General Assembly Contents

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1 General Assembly Contents 636 General Assembly, AL Extendo Boom Assembly, AL Boom Tube Assembly w/extra or Standard Circuit, FL Sway Control, AL Hydraulic Oil Reservoir Assembly, BL A (35.3 Gallon Capacity) Fuel Tank Assembly, BL-8743-B-- (32.4 Gallon Capacity) Inline Strainer, LL Operator's Compartment w/ Joystick Control Valve, SK Mirror Assembly, LL Instrument Panel/Dash Assembly, SK Instrument Panel Assembly, BL-9721-F Electrical Schematic for 636, AL Electrical Plug-Ins Schematic, BL Switch Panel Assembly w/ Lighting Package, FL Hinged Inspection Cover Ass'y for 636, RH Front, BL Hinged Inspection Cover Ass'y for 636, Right Hand/Rear, BL Hinged Inspection Cover Assy for 636, BL Fiberglass console Cover Assembly for 636 Extendo, BL

2 636 General Assembly, AL EXTENDO Standard General Assembly, AL Parts List REF Part No. Description Req'd 1 AL F2 Main Frame 1 2 AL Power Train 1 3 AL Boom Assembly 1 4 BL-8743 Fuel Tank Assembly 1 5 AL Wheel Assembly 4 6 LL Tire 4 7 AL Lift Cylinder Assembly 2 8 AL Fork Tilt Assembly 1 9 AL Sway Control 1 10 LL Mirror Assembly 1 1-2

3 Standard General Assembly, AL Parts List REF Part No. Description Req'd 11 AL Fork Frame BL Fork Tine 2 14 FL-3977 Fork Shaft 1 15 BL-9703 Counterweight, Rear 1 16 Omit 17 See Table Operators Compartment 1 18 FL Pin, Upper Lift Cylinder 1 19 FL Pin, Lower Lift Cylinder 1 20 FL Pin, Boom Pivot 2 21 FL Pin, Tilt Cylinder Base 1 22 LL-6025 Pin, Tilt Cylinder Rod 1 23 BL-9875 Cover, Front Lower 1 24 BL-9874 Cover, Front Upper 1 25 BL Cover, L.H. Side 1 26 BL Cover, R.H. Front 1 27 BL Cover, R.H. Rear 1 28 BL-9374 Hydraulic Tank Assembly 1 29 FL Pin, Boom Tip LL Capscrew, 1 NF x 9-1/ LL Nut, Nylock 1 NF 4 34 FL-8933 Cover, Rear 1 35 FL-8782 Brake Valve Cover 1 Note: For Hinged Side Panels See OptionsGroup. Table Assembly Number Item 17 Description AL SK w/ LL Manual Control Valve AL SK w/ LL Joystick Control Valve 1-3

4 Standard General Assembly, AL Notes Use Main frame AL when using rear stabilization. This Main Frame includes AL F3 main frame sub-weldment. Standard General Assembly, AL Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-4

5 Extendo Boom Assembly, AL foldout 1-5

6 Extendo Boom Assembly, AL EXTENDO foldout 1-6

7 Extendo Boom Assembly, AL Parts List REF Part No. Description Req'd 1 AL Large Boom Assembly 1 2 AL Middle Boom Assembly 1 3 AL Small Boom Assembly 1 4 AL Extension Cylinder 1 5 LL Leaf Chain, Retraction 10'5" 6 LL Leaf Chain, Extension 12'3" 7 FL-9143 Block, Chain Anchor 1 8 LL Bearing 1 9 LL Race, Inner 1 10 LL-4736 Sheave, Small Chain 1 11 FL-9125 Pin, 1-3/4" Dia. (Retraction Sheave) 1 12 FL Pin, 1-3/4" Dia. (Extension Sheave) 1 13 LL Spacer, 1/16 x 1-7/8 x 2-7/ FL Wearpad, 5/8 x 2-1/2 x LL Spacer 2 16 LL Wearpad, 5/8 x 2-1/2 x LL Wearpad, 2 x 9-1/ LL Wearpad, 5/8 x 6 x LL Wearpad, 6 x 10-1/ LL Shim, 2-1/2 x 6 AR 21 FL-8297 Spacer Block 2 22 FL-8298 Spacer Block 1 23 FL-8696 Spacer Block 2 24 LL-4400 Keeper 4 25 LL-6225 Keeper FL-6227 Pin, 1-3/4 x 18-1/ FL-6527 Chain Anchor (Extension) 1 29 FL-7976 Chain Anchor (Retraction) 1 30 LL Nut, 7/8-14 NF Nylock Gr LL Washer, H. Flat, 7/ LL Spring (Extension) 1 See Wear Pad Table in Appendix C-3 1-7

8 Extendo Boom Assembly, AL Parts List REF Part No. Description Req'd 33 LL Spring (Retraction) 1 34 LL-6232 Retainer, Sheave 2 35 FL-9295 Sheave, Large Chain Extension 1 36 LL Bronze Bushing 1 37 LL Bronze Bushing 1 38 LL Spacer, 1/4 x 1-7/8 x 2-7/ LL-4738 Pin, 3/8 Dia. x 2-13/ LL Cotter, Pin, 1/8 x 1 Lg 8 41 LL-4401 Pin, 3/8 Dia. x 1-5/ LL Nylock Nut, 1-14 NF 1 43 LL Washer, H. Flat 1" 1 44 LL Wearpad, 11/16 x 2-1/2 x LL Wearpad, 5/8 x 2 x 9-1/ LL Capscrew, Soc Hd. 1/2 -NC x 1 1/ FL Pin, 1-1/2 Dia. x 11-3/4 Lg 1 48 LL Capscrew, 3/8 NF - 1 Lg LLS Lockwasher, 3/ LL Capscrew, 1/2 NF - 1 Lg LLS Lockwasher, 1/ LL Capscrew, 1/2 NF - 1-1/4 Lg 4 53 LL Capscrew, 1/2 NC - 1-1/4 Lg 4 54 LL Bronze Bushing Ref. 55 LL Bronze Bushing Ref. 56 LL Str. Lube Fitting 1/8 NPT 3 57 LL Hx Hd Capscrew, 3/8 NC -3 Lg 1 58 LL Hx Nut, 3/8 NC 2 59 LL Hx Hd Capscrew 1/2 NC 4 1/ LL Bolt, 1/2 x 21/4 NF 4 61 LL Hx Hd Capscrew, 3/8 NC- 3 1/4 Lg 1 62 LL Hx Hd Capscrew, 5/16 NC- 5 Lg 2 63 LL Hx Hd Capscrew, 5/8 NF- 2 1/ LL Lockwasher, 5/ LL Flatwasher, 5/8" 2 67 LLI Star Washer, Int., 1/2" 4 68 LL Bolt, 1/2 x 1/2 NF 4 69 LLS Lockwasher, 1/2" 4 1-8

9 636 Boom Tube Assembly w/extra or Standard Circuit, FL

10 636 Boom Tube Assembly w/extra or Standard Circuit, FL-9418 Item Part Number Description Extra Cir Req d Std Cir. Req d 1 AL Bracket Ref Ref 2 AL Bracket Ref Ref 3 AL Bracket Ref Ref 4 AL Bracket Ref Ref 5 AL Bracket Ref Ref 6 AL Bracket Ref Ref 7 LL Wearpad LL Clamp, Twin 1/2 6-9 LA Clamp, Twin 5/ LL Clamp, Twin 3/ LA Clamp, Twin LL-6576 Gortrac Hose Mount LL Tube, Sliding LLF Tube, Sliding 2-15 LL Tube, Supply LLF Tube, Supply 2-17 LL Hose, Boom LL Hose, Boom 2-19 LL Chain Ass y SK Gortrac Guide LL Capscr, HH, 1/2NCx LL Lockwasher, 1/ LL Capscr, HH, 5/16NCx1 1/ LL Capscr, HH, 5/16NCx2 1/ LL Capscr, HH, 5/16NCx3 1/ LL Capscr, HH, 5/16NCx2 3/ LL Capscr, HH, 5/16NCx LL Capscr, HH, 5/16NCx1/ LL Nut, Hex, 5/16NC LL Flat Washer, 5/ LL Lockwasher, 5/ LL Spacer LL Capscr, HH, 5/16NCx1 3/4-1 LL Kit for Chains 1-10

11 Sway Control, AL

12 Sway Control, AL Parts List REF Part No. Description Req'd 1 AL Cylinder, Sway 1 2 LL-6025 Pin, Upper 1 3 LL Capscrew, 3/8 NC x LL Nut, Nylock, 3/8 NC 1 5 LL-6541 Mount, Sway 2 6 LL Capscrew, 3/4 NC x LL Nut, Nylock 3/4 NC 4 8 AL Main Frame Ref. 9 LL-6540 Pin, Lower 1 10 LL-6118 Axle Pivot Pin (Front) 1 Use AL in place of item 8 when using rear stabilization. Sway Control, AL Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes Inserted Lower Pin to Diagram Insterted Pivot pin to Diagram and Bill 1-12

13 Hydraulic Oil Reservoir Assembly, BL A (35.3 Gallon Capacity) 1-13

14 Hydraulic Oil Reservoir Assembly, BL-9374-A --Parts List REF Part No. Description Req'd BL-9374-A Oil Reservoir Assembly Ref. 1 AL-9811 Weldment, Oil Reservoir 1 2 FL-7955 Weldment, Cover 1 3 LL Filter 1 4 LL Nipple, Close, 2" 1 5 LL Cap & Dipstick, Filler 1 6 LL Valve, Vacuum Relief (Breather) 1 7 LL Plug, Pipe, 1/2 1 8 LL Capscrew, 3/8 NF x 1" Lg 8 9 LLS Lockwasher, 3/ LL * Magnet 1 * Magnet placed on bottom of tank. Hydraulic Oil Reservoir Assembly, BL-9374-A--Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-14

15 Fuel Tank Assembly, BL-8743-B-- (32.4 Gallon Capacity) 1-15

16 Fuel Tank Assembly, BL-8743-B --Parts List REF Part No. Description Req'd BL-8743-B Fuel Tank Assembly Ref. 1 AL-6733-D Weldment, Fuel Tank 1 2 LL-4743 Cover, Access 1 3 LL Gasket, Sending Unit 1 4 LL Cap, Filler 1 5 LL Strainer LL Plug, Std. Pipe, 3/4 NPT 1 8 LL Capscrew, 3/8 NF x 1" Lg 8 9 LLS Lockwasher, # LL Screw, # 10 x 1/2" Lg 5 11 LL Unit, Sending 1 12 LL Strainer 1 Fuel Tank Assembly, BL-8743-B--Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-16

17 Inline Strainer, LL Inline Strainer, LL Parts List REF Part No. Description Req'd LL Inline Strainer Ref. 1 LL Coupling, 1-1/4 x LL Nipple, 1-1/4 x 3-1/2 1 3 LL Bushing, 1 x 1-1/2 1 Inline Strainer, LL Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-17

18 Operator's Compartment w/ Joystick Control Valve, SK

19 Operator's Compartment w/ Joystick Control Valve, SK

20 Operator's Compartment w/ Joystick Control Valve, SK-893--Parts List REF Part No. Description Req'd 1 AL Weldment, Cab Ref. 2 SK Dash Unit Assembly 1 3 BL-6560 Steering Unit Assembly Ref. 4 LL Valve, Steering Selector Ref. 5 LL Control, Transmission Ref. 6 LL Pedal, Brake Ref. 7 BL-9918-F3 Pedal, Accelerator Ref. 8 LL Main Control Valve Ref. 9 LL Lock, Brake Ref. 10 FL Parking Brake Lever Assembly Ref. 11 FL-8782 Cover, Brake Valve 1 12 LL Flatwasher LLS Lockwasher LL Capscrew, Hex Head 8 15 AL Cover, Upper Side 1 18 LL Retainer, Nut 6 19 LLCS Screw, Truss Head Machine 6 20 LL Seat 1 21 LL Flatwasher 4 22 LLS Lockwasher 4 23 LL Nut, Hex 4 24 BL Roof Assembly 1 25 FL Guard, Roof 1 26 LL Capscrew, Hex Head 6 27 FL-4953 Tag, Weight 1 28 LL-4627 Decal, Brake Caution 1 29 LL-4633 Decal, Overhead Lines 1 30 LL-5613 Decal, Safety Caution

21 Operator's Compartment w/ Joystick Control Valve, SK-893--Parts List REF Part No. Description Req'd 31 LL Decal, Mico Caution 1 32 LL-6064 Decal, Load Chart 1 33 LL-4813 Decal, Operator Caution 1 34 LL-4779 Decal, Sway Warning 1 35 LL-5434 Decal, "No Riders" 1 36 LL-4773 Decal, "Watch Step" 1 37 LL-4624 Decal, Operator Warning 1 38 FL-4953 Decal, Weight Tag 1 39 LL Joystick Control Valve Assembly 1 40 LL Armrest 1 41 FL-8769 Armrest Mount 1 42 LL Operator's Manual Holder 1 43 FL Side Console Access Cover 2 44 SK-917 Seat Mount 1 Operator's Compartment w/ Joystick Control Valve, SK-893--Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-21

22 Mirror Assembly, LL EXTENDO 1-22

23 Mirror Assembly (Model D150), LL Item Part Number Description Req d 1 LL Head, Mirror 1 2 LL Head, Convex 1 3 LL Loop 1 4 LL Clamp 2 5 LL Gasket, Clamp 2 6 LL Lockwasher, Internal, 5/ LL Bolt, Acorn, 5/16-18 x 1-1/4 Lg. 2 8 LL Cobfoot 2 9 LL Bolt, Hex Head 5/16-18 x 1-1/ LL Cap, Retaining 1 11 LL Washer, Tension 1 12 LL Lockplate, 5/ LL Lockwasher, Int. / Ext., 5/ LL Washer, Flat 5/ LL Locknut, Elastic, 5/ LL Bolt, Hex Head 5/16-18 x 1 Lg LL Washer, Fiber, 5/16 2 NOTE: Lubricate Loop Lockpins with Lubriplate Marine Lube A or Equivalent before Assembling Lockplate. 1-23

24 Instrument Panel/Dash Assembly, SK

25 Instrument Panel/Dash Assembly, SK Parts List REF Part No. Description Req'd 1 AL Enclosure, Dash 1 2 LL Washer, Flat 4 3 LLS Lockwasher 4 4 LL Capscrew, Hex Head 4 5 LL Orbitrol Steering Unit Ref. 6 AL Panel, Dash 1 7 LLCP Screw, Truss Head Machine 7 8 LL Shift Control Unit Ref. 9 LLS Lockwasher 4 10 LL Nut, Hex 4 11 BL-9721-F1 Gauge Panel Assembly 1 12 BL-9720 Enclosure, Gauge 1 13 FL-8715 Guard, Gauge 1 14 LLS Screw, Round Head Machine 4 16 LL Inclinometer 1 17 LL Screw, Round Head Machine 2 18 LL Lockwasher 2 19 LL Nut, Hex 2 20 FL-8733 Switch Panel Assembly 1 21 LLS Fastener 4 22 BL-9714 Cover, Lower Dash 1 23 LL Steering Selector Valve Ref. 24 LL Switch, Ignition 1 25 LL Plug, Hole 1 26 LL Signal, Audible 1 27 LL /4 Turn Fastener Assembly 6 28 LL-5940 Decal, Steering Selector Decal, Backup Alarm 1 30 LL-4630 Decal, Hazards 1 31 LL Sway Switch

26 Instrument Panel Assembly, BL-9721-F2 1-26

27 Instrument Panel Assembly, BL-9721-F2--Parts List REF Part No. Description Req'd 1 BL-9742 Panel, Instrument 1 2 LL Bulb, Indicator Light 4 3 LL Diffuser, Light (Red) 4 4 LL Meter, Hour 1 5 LL Gauge, Fuel Level 1 6 LL Gauge, Engine Temperature 1 7 LL Gauge, Transmission Temperature PM-5-63 Plug 1 10 BL Harness, Panel Wiring 1 Ref: Not Shown-- PR Sending Unit (Drive Oil) is LL Instrument Panel & Dash--Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-27

28 Electrical Schematic for 636, AL EXTENDO See Foldout 1-28

29 Electrical Schematic for 636, AL Item Part Number Description Req d 1 LL Gauge, Fuel 1 2 LL Gauge, Water Temperature 1 3 LL Hourmeter 1 4 LL Gauge, Transmission Temperature 1 5 LL Gauge, Transmission Oil Pressure 1 6 LL Sender, Fuel Level 1 7 LL Sender, Water Temperature 1 8 LL Sender, Transmission Oil Temperature 1 9 LA Switch, Engine Oil Pressure 1 10 LL Switch, Brake Oil 1 11 LL Switch, Parking Brake 1 12 LL Sonalert 1 13 LL Relay 4 14 LL Fuse, 10 Amp 1 15 LL Fuse, 15 Amp 1 16 SM-7-54 Ignition Switch 1 17 LL Switch, Neutral Start - Quadrastat Shifter 1 18 LL Circuit Breaker 30 A 1 20 LL Button, Horn 1 21 LL Horn 1 22 LL Battery 1 23 w/engine Alternator 1 24 LL Solenoid Starter 1 25 w/engine Starter 1 26 LL Mico Lock 1 27 LL Switch, Declutch 1 28 LL Switch, Sway 1 29 LL Transmission Shifter Handle 1 30 LL Alarm, Back-up 1 31 LL Switch, Mico 1 32 LL Reostat 4 33 LL Switch, Wiper 1 34 LA Defroster 1 35 LL Head Lights

30 Electrical Schematic for 636, AL Item Part Number Description Req d 36 LA Brake/Tail Light 2 37 LA Heater Kit 1 38 LL Switch, Light 2 Electrical Schematic for 636, AL Service Bulletin Reference Item Date Subject Change 1-30

31 Electric Schematic Notes: 1-31

32 Electrical Plug-Ins Schematic, BL Service Information Plug 2 Shift Lever Key Switch Acc. Key Switch Ign. Fuel Level Sender Com. Low Volt Relay Plug 1 Cab - Engine 39 57A 7A 9 34 Key Switch Ign. Plug 2 Shift Lever Coil-Low Volt Relay Plug 3 Dash Plug 3 Dash Plug 3 Dash Plug 1 Engine Plug 1 Engine Brake Oil Switch Parking Brake Switch Plug 1 Engine Plug 3 Cab Dash - Torque Conv. Temp. Sender Oil Press. Switch Water Temp. Sender Start Sol. Coil Alt. Ind. Light Term Horn Pos. Wire Backup Horn Neg. Wire Alt. Ext. Term A A Note: Plugs are Located Under Lower Dash. Brake Oil Light Parking Brake Light Water Temp. Gauge Eng. Oil Light TC Temp. Gauge All Gauges & Lights Fuel Gauge Low Volt Light Plug 2 Shift Lever Backup Plug 1 Engine Key Switch St. Plug 1 Engine Key Switch Ign. Ground 1-32

33 Switch Panel Assembly w/ Lighting Package, FL

34 Switch Panel Assembly, FL Parts List REF Part No. Description Req'd 1 LL Panel, Switch Ref. 2 LL Switch, Toggle A.R. 3 LL Seal, Weather A.R. 4 LL Plug, Hole A.R. Note: Switches Illustrated in "ON" Position. Switch Panel Assembly, FL Service Bulletin Reference Service Bulletin Reference Number Date Subject Changes 1-34

35 Service Bulletin Reference Number Date Subject Change 1-35

36 Hinged Inspection Cover Ass'y for 636, RH Front, BL

37 Hinged Inspection Cover Ass'y for 636, RH Front, BL Item Part Number Description Req'd 1 BL A Inspection Cover Assy Weldment 1 2 FM-3-2 Latch 1 Hinged Inspection Cover Ass'y for 636, RH Front, BL Service Bulletin Reference Item Date Subject Change 1-37

38 Hinged Inspection Cover Ass'y for 636, Right Hand/Rear, BL

39 Hinged Inspection Cover Ass'y for 636, Right Hand/Rear, BL Item Part Number Description Req'd 1 BL A Inspection Cover Weldment 1 2 FM-3-2 Latch 1 Hinged Inspection Cover Ass'y for 636, Right Hand/Rear, BL Service Bulletin Reference Item Date Subject Change 1-39

40 Hinged Inspection Cover Assy for 636, BL

41 Hinged Inspection Cover Assy for 636, BL Item Part Number Description Req'd 1 BL A Inspection Cover Weldment 1 2 FM-3-2 Latch 1 Hinged Inspection Cover Assy for 636, BL Service Bulletin Reference Item Date Subject Change 1-41

42 Fiberglass console Cover Assembly for 636 Extendo, BL EXTENDO Item Part Number Description Req d 1 AL Munson Control Cover 1 2 LL Joystick 1 3 LL Armrest Pad 1 4 FL-8769 Armrest Mount 1 5 LL Mico Lever Lock 1 6 AL Cab Weldment Ref 7 LL Capscrew, Hex Hd, 1/4 -NC x LL Thumbscrew, Plastic, 1/4 -NC 2 9 LL Screw, Machine, Rnd Hd, 1/4 -NC x LL Trim, FL-9597 Console Mount Ref 1-42

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