Mustang 638 Telehandler Parts Manual 913208 - PDF DOWNLOAD

638 TELEHANDLER PARTS MANUAL PART #913208 Revision B - 02/09

Mustang Manufacturing Company, Inc.

Introduction

638 Telehandler

NOTE: This parts manual identifies both standard and optional features for this model.

Depending on the features of the machine, some of the items identified in the parts lists may, or may not be included with your machine.

The Table of Contents pages show the page location of various component groups on the machine.

When ordering service parts, specify the correct 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 frame. The following reference shows the breakdown of the serial number: Unit Number

Model

Mustang Manufacturing Company 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 it is (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 bolts are Grade 5, cadmium or zinc plated; hexagon nuts for Grade 5 cap screws and bolts are Grade 5.

If a part with a decal affixed is replaced, be sure to affix a new decal to the replacement part.

Engine

638 J U 02 80016 Month Year (U=03, V=04, etc.)

The positions right, left, front and rear are determined from a position standing behind the unit and facing the direction of travel.

913208/BP0209

PRINTED IN U.S.A.

638 Telehandler

Introduction

NOTE: Some of the later units are equipped

FILTER REFERENCE

with engines meeting the Tier II requirements.

These units can be identified by the type of throttle (accelerator) pedal being used; TIER II type units use an electronic throttle; other units use a mechanical throttle.

TYPE Engine Oil Note a Notes b and c

Electronic Throttle

Mechanical Throttle

PRINTED IN U.S.A.

1

PART NUMBER L99420 102173

Engine Fuel Note a Note b

L98978 102174

Engine Air Transmission Oil Hydraulic Oil

L120037 L99184 L97489

a

Used on units equipped with the mechanical throttle (accelerator) pedal.

b

Used on units equipped with the electronic throttle (accelerator) pedal.

c

Use dust seal P/N 102742 as needed.

913208/BP0209

Table of Contents

638 Telehandler Page

Introduction Filter Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Operator’s Station Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Cab without Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Air Conditioning Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Under Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Top Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Steering Column and Shifter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Accelerator and Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Chassis, Covers and Tanks Lights (including boom lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Frame - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Frame - Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Hoods and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Fuel Tank/Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Engine External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Radiator/Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Transmission External Components (including driveshafts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Axles Planetary and Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Outer Knuckle End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Power Brake/Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Hydraulic Circuit - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Hydraulic Circuit - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Boom Components Outer Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Intermediate Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Inner Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

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638 Telehandler

Table of Contents Page

Boom Hydraulics Hydraulic Circuit - Boom Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Hydraulic Circuit - Boom Tilt/Slave/Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Hydraulics Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Joystick/Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Hydraulic Components Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Frame Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Boom Extend Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Boom Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Fork-Shift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Rotating Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Boom Extend/Lift Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Tilt/Rotate Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Frame Level Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Priority Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Joystick Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Dual-Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Attachments Carriage Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Standard Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Fork-Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Rotating Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Truss Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Boom Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

PRINTED IN U.S.A.

3

913208/BP0209

Table of Contents

638 Telehandler Page

Decals General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Index Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

913208/BP0209

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PRINTED IN U.S.A.

638 Telehandler

PRINTED IN U.S.A.

Notes

5

913208/BP0209

Operator’s Station

638 Telehandler Cab

1

20 18

19

17 2 16 15 3

4 14 5 11

12

10

13 27

22 21 21 26

22

25

FRAME 22 21

FRONT 26

23 23

21

25

24 25

21 26 25

24 25

913208/BP0209

6

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station Cab

Ref. No.

Part No.

01

L66658 L99137 L65393 L50230 L50141 L50056 L64469 L50056 L50141 L64454 L50230 L50056 L530004 L50823 L50141 L530004 L64841 L50230 L50141 L530004 L50056 L64460 L50230 L64459 L50230 L50056 L50141 L50251 L50061 L64421 L50251 L50061 L50367 L50061 L99244

02

03

04

05

10 11

12

13 14a 15

16

210170 L42910 L64455 L50230 L50141 L530004 L64452 L50056

17 L99322 L66659

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

SIDE GLASS . . . . . . . . . . . . . . . . . . 1 GASKET . . . . . . . . . . . . . . . . . . . . . 1 SIDE WINDOW PANEL. . . . . . . . . . 1 CAP SCREW 5/16X3/4 . . . . . . . . . 3 5/16 PLAIN WASHER . . . . . . . . . . 3 5/16-18 SERR. FLNG.NUT. . . . . . 12 UPPER INSIDE PANEL. . . . . . . . . . 1 5/16-18 SERR FLNG NUT . . . . . . . 4 5/16 PLAIN WASHER . . . . . . . . . . 4 FRONT ACCESS PANEL . . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 6 5/16-18 SERR. FLNG. NUT . . . . . . 6 5/16-18 RETAINED NUT . . . . . . . . 6 CAP SCREW 5/16-18X1 . . . . . . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 1 5/16-18 RETAINED NUT . . . . . . . . 1 BOTTOM ACCESS PANEL . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 3 5/16 PLAIN WASHER . . . . . . . . . . 3 5/16-18 RETAINED NUT . . . . . . . . 7 5/16-18 SERR. FLNG. NUT . . . . . . 3 VALVE SIDE COVER . . . . . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 4 UPPER VALVE COVER . . . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 2 5/16-18 SERR. FLNG NUT . . . . . . 2 5/16 PLAIN WASHER . . . . . . . . . . 2 CAP SCREW 3/8-16X3/4 . . . . . . . . 2 3/8-16 SERR. FLNG. NUT . . . . . . . 2 VALVE MOUNT WELDMENT . . . . . 1 CAP SCREW 3/8-16X3/4 . . . . . . . . 2 3/8-16 SERR. FLNG. NUT . . . . . . . 2 CAP SCREW 3/8-16X1 . . . . . . . . . 2 3/8-16 SERR. FLNG. NUT . . . . . . . 2 HINGED SEAT PANEL . . . . . . . . . . 1 (Includes handle, side plate & hinge) SEAT (does not include arm rest) . . 1 SEAT BELT ASY, W/HDWR. . . . . . . 1 LOWER REAR ACCESS PANEL . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 9 5/16 PLAIN WASHER . . . . . . . . . . 9 5/16-18 RETAINED NUT . . . . . . . . 6 REAR WINDOW WELDMT . . . . . . . 1 5/16-18 SERR.FLNG.NUT . . . . . . . 7 REAR GLASS GASKET . . . . . . . . . . . . . . . . . . . . . 1 GLASS ONLY . . . . . . . . . . . . . . . . . 1

18

L65410

19

20

101948 L68511 L65412

21 22 23 24 25 26 27

L64124 L50319 L50383 L64196 L520007 L64197 L66612

00

L54002

00

Description

Qty. Req.

REAR GLASS ASY. . . . . . . . . . . . . . 1 (Includes items 16 & 17) OPER. STA. WELDMENT . . . . . . . . 1 Note b Note c SIDE GLASS ASY.. . . . . . . . . . . . . . 1 (Includes items 1 & 2) VIBRATION ISOLATOR. . . . . . . . . . 5 CAP SCREW 5/8-11X3-1/2 . . . . . . 3 CAP SCREW 5/8-11X4 . . . . . . . . . 2 SPACER, THICK . . . . . . . . . . . . . . 2 5/8-11 NYLON INSERT NUT . . . . . 5 SPACER, THIN . . . . . . . . . . . . . . . . 3 COVER / HEATER HOLE . . . . . . . . 1

-- ITEMS NOT SHOWN -SAFETY TREAD – (FLOOR). . . . . . 1 (Cut in 6x24” pcs) L62427 BOOT (Frame Level Lever) . . . . . . . 1 L50417 RHSS #8-32X1/2 . . . . . . . . . . . . . . 3

00 00 00

L66011 L50417 L66010 L50755 L50141 L50145

(LEVEL INDICATOR) LEVEL INDICATOR . . . . . . . . . . . . . 1 RND. HEAD SCREW #8-32X1 . . . . 2 MOUNTING PLATE . . . . . . . . . . . . . 1 5/16-18 ACORN NUT . . . . . . . . . . . 2 5/16” PLAIN WASHER . . . . . . . . . . 2 3/8” PLAIN WASHER . . . . . . . . . . . 4

00

L63634 L63887 L50051

(LOAD CHART) LOAD CHART PLATE . . . . . . . . . . . 7 U-BOLT 1/4-20 . . . . . . . . . . . . . . . . 2 1/4-20 SERR.FLNG. NUT. . . . . . . . 4

a

Early seats included a left-hand arm rest; replacement seats no longer include an arm rest.

The left-hand arm rest is available only for early style seats; order L99454 arm rest.

Units with electronic throttle Units with mechanical throttle

b c

Refer to hydraulic sections for joysticks, level valve, hydraulic manifold and other hydraulic components.

7

913208/BP0209

Operator’s Station

638 Telehandler

Cab without Air Conditioning - (Part 1)

4,5 17 3

13

16 2 15

12

1 9 10

6

11

7,8 18

14

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PRINTED IN U.S.A.

638 Telehandler

Operator’s Station

Cab without Air Conditioning - (Part 1) Ref. No.

Part No.

01

L66342 L47212 L50208 L66341 L47212 L50208 L65346 L99138 L50823 L50056 L65325 L66660 L99322 L65342 L50230 L50056 L50226 L66661 L99326 L66843 L50226 L50145 L50141 L50155 L99167 L66735

02

03 04 05 06

07 08 09

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

RT.WIRE TUBE, 36” . . . . . . . . . . . . 1 CLAMP, 3/8” . . . . . . . . . . . . . . . . . . 2 1/4-20X1/2 HX HD SCREW . . . . . . 2 LT.WIRE TUBE, 18” . . . . . . . . . . . . . 1 CLAMP, 3/8” . . . . . . . . . . . . . . . . . . 1 1/4-20X1/2 HX HD SCREW . . . . . . 1 TOP WELDMENT . . . . . . . . . . . . . . 1 FOAM STRIP 1 /4X1/2 120” . . . . . . 1 CAP SCREW 5/16-18X1 . . . . . . . . 9 5/16-18 SERR. FLNG. NUT . . . . . . 9 TOP WINDOW WELD . . . . . . . . . . . 1 TOP GLASS . . . . . . . . . . . . . . . . . . 1 RUBBER GASKET 102” . . . . . . . . . 1 FRONT GLASS PANEL. . . . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 3 5/16-18 SERR. FLNG. NUT . . . . . . 3 SELF TAP SCREW 5/16-18X1. . . . 6 FRONT GLASS . . . . . . . . . . . . . . . . 1 RUBBER GASKET 111” . . . . . . . . . 1 2-SPEED WIPER MOTOR . . . . . . . 1 SELF TAP SCREW 5/16-18X1. . . . 1 3/8 PLAIN WASHER . . . . . . . . . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 6 5/8 PLAIN WASHER . . . . . . . . . . . 6 NUT/WASHER/GASKET SET . . . . . 1 MOTOR COVER . . . . . . . . . . . . . . . 1

10 11 12 13

16 17

L61199 L61200 L66986 L64672 L50755 L66855 L68054 L52025 L50056 L650004 L66963 L66993 L50208 L500318 L65298

18

L65447

14

15

9

Description

Qty. Req.

BLADE ARM . . . . . . . . . . . . . . . . . . 1 WIPER BLADE . . . . . . . . . . . . . . . . 1 DEFROST FAN W/SW . . . . . . . . . . 1 HINGE STUD 5/16X3-7/8 . . . . . . . . 2 5/16-18 ACORN NUT . . . . . . . . . . . 4 ETHER KIT . . . . . . . . . . . . . . . . . . . 1 ROCKER SWITCH . . . . . . . . . . . . . 1 BUTTON HD BOLT 5/16-18X3/4 . . 2 516-18 SERR. FLNG. NUT. . . . . . . 2 TERMINAL BLOCK . . . . . . . . . . . . . 1 WIRE ASY w/ FUSE . . . . . . . . . . . . 1 DEFROSTER MT. PLATE . . . . . . . . 1 SELF TAP SCREW 1/4-20X1/2 . . . 2 VINYL STRIP 84”. . . . . . . . . . . . . . . 1 TOP PANEL w/ GLASS ASY . . . . . . 1 (incls. items 3,4 & 5) FRONT PANEL w/ GLASS ASY. . . . 1 (incls. items 6, 7 & 8)

913208/BP0209

Operator’s Station

638 Telehandler

Cab without Air Conditioning - (Part 2)

3

4 5

7

8 9 10

6 16

22 15 21 14

20

19

25

23,24

18

17

19 1

13

913208/BP0209

12

11

2

10

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station

Cab without Air Conditioning - (Part 2) Ref. No.

Part No.

01 02 03 04 05 06 07 08 09 10 11

L65316 L99140 L66663 L67430 L66662 L99078 L99127 L99129 L99125 L99126 L61085 L98615 L99157 L50925 L61086 L50208 L61080 L50226 L65301 L99138 L61195 L50226 L66997 L500448 L52025 L50056 L50815 L50056 L50141 L66733 L99141 L65481 L50226 L50367

12 13 14

15

16 17

PRINTED IN U.S.A.

Description

Qty. Req.

DOOR WELDMENT . . . . . . . . . . . . 1 VINYL DOOR STRIP 240”. . . . . . . . 1 SLIDE GLASS . . . . . . . . . . . . . . . . . 1 CLIP. . . . . . . . . . . . . . . . . . . . . . . . . 1 STATIONARY GLASS . . . . . . . . . . . 1 FELT STRIP 32” . . . . . . . . . . . . . . . 1 SPACER STRIP 60” . . . . . . . . . . . . 1 SLIDE CHANNEL 96” . . . . . . . . . . . 1 DOUBLE GASKET 120” . . . . . . . . . 1 GASKET LOCK STRIP 120” . . . . . . 1 OUTSIDE HANDLE . . . . . . . . . . . . . 1 LATCH KEY (Marked PK500) . . . . 1 LATCH KEY (Marked CH751) . . . . 1 SELF TAP SCREW #8-32X1/2. . . . 2 INSIDE LATCH . . . . . . . . . . . . . . . . 1 SELF TAP SCREW 1/4-20X1/2 . . . 2 STRIKER PLATE . . . . . . . . . . . . . . . 1 SELF TAP SCREW 5/16-18X1. . . . 2 DOOR FRAME WELD. . . . . . . . . . . 1 FOAM STRIP 1/4X1/2 120” . . . . . . . .

BUTTON . . . . . . . . . . . . . . . . . . . . . 8 SELF TAP SCREW 5/16-18X1. . . . 1 HEATER . . . . . . . . . . . . . . . . . . . . . 1 HEATER BLOWER MOTOR . . . . . 1 BUTTON HD BOLT 5/16-18X3/4 . . 3 5/16-18 SERR FLNG. NUT. . . . . . . 3 CAP SCREW 5/16-18X2-1/2 . . . . . 1 5/16-18 SERR. FLNG. SCREW . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 1 PULL-TYPE SWITCH. . . . . . . . . . . 1 HOSE 5/8 ID (120”) . . . . . . . . . . . . . 2 DOOR STOP CABLE ASY . . . . . . . 1 CAP SCREW 5/16-18X1 . . . . . . . . 1 CAP SCREW 3/8-16X1 . . . . . . . . . 1

Ref. No.

Part No.

18

L50061 L98869

19

11

20

L99142 L99143 L99144 L99145 L99110

21 22 23 24 25

L65593 L65344 L61081 L61064 L65366

Description

Qty. Req.

3/8-16 SERR. FLNG. NUT . . . . . . . 1 FLOOR MAT 3/8” . . . . . . . . . . . . . AR (Specify length; cut to fit.)

FOAM INSULATION . . . . . . . . . . . AR DOOR PANEL INSULATION . . . . . . 1 RIGHT SIDE PANEL INSULATION . 1 REAR VERTICAL INSULATION . . . 1 REAR FLAT PANEL INSULATION . 1 DOOR GLASS ASY. . . . . . . . . . . . . 1 (includes items 3-10) SUPPORT BRACKET . . . . . . . . . . . 1 HEATER BRACKET . . . . . . . . . . . . 1 DOOR HINGE (weld on) . . . . . . . . . 2 HINGE PIVOT (weld on) . . . . . . . . . 2 DOOR w/GLASS & GASKET . . . . . 1 (includes items 1,3-10)

913208/BP0209

Operator’s Station

638 Telehandler

Air Conditioning Group 1 4 2 13 3 6

12

8 9

7

11 10

17

15

16

14

913208/BP0209

12

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station Air Conditioning Group

Ref. No.

Part No.

01

L66692 L50403 L520005 L68461 L50403 L520005 L50251 L50147 L68569 L50836 L50147 L66675 L67655 L50277 L50147 L66547 L66687 L510008 L50143 L66679 L510008 L50143

02

03

04 05

06 07

08

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPRESSOR MOUNT . . . . . . . . 1 CAP SCREW 3/8-16X1-1/4 . . . . . . 4 3/8-16 NYLON INSERT NUT . . . . . 4 COMPRESSOR (R134a Refrig.) . . 1 CAP SCREW 3/8-16X1-1/4 . . . . . . 2 3/8-16 NYLON INSERT NUT . . . . . 2 CAP SCREW 3/8-16X3/4 . . . . . . . . 1 3/8 LOCK WASHER . . . . . . . . . . . . 1 ADD-ON PULLEY (J.D.) . . . . . . . . . 1 CAP SCREW 3/8-16X1-3/4 . . . . . . 4 3/8 LOCK WASHER . . . . . . . . . . . . 4 V-BELT. . . . . . . . . . . . . . . . . . . . . . . 1 ADJUST.BRACKET . . . . . . . . . . . . . 1 CAP SCREW 3/8-16X1-1/2 . . . . . . 1 3/8 LOCK WASHER . . . . . . . . . . . . 1 SPACER . . . . . . . . . . . . . . . . . . . . . 1 CONDENSER MOUNT . . . . . . . . . . 1 CAP SCREW 5/16-18X5/8 . . . . . . . 4 5/16 LOCK WASHER . . . . . . . . . . . 4 ELECTRIC CONDENSER. . . . . . . . 1 CAP SCREW 5/16-18X5/8 . . . . . . . 4 5/16 LOCK WASHER . . . . . . . . . . . 4

09

L66689 L50056 L66688 L50056 L66678 L510008 L99419 L67629 L50823 L50056 L99124 L68463 L510008 L50143 L66869 L66975 L66868 L66970

10 11

12

13

14 15 16 17

13

Description

Qty. Req.

RT.BLOWER BRACKET . . . . . . . . . 1 5/16-18 SERR. FLNG. NUT . . . . . . 2 LT.BLOWER BRACKET. . . . . . . . . . 1 5/6-18 SERR. FLNG. NUT . . . . . . . 2 EVAPORATOR BLOWER . . . . . . . . 1 CAP SCREW 5/16-18X5/8 . . . . . . . 6 BLOWER MOTOR . . . . . . . . . . . . . 1 OUTSIDE AIR KIT . . . . . . . . . . . . . . 1 CAP SCREW 5/16-18X1 . . . . . . . . 6 5/16 -18 SERR. FLNG. NUT . . . . . . 6 FILTER, A/C . . . . . . . . . . . . . . . . . . 1 RECEIVER/DRYER (R134a Refrig) 1 CAP SCREW 5/16-18X5/8 . . . . . . . 2 5/16 LOCK WASHER . . . . . . . . . . . 2 A/C HOSE 5/16 X 48” . . . . . . . . . . . 1 A/C HOSE 1/2 X 140. . . . . . . . . . . . 1 A/C HOSE, 5/16 X 96”. . . . . . . . . . . 1 A/C HOSE, 13/32 X 162 . . . . . . . . . 1

913208/BP0209

Operator’s Station

638 Telehandler Under Dash

1

11 10 3

12 9

4 2 5

6

7 5

8

FRONT

913208/BP0209

14

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station Under Dash

Ref. No.

Part No.

01

L64583 L64889 L50230 L50056 L650012 L66437 072340 L650004 L650005 L63699 L41848 L62949 089069 089070 L63610 L63640 L68638

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

Description

Qty. Req.

Ref. No.

MODULATOR CIRCUIT BOARD. . . 1 MOUNT BRACKET . . . . . . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 2 5/16”-18 FLANGE NUT . . . . . . . . . 2 BRAKE LIGHT SWITCH . . . . . . . . . 1 GAUGE, WATER TEMP . . . . . . . . . 1 GAUGE, HOUR METER . . . . . . . . . 1 BLOCK, TERMINAL 3 BANK . . . . AR JUMPER . . . . . . . . . . . . . . . . . . . AR BREAKER, CIRCUIT 15 AMP . . . . . 2 SWITCH, PUSH BUTTON. . . . . . . . 2 RELAY, DPDT 12VDC . . . . . . . . . . 2 SWITCH, IGNITION . . . . . . . . . . . . 1 KEY ONLY . . . . . . . . . . . . . . . . . . . 1 GAUGE, LIGHT CLUSTER . . . . . . . 1 GAUGE, FUEL . . . . . . . . . . . . . . . . 1 SWITCH, STEER SELECT . . . . . . . 1

00

00 00

101959 L68579 L63335 L66824

00b

101818

00b 00d

101877 101860

a

b c d

PRINTED IN U.S.A.

Part No.

15

Description

Qty. Req.

-- ITEMS NOT SHOWN -(ELECTRICAL) MAIN FRAME WIRE HARNESS . . . 1 Note b Note c RELAY (windshield wipers) . . . . . . . 1 WIRE HARNESS, CAB . . . . . . . . . . 1 (Heater, defroster and wiper motor) HARNESS, ENGINE TIER2 (Connects to electric foot pedal, ignition switch and engine fault switch.)

MODULE, F-N-R RELAY. . . . . . . . . 1 HARNESS, TRANS CONTROL . . . 1

These relays are replaced by Transmission Control module part #101877 when unit does not use the 1-2-3 shifter (as shown on page 18, items 4-7).

Units with electronic throttle.

Units with mechanical throttle.

Used on units without 1-2-3 shifter (as shown on page 18, items 4-7).

913208/BP0209

Operator’s Station

638 Telehandler Top Dash

1

2

FRONT

3

12

8

9

10

4

11 7

6

5

23 25

22

26

19 18

20

24

21

27

17

13

16

14

24 32

31

29

30 28

15

913208/BP0209

16

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station Top Dash

Ref. No.

Part No.

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

L62840 L62834 L64267 L64267 L66833 L66834 L50202 L63689 L66437 L63640 L63688 L68638 089069 089070 L41848 L63699 L50835 L650012 L63610 072340 L50230 L62484 L520017 L50546 L50056 L277568 L50655 L50896

14 15 16 17 18 19 20 21 22 23 24 25 26 27

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

DUST CAP. . . . . . . . . . . . . . . . . . . . 2 TEST PORT. . . . . . . . . . . . . . . . . . . 2 HOSE, -4, A4/DM6 53” . . . . . . . . . . 1 HOSE, -4, A4/DM6 53” . . . . . . . . . . 1 LIGHT, BRAKE FAILURE . . . . . . . . 1 PARK BRAKE LIGHT . . . . . . . . . . . 1 1/4”-20X5/8” BUTT. HD BOLT . . . . . 4 GAUGE, COVER PANEL . . . . . . . . 1 GAUGE, WATER TEMP. . . . . . . . . . 1 GAUGE, FUEL . . . . . . . . . . . . . . . . 1 PANEL, RECESSED GAUGE . . . . . 1 STEER SELECT SWITCH . . . . . . . 1 SWITCH, IGNITION . . . . . . . . . . . . 1 KEY ONLY . . . . . . . . . . . . . . . . . . . 1 SWITCH, PUSH BUTTON. . . . . . . . 2 BREAKER, CIRCUIT 15 AMP . . . . . 2 5/16-18X2” BOLT. . . . . . . . . . . . . . . 2 SWITCH, BRAKE LIGHT. . . . . . . . . 1 GAUGE, LIGHT CLUSTER . . . . . . . 1 GAUGE, HOUR METER . . . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 1 BRACKET, SWITCH MOUNT . . . . . 1 #6-32 NYLON INSERT NUT . . . . . . 2 #6-32X3/4” RD MACH SCREW . . . 2 5/16”-18 FLANGE NUT . . . . . . . . . . 3 LEVER, PARK BRAKE . . . . . . . . . . 1 #10-24X1/2” RD MACH. SCREW . . 4 #10-24 NUT . . . . . . . . . . . . . . . . . . . 4

28

L63932 L66850 L66849 L63937 L68054 L63938 101278 L66844 L50141 L43965 L43964

SWITCH, WASHER SYSTEM . . . . . 1 SWITCH, WIPER (2-Speed). . . . . . 1 SWITCH, HEATER FAN . . . . . . . . . 1 SWITCH, LIGHTS . . . . . . . . . . . . . . 1 SWITCH, ETHER . . . . . . . . . . . . . . 1 SWITCH, CLUTCH CUT OUT. . . . . 1 SWITCH, ENGINE FAULT (note b) . 1 PANEL, SWITCH . . . . . . . . . . . . . . . 1 5/16” FLAT WASHER . . . . . . . . . . . 6 SPACER, PARK BRAKE 1/2” . . . . 1 SPACER, PARK BRAKE 3/4” . . . . . 1

00

L64078

-- ITEMS NOT SHOWN-(ELECTRICAL) PARK BRAKE BUZZER . . . . . . . . . 1

00 00 00 00 00 00

L63633 L42342 L50607 L47275 L50403 L50061

(PARKING BRAKE) PARK BRAKE CABLE . . . . . . . . . . . 1 3/8”X1-1/4” CLEVIS PIN . . . . . . . . . 1 1/8”X1” COTTER PIN . . . . . . . . . . . 1 CLAMP, BRAKE CABLE . . . . . . . . . 1 3/8”-16X1-1/4” BOLT . . . . . . . . . . . . 1 3/8”-16 FLANGE NUT . . . . . . . . . . . 1

a b

Female coupling for test port is # L62933.

For use on units equipped with electronic throttle

29 30 31 32

17

Description

Qty. Req.

913208/BP0209

Operator’s Station

638 Telehandler

Steering Column and Shifter Group

1 2

FRONT

3

9

15

16

8

4

10 14 5 11 6

T 7 12 L P 13

913208/BP0209

18

12

R

STEER MOTOR PORTS

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station

Steering Column and Shifter Group Ref. No.

Part No.

01 02 03 04a 05a 06a

L40496 L41260 L41261 L98786 L50202 L66059

07a 08 09

L98787 L50101

10

L68280 L68772 L99425 L67832

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

STEERING WHEEL (15”) . . . . . . . . 1 CAP, STEERING WHEEL . . . . . . . . 1 NUT, STEERING WHEEL . . . . . . . . 1 SHIFT KNOB 1-2-3 SHIFTER . . . . . 1 1/4”-20X5/8” BOLT . . . . . . . . . . . . . 4 SHIFTER 1-2-3 . . . . . . . . . . . . . . . . 1 (Includes items 4, 6 & 7) SHIFT SWITCH . . . . . . . . . . . . . . . . 2 M5X.8X35mm HX SKTHD BOLT . . 2 F-N-R SHIFTER . . . . . . . . . . . . . . . 1 Note b (includes item #16) Note c (includes item #16) BOOT (used for either shifter) . . . . 1 RUBBER GROMMET . . . . . . . . . . . 1

11 12 13 14d 15 16

L52026 L444004 L64524 101880 L68285 L68282

3/8”-16X1-1/4” BUTTN HD BOLT . . 4 ADAP, -8ORM -8JICM STR. . . . . . . 3 CHECK VALVE . . . . . . . . . . . . . . . . 1 MOTOR, STEER . . . . . . . . . . . . . . . 1 COLUMN, STEERING. . . . . . . . . . . 1 CLAMP (included w/ item #9) . . . . . 1

00 00

L62933 L68281

-- ITEMS NOT SHOWN-FEMALE COUPLER (Test Port) . . . 1 WIRE HARNESS, FNR SHIFTER. . 1

a b c d

Used on earlier models.

Used on units equipped with items 4-7.

Used on units not equipped with items 4-7.

Refer to the Hydraulic Components section - Steer Motor, for more information.

19

Description

Qty. Req.

913208/BP0209

Operator’s Station

638 Telehandler

Accelerator and Brake Pedals Electronic Accelerator Pedal

11 22 16

23

12

18 1

13 15 14

19 MOUNT ON FLOOR UNDERSIDE

ENGINE THROTTLE

17 MOUNTS TO ENG. FLYWHEEL HOUSING

21 20 MOUNT ON FLOOR UNDERSIDE

9 10

2

4

5

6 7

5

5 8

3 4 5

913208/BP0209

20

PRINTED IN U.S.A.

638 Telehandler

Operator’s Station

Accelerator and Brake Pedals Ref. No.

Part No.

01a 02

L580009 L64770 L50261 L520005 L561004 L64774 L806001 L10151 L52026 L520005 L41770 L66815 L44859 L50607 L64772 L64890 L66814 L50261 L520005 L400265 L50367 L400270 L561004

03 04 05

06 07

08 09 10c

11a 12a 13a

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

BALL JOINT. . . . . . . . . . . . . . . . . . . 1 BRAKE PEDAL WELD . . . . . . . . . . 1 CAP SCREW 3/8-16X1-1/2 . . . . . . 2 3/8-16 NYLON INSERT NUT . . . . . 2 SPRING . . . . . . . . . . . . . . . . . . . . . . 1 PIVOT ARM WELD . . . . . . . . . . . . . 1 SPLIT BABBITTED BRG. . . . . . . . . 4 GREASE ZERK . . . . . . . . . . . . . . . 4 BUTT. HD. BOLT 3/8-16X1-1/4 . . . 8 3/8-16 NYLON INSERT NUT . . . . . 8 CLAMP . . . . . . . . . . . . . . . . . . . . . . 1 BRAKE LINK . . . . . . . . . . . . . . . . . . 1 CLEVIS PIN 1/2X27/64 . . . . . . . . . 2 COTTER PIN 1/8X1 . . . . . . . . . . . . 2 BRAKE SHIFT WELD . . . . . . . . . . . 1 BRAKE LIGHT SW . . . . . . . . . . . . . 1 POWER BRAKE BOOSTER ASY . . 1 CAP SCREW 3/8-16X1-1/2 . . . . . . 4 3/8-16 NYLON INSERT NUT . . . . . 4 ACCEL.PEDAL WELD. . . . . . . . . . . 1 CAP SCREW 3/8-16X1 . . . . . . . . . 2 PIVOT ARM WELD . . . . . . . . . . . . . 1 SPRING . . . . . . . . . . . . . . . . . . . . . . 1

14a

22b 23b

L806001 L10151 L52026 L580008 L64463 L66606 L64664 L64663 L50050 L41770 L50056 L630004 L50056 101945 105502

SPLIT-BABBITTED BRG. . . . . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . 1 BUTT. HD. BOLT 3/8-16X1-1/4 . . . 2 BALL JOINT. . . . . . . . . . . . . . . . . . . 1 THROTTLE CABLE. . . . . . . . . . . . . 1 BRACKET . . . . . . . . . . . . . . . . . . . . 1 COUPLER . . . . . . . . . . . . . . . . . . . . 1 EXTEND ROD . . . . . . . . . . . . . . . . . 1 #10-32 NUT . . . . . . . . . . . . . . . . . . 4 CLAMP . . . . . . . . . . . . . . . . . . . . . . 1 5/16-18 SERR. FLNG. NUT . . . . . . 1 GROUND STRAP . . . . . . . . . . . . . . 1 5/16-18 SERR. FLNG. NUT . . . . . . 2 MOUNT, ELECTRIC PEDAL . . . . . . 1 ELECTRIC FOOT PEDAL . . . . . . . . 1

00

L54002

-- ITEMS NOT SHOWN -SAFETY TREAD (anti-slip) . . . . . . . 1 (cut into 6”x24” pieces)

a b c

Units equipped with mechanical throttle.

Units equipped with electronic throttle.

Refer to the Axle Hydraulics Section - Power Brake /Master Cylinder Assembly for more information.

15a 16a 17a 18a 19a 20 21

21

Description

Qty. Req.

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler Lights

4

3

2

1

BOOM 5 RIGHT 7

LEFT

6 4 1

2

3 Note: The left and right sides use the same components.

5 8

RIGHT

LEFT

FRAME

FRONT

9

10

7 11

REAR 14 12

13

12

RIGHT LEFT

913208/BP0209

22

15

PRINTED IN U.S.A.

638 Telehandler

Chassis, Covers & Tanks Lights

Ref. No.

Part No.

01 02

L61115 L60539 L99208 L50208 L61147 L50051 L50141 L50230 L50251 L62814 L4445 L50056 L4446 L70200

03 04 05 06 07 08 09 10 11 12 13

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

FRONT LIGHT BRACKET. . . . . . . . 4 FRONT LIGHT. . . . . . . . . . . . . . . . . 4 BULB VH550 . . . . . . . . . . . . . . . . . 1 CUT SCREW 1/4-20X1/2 . . . . . . . . 8 LIGHT COVER PLATE . . . . . . . . . . 2 1/4-20 SERR. FLNG NUT . . . . . . . . 8 5/16” FLAT WASHER . . . . . . . . . . . 4 CAP SCREW 5/16-18X3/4 . . . . . . . 6 CAP SCREW 3/8-16X3/4 . . . . . . . . 4 REAR LIGHT BRACKET . . . . . . . . . 1 REAR LIGHT . . . . . . . . . . . . . . . . . . 1 5/16-18 SERR. FLNG. NUT. . . . . . . 2 TAIL LAMP. . . . . . . . . . . . . . . . . . . . 2 BACKUP ALARM. . . . . . . . . . . . . . . 1

14 15

L50202 L50051

Description

Qty. Req.

1/4”-20X5/8” BOLT, BTNHEAD . . . . 2 1/4”-20 FLANGE NUT . . . . . . . . . . . 2

-- ITEMS NOT SHOWN -00 00 00 00 00 00 00

23

L63699 L63335 L63937 L64987 L66828 L63284 L66467

CIRCUIT BREAKER 15 AMP . . . . . 2 RELAY . . . . . . . . . . . . . . . . . . . . . . . 1 LIGHT SWITCH, ROCKER . . . . . . . 1 WIRE HARNESS (tail light) . . . . . . . 1 WIRE HARNESS, LIGHT (cab) . . . . 1 WIRE HARNESS, (switch/relays) . . 1 WIRE HARNESS, BOOM . . . . . . . . 1

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler

Frame - Front

1 2

3

4

Retract

5

Extend

9 7 6

10

8 5

11 12

6

13 14 4 15

16 16

FRONT

913208/BP0209

18 17

24

PRINTED IN U.S.A.

638 Telehandler

Chassis, Tanks & Covers Frame - Front

Ref. No.

Part No.

01 02 03 04 05 06 07 08

L49619 L64818 L445002 L50275 L64837 L520005 L64280 L64817 L64174 L66017 L64280 L50956 650498 L64056 L277013 L520019 L50151

09 10 11 12 13 14

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

BUSHING . . . . . . . . . . . . . . . . . . . . 1 LEVEL CYLINDER ASSEMBLY . . . 1 ADAP, -8ORM - 8JICM 90º . . . . . . . 1 3/8”-16X3” BOLT . . . . . . . . . . . . . . . 2 PIVOT PIN . . . . . . . . . . . . . . . . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . 2 HOSE, -6 A8/A8121-1/2” . . . . . . . . . 1 BUSHING, 2” ID (note b) . . . . . . . . . 1 BUSHING, 1-1/4” ID (note c) . . . . . . 1 ADAP, -8ORM -8JICM W/ORF 90. . 1 HOSE, -6 A8/A8121-1/2” . . . . . . . . . 1 CAP SCREW 3/4”-10X1-1/4”. . . . . . 4 1/2”-13X6” BOLT . . . . . . . . . . . . . . . 1 FRONT TRUNNION PIVOT PIN . . . 1 GREASE ZERK . . . . . . . . . . . . . . . 1 1/2”-13 NYLON INSERT NUT . . . . . 2 1/2” PLAIN WASHER . . . . . . . . . . . 2

15b 16

L64830 L400207 L66045 L50519 L65815

17 18

Description

Qty. Req.

LEVEL CYL.MOUNT WELD . . . . . . 1 SPACER, THIN. . . . . . . . . . . . . . . AR SPACER, THICK . . . . . . . . . . . . . AR 3/4”-10 NYLON INSERT NUT . . . . . 4 FRONT AXLE ASSEMBLY . . . . . . . 1

-- ITEMS NOT SHOWN --

25

00 00

L41847 L570018

00

L41770

00 00

L570005 L47212

HORN . . . . . . . . . . . . . . . . . . . . . . . 1 CLAMP, 7/16” . . . . . . . . . . . . . . . . . 1 (Hoses To Frame Side) . . . . . . . . . . 1 CLAMP, 3/4” . . . . . . . . . . . . . . . . . . 2 (Hoses To Frame Side) CLAMP 7/8” . . . . . . . . . . . . . . . . . . . 2 CLAMP 3/8” . . . . . . . . . . . . . . . . . . . 2 (Wire Harness To Frame)

913208/BP0209

Chassis, Tanks & Covers

638 Telehandler

Frame - Rear

6 7

1

8

5 2 9

3 34 35

27

4

11

10

9 13 12

36 28

9

27 35 34

11 16

33

26

9

14 13 17

26 32 DUAL RELIEF VALVE

9 31 30

29

18

19

15

27 28 27

25 23

24

3

22

FRONT

913208/BP0209

26

PRINTED IN U.S.A.

638 Telehandler

Chassis Frame - Rear

Ref. No.

Part No.

01 02 03 04 05 06 07

L50892 L64060 L520019 L810005 L520005 L50371 L64113

08 09 10 11a 12 13 14 15 16 17 18 19

L48806 L445002 L64303

22 23 24 25 26a

L446026 L446017 L64294 L64660 L64295 L64296 L61866 L65609 L50273 L520005 L66746 L400207 L66045 L64056 L277013 650498

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

1/2”-13X4” BOLT . . . . . . . . . . . . . . . 2 PIN, BOOM TO UPRIGHT . . . . . . . 2 1/2”-13 NYLON INSERT NUT . . . AR PIVOT BEARING. . . . . . . . . . . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . . 4 3/8-16 X 2-1/2” BOLT . . . . . . . . . . . 4 PIN, ROD END SLAVE CYL. . . . . . 2 (1-1/4” DIA.) BUSHING, ROD END SLAVE CYL . 2 ADAP, -8ORM -8JICM 90º. . . . . . . . 8 HOSE, -8 A8/A8 58” . . . . . . . . . . . . 1 SLAVE CYL.ASY . . . . . . . . . . . . . . . 2 ADAP, -8JICM -8JICFS RUN TEE . 1 ADAP, -8JICM -8JICFS 90º . . . . . . . 2 HOSE, -8 A8/A8 53” . . . . . . . . . . . . 1 ADAP, -8ORM -8JICM RUN TEE . . 1 HOSE, -8 A8/A8 28” . . . . . . . . . . . . 1 HOSE, -8 A8/A8 38” . . . . . . . . . . . . 1 BUSHING, BUTT END . . . . . . . . . . 2 BUTT END PIVOT PIN.. . . . . . . . . . 2 (1-1/4” DIA.) CAP SCREW 3/8”-16X2-3/4” . . . . . 2 3/8”-16 NYLON INSERT NUT . . . . 2 REAR AXLE ASSEMBLY. . . . . . . . . 1 SPACER, THIN . . . . . . . . . . . . . . AR SPACER, THICK . . . . . . . . . . . . . AR TRUNNION PIVOT PIN. . . . . . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . 2 1/2”-13X6” BOLT . . . . . . . . . . . . . . . 1 BOOM LIFT CYL. ASY . . . . . . . . . . 2

27 28

L64123 L64122

29 30 31 32 33 34 35 36

L66282 L50143 L50245 L64297 L64297 L50312 L64590 L64621

00 00

L70200 L64600 L520004 L41770

00 00 00

00

a

27

Description

Qty. Req.

SPACER . . . . . . . . . . . . . . . . . . . . . 4 SPHERICAL BUSHING . . . . . . . . . . 4 RS6 (1-1/2” I.D.) ECCENTRIC PIN. . . . . . . . . . . . . . . 2 5/16” LOCK WASHER . . . . . . . . . . . 6 CAP SCREW 5/16”-18X1”. . . . . . . . 6 HOSE, -8 A8/A12 82” . . . . . . . . . . . 2 HOSE, -8 A8/A12 82” . . . . . . . . . . . 2 5/8”-11X1” BOLT . . . . . . . . . . . . . . . 4 WASHER, PIN RETAINER . . . . . . . 4 PIN, LIFT CYL.. ROD END . . . . . . . 2

-- ITEMS NOT SHOWN -BACKUP ALARM. . . . . . . . . . . . . . . 1 HOSE GUARD . . . . . . . . . . . . . . . . 1 5/16”-18 NYLON INSERT NUT . . . 2 CLAMP 3/4” . . . . . . . . . . . . . . . . . . . 2 (Hoses To Frame Side) L45666 CLAMP, 1” . . . . . . . . . . . . . . . . . . . . 1 (Tube To Frame Side) L47212 CLAMP, 3/8” . . . . . . . . . . . . . . . . . . 2 (Wire Harness To Frame) L50056 5/16”-18 SERR. FLNG. NUT . . . . . 1 L570005 CLAMP, 7/8” . . . . . . . . . . . . . . . . . . 4 (Hoses To Frame Side) L50056 5/16”-18 SERR. FLNG. NUT . . . . . 5

Refer to the Hydraulic Components section for a listing of hydraulic cylinders specific to this model.

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler

Hoods and Covers

16

12

10 15 14 13

8

5

9

4

15 8

7

11 17

6

1 7 15

3 2 15

3

FRONT

913208/BP0209

28

PRINTED IN U.S.A.

638 Telehandler

Chassis, Covers & Tanks Hoods and Covers

Ref. No.

Part No.

01

L64947 L50230 L530004 L50141 L66741 L50230 L530004 L50141 L66739 L62720 L62721 62722 L64673 L64727 L50230 L530004 L50141 L68617 L68617 L64695 L50214 L50051 L65896 L50214 L50051 L68229 L50230 L50141 L530004 L66721 L50230

02

03

04

05 06 07

08

09

10

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

FRONT COVER. . . . . . . . . . . . . . . . 1 CAP SCREW 5/16-18X3/4 . . . . . . . 8 5/16-18 RETAINED NUT . . . . . . . . 8 5/16 PLAIN NUT. . . . . . . . . . . . . . . 8 FRONT HOOD WELDMENT. . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 8 5/16”-18 RETAINED NUT. . . . . . . . 8 5/16” PLAIN NUT . . . . . . . . . . . . . . 8 ACCESS COVER . . . . . . . . . . . . . . 2 STUD FASTENER . . . . . . . . . . . . . 8 RETAINER . . . . . . . . . . . . . . . . . . . 8 RET.RECEPTACLE . . . . . . . . . . . . 8 HANDLE (note g) . . . . . . . . . . . . . . 2 MID-SEC.HOOD WELDMENT . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 4 5/16”-18 RETAINED NUT. . . . . . . . 4 5/16” PLAIN NUT . . . . . . . . . . . . . . 4 LEFT HAND SLIDE DOOR . . . . . . . 1 RIGHT HAND SLIDE DOOR . . . . . . 1 NYLATRON SLIDE . . . . . . . . . . . . . 4 1/4”-20X1” BOLT . . . . . . . . . . . . . . 8 1/4”-20 SERR. FLNG. NUT . . . . . . 8 NYLATRON GUIDE . . . . . . . . . . . . . 2 1/4”-20X1” BOLT . . . . . . . . . . . . . . 8 1/4”-20 SERR. FLNG. NUT . . . . . . 8 TOP HOOD WELDMENT . . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 6 5/16” PLAIN WASHER . . . . . . . . . . 6 5/16”-18 RETAINED NUT. . . . . . . . 6 LEFT HAND RAD.SEC.WLDMT . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 2

11

12

13 14

15

16 17

00

29

Part No. L50141 L50228 L530004 L66723 L50230 L50141 L50228 L530004 L66720 L50823 L530004 L50141 L64701 L50056 L66729 L50230 L530004 L50141 L64673 L50418 L50050

Description

Qty. Req.

5/16” PLAIN WASHER . . . . . . . . . . 4 5/16”-18X1/2” BOLT . . . . . . . . . . . . 2 5/16”-18 RETAINED NUT. . . . . . . . 2 RIGHT HAND RAD.SEC.WLDMT . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 2 5/16” PLAIN WASHER . . . . . . . . . . 4 5/16”-18X1/2” BOLT . . . . . . . . . . . . 2 5/16”-18 RETAINED NUT. . . . . . . . 2 BULKHEAD PLATE . . . . . . . . . . . . . 1 5/16”-18X1” BOLT . . . . . . . . . . . . . 2 5/16”-18 RETAINED NUT. . . . . . . . 2 5/16” PLAIN WASHER . . . . . . . . . . 2 REAR HOOD SUPPORT . . . . . . . . 1 5/16”-18 SERR. FLNG. NUT . . . . . 2 REAR HOOD WELDMENT . . . . . . . 1 5/16”-18X3/4” BOLT . . . . . . . . . . . . 6 5/16”-18 RETAINED NUT. . . . . . . . 6 5/16” PLAIN WASHER . . . . . . . . . . 6 HANDLE . . . . . . . . . . . . . . . . . . . . . 4 RND HD. SCREW 10-32X1/2” . . 12 10-32 NUT . . . . . . . . . . . . . . . . . . 12

-- ITEMS NOT SHOWN -FOAM INSULATION KIT . . . . . . . . 1 (used under hoods item 4 and 9) L64326 AXLE GREASE HOSE . . . . . . . . . . 2 L277013 GREASE ZERK . . . . . . . . . . . . . . . 2 L50145 3/8” PLAIN WASHER . . . . . . . . . . . 2 L70200 BACKUP ALARM. . . . . . . . . . . . . . . 1 L64985

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler

Fuel Tank / Battery Group (S/N 80017 and Up)

FRONT

19

18

27

24

20

25 21 23 28 17 22

26

16 1 15 14

13 2

3 4

12 5

6 8

9

7

11

10

913208/BP0209

30

PRINTED IN U.S.A.

638 Telehandler

Chassis, Covers & Tanks

Fuel Tank / Battery Group (S/N 80017 And Up) Ref. No.

Part No.

01 02 03 04 05

101456 L61117 L530003 L70146 101955 L64362

06

07 08 09 10 11 12 13 14 15 16

101954 L630001 L50061 101463 L52025 NSS L72175 101567 L520019 L50286 L62722 L62721 L62720

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

WELDMENT, FUEL TANK . . . . . . . . 1 BATTERY HOLDDOWN BAR . . . . . 1 3/8”-16 WINGNUT . . . . . . . . . . . . . . 2 ROD, BATTERY HOLDDOWN . . . . 2 CABLE, POS BATTERY . . . . . . . . . 1 Note a Note b CABLE, NEG BATTERY . . . . . . . . . 1 Note a Note b 3/8”-16 FLANGE NUT . . . . . . . . . . . 4 PLATE, BATTERY ACCESS . . . . . . 1 5/16”-18X3/4” BHSCS . . . . . . . . . . . 4 12VDC BC1 4DLT BATTERY . . . . . 1 1/2” NPT PIPE PLUG . . . . . . . . . . . 1 GROMMET, FUEL TANK. . . . . . . . . 1 1/2”-13 NYLON INSERT NUT . . . . . 6 1/2”-13X1-3/4” BOLT . . . . . . . . . . . . 6 FASTENER, RECEPTACLE . . . . . . 2 FASTENER, RETAINER. . . . . . . . . 2 FASTENER, STUD . . . . . . . . . . . . . 2

17 18

21 22 23 24 25 26 27 28

101486 101566 101505 L64673 L50418 L50050 L64672 L41854 L50755 L61867 104303 081379 L63756 103991

PLATE, TOOLBOX BOTTOM . . . . . 1 TOOLBOX COVER, WELDMENT. . 1 GASKET . . . . . . . . . . . . . . . . . . . . . 1 HANDLE, HOOD . . . . . . . . . . . . . . . 1 #10-32X1/2” RND HD SCREW . . . . 2 #10-32 NUT . . . . . . . . . . . . . . . . . . 2 STUD, HINGE . . . . . . . . . . . . . . . . . 2 GASKET, SENDER . . . . . . . . . . . . . 1 5/16”-18 ACORN NUT . . . . . . . . . . . 8 SENDER/FUEL LEVEL . . . . . . . . . . 1 CAP/FUEL ASSEMBLY . . . . . . . . . . 1 5/16”x1/2 FLAT LOCK BOLT . . . . . . 4 MIRROR, 6.5X10 CONVEX . . . . . . 1 MIRROR BRACKET . . . . . . . . . . . . 1

00 00

L630003 L630004

-- ITEMS NOT SHOWN -CABLE BOOT (Positive cable) . . . . 1 GROUND STRAP . . . . . . . . . . . . . . 1 (attaches to chassis)

a b

Used on units equipped with electronic throttle.

Used on units equipped with mechanical throttle.

19 20

31

Description

Qty. Req.

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler

Fuel Tank / Battery Group (S/N 80016 and before)

18 16

19

17

20

21 22

17

15 14 23 24 25 13

1

3

2

4 5

12

6 7

11 10 9

913208/BP0209

32

8

PRINTED IN U.S.A.

638 Telehandler

Chassis, Covers & Tanks

Fuel Tank / Battery Group (S/N 80016 and before) Ref. No.

Part No.

00

430136

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

NSS L64362 L630001 L630003 L64256 L50141 L50230 NSS L50061 L70146 L530003 L61117 L64257 L62721 L62722 L62720

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE FUEL TANK ASY. (Includes 1, 5, 13-14, 19, 21, 24-25) WELDMENT, FUEL TANK . . . . . . . . 1 CABLE, POS BATTERY . . . . . . . . . 1 CABLE, NEG BATTERY . . . . . . . . . 1 CABLE BOOT (Positive cable) . . . . 1 PLATE, BATTERY ACCESS . . . . . . 1 5/16” FLAT WASHER . . . . . . . . . . . 4 5/16”X3/4” BOLT . . . . . . . . . . . . . . . 4 12VDC BC1 4DLT BATTERY . . . . . 1 3/8”-16 FLANGE NUT . . . . . . . . . . . 4 ROD, BATTERY HOLDDOWN . . . . 2 3/8”-16 WINGNUT . . . . . . . . . . . . . . 2 BATTERY HOLDDOWN BAR . . . . . 1 TOOLBOX BOTTOM PLATE. . . . . . 1 RETAINER FASTENER . . . . . . . . . 2 RECEPTACLE . . . . . . . . . . . . . . . . 2 FASTNER, STUD . . . . . . . . . . . . . . 2

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

L97745 L50755 L64672 L50050 L50418 L64673 L64264 L97746 L64846 L64898 L120027 L61867 L41854

TOOL BOX HOOD. . . . . . . . . . . . . . 1 5/16”-18 ACORN NUT . . . . . . . . . . . 8 STUD/HINGE. . . . . . . . . . . . . . . . . . 2 NUT, #10-32 . . . . . . . . . . . . . . . . . . 4 SCREW MACH, #10-32 . . . . . . . . . 4 HANDLE, HOOD . . . . . . . . . . . . . . . 1 STUD, HINGE FUEL COVER . . . . . 2 HOOD, FUEL. . . . . . . . . . . . . . . . . . 1 MIRROR . . . . . . . . . . . . . . . . . . . . . 1 MIRROR BRACKET/BOX . . . . . . . . 1 FUEL CAP . . . . . . . . . . . . . . . . . . . . 1 SENDER/FUEL LEVEL . . . . . . . . . . 1 GASKET, SENDER . . . . . . . . . . . . 1

00 00 00 00

L630004 L72175 L50286 L520019

-- ITEMS NOT SHOWN -GROUND STRAP . . . . . . . . . . . . . . 1 1/2” NPT PIPE PLUG (Drain plug) . 1 1/2”-13X1-3/4” BOLT . . . . . . . . . . . . 6 1/2”-13 NYLON INSERT NUT . . . . . 6

33

Description

Qty. Req.

913208/BP0209

Chassis, Covers & Tanks

638 Telehandler

Hydraulic Tank

FRONT

Rear of Unit (behind radiator) 1

P2

P1

4

5 6

16

1

37 36

17

15

35 33 34

8

7

18 9

T

32

19

10 14

31

13

23

22

C2 C1

12 11

30

24

29

25

Located inside tank 26

27 28

913208/BP0209

34

PRINTED IN U.S.A.

638 Telehandler

Chassis, Covers & Tanks Hydraulic Tank

Ref. No.

Part No.

01 04 05 06 07 08 09a 10 11 12 13 14 15 16 17 18 19 22 23 24 25 26 27 28 29

L64599 L64301 L64301 L64294 L64296 L64660 L71066 L444004 L64302 L64302 L64856 L64652 L64651 L64321 P470472 L50823 L50141 L61572 L64300 L72419 L61620 L49327 L63309 L442023 L43221

Description

Qty. Req.

Ref. No.

Part No.

TUBE ASSEMBLY . . . . . . . . . . . . . . 1 HOSE, -8 A8/A8 19” . . . . . . . . . . . . 1 HOSE, -8 A8/A8 19” . . . . . . . . . . . . 1 HOSE, -8 A8/A8 53” (P2) . . . . . . . . 1 HOSE, -8 A8/A8 38” (P1) . . . . . . . . 1 ADAP, -8JICM -8ORM TEE . . . . . . . 2 RELIEF VALVE . . . . . . . . . . . . . . . . 1 ADAP, -8ORM -8JICM . . . . . . . . . . . 2 HOSE, -8 DM8/A8 96” (C2). . . . . . . 1 HOSE, -8 DM8/A8 96” (C1). . . . . . . 1 ADAP, -16JICM -16JICFS 90 . . . . . 1 ADAP, -16JICFS -16JICM TEE . . . . 1 ADAP, -10ORM -16JICM . . . . . . . . . 1 HOSE, -16 A16/A16 30” . . . . . . . . . 1 FILL CAP ASSEMBLY . . . . . . . . . . . 1 5/16”-18X1” BOLT . . . . . . . . . . . . . 10 5/16” FLAT WASHER . . . . . . . . . . 10 ADAP, -8JICM 12NPTM 90 . . . . . . . 1 HOSE, -8 A8/-- 72” . . . . . . . . . . . . . 1 ADAP, 1-1/2” NPT 90 ELBOW . . . . 1 ADAP, 1-1/2” PIPE NIPPLE. . . . . . . 1 STRAINER, HYD. OIL . . . . . . . . . . . 1 HOSE, -24 A24/A24 35” . . . . . . . . . 1 ADAP, -24JICM 24NPTM 90 . . . . . . 1 PLUG, 1/2”-14 MAGNETIC . . . . . . . 1

30

L64218

31 32

L50261 L65211 L50145 L50836 L65211 L64619 101879

Description

HYDRAULIC TANK ASY. . . . . . . . . . 1 (Includes 24-26,29 & 34) CAP SCREW 3/8-16X1-1/2 . . . . . . 2 3/8-16 RETAINED NUT . . . . . . . . . 2 3/8 PLN WASHER (Rt.Side Only) . 2 CAP SCREW 3/8-16X1-3/4 . . . . . . 2 3/8-16 RETAINED NUT . . . . . . . . . 2 SIGHT GLASS. . . . . . . . . . . . . . . . . 1 FILTER ASY. . . . . . . . . . . . . . . . . . . 1 (Includes #33 and all items shown) SEAL KIT (Note b) . . . . . . . . . . . . . 1 SEAL KIT (Note c) . . . . . . . . . . . . . 1 CAP SCREW 3/8-16X1-1/4 . . . . . . 4 HYDRAULIC FILTER ELEMENT. . . 1 ACCESS COVER . . . . . . . . . . . . . . 1 GASKET . . . . . . . . . . . . . . . . . . . . . 1 ADAP, 1-1/2”MNPT 1-1/4”FNPT . . . 1 ADAP, 1-1/4”MNPT 1”FNPT . . . . . . 1 ADAP, -16JICM 16NPT 90 . . . . . . . 1

35 36 37

102965 L98568 L50403 L97489 L65142 L65144 L60847 L72350 L442007

a b c

Replaces L64658 Relief valve SN 80020 and up SN 80019 and before

33 34

Qty. Req.

HOSE LOCATOR 02 04 05 06 07 11 12 16 21 23 27

HYDRAULIC TUBE (from hyd. tank) (RS8) RELIEF VALVE PORT “P2” (top of tee) (RS6) RELIEF VALVE PORT “P1” (top of tee) (RS6) RELIEF VALVE PORT “P2” (RS6) RELIEF VALVE PORT “P1” (RS6) RELIEF VALVE PORT “C1” (RS6) RELIEF VALVE PORT “C2” (RS6) RELIEF VALVE “T” (tee) (RS6) HYDRAULIC TANK (top rear corner) (RS8) HYDRAULIC TANK (top rear corner) (RS6) HYDRAULIC TANK (bottom)

PRINTED IN U.S.A.

BULKHEAD then HYD. COOLER “UPPER” BULKHEAD then TILT CYLINDER (retract) BULKHEAD then TILT CYLINDER (extend) SLAVE CYLINDER (LEFT) “UPPER TEE” (retract) SLAVE CYLINDER (LEFT) “LOWER TEE” (extend) TILT/ROTATE JOYSTICK “C” TILT/ROTATE JOYSTICK “D” HYDRAULIC COOLER “UPPER” (RS6) HYDRAULIC MANIFOLD (under cab) BRAKE VALVE/HYDROMAX PORT “T” (under cab) HYDRAULIC PUMP “IN”

35

913208/BP0209

Engine

638 Telehandler Engine - External Components

1

27

4

2 3

5

26

6

25 24

23

22

21 JOHN DEERE 4045TF (SHOWN) 20 8 9 7 19

10

18

12

12 11

14 15 17

16

TRANSMISSION MOUNTS

REAR

13 14 15 16

913208/BP0209

36

PRINTED IN U.S.A.

638 Telehandler

Engine

Engine - External Components Ref. No.

Part No.

01 02 03

NSS L41179

04 05 06 07b 08b 09b 10 11 12 13c 14 15 16 17 18

19 20 21 22 23

101924 L68571 L50209 L520003 L64437 L69166 L66606 L64664 L64663 L580009 L68531 L68533 L50319 L64196 L64124 L64197 L520007 L50704 103626 L64646 L68554 L68557 L50305 L69718 L68592

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

ENGINE . . . . . . . . . . . . . . . . . . . . . . 1 RELAY, ENGINE STARTER . . . . . . 1 MOUNT, RELAY . . . . . . . . . . . . . . . 1 Note a Note b 1/4”-20X1/2” BOLT . . . . . . . . . . . . . 2 1/4”-20 NYLON INSERT NUT . . . . 2 SENDER, WATER TEMP . . . . . . . . 1 FUEL LINE TUBE . . . . . . . . . . . . . . 1 BRACKET, THROTTLE (JD) . . . . . . 1 COUPLER, ROD-CABLE . . . . . . . . 1 ROD, THROTTLE EXTEND . . . . . . 1 BALL JOINT #10-32 ROD END. . . . 1 TRANS MOUNT (LEFT) . . . . . . . . . 1 TRANS MOUNT (RIGHT) . . . . . . . . 1 5/8”-11X3-1/2” BOLT . . . . . . . . . . . . 4 SPACER . . . . . . . . . . . . . . . . . . . . . 2 MOUNT, VIBRATION ISOLATOR . . 4 WASHER, ISOLATOR MOUNT. . . . 4 5/8”-11 NYLON INSERT NUT . . . . . 4 M12X1.175X40M BOLT GR8 . . . . . 4 SENDER, OIL PRESSURE . . . . . . . 1 Note a Note b ENGINE MOUNT (RIGHT) . . . . . . . 1 ENGINE MOUNT (LEFT) . . . . . . . . 1 M16-2X35M BOLT GR8.8 . . . . . . . . 4 ADAP, M18 -6NPTF STR . . . . . . . . 2 SHUTOFF, MANUAL/WATER . . . . . 1

24 25

L68591

37

Description

Qty. Req.

26d 27

L500598 L68613 L447005 L68616

STEM, HOSE . . . . . . . . . . . . . . . . . 1 FAN BELT . . . . . . . . . . . . . . . . . . . . 1 Note a Note b ADAP, M18 10 BEAD STR . . . . . . . 1 BRACKET, ALTERNATOR. . . . . . . . 1

00 00

L65570 L60587

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

00

L66855 L66360 L68054 L650004

(Ether) ETHER KIT (Optional) . . . . . . . . . . 1 CANISTER AND MOUNT. . . . . . . . 1 SWITCH, ROCKER (ETHER) . . . . 1 TERMINAL BLOCK . . . . . . . . . . . . 1

00 00 00 00

L442015 L442017 L68574 L66118

(Fuel Line) ADAP, -6 NPT -6JICM 45º. . . . . . . . 1 ADAP, -6 NPT -4JICM 45º. . . . . . . . 1 HOSE, -6 X 70” (supply) . . . . . . . . . 1 HOSE, -4 X 52” (return). . . . . . . . . . .

00

(Filters) Refer to page 1 for a listing of fuel and engine oil filters.

a b c d

Used on units equipped with electronic throttle.

Used on units equipped with mechanical throttle.

Used on units SN 80016 and before Replaces item 24 and (1) of item 22.

913208/BP0209

Engine

638 Telehandler Engine - Air Intake

5

FRONT

3 1

4

2

6

10 12 13 7 8 16 11 14 10 15

13

9

17

913208/BP0209

38

PRINTED IN U.S.A.

638 Telehandler

Engine Engine - Air Intake

Ref. No.

Part No.

00

L120021

01 02

L120037 L99066 L99067 L98646 L98648 NSS NSS L94580 L120022 L50230 L50056 L64863

03 04 05 06 07

08

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

AIR CLEANER ASY. . . . . . . . . . . . .1 (Includes 1-6 & 11) ELEMENT . . . . . . . . . . . . . . . . . . . .1 WING BOLT . . . . . . . . . . . . . . . . . . .1 RUBBER/STEEL GASKET . . . . . . .1 CLAMP . . . . . . . . . . . . . . . . . . . . . .1 THUMBSCREW . . . . . . . . . . . . . . .1 END CAP . . . . . . . . . . . . . . . . . . . . .1 GASKET . . . . . . . . . . . . . . . . . . . . .1 EVACUATOR . . . . . . . . . . . . . . . . . .1 MOUNTING BAND . . . . . . . . . . . . .2 CAPSCREW 5/16-18X3/4 . . . . . . .4 SERR. FLGE. NUT 5/16-18 . . . . . .4 INLET HOOD/CAP . . . . . . . . . . . . .1

09 10 11

L64864 L51781 NSS

12 13 14 15 16 17

L47419 L51099 L66877 L66594 L50251 L68545 L120041

90o RUBBER ELBOW, 4” DIA. . . . .1 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 3/8” x 3/4” BOLT . . . . . . . . . . . . . . .1 INTAKE TUBE . . . . . . . . . . . . . . . . .1 90o RUBBER ELBOW, 3” DIA. . . . .1

00 00

L68516 L68517

-- ITEMS NOT SHOWN -PRE-CLEANER (optional) . . . . . . . .1 REDUCER, 4” - 3” . . . . . . . . . . . . . .1

39

Description

Qty. Req.

913208/BP0209

Engine

638 Telehandler Engine - Exhaust

FRONT 2 1 3

4 5

11 11

9

6 8

10 7

913208/BP0209

40

PRINTED IN U.S.A.

638 Telehandler

Engine Engine - Exhaust

Ref. No.

Part No.

01 02 03 04 05 06

L68544 L99434 L65018 L64764 L120047 L64572 L50705 L50151

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

EXHAUST PIPE WELDMENT . . . .1 TURBO CLAMP (JD 4045) . . . . . . .1 TAIL PIPE . . . . . . . . . . . . . . . . . . . .1 HANGER . . . . . . . . . . . . . . . . . . . . .1 CLAMP, 2-1/2” . . . . . . . . . . . . . . . . .1 BRACKET . . . . . . . . . . . . . . . . . . . .1 CAP SCREW M12-1.75X30 . . . . . .2 PLAIN WASHER 1/2”

07

L61021 L50367 L50145 L520005 L50151 L50705 L64821 L60492

08 09 10 11

41

Description

Qty. Req.

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

913208/BP0209

Engine

638 Telehandler Radiator/Coolers 10

8

6

FRONT

11

7

2

4

9

5 3 1

2

12

13 14

17

4

16

4

18

15

19

24

22 23

2 25

27 28

22

2

29

26

30

TR

AN SM CO ISSIO OL ER N

20 21

26 HY DR CO AULIC OL ER

19 24

31

32

FRONT

913208/BP0209

42

PRINTED IN U.S.A.

638 Telehandler

Engine Radiator/Coolers

Ref. No.

Part No.

01 02 03

L50230 L50141

04 05 06 07 08 09 10

11 12 13 14 15 16 17 18

L63665 L67751 L76020 L50228 L68539 L47212 L66515 L76084 L99971 102063 L45934 L50667 L66265 L66709 L68580 L40805 L50151 L520019

Description

Qty. Req.

Ref. No.

Part No.

5/16”-18X3/4” BOLT . . . . . . . . . . .AR 5/16” FLAT WASHER . . . . . . . . . .AR FAN GUARD (Half) . . . . . . . . . . . . .2 (Standard) (When equipped with A/C) HOSE CLAMP #32 SAE . . . . . . . . .3 5/16”-18X1/2” BOLT . . . . . . . . . . . AR UPPER HOSE . . . . . . . . . . . . . . . . .1 VINYL CLAMP 3/8” HOSE . . . . . . . 2 SHROUD . . . . . . . . . . . . . . . . . . . . .1 HOSE CLAMP #24 SAE . . . . . . . . . 1 CAP, RADIATOR 10LB. . . . . . . . . . .1 2” DIA. PRESSURE SEAL 1-1/2” DIA. PRESSURE SEAL RADIATOR . . . . . . . . . . . . . . . . . . .1 M8-1.25X45M BOLT . . . . . . . . . . . . 4 FAN . . . . . . . . . . . . . . . . . . . . . . . . .1 FAN SPACER . . . . . . . . . . . . . . . . .1 LOWER HOSE . . . . . . . . . . . . . . . .1 DRAIN COCK . . . . . . . . . . . . . . . . .1 1/2” FLAT WASHER . . . . . . . . . . . .2 1/2”-13 NYLON INSERT NUT . . . . .2

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

L51621 L64321 L65439 L530004 L450002 L66114 L50230 L61092 L66136 L66119 L50228 L66136 L50145 L520005

Description

Qty. Req.

ADAP, -16ORM -16JICM . . . . . . . . .2 HOSE -16 A16/A16 30” . . . . . . . . . .1 HOSE -16 A16/DM16 86” . . . . . . . .1 5/16” NUT RETAINING CLIP . . . .AR OIL COOLER . . . . . . . . . . . . . . . .AR PLATE, COOLER MOUNTING . .AR 5/16”-18X3/4” BOLT . . . . . . . . . . .AR ADAP, -16ORM -12JICM . . . . . . . . .2 HOSE, -12 A12/DM12 104” . . . . . . .1 OIL COOLER . . . . . . . . . . . . . . . . . .1 5/16”-18X1/2” BOLT . . . . . . . . . . .AR HOSE, -12 A12/DM12 104” . . . . . . .1 3/8” FLAT WASHER . . . . . . . . . . .AR 3/8”-16 NYLON INSERT NUT . . .AR

HOSE LOCATOR 20 21 27 30

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

PRINTED IN U.S.A.

RELIEF VALVE (rear of unit) PORT “T” (tee fitting) BULKHEAD (under cab and then to hyd. manifold) TRANSMISSION (top right side - near filter) TRANSMISSION (left side - just under hyd. pump)

43

913208/BP0209

Transmission

638 Telehandler

Transmission - External Components

FRONT 1

2

4

3

28 26 25

27

24

6

5

12

7

9

8 23 22

20

11

21

12

17

10 18

19

10

16 15

10

14 13

REAR

913208/BP0209

44

PRINTED IN U.S.A.

638 Telehandler

Transmission

Transmission - External Components Ref. No.

Part No.

01

L63633 L42342 L47275 L50367 L50056 L446020 L444001 L66136 L444007 L66136 L444070 104425 L68550 L50468 L50319 L50704 L520007 L64197 L64124 L64196 L68553 103193 L68549

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

Description

Qty. Req.

Ref. No.

Part No.

PARK BRAKE CABLE . . . . . . . . . . . 1 CLEVIS PIN. . . . . . . . . . . . . . . . . . . 2 CABLE CLAMP . . . . . . . . . . . . . . . 1 3/8”-16X1” BOLT . . . . . . . . . . . . . . 1 3/8”-16 FLANGE NUT . . . . . . . . . . 1 ADAP, -12JICM -12JICFS 90º . . . . . 1 ADAP, -12ORM -12JICM STR. . . . . 1 HOSE, -12 A12/DM12 104” . . . . . . 1 ADAP, -10ORM -12JICM STR . . . . 1 HOSE, -12 A12/DM12 104” . . . . . . . 1 ADAP, -3ORM . . . . . . . . . . . . . . . . . 1 SWITCH, PRESSURE. . . . . . . . . . . 1 DRIVESHAFT, FRONT . . . . . . . . . . 1 3/8”-24X1-3/4” GR8 BOLT. . . . . . . 16 5/8”-11X3-1/2” BOLT . . . . . . . . . . . . 2 M12X1.75X40mm BOLT . . . . . . . . . 4 5/8”-11 NYLON INSERT NUT . . . . . 2 WASHER, ISOLATOR MOUNT. . . . 2 MOUNT, VIBRATION ISOLATOR . . 2 SPACER . . . . . . . . . . . . . . . . . . . . . 2 TRANS MOUNT, RIGHT . . . . . . . . . 1 TRANSMISSION,T12000 . . . . . . . . 1 DRIVESHAFT, REAR . . . . . . . . . . . 1

20

L99182 L10151 650965 L50147 L50833 L68552 L71637 L50952 L50727 L99184 L66965

21b 22c 23 24 25 26d 27 28 a b c d e

Description

Qty. Req.

UNIVERSAL JOINT . . . . . . . . . . . . . 4 GREASE ZERK . . . . . . . . . . . . . . . 2 3/8”-24X1-1/4” GR 8 BOLT . . . . . . . 8 3/8” LOCK WASHER . . . . . . . . . . . 8 3/8”-24X2” GRADE 8 BOLT . . . . . . 8 TRANS MOUNT, LEFT . . . . . . . . . . 1 BRACKET, PARK BRAKE . . . . . . . . 1 M10X1.5X25mm . . . . . . . . . . . . . . 10 M10X1.5X35mm . . . . . . . . . . . . . . . 2 FILTER, TRANSMISSION OIL . . . . 1 SENDER, TEMP 250º . . . . . . . . . . . 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 throttle bracket to transmission Used on units SN 80016 and before

HOSE LOCATOR 04 06

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

PRINTED IN U.S.A.

TRANSMISSION COOLER “LOWER” TRANSMISSION COOLER “UPPER”

45

913208/BP0209

Transmission

638 Telehandler

Transmission - Internal Components

NOTICE FOR INTERNAL PARTS OF THE 12000 SERIES TRANSMISSION , REFER TO SEPARATE MANUAL FORM NO. 907368. IF YOU DO NOT HAVE THIS MANUAL, IT CAN BE ORDERED THROUGH THE GEHL SERVICE PARTS DEPARTMENT.

913208/BP0209

46

PRINTED IN U.S.A.

638 Telehandler

Transmission Notes

PRINTED IN U.S.A.

47

913208/BP0209

Axles

638 Telehandler Planetary and Wheel Assembly

31

1

15

11 10

13

12

14

19

18

17

3

2 16

9 5

6

25 6

5

8 21

23 7

4

27

28 26 22

20

29

24

30

913208/BP0209

48

PRINTED IN U.S.A.

638 Telehandler

Axles

Planetary and Wheel Assembly Ref. No.

Part No.

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

L97645 L93777 L97108 L97128 L97109 L93129 L97127 L97864 L97113 L97866 L96744 L97868 L97869 L97870 L97871 L96738

Description

Qty. Req.

Ref. No.

Part No.

Description

DRIVE FLANGE . . . . . . . . . . . . . . . 1 PIPE PLUG . . . . . . . . . . . . . . . . . . . 1 VENT . . . . . . . . . . . . . . . . . . . . . . . . 1 HUB SEAL. . . . . . . . . . . . . . . . . . . . 1 SPACER . . . . . . . . . . . . . . . . . . . . . 6 NEEDLE BEARING . . . . . . . . . . . 150 INNER BRG. CONE. . . . . . . . . . . . . 1 SPUR PLANET GEAR . . . . . . . . . . 3 SPACER PIN . . . . . . . . . . . . . . . . . . 3 PLANET GEAR PIN . . . . . . . . . . . . 3 THRUST WASHER . . . . . . . . . . . . . 1 SNAP RING . . . . . . . . . . . . . . . . . . . 1 SPUR SUN GEAR. . . . . . . . . . . . . . 1 FLAT SPACER. . . . . . . . . . . . . . . . . 1 PLANET RING GEAR . . . . . . . . . . . 1 ROLL PIN . . . . . . . . . . . . . . . . . . . . 1

17a 18 19 20 21 22 23 24 25 26 27 28 29 30 31

L93103 L97122 L97123 L93101 L97124 L93097 L97126 L66626 L97111 L97858 L97856 L97857 NSS 100134 L99147

a

Spanner wrench PN L99234.

Qty. Req.

LOCK NUT . . . . . . . . . . . . . . . . . . . 1 OUTER BRG. CONE . . . . . . . . . . . . 1 OUTER BRG. CUP . . . . . . . . . . . . . 1 WHEEL MTG. NUT 3/4-16. . . . . . . 10 PLANET HUB . . . . . . . . . . . . . . . . . 1 WHL.MTG.STUD . . . . . . . . . . . . . . 10 INNER BRG. CUP . . . . . . . . . . . . . . 1 VALVE STEM (New Large Hole) . . . 4 SPACER RING BRG.. . . . . . . . . . . . 3 SPINDLE . . . . . . . . . . . . . . . . . . . . . 1 OUTER SHAFT BUSHING . . . . . . . 1 OUTER SHAFT OIL SEAL . . . . . . . 1 TIRE. . . . . . . . . . . . . . . . . . . . . . . . . 4 WHEEL RIM (24X9.00) . . . . . . . . . . 4 CAPSCREW . . . . . . . . . . . . . . . . . 12

COMPLETE AXLE L65815 L66746

PRINTED IN U.S.A.

FRONT AXLE . . . . . . . . . . . . . . . . . 1 REAR AXLE. . . . . . . . . . . . . . . . . . . 1

49

913208/BP0209

Axles

638 Telehandler Brake Caliper Assembly

1

3

9

7 4

5

6 16

8

14

11 12 18 17

PLANET HUB REF.

913208/BP0209

13

15

50

10

PRINTED IN U.S.A.

638 Telehandler

Axles Brake Caliper Assembly

Ref. No.

Part No.

00

L97780

01

L99199

03 04 05 06 07 08 09 10

L97153 L97766 L97155 L97765 NSS L97157 L97158 L97345 L97346 L97162

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

CALIPER ASSEMBLY.. . . . . . . . . . . 2 (Items 3-7 For Brake Fluid Appl.)

BRAKE PAD LINING KIT. . . . . . . . . 1 (Incl. 2 inner and 2 outer pads) DUST BOOT SHIELD . . . . . . . . . . . 2 DUST BOOT . . . . . . . . . . . . . . . . . . 2 PISTON . . . . . . . . . . . . . . . . . . . . . . 2 PISTON SEAL . . . . . . . . . . . . . . . . . 2 CALIPER HOUSING . . . . . . . . . . . . 1 TUBE INSERT SEAT. . . . . . . . . . . . 2 BLEEDER SCREW . . . . . . . . . . . . . 1 LF,RR CALIPER BRKT. . . . . . . . . . . 1 RF,LR CALIPER BRKT. . . . . . . . . . . 1 SOC. HD. SET SCREW . . . . . . . . . 1

11 12 13 14 15 16

L97160 L97161 L97163 L65226 L97328 L64901 L50230 L50143 L97858 L97162

17 18

51

Description

Qty. Req.

COMPRESSION SPRING. . . . . . . . 1 CALIPER SUPPORT KEY. . . . . . . . 1 DISC . . . . . . . . . . . . . . . . . . . . . . . . 1 HYD. FLUID FTG. . . . . . . . . . . . . . . 1 BOLT . . . . . . . . . . . . . . . . . . . . . . . . 9 BRAKE GUARD . . . . . . . . . . . . . . . 2 CAP SCREW 5/16-18X3/4 . . . . . . 4 LOCKWASHER 5/16 . . . . . . . . . . . 4 SPINDLE . . . . . . . . . . . . . . . . . . . . . 2 SOCKET HD. SCREW . . . . . . . . . . 1

913208/BP0209

Axles

638 Telehandler Outer Knuckle End

24

22

23

10

24

3

1

11 12

13

19

26 14

18

9

17 16

25 29

7

20

6

21

16 16 5 15

4

8 28 27

2

1 4 5 30 7

913208/BP0209

52

PRINTED IN U.S.A.

638 Telehandler

Axles Outer Knuckle End

Ref. No.

Part No.

01

L97843 L97844

02

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

101521 101520 101520 101522 L50378 L50151 L97134 L93067 L93068 L97847 L97644 L10465 L97136 L97855 L97341 L97135 L97340 L97854 L97853 L97851 L97641 L97859 L97860

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

RR & LF STR. KNUCKLE . . . . . . . . 1 LR & RF STR. KNUCKLE . . . . . . . . 1 CAPSCREW . . . . . . . . . . . . . . . . . 16 PLAIN WASHER . . . . . . . . . . . . . . 16 LT. REAR FENDER . . . . . . . . . . . . . 1 RT. REAR FENDER . . . . . . . . . . . . 1 LT. FRONT FENDER . . . . . . . . . . . . 1 RT. FRONT FENDER . . . . . . . . . . . 1 CAPSCREW 1/2-13X2 . . . . . . . . . 4 PLAIN WASHER 1/2 . . . . . . . . . . . 4 BRG. CONE. . . . . . . . . . . . . . . . . . . 4 SHIM .005 . . . . . . . . . . . . . . . . . . . . 3 SHIM .010 . . . . . . . . . . . . . . . . . . . . 3 TRUNION PIN . . . . . . . . . . . . . . . . . 4 CENTER YOKE . . . . . . . . . . . . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . . 4 SPINDLE MTG.STUD . . . . . . . . . . 12 AXLE HOUSING . . . . . . . . . . . . . . . 1 KING PIN SEAL. . . . . . . . . . . . . . . . 4 BEARING CUP . . . . . . . . . . . . . . . . 4 GREASE RETAINER. . . . . . . . . . . . 4 BUSHING . . . . . . . . . . . . . . . . . . . . 2 OIL SEAL. . . . . . . . . . . . . . . . . . . . . 2 OUTER YOKE SHAFT . . . . . . . . . . 2 CROSS ASY. . . . . . . . . . . . . . . . . . . 2 BRG.RACE . . . . . . . . . . . . . . . . . . . 8 SNAP RING . . . . . . . . . . . . . . . . . . 1

17 18 19

L97643 L97642 L97852 L97849

20 21

L97331 L97330

22

L97329

23a

L99428 L99432 L93140 L97646

24 25

L97781

53

Description

Qty. Req.

RF/LR INNER SHAFT (LONG) . . . . 1 LF/RR INNER SHAFT (SHORT) . . . 1 DEFLECTOR . . . . . . . . . . . . . . . . . . 2 TIE ROD ASY. . . . . . . . . . . . . . . . . . 1 (Incl. Items 19-22) CLAMP ASY . . . . . . . . . . . . . . . . . . 2 SOCKET ASY. . . . . . . . . . . . . . . . . . 1 (Course Thd) SOCKET ASY. . . . . . . . . . . . . . . . . . 1 (Fine Thd) LR & RF STEER CYL.. . . . . . . . . . . 2 RR & LF STEER CYL.. . . . . . . . . . . 2 SOCKET ASY . . . . . . . . . . . . . 2/CYL LF & RR (SHORT) JOINT . . . . . . . . 1 & SHAFT ASY. RF & LR (LONG) JOINT . . . . . . . . . 1 & SHAFT ASY. (Incl. Items 6,15-17) COTTER PIN, 5/32 X 2 . . . . . . . . . . 6 LOCKING NUT . . . . . . . . . . . . . . . 12 FLAT WASHER . . . . . . . . . . . . . . . 12 CASTLE NUT . . . . . . . . . . . . . . . . . 6 1/2”X1-1/2” C8 BOLT . . . . . . . . . . AR

26 27 28 29 30

L50631 L99150 L99151 L99221 651277

a

Refer to Hydraulic Components section.

913208/BP0209

Axles

638 Telehandler Differential Carrier

19

18

23

17 20 16 25 24 13

28 22

22

23 29 15 21 14 13

12

30 11

3

29

31

32 27

6 4 9 1

10

26

8 7 5 2

913208/BP0209

54

PRINTED IN U.S.A.

638 Telehandler

Axles Differential Carrier

Ref. No.

Part No.

00

01 02 03 04 05 06 07 08 08 09 10 11

Qty. Req.

Ref. No.

Part No.

L500549

COMPL.. CARRIER/DIFF. ASY. . . . 1 (Includes 1,2,4-12, 14-23,26-27,31)

26

L97815

27

NSS

28 29 30 31 32

L93038 L98023 L97855 L97811 L64582 L50836 L520005 L50145

16a 17a 18a 19a

L97803 L97805 L97804 L97806

PINION NUT . . . . . . . . . . . . . . . . . . 1 WASHER, PINION NUT . . . . . . . . . 1 DOWEL PIN. . . . . . . . . . . . . . . . . . . 2 END YOKE . . . . . . . . . . . . . . . . . . . 1 DEFLECTOR . . . . . . . . . . . . . . . . . . 1 OIL SEAL (PINION) . . . . . . . . . . . . . 1 THRUST WASHER . . . . . . . . . . . . . 1 BEARING CUP . . . . . . . . . . . . . . . . 1 BEARING CONE . . . . . . . . . . . . . . . 1 SHIM. . . . . . . . . . . . . . . . . . . . . . . AR SPACER . . . . . . . . . . . . . . . . . . . . . 1 SHIM .003. . . . . . . . . . . . . . . . . . . AR SHIM .005. . . . . . . . . . . . . . . . . . . AR SHIM .010. . . . . . . . . . . . . . . . . . . AR BEARING CUP . . . . . . . . . . . . . . . . 1 BEARING CONE . . . . . . . . . . . . . . . 1 AXLE PIVOT BUSHING . . . . . . . . . 2 RING & PINION SET. . . . . . . . . . . . 1 DURALOCK BOLT. . . . . . . . . . . . . 12 DIFFERENTIAL CASE . . . . . . . . . . 1 (includes items 15 - 21) THRUST WASHER . . . . . . . . . . . AR DIFF. GEAR. . . . . . . . . . . . . . . . . . . 2 THRUST WASHER . . . . . . . . . . . . . 2 DIFF. PINION GEAR . . . . . . . . . . . . 2

L97801 L97802 L97808 L97809 L97810 L64326 L277013

15

L41122 L41123 L98027 L99231 L98019 L97791 L97797 L41129 L41127 L97795 L97796 L97782 L97783 L97784 L88372 L97799 L98026 L99399 L500353 L97814

20a 21a 22 22 23 24 25

12 12 13 14

PRINTED IN U.S.A.

Description

a

55

Description

Qty. Req.

DIFF. SHAFT . . . . . . . . . . . . . . . . . . 1 ROLL PIN . . . . . . . . . . . . . . . . . . . . 1 BEARING CONE . . . . . . . . . . . . . . . 2 BEARING CUP . . . . . . . . . . . . . . . . 2 DIFF. ADJUST. RING. . . . . . . . . . . . 2 GREASE HOSE . . . . . . . . . . . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . . 2 PLAIN WASHER . . . . . . . . . . . . . . 2 CARRIER HOUSING. . . . . . . . . . . . 2 CAPSCREW. . . . . . . . . . . . . . . . . 14 PLAIN WASHER . . . . . . . . . . . . . 14 DIFF. BRG. CAP . . . . . . . . . . . . . . . 2 CAPSCREW. . . . . . . . . . . . . . . . . . 4 PLAIN WASHER . . . . . . . . . . . . . . 4 VENT . . . . . . . . . . . . . . . . . . . . . . . . 1 DRAIN/FILL PLUG. . . . . . . . . . . . . . 2 HOUSING . . . . . . . . . . . . . . . . . . . . 1 LOCK BRG.ADJ.NUT . . . . . . . . . . . 2 BRK.LINETEE MNT(1/FRT2/REAR) CAPSCREW 3/8-16X1-3/4 . . . . . . 3 NYLON INSERT NUT 3/8-16 . . . . . 3 PLAIN WASHER 3/8 . . . . . . . . . . . 3

DIFFERENTIAL SERVICE KIT: L97813 DIFF.CASE INNER PARTS SET . . . 1 (Incl. Items 16-21)

913208/BP0209

Axle Hydraulics

638 Telehandler

Power Brake/Master Cylinder Assembly

1

5 2

3

6

4

7

BOOSTER SECTION

13

8

12 9 10

MASTER CYL. SECTION 11

14

15

OLDER UNITS

913208/BP0209

56

PRINTED IN U.S.A.

638 Telehandler

Axle Hydraulics

Power Brake/Master Cylinder Assembly Ref. No.

Part No.

00

00ac 00ac 01 02 03 04 05 06

07 08 09 10 11

L66814 L99113 L99210 L99209 L99410 L99409 L99408 L99411 L62997 L500551 L71107 L97690 L98072 L97689 L99403 L500208 L99402

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY . . . . . . . . . 1 Note a Note b BOOSTER SECT. Less Motor. . . . . 1 MASTER CYL. SECT. ONLY. . . . . . 1

12 13

L97688

PEDAL ROD (spade type). . . . . . . . 1 PEDAL ROD (clevis type) . . . . . . . . 1 GROMMET . . . . . . . . . . . . . . . . . . . 1 BOOT. . . . . . . . . . . . . . . . . . . . . . . . 1 INLET FITTING (not shown) . . . . . . 1 FLOW SWITCH, HYDROMAX . . . . 1 Note a WIRE ADAPTER . . . . . . . . . . . . . . 1 Note b FACE SEAL . . . . . . . . . . . . . . . . . . . 2 SPECIAL BOLTS . . . . . . . . . . . . . . . 2 RESERVOIR CAP . . . . . . . . . . . . . . 2 RESERVOIR CAP GASKET . . . . . . 2 RESERVOIR . . . . . . . . . . . . . . . . . . 1

Description

Qty. Req.

ELEC. MTR. PUMP ASY. . . . . . . . . 1 RELAY . . . . . . . . . . . . . . . . . . . . . . . 1 Note a Note b PRESSURE SWITCH . . . . . . . . . . . 1 PRESSURE SWITCH . . . . . . . . . . . 1

14a 15b

L99245 L97701 L99335 L99335

a b

SN 80016 and before.

SN 80017 and up.

c

S/N 80016 and before; before; booster section, master cylinder section and seal kit are not available; order part number L99113 Kit, Hydromax Brake Replacement for a complete assembly with all necessary components for installation.

BRAKE RELAY

L97701

PRINTED IN U.S.A.

L99245

57

913208/BP0209

Axle Hydraulics

638 Telehandler Hydraulic Circuit - Brakes

FRONT 4 TO TRANSMISSION

5

LEFT

3 Dash

6

28

2 1 7 12

11 9

8

13

17 HYDRAULIC TANK

20

14 19 15 17

20 17

24

25

23

16 18

24

FR

25 26

AM MO E LE UN VEL T

21

27

28 20

21

23 18 19

20

22

21

19

17 20

20

RIGHT 22 21 19

REAR

913208/BP0209

58

PRINTED IN U.S.A.

638 Telehandler

Axle Hydraulics Hydraulic Circuit - Brakes

Ref. No.

Part No.

01 02 03 04 05

L66814 L62997 L64291 L62840 L62834 L62933 L64267 L60588 L445002 L446026 L64300 L75956 L64273 L62998

06 07 08 09 11 12 13 14

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

POWER BRAKE BOOSTER ASY . . 1 SPECIAL MALE ADAP..(-8JIC) . . . . 1 HOSE, -8 A8/DM8 68” . . . . . . . . . . . 1 DUST CAP. . . . . . . . . . . . . . . . . . . . 1 TEST PORT BLKHD NIPPLE . . . . . 1 FEMALE COUPLER (not shown). . 1 HOSE, -4 A4/DM6 53” . . . . . . . . . . 1 ADAP, -8JICF -6JICM . . . . . . . . . . . 1 ADAP, -8ORM -8JICM 90º. . . . . . . . 1 ADAP, -8 SWIVEL RUN TEE. . . . . . 1 HOSE, -8 A8/NONE 72” . . . . . . . . . 1 #10 CLAMP . . . . . . . . . . . . . . . . . . . 1 HOSE, -4 A4/DM4 24” . . . . . . . . . . . 1 ADAP, -4JICM HYDROMAX (9/16”) 1

15 16 17 19 20 21 22 23 24 25 26 27 28

L62741 L64273 L64848 L65226 L64274 L61833 L446042 L64582 L446046 L64633 L400935 L446044 L64268

59

Description

Qty. Req.

ADAP, -4JICM HYDROMAX (1/2”). . 1 HOSE, -4 A4/DM4 24” . . . . . . . . . . . 1 ADAP, -4JICM BULKHD 45º . . . . . . 4 ADAP, -4JICM BRAKE FITTING . . . 4 HOSE, -4 A4/DM4 20” . . . . . . . . . . . 6 HYDRAULIC TUBE,. -4 . . . . . . . . . . 4 ADAP, -4JICM TEE . . . . . . . . . . . . . 2 TEE MOUNT BRACKET . . . . . . . . . 2 ADAP, -4JICM BULKHEAD STR. . . 2 HYDRAULIC TUBE, -4 . . . . . . . . . . 2 ADAP, -4 JICM BULKHEAD 90º.. . . 2 ADAP, -4JICM SWIVEL RUN TEE . 1 HOSE, -4 A4/A4 57” . . . . . . . . . . . . 1

913208/BP0209

Axle Hydraulics

638 Telehandler

Hydraulic Circuit - Steering

1

FRONT

23 2 LS T

5

HYD. MANIFOLD UNDER CAB

LS

5

3

P

22

CF

4

L R

5

21

6 10

7 20

LEFT

8 19

16 8 18

8

17 P

A

B

12 11

8

T

16

RIGHT

15

14 13

7 9 8

REAR 10

913208/BP0209

60

PRINTED IN U.S.A.

638 Telehandler

Axle Hydraulics

Hydraulic Circuit - Steering Ref. No.

Part No.

01 02 03 04 05 06 07

101880 L64179 L51591 L64270 L444004 L64292 L99428

08 09 10

L445003 L64285 L99432

11

L64286

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

STEER MOTOR . . . . . . . . . . . . . . . 1 PRIORITY VALVE . . . . . . . . . . . . . . 1 ADAP, -4ORM -4JICM 90º. . . . . . . . 1 HOSE, -4 A4/B4 56” . . . . . . . . . . . . 1 ADAP, -8ORM -8JICM STR. . . . . . . 1 HOSE, -8 A8/DM8 52-1/2”. . . . . . . . 1 STEER CYLINDER . . . . . . . . . . . . . 2 (Left Rear & Right Front) ADAP, -6ORM -6JICM 90º. . . . . . . . 6 HOSE, -6 A6/A6 30” . . . . . . . . . . . . 1 STEER CYLINDER . . . . . . . . . . . . . 2 (Right Rear & Left Front) HOSE, -6 A6/A6 43” . . . . . . . . . . . . 1

12 13 14 15 16 17 18 19 20 21 22 23

L64289 L64290 L444002 L66132 L51762 L69747 L66122 L64285 L64286 L64287 L64307 L64524

61

Description

Qty. Req.

HOSE, -6X116” . . . . . . . . . . . . . . . . 1 HOSE, -6X135” . . . . . . . . . . . . . . . . 1 ADAP, -6ORM -6JICM. . . . . . . . . . . 4 HOSE, -6X56” . . . . . . . . . . . . . . . . . 1 ADAP -6JICM -6ORM TEE . . . . . . . 4 STEER SELECT VALVE . . . . . . . . . 1 HOSE, -6X52” . . . . . . . . . . . . . . . . . 1 HOSE, -6 A6/A6 30” . . . . . . . . . . . . 1 HOSE, -6 A6/A6 43” . . . . . . . . . . . . 1 HOSE, -6 A6/DM8 93” . . . . . . . . . . . 1 HOSE, -8 B8/DM8 84”. . . . . . . . . . . 1 CHECK VALVE -8JICM -8ORM. . . . 1

913208/BP0209

Boom Components

638 Telehandler Outer Boom

36 11

29

30

12

35

28

5

26 27

29 33 34 1

31 30 32

4

24

15 14 3 10

23

2

18 16 22

19 20

21

13 37 17 38

9 7

6 8

913208/BP0209

62

PRINTED IN U.S.A.

638 Telehandler

Boom Components Outer Boom

Ref. No.

Part No.

01 02

101597 L64950 L50141 L50056 L64992 L50145 L50061 L64949 L50141 L50056 L65638 L50491 L65640 L50141 L50056 L64737 L50056 L64113 L50273 L520005 L61869 L64060 L50892 L520019 L64123 L62715 L62734 NSS L64590 L50312 L64621 L64014 L64580

03

04

05

06 07

08 09

10 11 12 13 14 15 16 17

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

OUTER BOOM SECT. WELD. . . . . 1 REAR HOSE TRAY COVER . . . . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 6 5/16-18 SERR. FLGE. NUT . . . . . . 6 COVER PLATE . . . . . . . . . . . . . . . . 1 3/8 PLAIN WASHER . . . . . . . . . . . 4 3/8-16 SERR. FLGE. NUT . . . . . . . 4 FRONT HOSE TRAY COVER . . . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 7 5/16-18 SERR. FLGE. NUT . . . . . . 7 INCLINOMETER . . . . . . . . . . . . . . 1 RD. HD. SCREW #8-32X5/8 . . . . . 2 MOUNTING PLATE . . . . . . . . . . . . 1 5/16 PLAIN WASHER . . . . . . . . . . 2 5/16-18 SERR. FLGE. NUT . . . . . . 2 REAR COVER. . . . . . . . . . . . . . . . . 1 5/16-18 SERR. FLGE. NUT . . . . . . 4 ROD END SLAVE CYL. PIN . . . . . . 2 CAPSCREW 3/8-16X2-3/4 . . . . . . 2 5/16-18 NYLON INSERT NUT . . . . 2 SLAVE CYLINDER . . . . . . . . . . . . . 2 UPRIGHT PIVOT PIN . . . . . . . . . . . 2 CAP SCREW 1/2-13X4 . . . . . . . . . 2 1/2-13 NYLON INSERT NUT . . . . . 2 SPACER . . . . . . . . . . . . . . . . . . . . . 4 LOCK TAB . . . . . . . . . . . . . . . . . . . . 2 SHIM 1/8X3X4. . . . . . . . . . . . . . . . . 2 END SUPPORT PLATE. . . . . . . . . . 2 RETAINER. . . . . . . . . . . . . . . . . . . . 4 CAP SCREW 5/8-11X1 . . . . . . . . . 4 ROD END PIVOT PIN . . . . . . . . . . . 2 LIFT CYLINDER . . . . . . . . . . . . . . . 2 HOSE TRACK MNT (Weld On) . . . . 1

18

L64374 L66025 L50608 L64550 L400207 L64442 L510027 L520007 L68678 L500784 L50206 L50228 L520004 N/A L64384 L50380 L50152 L64468 L64466 L64359 L50092 N/A L61708 L50251 L62715 L61709 L510007 L62734 L61709 L50403 L64132 L64061 L61942

19 20 21 22

23 24

25 26

27 28 29 30 31 32 33 34 35 36 37 38

63

Description

Qty. Req.

HOSE TRAY GUIDE (Weld On) . . . 1 TRAY GUIDE EXT (Weld On) . . . . 1 COTTER PIN 5/16X4 . . . . . . . . . . . 2 ROD END MOUNT PIN. . . . . . . . . . 1 RETAINER. . . . . . . . . . . . . . . . . . . . 2 ROD END CYL.. MT. WELD . . . . . . 1 CAP SCREW 5/8-11X2-1/4 . . . . . . 8 5/8-11 NYLON INSERT NUT . . . . . 8 EXTEND CYLINDER ASY . . . . . . . 1 HOSE SLEEVE . . . . . . . . . . . . . . . . 1 DOUBLE CLAMP . . . . . . . . . . . . . . 2 CAPS CREW 5/16-18X1/2 . . . . . . 2 5/16-18 NYLON INSERT NUT . . . . 2 Refer to Intermediate Boom Group TOP FRONT CLEVIS BLOCK. . . . . 1 CAPSCREW 1/2-20X1-1/2 GR8 . . 2 1/2 LOCKWASHER . . . . . . . . . . . . 2 CLEVIS PIN. . . . . . . . . . . . . . . . . . . 1 CLEVIS PIN. . . . . . . . . . . . . . . . . . . 2 ADJUST. CLEVIS . . . . . . . . . . . . . . 2 JAM NUT 1-8 . . . . . . . . . . . . . . . . . 4 Refer to Intermediate Boom Group FRT. BOTT. SLIDE PAD 4X6. . . . . . 2 CAPSCREW 3/8X3/4 . . . . . . . . . . . 8 LOCK TAB . . . . . . . . . . . . . . . . . . . . 4 FRT. SIDE SLIDE PAD 3X4 . . . . . . 4 CAPSCREW 3/8-16X7/8 . . . . . . . . 8 SHIM 1/8X3X4. . . . . . . . . . . . . . . . . 2 FRT. TOP SLIDE PAD 3X4 . . . . . . . 2 CAPSCREW 3/8-16X1-1/4 . . . . . . . 4 SPACER 3/8X3X4 . . . . . . . . . . . . . . 2 COLLAR, 2.5” Dia. (Weld On) . . . . . 2 COLLAR, 1.50 Dia. (Weld On) . . . . 2

913208/BP0209

Boom Components

638 Telehandler Intermediate Boom 31

16

15

14

18 38

20 19 22

21

24 25 1

33

40

CHAIN HOOKUP DETAIL

31

23 17 3 7

OUTER BOOM

2

INTERMEDIATE BOOM

INNER BOOM

6 5 4

28 39

32

8

29 30

13 17

12

16 1

15 36 14 34 9

37

27

35 26 11

34 10

913208/BP0209

64

PRINTED IN U.S.A.

638 Telehandler

Boom Components Intermediate Boom

Ref. No.

Part No.

01 02

L71385 L66764 L50367 L520005 L66763 L61699 L50251 L50147 L61709 L50403 L50147 L61704 L62734 L500784 L64443 L50311 L520007 L64661 L50311 L520007 L68678 L61709 L50251 L50147 L71206 L50275 L520005 L10057 L64360 L49619 L49618 L64095 L71204 L50275 L520005 L10057

03 04

05

06 07 08 09

10

11 12

13

14 15 16 17 18

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

INTERM. SECT. WELD. . . . . . . . . . 1 INTERMEDIATE HOSE TRAY. . . . . 1 CAP SCREW 3/8-16X1 . . . . . . . . . 2 3/8-16 NYLON INSERT NUT . . . . . 2 INNER HOSE TRAY . . . . . . . . . . . . 1 BUMPER PAD . . . . . . . . . . . . . . . . . 1 CAP SCREW 3/8-16X3/4 . . . . . . . 1 3/8 LOCKWASHER . . . . . . . . . . . . 1 TRAY SLIDE PAD 3X4 . . . . . . . . . . 1 CAP SCREW 3/8-16X1-1/4 . . . . . . 2 3/8 LOCKWASHER . . . . . . . . . . . . 1 SPACER 1/4X3X4 . . . . . . . . . . . . . . 1 SHIM 1/8X3X4. . . . . . . . . . . . . . . . . 1 HOSE SLEEVE . . . . . . . . . . . . . . . . 1 LT. TRUNNION MT . . . . . . . . . . . . . 1 CAPS CREW 5/8-11X1 . . . . . . . . . 5 5/8-11 NYLON INSERT NUT . . . . . 5 RT. TRUNNION MT . . . . . . . . . . . . . 1 CAP SCREW 5/8-11X1 . . . . . . . . . 5 5/8-11 NYLON INSERT NUT . . . . . 5 BOOM EXTEND CYLINDER. . . . . . 1 CYL. SLIDE PAD 3X4 . . . . . . . . . . . 1 CAP SCREW 3/8-16X3/4 . . . . . . . 2 3/8 LOCKWASHER . . . . . . . . . . . . 2 REAR SHEAVE PIN . . . . . . . . . . . . 1 CAP SCREW 3/8-16X3 . . . . . . . . . 1 3/8-16 NYLON INSERT NUT . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . 1 SHEAVE . . . . . . . . . . . . . . . . . . . . . 3 INNER RING . . . . . . . . . . . . . . . . . . 3 ROLLER BRG . . . . . . . . . . . . . . . . . 3 LEAF CHAIN SECTION . . . . . . . . . 2 FRT. SHEAVE PIN. . . . . . . . . . . . . . 1 CAPSCREW 3/8-16X3 . . . . . . . . . 1 3/8-16 NYLON INSERT NUT . . . . . 1 GREASE ZERK . . . . . . . . . . . . . . . 1

19

L61709 L50403 L64143 L62715 L61708 L50251 L62715 L61709 L50403 L50147 L62733 L61709 L50251 L62715 L61708 L50403 L62732 L62731 L62715 L64095 L510007 L50147 L62731 L62734 L48805 L61709 L62733 L62734 L71205 L71205 L64378

20 21 22 23 24

25 26 27 28 29 30 31

32 33 34 35 36 37 38 39 40

65

Description

Qty. Req.

FRT. TOP SLIDE PAD 3X4 . . . . . . . 2 CAP SCREW 3/8-16X1-1/4 . . . . . . 4 SPACER 1/2X3X4 . . . . . . . . . . . . . . 2 FLAT LOCK . . . . . . . . . . . . . . . . . . . 2 FRT. BOTT. SLIDE PAD 4X6. . . . . . 2 CAP SCREW 3/8-16X3/4 . . . . . . . . 8 FLAT LOCK . . . . . . . . . . . . . . . . . . . 4 FRT. SIDE SLIDE PAD 3X4 . . . . . . 4 CAP SCREW 3/8-16X1-1/4 . . . . . . 8 3/8 LOCKWASHER . . . . . . . . . . . . 8 SHIM 1/16X3X4. . . . . . . . . . . . . . . . 4 REAR BOTT. SLIDE PAD 3X4 . . . . 2 CAP SCREW 3/8-16X3/4 . . . . . . . . 4 FLAT LOCK . . . . . . . . . . . . . . . . . . . 2 REAR TOP SLIDE PAD 4X6 . . . . . . 2 CAP SCREW 3/8-16X1-1/4 . . . . . . 8 SHIM 1/8X4X6. . . . . . . . . . . . . . . . . 2 SHIM 1/16X4X6. . . . . . . . . . . . . . . . 2 FLAT LOCK . . . . . . . . . . . . . . . . . . . 2 LEAF CHAIN SECTION . . . . . . . . . 1 CAPSCREW 3/8-16X7/8 . . . . . . . . 4 3/8 LOCKWASHER . . . . . . . . . . . . 4 SHIM 1/16X4X6 . . . . . . . . . . . . . . AR SHIM 1/8X3X4 . . . . . . . . . . . . . . . AR BUSHING . . . . . . . . . . . . . . . . . . . . 2 SIDE SLIDE PAD 3X4 . . . . . . . . . . . 2 SHIM 1/16X3X4 . . . . . . . . . . . . . . AR SHIM 1/8X3X4 . . . . . . . . . . . . . . . AR CHAIN SHEAVE WASHER . . . . . . . 4 CHAIN SHEAVE WASHER . . . . . . . 2 HOSE TRAY MOUNT. PLATE . . . . . 1 (Weld On)

913208/BP0209

Boom Components

638 Telehandler Inner Boom

2 7

29 23

21

30 5

24

1 25 27 28

22

26

3 11

20

6 19

12

1

13 14

9

15 18 10

913208/BP0209

8

4,16 17

14

66

PRINTED IN U.S.A.

638 Telehandler

Boom Components Inner Boom

Ref. No.

Part No.

01 02 03 04 05

L71383 L61868 L48809 L62733 L41770 L50056 L62032 L50273 L520005 L66763 L52026 L520005 L64359 L50092 L64466 L560003 N/A L64467 L50371 L66780 L50403 L66782 L66783 L50261 L62715

06

07

08 09 10 11 12 13

14

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

INNER BOOM SECTION WELD. . . 1 ATTACHMENT TILT CYLINDER. . . 1 BRONZE BUSING 1.75X1.75 . . . . . 4 SHIM 1/16X3X4. . . . . . . . . . . . . . . . 2 VINYL CLAMP 3/4” . . . . . . . . . . . . . 2 5/16-18 SERR. FLGE. NUT . . . . . . 1 BUTT END CYL. PIN. . . . . . . . . . . . 1 CAP SCREW 3/8-16X2-3/4 . . . . . . 1 3/8-16 NYLON INSERT NUT . . . . . 1 INNER HOSE TRAY . . . . . . . . . . . . 1 BUT. HD. BOLT 3/8-16X1-1/4 . . . . 1 3/8-16 NYLON INSERT NUT . . . . . 1 ADJUST.CLEVIS . . . . . . . . . . . . . . . 1 JAM NUT 1-8 . . . . . . . . . . . . . . . . . 2 CLEVIS PIN. . . . . . . . . . . . . . . . . . . 2 COTTER PIN 3/32X1-1/4 . . . . . . . . 2 Refer to Intermediate Boom Group REAR CHAIN PIN . . . . . . . . . . . . . . 1 COTTER PIN 3/32X1-1/4 . . . . . . . . 2 TOP SLIDE PAD 3X8 . . . . . . . . . . . 2 CAPSCREW 3/8-16X1-1/4 . . . . . . . 8 SHIM 1/16X3X8. . . . . . . . . . . . . . . . 2 SHIM 1/8X3X8. . . . . . . . . . . . . . . . . 2 CAP SCREW 3/8-16X1-1/2”. . . . . . 8 LOCK TAB . . . . . . . . . . . . . . . . . . . . 4

15

L61709 L50403 L50147 L62733 L61709 L50251 L62715 N/A L64560 L50646 101976 L66453

16 17 18 19 20 21 22 23 24 25 26

27

28 29 30

67

NSS L65097 L65098 L400193 L50367 L50147 L62032 L50273 L520005 L66456 L500784 L64379

Description

Qty. Req.

SIDE SLIDE PAD 3X4 . . . . . . . . . . . 2 CAP SCREW 3/8-16X1-1/4 . . . . . . 4 3/8 LOCKWASHER . . . . . . . . . . . . 4 SHIM 1/16X3X4. . . . . . . . . . . . . . . . 2 BOTT. SLIDE PAD 3X4 . . . . . . . . . . 2 CAP SCREW 3/8-16X3/4 . . . . . . . . 4 LOCK TAB . . . . . . . . . . . . . . . . . . . . 2 Refer to Intermediate Boom Group ATTACHMENT PIVOT PIN . . . . . . . 2 ROLL PIN 3/16X1-1/4 . . . . . . . . . . . 1 DYNATTACH ASY. (Items 21-25) . . 1 LOCK PLATE & PIN ASY. . . . . . . . . 1 (Incl. Item 24) LOCK PLATE PIN . . . . . . . . . . . . . . 1 LOCK SPRING . . . . . . . . . . . . . . . . 1 SPRING MOUNT . . . . . . . . . . . . . . 1 LOCK FLAT . . . . . . . . . . . . . . . . . . . 2 CAP SCREW 3/8-16X1 . . . . . . . . . 2 LOCKWASHER 3/8 . . . . . . . . . . . . 2 ROD END PIVOT PIN . . . . . . . . . . . 1 CAP SCREW 3/8-16X2-3/4 . . . . . . 1 3/8-16 NYLON INSERT NUT . . . . . 1 LOCK BUSHING . . . . . . . . . . . . . . . 2 HOSE SLEEVE . . . . . . . . . . . . . . . . 1 HOSE TRAY MOUNT PLATE . . . . . 1

913208/BP0209

Boom Hydraulics

638 Telehandler

Hydraulic Circuit - Boom Extend

REAR 1

LEFT

EXTEND

2

3

1 RETRACT

4

6 5 6

11 9 12

10

10

18

19 10

17

15 10

16

14

EXTEND

20

13 17 16

RETRACT

26

21 RETRACT

15

23 EXTEND

15 22 15

RIGHT

15

25

24 15

FRONT

913208/BP0209

68

PRINTED IN U.S.A.

638 Telehandler

Boom Hydraulics

Hydraulic Circuit - Boom Extend Ref. No.

Part No.

01 02 03 04 05 06 09 10 11 12 13 14 15 16

L445001 L65213 L64316 L65212 L64316 L446035 L64297 L445002 L64314 L64314 L64297 L64297 L446034 L446019

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

ADAP, -12ORM -12JICM 90º. . . . . . 1 TUBE ASY., -12 (LH) . . . . . . . . . . . . 1 HOSE, -12 DM12/H12 48”. . . . . . . . 1 TUBE ASY., -12 (RH) . . . . . . . . . . . 1 HOSE, -12 DM12/H12 48”. . . . . . . . 1 ADAP, -12JICM -12JICM STR. . . . . 2 HOSE, -8 A12/A8 82" . . . . . . . . . . . 1 ADAP, -8ORM -8JICM . . . . . . . . . . . 4 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -8 A12/A8 82" . . . . . . . . . . . 1 HOSE, -8 A12/A8 82" . . . . . . . . . . . 1 ADAP, -12JICM -12JICM 90 BLKH 6 ADAP, -12JICFS -12JICM TEE . . . . 2

17 18 19 20 21 22 23 24 25 26

L446035 L64297 L64554 L64555 L64557 L64558 L64314 L64314 L64314 L64314

ADAP, -12JICM -12JICM BLKHD . . 2 HOSE, -8 A12/A8 82" . . . . . . . . . . . 1 TUBE ASY., -12 . . . . . . . . . . . . . . . . 1 TUBE ASY., -12 . . . . . . . . . . . . . . . . 1 TUBE ASY., -12 . . . . . . . . . . . . . . . . 1 TUBE ASY., -12 . . . . . . . . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1

00

L570022

-- ITEMS NOT SHOWN -VINYL CLAMP, 1/2” . . . . . . . . . . . AR

NOTE: Refer to the Hydraulic Components section for a listing of hydraulic cylinders specific to this model.

PRINTED IN U.S.A.

69

913208/BP0209

Boom Hydraulics

638 Telehandler

Hydraulic Circuit - Boom Tilt/Slave/Auxiliary 2

3

1

36

4

REAR

RIGHT

35

4

3

34 5 33

6

32

31 7 7

30 10

29

28

11

RETRACT

9 7 10 12

EXTEND

7 13

BULKHEAD PLATE

7

SLAVE CYLINDER

27 23

EXTEND

23

RETRACT

22

25

24

22 EXTEND

LEFT

RETRACT

21

20

14

12

FRONT

19 12

15

RETRACT EXTEND

TILT/ROTATE VALVE IN CAB

18 17

TILT CYLINDER

913208/BP0209

70

16

PRINTED IN U.S.A.

638 Telehandler

Boom Hydraulics

Hydraulic Circuit - Boom Tilt/Slave/Auxiliary Ref. No.

Part No.

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

L64293 L64299 L64563 L64562 L64299 L64293 L445002 L64303 L446017 L446026 L64660 L64295 L64301 L64296 L64302 L64302 L444004 L71066 L64294 L64301 L446052

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

HOSE, -8 A8/H8 42” . . . . . . . . . . . . 1 HOSE -8 DM8/H8 X42" . . . . . . . . . . 1 TUBE ASY. -8 (Tilt) . . . . . . . . . . . . . 2 TUBE ASY. -8 (Auxiliary) . . . . . . . . . 2 HOSE -8 DM8/H8 X42" . . . . . . . . . . 1 HOSE, -8 A8/H8 42” . . . . . . . . . . . . 1 ADAP -8ORM -8JICM. . . . . . . . . . AR HOSE -8 A8/A8 58" . . . . . . . . . . . . . 1 ADAP -8JICM -8JICFS 90 . . . . . . . . 2 ADAP, -8JICFS -8JICM SWVL TEE 1 ADAP -8ORM -8JICM TEE. . . . . . AR HOSE -8 A8/A8 28" . . . . . . . . . . . . . 1 HOSE -8 A8/A8 19” . . . . . . . . . . . . . 1 HOSE -8 A8/A8 38" . . . . . . . . . . . . . 1 HOSE -8 DM8/A8 96” . . . . . . . . . . . 1 HOSE -8 DM8/A8 96” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM STR . . . . . AR DUAL RELIEF VALVE . . . . . . . . . . . 1 HOSE -8 A8/A8 53" . . . . . . . . . . . . . 1 HOSE -8 A8/A8 19” . . . . . . . . . . . . . 1 ADAP -8JICM BLKHEAD STR. . . . 2

23 24 25 27 28 29 30 31 32 33 34 35 36

L40347 L64298 L64298 L65273 L64283 101600 101600 L64283 L570022 L50056 L50056 L71705 L71748 L51035

ADAP, -8ORM -8JICM 90 BLKHD. . 2 HOSE, -8 A8/A8 114" . . . . . . . . . . . 1 HOSE, -8 A8/A8 114" . . . . . . . . . . . 1 QUICK COUPLER (SET) . . . . . . . . 1 HOSE -6 H8/A8 354”. . . . . . . . . . . . 1 HOSE, -8 H8/B8 343” . . . . . . . . . . . 1 HOSE, -8 H8/B8 343” . . . . . . . . . . . 1 HOSE -6 H8/A8 354”. . . . . . . . . . . . 1 CLAMP, VINYL 1/2" . . . . . . . . . . . AR 5/16”-18 FLANGE NUT . . . . . . . . AR 5/16”-18 FLANGE NUT . . . . . . . . AR CLAMP, BOOM HOSE . . . . . . . . . AR PLATE, TOP CLAMP . . . . . . . . . . AR 5/16”-18X2” BOLT . . . . . . . . . . . . AR

00 00 00

L41770 L570022 L64407

-- ITEMS NOT SHOWN -CLAMP, VINYL 3/4” . . . . . . . . . . . AR CLAMP, VINYL 1/2” . . . . . . . . . . . AR TILT/ROTATE VALVE . . . . . . . . . . . 1

NOTE: Refer to the Hydraulic Components section for a listing of hydraulic cylinders specific to this model.

PRINTED IN U.S.A.

71

913208/BP0209

Hydraulics

638 Telehandler Hydraulic Pump

1

FRONT

2

4 3

5

6

7 8 9

4

14 5

10 11 13

TRANSMISSION

12

913208/BP0209

72

PRINTED IN U.S.A.

638 Telehandler

Hydraulics Hydraulic Pump

Ref. No.

Part No.

01 02 03 04 05 06 07

L445014 L63309 L46865 L50184 L50283 L68743 L51536

Description

Qty. Req.

Ref. No.

Part No.

ADAP, -20ORM -24JICM 90º. . . . . . 1 HOSE, 24 A24/A24 35” . . . . . . . . . . 1 GASKET, PUMP . . . . . . . . . . . . . . . 1 1/2” SAE FLAT WASHER . . . . . . . . 2 1/2”-13X1.25” BOLT . . . . . . . . . . . . 2 HYDRAULIC PUMP . . . . . . . . . . . . 1 ADAP, -12ORM -12JICM TEE . . . . . 1

08 09 10 11 12 13 14

L51493 L64267 L60588 L64267 L64291 L64660 L64311

Description

Qty. Req.

ADAP, -12JICF -6JICM . . . . . . . . . . 1 HOSE, -4 A4/DM6 53” . . . . . . . . . . . 1 ADAP, -8JICF -6JICM . . . . . . . . . . . 1 HOSE, -4 A4/DM6 53” . . . . . . . . . . . 1 HOSE, -8 A8/DM8 68” . . . . . . . . . . . 1 ADAP, -8ORM -8JICM TEE . . . . . . . 1 HOSE, -12 A12/A12 21” . . . . . . . . . 1

HOSE LOCATOR 02 09 11 12 14

HYDRAULIC PUMP (IN) HYDRAULIC PUMP HYDRAULIC PUMP HYDRAULIC PUMP (PRIMARY) HYDRAULIC PUMP (SECONDARY)

PRINTED IN U.S.A.

HYDRAULIC TANK TEST PORT (UPPER DASH) TEST PORT (UPPER DASH) HYDROMAX BRAKE VALVE “P” PRIORITY VALVE “P”

73

913208/BP0209

Hydraulics

638 Telehandler Joysticks/Manifold

FRONT

6

8 9

BYD LIFT/ EXTEND

TILT/ ROTATE

A

11

2

FRAME LEVEL

C

1

5

3

7

4

C

8

10

OUT IN

6

A

13

6

12

19

OUT D

B

IN

18 A

B

14

17

D

B

25

24

BYD

IN

16

15

23

6

OUT

22 21

13

20

6 28

34

4

33

29 3

P

MANIFOLD

12

T

26 LS

PRIORITY VALVE

30

EF

20

14

32

CF

25

29

31

27 23

913208/BP0209

74

PRINTED IN U.S.A.

638 Telehandler

Hydraulics Joysticks/Manifold

Ref. No.

Part No.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19

L445002 L64302 L64317 L444001 L64407 L445001 L64408 L445012 L64314 L64314 L64411 L64320 L64312 L444004 L64280 L64280 L64314 L64313 L64314

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

ADAP, -8ORM -8JICM 90º. . . . . . . . 2 HOSE, -8 DM8/A8 96”. . . . . . . . . . . 1 HOSE, -12 DM12/B12 44”. . . . . . . . 1 ADAP, -12ORM -12JICM . . . . . . . . . 2 JOYSTICK, TILT/ROTATE . . . . . . . . 1 ADAP, -12ORM -12JICM 90º. . . . . . 5 JOYSTICK, LIFT/EXTEND . . . . . . . 1 ADAP, -12ORM -12JICM 45º. . . . . . 3 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 FRAME LEVEL VALVE . . . . . . . . . . 1 HOSE, -12 DM12/B12 30”. . . . . . . . 1 HOSE, -12 DM12/A12 35”. . . . . . . . 1 ADAP, -8ORM -8JICM . . . . . . . . . . . 3 HOSE, -6 A8/A8 121-1/2” . . . . . . . . 1 HOSE, -6 A8/A8 121-1/2” . . . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1 HOSE, -12 B12/A12 20-1/2” . . . . . . 1 HOSE, -12 A12/A12 27” . . . . . . . . . 1

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

L64315 L62138 650818 L50061 L64310 L64302 L446025 L64311 L64292 L64179 101511 L51591 L64270 L64307 L64771 L64322

a

Used when not equipped with auxiliary hydraulics.

HOSE, -12 B12/B12 30” . . . . . . . . . 1 SPACER BUSHING. . . . . . . . . . . . . 3 3/8”-16X3” BOLT . . . . . . . . . . . . . . . 3 3/8”-16 FLANGE NUT . . . . . . . . . . 3 HOSE, -12 B12/A12 30” . . . . . . . . . 1 HOSE, -8 DM8/A8 96”. . . . . . . . . . . 1 PLUG, -8ORM . . . . . . . . . . . . . . . . . 2 HOSE, -12 A12/A12 21” . . . . . . . . . 1 HOSE, -8 A8/DM8 52-1/2”. . . . . . . . 1 PRIORITY VALVE . . . . . . . . . . . . . . 1 HOSE, -4 A6/B6 60” . . . . . . . . . . . . 1 ADAP, -4ORM -4JICM . . . . . . . . . . . 1 HOSE, -4 A4/B4 56” . . . . . . . . . . . . 1 HOSE, -8 B8/DM8 84”. . . . . . . . . . . 1 MANIFOLD . . . . . . . . . . . . . . . . . . . 1 HOSE, -16 A16/B16 32” . . . . . . . . . 1

HOSE LOCATOR 02 03 09 10 12 13 15 16 17 18 19 20 23 24 26 27 29 31 32 34

TILT/ROTATE VALVE PORT “C” TILT/ROTATE VALVE PORT “OUT” LIFT/EXTEND VALVE PORT “A” LIFT/EXTEND VALVE PORT “C” FRAME LEVEL VALVE PORT “OUT” FRAME LEVEL VALVE PORT “BYD” FRAME LEVEL VALVE PORT “B” FRAME LEVEL VALVE PORT “A” LIFT/EXTEND VALVE PORT “D” FRAME LEVEL VALVE PORT “IN” LIFT/EXTEND VALVE PORT “B” LIFT/EXTEND VALVE PORT “OUT” LIFT EXTEND VALVE PORT “IN” TILT/ROTATE VALVE PORT “D” PRIORITY VALVE PORT “P” PRIORITY VALVE PORT “CF” PRIORITY VALVE PORT “T” PRIORITY VALVE PORT “LS” HYDRAULIC MANIFOLD HYDRAULIC MANIFOLD

PRINTED IN U.S.A.

RELIEF VALVE (rear of unit) PORT “C1” HYDRAULIC MANIFOLD EXTEND CYLINDER (extend) LIFT CYLINDER (right side - extend) HYDRAULIC MANIFOLD LIFT/EXTEND VALVE PORT “BYD” FRAME LEVEL CYLINDER (extend) FRAME LEVEL CYLINDER (retract) LIFT CYLINDER (left side - retract) LIFT/EXTEND VALVE PORT “BYD” EXTEND CYLINDER (retract) HYDRAULIC MANIFOLD PRIORITY VALVE PORT “EF” RELIEF VALVE (rear of unit) PORT “P2” HYDRAULIC PUMP STEER MOTOR PORT “P” HYDRAULIC MANIFOLD STEER MOTOR PORT “LS” STEER MOTOR PORT “T” BULKHEAD UNDER CAB (then to hyd. cooler)

75

913208/BP0209

Hydraulics Components

638 Telehandler

Steer Cylinder

5

3 4

5 6 2

5

5 1 5

913208/BP0209

76

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Steer Cylinder

Ref. No.

Part No.

00 00 01 02 03

L99428 L99432 NSS NSS L99952 L99953

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPL. LR&RF CYL. ASY. . . . . . .2 COMPL. RR&LF CYL. ASY. . . . . . .2 PISTON . . . . . . . . . . . . . . . . . . . . . .1 END GLAND . . . . . . . . . . . . . . . . . .1 LR & RF ROD, 070SL164-2X . . . . .1 RR & LF ROD, 070SL164-1X . . . . .1

04 05 06

NSS L99430 080319

77

Description

Qty. Req.

BARREL ASY. . . . . . . . . . . . . . . . . .1 CYL.SEAL KIT . . . . . . . . . . . . . . . . .1 LOCKNUT . . . . . . . . . . . . . . . . . . .1

913208/BP0209

Hydraulic Components

638 Telehandler

Frame Level Cylinder

5

2 7

1 8 10 6

3

9

4

913208/BP0209

78

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Frame Level Cylinder

Ref. No.

Part No.

00 01 02 03

L64818 L97676 L99405 L64175 L97889 L99398 NSS

04

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY. . . . . . . . . . . . . . .1 ROD . . . . . . . . . . . . . . . . . . . . . . . . .1 LOCKNUT . . . . . . . . . . . . . . . . . . . .1 COUNTER-BAL.VALVE . . . . . . . . . .1 CB SEAL KIT . . . . . . . . . . . . . . . . .1 CAP . . . . . . . . . . . . . . . . . . . . . . . .1 TUBE WELDMENT. . . . . . . . . . . . . .1

05 06

L99382 L64817

07 08 09 10

L97820 L97821 L99080 L98547

79

Description

Qty. Req.

CYLINDER SEAL KIT . . . . . . . . . . .1 ALUM./BRZ. BEARING . . . . . . . . . .1 2.0 X 2.25 X 3.0 PISTON . . . . . . . . . . . . . . . . . . . . . .1 END GLAND . . . . . . . . . . . . . . . . . .1 OIL LINE TUBE . . . . . . . . . . . . . . . .1 HEAD GLAND CAP . . . . . . . . . . . . .1

913208/BP0209

Hydraulic Components

638 Telehandler

Boom Lift Cylinder

Ref. No.

Part No.

00 01 02

L64014 L64122 L48868A L96838 L65272 NSS L97680 L99331 L97822

03 04 05 06

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

COMPL. ASY. (Less 12) . . . . . . . . .1 SPHERICAL BUSHING 1.5 ID . . . .2 COUNTER-BAL. VALVE . . . . . . . . .1 CB SEAL KIT . . . . . . . . . . . . . . . . .1 CAP . . . . . . . . . . . . . . . . . . . . . . . . .1 TUBE WLDMT. . . . . . . . . . . . . . . . .1 ROD WLDMT. . . . . . . . . . . . . . . . . .1 CYLINDER SEAL KIT . . . . . . . . . . .1 PISTON . . . . . . . . . . . . . . . . . . . . . .1

07 08 09 10 11

L97824 L97825 L98118 L97679 L10057 L10465 L99405 L97823

12 13

80

Description

Qty. Req.

END GLAND . . . . . . . . . . . . . . . . . .1 GLAND CAP . . . . . . . . . . . . . . . . . .1 HYD. OIL LINE TUBE . . . . . . . . . . .1 RETAINER RING . . . . . . . . . . . . . .2 GREASE. ZERK (Rod End) . . . . .1 GREASE. ZERK (Butt End) . . . . . .1 1-1/4”-12 LOCKNUT . . . . . . . . . . . .1 SPACER . . . . . . . . . . . . . . . . . . . . .1

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Boom Extend Cylinder

2

1

4 3 5 6

7 8 9

11 10

Ref. No.

Part No.

00 01 02

L68678 L500651 L48868A L96838 L98510 L99875 L500646

03 04 05

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPL. ASY . . . . . . . . . . . . . . . . . .1 RAM TUBE WELDMENT . . . . . . . .1 COUNTER BALANCE VALVE . . . . .1 SEAL KIT (CBV) . . . . . . . . . . . . . . .1 BUSHING (SAE 660) . . . . . . . . . . . .1 5/16”-18 X 5/8” SETSCREW . . . . .1 PISTON . . . . . . . . . . . . . . . . . . . . . .1

06 07 08 09 10 11a

L500650 L500649 L99875 L500648 NSS L99999

a

Items included in seal kit are not shown.

81

Description

Qty. Req.

ROD SPACER . . . . . . . . . . . . . . . . .1 HEAD GLAND . . . . . . . . . . . . . . . . .1 5/16”-18 X 1/4” SETSCREW . . . . .1 HEAD GLAND CAP . . . . . . . . . . . . .1 TUBE WELDMENT . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . . .1

913208/BP0209

Hydraulic Components

638 Telehandler

Boom Slave Cylinder

Ref. No.

Part No.

00 01 02 03 04 05

L61869 L99332 L61866 NSS L97831 L97832

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY . . . . . . . . . . . . . . .1 SEAL KIT . . . . . . . . . . . . . . . . . . . . .1 ROD END BUSHING . . . . . . . . . . . .1 TUBE WELDMENT . . . . . . . . . . . . .1 END GLAND . . . . . . . . . . . . . . . . . .1 PISTON . . . . . . . . . . . . . . . . . . . . . .1

06 07 08 09 10

L97833 L97834 L48806 L99405 L10057

82

Description

Qty. Req.

ROD WELDMENT . . . . . . . . . . . . . .1 SPACER . . . . . . . . . . . . . . . . . . . . .1 BUTT END BUSHING . . . . . . . . . . .1 LOCKNUT 1-1/4”-12 . . . . . . . . . . . .1 GREASE ZERK . . . . . . . . . . . . . . . .2

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Tilt Cylinder

Ref. No.

Part No.

00 01 02 03 04 05 06 07

L61868 L99385 L61866 NSS L98549 L97836 L97685 L98547

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY . . . . . . . . . . . . . . .1 CYL.SEAL KIT . . . . . . . . . . . . . . . . .1 BUSHING (BUTT END) . . . . . . . . . .1 TUBE WELDMENT . . . . . . . . . . . . .1 END GLAND . . . . . . . . . . . . . . . . . .1 PISTON . . . . . . . . . . . . . . . . . . . . . .1 ROD WELDMENT . . . . . . . . . . . . . .1 GLAND CAP . . . . . . . . . . . . . . . . . .1

08 09 10

L48806 L99405 L48868A L96838 L97835 L10057 L97837

11 12 13

83

Description

Qty. Req.

BUSHING . . . . . . . . . . . . . . . . . . . .1 LOCKNUT 1-1/4”-12 UN . . . . . . . . .1 COUNTER-BAL. VALVE . . . . . . . . .1 CB SEAL KIT . . . . . . . . . . . . . . . . .1 HYD. OIL LINE TUBE . . . . . . . . . . .1 GREASE ZERK . . . . . . . . . . . . . . . .2 SPACER . . . . . . . . . . . . . . . . . . . . .1

913208/BP0209

Hydraulic Components

638 Telehandler

Fork-Shift Cylinder

1

3

4

2

6 5

913208/BP0209

84

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Fork-Shift Cylinder

Ref. No.

Part No.

00 01 02 03 04

L68337 L500763 L500762 L500761 L500367

PRINTED IN U.S.A.

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 L500370

a

Items included in the seal kit are not shown.

85

Description

Qty. Req.

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

913208/BP0209

Hydraulic Components

638 Telehandler

Rotating Carriage Cylinder

1

2

5

4 3

6 7 2

8

9

Ref. No.

Part No.

00 01 02 03 04 05 06 07a

L70655 L500242 L64122 L99074 L97839 080313 NSS L97769

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

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

08 09

L48868A L96838 L500241

a

Items included in the seal kit are not shown.

86

Description

Qty. Req.

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

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Swing Carriage Cylinder

1

2

4

5

3

6

2

7 8

Ref. No.

Part No.

00 01 02 03 04 05

L63970 L500364 L63593 L500365 L98662 L500367

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

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

06 07a 08

L10465 L99944 NSS

a

Items included in the seal kit are not shown.

87

Description

Qty. Req.

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

913208/BP0209

Hydraulic Components

638 Telehandler

Hydraulic Pump

1

2

3

913208/BP0209

88

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Hydraulic Pump

Ref. No.

Part No.

01 02

103132 L46865

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

HYDRAULIC PUMP . . . . . . . . . . . . .1 GASKET, PUMP . . . . . . . . . . . . . . .1

03a

L500368

a

Items included in seal kit are not shown.

SEAL KIT . . . . . . . . . . . . . . . . . . . . .1

NOTE: Field service is limited to seals replacement.

PRINTED IN U.S.A.

89

913208/BP0209

Hydraulic Components

638 Telehandler Steer Motor

1

LS L T

R P

2

Ref. No.

Part No.

01 02

101880

L500968 L99002

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

Note: Steer motor part numbers are located on a tag on the bottom side of the steer motor.

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

a b

Use with Char-Lynn motor part #200-0017-001 Use with Eaton motor part #213-1089-002

NOTE: Field service is limited to seals replacement.

913208/BP0209

90

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Steer Select Valve

1

2

Ref. No.

Part No.

00

L69747

01 02

210018 NSS

PRINTED IN U.S.A.

Description

Qty. Req.

STEER SELECT VALVE, COMPL. . 1 (includes items 1 and 2) WEATHER PAK VALVE. . . . . . . . . . 1 MANIFOLD . . . . . . . . . . . . . . . . . . . 1

91

Ref. No.

Part No.

00

L68711

Description

Qty. Req.

-- ITEMS NOT SHOWN -WIRE HARNESS . . . . . . . . . . . . . . 2 (connects wire leads to frame wiring)

913208/BP0209

Hydraulic Components

638 Telehandler

Boom Extend/Lift Joystick

4 5 7

6 1

8

10

9

11 12

2

13 14

3 15

16 17 18

19

913208/BP0209

92

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Boom Extend/Lift Joystick

Ref. No.

Part No.

00

L64408 L50275 L62138 L63477 L69148 L97661 L98034 L50091 L98032 650588 L50139

01 02 03 04 05 06 07 08

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE VALVE ASY. . . . . . . . . 1 3/8”X3” BOLT . . . . . . . . . . . . . . . . . 3 SPACER . . . . . . . . . . . . . . . . . . . . . 3 KNOB. . . . . . . . . . . . . . . . . . . . . . . . 1 HANDLE . . . . . . . . . . . . . . . . . . . . . 1 MOLDED BELLOWS. . . . . . . . . . . . 1 HANDLE ADAPTER . . . . . . . . . . . . 1 JAM NUT . . . . . . . . . . . . . . . . . . . . . 1 PIVOT . . . . . . . . . . . . . . . . . . . . . . . 1 1/4”-20x1-1/2” BOLT . . . . . . . . . . . . 2 1/4” LOCK WASHER . . . . . . . . . . . . 2

09 10 11 12 13 14 15 16 17 18 19

L98038 L98036 L97495 L98030 NSS NSS NSS L98037 L98035 L62320 NSS L97659

93

Description

Qty. Req.

2ND SPOOL SLIDE BLOCK . . . . . . 1 1ST SPOOL SLIDE BLOCK . . . . . . 1 BALL CENTER . . . . . . . . . . . . . . . . 1 JAM NUT . . . . . . . . . . . . . . . . . . . . . 1 SOCKET HEAD SCREW . . . . . . . . 4 ENDPLATE RETAINER . . . . . . . . . . 1 ENDPLATE ASSEMBLY . . . . . . . . . 1 SPOOL ADAPTER. . . . . . . . . . . . . . 2 SPRING PIN . . . . . . . . . . . . . . . . . . 2 CARTRIDGE, RELIEF VALVE. . . . . 1 VALVE BODY . . . . . . . . . . . . . . . . . 1 O-RING KIT . . . . . . . . . . . . . . . . . . 1 (Includes (2) L97880 o-rings and (4) L97881 o-rings.)

913208/BP0209

Hydraulic Components

638 Telehandler

Tilt/Rotate Joystick

4 7 5 8

1

6

11 9 12

10 2

13

14

15

3

16 17

18 19 20 21 22

23 24

913208/BP0209

13

94

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Tilt/Rotate Joystick

Ref. No.

Part No.

00a

L64407 L50873 L97662 L97660 L97661 L98034 L50091 L98032 650588 L50139 L98038 L98036 L97495 L98030 NSS

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

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE VALVE ASY. . . . . . . . . 1 3/8” X2” BOLT . . . . . . . . . . . . . . . . 3 KNOB. . . . . . . . . . . . . . . . . . . . . . . . 1 HANDLE (7/16”-20X9”) . . . . . . . . . . 1 MOLDED BELLOWS. . . . . . . . . . . . 1 HANDLE ADAPTER . . . . . . . . . . . . 1 JAM NUT 3/4”-16 RH . . . . . . . . . . . 1 PIVOT . . . . . . . . . . . . . . . . . . . . . . . 1 1/4”-20x1-1/2” BOLT . . . . . . . . . . . . 2 1/4” LOCK WASHER . . . . . . . . . . . . 2 2ND SPOOL SLIDE BLOCK . . . . . . 1 1ST SPOOL SLIDE BLOCK . . . . . . 1 BALL CENTER . . . . . . . . . . . . . . . . 1 JAM NUT . . . . . . . . . . . . . . . . . . . . . 1 SOCKET HEAD SCREW . . . . . . . . 4

14 15 16 17 18 19

NSS NSS L98037 L98035 NSS NSS L97659

20 21 22 23 24

L99202 L98744 L99200 L99194 L98743

a

Includes ALL items shown, including item 1 and 2.

95

Description

Qty. Req.

ENDPLATE RETAINER . . . . . . . . . . 1 ENDPLATE ASSEMBLY . . . . . . . . . 1 SPOOL ADAPTER. . . . . . . . . . . . . . 2 SPRING PIN . . . . . . . . . . . . . . . . . . 2 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 1 VALVE BODY . . . . . . . . . . . . . . . . . 1 O-RING KIT . . . . . . . . . . . . . . . . . . 1 (Includes (2) L97880 o-rings and (4) L97881 o-rings.)

INNER STOP CUP . . . . . . . . . . . . . 2 OUTER CUP SPRING. . . . . . . . . . . 2 OUTER CUP . . . . . . . . . . . . . . . . . . 2 END CAP. . . . . . . . . . . . . . . . . . . . . 2 LOAD CHECK SPRING . . . . . . . . . 2

913208/BP0209

Hydraulic Components

638 Telehandler

Frame Level Control Valve

10

18 8

20

15 12,13

19

11,13

16

9 2 14 1

21 4 7 6 17 5

2

4 3

913208/BP0209

96

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Frame Level Control Valve

Ref. No.

Part No.

00 01 02 03 04 05 06 07 08 09 10

L68313 NSS NSS NSS L97299 L98743 NSS NSS NSS L62232 L97662

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPL.ASY. . . . . . . . . . . . . . . . . . 1 BODY . . . . . . . . . . . . . . . . . . . . . . . 1 SPOOL . . . . . . . . . . . . . . . . . . . . . .1 LOAD CHECK PLUG . . . . . . . . . . . 2 SEAL KIT . . . . . . . . . . . . . . . . . . . . 1 LOAD CHECK SPRING . . . . . . . . . 1 LOAD CHECK POPPET . . . . . . . . . 1 BACKUP RING . . . . . . . . . . . . . . . . 1 INNER STOP CUP . . . . . . . . . . . . . 1 HANDLE . . . . . . . . . . . . . . . . . . . . . 1 KNOB . . . . . . . . . . . . . . . . . . . . . . . 1

11 12 13 14 15 16 17 18 19 20 21

L98127 L98128 L50612 L97959 L98744 L99194 NSS L62320 L99200 L62427 L99186

97

Description

Qty. Req.

CLEVIS PIN . . . . . . . . . . . . . . . . . . 1 CLEVIS PIN . . . . . . . . . . . . . . . . . . 2 COTTER PIN . . . . . . . . . . . . . . . . . 2 CLEVIS BRACKET . . . . . . . . . . . . . 1 SPRING . . . . . . . . . . . . . . . . . . . . . 1 END CAP . . . . . . . . . . . . . . . . . . . . 1 RETAINER PLATE . . . . . . . . . . . . . 1 RELIEF CARTRIDGE . . . . . . . . . . . 1 OUTER STOP CUP . . . . . . . . . . . . 1 BOOT . . . . . . . . . . . . . . . . . . . . . . . .1 POWER BEYOND SLEEVE . . . . . .1

913208/BP0209

Hydraulic Components

638 Telehandler

Priority Flow Divider

00

P 1

T

PP

LS 5

EF CF 4 3 2

6

Ref. No.

Part No.

00 01 02 03

L64179 L97654 NSS NSS

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

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

04 05 06a

NSS NSS L97655

a

Items in seal kit are not shown.

98

Description

Qty. Req.

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

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Flow Divider

1

4 2 3

5

6

4 1

Ref. No.

Part No.

00 01 02 03

L61878 NSS NSS NSS

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPL. ASY. . . . . . . . . . . . . . . . . .1 PLUG . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING . . . . . . . . . . . . . . . . . . . . . 1 PLUG W/ORIFICE . . . . . . . . . . . . . 1

04 05 06 07

L97286 NSS NSS NSS

99

Description

Qty. Req.

O-RING SEAL . . . . . . . . . . . . . . . . 2 BODY . . . . . . . . . . . . . . . . . . . . . . . .1 METERING SPOOL . . . . . . . . . . . .1 PLUG . . . . . . . . . . . . . . . . . . . . . . . 2

913208/BP0209

Hydraulic Components

638 Telehandler

Joystick Relief Valve

1

3

5 7 6 4 8 2 3 9

Ref. No.

Part No.

00 01 02 03 04 05

L60523 NSS NSS L97019 NSS NSS

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASY. . . . . . . . . . . . . . .1 HOUSING . . . . . . . . . . . . . . . . . . . .1 SHIM . . . . . . . . . . . . . . . . . . . . . . .AR SEAL KIT . . . . . . . . . . . . . . . . . . . . .1 STANDARD SPRING . . . . . . . . . . .1 RELIEF SEAT . . . . . . . . . . . . . . . . .1

06 07 08 09 10

NSS NSS NSS NSS L97020

100

Description

Qty. Req.

SPRING SPACER . . . . . . . . . . . . . .1 RELIEF BALL . . . . . . . . . . . . . . . . .1 SPACER WASHER . . . . . . . . . . . .AR BODY . . . . . . . . . . . . . . . . . . . . . . . .1 SERVICE KIT (Not Shown) . . . . . . .1 (Includes items 3-5,7)

PRINTED IN U.S.A.

638 Telehandler

Hydraulic Components Dual-Relief Valve

1

3, 4, 5

6 2

7

Ref. No.

Part No.

01 02 03 04

L71066 L500329 L500330 L500331

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

COMPLETE ASSEMBLY . . . . . . . . . 1 RELIEF VALVE . . . . . . . . . . . . . . . . 2 HEX PLUG . . . . . . . . . . . . . . . . . . . 2 CHECK POPPET . . . . . . . . . . . . . . 2

05 06 07

L500332 L500333 L500334

101

Description

Qty. Req.

SPRING . . . . . . . . . . . . . . . . . . . . . . 2 PLUG . . . . . . . . . . . . . . . . . . . . . . . . 2 SEAL KIT . . . . . . . . . . . . . . . . . . . . . 1

913208/BP0209

Attachments

638 Telehandler Carriage Forks

6

5 4

Forks with 2” Shaft Bore

3 2

1

48” Long

9 42” Long 8 7

72” Long 60” Long

913208/BP0209

102

PRINTED IN U.S.A.

638 Telehandler

Attachments Carriage Forks

Ref. No.

Part No.

01 02a 03 04 05 06

L71350 L61001 L61017 L66406 L400929 L47263

Description

Qty. Req.

Ref. No.

Part No.

Description

FORK, 42”X4”X2” (8,400 lbs.) . . . . . 2 FORK, 48”X2”X2” (4,200 lbs.) . . . . . 4 FORK, 48”X4”X2” (8,400 lbs.) . . . . . 2 FORK, 48”X4”X2-1/4” (12,000 lbs.). 2 FORK, 48”X5”X1-3/4” (8,500 lbs.). . 2 FORK, 48”X5”X2” (10,500 lbs.) . . . . 2

07 08 09

L47265 L60961 L68331

a

Requires two sets (four forks).

Qty. Req.

FORK, 60”X5”X2” (10,500 lbs.) . . . . 2 FORK, 60”X6”X2-1/4” (12,500 lbs.). 2 FORK, 72”X5”X2” (10,500 lbs.) . . . . 2

Note: Ratings are based on two forks and the load at 24” on center, except for item 2, for which four forks are required.

WARNING When ordering forks, select forks with a rating capacity that meets or exceeds the lifting capacity of the machine; failure to use the correct forks could result in injury or death.

For more information contact dealer (or manufacturer).

PRINTED IN U.S.A.

103

913208/BP0209

Attachments

638 Telehandler Standard Carriage

1

4 2

4 5

3 3

5

913208/BP0209

104

PRINTED IN U.S.A.

638 Telehandler

Attachments Standard Carriage

Ref. No.

Part No.

01 L99190 L99191 210407 02 L65223 L64561 L68493

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

CARRIAGE WELDMENT . . . . . . . . 1 48” (uses 2” pin) . . . . . . . . . . . . . . . 1 66” (uses 2” pin) . . . . . . . . . . . . . . . 1 72” (uses 2” pin) . . . . . . . . . . . . . . . 1 FORK SHAFT BAR . . . . . . . . . . . . 1 (2”X51-1/2”) . . . . . . . . . . . . . . . . . . . 1 (2”X69-1/2”) . . . . . . . . . . . . . . . . . . . 1 (2”X75-1/2”) . . . . . . . . . . . . . . . . . . . 1

03 04 05

L400425 L510003 L520019

105

Description

Qty. Req.

FORK SHAFT WASHER . . . . . . . . . 2 BOLT, 1/2”X2-3/4” BOLT . . . . . . . . . 2 1/2”-13 NYLON INSERT NUT . . . . . 2

913208/BP0209

Attachments

638 Telehandler Fork-Shift Carriage

1

19 20

18 14 15

13 2 11

15

9

12

16

17

9 10 8

7 6 5 2 3 4

913208/BP0209

106

PRINTED IN U.S.A.

638 Telehandler

Attachments Fork-Shift Carriage

Ref. No.

Part No.

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

L500213 L50519 L400425 L50333 L66919 L66931 L50875 Note a L63715 L50242 L63716 L520004 NSS

PRINTED IN U.S.A.

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 L66918 L68337 L50562 L63143 L66950 L66949

a

For 4” wide forks use P/N L66921.

For 5” wide forks use P/N L66948.

b

Order P/N L65273 Coupler Set.

107

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

913208/BP0209

Attachments

638 Telehandler Rotating Carriage

48” Carriage (shown)

1 7

2 6 3

4 5 8

8

23

14 13

26 9

25

12

9 11

7 10

24 23

22 21 20

15

17 27

9

16

19 18

913208/BP0209

108

PRINTED IN U.S.A.

638 Telehandler

Attachments Rotating Carriage

Ref. No.

Part No.

01

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

103517 103518 L50982 L65181 L61307 L65273 L444004 L64294 L50273 L520005 L62026 L66017 L70655 L66017 L65180

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

CARRIAGE, ROTATING . . . . . . . . . 1 (48” Carriage) 2” dia. fork shaft (66” Carriage) 2” dia. fork shaft 1/2”X4” BOLT. . . . . . . . . . . . . . . . . . 1 PIN, ROTATOR ROD END . . . . . . . 1 SPACER . . . . . . . . . . . . . . . . . . . . . 4 QUICK COUPLER SET. . . . . . . . . . 1 ADAP -8ORM -8JICM STR . . . . . . . 2 HOSE -8 A8/A8 53” . . . . . . . . . . . . . 2 3/8”X2-3/4” BOLT . . . . . . . . . . . . . . 3 3/8”-16 NYLON INSERT NUT . . . AR LOCK COLLAR 1.5” OD . . . . . . . . . 2 ADAP -8ORM -8JICM 90 w/ORF. . . 2 ROTATE CYLINDER . . . . . . . . . . . . 1 ADAP -8ORM -8JICM 90 w/ORF. . . 2 PIN, ROTATOR BASE END . . . . . . 1

15 16 17 18 19 20 21 22 23 24 25

L50145 101003 L50801 101999 L61709 L50147 L50261 L50718 L520019 L400425 L510003

26

27

109

L65223 L64561 100990 L61287

Description

Qty. Req.

3/8” FLAT WASHER . . . . . . . . . . . AR ROTATOR PIN. . . . . . . . . . . . . . . . . 1 3/8”X4” BOLT. . . . . . . . . . . . . . . . . . 1 ROTATOR PLATE WELDMENT . . . 1 SLIDE PAD . . . . . . . . . . . . . . . . . . . 3 3/8” LOCK WASHER . . . . . . . . . . . . 6 3/8”X1-1/2” BOLT . . . . . . . . . . . . . . 6 2-1/2”-12 CASTELL NUT. . . . . . . . . 1 1/2”-13 NYLON INSERT NUT . . . . . 4 FORK SHAFT WASHER (2” ID) . . . 2 BOLT, 1/2”X2-3/4” . . . . . . . . . . . . . . 2 (2” dia. shaft) FORK SHAFT BAR . . . . . . . . . . . . . 1 (48” Carriage) 2” dia. fork shaft (66” Carriage) 2” dia. fork shaft BEARING (not shown). . . . . . . . . . . 2 WASHER (not shown) . . . . . . . . . AR

913208/BP0209

Attachments

638 Telehandler Swing Carriage

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

913208/BP0209

110

PRINTED IN U.S.A.

638 Telehandler

Attachments Swing Carriage

Ref. No.

Part No.

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

L520019 L400425 L510003 L64561 L500216 NSS L63143 L66958 NSS L63984 650833 L50835 L520003 L50452 L63995 L63593 L63970

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

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

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

L445004 100631 L446049 L445003 L50561 L50143 L63715 L63716 L71651 L63233 L50056 NSS L63994 L70719 L520005 L50273 L63951 L63468

a

Order P/N L65273 Coupler Set.

111

Description

Qty. Req.

ADAP -6ORM -6JICM 45. . . . . . . . . 4 HOSE -4 A6/A6 36” . . . . . . . . . . . . . 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 NAME PLATE . . . . . . . . . . . . . . . . . 1 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)

913208/BP0209

Attachments

638 Telehandler Truss Booms

5’ TRUSS 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

913208/BP0209

112

PRINTED IN U.S.A.

638 Telehandler

Attachments Truss Booms

Ref. No.

Part No.

01

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

L500218 L99236 L99235 L42871 NSS L64294 L64660 L50841 L520003 L444004 NSS NSS L445002 L82358 100963 L50286 L520019 L444008 L400398 L50815 100076 L520004 L65338 L71266

19b

L66946

20

L50371

02 03 04

PRINTED IN U.S.A.

Description

Qty. Req.

Ref. No.

Part No.

5’ TRUSS WELDMENT . . . . . . . . . . 1 12’ TRUSS WELDMENT . . . . . . . . . 1 15’ TRUSS WELDMENT . . . . . . . . . 1 1/8” POP RIVET . . . . . . . . . . . . . . . 4 NAME PLATE . . . . . . . . . . . . . . . . . 1 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 90º . . . . . . . . 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

21 22 23 24 25 26c

L50147 L60451 L61411 L50380 L50152 L446017

3/8” LOCK WASHER . . . . . . . . . . . . 2 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

L500223

-- ITEMS NOT SHOWN-PLATE, AUGER ADAPTER . . . . . . . 1 (used with auger)

a

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

b

Used with 5’ truss booms with winch.

c

Not used on all attachments.

d

Sold as a set, order P/N L65273 Coupler Set.

113

Description

Qty. Req.

913208/BP0209

Attachments

638 Telehandler Bucket

1

Ref. No.

Part No.

01

L500374 L68831

913208/BP0209

Description

Qty. Req.

Ref. No.

Part No.

Description

Qty. Req.

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

114

PRINTED IN U.S.A.

638 Telehandler

Attachments Notes

PRINTED IN U.S.A.

115

913208/BP0209

Decals

638 Telehandler

GENERAL INFORMATION

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.

If a part with a decal affixed is replaced, be sure to apply a new decal to the replacement part.

NEW DECAL APPLICATION 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 masked 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.

PAINT FINISH Use this list to order paint for refinishing: 167763 167765 167754 167755

One Gallon Yellow (Four-pack Quarts) Six (12 oz. Spray Cans) Yellow One Gallon Gray (Four-pack Quarts) Six (12 oz. Spray Cans) Gunmetal Gray

DECAL KITS L500588

Model 638

NOTE: Decals may be purchased in kits or individually.

Boom Attachment Decals L65927 L65348 L66042

913208/BP0209

116

WARNING - PINCH POINT WARNING - WINCH WARNING - TRUSS BOOM TILT

PRINTED IN U.S.A.

638 Telehandler

Decals 7

5

4 2

24

3

20

6

21 1 12

14

13 8

23

22 9

10

16

17

18

19 11

REF. NO.

DESCRIPTION

638

01 02 03 04 05

DANGER - PERSONNEL LIFT WARNING - OPERATOR STEER SELECT F-N-R SHIFT STEERING WHEEL 2.0” DIA.

L65928 L63690 L63618 L68295 100401

06 07 08

09 10 11

HYDRAULIC PRESSURE SETTINGS WARNING - PARK BRAKE STANDARD CARRIAGE LOAD CHART ROTATING CARRIAGE LOAD CHART BUCKET LOAD CHART TRUSS BOOM LOAD CHART WINCH LOAD CHART ATTACHMENT CONTROL BOOM CONTROL FRAME LEVEL CONTROL

L64643 L65925 100206 100207 100208 100210 100209 100400 L63631 L63311

12 13 14 15 16

MADE IN USA IGNITION/START/HORN WARNING - SEAT BELT OPERATOR MANUAL INSIDE WARNING - CARRY LOAD LOW

137654 L68513 L65440 137628 093475

17 18 19 20 21 22 23 24

WARNING - MACHINE LEVEL DANGER - HIGH VOLTAGE DANGER - PANEL IN PLACE WARNING - TRUSS BOOM TILT WARNING - NO RIDERS BRAKE FLUID LEVEL WARNING - READ OPERATOR’S MANUAL WARNING - BACKUP ALARM

L65930 L65929 L65948 L66042 L65932 L65934 100359 L500445

PRINTED IN U.S.A.

117

913208/BP0209

Decals

638 Telehandler 7

2

1

3

2

5

16

8 17

2

4

9

6

10

13

15 11

14

12

DECAL LOCATIONS - FRAME AND BOOM REF. NO.

DESCRIPTION

638

01 02 03 04 05

DANGER - ROTATING FAN (1 ea.)

WARNING - PINCH POINT (3 ea.)

MUSTANG - BOOM SIDE 638 - RIGHT SIDE HYDRAULIC OIL FILL

L65924 L65927 100258 100154 072794

06 07 08 09 10

HYDRAULIC OIL LEVEL GRID - BOOM RIGHT SIDE HORSE - RIGHT SIDE WARNING - NO RIDERS WARNING - COOLANT UNDER PRESSURE

L65921 100142 100146 L65932 072798

11 12 13 14 15 16 17

ANTI-FREEZE FILTER CHART LUBE CHART MUSTANG - REAR GREASE DAILY WARNING - CARRY LOAD LOW DIESEL FUEL

056859 100399 L64931 100155 L65920 L65926 137634

913208/BP0209

118

PRINTED IN U.S.A.

638 Telehandler 12

Decals 8

6

11

1

3

9

3

7 5

2 4

3

10 13

3 15

3

14

REF. NO.

DESCRIPTION

638

01 02 03 04 05

DANGER - ROTATING FAN 638 - LEFT SIDE WARNING - PINCH POINT WARNING - JUMP START HORSE - LEFT SIDE

L659244 100153 L65927 L65933 100145

06 07 08 09 10

WARNING - NO RIDERS (1 ea.)

QUICK-ATTACH DIAGRAM (1 ea.)

MUSTANG - BOOM SIDE GRID - BOOM LEFT SIDE MUSTANG - FRONT

L65932 L65937 100258 100141 100156

11 12

HALF ZONE MARKER (5 ea.)

NO. “0” EXTENSION MARKER (1 ea.)

NO. “1” EXTENSION MARKER (1 ea.)

NO. “2” EXTENSION MARKER (1 ea.)

NO. “3” EXTENSION MARKER (1 ea.)

L62583 L67718 L67719 L67720 L67721

NO. “4” EXTENSION MARKER (1 ea.)

NO. “5” EXTENSION MARKER (1 ea.)

DANGER - PERSONNEL LIFT QUICK-ATTACH UNLOCKED GREASE DAILY

L67722 L67723 L65928 L66613 L65920

13 14 15

PRINTED IN U.S.A.

119

913208/BP0209

Numerical Index Part No.

Page No.

Ref. No.

056859 072340 072340 072794 072797 072798 080313 080319 089069 089069 089070 089070 093475 100076 100134 100141 100142 100145 100146 100153 100154 100155 100156 100206 100207 100208 100209 100210 100258 100258 100359 100399 100400 100401 100631 100963 100990 101003 101278 101456 101463 101486 101505 101511 101520 101520 101521 101522 101566 101567 101597 101600 101600 101818 101860 101877 101879

118 15 17 118 118 118 86 77 15 17 15 17 117 113 49 119 118 119 118 119 118 118 119 117 117 117 117 117 118 119 117 118 117 117 111 113 109 109 17 31 31 31 31 75 53 53 53 53 31 31 63 71 71 15 15 15 35

11 04 19 05 17 10 05 06 09 13 09 13 16 16 30 09 07 05 08 02 04 14 10 08 08 08 08 08 03 08 23 12 09 05 19 10 27 16 28 01 08 17 18 29 02 02 02 02 18 12 01 29 30 00 00 00 32

913208/BP0209

638 Telehandler

Part No.

Page No.

Ref. No.

101880 101880 101880 101924 101945 101948 101954 101955 101959 101976 101999 102063 102965 103132 103193 103517 103518 103626 103991 104303 104425 105502 137628 137654 167754 167755 167763 167765 210018 210170 210407 L10057 L10057 L10057 L10465 L10465 L120021 L120022 L120027 L120037 L120041 L120047 L277013 L277568 L400193 L400207 L400207 L400207 L400265 L400270 L400398 L400425 L400425 L400425 L400425 L400929 L400935

19 61 90 37 21 7 31 31 15 67 109 43 35 89 45 109 109 37 31 31 45 21 117 117 116 116 116 116 91 7 105 80 82 83 53 80 39 39 33 39 39 41 55 17 67 25 27 63 21 21 113 105 107 109 111 103 59

14 01 01 03 22 00 06 05 00 22 18 10 32 01 18 01 01 18 28 25 08 23 15 12 00 00 00 00 01 14 01 11 10 12 07 11 00 07 24 01 17 05 25 25 26 16 23 21 11 12 14 03 03 24 02 05 26

Part No.

Page No.

Ref. No.

L40347 L40496 L40805 L41122 L41123 L41127 L41129 L41179 L41260 L41261 L41770 L41770 L41770 L41770 L41770 L41770 L41847 L41848 L41848 L41854 L42871 L42910 L43221 L43964 L43965 L442007 L442015 L442017 L442023 L444001 L444001 L444002 L444004 L444004 L444004 L444004 L444004 L444004 L444004 L444007 L444008 L444070 L4445 L4446 L445001 L445001 L445002 L445002 L445002 L445002 L445002 L445002 L445002 L445003 L445003 L445004 L445012

71 19 43 55 55 55 55 37 19 19 21 21 25 27 67 71 25 15 17 31 113 7 35 17 17 35 37 37 35 45 75 61 19 35 61 71 75 109 113 45 113 45 23 23 69 75 25 27 59 69 71 75 113 61 111 111 75

23 01 16 01 02 08 08 02 02 03 06 20 00 00 05 00 00 07 14 22 01 00 29 32 31 37 00 00 28 03 04 14 12 10 05 18 14 06 05 05 13 07 10 12 01 06 03 09 08 10 07 01 08 08 21 18 08

148

Part No.

Page No.

Ref. No.

L445014 L446017 L446017 L446017 L446019 L446020 L446025 L446026 L446026 L446026 L446034 L446035 L446035 L446042 L446044 L446046 L446049 L446052 L447005 L450002 L45666 L45934 L46865 L46865 L47212 L47212 L47212 L47263 L47265 L47419 L48805 L48806 L48806 L48806 L48809 L48868A L48868A L48868A L48868A L49327 L49618 L49619 L49619 L500208 L500213 L500216 L500218 L500223 L500241 L500242 L500318 L500329 L500330 L500331 L500332 L500333 L500334

73 27 71 113 69 45 75 27 59 71 69 69 69 59 59 59 111 71 37 43 27 43 73 89 25 27 43 103 103 39 65 27 82 83 67 80 81 83 86 35 65 25 65 57 107 111 113 113 86 86 9 101 101 101 101 101 101

01 13 10 26 16 02 25 12 09 11 15 06 17 22 27 24 20 22 26 23 00 11 03 02 00 00 07 06 07 12 34 08 08 08 03 02 02 10 08 26 16 01 15 10 01 05 01 00 09 01 16 02 03 04 05 06 07

PRINTED IN U.S.A.

638 Telehandler Part No.

Page No.

Ref. No.

L500353 L500364 L500365 L500368 L500370 L500374 L500445 L50050 L500549 L500551 L500588 L500598 L500646 L500648 L500649 L500650 L500651 L500761 L500762 L500763 L500784 L500784 L500784 L50091 L50091 L500968 L50101 L50184 L50208 L50230 L50245 L50251 L50305 L50417 L50418 L50418 L50546 L50608 L50612 L50631 L50646 L50655 L50667 L50704 L50705 L50718 L50727 L50896 L50952 L50956 L510003 L51099 L51493 L51536 L51591 L51591 L51621

55 87 87 89 85 114 117 33 55 57 116 37 81 81 81 81 81 85 85 85 63 65 67 93 95 90 19 73 23 23 27 23 37 7 31 33 17 63 97 53 67 17 43 37 41 109 45 17 45 25 109 39 73 73 61 75 43

14 01 03 03 06 01 24 17 00 06 00 25 05 09 07 06 01 03 02 01 24 08 29 05 05 02 08 04 03 07 31 08 21 00 20 18 23 19 13 26 21 26 12 17 09 22 26 27 25 11 25 13 08 07 03 30 19

PRINTED IN U.S.A.

Numerical Index

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

L51762 L51781 L520005 L520007 L520017 L54002 L54002 L561004 L561004 L570005 L570005 L570018 L570022 L570022 L570022 L580008 L580009 L580009 L60451 L60492 L60523 L60539 L60587 L60588 L60588 L60847 L60961 L61001 L61017 L61021 L61064 L61080 L61081 L61085 L61086 L61092 L61115 L61117 L61117 L61147 L61199 L61200 L61287 L61307 L61411 L61572 L61620 L61699 L61704 L61708 L61708 L61708 L61709 L61709 L61709 L61709 L61709

61 39 25 7 17 7 21 21 21 25 27 25 69 71 71 21 21 37 113 41 100 23 37 59 73 35 103 103 103 41 11 11 11 11 11 43 23 31 33 23 9 9 109 109 113 35 35 65 65 63 65 65 63 63 65 65 65

16 10 06 25 22 00 00 03 13 00 00 00 00 00 32 15 01 09 22 11 00 02 00 07 10 35 08 02 03 07 24 13 23 11 12 26 01 02 12 04 10 11 27 04 23 22 25 04 06 31 22 28 33 35 05 12 19

L61709 L61709 L61709 L61709 L61709 L61709 L61833 L61866 L61866 L61866 L61867 L61867 L61868 L61868 L61869 L61869 L61878 L61942 L62026 L62032 L62032 L62032 L62138 L62138 L62232 L62320 L62320 L62427 L62427 L62484 L62583 L62715 L62715 L62715 L62715 L62715 L62715 L62715 L62715 L62720 L62720 L62721 L62721 L62722 L62722 L62731 L62731 L62732 L62733 L62733 L62733 L62733 L62734 L62734 L62734 L62734 L62734

65 65 65 67 67 109 59 27 82 83 31 33 67 83 63 82 99 63 109 25 67 67 75 93 97 93 97 7 97 17 119 63 63 65 65 65 65 67 67 31 33 31 33 31 33 65 65 65 65 65 67 67 63 63 65 65 65

24 26 35 15 17 19 21 18 02 02 24 25 02 00 08 00 00 38 10 05 06 27 21 00 09 18 18 00 20 21 11 11 32 21 23 27 30 14 18 16 13 00 13 15 13 00 32 29 25 36 04 16 12 34 07 33 37

149

Part No.

Page No.

Ref. No.

L62741 L62814 L62834 L62834 L62840 L62840 L62933 L62933 L62949 L62997 L62997 L62998 L630001 L630001 L630003 L630003 L630004 L630004 L630004 L63143 L63143 L63233 L63284 L63311 L63335 L63335 L63468 L63477 L63593 L63593 L63610 L63610 L63618 L63631 L63633 L63633 L63634 L63640 L63640 L63665 L63688 L63689 L63690 L63699 L63699 L63699 L63715 L63715 L63716 L63716 L63756 L63887 L63932 L63937 L63937 L63938 L63951

59 23 17 59 17 59 19 59 15 57 59 59 31 33 31 33 21 31 33 107 111 111 23 117 15 23 111 93 87 111 15 17 117 117 17 45 7 15 17 43 17 17 117 15 17 23 107 111 107 111 31

15 09 02 05 01 04 00 00 08 05 02 14 06 03 00 04 21 00 00 18 07 27 00 11 00 00 35 01 02 16 10 18 03 10 00 01 00 11 10 03 11 08 02 06 15 00 09 24 11 25 27 00 28 28 00 28 34

17 17 23 17 111

913208/BP0209

Numerical Index

638 Telehandler

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

L63970 L63970 L63984 L63994 L63995 L64014 L64014 L64056 L64056 L64060 L64060 L64061 L64078 L64095 L64095 L64113 L64113 L64122 L64122 L64122 L64123 L64123 L64124 L64124 L64124 L64132 L64143 L64174 L64174 L64175 L64179 L64179 L64179 L64196 L64196 L64196 L64197 L64197 L64197 L64218 L64256 L64257 L64258 L64264 L64267 L64267 L64267 L64267 L64267 L64268 L64270 L64270 L64273 L64273 L64274 L64280 L64280

87 111 111 111 111 63 80 25 27 27 63 63 17 65 65 27 63 27 80 86 27 63 7 37 45 63 65 25 25 79 61 75 98 7 37 45 7 37 45 35 33 33 33 33 17 17 59 73 73 59 61 75 59 59 59 25 25

00 17 10 30 15 16 00 13 24 02 09 37 00 17 31 07 07 28 01 02 27 10 21 14 15 36 20 01 08 03 02 28 00 24 13 16 26 15 14 30 05 13 00 20 03 04 06 09 11 28 04 31 13 16 20 07 10

L64280 L64280 L64283 L64283 L64285 L64285 L64286 L64286 L64287 L64289 L64290 L64291 L64291 L64292 L64292 L64293 L64293 L64294 L64294 L64294 L64294 L64294 L64295 L64295 L64296 L64296 L64296 L64297 L64297 L64297 L64297 L64297 L64297 L64298 L64298 L64299 L64299 L64300 L64300 L64301 L64301 L64301 L64301 L64302 L64302 L64302 L64302 L64302 L64302 L64303 L64303 L64307 L64307 L64310 L64311 L64311 L64312

75 75 71 71 61 61 61 61 61 61 61 59 73 61 75 71 71 27 35 71 109 113 27 71 27 35 71 27 27 69 69 69 69 71 71 71 71 35 59 35 35 71 71 35 35 71 71 75 75 27 71 61 75 75 73 75 75

15 16 28 31 09 19 11 20 21 12 13 03 12 06 27 01 06 14 06 20 07 02 16 13 17 07 15 32 33 09 13 14 18 24 25 02 05 23 11 04 05 14 21 11 12 16 17 02 24 10 09 22 32 23 14 26 13

L64313 L64314 L64314 L64314 L64314 L64314 L64314 L64314 L64314 L64314 L64314 L64315 L64316 L64316 L64317 L64320 L64321 L64321 L64322 L64326 L64326 L64359 L64359 L64360 L64362 L64362 L64374 L64378 L64379 L64384 L64407 L64407 L64407 L64408 L64408 L64411 L64421 L64437 L64442 L64443 L64452 L64454 L64455 L64459 L64460 L64463 L64466 L64466 L64467 L64468 L64469 L64524 L64524 L64550 L64554 L64555 L64557

75 69 69 69 69 69 69 75 75 75 75 75 69 69 75 75 35 43 75 29 55 63 67 65 31 33 63 65 67 63 71 75 95 75 93 75 7 37 63 65 7 7 7 7 7 21 63 67 67 63 7 19 61 63 69 69 69

18 11 12 23 24 25 26 09 10 17 19 20 03 05 03 12 16 20 34 17 24 29 08 14 05 02 18 40 30 26 00 05 00 07 00 11 12 04 22 09 16 04 15 11 10 16 28 09 11 27 03 13 23 20 19 20 21

L64558 L64560 L64561 L64561 L64561 L64562 L64563 L64572 L64580 L64582 L64582 L64583 L64590 L64590 L64599 L64600 L64619 L64621 L64621 L64633 L64643 L64646 L64651 L64652 L64660 L64660 L64660 L64660 L64660 L64661 L64663 L64663 L64664 L64664 L64672 L64672 L64672 L64673 L64673 L64673 L64673 L64695 L64701 L64727 L64737 L64764 L64770 L64771 L64772 L64774 L64817 L64817 L64818 L64818 L64821 L64830 L64837

69 67 105 109 111 71 71 41 63 55 59 15 27 63 35 27 35 27 63 59 117 37 35 35 27 35 71 73 113 65 21 37 21 37 9 31 33 29 29 31 33 29 29 29 63 41 21 75 21 21 25 79 25 79 41 25 25

22 20 02 26 04 04 03 06 17 32 23 01 35 14 01 00 31 36 15 25 06 18 15 14 15 08 12 13 03 10 19 08 18 07 13 21 16 00 15 19 19 07 13 04 06 04 02 33 08 04 08 06 02 00 10 15 05

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L64841 L64846 L64848 L64856 L64863 L64864 L64889 L64890 L64898 L64901 L64931 L64947 L64949 L64950 L64985 L64987 L64992 L650004 L650004 L650004 L650005 L650012 L650012 L65018 L65097 L65098 L65142 L65144 L65180 L65181 L65211 L65212 L65213 L65223 L65223 L65226 L65226 L65272 L65273 L65273 L65298 L65301 L65316 L65325 L65338 L65342 L65344 L65346 L65348 L65366 L65393 L65410 L65412 L65439 L65440 L65447 L65481

7 33 59 35 39 39 15 21 33 51 118 29 63 63 29 23 63 9 15 37 15 15 17 41 67 67 35 35 109 109 35 69 69 105 109 51 59 80 71 109 9 11 11 9 113 9 11 9 116 11 7 7 7 43 117 9 11

05 22 17 13 08 09 01 09 23 16 13 01 04 02 16 00 03 14 05 00 05 02 17 03 25 00 34 34 14 03 00 04 02 02 26 14 19 02 27 05 17 14 01 03 18 06 22 02 00 25 02 18 20 21 14 18 17

PRINTED IN U.S.A.

Numerical Index

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

L65570 L65593 L65609 L65638 L65640 L65815 L65896 L65920 L65920 L65921 L65924 L659244 L65925 L65926 L65927 L65927 L65927 L65928 L65928 L65929 L65930 L65932 L65932 L65932 L65933 L65934 L65937 L65948 L66010 L66011 L66017 L66017 L66017 L66025 L66042 L66042 L66045 L66045 L66059 L66064 L66064 L66114 L66118 L66119 L66122 L66132 L66136 L66136 L66136 L66136 L66265 L66282 L66341 L66342 L66360 L66406 L66437

37 11 27 63 63 25 29 118 119 118 118 119 117 118 116 118 119 117 119 117 117 117 118 119 119 117 119 117 7 7 25 109 109 63 116 117 25 27 19 35 73 43 37 43 61 61 43 43 45 45 43 27 9 9 37 103 15

00 21 19 05 00 18 08 15 15 06 01 01 07 16 00 02 03 01 13 18 17 21 09 06 04 22 07 19 00 00 09 11 13 00 00 20 16 00 06 27 02 24 00 28 18 15 27 30 04 06 13 29 00 01 00 04 03

L66437 L66453 L66456 L66467 L66515 L66547 L66594 L66606 L66606 L66612 L66613 L66626 L66658 L66659 L66660 L66661 L66662 L66663 L66675 L66678 L66679 L66687 L66688 L66689 L66692 L66709 L66720 L66721 L66723 L66729 L66733 L66735 L66739 L66741 L66746 L66763 L66763 L66764 L66780 L66782 L66783 L66814 L66814 L66814 L66815 L66824 L66828 L66833 L66834 L66843 L66844 L66849 L66850 L66855 L66855 L66868 L66869

17 67 67 23 43 13 39 21 37 7 119 49 7 7 9 9 11 11 13 13 13 13 13 13 13 43 29 29 29 29 11 9 29 29 27 65 67 65 67 67 67 21 57 59 21 15 23 17 17 9 17 17 17 9 37 13 13

09 23 28 00 08 06 15 17 06 27 14 24 01 17 04 07 05 03 04 11 08 07 10 09 01 14 12 10 11 14 00 09 03 02 22 03 07 02 12 13 00 10 00 01 07 00 00 05 06 09 29 28 28 14 00 16 14

L66877 L66918 L66919 L66931 L66949 L66950 L66958 L66963 L66965 L66970 L66975 L66986 L66993 L66997 L67430 L67629 L67655 L67718 L67719 L67720 L67721 L67722 L67723 L67751 L67832 L68054 L68054 L68054 L68229 L68280 L68281 L68282 L68285 L68295 L68313 L68331 L68337 L68337 L68461 L68463 L68493 L68511 L68513 L68516 L68517 L68531 L68533 L68539 L68544 L68545 L68549 L68550 L68552 L68553 L68554 L68557 L68569

39 107 107 107 107 107 111 9 45 13 13 9 9 11 11 13 13 119 119 119 119 119 119 43 19 9 17 37 29 19 19 19 19 117 97 103 85 107 13 13 105 7 117 39 39 37 37 43 41 39 45 45 45 45 37 37 13

14 15 05 06 20 19 08 14 28 17 15 12 15 15 04 12 05 12 12 12 12 12 12 03 10 00 28 00 09 10 00 16 15 04 00 09 00 16 02 13 02 00 13 00 00 10 11 06 01 16 19 09 23 17 19 20 03

151

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Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

Part No.

Page No.

Ref. No.

L68571 L68574 L68579 L68580 L68591 L68592 L68613 L68616 L68617 L68617 L68638 L68638 L68678 L68678 L68678 L68711 L68743 L68772 L68831 L69148 L69166 L69718 L69747 L69747 L70146 L70146 L70200 L70200 L70200 L70655 L70655 L70719 L71006 L71066 L71066 L71075 L71107 L71204 L71205 L71205 L71206 L71350 L71383 L71385 L71637 L71651 L71748 L72175 L72175 L72350 L72419 L75956 L76020 L76084 L806001 L806001 L810005

37 37 15 43 37 37 37 37 29 29 15 17 63 65 81 91 73 19 114 93 37 37 61 91 31 33 23 27 29 86 109 111 71 35 101 71 57 65 65 65 65 103 67 65 45 111 71 31 33 35 35 59 43 43 21 21 27

03 00 00 15 24 23 25 27 05 06 12 12 23 11 00 00 06 11 01 02 05 22 17 00 04 10 13 00 00 00 12 31 19 09 01 34 06 18 38 39 13 01 01 01 24 26 35 11 00 36 24 12 04 09 05 14 04

L82358 L88372 L93038 L93067 L93068 L93097 L93101 L93103 L93129 L93140 L93777 L94580 L96738 L96744 L96838 L96838 L96838 L96838 L97019 L97020 L97108 L97109 L97111 L97113 L97122 L97123 L97124 L97126 L97127 L97128 L97134 L97135 L97136 L97153 L97155 L97157 L97158 L97160 L97161 L97162 L97162 L97163 L97286 L97299 L97328 L97329 L97330 L97331 L97340 L97341 L97345 L97346 L97489 L97495 L97495 L97641 L97642

113 55 55 53 53 49 49 49 49 53 49 39 49 49 80 81 83 86 100 100 49 49 49 49 49 49 49 49 49 49 53 53 53 51 51 51 51 51 51 51 51 51 99 97 51 53 53 53 53 53 51 51 35 93 95 53 53

09 12 28 04 04 22 20 17 06 24 02 06 16 11 02 02 10 08 03 10 03 05 25 09 18 19 21 23 07 04 03 11 08 03 05 08 09 11 12 00 18 13 04 04 15 22 21 20 12 10 10 10 33 11 11 16 00

L97643 L97644 L97645 L97646 L97654 L97655 L97660 L97661 L97661 L97662 L97662 L97676 L97679 L97680 L97685 L97688 L97689 L97690 L97701 L97745 L97746 L97765 L97766 L97769 L97780 L97781 L97782 L97783 L97784 L97791 L97795 L97796 L97797 L97799 L97801 L97802 L97803 L97804 L97805 L97806 L97808 L97809 L97810 L97811 L97813 L97814 L97815 L97820 L97821 L97822 L97823 L97824 L97825 L97831 L97832 L97833 L97834

53 53 49 53 98 98 95 93 95 95 97 79 80 80 83 57 57 57 57 33 33 51 51 86 51 53 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 79 79 80 80 80 80 82 82 82 82

17 06 01 25 01 06 02 03 03 01 10 01 10 04 06 12 08 06 13 14 21 06 04 07 00 25 11 11 11 06 09 10 07 12 20 21 16 18 17 19 22 22 23 31 00 15 26 07 08 06 13 07 08 04 05 06 07

L97835 L97836 L97837 L97839 L97843 L97844 L97847 L97849 L97851 L97852 L97853 L97854 L97855 L97855 L97856 L97857 L97858 L97858 L97859 L97860 L97864 L97866 L97868 L97869 L97870 L97871 L97889 L97959 L98019 L98023 L98026 L98027 L98030 L98030 L98032 L98032 L98034 L98034 L98035 L98035 L98036 L98036 L98037 L98037 L98038 L98038 L98072 L98118 L98127 L98128 L98510 L98547 L98547 L98549 L98568 L98615 L98646

83 83 83 86 53 53 53 53 53 53 53 53 53 55 49 49 49 51 53 53 49 49 49 49 49 49 79 97 55 55 55 55 93 95 93 95 93 95 93 95 93 95 93 95 93 95 57 80 97 97 81 79 83 83 35 11 39

11 05 13 04 01 01 05 19 15 18 14 13 09 30 27 28 26 17 16 16 08 10 12 13 14 15 03 14 05 29 13 03 12 12 06 06 04 04 17 17 10 10 16 16 09 09 07 09 11 12 03 10 07 04 32 00 03

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L98648 L98662 L98743 L98743 L98744 L98744 L98786 L98787 L98869 L99002 L99066 L99067 L99074 L99078 L99080 L99110 L99113 L99113 L99124 L99125 L99126 L99127 L99129 L99137 L99138 L99138 L99140 L99141 L99142 L99143 L99144 L99145 L99147 L99150 L99151 L99157 L99167 L99182 L99184 L99186 L99190 L99191 L99194 L99194 L99199 L99200 L99200 L99202 L99208 L99209 L99210 L99221 L99231 L99235 L99236 L99244 L99245

39 87 95 97 95 97 19 19 11 90 39 39 86 11 79 11 57 57 13 11 11 11 11 7 9 11 11 11 11 11 11 11 49 53 53 11 9 45 45 97 105 105 95 97 51 95 97 95 23 57 57 53 55 113 113 7 57

04 04 24 05 21 15 04 07 18 02 02 02 03 06 09 20 00 00 00 09 10 07 08 01 02 14 02 16 19 19 19 19 31 27 28 00 09 20 27 21 01 01 23 16 01 22 19 20 02 00 00 29 04 01 01 13 13

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Numerical Index

Part No.

Page No.

Ref. No.

L99322 L99322 L99326 L99331 L99332 L99335 L99335 L99382 L99385 L99398 L99399 L99402 L99403 L99405 L99405 L99405 L99405 L99408 L99409 L99410 L99411 L99419 L99425 L99428 L99428 L99428 L99430 L99432 L99432 L99432 L99434 L99944 L99952 L99953 L99971 L99999 P470472

7 9 9 80 82 57 57 79 83 79 55 57 57 79 80 82 83 57 57 57 57 13 19 53 61 77 77 53 61 77 41 87 77 77 43 81 35

17 05 08 05 01 14 15 05 01 03 14 11 09 02 12 09 09 03 02 01 04 00 12 23 07 00 05 23 10 00 02 07 03 03 10 11 17

Part No.

153

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Index

638 Telehandler PAGE

A Air Conditioning A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A/C Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A/C Engine Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A/C Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A/C Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Air Cleaner Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Air Conditioner Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Air Filter Pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25, 49 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 49

B Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 27, 29 Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Belt, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Bleeder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65, 67 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Slide Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Booster, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Boot, Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Bracket Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Switch Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 59 Failure Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 21 Brake Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

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INDEX PAGE

Brake Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Brake, Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Brake, Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Brake, Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Breaker, Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 23 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

C Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 23 Cable Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 45 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Caliper, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Castle Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 23 Compressor, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Condenser Mount, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Counter-Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79, 80, 83, 86 Cover, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Cover, Hose Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Cutting Edge, Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Cylinder Boom Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63, 65 Fork-Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Rotating-Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

D Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116, 117, 118, 119 Defroster Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49, 55 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

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Drain, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Dual Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

E Elbow, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Electronic Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Ether Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 37 Evaporator Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

F Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Defroster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Fill Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Filter A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Assembly, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Chart Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Floor Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Flow Switch, Hydromax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Fork, Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Fork-Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Frame Level Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Front Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Level, Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Line Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33

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G Gasket Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73, 89 Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Gauge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Light Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Gear, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Ground Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 31, 33

H Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29, 31, 33, 93, 95, 97 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Hinge, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Hood Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Fuel Filter Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Hose, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Hydraulic Controls, Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 35 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Oil Line Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80, 83 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73, 89 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

I Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

J Joystick, Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

K Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11, 15, 17

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L Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Lever Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Lever, Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Light Cluster Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Brake Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Load Chart Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

M Master Cylinder, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Modulator Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Module, F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Motor, Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Mount Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 45 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

O Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

P Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Park Brake Buzzer (Alarm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 45 Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Pedal, Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Pedal, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Plug, Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Power Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61, 75 Pulley, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Pump Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73, 89 Pump, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73, 89

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Q Quick Coupler Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71, 109

R Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Rear Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 23, 37 Relief Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Reservoir, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Rim, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Ring and Pinion Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7, 57, 97

S Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sender, Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 33 Sender, Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 45 Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Shifter Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Shut-off, Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Slide Pad, Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61, 90 Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61, 91 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Strainer, Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Strap, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 31, 33 Striker Plate, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

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Switch Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17, 21 Clutch Cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Engine Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 37 Flow - Hydromax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Heater Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 23 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45, 57 Pull-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Rocker-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Steer Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

T Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Tail Light Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Tail Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Tank, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 15, 37 Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Top Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 45 Truss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

U Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

V Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93, 95 Dual PO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Frame Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Tilt/Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49, 55 913208/BP0209

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W Washer System Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17 Water Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Wheel Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 19, 23, 57, 91 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Switches and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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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

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

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

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

Metric Course Thread

Grade 8.8 Dry

Lubed

Dry

Lubed

Dry

Lubed

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

8 19 37.5 65 103.5 158.5

6 14 28 48 76.5 117.5

11 27 53 91.5 145.5 223.5

7 20 39 67.5 108 165.5

13.5 32.5 64 111.5 176.5 271

10* 24* 47 82 131 200

Grade 10.9

Grade 12.9

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

For metric torque value (Nm), multiply lbs.-ft. x 1.355 or lbs.-in. value x 0.113.

Mustang Manufacturing Co., Inc. 143 Water St., P. O. Box 179, West Bend, WI 53095-0179 USA www.mustangmfg.com

913208/BP0209

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