Illustrated Parts Manual

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1 AIW 2010 Series Illustrated Parts Manual Parts & Service Call: Customer Support Call: Revised October 7, 2013 Part Number

2 IMPORTANT SAFETY INFORMATION FOR PERSONS PERFORMING MAINTENANCE This Illustrated Parts Manual provides information that pertains to spare parts for the carrier manufactured by Kimble Custom Chassis. In performing maintenance on the vehicle, review and thoroughly understand the recommended and required maintenance procedures in component manuals, including but not limited to, parts books, owners manuals, operator s manuals, maintenance manuals and/or service manuals. These publications should be carefully checked for original equipment manufacturers recommended and required maintenance procedures and instructions as well as all applicable DANGER, WARNING and CAUTION notices. In addition to manufacturer supplied manuals or publications, be sure to also review and thoroughly understand all procedures, including but not limited to, safety procedures, required by the United States Occupational Safety and Health Administration (O.S.H.A) and those of any other governmental regulatory body that may pertain to the work intended on being performed. Finally review and understand any applicable maintenance procedures and safety practices recommended by Truck Manufacturers Association ( before beginning maintenance work. ORDERING GENUINE KIMBLE PARTS FOR YOUR CARRIER Original Kimble parts are designed to meet exacting requirements for each particular application. Imitation parts are not the same as Kimble original parts and in some cases, in addition to not lasting as long, they can cause safety hazards. Kimble parts are engineered with safety and longevity, imitations may expose associates to injury or worse. When ordering parts for your Kimble vehicle having your model and serial number will be helpful. If ordering a large component there may be a model and serial number on that component as well. This will ensure the identification of correct parts.

3 EFFECTIVITY PAGE September 17, Original Issue Of Manual October 31, B - Revised Figure 3-2 October 7, C - Revised Figure 8-2 & 9-1, Removed Options AIW 2010 Series i

4 EFFECTIVITY PAGE -ii AIW 2010 Series

5 TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 FRAME & ATTACHING PARTS Frame Assembly Front Bumper Assembly Cab Step Assembly Engine Enclosure & Deck Assembly Horn & Back-Up Alarm Assemblies SECTION 2 ENGINE & ATTACHING PARTS Powertrain Assembly Radiator Assembly Air Cleaner Assembly Exhaust Assembly SECTION 3 DRIVE TRAIN Drivetrain Installation Front Axle Assembly Front Drive Steer Axle - Housing Front Drive Steer Axle - Differential Front Drive Steer Axle - Components Front Drive Steer Axle - Brakes Rear Axle Assembly Rear Axle - Brake Assembly Driveshafts Assembly PTO Installation SECTION 4 CAB Operators Cab Installation Door Assembly, LH Door Assembly, RH Seat Assembly Seat Components Cab Interior Installation Shifter Console Assembly Dash Panel Assembly Cab Overhead Installation Windshield & Wiper Assembly HVAC Unit Assembly AIW 2010 Series iii

6 TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 5 CONTROLS Steering Column Assembly Floor Control Installation Treadle Valve Piping Installation SECTION 6 CIRCUITS Power Steering Installation Steering Component Assembly Antilock Brake Installation Fuel System Installation HVAC Plumbing Installation DEF Plumbing Installation SECTION 7 AIR SYSTEM Air System Schematic SECTION 8 ELECTRICAL Battery Installation Battery Cable Assembly Power Distribution Manager Power Panel Wiring Engine Wiring Transmission Wiring Chassis Wiring Cab Wiring Cab Dash Wiring Power Mirror Wiring Tail Light Wiring SECTION 9 DECALS Decal Installation SECTION 10 RECOMMENDED SPARE PARTS SECTION 11 PART NUMBER INDEX iv AIW 2010 Series

7 SERVICE KITS Section Page No. Part No. Description AIW 2010 Series v

8 SERVICE KITS Section Page No. Part No. Description vi AIW 2010 Series

9 SECTION 1 FRAME & ATTACHING PARTS AIW 2010 Series

10 FRAME & ATTACHING PARTS Figure 1-1 Frame Assembly PD AIW 2010 Series

11 FRAME & ATTACHING PARTS Figure 1-1 Frame Assembly Item Part Number Qty. Description Rev FRAME WELDMENT, (consult factory) 558-C FRONT TOW DEVICE ASSY, (includes items 101 thru 104) 101 C BOLT, 5/8-11 X 3, HCS, SS WASHER, FLAT, SAE, 5/8 DIA, THRU HARD, ZINC PL 103 C NUT, 5/8-11, H, SV, PL HEX FLG HD CAP SCR, 5/8-18 X 2-1/2 LG, GR 8, ZINC NUT, HEX FLG, 5/8-18, STOVER, GR G, ZINC PL TOW HOOK UNION, RH TOW HOOK UNION, LH 201 Ref CAB INSTALLATION, (see Figure 4-1 for details) 202 Ref ENGINE INSTALLATION, (see Figure 2-1 for details) 203 Ref ENGINE ENCLOSURE, (see Figure 1-4 for details) 204 Ref DRIVETRAIN INSTALLATION, (see Figure 3-1 for details) 205 Ref REAR FENDER ASSY, (not equipped on this vehicle) 206 Ref FRONT BUMPER ASSY, (see Figure 1-2 for details) AIW 2010 Series 1-3

12 FRAME & ATTACHING PARTS Figure 1-2 Front Bumper Assembly PD AIW 2010 Series

13 FRAME & ATTACHING PARTS Figure 1-2 Front Bumper Assembly Item Part Number Qty. Description Rev FRONT BUMBER ASSY, (includes items 1 thru 18) WELDMENT, BUMPER, FRONT TURN SIGNAL PLATE LAMP, MARKER/TURN/REFLECTOR, AMBER, FRONT BACKER PLATE ASSY, HEADLAMP, CHROME, RH ASSY, HEADLAMP, CHROME, LH LAMP, MARKER, KIT, 2-1/2, AMBER REFLECTOR, 3, AMBER BRACKET, BUMPER MTG BOLT, CARRIAGE, 1/2-13 X 1 1/2 LG, STNL STL LOCK WSHR, SPLIT, MEDIUM, 1/2, ZINC PL WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL TRUSS HD MACH SCR, PHILLIPS, X 3/4 LG, STNL STL NUT, HEX, NYLOK, 10-32, ZINC PL HEX HD CAP SCR, 3/8-16 X 3/4 LG, GR 5, ZINC PL NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL WSHR, FLAT, 1/4, 18-8 STNL STL LAMP, GROMMET, 2-1/ AIW 2010 Series 1-5

14 FRAME & ATTACHING PARTS Figure 1-3 Cab Step Assembly FIRE EXTINGUISHER HERE PD AIW 2010 Series

15 FRAME & ATTACHING PARTS Figure 1-3 Cab Step Assembly Item Part Number Qty. Description Rev CAB STEP ACCESS ASSY, (includes items 1 thru 26) WELDMENT, STEP WELDMENT, STEP BRACE, BUMPER PLATE, STEP MTG PLATE, STEP MTG LAMP, STEP, 2-1/2, CLEAR, GRMT MNT LAMP, GROMMET, KIT W/PIGTAIL, 2-1/ STAIRTREAD, 1X1/8 BAR, 8-9/16W X 21 11/16 LG LATCH, LEVER COMPRESSION PLATE, LATCH, STEP CONSOLE FIRE EXTINGUISHER, 2-1/2 LB, CLASS AB&C STAIR, GRIP STRUT, 7 X 2 X 22 LG PLATE, STEP MOUNT PLATE, STEP COVER PLATE, STRAP, STEP STEP SUPPORT ROAD KIT TRIANGLE REFLECTORS DECAL, FIRE EXTINGUISHER HERE HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL NUT, HEX FLG, 3/8-16, STOVER, GR G, ZINC PL TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1 LG, STNL STL WSHR, FLAT, 1/4, 18-8 STNL STL NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL HEX FLG HD CAP SCR, 3/8-16 X 1-1/2 LG, GR 8, ZINC PL HEX FLG HD CAP SCR, 1/2-13 X 1-1/2 LG, GR 8, ZINC NUT, HEX FLG, 1/2-13, STOVER, GR G, ZINC PL AIW 2010 Series 1-7

16 FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly PD AIW 2010 Series

17 FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) PD AIW 2010 Series 1-9

18 FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev ENGINE ENCLOSURE & DECK ASSY, (includes items 1 thru 49) WELDMENT, TOP PANEL WELDMENT, PANEL, LH WELDMENT, PANEL, RH WELDMENT, REAR PANEL WELD, FENDER EXTENSION WELD, LH FENDER WELD, RH FENDER LH FENDER EXTENSION WELDMENT, FENDER SUPPORT, LH REAR WELDMENT, FENDER SUPPORT, RH REAR WELDMENT, FENDER SUPPORT, LH CENTER WELDMENT, FENDER SUPPORT, RH CENTER WELDMENT, FENDER SUPPORT, LH FRONT WELDMENT, FENDER SUPPORT, RH FRONT WELDMENT, BATTERY TRAY LH FENDER TRIM RH FENDER TRIM PLATE, FUEL FILTER MTG LH ROLL-UP SHUTTER MTG RH ROLL-UP SHUTTER MTG ENGINE ENCLOSURE GRILLE BAFFLE, RUBBER BAFFLE, RUBBER RETAINING STRIP, LIGHT, ENGINE ENCLOSURE ASSY, RESERVOIR & PUMP MUD-FLAP, BLACK ROLL-UP SHUTTER TRIM, DRIP EDGE, ROOF NUT, HEX, FLG, STOVER, 3/ NUT, HEX, FLG, STOVER, 1/ TRUSS HD SCR, X 3/4 LG, SS TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 3/4 LG, STNL STL HEX HD CAP SCR, 1/4-20 X 1 LG, STNL STL HEX HD CAP SCREW, 3/8-16 X 1.0 LG, 18-8 SS NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL WSHR, FLAT, 1/4 ID X 1-1/4 OD WSHR, FLAT, 15/16 ID X 3-7/8 OD X 1/4 THK WSHR, FLAT, 1/2 X 1-3/4 OD STANCHION, CHROME, GRABHANDLE TUBE, GRABHANDLE, 24 LG PLUG, PIPE, 2-1/2 NPT, MAGNETIC ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID WSHR, FLAT, 1/4, 18-8 STNL STL WSHR, FLAT, 3/8, 18-8 STNL STL SCR, SELF DRILL, S.S., PAN HD, #8 X 3/ HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL 1-10 AIW 2010 Series

19 FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev HEX FLG HD CAP SCR, 3/8-16 X 1-1/4 LG, GR 8, ZINC PL HEX FLG HD CAP SCR, 1/2-13 X 2-1/4 LG, GR 8, ZINC PL AIW 2010 Series 1-11

20 FRAME & ATTACHING PARTS Figure 1-5 Horn & Back-Up Alarm Assemblies PD AIW 2010 Series

21 FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev. 726-C ELECTRIC HORN ASSY, (includes items 1 thru 4) ELECTRIC HORN WASHER, 1/4, LOCKWASHER, 1/ HEX HD CAPSCREW, 1/4-20X3/ ALARM, BACK-UP, BOLT-ON, 12 VDC AIW 2010 Series 1-13

22 FRAME & ATTACHING PARTS This Page Intentionally Left Blank 1-14 AIW 2010 Series

23 SECTION 2 ENGINE & ATTACHING PARTS AIW 2010 Series

24 ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly PD AIW 2010 Series

25 ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) ATTACHES TO AIR COMPRESSOR FRONT OF ENGINE RH SIDE OF ENGINE PD AIW 2010 Series 2-3

26 ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) Item Part Number Qty. Description Rev ENGINE SUPPORT ASSY, (includes items 1 thru 70) ENGINE, ISX SV, 2010 EPA/CARB, WITH BRAKE BELT, FAN CLAMP MOUNT COMPRESSOR, REFRIGERANT, R134a, 155 CC FTG, SERVICE 1-14 FEM #8 ML HEX HD CAP SCR, M X 100MM LG, GR 8.8, ZINC PL WSHR, FLAT, SAE, 3/8 DIA, GR 8, ZINC PL BELT, FREON DRIVE, 2010 ISX11.9, 6PK, LG ALTERNATOR, 220 AMP, 12 VDC, PAD MNT HEX HD CAP SCR, M X 100MM LG, GR WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL HEX FLG HD CAP SCR, 5/8-11 X 1-3/4 LG, GR 8, ZINC STARTER, CUMMINS TRANSMISSION, ALLISON, 4500RDS, TC-541, ISX HEX HD CAP SCR, M16-2 X 40MM LG, GR 10.9, ZINC PL HEX FLG HD CAP SCR, 7/16-14 X 1-1/2 LG, GR 8, ZINC PL PTO CLUTCH, FAN FAN, SUCTION, 36 DIA. X 9 BLADE, PILOT FAN RING FAN RING MOUNT WELD FAN RING MOUNT FAN, RH, SHROUD MOUNT FAN, LH, SHROUD MOUNT FAN SEAL NUT, HEX, 3/8-16, GR C, ZINC PL HEX FLG HD CAP SCR, M X 40MM LG, GR 10.9 ZINC PL 28 Ref AIR LINE ADAPTER, STR, 1/8 NPT X -4 AB TUBE, BRASS HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL VALVE, SOLENOID, PNEUMATIC, FAN CLUTCH NUT, HEX FLG, 3/8-16, STOVER, GR G, ZINC PL HEX HD CAP SCR, M X 30 MM LG, GR 10.9, ZINC PL WSHR, FLAT, SAE, 7/16, THRU HARD, ZINC PL HEX HD CAP SCR, M X 35MM LG, GR 10.9, ZINC PL ADAPTER, ELBOW, 90 DEG, -8 SAE O-RING X -8 JIC ADAPTER, ELBOW, 90 DEG, -12 SAE O-RING X -16 JIC GASKET, PUMP, SAE PUMP, POWER STEERING, 28CC ADAPTER, BUSHING, 3/4 NPT X 1/2 FEMALE NPT, BRASS ADAPTER, STR, M DIN O-RING X 3/4 FEMALE NPT VALVE, NEEDLE, 90 DEG, 3/8 NPT X 5/8 HOSE BEAD, BRASS ADAPTER, BUSHING, 3/4 NPT X 3/8 FEMALE NPT GOVERNOR, AIR, 105 PSI, 1/8 NPT ADAPTER, STR, 1/8 NPT X -4 JIC HEX HD CAP SCR, M X 70MM LG, GR. 8.8, ZINC PL HOSE END, STR, -4 JIC FEMALE SWIVEL X -4 PUSHLOK BRASS PLUG, PIPE, HEX SOCKET, 1/8 NPT 2-4 AIW 2010 Series

27 ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) Item Part Number Qty. Description Rev VENT, AIR ISOLATOR, RUBBER ISOLATOR, RUBBER BRACKET, FORMED, CHARGE AIR MTG WELDMENT, REAR ENG, MTG, LH WELDMENT, REAR ENG, MTG, RH ADAPTER, ELBOW, 90 DEG, 1/2 NPT X 5/8 HOSE BARB, BRASS ADAPTER, STR, M DIN O-RING X 3/4 FEMALE NPT ADAPTER, ELBOW, 90 DEG, STREET, 3/4 NPT ADAPTER, STR, 3/4 NPT X 3/4 HOSE BARB, BRASS ADAPTER, STR, 1/4 NPT X -4 HOSE BARB, BRASS ADAPTER, STR, M DIN O-RING X 1/4 FEMALE NPT ADAPTER, TEE, BRANCH, 1/4 NPT, BRASS ADAPTER, ELBOW, 45 DEG, 1/4 NPT X -4 AB TUBE, BRASS ADAPTER, STR, 1/4 NPT X -4 AB TUBE, BRASS ADAPTER, ELBOW, 45 DEG, 1/2 NPT X 5/8 HOSE BARB, BRASS HEX HD CAP SCR, M16-2 X 45MM LG, GR 10.9, ZINC PL WASHER, FLAT, SPL, 5/8 X 2-1/4 OD X 1/8 THK HEX HD CAP SCR, M X 60MM LG, GR 10.9, ZINC PL WASHER, FLAT, HEAVY, 7/ BRACKET, CONNECTOR, TRANSMISSION MTD DIPSTICK DIPSTICK TUBE AIW 2010 Series 2-5

28 ENGINE & ATTACHING PARTS Figure 2-2 Radiator Assembly PD AIW 2010 Series

29 ENGINE & ATTACHING PARTS Figure 2-2 Radiator Assembly Item Part Number Qty. Description Rev COOLING SYSTEM ASSY, (includes items 1 thru 25) TUBE, CHARGE AIR, OUTLET TUBE, CHARGE AIR, INLET HUMP, AIR INTAKE, 4 ID X 7-1/2 LG, SILICONE CLAMP, HOSE, SPRING LOADED, 4 DIA, STNL STL ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID 6 C WASHER, 1/2 X 1 3/4, FW, TYPE B, Z NUT, HEX FLG, 5/8-11, STOVER, GR G, ZINC PL ASSY, RDTR/CAC, AKG, ISX CONDENSER, A/C, WITH ELECTRIC FAN STAY ROD, 1/2-13 X 11.0 LG GR SURGE TANK, 2010 ISX WSHR, FLAT, SPL, 5/8 X 2-1/2 OD RUBBER ISOLATOR MOUNT, TWO PIECE, 2.55 OD.657ID TUBE, RADIATOR, UPPER TUBE, RADIATOR, LOWER TUBE, RADIATOR, LOWER HOSE, COOLANT, 2-1/2 DIA X 6 LG HOSE, COOLANT, 2-1/2 DIA X 4 LG CLAMP, HOSE, CONSTANT TENSION, 2-1/4 THRU 3-1/8 DIA CLAMP, GUILLOTINE, 2-1/2 DIA SENSOR, COOLANT LEVEL, CUMMINS NUT, HEX, 1/2-13, GR 8, ZINC PL WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL HEX HD CAP SCR, 5/16-18 X 3/4 LG, GR 5, ZINC PL LOCK WSHR, SPLIT, MEDIUM, 5/16, ZINC PL AIW 2010 Series 2-7

30 ENGINE & ATTACHING PARTS Figure 2-3 Air Cleaner Assembly PD AIW 2010 Series

31 ENGINE & ATTACHING PARTS Figure 2-3 Air Cleaner Assembly Item Part Number Qty. Description Rev AIR INTAKE INSTALLATION, (includes items 1 thru 14) HOOD, INTAKE, AIR CLNR, RAM AIR, 7 ID INLET AIR CLNR, 5.5 IN MTG BAND, AIR CLNR, 7 DIA GAUGE, AIR RESTRICTION, 25 IN WELDMENT, INTAKE, TUBE TUBE, AIR CEANER TUBE, AIR CLEANER INLET CLAMP, T-BAR, 5 DIA, STNL STL CLAMP, T-BAR, 6 DIA, STNL STL CLAMP, T-BAR, 7 DIA, STNL STL HUMP, AIR INTAKE, 7 ID ELBOW, AIR INTAKE, 90 DEG, 7 ID HUMP, REDUCER, AIR INTAKE, 7 ID X 5 ID ELBOW, 90 DEGREE, 4 DIA TO 5 DIA AIW 2010 Series 2-9

32 ENGINE & ATTACHING PARTS Figure 2-4 Exhaust Assembly PD AIW 2010 Series

33 ENGINE & ATTACHING PARTS Figure 2-4 Exhaust Assembly Item Part Number Qty. Description Rev DPF INSTALLATION, (includes item 1 thru 7) STAY ROD, 1/2-13 X 8 LG NUT, HEX FLG, 5/8-11, STOVER, GR G, ZINC PL NUT, HEX, 1/2-13, GR 8, ZINC PL ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL HEX FLG HD CAP SCR, 5/8-18 X 1-1/2 LG, GR 8, ZINC PL 7 C WASHER, 1/2 X 1 3/4, FW, TYPE B, Z DPF ASSY, (includes items 101 thru 114) WELDMENT, EXHAUST MTG SCR, CUMMINS ISX, ELBOW, 90 DEG. INSULATED, CUMMINS ISX, DECOMP REACTOR, SCR, CUMMINS ISX, DPF, CUMMINS ISX, GASKET, SCR, 5 SPHERICAL MARMON CLAMP, SCR, 5 SPHERICAL MARMON TUBE, EXHAUST, ISX WELD, EXHAUST STRAP SPACER, EXHAUST STRAP STACK PIPE, EXHAUST, CURVED, 5 OD x 24 LG, CHROME CLAMP, EXHAUST, WIDE BAND, 5 DIA, STNL STL, BRIGHT GASKET, SCR, 5 STD MARMON CLAMP, SCR, 5 STD MARMON AIW 2010 Series 2-11

34 ENGINE & ATTACHING PARTS This Page Intentionally Left Blank 2-12 AIW 2010 Series

35 SECTION 3 DRIVE TRAIN AIW 2010 Series

36 DRIVE TRAIN Figure 3-1 Drivetrain Installation PD AIW 2010 Series

37 DRIVE TRAIN Figure 3-1 Drivetrain Installation Item Part Number Qty. Description Rev. 1 Ref FRONT AXLE SUSPENSION, (see Figure 3-2 for details) 2 Ref FRONT AXLE ASSY, (see Figure 3-2 for details) 3 Ref REAR AXLE ASSY, (see Figure 3-7 for details) 4 Ref DRIVESHAFTS, (see Figure 3-9 for details) FRONT WHEEL ASSY, (includes items 101 & 105) TIRE, 425/65R WHEEL, 22.5 X 13.00, 6.12 INSET, HUB PILOT, ALUM, POLISHED WHEEL, 22.5 X 12.25, 0.56 OFFSET, HUB PILOT, ALUM, POLISHED INSULATOR, WHEEL, 10-HOLE, 335MM BC, 22MM DIA STUD INSULATOR, WHEEL, 10-HOLE AIW 2010 Series 3-3

38 DRIVE TRAIN Figure 3-2 Front Axle Assembly PD AIW 2010 Series

39 DRIVE TRAIN Figure 3-2 Front Axle Assembly Item Part Number Qty. Description Rev FRONT AXLE ASSY, (includes items 1 thru 12) KIT, SUSPENSION, LEAF SPRING, TANDEM AXLE, STEER, TUBULAR, 24k, SPRING CENTER AXLE, MH MT22H, 5.38 RATIO, NO SPRING PADS, STEER ARM WELDMENT, SHOCK MOUNT, LH WELDMENT, SHOCK MOUNT, RH WELDMENT, SHOCK MOUNTING SPACER, SPRING, 2 IN U-BOLT, 6-3/8 ID X 19-1/2 LG X 7/8-14, GR NUT, HEX, 7/8-14, GR PLATE, STOP SPACER STOP PLATE WSHR, FLAT, HEAVY, 7/ FRONT AXLE SHOCK INSTALLATION, (includes items 101 thru 107) SHOCK, FRONT WSHR, SHOCK, 3/ WSHR, SHOCK, NUT, HEX FLG, 3/4-16, STOVER, GR G, ZINC PL SLEEVE, SHOCK ABSORBER MNT HEX HD CAP SCR, 3/4-16 X 5 LG, GR 8, ZINC PL HEX HD CAP SCR, 3/4-16 X 4-1/2 LG, GR 8, ZINC PL AXLE STOP INSTALL, (includes items 201 thru 207) NUT, HEX FLG, 5/8-18, STOVER, GR G, ZINC PL HEX FLG HD CAP SCR, 5/8-18 X 1-3/4 LG, GR 8, ZINC WELDMENT, TIMBREN STOP SPRING, HOLLOW RUBBER, TIMBREN WSHR, FLAT, 1/2 ID X 1-1/4 OD NUT, HEX, 1/2-13 PLAIN STOP PLATE AIW 2010 Series 3-5

40 DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing PD AIW 2010 Series

41 DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing Item Part Number Qty. Description Rev. 1 HOUSING ASSY, (includes items 1 thru 75) AXLE HOUSING VENT EXTENSION VENT FILL PLUG DRAIN PLUG, MAGNETIC SPECIAL HEX BOLT DOWEL PIN SNAP RING ROLLER BEARING, AXLE SHAFT, INNER OIL SEAL, AXLE SHAFT, INNER SEAL HOLDER FELT WIPER YOKE HOUSING, LH YOKE HOUSING, RH, (not shown) AR TRUNNION SHIM, 1.00 MM AR TRUNNION SHIM, 1.20 MM AR TRUNNION SHIM, 0.40 MM AR TRUNNION SHIM, 0.60 MM AR TRUNNION SHIM, 1.40 MM LOCK PIN HEX NUT, M16X BEARING CASE, UPPER O-RING THRUST DISK BEARING CASE, LOWER KNUCKLE SPINDLE ASSY, LH KNUCKLE SPINDLE ASSY, RH ABS SENSOR, (Wabco) SENSOR SPRING CLIP SPECIAL HEX BOLT DOWEL PIN WEAR SLEEVE HUB SEAL DUST SHIELD HEX BOLT, M8X LOCKWASHER, M WHEEL BEARING NUT WHEEL BEARING LOCK RING OIL SEAL, TRUNNION PIN TRUNNION PIN BUSHING TRUNNION PIN, UPPER (short) TRUNNION PIN COVER SNAP RING GREASE FITTING, 45 DEGREES TRUNNION PIN, LOWER, (long) ADAPTER TRUNNION COVER GASKET TRUNNION COVER BOLT, M8X AIW 2010 Series 3-7

42 DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing (Continued) Item Part Number Qty. Description Rev LOCKWASHER, M ADAPTER FITTING ELBOW FITTING, VENT JAM NUT LOCKWASHER, M HEX BOLT, M10X BRACKET VENT, LH BRACKET VENT, RH, (not shown) RETAINING RING UNION NUT TUBE VENT, LH, (includes items 51 & 52) TUBE VENT, RH PIPE FITTING BOLT, M20X BOLT, TURN STOP, M20X BOLT, TURN STOP, M20X SPECIAL HEX NUT DOWEL PIN STEERING ARM STUD BRAKE CHAMBER BRACKET, LH BRAKE CHAMBER BRACKET, RH STEERING ARM, LH STEERING ARM, RH, (not shown) AR LOCK WIRE CASTLE NUT TIE ROD ARM, LH TIE ROD ARM, LH, (0000, 11, 06) TIE ROD ARM, RH, (not shown) TIE ROD ARM, RH, (0000, 11, 06), (not shown) STUD TIE ROD ARM STUD TIE ROD ARM, (0000, 11, 06) ROLLER BEARING, AXLE SHAFT, OUTER SNAP RING OIL SEAL, AXLE SHAFT, OUTER DUST SHIELD, AXLE SHAFT FELT LOCKWASHER, M HEX BOLT, M6X THRUST BEARING KIT, (includes items 17 thru 20) O-RING SEAL HOLDER ASSY, (includes items 10, 11 & 12) 3-8 AIW 2010 Series

43 DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing (Continued) Item Part Number Qty. Description Rev AIW 2010 Series 3-9

44 DRIVE TRAIN Figure 3-4 Front Drive Steer Axle - Differential PD AIW 2010 Series

45 DRIVE TRAIN Figure 3-4 Front Drive Steer Axle - Differential Item Part Number Qty. Description Rev. 1 DIFFERENTIAL ASSY, (includes items 1 thru 26) DIFFERENTIAL CASE HALVES ASSY SPECIAL HEX BOLT SPECIAL WASHER OIL BAFFLE PLATE DIFFERENTIAL CROSS NEST SET WASHER, DIFFERENTIAL PINION GEAR WASHER, DIFFERENTIAL SIDE GEAR RING & GEAR PINION FLANGED RING GEAR BOLT BEARING CAGE ASSY OIL BAFFLE PLATE SPECIAL FLANGED BOLT AR SHIM, 1.0 MM AR SHIM,.50 MM AR SHIM,.30 MM AR SHIM,.25 MM AR SHIM,.20 MM PINION BEARING, INNER PINION BEARING, OUTER COVER OIL SEAL KIT, PINION HEX BOLT, M8X LOCKWASHER, M COMPANION FLANGE, 1610 SERIES COMPANION FLANGE, 1610 SERIES PINION LOCKNUT PINION CASTLE NUT COTTER PIN SPECIAL WASHER DISTANCE SLEEVE 1 DIFFERENTIAL CARRIER HOUSING ASSY, (includes items 101 thru 109) DIFFERENTIAL CARRIER HOUSING FLANGED BOLT DIFFERENTIAL SIDE BEARING ASSY DIFFERENTIAL SIDE BEARING ASSY BEARING ADJUSTER LOCK PLATE LOCK PLATE HEX BOLT, M8X15, GR LOCKWASHER, (nord-lock) AIW 2010 Series 3-11

46 DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components PLANETARY WHEEL HUB, BRAKE DRUM PD AIW 2010 Series

47 DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components (Continued) AXLE SHAFT ASSY TIE ROD 307 PD AIW 2010 Series 3-13

48 DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components Item Part Number Qty. Description Rev. 1 PLANETARY ASSY, (includes items 1 thru 25) PLANET GEAR PIN STEEL BALL DISTANCE PLATE ROLLER BEARING ASSY PLANET GEAR MAGNETIC DRAIN PLUG FILL PLUG HEX BOLT, M10X END COVER PLANET GEAR CARRIER HUB PILOT PLANETARY RING GEAR RING GEAR SUPPORT HUB RETAINING RING SNAP RING SPACER SUN GEAR HEX BOLT, M10X SNAP RING AR SHIM, 0.25 MM AR SHIM, 0.50 MM AR SHIM, 2.00 MM FRICTION DISK DISTANCE RING FRICTION DISK PLANET GEAR CARRIER ASSY PLANET GEAR KIT SUN GEAR/FRICTION DISK KIT 1 WHEEL HUB & BRAKE DRUM ASSY, (includes items 101 thru 112) HUB ASSY WHEEL STUD HUB PILOT FLANGE WHEEL NUT HEX BOLT, M10X BRAKE DRUM WHEEL BEARING CONE, (outer) WHEEL BEARING CUP, (outer) WHEEL BEARING CUP, (inner) WHEEL BEARING CONE, (inner) EXCITER RING HUB SEAL BEARING KIT HUB, (includes items 106 thru 109) 1 AXLE SHAFT ASSY, (includes items 201 thru 213) AXLE SHAFT, SHORT SPLINE AXLE SHAFT LONG SPLINE 202 NSS DOUBLE CARDAN STEERING JOINT 3-14 AIW 2010 Series

49 DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components (Continued) Item Part Number Qty. Description Rev. 203 NSS OUTER AXLE SHAFT 204 NSS INNER AXLE SHAFT 205 NSS COUPLE HOUSING 206 NSS CROSS SHAFT 207 NSS BEARING CUP ASSY 208 NSS SNAP RING 209 NSS BEARING CUP PLUG 210 NSS AXLE SHAFT PIN 211 NSS AXLE PIN SET SCREW 212 NSS BEARING CUP ASSY TIE ROD ASSY, (includes items 301 thru 308) TIE ROD BALL STUD ASSY, RH BALL STUD ASSY, LH SPECIAL HEX BOLT CASTLE NUT, M16X COTTER PIN, 1/8X1-1/ TIE ROD CASTLE NUT COTTER PIN, 1/4X AIW 2010 Series 3-15

50 DRIVE TRAIN Figure 3-6 Front Drive Steer Axle - Brakes PD AIW 2010 Series

51 DRIVE TRAIN Figure 3-6 Front Drive Steer Axle - Brakes Item Part Number Qty. Description Rev. 1 BRAKE ASSY, FRONT DRIVE STEER, (includes items 1 thru 27) BRAKE SHOE ASSY BRAKE SHOE RETURN SPRING RETURN SPRING, SHORT PIN, SPRING SUPPORT BRAKE SHOE ROLLER BRAKE SHOE PIN BUSHING OIL SEAL GREASE FITTING SPANNER HOUSING ASSY, LH, (includes items 7, 8 & 9) SPANNER HOUSING ASSY, RH, (includes items 7, 8 & 9) SPECIAL HEX BOLT SPECIAL WASHER CAM SHAFT, LH CAM SHAFT, RH SPACER AR SHIM,.50 MM AUTOMATIC SLACK ADJUSTER, LH AUTOMATIC SLACK ADJUSTER, RH SPACER WEAR INDICATION DISK SNAP RING SNAP RING BUMPER ASSY, LH BUMPER ASSY, RH BOLT, M8X LOCKWASHER, M GREASE FITTING, 1/ GREASE FITTING, M8X BUSHING CAP, AUTOMATIC SLACK ADJUSTER, LH CAP, AUTOMATIC SLACK ADJUSTER, RH BOLT, M8X BOLT, M6X ROLLER SPRING, (optional) BRAKE SPRING & ROLLER KIT, (includes items 2, 3, 5, 6 & 27) AIW 2010 Series 3-17

52 DRIVE TRAIN Figure 3-7 Rear Axle Assembly PD AIW 2010 Series

53 DRIVE TRAIN Figure 3-7 Rear Axle Assembly Item Part Number Qty. Description Rev REAR AXLE ASSY, (includes items 1 thru 3) FRONT REAR AXLE REAR REAR AXLE SUSPENSION KIT, 46K TANDEM ASSY, (includes items 101 thru 107) TORQUE ROD FRAME BRACKET TORQUE ROD ASSY TORQUE ROD ASSY THRUST WASHER BEAM CENTER SLEEVE BEAM END MOUNITNG HARDWARE EQUALIZER BEAM ASSY, AIW 2010 Series 3-19

54 DRIVE TRAIN Figure 3-8 Rear Axle - Brake Assembly PD AIW 2010 Series

55 DRIVE TRAIN Figure 3-8 Rear Axle - Brake Assembly Item Part Number Qty. Description Rev BRAKE ASSY, FORWARD/REAR AXLE LH, (includes items 1 thru 23) BRAKE ASSY, FORWARD/REAR AXLE RH, (includes items 1 thru 23) BRAKE ASSY, REAR/REAR AXLE LH, (includes items 1 thru 23) BRAKE ASSY, REAR/REAR AXLE RH, (includes items 1 thru 23) SPIDER & PIN ASSY GUSSET BRACKET ASSY, FORWARD/REAR AXLE LH GUSSET BRACKET ASSY, FORWARD/REAR AXLE RH GUSSET BRACKET ASSY, REAR/REAR AXLE LH GUSSET BRACKET ASSY, REAR/REAR AXLE RH GREASE SEAL CAMSHAFT BUSHING GREASE FITTING SHOE & LINING ASSY CAMSHAFT, FORWARD/REAR AXLE LH, CCW CAMSHAFT, FORWARD/REAR AXLE RH, CW CAMSHAFT, REAR/REAR AXLE LH, CW CAMSHAFT, REAR/REAR AXLE RH, CCW SLACK ADJUSTER SLACK ANCHOR BRACKET HARDWARE ASSY, (includes items 10 thru 16) AR CAMSHAFT SHIM WASHER, AR CAMSHAFT SHIM WASHER, BRACKET MOUNTING CAPSCREW SLACK ADJUSTER INNER WASHER BRACKET MOUNTING LOCKWASHER CAMSHAFT RETAINER SNAP RING CAM HEAD WASHER ROLLER & SPRING ASSY, (includes items 17 thru 20) CAM ROLLER ROLLER RETAINER SHOE RETURN SPRING SHOE RETAINER SPRING DUSTSHIELD ASSY, (includes items 21 thru 23) DUSTSHIELD DUSTSHIELD SCREW PLUG AIW 2010 Series 3-21

56 DRIVE TRAIN Figure 3-9 Driveshafts Assembly REAR-REAR AXLE 5 FRONT-REAR AXLE TRANSMISSION FRONT AXLE 10 PD AIW 2010 Series

57 DRIVE TRAIN Figure 3-9 Driveshafts Assembly Item Part Number Qty. Description Rev DRIVESHAFT ASSY, (includes items 1 thru 10) DRIVESHAFT, 1710, HALF RND, 20 LG DRIVESHAFT, 1710, HALF RND, 52.5 LG COUPLESHAFT, 1710, HALF RND, LG JACKSHAFT, 1710, 57.2, HALF ROUND DRIVESHAFT, 1810, HALF RND, LG JACKSHAFT, 1810, WELDMENT, DRIVESHAFT SUPPORT WELDMENT, CENTER BEARING SUPPORT WELDMENT, CENTER BEARING SUPPORT PLATE, BENT, CENTER BEARING AIW 2010 Series 3-23

58 DRIVE TRAIN Figure 3-10 PTO Installation PD AIW 2010 Series

59 DRIVE TRAIN Figure 3-10 PTO Installation Item Part Number Qty. Description Rev. 605-C PTO MOUNTING ASSY, (includes items 1 thru 3) NUT, HEX FLG, 1/2-13, STOVER, GR G, ZINC PL HEX FLG HD CAP SCR, 1/2-13 X 1-1/2 LG, GR 8, ZINC PL WELDMENT, PUMP SUPPORT 101 Ref TANDEM PTO PUMP, (see final stage manufacturer) 102 Ref PTO MOUNTING FLANGE, (see final stage manufacturer) AIW 2010 Series 3-25

60 DRIVE TRAIN This Page Intentionally Left Blank 3-26 AIW 2010 Series

61 SECTION 4 CAB AIW 2010 Series

62 CAB Figure 4-1 Operators Cab Installation PD AIW 2010 Series

63 CAB Figure 4-1 Operators Cab Installation Item Part Number Qty. Description Rev CAB ASSY, (includes items 1 thru 16) LAMP, CLEARANCE, CAB, AMBER FRONT GRILL BRKT, MTG, HORN, AIR PLATE, WEB HORN, AIR, BLACK NUT, HEX FLG, 5/8-18, STOVER, GR G, BLK PHOS HEX HD CAP SCR, 5/8-18 X 5-1/2 LG, GR 8, ZINC PL ISOLATOR, MTG, RUBBER, 700 LB WSHR, FLAT, SAE, 5/8 DIA, THRU HARD, ZINC PL STANCHION, CHROME, GRABHANDLE TUBE, GRABHANDLE, 36 LG TRIM, DRIP EDGE, LH TRIM, DRIP EDGE, RH TRIM, DRIP EDGE, DOOR LH TRIM, DRIP EDGE, DOOR RH SCR, SELF DRILL, SS, PAN HD, #8 X 3/ SPOTLIGHT INSTALLATION, (includes items 101 thru 102) LAMP, SPOT, REMOTE CONTROL, GO LIGHT INSERT, THREADED, 10-32, ALUM HEX SOC BUTTON HD CAP SCR, X 3/4 LG, STNL STL MIRROR, LOOKDOWN MIRROR KIT, CONVEX AIW 2010 Series 4-3

64 CAB Figure 4-2 Door Assembly, LH PD AIW 2010 Series

65 CAB Figure 4-2 Door Assembly, LH Item Part Number Qty. Description Rev DOOR ASSY, LH, (includes items 101 thru 199) DOOR WELDMENT, LH PULL DOOR HANDLE INSIDE DOOR HANDLE, LH REGULATOR BRACKET, LH ROTORY LATCH, LH GRAB HANDLE FOOTMAN LOOP REMOTE HEATED MIRROR, LH INTERIOR LOCK ROD, LH REGULATOR BRACKET SHIM ROTARY LATCH ADAPTER EXTERIOR LOCK ROD EXTERIOR LATCH ROD, LH INTERIOR LATCH ROD, LH REGULATOR MOUNTING BRACKET ROLL DOWN WINDOW, LH RUBBER BUMPER DOOR KICK PANEL, LH RUBBER TRIM RUBBER BULB SEAL RUBBER-D, RUBBER-D, RUBBER-D, GROMMET CHECK STRAP POWER WINDOW SWITCH PLATE, SWITCH MOUNT CHANNEL, WINDOW FLAT SOCKET HEAD CAP SCREW, X 3/4 LG, BLACK OXIDE LOCK WSHR, SPLIT, MEDIUM, 1/4, STNL STL NUT, HEX, THIN, 1/ STNL STL TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1-1/4 LG, STNL STL WASHER, 1/ PAN HD SCREW, 1/4-20X WASHER, #10, PAN HD SCREW, #10-32X3/4, HEX HD CAPSCREW, 1/4-20X1-1/4, LOCKNUT, 1/4-20, GR PAN SCREW, M6-1X25MM LOCKNUT, # WASHER, EXTERNAL TOOTH, # PAN HD SCREW, #10-32X1/2, PAN HD SCREW, 1/4-20X PAN HD SCREW, 1/4-20X1/2, OVAL HD MACHINE SCREW, 10-32X3/ WASHER PAN HD SCREW, 1/4-20X3/4, 18-8 APPLY BLUE LOCTITE TO ALL BOLTS & NUTS USING LOCKNUTS AIW 2010 Series 4-5

66 CAB Figure 4-3 Door Assembly, RH PD AIW 2010 Series

67 CAB Figure 4-3 Door Assembly, RH Item Part Number Qty. Description Rev DOOR ASSY, RH, (includes items 101 thru 199) DOOR WELDMENT, RH ROTORY LATCH, RH INSIDE DOOR HANDLE, RH PULL DOOR HANDLE INTERIOR LATCH ROD, RH INTERIOR LOCK ROD, RH ROTARY LATCH ADAPTER EXTERIOR LATCH ROD, RH EXTERIOR LOCK ROD REGULATOR BRACKET, RH ROLL DOWN WINDOW, RH REGULATOR MOUNTING ANGLE. RH GRAB HANDLE RUBBER BUMPER REMOTE HEATED MIRROR, RH REGULATOR BRACKET SHIM FOOTMAN LOOP DOOR KICK PANEL, RH RUBBER-D, RUBBER-D, RUBBER-D, RUBBER BULB SEAL RUBBER TRIM GROMMET POWER WINDOW SWITCH CHECK STRAP PLATE, SWITCH MOUNT FLAT SOCKET HEAD CAP SCREW, X 3/4 LG, BLACK OXIDE CHANNEL, WINDOW LOCK WSHR, SPLIT, MEDIUM, 1/4, STNL STL NUT, HEX, THIN, 1/ STNL STL TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1-1/4 LG, STNL STL WASHER, 1/ PAN HD SCREW, 1/4-20X WASHER, #10, PAN HD SCREW, #10-32X3/4, HEX HD CAPSCREW, 1/4-20X1-1/4, LOCKNUT, 1/4-20, GR PAN SCREW, M6-1X25MM LOCKNUT, # WASHER, EXTERNAL TOOTH, # PAN HD SCREW, #10-32X1/2, PAN HD SCREW, 1/4-20X PAN HD SCREW, 1/4-20X1/2, OVAL HD MACHINE SCREW, 10-32X3/ WASHER PAN HD SCREW, 1/4-20X3/4, 18-8 APPLY BLUE LOCTITE TO ALL BOLTS & NUTS USING LOCKNUTS AIW 2010 Series 4-7

68 CAB Figure 4-4 Seat Assembly PD AIW 2010 Series

69 CAB Figure 4-4 Seat Assembly Item Part Number Qty. Description Rev DRIVER SEAT ASSY, (includes items 1 thru 11) WSHR, FLAT, SAE, 5/16 DIA, GR 8, ZINC PL NUT, HEX, LOCKING, NYLOK, 5/16-18, GR 2, ZINC PL HEX HD CAP SCR, 5/8-18 X 5 LG, GR 8, ZINC PL HEX HD CAP SCR, 5/16-18 X 1 LG, GR 5, ZINC PL SEAT, AIR RIDE, HI-BACK, VINYL, PACIFIC GRAY ARM REST, SEAT GRAY, KIT, 2 EACH SEAT BELT, 3-PT SHOULDER, RH, BK NUT, HEX, 7/16-20, ZINC PL LOCK WSHR, SPLIT, MEDIUM, 7/16, ZINC PL HEX HD CAP SCR, 7/16-20 X 1-1/2 LG, GR 8, ZINC PL SPACER, TUBE SEATBELT BUCKLE AIW 2010 Series 4-9

70 CAB Figure 4-5 Seat Components PD AIW 2010 Series

71 CAB Figure 4-5 Seat Components Item Part Number Qty. Description Rev SUSPENSION HARDWARE KIT, (includes items 2 thru 10) 2 2 RUBBER BUMPER 3 2 SPACER ROLLER 4 6 MULTILUBE BEARING 5 4 BEARING BLOCK 6 6 CAPSCREW, M8X SHOULDER BOLT, M7X SLIDE BLOCK 9 2 STOP BLOCK ASSY 10 3 LOCKNUT, M8X AIR VALVE KIT, (includes items 12 thru 15) 12 1 CLAMP CABLE 13 1 NYLON TUBING, 1/ SCREW 15 1 PNEUMATIC VALVE STANDARD DAMPER KIT, (includes items 18 thru 21) 18 2 MULTILUBE BEARING 19 2 WASHER 20 2 PUSH-ON FASTENER 21 1 DAMPER AIR SPRING KIT, (includes items 22 thru 24) 22 1 AIR SPRING ASSY 23 1 NYLON TUBING, 1/ FLAT HEAD SCREW, M UPPER PLATE ASSY INNER LEVER ASSY OUTER LEVER ASSY BASE WELDMENT ASSY ICP BRACKETS KIT, (includes items 38 & 39) 38 4 CAPSCREW, M8X12MM 39 2 SEAT BELT BRACKET SEAT FOAM, (not shown) HIGH BACK FOAM, (not shown) LOW BACK FOAM, (not shown) SEAT COVER, (not shown) HIGH BACK COVER, (not shown) MID BACK COVER, (not shown) MID BACK FOAM, (not shown) LOW BACK COVER, (not shown) AIW 2010 Series 4-11

72 CAB Figure 4-6 Cab Interior Installation PD AIW 2010 Series

73 CAB Figure 4-6 Cab Interior Installation (Continued) PD AIW 2010 Series 4-13

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