLER “LOWER” HYDRAULIC COOLER “UPPER” TRANSMISSION COOLER “UPPER”

TRANSMISSION (left side - just under hyd. pump) MAIN VALVE “OUT” BULKHEAD (connects hyd. tube to in-tank hyd. filter) TRANSMISSION (top right side - near filter)

61

TABLE OF CONTENTS

Transmission External Components Group

FRONT

7 5

RIGHT

3

6 8

4

2

10 16

9

1

18 10 17

11 12

21 20

13

11

10

19

13

14

24

10 15 11 23

16 22

17

11

LEFT 18

21 20 19

62

TABLE OF CONTENTS

Transmission External Components Group Ref. No. 01

Part No.

02 03 04 05 06d 07e 08 09c 10

808842 808452 808289 808447 808004 808828 808636 808144 808650 808641 809107

11a 12 13b

808623 808115 808416

Description

Qty. Req.

SWITCH, PRESSURE. . . . . . . . . . . 1 ADAP, -3ORM (not shown). . . . . . . 1 HOSE, -12 DS12/A12 102” . . . . . . . 1 ADAP, -10ORM -12JICM STR . . . . 1 FILTER, TRANSMISSION OIL . . . . 1 SENDER, TEMP 250 DEGREE . . . 1 M10X1.5X35mm . . . . . . . . . . . . . . . 2 BRACKET, HARNESS MOUNT . . . 1 M10X1.5X25mm . . . . . . . . . . . . . . 10 3/8”-24X2” GRADE 8 BOLT . . . . . . 8 UNIVERSAL JOINT . . . . . . . . . . . . . 4 (includes bolts) 3/8”-24X1-3/4” GR8 BOLT. . . . . . . 16 DRIVESHAFT, REAR . . . . . . . . . . . 1 3/8”-24X1-1/4” GR 8 BOLT . . . . . . . 8

Ref. No.

Part No.

14 15 16 17 18 19 20 21 22 23 24

808593 808461 808289 808615 808111 809212 808664 808749 808744 808235 808114 808442

a b c d e

Description

3/8” LOCK WASHER . . . . . . . . . . . 8 ADAP, -12JICM -12JICFS 90 DEG . 1 HOSE, -12 DM12/A12 102”. . . . . . . 1 5/8”-11X3-1/2” BOLT . . . . . . . . . . . . 2 TRANS MOUNT . . . . . . . . . . . . . . . 2 M12X1.75X40mm BOLT . . . . . . . . . 4 5/8”-11 NYLON INSERT NUT . . . . . 2 WASHER, ISOLATOR MOUNT. . . . 2 MOUNT, VIBRATION ISOLATOR . . 2 TRANSMISSION, 1106 T12000 . . . 1 DRIVESHAFT, FRONT . . . . . . . . . . 1 ADAP, -12ORM -12JICM STR. . . . . 1

Used to fasten universal joint to transmission and to axle yokes.

Used to fasten universal joint to driveshaft.

Used to fasten flex plate to flywheel.

Used to fasten wire harness bracket to transmission Used with 115 hp TIER II engine with electronic throttle pedal. For 99 hp TIER II engine with manual throttle pedal subsititue Throttle cable bracket P/N 808813.

HOSE LOCATOR 02 15

TRANSMISSION (top right side - near filter) TRANSMISSION (left side - just under hyd. pump)

TRANSMISSION COOLER “UPPER” TRANSMISSION COOLER “LOWER”

63

Qty. Req.

TABLE OF CONTENTS

Transmission Converter Housing Group

14 5 6 1

7 4

2 3

11 9 13 11

12 13 8

10

15

11 3

12

2

64

TABLE OF CONTENTS

Transmission Converter Housing Group Ref. No.

Part No.

01 02

809120 NSS

03

809118

04 05

809213 NSS

06

809118

Description

Qty. Req.

Ref. No.

HOUSING/CONVERTER . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 4 (includes item 3) O-Ring/Plug . . . . . . . . . . . . . . . . . . . 4 (part of item 2) PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 (includes item 6) O-Ring/Plug . . . . . . . . . . . . . . . . . . . 1 (part of item 5)

07 08 09 10 11 12 13 14 15

65

Part No. 809115 809119 809214 809215 809096 809214 809096 809078 809216

Description

Qty. Req.

PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 SCREW . . . . . . . . . . . . . . . . . . . . . . 6 SCREW . . . . . . . . . . . . . . . . . . . . . . 3 SCREW . . . . . . . . . . . . . . . . . . . . . . 1 WASHER/LOCK . . . . . . . . . . . . . . 10 SCREW . . . . . . . . . . . . . . . . . . . . . 13 WASHER/LOCK . . . . . . . . . . . . . . 13 GASKET/HSG. TO PLATE. . . . . . . . 1 PLUG/TEMP PICKUP . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Case and Plate Group

7

31 29

28

24 10

30

25

27 13 36

12 31

21 19

17 29

18

30 11

15

2

16

23 14 21

18 20 19

17 6

33

3 4 26

32

22 35 34

1

8

9 5

66

TABLE OF CONTENTS

Transmission Case and Plate Group Ref. No.

Part No.

01 02 03

NSS 808953 809217

04

809095

05 06 07 08 09 10 11 12 13 14 15 16 17 18

809114 809075 809074 808968 808966 808328 809077 809076 808992 808988 808987 809213 NSS 809118

Description

Qty. Req.

Ref. No.

CASE-TRANSMISSION . . . . . . . . . 1 BREATHER/AIR . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2 (includes item 4) O-RING/PLUG . . . . . . . . . . . . . . . . . 2 (part of item item 3) PLUG/MAGNETIC DRAIN. . . . . . . . 1 PIN/DOWEL PLATE TO CASE . . . . 2 GASKET/PLATE TO CASE . . . . . . . 1 RING/TUBE SEAL. . . . . . . . . . . . . . 1 CLIP/OIL TUBE RETAINER . . . . . . 1 PLATE, SPACER . . . . . . . . . . . . . . . 1 SEAT/SAFETY VALVE . . . . . . . . . . 1 SNAP RING . . . . . . . . . . . . . . . . . . . 1 POPPET/SAFETY VALVE . . . . . . . . 1 SPRING . . . . . . . . . . . . . . . . . . . . . . 1 WASHER/POPPET . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 3 O-RING/PLUG . . . . . . . . . . . . . . . . . 3

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

67

Part No. 809218 809099 809096 808967 809219 809213 809115 809220 809071 809072 809121 809125 809122 809119 809123 809124 809221

Description

Qty. Req.

SCREW . . . . . . . . . . . . . . . . . . . . . . 7 SCREW . . . . . . . . . . . . . . . . . . . . . . 2 WASHER/LOCK . . . . . . . . . . . . . . . 9 ASSY/TUBE & SCREEN . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 TUBE/TRANS DIPSTICK . . . . . . . . 1 TRANS DIPSTICK TUBE . . . . . . . . 1 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 SCREW . . . . . . . . . . . . . . . . . . . . . . 2 SCREW . . . . . . . . . . . . . . . . . . . . . . 1 WASHER/SEAL . . . . . . . . . . . . . . . . 1 WASHER/SCREW. . . . . . . . . . . . . . 1 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Torque Converter Group

7

8

13

10

11 13 6 9

3 1 4

14

12 2 16

5 6

15

68

TABLE OF CONTENTS

Transmission Torque Converter Group Ref. No. 01 02 03 04 05 06 07 08

Part No. 808979 808980 808973 808977 808978 808976 808971 809126

Description

Qty. Req.

Ref. No.

ASSY/STATOR SUPPORT . . . . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 1 BEARING/FRONT . . . . . . . . . . . . . . 1 RING/PISTON . . . . . . . . . . . . . . . . . 1 EXPANDER/RING . . . . . . . . . . . . . . 1 RING/SNAP . . . . . . . . . . . . . . . . . . . 2 SEAL/OIL CONV. HSG. . . . . . . . . . . 1 ASSY/TORQUE CONVERTER . . . . 1

09 10 11 12 13 14 15 16

69

Part No. 808969 808956 808957 808975 808970 808981 808974 808972

Description

Qty. Req.

PLUG/BORE . . . . . . . . . . . . . . . . . . 1 O-RING/BORE PLUG . . . . . . . . . . . 1 RING/RET. BORE PLUG. . . . . . . . . 1 IMPELLER/HUB GEAR . . . . . . . . . . 1 SNAP RING/IMPELLER HUB . . . . . 2 WASHER/HUB GEAR . . . . . . . . . . . 1 BEARING/TORQUE CONVERTER. 1 RING/OIL DISTRIBUTOR . . . . . . . . 1

TABLE OF CONTENTS

Transmission Gear Group 13 12 11

9

5

10 6

4

1 3

2

15

7 14 8

16

70

TABLE OF CONTENTS

Transmission Gear Group Ref. No.

Part No.

01

NSS

02

809014

03

809015

04

NSS

05

809014

06

809015

07

808508

Description

Qty. Req.

Ref. No.

ASSY/REV. GEAR & BEARING . . . 1 (includes ittems 2 and 3) BEARING/NEEDLE . . . . . . . . . . . . . 2 (part of item 1) SPACER/CLUTCH GEAR . . . . . . . . 1 (part of item 1) ASSY/FOR. GEAR & BEARING . . . 1 (includes items 5 and 6) BEARING/NEEDLE . . . . . . . . . . . . . 2 (part of item 4) SPACER/CLUTCH GEAR . . . . . . . . 1 (part of item 4) ASY. 3RD CLUTCH GEAR . . . . . . . 1 (includes item 8)

71

Part No.

08

808536

09

809094

10

809014

11

809025

12

809014

13 14 15 16

809026 809031 809222 808510

Description

Qty. Req.

BEARING-3RD CLUTCH GEAR . . . 2 (part of item 7) 1st CLUTCH GEAR/BRG. ASSY . . . 1 (includes item 9) BEARING/NEEDLE . . . . . . . . . . . . . 2 (part of item 9) 2nd CLUTCH GEAR/BRG. ASSY . . 1 (includes item 12) BEARING/NEEDLE . . . . . . . . . . . . . 2 (part of item 11) GEAR/THIRD DRIVEN - 18T . . . . . 1 GEAR/OUTPUT SHAFT - 40T . . . . 1 GEAR/REVERSE IDLER - 28T . . . . 1 GEAR/FIRST DRIVEN - 27T . . . . . . 1

TABLE OF CONTENTS

Transmission Pump Drive Group

7

5

6 1 3

4 6

Ref. No.

2

Part No.

01

809082

02

809083

03

809081

Description

Qty. Req.

Ref. No.

IDLER/SHAFT & PIN. . . . . . . . . . . . 1 (includes item 2) ROLL PIN . . . . . . . . . . . . . . . . . . . . 1 (part of item1) GEAR/IDLER,PUMP DRIVE . . . . . . 1

04 05 06 07

72

Part No. 809080 808982 809079 808983

Description

Qty. Req.

BEARING/IDLER GEAR . . . . . . . . . 1 GEAR/DRIVE. . . . . . . . . . . . . . . . . . 1 WASHER/THRUST . . . . . . . . . . . . . 2 RING/SNAP . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Charge Pump Group

14

13

15 1

16 12 17 11 6 7

10

8

4

2

5

9 3

Ref. No.

Part No.

01 02 03 04 05 06 07

808990 808004 809088 809086 809087 808991 809085

08

808985

Description

Qty. Req.

Ref. No. 09 10 11 12 13 14 15 16 17

PUMP/T12000 CHARGE. . . . . . . . . 1 ASSY/ HYDRAULIC SPIN FILTER . 1 SLEEVE. . . . . . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 SPRING . . . . . . . . . . . . . . . . . . . . . . 1 PIN/CLARK TRANS. . . . . . . . . . . . . 1 ASSY/BALL CHECK VALVE . . . . . . 1 (includes items 8 thru 11) BALL . . . . . . . . . . . . . . . . . . . . . . . . 1

73

Part No. 808986 808984 809084 808989 809223 809224 809225 809226 809096

Description

Qty. Req.

SPRING . . . . . . . . . . . . . . . . . . . . . . 1 PIN. . . . . . . . . . . . . . . . . . . . . . . . . . 1 O-RING . . . . . . . . . . . . . . . . . . . . . . 1 GASKET/CHARGE PUMP . . . . . . . 1 SCREW . . . . . . . . . . . . . . . . . . . . . . 4 SCREW . . . . . . . . . . . . . . . . . . . . . . 1 WASHER/LOCK . . . . . . . . . . . . . . . 5 SCREW . . . . . . . . . . . . . . . . . . . . . . 1 WASHER/LOCK . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Reverse Idler Group

6 7 5 9

8

3 4

1 2

74

TABLE OF CONTENTS

Transmission Reverse Idler Group Ref. No. 01 02 03 04

Part No. 808994 808993 808996 808995

Description

Qty. Req.

Ref. No. 05 06 07 08

SHAFT IDLER & PILOT . . . . . . . . . 1 RING/SNAP . . . . . . . . . . . . . . . . . . . 1 BEARING/REV IDLR GEAR . . . . . . 1 WASHER/THRUST . . . . . . . . . . . . . 1

75

Part No. 808997 809227 809228 808998

Description

Qty. Req.

END PLATE . . . . . . . . . . . . . . . . . . . 1 CAPSCREW . . . . . . . . . . . . . . . . . . 1 WASHER . . . . . . . . . . . . . . . . . . . . . 1 END PLATE . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Forward and Reverse Group

21

11

19 20 19 16

12

14

17

11

13 15

17 10 5

8 9

18

7

17

16

16 19 1

6

19 17

7

17

17 6

17

5

20

17 9

3

8 16 10

15 12

22

13

14

2 4

76

TABLE OF CONTENTS

Transmission Forward and Reverse Group Ref. No.

Part No.

01 02 03 04 05

809010 809013 809229 809012 809116

06

809008

07

809009

08 09 10 11

809002 809001 809007 809092

Description

Qty. Req.

Ref. No.

ASY/TURB SHFT DRUM & PLUG . 1 SLEEVE/OIL DISTRIBUTOR. . . . . . 1 SCREW . . . . . . . . . . . . . . . . . . . . . . 1 RING/PISTON . . . . . . . . . . . . . . . . . 3 ASY/PISTON . . . . . . . . . . . . . . . . . . 2 (includes items 6 and 7) SEAL/OUTER PISTON . . . . . . . . . . 2 (part of item 5) SEAL/INNER PISTON . . . . . . . . . . . 2 (part of item 5) PLATE/END . . . . . . . . . . . . . . . . . . . 2 RING/SNAP . . . . . . . . . . . . . . . . . . . 2 PLATE/WEAR . . . . . . . . . . . . . . . . . 2 ASY/DISC SPRING Pkg 5. . . . . . . . 2

77

Part No.

12 13 14 15 16 17 18 19 20 21

809006 809005 809004 809003 809000 808999 809011 809014 809015 809230

22

809231

Description

Qty. Req.

RETAINER. . . . . . . . . . . . . . . . . . . . 2 RETAINER/SNAP RING . . . . . . . . . 2 CLUTCH/OUTER FWD . . . . . . . . . 12 CLUTCH/INNER FWD. . . . . . . . . . 12 BEARING. . . . . . . . . . . . . . . . . . . . . 4 WASHER/THRUST . . . . . . . . . . . . . 8 BEARING/REAR . . . . . . . . . . . . . . . 1 BEARING/CLUTCH GEAR . . . . . . . 4 SPACER/CLUTCH GEAR . . . . . . . . 2 ASSY/REV. AND BRG. . . . . . . . . . . 1 (includes items 19 and 20) ASSY/FOR. GEAR AND BRG. . . . . 1 (includes items 19 and 20)

TABLE OF CONTENTS

Transmission Third Shaft Group

10

1

21

24 4 3

12 7

5

11

6 17

18

16 2 21 15

20 19

8 20

9 22 23 19

20

20 21 14 13

78

22

TABLE OF CONTENTS

Transmission Third Shaft Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12

Part No. 808511 808512 808503 809232 809017 809016 809012 809117 809008 809009 809004 809003

Description

Qty. Req.

Ref. No.

ASY-3RD SHAFT, DRUM & PLUG . 1 BEARING-ROLLER . . . . . . . . . . . . . 1 ASSY/BEARING & SEAL . . . . . . . . 1 WASHER-BEARING SUPPORT . . . 1 SLEEVE/OIL DISTRIBUTOR. . . . . . 1 SCREW/SLEEVE LOCK . . . . . . . . . 1 RING/PISTON . . . . . . . . . . . . . . . . . 2 ASSY/CLTCH PISTON & BALL. . . . 1 SEAL/OUTER PISTON . . . . . . . . . . 1 SEAL/INNER PISTON . . . . . . . . . . . 1 CLUTCH/OUTER FWD . . . . . . . . . . 5 CLUTCH/INNER FWD. . . . . . . . . . . 5

13 14 15 16 17 18 19 20 21 22 23 24

79

Part No. 809002 809001 809007 809092 809006 809005 808513 808514 809132 808509 808508 808509

Description

Qty. Req.

PLATE/END . . . . . . . . . . . . . . . . . . . 1 RING/SNAP . . . . . . . . . . . . . . . . . . . 1 RING/SNAP . . . . . . . . . . . . . . . . . . . 1 ASY/DISC SPRG PKG 5. . . . . . . . . 1 RETAINER. . . . . . . . . . . . . . . . . . . . 1 RETAINER/SNAP RING . . . . . . . . . 1 BEARING-THRUST NEEDLE . . . . . 2 WASHER/CLTCH GEAR THRUST . 4 RING/SNAP . . . . . . . . . . . . . . . . . . . 3 BEARING-3RD CLUTCH GEAR . . . 2 ASY. 3RD CLUTCH GEAR . . . . . . . 1 GEAR-FIRST DRIVEN . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission First and Second Shaft Group

25 12 24 13

15 3

20

14 13

4

18

16 11 19 10

21 8

5

27

9 15

7

17

1 16 16

6

7

24

26

6

15

16

5 10 9 8

15 23 22 14

2

80

TABLE OF CONTENTS

Transmission First and Second Shaft Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

Part No. 809023 809024 808503 809012 809098 809008 809009 809002 809001 809007 809092 809093 809006 809005 809000

Description

Qty. Req.

Ref. No.

ASY-1ST 2ND SHAFT . . . . . . . . . . . 1 BEARING/REAR . . . . . . . . . . . . . . . 1 ASSY/BEARING & SEAL . . . . . . . . 1 RING/PISTON . . . . . . . . . . . . . . . . . 2 PISTON/CLUTCH & SEALS . . . . . . 2 SEAL/OUTER PISTON . . . . . . . . . . 2 SEAL/INNER PISTON . . . . . . . . . . . 2 PLATE/END . . . . . . . . . . . . . . . . . . . 2 RING/SNAP . . . . . . . . . . . . . . . . . . . 2 PLATE/WEAR . . . . . . . . . . . . . . . . . 2 ASSY/DISC SPRG PKG 5 . . . . . . . 1 SPRING/DISC ASSY PKG (7). . . . . 1 RETAINER. . . . . . . . . . . . . . . . . . . . 2 RETAINER/SNAP RING . . . . . . . . . 2 BEARING. . . . . . . . . . . . . . . . . . . . . 4

81

Part No.

16 17 18 19 20 21 22 23 24 25

808999 809018 809022 809016 809004 809003 809004 809003 809014 809094

26

809025

27

809026

Description

Qty. Req.

WASHER/THRUST . . . . . . . . . . . . . 8 RING/SNAP . . . . . . . . . . . . . . . . . . . 2 SLEEVE/OIL DISTRIBUTOR. . . . . . 1 SCREW/SLEEVE LOCK . . . . . . . . . 1 CLUTCH/OUTER FWD . . . . . . . . . 10 CLUTCH/INNER FWD. . . . . . . . . . 10 CLUTCH/OUTER FWD . . . . . . . . . . 5 CLUTCH/INNER FWD. . . . . . . . . . . 5 BEARING/CLUTCH GEAR . . . . . . . 4 1ST CLUTCH GEAR/BRG ASSY . . 1 (includes item 24) 2ND CLUTCH GEAR/BRG ASSY . . 1 (includes item 24) GEAR/3RD DRIVEN . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Output Shaft Group

7 6 2 3 5 4 6 1

8 9

6 4 3 2 6

82

5

TABLE OF CONTENTS

Transmission Output Shaft Group Ref. No. 01 02 03 04 05

Part No. 808504 809030 809029 809021 808954

Description

Qty. Req.

Ref. No.

SHAFT/OUTPUT . . . . . . . . . . . . . . . 1 BEARING/SHAFT . . . . . . . . . . . . . . 2 SLEEVE/OIL SEAL . . . . . . . . . . . . . 2 O-RING/SLEEVE. . . . . . . . . . . . . . . 2 SEAL/OUTPUT SHAFT OIL . . . . . . 2

06 07 08 09

83

Part No. 809019 809020 809028 809027

Description

Qty. Req.

RING/SNAP . . . . . . . . . . . . . . . . . . . 4 RING/SNAP . . . . . . . . . . . . . . . . . . . 2 FLANGE/OUTPUT & PLUG ASSY . 1 PLUG/FLANGE . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Transmission Control Group

5

4

3

2 1 10 12 11

9

8

7 6

84

TABLE OF CONTENTS

Transmission Control Group Ref. No.

Part No.

01

808329

02

808330

03

808331

04

808332

05

808333

06

808334

Description

Qty. Req.

Ref. No.

SOLENOID, W / DEUTSCH CON. . 4 (includes items 2 thru 5) O-RING, 21.5 X 1.5MM . . . . . . . . . . 4 (included with item 1) O-RING, 15.1 X 1.60MM . . . . . . . . . 4 (included with item 1) O-RING, 14.1 X 1.60MM . . . . . . . . . 4 (included with item 1) O-RING, 12.1 X 1.60MM . . . . . . . . . 4 (included with item 1) PLUG, SOLENOID BORE . . . . . . . . 1 (includes items 7, 8 and 9)

85

Part No.

07

808335

08

808331

09

808333

10 11 12

808336 808337 808338

Description

Qty. Req.

O-RING, 18.0 X 2.20MM . . . . . . . . . 1 (included with item 6) O-RING, 15.1 X 1.60MM . . . . . . . . . 1 (included with item 6) O-RING, 12.1 X 1.60MM . . . . . . . . . 1 (included with item 6) CLAMP, SOLENOID . . . . . . . . . . . . 6 CAPSCREW . . . . . . . . . . . . . . . . . 12 WASHER, PLAIN. . . . . . . . . . . . . . 12

TABLE OF CONTENTS

Transmission Drive Plate Group

1

2 6

2

3

5 4

Ref. No.

Part No.

01

NSS

02

NSS

03

809044

Description

Qty. Req.

Ref. No.

ASSY/DRIVE PLATE . . . . . . . . . . . . 1 (included in item 6) DRIVE PLATE . . . . . . . . . . . . . . . . . 2 (included in item 6) RING/DRIVE PLATE BACKING . . . 1

04 05 06

86

Part No. 809133 809097 809045

Description

Qty. Req.

SCREW/DRIVE PLATE MNTG . . . . 6 LOCKWASHER/DRIVEPLATE . . . . 6 KIT/DRIVE PLATE ASSY . . . . . . . . 1 (includes items 1 thru 5)

TABLE OF CONTENTS

Transmission Modulation Valve Group

1 7 2 8 3

9 10

4

11 5 15

12

6

13 14

Ref. No. 01 02 03 04 05 06 07 08

Part No. 809032 809033 809035 809036 809042 809037 809043 809034

Description

Qty. Req.

Ref. No.

HOUSING MODULATOR VALVE . . 1 O-RING . . . . . . . . . . . . . . . . . . . . . . 1 SPRING INNER. . . . . . . . . . . . . . . . 1 SPRING MIDDLE . . . . . . . . . . . . . . 1 SPRING OUTER . . . . . . . . . . . . . . . 1 SLEEVE-MODULATION VALVE . . . 1 O-RING . . . . . . . . . . . . . . . . . . . . . . 1 PIN STOP . . . . . . . . . . . . . . . . . . . . 1

09 10 11 12 13 14 15

87

Part No. 809041 809091 809038 809040 809039 809089 809090

Description

Qty. Req.

SPOOL ACCUMULATOR . . . . . . . . 1 SPOOL . . . . . . . . . . . . . . . . . . . . . . 1 SPRING . . . . . . . . . . . . . . . . . . . . . . 1 RETAINER. . . . . . . . . . . . . . . . . . . . 1 SPACER . . . . . . . . . . . . . . . . . . . . . 1 PIN-UPPER . . . . . . . . . . . . . . . . . . . 1 PIN-LOWER . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Axles External Components

2 3

FRONT 1

LEFT

4

AXLE MODEL AND

5

SERIAL NUMBER PLATE

6

7 10 8 9

11 22

RIGHT

23

Driveshaft info found in transmission section 21 14 15 14

20 13

12 Front axle (shown)

Located on rear axle 16 19 18 17

88

TABLE OF CONTENTS

Axles External Components Ref. No.

Part No.

Qty. Req.

Ref. No.

Part No.

808472 809233

TIRE. . . . . . . . . . . . . . . . . . . . . . . . . 4 13.00X24 13.00X24 (Rock)

808607 809164 808075 808559 808643 808180 808165 808599 808634 808109 808876

3/8”-16 BUTTON HD BOLT . . . . . . . 6 FENDER . . . . . . . . . . . . . . . . . . . . . 1 FENDER MOUNT (LF/RR) . . . . . . . 1 3/8”-16 FLANGE LOCK NUT . . . . . 4 3/8”-16X1-3/4” BOLT . . . . . . . . . . . . 4 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 4 MOUNT (LF/RR) . . . . . . . . . . . . . . . 1 M20-2.5 CLASS 10 LOCK NUT . . . 4 3/4”-10X9” GR8 BOLT . . . . . . . . . . . 8 FRAME LEVEL MNT (front axle). . . 1 M22-1.5 WHEEL NUT . . . . . . . . . AR

13 14 15 16 17 18 19 20 21 22 23b

808583 809199 808418 808553 808554 809046 808543 808552 808118 809234

01

02a 03a 04a 05a 06a 07a 08a 09 10 11 12

Description

808107 808108 a b

89

Description

Qty. Req.

3/4”-10 GR8 LOCK NUT . . . . . . . . . 8 PLATE, MOUNT . . . . . . . . . . . . . . . 2 M20-2.50X130 C10.9 BOLT . . . . . . 4 THRUST BUSHING. . . . . . . . . . . . . 2 SUPPORT . . . . . . . . . . . . . . . . . . . . 2 GREASE FITTING. . . . . . . . . . . . . . 2 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2 REDUCTION BUSING . . . . . . . . . . 4 STABILIZER MOUNT (rear axle). . . 1 WHEEL RIM 24X9.00 . . . . . . . . . . . 4 AXLE ASSEMBLY, 212 HY . . . . . . .

FRONT (with internal park brake) . . 1 REAR. . . . . . . . . . . . . . . . . . . . . . . . 1

Available only on the left side of the front axle.

Does not include any other items shown in illustration.

TABLE OF CONTENTS

Axles Brake and Steering Lines Group FRONT 4 2 SERVICE BRAKE PORT

2 1

6

5

24

PARK BRAKE PORT

3 1

7

FRONT AXLE

19

STEER SELECT VALVE

8 9

A T

11

18 10

16

B

16

17 STEER MOTOR PORT

14

“R”

15

BRAKE MASTER

6

CYLINDER

10

“TEE”

FLOW DIVIDER PORT

“PB”

12 23 2

3

20

SERVICE BRAKE PORT

13 1

21

1

5

BRAKE MANIFOLD

22 BRAKE MASTER CYLINDER

“TEE”

REAR AXLE

RIGHT 8

8 25

LEFT

15

9

90

14

9

TABLE OF CONTENTS

Axles Brake and Steering Lines Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13

Part No. 808804 808679 809173 808884 808281 808278 808884 808076 808459 808287 808286 808279 808884

Description

Qty. Req.

ADAP, M14X1.5ORM -6JICM . . . . . 6 ADAP, -6JICFS -6JICM 90 . . . . . . . 3 ADAP, -6 SWIVEL TEE . . . . . . . . . . 3 HOSE, -4 A6/A6 25” . . . . . . . . . . . . 1 HOSE, -4 A6/A4 66” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 57” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 25” . . . . . . . . . . . . 1 ADAP, M18 ORM - 8JICM STR. . . . 4 ADAP, -8JICFS -8JICM 90 . . . . . . . 4 HOSE, -6 A6/A8 48” . . . . . . . . . . . . 1 HOSE, -6 A8/DS8 82” . . . . . . . . . . . 1 HOSE, -4 A4/A6 90” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 25” . . . . . . . . . . . . 1

91

Ref. No.

Part No.

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

808885 808885 808455 808443 808126 808877 808905 808457 808280 808656 808107 808108

Description

Qty. Req.

HOSE, -6 A6/A8 100” . . . . . . . . . . . 1 HOSE, -6 A6/A8 100” . . . . . . . . . . . 1 ADAP, -6ORM -6JICM 90 DEG . . . . 2 ADAP, -6ORM -6JICM STR. . . . . . . 2 FLOW DIVIDER VALVE . . . . . . . . . 1 VALVE, STEER SELECT . . . . . . . . 1 MANIFOLD, BRAKE LINE. . . . . . . . 1 ADAP, -4ORM -4JJICM STR . . . . . . 1 HOSE, -4 A4/A4 38” . . . . . . . . . . . . 1 ADAP, -4ORM -4JICM 90 DEG . . . . 1 AXLE, FRONT (w/ int. park brake) . 1 AXLE, REAR . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Axles Steering and Center Housing / Front and Rear Axle

9

11

10

1 2 8

11

1 3

4

5 6 7

12

1

16

13 15 14

92

TABLE OF CONTENTS

Axles Steering and Center Housing / Front and Rear Axle Ref. No.

01 02 03 04 05 06 07 08

Part No.

Description

Qty. Req.

Ref. No.

NOTE: All quantities are per axle 809057 O-RING . . . . . . . . . . . . . . . . . . . . . . 3 808515 INTERMEDIATE COVER . . . . . . . . 1 809235 HOUSING . . . . . . . . . . . . . . . . . . . . 1 808168 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 808516 VENT . . . . . . . . . . . . . . . . . . . . . . . . 1 808169 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 808170 MAGNETIC PLUG. . . . . . . . . . . . . . 1 809050 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 1

09 10 11 12 13 14 15 16

93

Part No. 808551 808171 808172 808552 808553 808554 809046 808543

Description

Qty. Req.

CYLINDER BOLT . . . . . . . . . . . . . . 4 CYLINDER. . . . . . . . . . . . . . . . . . . . 1 ARTICULATED TIE ROD . . . . . . . . 2 REDUCTION BUSHING . . . . . . . . . 4 THRUST BUSHING. . . . . . . . . . . . . 2 SUPPORT . . . . . . . . . . . . . . . . . . . . 2 GREASE FITTING. . . . . . . . . . . . . . 2 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2

TABLE OF CONTENTS

Axles Differential / Front and Rear Axle

8

7

24 11

6

13 5

12 14

24

4

3

12

11

13

13

24 14

16

11 16

11 12

18

7 10

12

9 24

20

15

22

4 5

1

17 2 19 21 23

94

TABLE OF CONTENTS

Axles Differential / Front and Rear Axle Ref. No.

01 02

03

04 05 06 07 08 09 10 11

Part No.

Description

Qty. Req.

Ref. No.

NOTE: All quantities are per axle 808517 O-RING . . . . . . . . . . . . . . . . . . . . . . 1 808518 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 808519 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 808520 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 808521 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 BEVEL GEAR SET . . . . . . . . . . . . . 1 808173 (Front Axle) . . . . . . . . . . . . . . . . . . . 1 808174 (Rear Axle). . . . . . . . . . . . . . . . . . . . 1 809051 TAPER ROLLER BEARING . . . . . . 2 808522 RING NUT . . . . . . . . . . . . . . . . . . . . 2 808523 CYLINDER BOLT . . . . . . . . . . . . . . 4 808524 CYLINDER BOLT . . . . . . . . . . . . . . 2 808525 BOLT . . . . . . . . . . . . . . . . . . . . . . . 12 808526 FRICTION WASHER . . . . . . . . . . . . 2 808527 DIFFERENTIAL SIDE GEAR . . . . . 2 808528 PIN. . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 13 14 15 16 17

18 19 20 21 22 23 24

95

Part No. 808529 808530 808531 808532 809236 809055 809056 808533 808534 808535 809054 809053 809052 808300 808536 808537

Description

Qty. Req.

CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 4 FRICTION WASHER . . . . . . . . . . . . 4 DIFFERENTIAL PINION . . . . . . . . . 4 DIFFERENTIAL CARRIER . . . . . . . 1 TAPER ROLLER BEARING . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 1 SPACER . . . . . . . . . . . . . . . . . . . . . 1 RING NUT . . . . . . . . . . . . . . . . . . . . 1 SEAL . . . . . . . . . . . . . . . . . . . . . . . . 1 COVER PLATE . . . . . . . . . . . . . . . . 1 FLANGE . . . . . . . . . . . . . . . . . . . . . 1 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 1 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 4

TABLE OF CONTENTS

Axles Outer End / Front and Rear Axle

44

9

3 51

4

46 5

1

42

8 7

52

10

50 15

16 17 18 43

2 45

11 6

20 13

25

23 22, 26

5 46

24

12 29

27 28

30 31 28

47 21 20

19 17 40

14 16

49 32 33

41

38 39

34

53

35 37 25

48 36

96

TABLE OF CONTENTS

Axles Outer End / Front and Rear Axle Ref. No.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part No.

Description

Qty. Req.

Ref. No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

NOTE: All quantities are per axle 808538 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 2 808175 BOLT . . . . . . . . . . . . . . . . . . . . . . . . 2 808176 AXLE CASE. . . . . . . . . . . . . . . . . . . 2 808178 STUD . . . . . . . . . . . . . . . . . . . . . . . 24 808539 WASHER . . . . . . . . . . . . . . . . . . . . 32 808540 REDUCTION BUSHING . . . . . . . . . 2 (incl. 7, 8, 10 and 42) 808541 SEAL . . . . . . . . . . . . . . . . . . . . . . . . 2 809048 BALL BEARING. . . . . . . . . . . . . . . . 2 809049 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 2 808542 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 808179 JOINT . . . . . . . . . . . . . . . . . . . . . . . 2 808181 THRUST BUSHING. . . . . . . . . . . . . 2 808182 BUSHING . . . . . . . . . . . . . . . . . . . . 2 808525 BOLT . . . . . . . . . . . . . . . . . . . . . . . 12 808313 STUD . . . . . . . . . . . . . . . . . . . . . . . . 8 808543 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 4 809046 GREASE FITTING. . . . . . . . . . . . . . 4 808183 PIVOT PIN . . . . . . . . . . . . . . . . . . . . 2 808184 PIVOT PIN . . . . . . . . . . . . . . . . . . . . 2 808185 DUST EXCLUDER . . . . . . . . . . . . . 4 808186 BEARING. . . . . . . . . . . . . . . . . . . . . 2 808187 STEERING CASE (LF and RR) . . . 1 (includes item 12) 808188 SEAL . . . . . . . . . . . . . . . . . . . . . . . . 2 808170 MAGNET PLUG. . . . . . . . . . . . . . . . 2 808169 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 4 808189 STEERING CASE (RF and LR) . . . 1 (includes item 12)

44 45 46 47 48 49 50 51 52 53

97

Part No. 808190 808191 808192 808193 808194 808195 808196 808197 808198 808546 808316 808547 808548 808199 808200 809050 808201 808202 808203 809057 808204 808205 808141 808206 808876 808177 808180 808314 808315

Description

Qty. Req.

SEAL . . . . . . . . . . . . . . . . . . . . . . . . 2 BEARING. . . . . . . . . . . . . . . . . . . . . 4 WHEEL STUD . . . . . . . . . . . . . . . . 20 WHEEL HUB . . . . . . . . . . . . . . . . . . 2 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 RING GEAR . . . . . . . . . . . . . . . . . . 2 RING GEAR SUPPORT . . . . . . . . . 2 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 6 DIFFERENTIAL PINION . . . . . . . . . 6 COUNTERSUNK BOLT. . . . . . . . . . 4 BEARING. . . . . . . . . . . . . . . . . . . . . 6 STUD . . . . . . . . . . . . . . . . . . . . . . . 20 NUT . . . . . . . . . . . . . . . . . . . . . . . . 20 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 2 LOCKING PLATE . . . . . . . . . . . . . . 2 CIRCLIP. . . . . . . . . . . . . . . . . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 STUD . . . . . . . . . . . . . . . . . . . . . . . . 8 NUT . . . . . . . . . . . . . . . . . . . . . . . . 32 STEERING ADJUST BOLT ASY . . . 4 PLANET GEAR CARRIER . . . . . . . 2 WHEEL NUT . . . . . . . . . . . . . . . . . 20 WASHER . . . . . . . . . . . . . . . . . . . . . 8 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 8 HEXAGON BOLT. . . . . . . . . . . . . . . 4 BEARING. . . . . . . . . . . . . . . . . . . . . 6

TABLE OF CONTENTS

Axles Brakes - Front Axle

1 23

2

22

4

25 26

5

19

10 3

18 6

14

7

8 9 11 21

20 17

12 13 15

16 24

Ref. No.

Part No.

Description

Qty. Req.

Ref. No.

NOTE: All quantities are per axle 01 808207 SPACER . . . . . . . . . . . . . . . . . . . . . 2 02 808208 SPRING . . . . . . . . . . . . . . . . . . . . . . 4 03 808209 PISTON . . . . . . . . . . . . . . . . . . . . . . 2 04 808210 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 05 808211 O-RING . . . . . . . . . . . . . . . . . . . . . . 4 06 808212 BACKUP RING . . . . . . . . . . . . . . . . 4 07 808213 COVER . . . . . . . . . . . . . . . . . . . . . . 2 08 809047 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 09 808214 BACKUP RING . . . . . . . . . . . . . . . . 2 10 808215 PISTON . . . . . . . . . . . . . . . . . . . . . . 2 11 808216 INTERMEDIATE BRAKE DISC . . . . 2 12 808217 SPRING . . . . . . . . . . . . . . . . . . . . . . 6 13 808218 ADJUSTING BOLT . . . . . . . . . . . . . 6 14 808549 BRAKE DISC. . . . . . . . . . . . . . . . . . 8

15 16 17 18 19 20 21 22 23 24

25 26

98

Part No. 808550 808219 808220 808221 808222 808223 808224 809058 808543 808225 808226 808227 808228 808229

Description

Qty. Req.

INTERMEDIATE BRAKE DISC . . . . 8 SPACER . . . . . . . . . . . . . . . . . . . . . 2 BOLT . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTING BOLT . . . . . . . . . . . . . 6 SPRING . . . . . . . . . . . . . . . . . . . . . . 6 NUT . . . . . . . . . . . . . . . . . . . . . . . . . 4 LOCK WASHER . . . . . . . . . . . . . . . 4 BLEEDING BOLT . . . . . . . . . . . . . . 4 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 4 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . 2 BOLT . . . . . . . . . . . . . . . . . . . . . . . . 4 SEAL WASHER . . . . . . . . . . . . . . . . 4

TABLE OF CONTENTS

Axles Brakes - Rear Axle 3 4

1

5 6

2

8

7 19

9

18

10

17

1

16

15 11 14 13 12

Ref. No.

Part No.

Description

Qty. Req.

Ref. No.

NOTE: All quantities are per axle 01 809237 SPACER . . . . . . . . . . . . . . . . . . . . . 2 02 808212 BACK-UP RING. . . . . . . . . . . . . . . . 2 03 808543 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2 04 809058 BLEEDING BOLT . . . . . . . . . . . . . . 2 05 808228 BOLT . . . . . . . . . . . . . . . . . . . . . . . . 2 06 808229 SEAL WASHER . . . . . . . . . . . . . . . . 2 07 809238 PISTON . . . . . . . . . . . . . . . . . . . . . . 2 08 808222 SPRING . . . . . . . . . . . . . . . . . . . . . . 6 09 809239 ADJUSTING BOLT . . . . . . . . . . . . . 6

10 11 12 13 14 15 16 17 18 19

99

Part No. 808549 808219 808550 808218 808217 808216 808214 809047 809240 808211

Description

Qty. Req.

BRAKE DISC. . . . . . . . . . . . . . . . . . 8 SPACER . . . . . . . . . . . . . . . . . . . . . 2 INTERMEDIATE BRAKE DISC . . . . 8 ADJUSTING BOLT . . . . . . . . . . . . . 6 SPRING . . . . . . . . . . . . . . . . . . . . . . 6 INTERMEDIATE BRAKE DISC . . . . 2 BACKUP RING . . . . . . . . . . . . . . . . 2 O-RING . . . . . . . . . . . . . . . . . . . . . . 2 COVER . . . . . . . . . . . . . . . . . . . . . . 2 O-RING . . . . . . . . . . . . . . . . . . . . . . 2

TABLE OF CONTENTS

Boom Outer Boom - Front Section

26

13

27

25

31

32

24 28 30 21 23

1

29

20

16

22

20 19

21 3

20 2

4

22

5

21 18

16 15 17

9

13 10

16

12 11

100

7 8

14

6

TABLE OF CONTENTS

Boom Outer Boom - Front Section Ref. No.

Part No.

01

02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

808119 808122 808902 808800 808590 808669 808624 808587 808799 808662 808559 808668 808916 808890 808906 808663 808642 808606 808696 808692

Description

Qty. Req.

OUTER BOOM WELDMENT . . . . . 1 Used on 42’ boom models Used on 44’ boom models 5/16-18 NUT INSERT . . . . . . . . . . . 2 BOOM ANGLE IND. PLATE . . . . . . 1 5/16” FLAT WASHER . . . . . . . . . . . 2 5/16-18X1” BUTTON HD BOLT. . . . 2 #8X5/8” RND HD MACH SCREW. . 2 #10 LOCK WASHER . . . . . . . . . . . . 2 INCLINOMETER - ANGLE IND. . . . 1 5/16-18 NYLON INSERT NUT . . . . 2 3/8-16 FLARE NUT . . . . . . . . . . . . . 2 3/8-16X1-1/4” BOLT . . . . . . . . . . . . 4 BOOM LIGHT BRACKET (LH) . . . . 1 WORK LIGHT . . . . . . . . . . . . . . . . . 2 LIGHT HARNESS (not shown) 3/8-16 NYLON INSERT NUT . . . . . 4 5/16-18X2” BOLT. . . . . . . . . . . . . . . 2 3/8”-16X3/4” BOLT . . . . . . . . . . . . 16 FLAT-BOLT LOCK . . . . . . . . . . . . . . 4 SLIDE PAD . . . . . . . . . . . . . . . . . . . 2

Ref. No.

Part No.

19 20 21 22 23 24 25 26 27 28 29 30 31 32

808693 808593 808701 808702 808745 808621 808915 808753 808619 808673 808757 808762 808596 Note a

a

Refer to Intermediate Boom - Chain Group for a listing of chain components.

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

101

Description

Qty. Req.

SLIDE PAD . . . . . . . . . . . . . . . . . . . 6 3/8” LOCK WASHER . . . . . . . . . . . 12 1/16”X3”X4” SHIM . . . . . . . . . . . . . . 6 1/8”X3”X4” SHIM . . . . . . . . . . . . . . . 4 3/8” PAD SPACER. . . . . . . . . . . . . . 2 3/8”-16X1-1/4” BOLT . . . . . . . . . . . . 4 BOOM LIGHT BRACKET (RH) . . . . 1 ADJUSTABLE CLEVIS PIN. . . . . . . 3 1/2-20X1-1/4” GRD 8 BOLT . . . . . . 3 3/32X1-1/4” COTTER PIN . . . . . . . . 2 CLEVIS . . . . . . . . . . . . . . . . . . . . . . 1 CHAIN PIN . . . . . . . . . . . . . . . . . . . 1 1/2” LOCK WASHER . . . . . . . . . . . . 3 LEAF CHAIN . . . . . . . . . . . . . . . . . . 3

TABLE OF CONTENTS

Boom Outer Boom - Rear Section

2

14

4

5

3 13

1

12 9

8 10

7

6

2

11 15

FRAME (REAR)

102

TABLE OF CONTENTS

Boom Outer Boom - Rear Section Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808128 808414 808671 808251 808603 808631 808429 808888 808626

Description

Qty. Req.

EXTEND CYLINDER, WELDMENT 1 3/4”-10X3” BOLT GR8 . . . . . . . . . . . 8 5/16” FASTENER, RETAINED . . . . 4 COVER, REAR BOOM . . . . . . . . . . 1 5/16”-18x3/4” BOLT . . . . . . . . . . . . . 4 PIN, COTTER 3/16”X4” . . . . . . . . . . 2 WASHER, THRUST . . . . . . . . . . . . 2 PIN, ROD END . . . . . . . . . . . . . . . . 1 3/4”-10 NYLON INSERT NUTS. . . . 8

Ref. No.

Part No.

10 11 12 13 14 15

808904 808929 808665 808742 808648 808950

a

Refer to Intermediate Boom - Chain Group for a listing of chain components.

103

Description

Qty. Req.

SHIM, TRUNNION. . . . . . . . . . . . . . 1 SWITCH, PROXIMITY. . . . . . . . . . . 1 1/2”-13 NYLON INSERT NUT . . . . . 2 PIN, BOOM . . . . . . . . . . . . . . . . . . . 2 1/2”-13X4” BOLT . . . . . . . . . . . . . . . 2 BEARING, SELF ALIGNING . . . . . . 2

TABLE OF CONTENTS

Boom Outer Boom - Side Cover

4 5

6

4 3

1 2

104

TABLE OF CONTENTS

Boom Outer Boom - Side Cover Ref. No.

Part No.

01

02

808119 808122 808949

Description

Qty. Req.

OUTER BOOM WELDMENT . . . . . 1 Used on 42’ boom models Used on 44’ boom models CLAMP ASSEMBLY . . . . . . . . . . . . 1

Ref. No.

Part No.

03 04 05 06

808555 808653 808125 808671

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

105

Description

Qty. Req.

5/16”-18 WHIZ LOCK NUT . . . . . . . 4 5/16”-18X5/8” BOLT . . . . . . . . . . . . 8 COVER, BOOM SIDE . . . . . . . . . . . 1 5/16” FASTENER, RETAINED . . . . 4

TABLE OF CONTENTS

Boom Intermediate Boom - Front Section

3 1 2

4 7

5 8 6

9 4

10 2 9 11 4

106

8

7

TABLE OF CONTENTS

Boom Intermediate Boom - Front Section Ref. No.

Part No.

01

02 03 04 05

808120 808123 808696 808608 808701 808702

Description

Qty. Req.

INTERMEDIATE WELDMENT. . . . . 1 Used on 42’ boom models Used on 44’ boom models FLAT-BOLT LOCK . . . . . . . . . . . . . . 6 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 4 1/16”X3”X4” SHIM . . . . . . . . . . . . . . 6 1/8”X3”X4” SHIM . . . . . . . . . . . . . . . 2

Ref. No.

Part No.

06 07 08 09 10 11

808747 808617 808593 808693 808692 808606

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

107

Description

Qty. Req.

1/2”X3”X4” SHIM . . . . . . . . . . . . . . . 2 3/8”-16X1” BOLT . . . . . . . . . . . . . . . 8 3/8” LOCK WASHER . . . . . . . . . . . . 8 SLIDE PAD . . . . . . . . . . . . . . . . . . . 6 SLIDE PAD . . . . . . . . . . . . . . . . . . . 2 3/8-16X3/4” BOLT . . . . . . . . . . . . . . 8

TABLE OF CONTENTS

Boom Intermediate Boom - Rear Section

1

2 9 3

8 7 4 6

4

5

6

4

7 8 9

6

4

9

108

TABLE OF CONTENTS

Boom Intermediate Boom - Rear Section Ref. No. 01 02 03 04

Part No. 808692 808746 808700 808696

Description

Qty. Req.

SLIDE PAD . . . . . . . . . . . . . . . . . . . 2 1/2”X4”X6” SPACER . . . . . . . . . . . . 2 1/16”X4”X6” SHIM . . . . . . . . . . . . . . 2 FLAT-BOLT LOCK . . . . . . . . . . . . . 10

Ref. No.

Part No.

05 06 07 08 09

808621 808606 808701 808702 808693

109

Description

Qty. Req.

3/8-16X1-1/4” BOLT . . . . . . . . . . . . 8 3/8-16X3/4” BOLT . . . . . . . . . . . . . . 8 1/16”X3”X4” SHIM . . . . . . . . . . . . . . 2 1/8”X3”X4” SHIM . . . . . . . . . . . . . . . 2 SLIDE PAD . . . . . . . . . . . . . . . . . . . 4

TABLE OF CONTENTS

Boom Intermediate Boom - Hose Tray Group

9 8 7

6

10

5 1 4 3 2

1

110

TABLE OF CONTENTS

Boom Intermediate Boom - Hose Tray Group Ref. No.

Part No.

01

02 03 04 05

808120 808123 808662 808869 809241 808591 808653

Description

Qty. Req.

INTERMEDIATE WELDMENT. . . . . 1 Used on 42’ boom models Used on 44’ boom models 5/16-18 NYLON INSERT NUT . . . . 2 TRAY BRACKET . . . . . . . . . . . . . . . 1 PLATE, CUSHION MNT (weld on) 5/16” LOCK WASHER . . . . . . . . . . . 2 5/16-18X5/8” BOLT . . . . . . . . . . . . . 4

Ref. No.

Part No.

06

07 08 09 10

808865 808866 808691 808593 808606 808555

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

3

111

Description

Qty. Req.

TRAY WELDMENT . . . . . . . . . . . . . 1 Used on 42’ boom models Used on 44’ boom models 2X3X1 SLIDE PAD . . . . . . . . . . . . . 1 3/8” LOCK WASHER . . . . . . . . . . . . 1 3/8-16X3/4” BOLT . . . . . . . . . . . . . . 1 5/16-18 FLARE NUT . . . . . . . . . . . . 1

TABLE OF CONTENTS

Boom Intermediate Boom - Chain Group

1

2

3 4 5

6

3

2 7

13 11

21 3

11 15

16 10

14

10

22

9

5

6

13

19

18 4

9 3 8

12

17 11

3

10

20

112

8

TABLE OF CONTENTS

Boom Intermediate Boom - Chain Group Ref. No.

Part No.

01 02 03 04 05 06 07 08 09 10

808423 808429 808931 808754 808477 808478 808932 808610 808663 808116

11 12

808673 808760

Description

Qty. Req.

1/4-28 ZERK, 90 DEG. . . . . . . . . . . 1 THRUST WASHER . . . . . . . . . . . . . 3 CHAIN SHEAVE WASHER . . . . . . . 6 CHAIN SHEAVE . . . . . . . . . . . . . . . 3 ROLLER BEARING . . . . . . . . . . . . . 3 INNER RING . . . . . . . . . . . . . . . . . . 3 REAR SHEAVE PIN . . . . . . . . . . . . 1 3/8-16X3 BOLT . . . . . . . . . . . . . . . . 3 3/8-16 NYLON INSERT NUT . . . . . 2 LEAF CHAIN . . . . . . . . . . . . . . . . . . 3 (BL646 leaf 259 pitches) 3/32X1-1/4 COTTER PIN . . . . . . . 10 CHAIN ADJUST CLEVIS PIN . . . . . 3

Ref. No.

Part No.

13 14 15 16 17 18 19 20 21 22

808753 808584 808619 808761 808596 808757 808762 808930 808424 NSS

113

Description

Qty. Req.

ADJUSTABLE CLEVIS . . . . . . . . . . 3 1”-8 NUT . . . . . . . . . . . . . . . . . . . . . 6 1/2-20X1-1/4” BOLT . . . . . . . . . . . . 3 PIN, REAR CHAIN LOW INNER. . . 1 1/2” LOCK WASHER . . . . . . . . . . . . 3 CLEVIS, TOP REAR INNER . . . . . . 1 PIN, CHAIN REAR UPPER INNR . . 1 PIN, CHAIN SHEAVE . . . . . . . . . . . 1 1/4-28 ZERK, STR. . . . . . . . . . . . . . 1 (Items 4, 5 and 6 are shown preassembled.)

TABLE OF CONTENTS

Boom Inner Boom - Front Section

8

9

7

10 11

6

5

4 3 2

1

Attachment Pivot

114

TABLE OF CONTENTS

Boom Inner Boom - Front Section Ref. No.

Part No.

01

02 03 04 05

808121 808124 808662 808870 809242 808591 808653

Description

Qty. Req.

INNER WELDMENT . . . . . . . . . . . . 1 Used on 42’ boom models Used on 44’ boom models 5/16-18 NYLON INSERT NUT . . . . 2 INNER TRAY BRACKET . . . . . . . . . 1 PLATE, CUSHION MNT (weld on) 5/16” LOCK WASHER . . . . . . . . . . . 2 5/16-18X5/8” BOLT . . . . . . . . . . . . . 4

Ref. No.

Part No.

06

07 08 09 10 11

808867 808868 808593 808606 808949 808555 808691

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

115

Description

Qty. Req.

INNER TRAY WELDMENT . . . . . . . 1 Used on 42’ boom models Used on 44’ boom models 3/8” LOCK WASHER . . . . . . . . . . . . 1 3/8”-16X3/4” BOLT . . . . . . . . . . . . . 1 HOSE CLAMP ASSEMBLY . . . . . . . 1 5/16-18 FLARE NUT . . . . . . . . . . . . 1 2X3X1” SLIDE PAD . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Boom Inner Boom - Rear Section

7

1 8

2 3 4 5

9 6 3 10

4 3

11

2

3

1 1

116

TABLE OF CONTENTS

Boom Inner Boom - Rear Section Ref. No. 01 02 03 04 05 06

Part No. 808693 808701 808696 808617 808761 808673

Description

Qty. Req.

SLIDE PAD . . . . . . . . . . . . . . . . . . . 6 0.06X3X4 SHIM. . . . . . . . . . . . . . . . 4 FLAT-BOLT LOCK . . . . . . . . . . . . . 10 3/8-16X1” BOLT. . . . . . . . . . . . . . . . 8 PIN, CHAIN REAR LOW INNER. . . 1 3/32X1-1/4” COTTER PIN . . . . . . . . 2

Ref. No.

Part No.

07 08 09 10 11

808817 808818 808819 808643 808606

117

Description

Qty. Req.

SLIDE PAD . . . . . . . . . . . . . . . . . . . 2 0.06X3X8” SHIM. . . . . . . . . . . . . . AR 0.105X3X8” SHIM . . . . . . . . . . . . . . 2 3/8-16X1-3/4” BOLT . . . . . . . . . . . . 8 3/8-16X3/4” BOLT . . . . . . . . . . . . . . 4

TABLE OF CONTENTS

Boom Quickattach

FRONT

1

2

17

2 3

15

4

13

16

5 14

12

10 11

6 7

9

8

5

18

118

TABLE OF CONTENTS

Boom Quickattach Ref. No. 01 02 03 04 05 06 07 08a 09a 10 11

Part No. 808082 808424 808786 808787 808811 808633 808038 NSS NSS 808875 808873

Description

Qty. Req.

QUICKATTACH WELDMENT . . . . . 1 1/4” -28 STR GREASE ZERK . . . . . 2 LOCK SPRING . . . . . . . . . . . . . . . . 1 SPRING MOUNT. . . . . . . . . . . . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 2 3/16”X1-3/4” ROLL PIN . . . . . . . . . . 1 DECAL, QUICKATTACHUNLOCKED . . 1 LOCK WELDMENT . . . . . . . . . . . . . 1 PIN. . . . . . . . . . . . . . . . . . . . . . . . . . 1 PIN, TILT CYLINDER . . . . . . . . . . . 1 PIN CAP . . . . . . . . . . . . . . . . . . . . . 1

Ref. No.

Part No.

12 13 14 15 16 17 18

808603 808085 809150 808130 808665 808651 808810

a

Not sold seperately, order item #18 P/N 808810 Lock and Pin Assembly

119

Description

Qty. Req.

5/16”X3/4” BOLT . . . . . . . . . . . . . . . 2 BUSHING . . . . . . . . . . . . . . . . . . . . 1 BUSHING, TILT CYL. (rod end). . . . 1 PIN, QUICKATTACH PIVOT . . . . . 1 1/2”-13 NYLON INSERT NUT . . . . . 1 1/2”-13X4-1/2” BOLT GR8. . . . . . . . 1 LOCK AND PIN ASSEMBLY . . . . . . 1 (Includes items 6, 8 and 9)

TABLE OF CONTENTS

Boom Hydraulics Extend Cylinder Group

4 11 3

FRONT

5

8

6

9

10 12

2

13 7 17 1

6

28 14 27

15

25 16 24 17

23

16

22 26

Bulkhead Plate 18 19 20 21

Main Valve 2nd Section (Boom Extend)

120

TABLE OF CONTENTS

Boom Hydraulics Extend Cylinder Group Ref. No.

Part No.

01a

02 03 04 05 06 07 08 09 10 11 12

808160 808161 808770

13 14

808597 808614 808475 808453 808159 808631 808888 808429 808414 808128 808904 808626 808759

15

808158

Description

Qty. Req.

EXTEND CYLINDER. . . . . . . . . . . . 1 USED ON 42’ BOOM USED ON 44’ BOOM TRUNNION MOUNT (RH). . . . . . . . 1 (Includes item 5) 5/8” LOCK WASHER . . . . . . . . . . . 10 5/8-11x1-1/2” BOLT . . . . . . . . . . . . 10 BUSHING 2.O” ID X 1.0” LENGTH . 2 ADAP -12ORM -12JICM 90 DEG . . 2 EXTEND CLYINDER TUBE (RH) . . 1 3/16X4” COTTER PIN . . . . . . . . . . . 2 EXTEND CYLINDER PIN . . . . . . . . 1 THRUST WASHER . . . . . . . . . . . . . 2 3/4-10X3” GR8 BOLT . . . . . . . . . . . 8 WELDMENT, EXTEND CYL MNT . . 1 TRUNNION SHIM (not shown). . . . 1 3/4-10 NYLON INSERT NUT . . . . . 8 TRUNNION MOUNT (LH) . . . . . . . . 1 (Includes item 5) EXTEND CYLINDER TUBE (LH) . . 1

Ref. No.

Part No.

Description

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

808752 808752 808290 808290 808442 808463 808642 808591 808150 808149 808693 808593 808606

a

Refer to Hydraulic Breakdown Section for individual cylinder components.

HOSE, -12 A12/DS12 48” . . . . . . . . 1 HOSE, -12 A12/DS12 48” . . . . . . . . 1 HOSE, -12 A12/DS12 18” . . . . . . . . 1 HOSE, -12 A12/DS12 18” . . . . . . . . 1 ADAP -12ORM -12JICM STR. . . . . 2 ADAP -12JICM BLKHD 90 DEG . . . 4 5/16”-18X2 GR5 BOLT . . . . . . . . . . 1 5/16” FLAT WASHER . . . . . . . . . . . 1 PLATE, TOP CLAMP. . . . . . . . . . . . 1 CLAMP BODY TWIN CUSHION . . . 1 SLIDE PAD . . . . . . . . . . . . . . . . . . . 1 3/8” LOCK WASHER . . . . . . . . . . . . 2 3/8-16X3/4” BOLT . . . . . . . . . . . . . . 2

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

HOSE LOCATOR 16 17 18 19

EXTEND CYLINDER “LEFT SIDE” (extend) EXTEND CYLINDER “RIGHT SIDE” (retract) MAIN VALVE “BOOM EXTEND” (retract; right side) MAIN VALVE “BOOM EXTEND” (extend; left side)

121

BULKHEAD BULKHEAD BULKHEAD BULKHEAD

Qty. Req.

PLATE PLATE PLATE PLATE

“LEFT SIDE” “RIGHT SIDE” “RIGHT SIDE” “LEFT SIDE”

TABLE OF CONTENTS

Boom Hydraulics Tilt Cylinder Group

FRONT 5

6 1

11

5

2 3

7

4 11 28

12

4 3

2

13

1

27

Bulkhead Plate

14 15

17

8

26 16 10

18

25

9 Main Valve 24

23 19 4th Section (Tilt)

22 21

20

122

TABLE OF CONTENTS

Boom Hydraulics Tilt Cylinder Group Ref. No.

Part No.

01 02 03 04 05 06

808628 808591 808727 808832 808949

07 08 09 10 11 12 13 14 15 16 17

808272 808291 809171 809243 808162 808880 808881 808591 808645 808663 808871

Description

Qty. Req.

5/16”-18X1-3/4” BOLT . . . . . . . . . AR 5/16” FLAT WASHER . . . . . . . . . . AR HOSE CUSHION TOP PLATE . . . . 2 TUBE CUSHION DBL 5/8” . . . . . . . 4 HOSE CLAMP ASSEMBLY . . . . . . . 2 BOOM HOSES . . . . . . . . . . . . . . . . 1 Note a Note b HOSE -8 H10/DS10 42” . . . . . . . . . 2 HOSE -8 A10/DS10 25”. . . . . . . . . . 2 ADAP, -12ORM -10JICM . . . . . . . . . 2 ADAP, -10 BULK HD TEE . . . . . . . . 2 TILT CYLINDER TUBE . . . . . . . . . . 2 CLAMP, DBL TUBE .62” . . . . . . . . . 6 PLATE, TOP DBL CUSHION. . . . . . 6 5/16” FLAT WASHER . . . . . . . . . . . 6 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 6 3/8” NYLON INSERT NUT . . . . . . . 1 PIN, TILT CYL BASE END . . . . . . . 1

Ref. No.

Part No.

Description

18 19 20 21 22 23 24 25 26 27 28

808610 808859 808603 808873 808875 808449 809172 808657 808893 808864 808863

a

42’ BOOM models; Uses (1) 808582 protective sleeve and (2) 808894 Hose, -8 H10/H10 360”

b

44’ BOOM models; Uses (1) 808582 protective sleeve and (2) 808886 Hose, -8 H10/H10 380”

3/8”-16X3” BOLT . . . . . . . . . . . . . . . 1 TILT CYLINDER - 5.5X20.0. . . . . . . 1 5/16-18X3/4” BOLT . . . . . . . . . . . . . 2 PIVOT PIN CAP . . . . . . . . . . . . . . . 1 PIN, TILT CYL ROD END . . . . . . . . 1 ADAP, -10ORM -10JICM STR. . . . . 1 ADAP, -10JICFS -10JICM 9O DEG. 1 ADAP -10ORM -10JICM 90 DEG . . 1 HOSE, -8 A10/H10 20” . . . . . . . . . . 2 TILT CYLINDER TUBE . . . . . . . . . . 1 TILT CYLINDER TUBE . . . . . . . . . . 1

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

HOSE LOCATOR 06 07 08 26

HYDRUALIC TILT TUBES (under boom) BULKHEAD PLATE (tee fitting) MAIN VALVE (tilt section - 4th from front) HYDRUALIC TUBES (upper front boom)

HYDRAULIC TUBES (upper front boom) HYDRUALIC TILT TUBES (under boom) BULKHEAD PLATE (tee fitting) TILT CYLINDER

123

Qty. Req.

TABLE OF CONTENTS

Boom Hydraulics Slave Cylinder Group

FRONT 3 5 4 7

6 1

20 2 7 1 8 Bulkhead Plate 9

11 12 13

7

7

19

18

14 6

17 15

21

16

10 RIGHT LEFT

22

25 TOP BOTTOM

20 24 13 21 23

124

TABLE OF CONTENTS

Boom Hydraulics Slave Cylinder Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13

Part No. 808860 808663 808609 808143 808709 808423 808445 808295 809243 808296 808296 808662 808590

Description

Qty. Req.

SLAVE CYLINDER . . . . . . . . . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . . 2 3/8”-16X2-3/4” BOLT . . . . . . . . . . . . 2 PIN, SLAVE CYL. (rod end) . . . . . . 2 BUSHING 660 1.5IDX3.0 . . . . . . . . 2 1/4”-28 GREASE ZERK 90 DEG. . . 4 ADAP, -8ORM -8JICM STR. . . . . . . 4 HOSE, -8 A8/DS8 46” . . . . . . . . . . . 1 ADAP, -10 BULK HD RUN TEE . . . 2 HOSE, -8 DS8/DS10 16”. . . . . . . . . 1 HOSE, -8 DS8/DS10 16”. . . . . . . . . 1 5/16-18 NYLON INSERT NUT . . . AR 5/16” FLAT WASHER . . . . . . . . . . AR

Ref. No.

Part No.

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

808640 808609 808593 809244 808142 808831 808295 808294 808132 809245 808640 808294

Description

Qty. Req.

5/16-18X1” BOLT . . . . . . . . . . . . . AR 3/8”-16X1-1/4” BOLT . . . . . . . . . . . . 2 3/8” LOCK WASHER . . . . . . . . . . . . 2 LOCK PIN . . . . . . . . . . . . . . . . . . . . 2 PIN, SLAVE CYL. (base end). . . . . 2 BUSHING . . . . . . . . . . . . . . . . . . . . 2 HOSE, -8 A8/DS8 46” . . . . . . . . . . . 1 HOSE, -8 A8/DS8 28” . . . . . . . . . . . 1 BRACKET, BULKHEAD PLATE . . . 1 ADAP, BULK HD BRANCH TEE . . . 2 5/16-18X1” BOLT. . . . . . . . . . . . . . . 4 HOSE, -8 A8/DS8 28” . . . . . . . . . . . 1

HOSE LOCATOR 08 10 11 20 21 25

LEFT SLAVE CYLINDER “TOP” BULKHEAD TEE “LEFT” BULKHEAD TEE “RIGHT” RIGHT SLAVE CYLINDER “TOP” RIGHT SLAVE CYLINDER “BOTTOM” LEFT SLAVE CYLINDER “BOTTOM”

BRANCH TEE BRANCH TEE BRANCH TEE BRANCH TEE BRANCH TEE BRANCH TEE

125

“TOP” (under bulkhead plate) “TOP-FRONT” (under bulkhead plt) “BOTTOM-FRONT” (under bulkhead) “TOP” (under bulkhead plate) “BOTTOM” (under bulkhead plate) “BOTTOM” (under bulkhead plate)

TABLE OF CONTENTS

Boom Hydraulics Lift Cylinder Group

5

6

7

2

3

4

4

3

FRONT

2

1 1

RIGHT 11 12

10 9 8 12

15 14 13

5 15 4 13 14

6 12

4 LEFT

12 4

6

5

4 8

11

10 16 16

17

9

3rd Section (Boom Lift)

126

Main Valve

TABLE OF CONTENTS

Boom Hydraulics Lift Cylinder Group Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808820 808614 808767 809246 808963 809247 808766 808293 808292

Description

Qty. Req.

LIFT CYLINDER . . . . . . . . . . . . . . . 2 5/8”X1-1/2” BOLT GR5 . . . . . . . . . . 4 WASHER, PIN RETAINER . . . . . . . 4 SPACER . . . . . . . . . . . . . . . . . . . . . 8 SNAP RING . . . . . . . . . . . . . . . . . AR BEARING, SPHERICAL . . . . . . . . AR PIN, LIFT CYL (rod end) . . . . . . . . . 2 HOSE, -8 A8/A12 88” . . . . . . . . . . . 1 HOSE, -8 A8/A12 66” . . . . . . . . . . . 1

Ref. No.

Part No.

10 11 12 13 14 15 16 17

808292 808293 808454 808807 808591 808605 808460 808453

Description

HOSE, -8 A8/A12 66” . . . . . . . . . . . 1 HOSE, -8 A8/A12 88” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM 90 DEG . . . . 4 PIN, ECCENTRIC . . . . . . . . . . . . . . 4 5/16” LOCK WASHER . . . . . . . . . . . 6 5/16”-24X1” GR5 BOLT . . . . . . . . . . 6 ADAP, -12 SWVL TEE . . . . . . . . . . . 2 ADAP, -12ORM -12JICM . . . . . . . . . 2

HOSE LOCATOR 08 09 10 11

LEFT LIFT CYLINDER “LEFT SIDE ” (retract) LEFT LIFT CYLINDER “RIGHT SIDE ” (extend) RIGHT LIFT CYLINDER “LEFT SIDE ” (retract) RIGHT LIFT CYLINDER “RIGHT SIDE ” (extend)

MAIN MAIN MAIN MAIN

127

VALVE VALVE VALVE VALVE

Qty. Req.

(3rd (3rd (3rd (3rd

section section section section

-

right side [retract]) left side [extend]) right side [retract]) left side [extend])

TABLE OF CONTENTS

Boom Hydraulics Auxiliary Hydraulics Group (Option)

FRONT 5

6 11

5

7 11 12 1

2

13

3

Bulkhead Plate

14 15

4

4

8

10

6

9

16

Main Valve

17

18 5th Section (Auxiliary) (Optional)

128

TABLE OF CONTENTS

Boom Hydraulics Auxiliary Hydraulics Group (Option) Ref. No.

Part No.

01 02 03 04 05 06

808647 808591 808729 808730 808949

07 08 09 10 11 12 13 14 15 16

808272 808271 809171 808441 808163 808880 808881 808591 808645 808450

Description

Qty. Req.

5/16”-18X2-1/4” BOLT . . . . . . . . . . . 2 5/16” FLAT WASHER . . . . . . . . . . . 2 HOSE CUSHION TOP PLATE . . . . 2 TUBE CUSHION DBL .88” . . . . . . . 4 HOSE CLAMP ASSEMBLY . . . . . . . 2 AUXILIARY HYD. HOSES. . . . . . . . 1 Note a Note b HOSE -8 H10/DS10 42” . . . . . . . . . 2 HOSE -8 A10/DS10 30”. . . . . . . . . . 2 ADAP, -12ORM -10JICM . . . . . . . . . 2 ADAP, -10JICM BULK HD 90 DEG . 2 AUX HYD TUBE . . . . . . . . . . . . . . . 2 CLAMP, DBL TUBE .62” . . . . . . . . . 6 PLATE, TOP DBL CUSHION. . . . . . 6 5/16” FLAT WASHER . . . . . . . . . . . 6 3/8”-16X1-1/2” BOLT . . . . . . . . . . . . 6 ADAP, -8ORM -10JICM STR. . . . . . 2

Ref. No.

Part No.

Description

17 18

808796 808134 808266

00

808064

a

42’ BOOM models; Use (1) 808582 protective sleeve and (2) 808895 Hose, -8 H10/H10 380”

b

44’ BOOM models; Use (1) 808582 protective sleeve and (2) 808887 Hose, -8 H10/H10 400”

QUICK COUPLER SET. . . . . . . . . . 1 KIT, AUX HYD SECTION . . . . . . . . 1 KIT, FIVE SECTION TIE BOLT . . . 4 (each kit contains [1] bolt, [2] washers and [2] nuts)

-- ITEMS NOT SHOWN -DECAL, AUXILIARY CONTROL . . 1

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

129

Qty. Req.

TABLE OF CONTENTS

Attachments Standard Carriage Attachment Group

1 5 3

2

5 3

130

TABLE OF CONTENTS

Attachments Standard Carriage Attachment Group Ref. No.

Part No.

Description

Qty. Req.

01 01

809248 809249

STD. CARR. WELD. 48” . . . . . . . . . 1 STD. CARR. WELD. 66” . . . . . . . . . 1

03 03

808794 808764

FORK SHAFT BAR 48” (51.5” OAL) 1 FORK SHAFT BAR 66” (69.5” OAL) 1

Ref. No.

Part No.

05

808431 808652 808665

131

Description

Qty. Req.

RETAINER. . . . . . . . . . . . . . . . . . . . 2 CAP SCREW 1/2-13X2-3/4 . . . . . . 2 1/2-13 NYLON INSERT NUT . . . . . 2

TABLE OF CONTENTS

Attachments Fork Shift Carriage Attachment Group (Optional)

1

19 20

18 14 15

13 2 11

15

9

12

16

17

9 10 8

7 6 5 2 3 4

132

TABLE OF CONTENTS

Attachments Fork Shift Carriage Attachment Group (Optional) Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13b

Part No. 809250 808626 808431 808616 808822 808824 808646 Note a 808727 809251 808728 808662 NSS

Description

Qty. Req.

Ref. No.

Part No.

FORK SHIFT CARRIAGE . . . . . . . . 1 3/4”-10 NYLON INSERT NUT . . . . . 3 FORK SHAFT WASHER . . . . . . . . . 1 3/4”-10X3” BOLT . . . . . . . . . . . . . . 1 FORK SHAFT, 50” . . . . . . . . . . . . . . 1 FORK SLIDE PLATE . . . . . . . . . . . . 2 3/4”-10X1-1/2” BOLT . . . . . . . . . . . . 1 FORK SLIDE COUPLER. . . . . . . . . 1 TWIN CUSHION TOP PLATE . . . . . 2 5/16”-18X2-1/4” BOLT . . . . . . . . . . . 2 TWIN HOSE CUSHION. . . . . . . . . . 1 5/16”-18 NYLON INSERT NUT . . . . 2 COUPLER, MALE . . . . . . . . . . . . . . 1

14b 15 16 17 18 19 20

NSS 809252 808834 809253 808710 809254 808826

a

For 4” wide forks use P/N 808823.

For 5” wide forks use P/N 809276.

b

Order P/N 808796 Coupler Set.

133

Description

Qty. Req.

COUPLER, FEMALE. . . . . . . . . . . . 1 CYLINDER MOUNT . . . . . . . . . . . . 2 FORK SHIFT CYLINDER . . . . . . . . 1 3/4”-10X4” BOLT . . . . . . . . . . . . . . . 2 ADAP -8ORM -6JICM W/.06 ORF . 2 HOSE -6 A6/A6 59” . . . . . . . . . . . . . 1 HOSE -6 A6/A6 56” . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Attachments Rotate Carriage Attachment Group (Optional)

9 11 12

8

13

14

10

15

7 19

16

1

6

13 17 7

5

3

18

2 4

21

20

6

1

25

26 27

22 23

15 24

28

134

TABLE OF CONTENTS

Attachments Rotate Carriage Attachment Group (Optional) Ref. No. 01 02 03 04 05 06 07 08 09a 10 11 12 13 14 15 16

Part No. 808665 808431 808652 808794 808764 809255 809256 808803 808750 808445 NSS 809257 808688 808695 808609 808792 808663 808918

Description

Qty. Req.

Ref. No.

Part No.

1/2”-13 NYLON INSERT NUT . . . . . 4 FORK SHAFT WASHER . . . . . . . . . 2 1/2”X2-3/4” BOLT . . . . . . . . . . . . . . 2 FORK SHAFT BAR (48” Carriage) . 1 FORK SHAFT BAR (66” Carriage) . 1 48” CARRIAGE, ROTATING . . . . . . 1 66” CARRIAGE, ROTATING . . . . . . 1 ADAP -8ORM -8JICM 90 W/ORF . . 2 HOSE -8 A8/A8 53” . . . . . . . . . . . . . 2 ADAP -8ORM -8JICM STR . . . . . . . 2 COUPLER, MALE . . . . . . . . . . . . . . 1 1/2”X4” BOLT. . . . . . . . . . . . . . . . . . 2 SPACER . . . . . . . . . . . . . . . . . . . . . 4 LOCK COLLAR 1.5” OD . . . . . . . . . 2 3/8”X2-3/4” BOLT . . . . . . . . . . . . . . 2 PIN, ROTATOR ROD END . . . . . . . 1 3/8”-16 NYLON INSERT NUT . . . . . 3 ROTATE CYLINDER . . . . . . . . . . . . 1

17 18 19a 20 21

808649 808791 NSS NSS 808790

22 23 24 25 26 27 28

808693 808687 808638 808635 808593 808608 808950

a

Order P/N 808796 Coupler Set.

135

Description

Qty. Req.

1/2”-13X4-1/2” BOLT . . . . . . . . . . . . 1 PIN, ROTATOR BASE END . . . . . . 1 COUPLER, FEMALE. . . . . . . . . . . . 1 ROTATOR PIN. . . . . . . . . . . . . . . . . 1 ROTATOR PLATE WELDMENT . . . 1 (Includes Item 20) SLIDE PAD . . . . . . . . . . . . . . . . . . . 3 4”ODX2.5”ID WASHER . . . . . . . . . . 1 3/8”X4” BOLT. . . . . . . . . . . . . . . . . . 1 2-1/2”-12 CASTELL NUT. . . . . . . . . 1 3/8” LOCK WASHER . . . . . . . . . . . . 6 3/8”X1-1/2” BOLT . . . . . . . . . . . . . . 6 PIVOT BEARING (not shown). . . . . 1 (Included in item 5)

TABLE OF CONTENTS

Attachments Swing Carriage Attachment Group (Optional)

8

13

14 15 17

16 7

12 9

6 5 25

24

10 18 20

11 18

23 22 21

30

26

3

1

19

10

27 4 28

29

2

31 32

35

33 34

136

TABLE OF CONTENTS

Attachments Swing Carriage Attachment Group (Optional) Ref. No. 01 02 03 04 05 06a 07 08 09a 10 11 12 13 14 15 16 17

Part No. 808665 808431 808652 808764 809258 NSS 808710 808827 NSS 808739 808415 808642 808661 808622 808741 808720 808738

Description

Qty. Req.

1/2”-13 NYLON INSERT NUT . . . . . 2 FORK SHAFT WASHER . . . . . . . . . 2 1/2”X2-3/4” BOLT . . . . . . . . . . . . . . 2 FORK SHAFT BAR (66” Carriage) . 1 66” CARRIAGE, SWING . . . . . . . . . 1 COUPLER, FEMALE. . . . . . . . . . . . 1 ADAP -8ORM -6JICM STR W.06 . . 2 HOSE -6 A6/A6 89” . . . . . . . . . . . . . 2 COUPLER, MALE . . . . . . . . . . . . . . 1 HOSE -4 DS6/A6 22” . . . . . . . . . . . 2 5/16”X3” BOLT. . . . . . . . . . . . . . . . . 1 5/16”X2” BOLT. . . . . . . . . . . . . . . . . 1 1/4” NYLON INSERT NUT . . . . . . . 4 1/4”X2-1/4” BOLT . . . . . . . . . . . . . . 4 PIN, SWING CYLINDER . . . . . . . . . 4 BUSHING . . . . . . . . . . . . . . . . . . . . 4 SWING CYLINDER . . . . . . . . . . . . . 2

Ref. No.

Part No.

18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35

808456 808080 808464 808455 808628 808591 808727 808728 808937 809259 808555 808740 808920 808663 808609 808737 809260

a

Order P/N 808796 Coupler Set.

137

Description

Qty. Req.

ADAP -6ORM -6JICM 45. . . . . . . . . 4 HOSE -4 A6/A6 36” (3000 psi) . . . . 2 ADAP -6JICFS -6JICM TEE . . . . . . 2 ADAP -6ORM -6JICM 90. . . . . . . . . 2 5/16”-18X1-3/4” BOLT . . . . . . . . . . . 2 5/16” LOCK WASHER . . . . . . . . . . . 2 TWIN CUSH. TOP PLATE. . . . . . . . 1 TWIN HOSE CUSHION. . . . . . . . . . 2 VALVE, DUAL PO . . . . . . . . . . . . . . 1 HOSE CUSH. TOP PLATE . . . . . . . 1 5/16” FLARE NUT . . . . . . . . . . . . . . 2 PIN, CARRIAGE PIVOT . . . . . . . . . 2 SWING PIVOT WELDMENT . . . . . . 1 3/8”-16 NYLON INSERT NUT . . . . . 2 3/8”-16X2-3/4” BOLT . . . . . . . . . . . . 2 THRUST WASHER . . . . . . . . . . . . . 6 BUSHING, CARRIAGE PIVOT . . . . 2 (Not shown)

TABLE OF CONTENTS

Attachments Truss Boom Attachment Group

5’ JIB BOOM

1

1 12’ AND 15’ TRUSS BOOM

24

25 15

16 18 17

7

6

23

26

5

22

14 21

13 20

19 10

3 2

12 8

11

4 9

138

8

TABLE OF CONTENTS

Attachments Truss Boom Attachment Group Ref. No.

Part No.

Description

Qty. Req.

Ref. No.

Part No.

22 23 24 25 26c

808677 808689 808619 808596 808459

WINCH BALL. . . . . . . . . . . . . . . . . . 1 PINTLE HOOK . . . . . . . . . . . . . . . . 1 1/2”-20X1-1/4” GR 8 BOLT . . . . . . . 4 1/2” LOCK WASHER . . . . . . . . . . . . 4 ADAP -8JICFS -8JICM 90 . . . . . . . . 2

00

808499

-- ITEMS NOT SHOWN-ADAPTER PLATE . . . . . . . . . . . . . . 1 (used with auger and other items)

a

Used with 12’ and 15’ Truss booms with winch.

b

Used with 5’ trus booms with winch.

c

Not used on all attachments.

d

Sold as a set, order P/N 808796 Coupler Set

01

809261 809262 809263

5’ TRUSS WELDMENT . . . . . . . . . . 1 12’ TRUSS WELDMENT . . . . . . . . . 1 15’ TRUSS WELDMENT . . . . . . . . . 1

02 03 04 05 06d 07d 08 09 10 11 12 13 14 15 16 17 18 19a

808750 808769 808644 808661 808445 NSS NSS 808454 808951 808081 808612 808665 808448 808430 808639 808077 808662 808797 808933

19b

808825

20 21

808618 808593

HOSE -8 A8/A8 53” . . . . . . . . . . . . . 2 ADAP -8ORM -8JICM RUN TEE. . . 1 1/4-20”X2” BOLT . . . . . . . . . . . . . . . 2 1/4”-20 NYLON INSERT NUT . . . . 2 ADAP -8ORM -8JICM STR . . . . . . . 2 COUPLER, MALE . . . . . . . . . . . . . . 1 COUPLER, FEMALE. . . . . . . . . . . . 1 ADAP -8ORM -8JICM 90 DEG . . . . 2 RELIEF VALVE . . . . . . . . . . . . . . . . 1 HYDRAULIC WINCH. . . . . . . . . . . . 1 1/2”-13X1-3/4” GR 8 BOLT . . . . . . . 6 1/2-13 NYLON INSERT NUT . . . . . 6 ADAP -10ORM -8JICM . . . . . . . . . . 2 HOSE -6 A8/A8 18.5” . . . . . . . . . . . 2 5/16”X2-1/2” BOLT . . . . . . . . . . . . . 2 PIN, TRUSS WINCH . . . . . . . . . . . . 1 5/16”-18 NYLON INSERT NUT . . . . 2 WINCH SHEAVE . . . . . . . . . . . . . . . 1 3/8”X100’ WINCH CABLE . . . . . . . . 1 (includes hook and swivel) 3/8”X60’ WINCH CABLE . . . . . . . . . 1 (includes hook and swivel) 3/8”X2-1/2” BOLT . . . . . . . . . . . . . . 2 3/8” LOCK WASHER . . . . . . . . . . . . 2

139

Description

Qty. Req.

TABLE OF CONTENTS

Attachments Bucket Attachment

1

140

TABLE OF CONTENTS

Attachments Bucket Attachment Ref. No. 01

Part No. 809264 808854

Description

Qty. Req.

Ref. No.

1.3 CU. YD. BUCKET WELDMNT . 1 CUTTING EDGE 98” (weld on) . . . 1

141

Part No.

Description

Qty. Req.

TABLE OF CONTENTS

Hydraulics Hydraulic Pump Group

2

1 3

Hydraulic Tank (Bottom)

HYDRAULIC PUMP

6 9

5 IN

FLOW DIVIDER

4 8 EP

6

10 S

11

12 MAIN VALVE (IN)

PRIORITY VALVE

P

7 13 16 CF

EF

HYDRAULIC TANK

6 14

15

FRONT

STEER MOTOR [P]

142

TABLE OF CONTENTS

Hydraulics Hydraulic Pump Group Ref. No. 01 02 03

04 05 06 07 08 09 10a 11a

Part No. 808713 809265 808146 808469 808629 808685 808273 808453 808748 808751 808126 808442 808277

Description

Qty. Req.

HOSE, -24 A24/A24 35” . . . . . . . . . 1 ADAP, -24ORM -24JICM 90 DEG . . 1 HYDRAULIC PUMP . . . . . . . . . . . . 1 GASKET (not shown) . . . . . . . . . . . 1 1/2”-13x1-1/2” BOLT (not shown). . 2 ADAP, -16orm -12jicm 90 DEG . . . . 1 HOSE, -12 A12/DS12 13” . . . . . . . . 1 ADAP, -12ORM -12JICM . . . . . . . . . 3 PRIORITY VALVE . . . . . . . . . . . . . . 1 HOSE, -12 A12/A12 21” . . . . . . . . . 1 FLOW DIVIDER VALVE . . . . . . . . . 1 ADAP, -12ORM -12JICM . . . . . . . . . 1 HOSE, -12 A12/A12 115” . . . . . . . . 1

Ref. No.

Part No.

Description

12 13 14 15 16

808443 808275 808769 808274 808326

a

Note: if the unit is equipped with the outrigger option, there will be two additional hoses. Hose P/N 808268; -12 A12/DS12 74” will attach to fitting item #10 and will go to the outrigger valve. Hose P/N 808269; -12 H12/A12 58” will return from the outrigger valve and will connect to the existing hose, item 11. Please refer to the Outrigger pages located in the Chasis section for more information.

ADAP, -6ORM -6JICM . . . . . . . . . . . 2 HOSE, -6 A8/DS6 19” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM TEE . . . . . . . 1 HOSE, -6 A8/DS8 50” . . . . . . . . . . . 1 HOSE, -6 AS/DS6 18” . . . . . . . . . . . 1

HOSE LOCATOR 01 05 08

HYDRAULIC PUMP “IN” HYDRAULIC PUMP “OUT” PRIORITY VALVE “EF” (bottom of valve)

HYDRAULIC TANK “BOTTOM - OUT” PRIORITY VALVE “P” (top of valve) FLOW DIVIDER “IN” (side)

11a 11a

FLOW DIVIDER “EP” (front of valve) (STANDARD) OUTRIGGER VALVE/HOSE (OUTRIGGER OPTION)

MAIN VALVE “IN” MAIN VALVE “IN”

13 15 16

PRIORITY VALVE “CF” (bottom of valve - tee) PRIORITY VALVE “CF” (bottom of valve - tee) FLOW DIVIDER “T” (front of valve)

FLOW DIVIDER “S” (bottom of valve) STEER MOTOR “P” HYDRAULIC TANK RETURN (return manifold)

143

Qty. Req.

TABLE OF CONTENTS

Hydraulics Steer Motor and Valve Group LEFT 1 LS

T

3

2

FRONT

L

P

R

9

4 3

3 FRONT AXLE STEER CYLINDER (RIGHT SIDE)

7

8

5

10

6

11 STEER SELECT

12 HYDRAULIC TANK

P T

22 A

12

21

B

PRIORITY VALVE

13 T

LS

CF

15 7

23

20

14

19 18

FRONT AXLE STEER CYLINDER (LEFT SIDE)

FLOW DIVIDER

9

24 17

16

6 REAR AXLE STEER CYLINDER (LEFT SIDE)

HYDRAULIC TANK

144

REAR AXLE STEER CYLINDER (RIGHT SIDE)

TABLE OF CONTENTS

Hydraulics Steer Motor and Valve Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12

Part No. 808101 809266 808445 808763 808716 808274 808285 808286 808276 808545 808877 808455

Description

Qty. Req.

STEER MOTOR . . . . . . . . . . . . . . . 1 ADAP, -4ORM -6JICM 90 DEG . . . . 1 ADAP, -8ORM -8JICM STR. . . . . . . 3 VALVE, CHECK . . . . . . . . . . . . . . . . 1 HOSE, -6 A6/DS8 52” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 50” . . . . . . . . . . . 1 HOSE, -6 A6/DS8 58” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 82” . . . . . . . . . . . 1 HOSE, -4 A4/A4 52” . . . . . . . . . . . . 1 1/4”-20 WHIZ LOCK NUT . . . . . . . . 2 VALVE, STEER SELECT . . . . . . . . 1 ADAP, -6ORM -6JICM 90 DEG . . . . 2

Ref. No.

Part No.

13 14 15 16 17 18 19 20 21 22 23 24

808443 808627 808287 808885 808885 808769 808656 808853 808451 808748 808555 808275

145

Description

Qty. Req.

ADAP, -6ORM -6JICM STR. . . . . . . 2 1/4”-20X3” BOLT . . . . . . . . . . . . . . . 2 HOSE, -6 A6/A8 48” . . . . . . . . . . . . 1 HOSE, -6 A6/A8 100” . . . . . . . . . . . 1 HOSE, -6 A6/A8 100” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM TEE . . . . . . . 1 ADAP, -4ORM -4JICM 90 DEG . . . . 1 HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1 ADAP, -6ORM -4JICM STR. . . . . . . 1 PRIORITY VALVE . . . . . . . . . . . . . . 1 5/16-18 WHIZ LOCK NUT. . . . . . . . 2 HOSE, -6 A8/DS6 19” . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Main Valve Group FRONT FRAME LEVEL CYLINDER

(EXTEND)

STABILIZER MANIFOLD

FLOW

5

4

2

1

DIVIDER

3

BOOM

(RETRACT) LEFT LIFT CYLINDER

(RETRACT) BOOM

(EXTEND) RIGHT LIFT CYLINDER

6

RIGHT LIFT CYLINDER

(EXTEND)

(RETRACT)

8 9

LEFT LIFT CYLINDER

33

(EXTEND)

7 7

TILT

(EXTEND)

11

32

11

31

10

AUX. (RETRACT)

12 10 TILT

13

14

(RETRACT)

30 15 14

AUX.

(EXTEND)

14

16

29

17 18 14

28

19

22 27 26 25 20 21 24

22

23 Main Valve shown with Auxiliary Hydraulics Option

146

HYDRAULIC COOLER

TABLE OF CONTENTS

Hydraulics Main Valve Group Ref. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15a 16a 17a 18a 19a 20 21

Part No. 808277 808685 808458 808302 809200 808290 808442 808293 808292 808460 808453 808291 808271 809171 808284 808283 808283 808284 808270 808288 808658

Description

Qty. Req.

Ref. No.

Part No.

HOSE, -12 A12/A12 115” . . . . . . . . 1 ADAP, -16ORM -12JICM 90 DEG . . 1 ADAP, -12ORM -8JICM 90 DEG . . . 2 HOSE, -8 A8/A8 190” . . . . . . . . . . . 1 HOSE, -8 A8/A8 26” . . . . . . . . . . . . 1 HOSE, -12 A12/DS12 18” . . . . . . . . 1 ADAP, -12ORM -12JICM STR. . . . . 2 HOSE, -8 A8/A12 88” . . . . . . . . . . . 1 HOSE, -8 A8/A12 66” . . . . . . . . . . . 1 ADAP, -12 SWVL RUN TEE . . . . . . 2 ADAP, -12ORM -12JICM . . . . . . . . . 2 HOSE -8 A10/DS10 25”. . . . . . . . . . 2 HOSE -8 A10/DS10 30”. . . . . . . . . . 2 ADAP, -12ORM -10JICM . . . . . . . . . 2 HOSE, -4 A6/DS6 120” . . . . . . . . . . 1 HOSE, -4 A6/DS6 108” . . . . . . . . . . 1 HOSE, -4 A6/DS6 108” . . . . . . . . . . 1 HOSE, -4 A6/DS6 120” . . . . . . . . . . 1 HOSE, -4 A6/DS6 102” . . . . . . . . . . 1 HOSE -16 A16/A16 42” . . . . . . . . . .1 ADAP, -16ORM -16JICM . . . . . . . . . 1

22 23b

808409 808129 808134 808266 808270 808284 808283 808283 808284 808271 808291 808292 808293 808290

24a 25a 26a 27a 28a 29 30 31 32 33

Description

Qty. Req.

ADAP, 1/4BSP -6JICM STR . . . . . AR MAIN VALVE . . . . . . . . . . . . . . . . . . 1 KIT, AUX HYD SECTION (optional) 1 KIT, FIVE SECTION TIE BOLT . . . 4 HOSE, -4 A6/DS6 102” . . . . . . . . . . 1 HOSE, -4 A6/DS6 120” . . . . . . . . . . 1 HOSE, -4 A6/DS6 108” . . . . . . . . . . 1 HOSE, -4 A6/DS6 108” . . . . . . . . . . 1 HOSE, -4 A6/DS6 120” . . . . . . . . . . 1 HOSE -8 A10/DS10 30”. . . . . . . . . . 2 HOSE -8 A10/DS10 25”. . . . . . . . . . 2 HOSE, -8 A8/A12 66” . . . . . . . . . . . 1 HOSE, -8 A8/A12 88” . . . . . . . . . . . 1 HOSE, -12 A12/DS12 18” . . . . . . . . 1

a

Refer to next page for information regarding the location of these hoses.

b

The illustration on the facing page shows the (optional) auxiliary hydraulic work section with the main valve.

147

TABLE OF CONTENTS

Hydraulics Main Valve / Hydraulic Controls TILT

FRONT

LEVEL

3 LIFT

2

EXTEND

HYDRAULIC

4

OPTION

1

TILT “FORWARD” (R)

LEVEL “LEFT” (E)

4 TILT “BACK”(E) BOOM “IN” (R)

BOOM “UP”(E)

LEVEL “RIGHT” (R)

5

BOOM “DOWN”(R) BOOM “OUT” (E)

5 6

EXTEND

6

RETRACT

5

5

6 6

4 7

7

LEVE

L (LE

BOO BOO TILT HYDR

FT)

M (IN

)

M (U

P)

(FOR WAR D)

AULIC

9

OPTIO

N LEVE

L (RIG

BOO

9

BOO

UT)

M (D

(R) = retract (E) = extend

TILT HYDR

Main Valve shown with Auxiliary Hydraulics Option

8

148

OWN

)

(BAC

AULIC

HT)

M (O

K)

OPTIO

N

TABLE OF CONTENTS

Hydraulics Main Valve / Hydraulic Controls Ref. No. 01 02 03 04 05 06 07

Part No. 808139 808138 808263 808443 808284 808283 808270

Description

Qty. Req.

Ref. No.

Part No.

CONTROLLER, AUX. HYD . . . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 CONTROLLER, TILT/LEVEL. . . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR HOSE, -4 A6/DS6 120” . . . . . . . . . . 4 HOSE, -4 A6/DS6 108” . . . . . . . . . . 4 HOSE, -4 A6/DS6 102” . . . . . . . . . . 2

08a

808129 808134 808266

09

808409

a

The illustration on the facing page shows the (optional) auxiliary hydraulic work section with the main valve.

149

Description

Qty. Req.

MAIN VALVE . . . . . . . . . . . . . . . . . . 1 KIT, AUX HYD SECTION (optional) 1 KIT, FIVE SECTION TIE BOLT . . . 4 (each kit contains [1] bolt, [2] washers and [2] nuts) ADAP, 1/4BSP -6JICM STR . . . . AR

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - No Options FRONT

TILT LEVEL

1 LIFT EXTEND

2 P

3 T P T

4

3

5 5

4 4 6

FRONT FLOW DIVIDER

7 J

8

9 HYDRAULIC TANK

150

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - No Options Ref. No. 01 02 03 04 05

Part No. 808263 808138 808443 808882 808882

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR. . . . . . . 4 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1

Ref. No.

Part No.

06 07 08 09

808282 808126 808455 808265

151

Description

Qty. Req.

HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 ADAP, -6ORM -6JICM 90 DEG . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - Auxiliary Hydraulic Option FRONT

TILT LEVEL

1

LIFT EXTEND

2 P

3 T

4

P HYDRAULIC OPTION

T

8 14

3

10 7

4 3 5

8

T

12

9

P

11 10

6 9 7

FRONT FLOW DIVIDER

13 J

6

11 HYDRAULIC TANK

152

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - Auxiliary Hydraulic Option Ref. No. 01 02 03 04 05 06 07

Part No. 808263 808138 808443 808464 808679 808455 808850

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1

Ref. No.

Part No.

08 09 10 11 12 13 14

808882 808850 808882 808265 808282 808126 808139

153

Description

Qty. Req.

HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 CONTROLLER, AUX. HYD . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - Outrigger Option FRONT

TILT LEVEL

1

LIFT EXTEND

2 P OUTRIGGER

3 T

4 P

T

8

14 3

10 7

4 3 8

5 T

12

9

P

11 6

10

9 7

FRONT FLOW DIVIDER

13 J

6

11 HYDRAULIC TANK

154

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - Outrigger Option Ref. No. 01 02 03 04 05 06 07

Part No. 808263 808138 808443 808464 808679 808455 808853

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1

Ref. No.

Part No.

08 09 10 11 12 13 14

808882 808853 808882 808265 808282 808126 808140

155

Description

Qty. Req.

HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 CONTROLLER, OUTRIGGERS . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS Only FRONT

TILT LEVEL

1 LIFT EXTEND

2

P

3 T P

T

5

8

3 7 4 7

6

T

13

4

9

FLOW DIVIDER

FRONT

3 WPS VALVE

10 T

11

11

P

J

12 3 J1 J2

5

HYDRAULIC TANK

8

156

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS Only Ref. No. 01 02 03 04 05 06 07

Part No. 808263 808138 808443 808464 808265 808282 808882

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1

Ref. No.

Part No.

08 09 10 11 12 13

808265 808126 808127 808455 808715 808326

157

Description

Qty. Req.

HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 MANIFOLD, WPS JOYSTICK . . . . . 1 ADAP, -6ORM -6JICM 90 DEG . . . . 2 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 2 HOSE, -6AS/DS6 18” . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS and Outriggers FRONT

TILT LEVEL

1 LIFT EXTEND

2

P

OUTRIGGER

T P

3 T

16

4

10

3

8

5

T

7

4

3

11

9

12

P

6 9 7

T

17

4

13

FLOW DIVIDER

FRONT

3 WPS VALVE

14 T

6

6

P

J

15 3 J1 J2

10 HYDRAULIC TANK

8

158

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS and Outriggers Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808263 808138 808443 808464 808679 808455 808853 808265 808853

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1

T

13

4

9

Ref. No.

Part No.

10 11 12 13 14 15 16 17

808265 808882 808282 808126 808127 808715 808140 808326

FLOW DIVIDER

Description

HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 MANIFOLD, WPS JOYSTICK . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 2 CONTROLLER, OUTRIGGERS . . . 1 HOSE, -6 A6/DS6 18” . . . . . . . . . . . 1

FRONT

3 WPS VALVE

10 T

11

11

P

J

12 3 J1 J2

5 8

159

Qty. Req.

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS and Aux. Hydraulic Option FRONT

TILT LEVEL

1 LIFT EXTEND

2 P

3

T

4 P

HYDRAULIC OPTION

T

16 11

3

7

4

3 5

8

10

T

9 P

12 6 9 7

T

17

4

13

FLOW DIVIDER

FRONT

3 WPS VALVE

14 T

6

6

P

J

15 3 J1 J2 HYDRAULIC TANK

11 8

160

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - WPS and Aux. Hydraulic Option Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808263 808138 808443 808464 808679 808455 808850 808265 808850

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1

Ref. No.

Part No.

10 11 12 13 14 15 16 17

808882 808265 808282 808126 808127 808715 808139 808326

161

Description

Qty. Req.

HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 MANIFOLD, WPS JOYSTICK . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 1 CONTROLLER, AUX. HYD . . . . . . . 1 HOSE, -6 A6/DS6 18” . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - All Options with WPS FRONT

TILT LEVEL

1 LIFT EXTEND

2 P

3

OUTRIGGER

T

4 P HYDRAULIC OPTION

19

7

T

11 3

18

4 3 5

8

9

10

T

12 3 5

T

P

7 6

P

4 9

6 16 17

T

20

4

13

FLOW DIVIDER

FRONT

3 WPS VALVE

14 T

6

6

P

J

15 3 J1 J2 HYDRAULIC TANK

11 8

162

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - All Options Ref. No. 01 02 03 04 05 06 07 08 09 10

Part No. 808263 808138 808443 808464 808679 808455 808850 808265 808850 808882

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/DS6 26” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1

Ref. No.

Part No.

11 12 13 14 15 16 17 18 19 20

808265 808282 808126 808127 808715 808715 808715 808139 808140 808326

163

Description

Qty. Req.

HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 MANIFOLD, WPS JOYSTICK . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 2 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 1 CONTROLLER, AUX. HYD . . . . . . . 1 CONTROLLER, OUTRIGGERS . . . 1 HOSE, -6 A6/DS6 18” . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - All Options without WPS FRONT

TILT LEVEL

1

LIFT EXTEND

2 P OUTRIGGER

3 T

4 P HYDRAULIC OPTION

T

8 3

14

10 7

4 15

3

8 5

T

3 5

12

9

P

11

7

10

T

6

P

6

4

9

16 17

17

FRONT

16

FLOW DIVIDER

13 J

6

11 HYDRAULIC TANK

164

TABLE OF CONTENTS

Hydraulics Hydraulic Controls - All Options without WPS Ref. No. 01 02 03 04 05 06 07 08 09

Part No. 808263 808138 808443 808464 808679 808455 808853 808882 808853

Description

Qty. Req.

CONTROLLER, TILT/LEVEL. . . . . . 1 CONTROLLER, LIFT/EXTEND . . . . 1 ADAP, -6ORM -6JICM STR . . . . . AR ADAP, -6 SWIVEL RUN TEE . . . . AR ADAP, -6JICM -6JICFS 90 DEG . AR ADAP, -6ORM -6JICM 90 DEG . . AR HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/DS6 20” . . . . . . . . . . . 1

Ref. No.

Part No.

10 11 12 13 14 15 16 17

808882 808265 808282 808126 808140 808139 808715 808715

165

Description

Qty. Req.

HOSE, -4 A6/DS6 17” . . . . . . . . . . . 1 HOSE, -4 A6/A6 54” . . . . . . . . . . . . 1 HOSE, -4 A6/D6 35” . . . . . . . . . . . . 1 MANIFOLD, JOYSTICK RELIEF. . . 1 CONTROLLER, OUTRIGGERS . . . 1 CONTROLLER, AUX. HYD. . . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 15” . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Outrigger Main Valve / Controller

1 2

5

3

T

AC

10

4

R ET

R

6

6

7

8

23 12 9

13

11

14

RIGHT SECTION LEFT SECTION

6 16

15

D

N

E XT

6

E

18

19

17

20

21 22

FRONT

166

TABLE OF CONTENTS

Hydraulics Outrigger Main Valve / Controller Ref. No. 01 02 03 04 05 06a 07 08 09 10 11 12 13

Part No. 808459 808851 808851 808851 808851 808409 808679 808883 808883 808269 808268 808685 808444 808638

Description

Qty. Req.

ADAP, -8ORM -8JICFS 90 DEG . . . 4 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 HOSE, -6 A8/DS8 54” . . . . . . . . . . . 1 ADAP, 1/4BSP -6JICM STRAIGHT . 4 ADAP, -6ORM -6JICFS SWVL 90 . . 4 HOSE, -4 A6/A6 81” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 81” . . . . . . . . . . . . 1 HOSE, -12 H12/DS12 58” . . . . . . . . 1 HOSE, -12 A12/DS12 57” . . . . . . . . 1 ADAP, -16ORM -12JICM 90 DEG . . 1 ADAP, -12ORM -8JICM STR. . . . . . 4 3/8”-16X4” BOLT . . . . . . . . . . . . . . . 3

Ref. No.

Part No.

14 15 16 17 18

808133 808779 808852 808852 808267 808461 808602 808590 808151 808663 808453 808443 808140

19 20 21 22 23 24 25 a

Description

Qty. Req.

VALVE, OUTRIGGER . . . . . . . . . . . 1 ADAP, -16ORM -12JICM STR. . . . . 1 HOSE, -4 A6/A6 96” . . . . . . . . . . . . 1 HOSE, -4 A6/A6 96” . . . . . . . . . . . . 1 HOSE, -12 A12/A12 30” . . . . . . . . . 1 ADAP, -12JICM -12JICFS 90 DEG 1 5/16”-18X1/2” BOLT . . . . . . . . . . . . 2 5/16” FLAT WASHER . . . . . . . . . . . 2 MOUNT, OUTRIGGER VALVE . . . . 1 3/8”-16 LOCK NUT . . . . . . . . . . . . . 3 ADAP, -12ORM -12JICM 90 DEG . . 1 ADAP, -6ORM -6JICM STR. . . . . . . 4 CONTROLLER, OUTRIGGERS . . . 1

Note; the illustration on the facing page does not show the parts individually.

RIGHT SECTION

LEFT SECTION

25

24 FRONT

8

7

17

16 EXTEND

RETRACT

HOSE LOCATOR 02 03 04 05 07 08 09 10 16 17 18

OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER

VAVLE “RIGHTSECTION” (retract) VAVLE “RIGHTSECTION” (extend) VAVLE “LEFT SECTION” (extend) VAVLE “LEFT SECTION” (retract) VAVLE “RIGHTSECTION” (retract) VAVLE “LEFT SECTION” (retract) MAIN VALVE “OUT” MAIN VALVE “IN” VAVLE “RIGHTSECTION” (extend) VAVLE “LEFT SECTION” (extend) MAIN VALVE “TANK”

OUTRIGGER CYLINDER “RIGHT SIDE” (retract) OUTRIGGER CYLINDER “RIGHT SIDE” (extend) OUTRIGGER CYLINDER “LEFT SIDE” (extend) OUTRIGGER CYLINDER “LEFT SIDE” (retract) OUTRIGGER CONTROLLER “RIGHT SIDE” (retract) OUTRIGGER CYLINDER “LEFT SIDE” (retract) SPLICE TO HOSE FROM MAIN VALVE “IN” FLOWDIVIDER VALVE “EP” OUTRIGGER CONTROLLER “RIGHT SIDE”(extend) OUTRIGGER CONTROLLER “LEFT SIDE” (extend) HYDRAULIC TANK “RETURN” (front side of tank)

167

TABLE OF CONTENTS

Hydraulics Frame Level Cylinder - Breakdown

1

7

2

6

5 3

8

4

9

11

10

12

168

TABLE OF CONTENTS

Hydraulics Frame Level Cylinder - Breakdown Ref. No. 00 01 02 03 04 05 06 07

Part No. 808304 809059 808708 809067 809136 809061 809068 809128

Description

Qty. Req.

FRAME LEVEL CYL. (Complete) . . 1 ROD. . . . . . . . . . . . . . . . . . . . . . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 1 HEAD GLAND CAP. . . . . . . . . . . . . 1 5/16”-18x1/4” SET SCREW. . . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 1-1/4”-12 UNF LOCKNUT . . . . . . . . 1

Ref. No.

Part No.

08 09 10 11

808756 NSS 809062 809267 808965 809060

12

169

Description

Qty. Req.

BUSHING 2.0X2.25X2.0” . . . . . . . . 1 TUBE WELDMENT . . . . . . . . . . . . . 1 OIL LINE TUBE ASSEMBLY . . . . . . 1 COUNTER BALANCE VALVE . . . . . 2 SEAL KIT (CBV) . . . . . . . . . . . . . . . 1 CYLINDER SEAL KIT . . . . . . . . . . . 1 (Items included are not shown)

TABLE OF CONTENTS

Hydraulics Stabilizing Cylinder - Breakdown

2

1

4 3

5

6 3

5

7

8

170

TABLE OF CONTENTS

Hydraulics Stabilizing Cylinder - Breakdown Ref. No. 00 01 02 03 04

Part No. 808117 808858 808346 809159 809160

Description

Qty. Req.

STABILIZING CYL. (Complete) . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 1 ROD WELDMENT . . . . . . . . . . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 2 PISTON . . . . . . . . . . . . . . . . . . . . . . 1

Ref. No.

Part No.

05 06 07 08

808878 NSS 809158 809161

171

Description

Qty. Req.

BUSHING . . . . . . . . . . . . . . . . . . . . 2 TUBE WELDMENT . . . . . . . . . . . . . 1 CYLINDER ROD . . . . . . . . . . . . . . . 1 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

TABLE OF CONTENTS

Hydraulics Lift Cylinder - Breakdown

1

8

7 6

2 3 3

5 4

10

9

11

172

2

TABLE OF CONTENTS

Hydraulics Lift Cylinder - Breakdown Ref. No. 01 02 03 04 05 06

Part No. 808820 NSS 808962 808963 809105 809102 808964

Description

Qty. Req.

COMPL. ASSEMBLY . . . . . . . . . . . .1 ROD WELDMENT. . . . . . . . . . . . . . .1 SPHERICAL BUSHING 1.5 ID . . . .2 RETAINER RING . . . . . . . . . . . . . . .2 LOCKING INSERT . . . . . . . . . . . . .1 END GLAND . . . . . . . . . . . . . . . . . .1 PISTON . . . . . . . . . . . . . . . . . . . . . .1

Ref. No.

Part No.

07 08

809104 808476 808955 808795 NSS 809103 809127

09 10 11a a

173

Description

Qty. Req.

LOCKNUT 1-3/4-12 . . . . . . . . . . . .1 COUNTERBAL. VALVE . . . . . . . . . .1 CB SEAL KIT . . . . . . . . . . . . . . . . .1 CAP . . . . . . . . . . . . . . . . . . . . . . . . .1 TUBE WELDMENT. . . . . . . . . . . . . .1 HYD. OIL LINE TUBE . . . . . . . . . . .1 CYLINDER SEAL KIT . . . . . . . . . . .1

Items included with seal kit are not shown

TABLE OF CONTENTS

Hydraulics Boom Extend Cylinder - Breakdown

3

4 1

10 9 8 2

7 5

6

12 11

174

TABLE OF CONTENTS

Hydraulics Boom Extend Cylinder - Breakdown Ref. No. a b 01 02 03

Part No. 808160 808161 808756 808424 808903 809162

04

05 06

809145 808311 808556 809144

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY COMPLETE ASSEMBLY BUSHING (ROD END) . . . . . . . . . . 1 1/4”-28 GREASE ZERK. . . . . . . . . . 1 COUNTER BALANCE VALVE . . . . . 1 CBAL VALVE SEAL KIT . . . . . . . . . 1 ROD WELDMENT . . . . . . . . . . . . . . 1 Note a Note b HEAD GLAND CAP. . . . . . . . . . . . . 1 5/16-18X5/16” SET SCREW . . . . . . 1

07 08 09 10 11 12c

809100 808312 809143 809142 NSS 809141

a b c

Used with 42’ Boom Used with 44’ Boom Items included in the seal kit are not shown.

MT6642T/XT - 42’ BOOM MT8044XT - 44’ BOOM

175

Description

Qty. Req.

HEAD GLAND . . . . . . . . . . . . . . . . . 1 ROD SPACER . . . . . . . . . . . . . . . . . 1 5/16-18X5/8” SET SCREW . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 CYLINDER TUBE WELDMENT . . . 1 CYLINDER SEAL KIT . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Slave Cylinder - Breakdown

1 2

3 8

7

5 4

9

6

10 11 12

176

TABLE OF CONTENTS

Hydraulics Slave Cylinder - Breakdown Ref. No. 01 02 03 04 05 06

Part No. 808860 808424 809138 808709 809067 809139 809136

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY . . . . . . . . . 1 1/4-28 GREASE ZERK STR . . . . . . 1 ROD WELDMENT . . . . . . . . . . . . . . 1 BUSHING (ROD END) . . . . . . . . . . 1 HEAD GLAND CAP. . . . . . . . . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 1 5/16-18X1/4” SET SCREW . . . . . . 1

07 08 09 10 11a 12

809137 808578 808423 808831 809140 NSS

a

Items included in the seal kit are not shown.

177

Description

Qty. Req.

PISTON . . . . . . . . . . . . . . . . . . . . . . 1 1-3/8-12 UNF LOCKNUT. . . . . . . . . 1 1/4-28 GREASE ZERK 90 DEG . . . 1 BUSHING (BASE END). . . . . . . . . . 1 CYLINDER SEAL KIT . . . . . . . . . . . 1 CYLINDER TUBE WELDMENT . . . 1

TABLE OF CONTENTS

Hydraulics Tilt Cylinder - Breakdown

1

2

8 7 6 5 3

9

4

10

14

12

11

178

13

TABLE OF CONTENTS

Hydraulics Tilt Cylinder - Breakdown Ref. No. 01 02 03 04 05 06 07 08

Part No. 808859 809150 809148 809135 809144 809149 809134 809147 809104

Description

Qty. Req.

COMPLETE ASSEMBLY . . . . . . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 1 ROD WELDMENT . . . . . . . . . . . . . . 1 HEAD GLAND CAP. . . . . . . . . . . . . 1 5/16”-18X5/16” SET SCREW . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 1 THRUST WASHER . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 1-3/4” UNF LOCKNUT. . . . . . . . . . . 1

Ref. No.

Part No.

09 10 11 12 13a 14

808857 808907 808955 NSS 809155 809146 808424

a

Items included in the seal kit are not shown.

179

Description

Qty. Req.

BUSHING (BASE END). . . . . . . . . . 1 COUNTER BALANCE VALVE . . . . . 1 CB VALVE SEAL KIT . . . . . . . . . . . 1 CYLINDER TUBE WELDMENT . . . 1 PLUG -4. . . . . . . . . . . . . . . . . . . . . . 1 CYLINDER SEAL KIT . . . . . . . . . . . 1 1/4-28 GREASE ZERK STR . . . . . . 1

TABLE OF CONTENTS

Hydraulics Outrigger Cylinder - Breakdown

1

2 3

6 5

4

7

8

9 11 10

9

180

TABLE OF CONTENTS

Hydraulics Outrigger Cylinder - Breakdown Ref. No. 01 02 03 04 05 06

Part No. 808910 809168 808424 808911 809169 809268 808578

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY ROD WELDMENT . . . . . . . . . . . . . . 1 1/4”-28 GREASE ZERK. . . . . . . . . . 2 BUSHING (ROD END) . . . . . . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 1-3/8”-12 UNF LOCKNUT . . . . . . . . 1

07 08 09 10 11a

808858 809155 809166 NSS 809167

a

Items included in the seal kit are not shown.

181

Description

Qty. Req.

BUSHING (BASE END). . . . . . . . . . 1 PLUG, -40RM . . . . . . . . . . . . . . . . . 1 PO CHECK VALVE . . . . . . . . . . . . . 2 CYLINDER TUBE WELDMENT . . . 1 CYLINDER SEAL KIT . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Fork Shift Cylinder - Breakdown

1

3

4

2

6 5

182

TABLE OF CONTENTS

Hydraulics Fork Shift Cylinder - Breakdown Ref. No. 01 02 03 04

Part No. 808834 808581 808580 808579 808071

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY ROD WELDMENT . . . . . . . . . . . . . . 1 HEAD GLAND . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 3/4”-16 UNF LOCKNUT. . . . . . . . . . 1

05 06a

NSS 808506

a

Items included in the seal kit are not shown.

183

Description

Qty. Req.

TUBE WELDMENT . . . . . . . . . . . . . 1 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Rotate Carriage Cylinder - Breakdown

1

2

5

4 3

6 7 2

8

9

Ref. No. 01 02 03 04 05 06 07a

Part No. 808918 808502 808743 809101 808961 808070 NSS 808960

Description

Qty. Req.

COMPLETE ASSEMBLY ROD WELDMENT . . . . . . . . . . . . . . 1 SPHERICAL BEARING . . . . . . . . . . 2 HEAD GLAND . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 1”-14 UNS THIN COL. LOCKNUT . 1 TUBE WELDMENT . . . . . . . . . . . . . 1 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

Ref. No.

Part No.

08 09

808476 808955 808501

a

Items included in the seal kit are not shown.

184

Description

Qty. Req.

CB VALVE (3000 psi) . . . . . . . . . . . 2 CB VALVE SEAL KIT . . . . . . . . . . . 1 HYDRAULIC LINE ASSEMBLY. . . . 1

TABLE OF CONTENTS

Hydraulics Swing Carriage Cylinder - Breakdown

1

2

4

5

3

6

2

7 8

Ref. No. 01 02 03 04 05

Part No. 808738 809269 808720 809270 809271 808071

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY ROD WELDMENT . . . . . . . . . . . . . . 1 BUSHING . . . . . . . . . . . . . . . . . . . . 2 HEAD GLAND . . . . . . . . . . . . . . . . . 1 PISTON . . . . . . . . . . . . . . . . . . . . . . 1 3/4”-16 UNF LOCKNUT. . . . . . . . . . 1

06 07a 08

808424 809163 NSS

a

Items included in the seal kit are not shown.

185

Description

Qty. Req.

1/4”-28 GREASE ZERK. . . . . . . . . . 2 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1 TUBE WELDMENT . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Hydraulic Pump - Breakdown

1

2

Ref. No.

Part No.

01

808146 808469

02a

808350

Description

Qty. Req.

HYDRAULIC PUMP . . . . . . . . . . . . .1 GASKET, PUMP . . . . . . . . . . . . . . .1 (between pump and transmission) SEAL KIT . . . . . . . . . . . . . . . . . . . . .1

Ref. No. a

Part No.

Description

Qty. Req.

Items included in seal kit are not shown.

NOTE: Field service is limited to seals replacement.

186

TABLE OF CONTENTS

Hydraulics Master Cylinder Brake Valve - Breakdown

1

2

REPAIR KIT

3

7

4 5

6

Ref. No.

Part No.

00

808714

01 02

809063 NSS 809064 NSS NSS 809065

03 04 05

Description

Qty. Req.

Ref. No.

Part No.

BRAKE VALVE ASY. (Complete). . . .

(Two brake valves are required) BAIL WIRE. . . . . . . . . . . . . . . . . . . . 1 COVER . . . . . . . . . . . . . . . . . . . . . . 1 DIAPHRAM GASKET . . . . . . . . . . . 1 BODY TUBE SEAT (not shown) . . . . . . . . . 1 RUBBER BOOT . . . . . . . . . . . . . . . 1

06 07a

NSS 809066

a

Repair kit includes seals, cups, return spring, second arm piston, and snap ring. Piston is not included or sold seperately.

187

Description

Qty. Req.

PUSH ROD . . . . . . . . . . . . . . . . . . . 1 REPAIR KIT . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

TABLE OF CONTENTS

Hydraulics Power Steer Motor - Breakdown

1

LS L T

R P

2

Ref. No. 01 02

Part No. 808101 808585

Description

Qty. Req.

Ref. No.

STEERING CONTROL UNIT . . . . . 1 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

NOTE: Field service is limited to seals replacement.

188

Part No.

Description

Qty. Req.

TABLE OF CONTENTS

Hydraulics Steer Select Valve - Breakdown

1

2 3 4 5

Ref. No.

Part No.

01

808877

02 03

808398 808393

04

808397

Description

Qty. Req.

STEER SELECT VALVE . . . . . . . . . 1 (Includes all items shown) ORING . . . . . . . . . . . . . . . . . . . . . . . 2 COIL 12VDC W/CONNECTOR . . . . 2 (Includes item 5; nut) ORING . . . . . . . . . . . . . . . . . . . . . . . 2

Ref. No.

Part No.

05

NSS

00

809272

189

Description

Qty. Req.

NUT . . . . . . . . . . . . . . . . . . . . . . . . . 2 (Included with item 3) -- ITEMS NOT SHOWN -WIRE HARNESS . . . . . . . . . . . . . . 2 (connects wire leads to frame wiring)

TABLE OF CONTENTS

Hydraulics Priority Flow Divider - Breakdown

00

P 1

T

PP

LS 5

EF CF 4 3 2

6

Ref. No. 00 01 02 03

Part No. 808748 808958 NSS NSS

Description

Qty. Req.

Ref. No.

Part No.

COMPL. ASY. . . . . . . . . . . . . . . . . .1 RELIEF CARTRIDGE ASY. . . . . . . 1 PLUG ASY . . . . . . . . . . . . . . . . . . . .1 SPRING . . . . . . . . . . . . . . . . . . . . .1

04 05 06a

NSS NSS 808959

a

Items in seal kit are not shown.

190

Description

Qty. Req.

SPOOL . . . . . . . . . . . . . . . . . . . . . .1 PLUG . . . . . . . . . . . . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . .1

TABLE OF CONTENTS

Hydraulics Flow Divider - Breakdown 9 10 8

1

7

6

2 5

3

4

Ref. No. 01 02 03

Part No. 808126

04

808349 809157 809156 NSS

05

809151

06

809152 809153 809174

07

Description

Qty. Req.

MANIFOLD, FLOW DIVIDER . . . . .1 (includes items 1-7) PILOTED SPOOL LOGIC ELEM. . .1 RELIEF VALVE . . . . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . .1 NUT, SOLENOID VALVE . . . . . . . . .1 (included with item 5) 12 VDC WEATHER PACK COIL . . .1 (includes item 4) SOLENOID VALVE . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . .1 TEST PORT . . . . . . . . . . . . . . . . . . .3

Ref. No.

Part No.

08 09 10

808704 809273 808589 808588

Description

CAP, DUST COVER (not shown) . .3 1/4”-20X3-1/2” BOLT . . . . . . . . . . . .2 1/4” LOCK WASHER . . . . . . . . . . . .2 1/4” FLAT WASHER . . . . . . . . . . . .2

NOTE: Items included in seal kits are not shown.

191

Qty. Req.

TABLE OF CONTENTS

Hydraulics Stabilizing Valve - Breakdown

2

1

5 3 5

3

4

2 6

192

4

TABLE OF CONTENTS

Hydraulics Stabilizing Valve - Breakdown Ref. No.

Part No.

01

808305

02

809267 808965 NSS

03

Description

Qty. Req.

COMPLETE. VALVE ASSEMBLY . . 1 (includes all items shown) COUNTER BAL. VALVE 3700PSI . . 2 CBV SEAL KIT . . . . . . . . . . . . . . . . 2 NUT (Included with item 5) . . . . . . . 2

Ref. No.

Part No.

04 05

808407 808408 809154 809155

06

Description

E-COIL 12VDC . . . . . . . . . . . . . . . . 2 CARTRIDGE (only) . . . . . . . . . . . . . 2 SEAL KIT (included with cartridge) 2 PLUG -4ORM . . . . . . . . . . . . . . . . . 2

NOTE: Items included in seal kits are not shown.

193

Qty. Req.

TABLE OF CONTENTS

Hydraulics Main Valve - Breakdown

25 24

20 21 19

15

16 14

10

24 11

23

9 22

7

6

19 17

3 14 13 12 9 8

25 6 2 1

5

4

26

FRONT

194

18

TABLE OF CONTENTS

Hydraulics Main Valve - Breakdown Ref. No.

Part No.

01a

808129 808362

02h 03h 04 05b

808359 808358 808357 808363

06g 07h 08c

808361 808360 808364

09g 10h 11h 12h 13d

808361 808356 808360 808354 808365

14g 15h 16h

808361 808354 808360

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY. . . . . . . . . . . . . . .1 INLET SECTION . . . . . . . . . . . . . . .1 (includes items 1-4) PLUG KIT 1-5/16” UNF . . . . . . . . . .1 PLUG KIT . . . . . . . . . . . . . . . . . . . .1 PILOT OPERATED RELIEF VLV . . .1 WORK SECTION (Frame Level) . . .1 (includes items 5-7) HYD. CONTROL KIT . . . . . . . . . . . .1 CHECK VALVE . . . . . . . . . . . . . . . .1 WORK SECTION (Boom In/out) . . .1 (includes items 8-12) HYD. CONTROL KIT . . . . . . . . . . . .1 ANTISHOCK VALVE (140 BAR) . . .1 CHECK VALVE . . . . . . . . . . . . . . . .1 ANTICAVITATION VALVE . . . . . . . .1 WORK SECTION (Boom Up/Down) 1 (includes items 13-17) HYD. CONTROL KIT . . . . . . . . . . . .1 ANTICAVITATION VALVE . . . . . . . .1 CHECK VALVE . . . . . . . . . . . . . . . .1

17h 18e

808355 808366

19g 20h 21h 22h 23

808361 808353 808360 808353 808369

24h 25 26f

808375 808367 808370

a b c d e f g

Use seal kit #808371 for all related seals Use seal kit #808382 for all related seals Use seal kit #808372 for all related seals Use seal kit #808373 for all related seals Use seal kit #808374 for all related seals Items included with seal kit are not shown in detail.

Includes outer caps, orings, bolts, plug and internal spool spring for this work section, does not include orings for valves/plugs or the spool.

Includes required seals/orings for this valve/plug.

Seals/orings for this valve are not sold individually, however they are included with the work section seal kit where this valve is used.

h

195

Description

Qty. Req.

KIT PLUG . . . . . . . . . . . . . . . . . . . .1 WORK SECTION (Tilt) . . . . . . . . . .1 (includes items 18-22) HYD. CONTROL KIT . . . . . . . . . . . .1 COMBINATED VALVE . . . . . . . . . . .1 CHECK VALVE . . . . . . . . . . . . . . . .1 COMBINATED VALVE . . . . . . . . . . .1 OUTLET SECTION . . . . . . . . . . . . .1 (includes item 24) PLUG . . . . . . . . . . . . . . . . . . . . . .AR TIE ROD KIT (4 section valve) . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . . .1

TABLE OF CONTENTS

Hydraulics Main Valve - Aux. Hydraulics Work Section - Breakdown

3

4

2 3

2 1

5

FRONT

196

TABLE OF CONTENTS

Hydraulics Main Valve - Aux. Hydraulics Work Section - Breakdown Ref. No. 01 02a 03c 04c 05b

Part No. 808134 808361 808391 808360 808392

Description

Qty. Req.

AUXILIARY HYD WORK SECT. . . .1 (includes items 1-4) HYD. CONTROL KIT . . . . . . . . . . . .1 ANTISHOCK VALVE . . . . . . . . . . . .1 CHECK VALVE . . . . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . . .1

Ref. No.

Part No.

00

808266

a

Includes outer caps, orings, bolts, plug and internal spool spring for this work section, does not include orings for valves/plugs or the spool.

b

Items included with seal kit are not shown in detail.

c

Seals/orings for this valve are not sold individually, however they are included with the work section seal kit where this valve is used.

197

Description

Qty. Req.

-- ITEMS NOT SHOWN -KIT, FIVE SECTION TIE BOLT . . . . 4 (includes 1 bolt, 2 nuts & 2 washers)

TABLE OF CONTENTS

Hydraulics Outrigger Control Valve - Breakdown

10 12

7 6 12 7 6 9

3

8

6 5 10 6 5 2 1

4

11

FRONT

198

TABLE OF CONTENTS

Hydraulics Outrigger Control Valve - Breakdown Ref. No.

Part No.

01a

808133 808377

02cf 03cf 04 05b

808368 808358 808357 808378

06d 07cf 08

808361 808360 808379

09cf

808375 808380

10

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY. . . . . . . . . . . . . . .1 INLET SECTION . . . . . . . . . . . . . . .1 (includes items 1-4) PLUG KIT 1-1/16” UNF . . . . . . . . . .1 PLUG KIT . . . . . . . . . . . . . . . . . . . .1 PILOT OPERATED RELIEF VLV . . .1 WORK SECTION . . . . . . . . . . . . . . .2 (includes items 5-7) HYD. CONTROL KIT (per section) .1 CHECK VALVE . . . . . . . . . . . . . . . .1 OUTLET SECTION . . . . . . . . . . . . .1 (includes item 9) PLUG . . . . . . . . . . . . . . . . . . . . . .AR TIE ROD KIT (2 section valve) . . . .1

11e 12

808376 808383

a b c d

Use seal kit #808381 for all related seals Use seal kit #808382 for all related seals Includes orings for valve/plug.

Includes outer caps, orings, bolts, plug and internal spool spring for this work section, does not include orings for valves/plugs or the spool.

Items included with seal kit are not shown in detail.

e f

199

Description

Qty. Req.

SEAL KIT . . . . . . . . . . . . . . . . . . . . .1 3/8” CONIC PLUG . . . . . . . . . . . . . .2

Seals/orings for this valve are not sold individually, however they are included with the work section seal kit where this valve is used.

TABLE OF CONTENTS

Hydraulics Controller - Tilt / Frame Level - Breakdown

1

2

3

4

5

6

7

8

9

10

200

TABLE OF CONTENTS

Hydraulics Controller - Tilt / Frame Level - Breakdown Ref. No. 00 01 02 03 04 05 06 07

Part No. 808263 808406 808399 808400 809274 808401 808402 808403

Description

Qty. Req.

Ref. No.

Part No.

HYD. CONTROLLER (Complete) . 1 KNOB. . . . . . . . . . . . . . . . . . . . . . . . 1 LEVER ROD (as shown) . . . . . . . . . 1 BOOT. . . . . . . . . . . . . . . . . . . . . . . . 1 LOCK GATE . . . . . . . . . . . . . . . . . . 1 SELECTOR DISC . . . . . . . . . . . . . . 1 PIVOT/ BALL JOINT . . . . . . . . . . . . 1 PLATE / BOOT MOUNT . . . . . . . . . 1

08 09 10a

808386 808387 808404

a

Items included in seal kit are not shown.

201

Description

Qty. Req.

METERING CURVE (as shown) . . . 4 RETURN SPRING. . . . . . . . . . . . . . 4 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Controller - Lift / Extend - Breakdown

1

2

3

4

5

6

7

8

9

202

TABLE OF CONTENTS

Hydraulics Controller - Lift / Extend - Breakdown Ref. No. 00 01 02 03 04 05 06

Part No. 808138 808406 808399 808400 808401 808402 808403

Description

Qty. Req.

Ref. No.

Part No.

HYD. CONTROLLER (Complete) . 1 KNOB. . . . . . . . . . . . . . . . . . . . . . . . 1 LEVER ROD (as shown) . . . . . . . . . 1 BOOT. . . . . . . . . . . . . . . . . . . . . . . . 1 SELECTOR DISC . . . . . . . . . . . . . . 1 PIVOT/ BALL JOINT . . . . . . . . . . . . 1 PLATE /BOOT MOUNT . . . . . . . . . . 1

07 08 09a

808386 808387 808404

a

Items included in seal kit are not shown.

203

Description

Qty. Req.

METERING CURVE (as shown) . . . 4 RETURN SPRING. . . . . . . . . . . . . . 4 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Controller - Outrigger (Option) - Breakdown

1

1

2

3 2

4

3 5

6

204

TABLE OF CONTENTS

Hydraulics Controller - Outrigger (Option) - Breakdown Ref. No. 00 01 02 03

Part No. 808140 808388 809275 808385

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE VALVE ASY. . . . . . . . . 1 LEVER ROD (as shown) . . . . . . . . . 2 BOOT (included with item #3) . . . . . 2 CONTROL KIT. . . . . . . . . . . . . . . . . 2 (includes item #2 Boot)

04 05 06a

808386 808387 808389

a

Items included in seal kit are not shown.

205

Description

Qty. Req.

METERING CURVE (as shown) . . . 4 RETURN SPRING. . . . . . . . . . . . . . 4 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Controller - Auxiliary Hydraulics (Option) - Breakdown

1

2

3

4

5

6

206

TABLE OF CONTENTS

Hydraulics Controller - Auxiliary Hydraulics (Option) - Breakdown Ref. No.

Part No.

00 01 02 03

808139 808384 809275 808385

04

808386

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE VALVE ASY. . . . . . . . . 1 LEVER ROD (as shown) . . . . . . . . . 1 BOOT (included with item #3) . . . . . 1 CONTROL KIT. . . . . . . . . . . . . . . . . 1 (includes item #2 Boot) METERING CURVE (as shown) . . . 2

05 06a

808387 808390

a

Items included in seal kit are not shown.

207

Description

Qty. Req.

RETURN SPRING. . . . . . . . . . . . . . 2 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

TABLE OF CONTENTS

Hydraulics Steer Cylinder - Breakdown

1

2

Ref. No. 01

Part No. 808171 808551

Description

Qty. Req.

STEER CYLINDER . . . . . . . . . . . . . 1 STEER CYLINDER BOLT . . . . . . . 4

Ref. No.

Part No.

02

808405

Description

SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

NOTE: Quantities are per axle

208

Qty. Req.

TABLE OF CONTENTS

Hydraulics PWP Manifold - Breakdown

Ref. No.

Part No.

00

808127

01

NSS

02 03

809151 809277 809153

Description

Qty. Req.

MANIFOLD, PWP JOYSTICK. . . . . 1 (Complete assembly) NUT, SOLENOID VALVE . . . . . . . . 2 (included with item 3 and 4) 12 VDC WEATHER PACK COIL. .. 2 SOLENOID VALVE. . . . . . . . . . . . 1 SEAL KIT. . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

Ref. No.

Part No.

04

809152 809153

SOLENOID VALVE. . . . . . . . . . . . 1 SEAL KIT. . . . . . . . . . . . . . . . . . . . 1 (Items included are not shown)

05

NSS

MANIFOLD . . . . . . . . . . . . . . . . . . 1

209

Description

Qty. Req.

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

808001 808002 808004 808004 808005 808006 808025 808026 808027 808028 808029 808030 808031 808032 808033 808034 808035 808036 808037 808038 808039 808040 808041 808042 808063 808064 808066 808067 808069 808070 808071 808071 808072 808073 808074 808075 808076 808077 808078 808079 808080 808081 808082 808083 808084 808085 808086 808087 808088 808089 808090 808090 808091 808092 808093

55 1 1 63 4 73 2 49 34 49 0 6 6 6 6 6 6 7,8,9,10 7,8 7,8,9,10 7,8 7,8 7,8 9,10 9,10,119 11 11 11 11 37 0 129 0 57 3 57 4 23 15 184 5 183 4 185 5 47 21 23 19 23 19 89 4a 91 8 139 16 45 29 1 137 19 139 10 119 1 23 4 33 25b 119 13 21 22 47 27 47 5 17 20 13 21 13 24 47 2 35 5 17 17

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

808094 808095 808096 808097 808098 808099 808100 808101 808101 808101 808102 808103 808104 808105 808106 808107 808107 808108 808108 808109 808109 808110 808111 808112 808113 808114 808115 808116 808117 808117 808118 808118 808119 808119 808120 808120 808121 808122 808122 808123 808123 808124 808125 808126 808126 808126 808126 808126 808126 808126 808126 808126 808126 808126 808127 808127 808127

21 15 15 21 53 27 49 27 145 188 53 53 47 47 61 89 91 89 91 39 89 49 63 53 53 63 63 113 41 171 41 89 101 105 107 111 115 101 105 107 111 115 105 91 143 151 153 155 157 159 161 163 165 191 51 157 159

19 13 15a 20 00a 0 27 11 1 1 3 6 22 23 7 23 24 23 25 14 11 12 17 7 8 23 12 10 4 0 18 21 1 1 1 1 1 1 1 1 1 1 5 18 9 7 13 13 9 13 13 13 13 1 2 10 14

808127 808127 808127 808128 808128 808129 808129 808129 808130 808131 808132 808132 808133 808133 808134 808134 808134 808134 808135 808136 808137 808138 808138 808138 808138 808138 808138 808138 808138 808138 808138 808139 808139 808139 808139 808139 808139 808140 808140 808140 808140 808140 808140 808141 808142 808143 808144 808145 808146 808146 808147 808148 808149 808150 808151 808152 808153

161 163 209 103 121 147 149 195 119 50 43 125 167 199 129 147 149 197 43 43 45 149 151 153 155 157 159 161 163 165 203 149 153 161 163 165 207 155 159 163 165 167 205 97 125 125 63 21 143 186 47 47 121 121 167 49 49

14 14 0 1 12 23b 8a 0 15 1 9 22 14 0 18 23 8 1 21 20 5 2 2 2 2 2 2 2 2 2 0 1 14 16 18 15 0 14 16 19 14 25 0 47 18 4 7e 13 3 1 1 6 25 24 21 6 5

808154 808155 808156 808157 808157 808158 808159 808160 808160 808161 808161 808162 808163 808164 808165 808166 808168 808169 808169 808170 808170 808171 808171 808172 808173 808174 808175 808176 808177 808178 808179 808180 808180 808181 808182 808183 808184 808185 808186 808187 808188 808189 808190 808191 808192 808193 808194 808195 808196 808197 808198 808199 808200 808201 808202 808203 808204

33 33 33 55 57 121 121 121 175 121 175 123 129 37 89 45 93 93 97 93 97 93 208 93 95 95 97 97 97 97 97 89 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97 97

8 5 15 15 14 15 7 1 a 1 b 11 11 8 8a 00b 4 6 25 7 24 10 1 11 3 3 2 3 50 4 11 7a 51 12 13 18 19 20 21 22 23 26 27 28 29 30 31 32 33 34 35 40 41 43 43 43 45

210

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

808205 808206 808207 808208 808209 808210 808211 808211 808212 808212 808213 808214 808214 808215 808216 808216 808217 808217 808218 808218 808219 808219 808220 808221 808222 808222 808223 808224 808225 808226 808227 808228 808228 808229 808229 808230 808231 808231 808232 808233 808234 808235 808236 808237 808238 808239 808240 808241 808242 808242 808243 808244 808245 808246 808247 808248 808249

97 97 98 98 98 98 98 99 98 99 98 98 99 98 98 99 98 99 98 99 98 99 98 98 98 99 98 98 98 98 98 98 99 98 99 43 13 23 45 51 27 63 13 43 21 21 15 13 13 15 19 19 13 21 15 13 13

46 48 1 2 3 4 5 19 6 2 7 9 16 10 11 15 12 14 13 13 16 11 17 18 19 8 20 21 24 24 24 25 5 26 6 0 0 20b 00a 0 0 22 21 7 3 4 12 3 12 9 7 1a 24 2 11 2 16

808249 808250 808251 808252 808253 808254 808255 808256 808257 808258 808259 808260 808261 808262 808263 808263 808263 808263 808263 808263 808263 808263 808263 808263 808264 808265 808265 808265 808265 808265 808265 808265 808265 808265 808265 808265 808265 808266 808266 808266 808266 808267 808267 808268 808269 808270 808270 808270 808271 808271 808271 808272 808272 808273 808274 808274 808275

15 19 103 19 19 15 15 61 13 13 35 13 13 27 149 151 153 155 157 159 161 163 165 201 33 151 153 155 157 157 159 159 161 161 163 163 165 129 147 149 197 49 167 167 167 147 147 149 129 147 147 123 129 143 143 145 143

10 6 4 3 10 19a 20a 4 18a 17a 3 19 20 12 3 1 1 1 1 1 1 1 1 0 4 9 11 11 5 8 8 10 8 11 8 11 11 18 23 8 0 32b 18 10 9 19a 24a 7 8 13 29 7 7 5 15 6 13

808275 808276 808277 808277 808278 808279 808279 808280 808280 808281 808281 808282 808282 808282 808282 808282 808282 808282 808282 808282 808283 808283 808283 808283 808283 808284 808284 808284 808284 808284 808285 808286 808286 808287 808287 808288 808288 808289 808289 808289 808289 808290 808290 808290 808290 808291 808291 808291 808292 808292 808292 808292 808293 808293 808293 808293 808294

145 145 143 147 91 31 91 31 91 31 91 49 151 153 155 157 159 161 163 165 147 147 147 147 149 147 147 147 147 149 145 91 145 91 145 61 147 61 61 63 63 121 121 147 147 123 147 147 127 127 147 147 127 127 147 147 125

24 9 11a 1 6 13 12 8 22 7 5 17 6 12 12 6 12 12 12 12 16a 17a 26a 27a 6 15a 18a 25a 28a 5 7 11 8 10 15 25 20 23 29 2 15 18 19 6 33 8 12 30 9 10 9 31 8 11 8 32 21

808294 808295 808295 808295 808295 808296 808296 808297 808297 808298 808298 808299 808299 808300 808301 808302 808302 808302 808303 808304 808304 808305 808305 808306 808307 808308 808308 808309 808310 808311 808312 808313 808314 808315 808316 808317 808318 808319 808320 808321 808322 808323 808324 808325 808326 808326 808326 808326 808326 808326 808327 808328 808329 808330 808331 808331 808332

125 41 41 125 125 125 125 39 41 47 53 31 31 95 33 39 41 147 21 39 169 41 193 13 13 13 23 35 21 175 175 97 97 97 97 21 25 17 17 17 53 21 25 25 49 143 157 159 161 163 21 67 85 85 85 85 85

25 6 11 8 20 10 11 8 27 34 0 1 2a 22 26b 9 1 4 1 1 0 29 1 9 13 25b 17 7 21 4 8 15 52 53 37 12 1 11 9 0 0 15 3 4 15 16 13 17 17 20 20 10 1 2 3 8 4

211

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

808333 808333 808334 808335 808336 808337 808338 808339 808341 808342 808343 808344 808346 808347 808348 808349 808350 808351 808352 808353 808353 808354 808354 808355 808356 808357 808357 808358 808358 808359 808360 808360 808360 808360 808360 808360 808361 808361 808361 808361 808361 808361 808362 808363 808364 808365 808366 808367 808368 808369 808370 808375 808375 808376 808377 808378 808379

85 85 85 85 85 85 85 49 45 31 29 45 171 17 21 191 186 25 25 195 195 195 195 195 195 195 199 195 199 195 195 195 195 195 197 199 195 195 195 195 197 199 195 195 195 195 195 195 199 195 195 195 199 199 199 199 199

5 9 6 7 10 11 12 33 4 11 13 0 2 0 0 2 2a 1 5 20h 22h 12h 15h 17h 10h 4 4 3h 3cf 2h 7h 11h 16h 21h 4c 7cf 6g 9g 14g 19g 2a 6d 1a 5b 8c 13d 18e 25 2cf 23 26f 24h 9cf 11e 1a 5b 8

808380 808383 808384 808385 808385 808386 808386 808386 808386 808387 808387 808387 808387 808388 808389 808390 808391 808392 808393 808394 808394 808394 808395 808395 808395 808395 808396 808397 808398 808399 808399 808400 808400 808401 808401 808402 808402 808403 808403 808404 808404 808405 808406 808406 808407 808408 808409 808409 808409 808410 808411 808412 808413 808414 808414 808415 808416

199 199 207 205 207 201 203 205 207 201 203 205 207 205 205 207 197 197 189 23 23 23 23 23 23 23 45 189 189 201 203 201 203 201 203 201 203 201 203 201 203 208 201 203 193 193 147 149 167 49 25 25 21 103 121 137 63

10 12 1 3 3 8 7 4 4 9 8 5 5 1 6a 6a 3c 5b 3 23 27 28 29 30 31 32 00b 4 2 2 2 3 3 5 4 6 5 7 6 10a 09a 2 1 1 4 5 22 9 6a 26 6 9 17 2 11 11 13b

808417 808418 808419 808420 808420 808421 808422 808422 808422 808423 808423 808423 808423 808424 808424 808424 808424 808424 808424 808424 808424 808424 808424 808425 808426 808427 808427 808428 808429 808429 808429 808430 808431 808431 808431 808431 808432 808433 808434 808435 808436 808437 808438 808439 808440 808441 808442 808442 808442 808442 808443 808443 808443 808443 808443

21 89 21 15 19 15 15 19 21 41 113 125 177 33 37 41 113 119 175 177 179 181 185 55 55 55 57 59 103 113 121 139 131 133 135 137 27 61 53 27 27 43 23 47 49 129 63 121 143 147 49 91 143 145 149

11 15 5 2 9 3 6 8 6 16 1 6 9 10 0 28 21 2 2 1 14 2 6 0 7 17 15 5 7 2 10 14 5 3 2 2 1 0 2 2 3 0 18 14 13 10 24 20 10a 7 20 17 12 13 4

808443 808443 808443 808443 808443 808443 808443 808443 808443 808444 808445 808445 808445 808445 808445 808445 808445 808446 808447 808448 808449 808450 808451 808452 808453 808453 808453 808453 808453 808453 808454 808454 808454 808454 808455 808455 808455 808455 808455 808455 808455 808455 808455 808455 808455 808455 808456 808457 808457 808458 808458 808459 808459 808459 808460

151 153 155 157 159 161 163 165 167 167 27 37 41 125 135 139 145 31 63 139 123 129 145 63 49 121 127 143 147 167 39 41 127 139 49 91 137 145 151 153 155 157 159 161 163 165 137 47 91 41 147 91 139 167 127

3 3 3 3 3 3 3 3 24 12 9 13 5 7 8 5 3 6 3 13 23 16 21 1 31b 6 17 6 11 23 7 23 12 8 19 16 21 12 8 6 6 11 6 6 6 6 18 32 21 3 3 9 26c 1 16

212

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

808460 808461 808461 808462 808462 808463 808464 808464 808464 808464 808464 808464 808464 808464 808465 808466 808467 808468 808469 808469 808470 808471 808472 808473 808474 808475 808476 808476 808477 808478 808479 808480 808481 808482 808483 808483 808483 808483 808484 808484 808485 808486 808487 808488 808489 808490 808490 808490 808491 808491 808491 808492 808493 808494 808495

147 63 167 47 49 121 137 153 155 157 159 161 163 165 53 33 61 61 143 186 13 13 89 55 33 121 173 184 113 113 17 17 15 13 13 15 19 21 13 21 15 15 15 15 21 15 19 21 15 19 21 13 13 17 15

10 14 18 31 24 21 20 4 4 4 4 4 4 4 18c 11 3 6 3 1 30 19 1 12 7 5 8 8 5 6 2 18 16 7 8 5 4 8 6 21 8 14 18 17 16 1 2 9 4 5 7 4 4 8 7

Part No.

Page No.

808496 808497 808498 808499 808500 808501 808502 808503 808503 808504 808505 808506 808507 808508 808508 808509 808509 808510 808511 808512 808513 808514 808515 808516 808517 808518 808519 808520 808521 808522 808523 808524 808525 808525 808526 808527 808528 808529 808530 808531 808532 808533 808534 808535 808536 808536 808537 808538 808539 808540 808541 808542 808543 808543 808543

25 13 13 139 43 184 184 79 81 83 45 183 47 71 79 79 79 71 79 79 79 79 93 93 95 95 95 95 95 95 95 95 95 97 95 95 95 95 95 95 95 95 95 95 71 95 95 97 97 97 97 97 89 93 97

Ref. No. 8 19 19 0 9 1 3 3 1 7 6a 6 7 23 22 24 16 1 2 19 20 2 5 1 2 2 2 2 5 6 7 8 14 9 10 11 12 13 14 15 17 17 18 8 23 24 1 5 6 7 10 19 16 16

Part No.

Page No.

808543 808543 808544 808544 808544 808545 808545 808545 808545 808545 808546 808547 808548 808549 808549 808550 808550 808551 808551 808552 808552 808553 808553 808554 808554 808555 808555 808555 808555 808555 808555 808555 808555 808556 808557 808558 808559 808559 808559 808560 808561 808562 808563 808564 808565 808566 808568 808569 808570 808571 808572 808573 808574 808575 808576

98 99 47 53 53 13 33 43 45 145 97 97 97 98 99 98 99 93 208 89 93 89 93 89 93 29 33 55 105 111 115 137 145 175 53 45 47 89 101 17 17 17 17 17 17 17 17 17 17 17 17 17 17 33 45

213

Ref. No. 23 3 8

5 24 17 6 10 36 38 39 14 10 15 12 9 1 20 12 16 13 17 14 9 3 7 3 10 10 28 23 5 17 9 29 5a 10 19c 4 3 15 12 6 11 13 10 5c 14 16 1 7 14 00b

Part No.

Page No.

Ref. No.

808577 808578 808578 808579 808580 808581 808583 808583 808583 808583 808584 808585 808586 808587 808588 808588 808589 808589 808589 808590 808590 808590 808590 808590 808590 808590 808590 808591 808591 808591 808591 808591 808591 808591 808591 808591 808591 808592 808592 808592 808592 808592 808593 808593 808593 808593 808593 808593 808593 808593 808593 808594 808595 808595 808595

45 177 181 183 183 183 37 39 41 89 113 188 27 101 41 191 13 41 191 29 33 43 49 61 101 125 167 41 111 115 121 123 123 127 129 129 137 33 45 49 59 61 63 101 107 111 115 121 125 135 139 33 33 59 61

00b 8 6 3 2 1 7 16 20 13 14 2 4 7 26 10 14 25 9 8 29b 3 9 2 4 13 20 8 4 4 23 2 14 14 2 14 23 17 2 22 7 27 13b 20 8 8 7 27 16 26 21 19 6 8 19

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

808596 808596 808596 808597 808598 808599 808600 808600 808600 808600 808600 808601 808602 808602 808602 808602 808603 808603 808603 808603 808603 808603 808603 808603 808604 808605 808606 808606 808606 808606 808606 808606 808606 808607 808608 808608 808608 808608 808608 808609 808609 808609 808609 808610 808610 808610 808611 808612 808612 808613 808614 808614 808615 808615 808616

101 113 139 121 29 89 13 15 21 25 45 43 33 43 61 167 37 41 43 55 61 103 119 123 33 127 101 107 109 111 115 117 121 89 31 33 49 107 135 125 125 135 137 37 113 123 39 47 139 53 121 127 53 63 133

31 17 25 3 4 9 15 0 21 7 6 16 28b 11 16 19 1 7 2 7 14 5 12 20 2 15 16 11 6 9 8 11 28 2a 16 16 21 3 27 3 15 13 33 21 8 18 3 3 11 9 4 2 10 16 4

808617 808617 808617 808618 808619 808619 808619 808620 808621 808621 808621 808621 808621 808621 808622 808623 808624 808625 808626 808626 808626 808627 808628 808628 808629 808630 808631 808631 808632 808633 808634 808634 808634 808635 808636 808637 808638 808638 808639 808640 808640 808640 808640 808640 808640 808641 808642 808642 808642 808642 808643 808643 808643 808644 808645

59 107 117 139 101 113 139 37 35 39 41 49 101 109 137 63 101 29 103 121 133 145 123 137 143 33 103 121 33 119 39 41 89 135 63 47 135 167 139 29 43 49 61 125 125 63 31 101 121 137 31 89 117 139 123

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

Part No.

Page No.

808645 808646 808647 808648 808649 808650 808651 808652 808652 808652 808653 808653 808653 808654 808654 808655 808655 808656 808656 808656 808657 808658 808658 808659 808659 808660 808661 808661 808661 808661 808662 808662 808662 808662 808662 808662 808662 808662 808662 808663 808663 808663 808663 808663 808663 808663 808663 808663 808663 808663 808663 808663 808663 808664 808664

129 133 129 103 135 63 119 131 135 137 105 111 115 29 33 55 57 31 91 145 123 61 147 55 57 41 21 47 137 139 21 31 43 101 111 115 125 133 139 31 33 37 39 45 59 61 101 113 123 125 135 137 167 53 63

214

Ref. No. 15 7 1 14 17 8 17 5 3 3 4 5 5 3 20 13 10 5 23 19 25 24 21 10 8 22 21 20 13 4 14 17 8 9 2 2 12 12 17 15 18 20 4 3 7 26 14 9 16 2 15 32 22 13 19

Part No.

Page No.

Ref. No.

808665 808665 808665 808665 808665 808665 808665 808665 808666 808666 808667 808667 808667 808667 808668 808668 808669 808670 808671 808671 808671 808671 808671 808671 808672 808673 808673 808673 808674 808675 808676 808677 808678 808679 808679 808679 808679 808679 808679 808679 808679 808679 808680 808681 808682 808683 808684 808685 808685 808685 808685 808686 808687 808688 808689

47 61 103 119 131 135 137 139 13 33 13 13 33 47 27 101 101 47 33 43 43 61 103 105 13 101 113 117 33 33 53 139 59 49 91 153 155 159 161 163 165 167 43 31 43 43 59 61 143 147 167 47 135 135 139

4 20 12 16 5 1 1 12 11 24 10 23 27b 28 8 11 5 24 27 4 10 5 3 6 0 28 11 6 0 13 23b 22 11 36 2 5 5 5 5 5 5 6 12 3b 15 26 7 22 4 2 11 25 23 11 23

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

808690 808691 808691 808692 808692 808692 808693 808693 808693 808693 808693 808693 808694 808695 808696 808696 808696 808696 808697 808697 808698 808698 808699 808699 808700 808701 808701 808701 808701 808702 808702 808702 808703 808704 808705 808706 808707 808707 808708 808708 808709 808709 808710 808710 808711 808712 808713 808713 808714 808714 808714 808715 808715 808715 808715

49 111 115 101 107 109 101 107 109 117 121 135 47 135 101 107 109 117 43 47 43 47 43 47 109 101 107 109 117 101 107 109 31 191 33 47 43 47 39 169 125 177 133 137 33 39 49 143 31 33 187 157 159 161 163

0 7 11 18 10 1 19 9 9 1 26 22 16 12 17 2 4 3 24 11 23 11 22 12 3 21 4 7 2 22 5 8 12 7 23a 22 0 0 10 2 5 3 18 7 1 5 14 1 20 21 0 12 15 15 15

808715 808715 808715 808715 808716 808716 808717 808717 808718 808719 808720 808720 808721 808722 808723 808724 808725 808725 808726 808727 808727 808727 808728 808728 808729 808730 808731 808732 808733 808733 808734 808735 808736 808737 808738 808738 808739 808740 808741 808742 808743 808744 808744 808745 808746 808747 808748 808748 808748 808749 808749 808750 808750 808751 808752

163 163 165 165 49 145 33 53 47 31 137 185 23 33 13 23 31 31 61 123 133 137 133 137 129 129 47 47 13 35 13 45 47 137 137 185 137 137 137 103 184 53 63 101 109 107 143 145 190 53 63 135 139 143 121

16 17 16 17 18 5 00a 00b 13 19 16 2 16 22a 26c 1 9 10 13 3 9 24 11 25 3 4 18 17 00a 0 27 0 19 34 17 0 10 30 15 13 2 11 21 23 2 6 7 22 0 12 20 7 2 8 16

808752 808753 808753 808754 808755 808756 808756 808756 808757 808757 808758 808759 808760 808761 808761 808762 808762 808763 808763 808764 808764 808764 808765 808766 808767 808768 808769 808769 808769 808770 808771 808771 808772 808772 808773 808774 808774 808775 808776 808777 808778 808779 808780 808781 808781 808782 808782 808783 808784 808785 808786 808787 808788 808789 808790

121 101 113 113 47 39 169 175 101 113 53 121 113 113 117 101 113 27 145 131 135 137 59 127 127 49 139 143 145 121 33 53 33 53 47 43 47 43 43 59 59 167 49 55 57 55 57 37 37 59 119 119 49 49 135

17 26 13 4 23 2 8 1 29 18 4 14 12 16 5 30 19 10 4 3 4 4 6 7 3 1 3 14 18 2 0 22b 0 21b 10 14 8 18 19 4 10 15 30 8 7 9 17 19 18 3 3 4 10 11 21

808791 808792 808793 808794 808794 808795 808796 808797 808798 808799 808800 808801 808802 808803 808803 808804 808805 808806 808807 808808 808809 808810 808811 808812 808813 808814 808815 808816 808817 808818 808819 808820 808820 808822 808824 808825 808826 808827 808828 808830 808831 808831 808832 808833 808834 808834 808835 808836 808837 808838 808839 808840 808840 808841 808842

135 135 49 131 135 173 129 139 53 101 101 43 13 39 135 91 31 61 127 43 23 119 119 61 53 43 61 43 117 117 117 127 173 133 133 139 133 137 63 27 125 177 123 27 133 183 29 55 55 61 59 55 57 61 63

215

Ref. No. 18 14 23 3 4 8 17 18 0 8 3 6 22 6 6 1 0 11 13 2 18 5 30 20be 1 12 25 7 8 9 1 0 5 6 19b 20 8 5 5 19 10 4 7 16 0 12b 0 0 9 1 16 13 18 1

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

808843 808844 808845 808846 808847 808848 808849 808850 808850 808850 808850 808850 808850 808851 808851 808851 808851 808851 808851 808851 808851 808852 808852 808853 808853 808853 808853 808853 808853 808853 808853 808854 808855 808855 808856 808856 808857 808858 808858 808858 808858 808859 808859 808860 808860 808861 808862 808863 808864 808865 808866 808867 808868 808869 808870

53 53 53 53 43 33 27 153 153 161 161 163 163 37 37 37 37 167 167 167 167 167 167 49 145 155 155 159 159 165 165 141 39 41 39 41 179 37 41 171 181 123 179 125 177 53 13 123 123 111 111 115 115 111 115

16 15 17 19 13 24a 6 7 9 7 9 7 9 9 10 11 12 2 3 4 5 16 17 16 20 7 9 7 9 7 9 1 11 14 13 15 9 4 17 1 7 19 0 1 0 5 23 28 27 6 6 6 6 3 3

808871 808872 808873 808873 808873 808874 808875 808875 808876 808876 808877 808877 808877 808878 808878 808879 808880 808880 808881 808881 808882 808882 808882 808882 808882 808882 808882 808882 808882 808882 808882 808882 808883 808883 808884 808884 808884 808885 808885 808885 808885 808888 808888 808889 808890 808891 808892 808892 808893 808896 808897 808898 808899 808900 808901

123 53 37 119 123 37 119 123 89 97 91 145 189 41 171 41 123 129 123 129 151 151 153 153 155 155 157 159 161 163 165 165 167 167 91 91 91 91 91 145 145 103 121 45 101 21 23 23 123 47 45 29 29 47 45

Ref. No. 17 14 5 11 21 2 10 22 12 49 19 11 1 10 5 9 12 12 13 13 4 5 8 10 8 10 7 11 10 10 8 10 7 8 4 7 13 14 15 16 17 8 9 1 13 21 21 22 26 26 6 7a 6 7 0

Part No.

Page No.

Ref. No.

Part No.

Page No.

808902 808903 808904 808904 808905 808905 808906 808907 808908 808909 808910 808910 808911 808911 808912 808913 808914 808915 808916 808918 808918 808919 808920 808921 808922 808923 808923 808924 808925 808925 808926 808927 808928 808929 808930 808931 808932 808933 808935 808936 808937 808938 808938 808939 808940 808941 808942 808943 808944 808945 808945 808947 808948 808949 808949

101 175 103 121 31 91 101 179 37 37 37 181 37 181 37 53 29 101 101 135 184 45 137 23 23 23 23 23 23 53 23 23 23 103 113 113 113 139 51 45 137 23 51 51 50 50 50 50 50 51 51 61 61 105 115

2 3 10 12 4 20 13 10 17 16 14a 0 15 3 3 00d 2 25 12 16 0 8 31 6 3 13 14 9 12 0 7 8 5 11 20 3 7 19a 1 10 26 10 0 3 3 2 0 5 4 4a 5a 10 8 2 9

808949 808949 808950 808950 808950 808951 808952 808953 808954 808955 808955 808955 808956 808957 808958 808959 808960 808961 808962 808963 808963 808964 808965 808965 808966 808967 808968 808969 808970 808971 808972 808973 808974 808975 808976 808977 808978 808979 808980 808981 808982 808983 808984 808985 808986 808987 808988 808989 808990 808991 808992 808993 808994 808995 808996

123 129 43 103 135 139 55 67 83 173 179 184 69 69 190 190 184 184 173 127 173 173 169 193 67 67 67 69 69 69 69 69 69 69 69 69 69 69 69 69 72 72 73 73 73 67 67 73 73 73 67 75 75 75 75

216

Ref. No. 5 5 27 15 28 9 6 2 5 8 10 8 10 11 1 6a 7a 4 2 5 3 6 11 9 22 8 9 13 7 16 3 15 12 6 4 5 1 2 14 5 7 10 8 9 15 14 12 1 6 13 2 1 4 3

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

808997 808998 808999 808999 809000 809000 809001 809001 809001 809002 809002 809002 809003 809003 809003 809003 809004 809004 809004 809004 809005 809005 809005 809006 809006 809006 809007 809007 809007 809008 809008 809008 809009 809009 809009 809010 809011 809012 809012 809012 809013 809014 809014 809014 809014 809014 809014 809015 809015 809015 809016 809016 809017 809018 809019

75 75 77 81 77 81 77 79 81 77 79 81 77 79 81 81 77 79 81 81 77 79 81 77 79 81 77 79 81 77 79 81 77 79 81 77 77 77 79 81 77 71 71 71 71 77 81 71 71 77 79 81 79 81 83

Ref. No. 5 8 17 16 16 15 9 14 9 8 13 8 15 12 21 23 14 11 20 22 13 18 14 12 17 13 10 15 10 6 9 6 7 10 7 1 18 4 7 4 2 2 5 10 12 19 24 3 6 20 6 19 5 17 6

Part No.

Page No.

809020 809021 809022 809023 809024 809025 809025 809026 809026 809027 809028 809029 809030 809031 809032 809033 809034 809035 809036 809037 809038 809039 809040 809041 809042 809043 809044 809045 809046 809046 809046 809047 809047 809048 809049 809050 809050 809051 809052 809053 809054 809055 809056 809057 809057 809058 809058 809059 809060 809061 809062 809063 809064 809065 809066

83 83 81 81 81 71 81 71 81 83 83 83 83 71 87 87 87 87 87 87 87 87 87 87 87 87 86 86 89 93 97 98 99 97 97 93 97 95 95 95 95 95 95 93 97 98 99 169 169 169 169 187 187 187 187

Ref. No. 7 4 18 1 2 11 26 13 27 9 8 3 2 14 1 2 8 3 4 6 11 13 12 9 5 7 3 6 18 15 17 8 17 8 9 8 42 4 21 20 19 17 17 1 44 22 4 1 12 5 10 1 1 5 7a

Part No.

Page No.

809067 809067 809068 809069 809070 809071 809072 809073 809074 809075 809076 809077 809078 809079 809080 809081 809082 809083 809084 809085 809086 809087 809088 809089 809090 809091 809092 809092 809092 809093 809094 809094 809095 809096 809096 809096 809096 809097 809098 809099 809100 809101 809102 809103 809104 809104 809105 809106 809107 809108 809109 809109 809110 809110 809111

169 177 169 55 55 67 67 33 67 67 67 67 65 72 72 72 72 72 73 73 73 73 73 87 87 87 77 79 81 81 71 81 67 65 65 67 73 86 81 67 175 184 173 173 173 179 173 47 63 47 47 53 49 61 49

217

Ref. No. 3 4 6 3 4 27 28 24 7 6 12 11 14 6 4 3 1 2 11 7 4 5 3 14 15 10 11 16 11 12 9 25 4 11 13 21 17 5 5 20 7 3 5 10 7 8 4 7 10 8 33 0 2 28 3

Part No.

Page No.

Ref. No.

809112 809113 809114 809115 809115 809116 809117 809118 809118 809118 809119 809119 809120 809121 809122 809123 809124 809125 809126 809127 809128 809130 809131 809132 809133 809134 809135 809136 809136 809137 809138 809139 809140 809141 809142 809143 809144 809144 809145 809146 809147 809148 809149 809150 809150 809151 809151 809152 809152 809153 809153 809153 809154 809155 809155

49 49 67 65 67 77 79 65 65 67 65 67 65 67 67 67 67 67 69 173 169 27 59 79 86 179 179 169 177 177 177 177 177 175 175 175 175 179 175 179 179 179 179 119 179 191 209 191 209 191 209 209 193 179 181

4 25a 5 7 25 5 8 3 6 18 8 32 1 29 31 33 34 30 8 11a 7 6 2 21 4 6 3 4 6 7 2 5 11a 12c 10 9 6 4 4 13a 7 2 5 14 1 5 2 6 4 6 4 12 8

TABLE OF CONTENTS

Numerical Index Part No.

Page No.

Ref. No.

Part No.

Page No.

809155 809156 809157 809158 809159 809160 809161 809162 809163 809164 809165 809166 809167 809168 809169 809170 809171 809171 809171 809172 809173 809174 809175 809176 809177 809178 809179 809180 809181 809182 809183 809184 809185 809186 809187 809188 809189 809190 809190 809190 809192 809193 809194 809195 809196 809197 809198 809199 809199 809199 809200 809200 809201 809202 809203

193 191 191 171 171 171 171 175 185 89 25 181 181 181 181 49 123 129 147 123 91 191 49 13 13 13 13 15 15 17 17 21 21 21 21 21 21 23 23 23 25 25 29 29 35 35 35 39 41 89 41 147 41 49 53

6 3 3 7 3 4 8 3 7a 3a 5 9 11a 1 4 7 9 9 14 24 3 7 29 1 22 28 29 0 0 0 0 10 21 21 22 22 22 24 25 26 2 0 1 10a 1 2 4 15 19 14 2 5 24 0 3

809204 809205 809206 809207 809208 809209 809210 809211 809212 809213 809213 809213 809214 809214 809215 809216 809217 809218 809219 809220 809221 809222 809223 809224 809225 809226 809227 809228 809229 809230 809231 809232 809233 809234 809235 809236 809237 809238 809239 809240 809241 809242 809243 809243 809244 809245 809246 809247 809248 809249 809250 809251 809252 809253 809254

53 55 55 55 59 61 61 61 63 65 67 67 65 65 65 65 67 67 67 67 67 71 73 73 73 73 75 75 77 77 77 79 89 89 93 95 99 99 99 99 111 115 123 125 125 125 127 127 131 131 133 133 133 133 133

Ref. No. 0 2 2 14 9 15 17 21 18 4 16 24 9 12 10 15 3 19 23 26 35 15 13 14 15 16 6 7 3 21 22 4 1 22 3 16 1 7 9 18 3 3 10 9 17 23 4 6 1 1 1 10 15 17 19

Part No.

Page No.

809255 809256 809257 809258 809259 809260 809261 809262 809263 809264 809265 809266 809267 809267 809268 809269 809270 809271 809272 809273 809274 809275 809275 809277 809278 809279 809280 809281 809282 809283 809284 809285 809286 809287 809288 809289 809290 809291 809292 809293

135 135 135 137 137 137 139 139 139 141 143 145 169 193 181 185 185 185 189 191 201 205 207 209 57 57 57 57 57 57 57 57 1 1 1 1 5 5 5 5

218

Ref. No. 5 5 10 5 27 35 1 1 1 1 2 2 11 2 5 1 3 4 0 8 4 2 2 3 0 2 9 11 6 12 16 18

Part No.

Page No.

Ref. No.

TABLE OF CONTENTS

Torque Specifications Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread-forming and metal screws) unless otherwise specified.

Grade 5

Grade 8

Unified National Thread

Grade 2 Dry

Lubed

Dry

Lubed

8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-14

19* 20* 27* 31* 66* 76* 11 12 20 23 32 36 35 40 55 60 75 85 130 150 125 140 190 210

14* 15* 21* 23* 50* 56* 9 9 15 17 24 27 35 40 55 60 75 85 130 150 125 140 190 210

30* 31* 43* 49* 9 10 17 19 30 35 50 55 75 90 110 120 150 180 260 300 430 470 640 710

22* 23* 32* 36* 75* 86* 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 360 480 530

Metric Course Thread

Grade 8.8

M6-1 24M8-1.25 M10-1.5 M12-1.75 M14-2 M16-2

8 19 37.5 65 103.5 158.5

Dry

Grade 10.9 Lubed

Dry

6 14 28 48 76.5 117.5

11 27 53 91.5 145.5 223.5

41* 43* 60* 68* 12 14 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000

Lubed 31* 32* 45* 51* 9 10 18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740

Grade 12.9 Lubed

Dry

Lubed

7 20 39 67.5 108 165.5

13.5 32.5 64 111.5 176.5 271

10* 24* 47 82 131 200

* All torque values are in lb-ft except those marked with an * which are in lb-in.

For metric torque value (Nm) muiltiply lb-ft x 1.355 or lb-in value x 0.113.

219

Dry

TABLE OF CONTENTS

220