Parts Manual. Model 502. Compact Excavator. Serial Number AB00473 to AB Form No Revision C July 2007

Transcription

1 Model 502 Form Revision C July 2007 Compact Excavator Serial Number AB00473 to AB02974 Parts Manual 2007 Gehl Company All Rights Reserved. Printed in USA

2 INTRODUCTION When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. For your safety and continued proper operation, use only genuine GEHL service parts. The model and serial number for this unit are on a tag located on a panel on the front of the cab. Right and left are determined from a position sitting on the operator s seat and facing forward. GEHL 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 previously delivered units. Refer to the abbreviations table located on this page for special parts descriptions. Standard attaching hardware torque values are also provided near the back of this manual. Metric torque values shown in the illustrations are in Newton-meters and are converted to foot-pounds by multiplying by Specific reference numbers, indicating a complete assembly, are circled in some illustrations. A small bag, pictured in some illustrations, indicates a seal kit (seals, o-rings, etc.). In the exploded view parts list, additional information may follow the Reference Number. Serial number breaks are indicated as follows: (SN 999 and before) - indicates serial numbers up to and including 999. (SN ) - indicates serial numbers between 1000 and (SN 999 and up) - indicates serial numbers including 999 and after. Serial number exceptions and inclusion are indicated as follows: (SN 999 and before except 997) - indicates serial numbers up to and including 999, EXCEPT 997. (SN except 1996 including 997) - indicates serial numbers between 1000 and 2000, INCLUDING 997 EXCEPT (SN 2001 and up including 1996) - indicates serial numbers including 2001 and after, INCLUDING Unless otherwise specified, all cap screws and bolts are Grade 8.8, cadmium or zinc plated. NOTE:The following abbreviations may be used herein: ASSD...Assembled ASY...Assembly ASSY...Assembly AR...As Required CB...Carriage Bolt CP...Cotter Pin CS...Cap Screw (Hexagon Head) CYL...Cylinder DIA...Diameter FHCS...Flat Head Cap Screw GR...Grade HB...Hex Bolt HLN...Hex Lock Nut HN...Hex Nut HP...High Pressure HYD...Hydraulic INS...Insert LH...Left Hand LN...Lock Nut LT...Left LW...Lock Washer M...Meter or Meters MM/mm...Millimeter NPT...National Pipe Threaded NSS...Not Sold Separately RH...Right Hand RT...Right SHCS...Socket Head Cap Screw SLTD...Slotted SN...Serial Number or Slotted Nut SQ...Square W/...With W/O...Without

3 Introduction...i Table of Contents... 1 Decal Locations... 3 Undercarriage, Rubber Track... 8 Undercarriage, Steel Track... 9 Supporting Roller Track Tensioner, Rubber Track Track Tensioner, Steel Track Bottom Roller Dozer Blade Chassis Chassis Covers Chassis Lubrication Rear Plate Counterweight Engine Hood Valve Cover Hose Cover Hydraulic Tank Cover Isolation Mats Tool Case Boom Dipper Arm Connecting Link Cab Mounting Cab Cab Cab Cab (Cont.) Cab (Cont.) Cab Interior Cover Trim Cab Interior Cover Trim Main Wiring Harness Front Window Cab Windows Cab Sliding Window Cab Door Cab Door Rotating Beacon (Option) Heater Operator s Seat Operator s Seat Blower driver seat Blower Mounting Kit driver seat Diesel Engine Engine Mounts TABLE OF CONTENTS Cylinder Head Cylinder Block Seal Crankshaft Oil Pan Camshaft Crankshaft & Pistons Oil Lubrication System Cooling System Fuel Injection System Fuel Tank fuel tank Fuel System Throttle Assembly Cooling System Air Intake System Exhaust System Hydraulic Pump Drive Hydraulic Tank Oil Cooler Drive Motor Swivel Joint Hydraulic Pump External Parts Hydraulic Pump Internal Parts Turntable Drive Unit Swivel Drive Valve Block Valve Block Pilot Oil Supply Unit Valve Block Manifold Block Reversing Valve Hand Levers Dozer Blade Valve Dozer Blade Valve Pilot Valve Travel Auxiliary Hydraulics Pilot Valve /3 Valve (Option) Solenoid Valve (Option) ISO/SAE Pattern Valve (Option) Boom Cylinder Boom Cylinder Dipper Arm Cylinder Dipper Arm Cylinder Bucket Cylinder Swivel Cylinder Dozer Blade Cylinder Hydraulic Pump Hose Installation Oil Cooler Hose Installation Printed in U.S.A /CP0707

4 Turntable Drive Unit Hose Installation Turntable Drive Unit Hose Installation Travel Motor Hose Installation Valve Hose Installation Valve Hose Installation Pilot Oil Supply Hose Installation Swivel Cylinder Hose Installation Dozer Blade Cylinder Hose Installation. 108 Boom Hose Installation Hand Levers Hose Installation ISO/SAE Valve Hose Installation (Option)111 Pilot Pressure Hose Installation Electrical Auxiliary Hose Installation (Option) 113 Engine Wire Harness Right Armrest Wire Harness Right Armrest Wire Harness Left Armrest Wire Harness Chassis Wire Harness Relay Box Relay Box Installation Chassis Headlight Boom Headlight Cab Headlight (Option) Battery Horn Tools Numerical Index TABLE OF CONTENTS /CP Printed in U.S.A

5 GENERAL INFORMATION Decal location 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. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations. To ensure proper selection of the correct replacement decals, compare all of the various closeup location drawings to your machine before starting to refinish the unit. Then circle each decal shown (applicable to your machine) while checking off its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal. NOTE:Refer to the SAFETY chapter of the Operator's Manual for the specific information provided on all of the various safety decals furnished in the decal kit(s). NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new decal. To apply, 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. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth out the decal surface. CAUTION ALWAYS follow safety precautions on decals. Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE all applicable decals are affixed to your unit. DECAL LOCATIONS PAINT NOTICE Use this list to order paint for refinishing: qts. Construction Yellow (GEHL) qts. Light Gray (GEHL) qts. Dark Gray (GEHL) (12.8 oz. Spray Cans) Yellow (GEHL) (12.8 oz. Spray Cans) Dark Gray (GEHL) (12.8 oz. Spray Cans) Light Gray (GEHL) The decal kit for the Compact Excavator is listed below: Part Description & Quantity Decal Kit Diesel Fuel Hydraulic Oil Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan Travel Left Travel Right WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface (2 places) WARNING - Avoid Injury (2 places) Dozer Blade - Up/Down Right Joystick Control Left Joystick Control Control Pattern Left Graphic (SN AB00988 and before) Left Graphic (SN AB00989 and up) Right Graphic Engine Compartment Latch Hydraulics Compartment Latch GEHL GEHL (2 places) GEHL Protective Structure Lifting Capacity Warning - Hydraulic Reservoir Lubrication Printed in U.S.A /CP0707

6 DECAL LOCATIONS Both Sides 5 Both Sides /CP Printed in U.S.A

7 DECAL LOCATIONS Overhead Panel Decals - positioning may vary by model and cabin style Printed in U.S.A /CP0707

8 The decal listing has been repeated for your convenience: Part Description & Quantity Decal Kit Diesel Fuel Hydraulic Oil Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan Travel Left Travel Right WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface (2 places) WARNING - Avoid Injury (2 places) Dozer Blade - Up/Down Right Joystick Control Left Joystick Control Control Pattern Left Graphic (SN AB00988 and before) Left Graphic (SN AB00989 and up) Right Graphic Engine Compartment Latch Hydraulics Compartment Latch GEHL GEHL (2 places) GEHL Protective Structure Lifting Capacity Warning - Hydraulic Reservoir Lubrication DECAL LOCATIONS /CP Printed in U.S.A

9 DECAL LOCATIONS Printed in U.S.A /CP0707

10 502 - UNDERCARRIAGE, RUBBER TRACK UNDERCARRIAGE TRACK TENSIONER COMPLETE 2 See page 12 for individual components VALVE RING BOTTOM ROLLER 10 See page 15 for individual components SUPPORTING ROLLER 2 See page 11 for individual components TRAVELING GEAR SPROCKET RUBBER TRACK SWIVEL JOINT II 1 (SN AB00478 and up) See page 73 for individual components SWIVEL JOINT 1 (SN AB00477 and before) See page 73 for individual components TURNTABLE SPROCKET GUARD LT SPROCKET GUARD RT COVER COVER COVER COVER LW SPRING B14 DIN SEAL KIT/TRACK TENSION CYLINDER PLUG GREASE ZERK (9mm HEX HEAD) PROTECTION CAP SHCS M X ZO HB M X 70 C10.9 ZO HLN INS M ZO SHCS M X ZO SHCS M X ZO SHCS M X ZY CS M X 30 C10.9 ZO SHCS M X ZO CS M X 25 C10.9 ZO CS M X 20 C8.8 ZO SHCS M8-1.2 X ZO WASHER TENSION CYLINDER WASHER/ROUND HI-TENS LOCKWASHER S WASHER WASHER GR A WASHER/NORD-LOCK NL WASHER SPRINGS TENSION ROLLER SEAL KIT/BOTTOM ROLLER SEAL (2.0M) /CP Printed in U.S.A

11 502 - UNDERCARRIAGE, STEEL TRACK UNDERCARRIAGE TRACK TENSIONER COMPLETE 2 (SN AB01588 and up) See page 13 for individual components * TRACK TENSIONER COMPLETE 2 (SN AB01587 and before) See page 13 for individual components TENSION CYLINDER VALVE RING SUPPORTING ROLLER 2 See page 11 for individual components TRAVELING GEAR SPROCKET STEEL TRACK STEEL TRACK/RUBBERIZED TURNTABLE SPROCKET GUARD LT SPROCKET GUARD RT COVER COVER COVER COVER LW SPRING B14 DIN SEAL KIT/TRACK TENSION CYLINDER PLUG GREASE ZERK (9mm HEX HEAD) PROTECTION CAP SHCS M X ZO HB M X 70 C10.9 ZO HLN INS M Z SHCS M X ZO SHCS M X ZO FHCS M X ZO CS M X 30 C10.9 ZO SHCS M X ZO CS M X 25 C10.9 ZO CS M X 20 C8.8 ZO SHCS M8-1.2 X ZO WASHER WASHER WASHER/ROUND HI-TENS LOCKWASHER S WASHER WASHER GR A WASHER/NORD-LOCK NL WASHER SPRINGS TENSION ROLLER 2 (SN AB01588 and up) TENSION ROLLER (SN AB01587 and before) 2 * Replaced by P/N for service. Printed in U.S.A /CP0707

12 502 - UNDERCARRIAGE, STEEL TRACK BOTTOM ROLLER Individual Components on page SWIVEL JOINT II 1 (SN AB00478 and up) See page 73 for individual components SWIVEL JOINT 1 (SN AB00477 and before) See page 73 for individual components CHAIN GUARD LT CHAIN GUARD RT SEAL KIT CHAIN LINK STEEL PIN/MASTER STEEL PIN SEAL (2.0M) /CP Printed in U.S.A

13 502 - SUPPORTING ROLLER SUPPORTING ROLLER LOCKWASHER S SET SCREW BEARING SEAL WASHER WASHER SHCS M5-0.8 X 16 C8.8 ZY 3 Printed in U.S.A /CP0707

14 502 - TRACK TENSIONER, RUBBER TRACK TRACK TENSIONER COMPLETE VALVE RING SHCS M X ZY WASHER/ROUND HI-TENS SPRING TENSION ROLLER TENSION CYLINDER SEAL KIT/TENSION CYLINDER SEAL KIT/TENSION ROLLER BUSHING BRACKET SHAFT PLUG SCREW WASHER /CP Printed in U.S.A

15 502 - TRACK TENSIONER, STEEL TRACK SN AB01588 AND UP TRACK TENSIONER COMPLETE VALVE RING SHCS M X ZY WASHER/ROUND HI-TENS SPRING TENSION ROLLER TENSION CYLINDER SEAL KIT/TENSION CYLINDER SEAL KIT/TENSION ROLLER BUSHING BRACKET SHAFT PLUG SCREW WASHER 8 Printed in U.S.A /CP0707

16 502 - TRACK TENSIONER, STEEL TRACK SN AB01587 AND BEFORE TRACK TENSIONER COMPLETE VALVE RING SHCS M X ZY WASHER/ROUND HI-TENS SPRING TENSION ROLLER TENSION CYLINDER SEAL KIT/TENSION CYLINDER SEAL KIT/TENSION ROLLER BUSHING BRACKET SHAFT PLUG SCREW WASHER /CP Printed in U.S.A

17 502 - BOTTOM ROLLER BOTTOM ROLLER BUSHING SEAL KIT PLUG 1 Printed in U.S.A /CP0707

18 502 - DOZER BLADE (5, 7, 8) x DOZER BLADE/PRE-ASSEMBLED PIN PIN PIN BUSHING PIN/SPRING M8 X 80 ZO GREASE ZERK (9mm HEX HEAD) CAP BUSHING PIN SEAL BLADE CYLINDER/PRE-ASSEMBLED See page 98 for individual components /CP Printed in U.S.A

19 502 - CHASSIS TURNTABLE DRIVE UNIT COMPLETE 1 (SN AB01533 and up) See page 76 for individual components * TURNING GEAR 1 (SN AB01532 and before) SWING BRACKET TURNTABLE SEAL (2.0M) BUSHING SWIVEL CYLINDER 1 See page 97 for individual components PIN PIN PIN/SPRING M8 x GREASE ZERK (7mm HEX HEAD) CAP O-RING HN SLTD M48-3 ZO PIN/SPRING M8 X 80 ZO SCREW LOCKWASHER S SCREW WASHER/NORD-LOCK NL WASHER GR A CS M X 25 C10.9 ZO LOCKWASHER S FHCS M X ZO 10 (SN AB01533 and up) CS M X 35 C10.9 ZO 10 (SN AB01532 and before) WASHER BUSHING PIN SEAL PIN SEAL POP RIVET A4 x WASHER GR A15 DIN WASHER WASHER GR A REFLECTOR BRACKET AIR INTAKE FILTER SCREW HEX NUT M WASHER GR A PIN 1 * Replaced by P/N for service. Printed in U.S.A /CP0707

20 502 - CHASSIS COVERS COVER COVER COVER COVER COVER SHCS M X 20 C8.8 ZY WASHER SPACER SEAL FOAM (7.0M) FASTEN PLATE (SN AB02930 and up) COVER 1 (SN AB02930 and up) WASHER (SN AB02930 and up) CS M X 30 C8.8 ZY (SN AB02930 and up) /CP Printed in U.S.A

21 502 - CHASSIS LUBRICATION LUBRICATION ZERK BLOCK CS M6-1.0 X 30 C8.8 ZO LOCKWASHER S GREASE ZERK (7mm HEX HEAD) CAP SCREW JOINT LUBRICATION TUBE (1.0M) HP HOSE NUT WASHER SCREW JOINT ELBOW SET SCREW 1 Printed in U.S.A /CP0707

22 502 - REAR PLATE REAR WALL COVER ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT SHCS M X 35 C10.9 ZY WASHER WASHER GR A SHCS M X 25 C8.8 ZY BRACKET HEX SCREW LOCKWASHER S LOCKWASHER S SCREW CAGE NUT M FHCS M5-0.8 X 16 C8.8 ZY ISOLATION MAT ISOLATION MAT WASHER /CP Printed in U.S.A

23 502 - COUNTERWEIGHT COUNTERWEIGHT WASHER/ROUND HI-TENS CS M X 70 C8.8 ZY BRACKET BRACKET SCREW LOCKWASHER S LW SPRING 6 DIN CS M X 25 C8.8 ZY WASHER WASHER GR A CABLE (3.2M) SCREW HN M6-1 C8 ZY CABLE LOCK COVER RETAINER REFLECTOR POP RIVET A4 X CS M X 45 C8.8 ZO WASHER WASHER WASHER GR A6.4 ZO DIN BELLOWS ANGLE 1 Printed in U.S.A /CP0707

24 502 - ENGINE HOOD ENGINE HOOD ISOLATION MAT/HOOD HINGE PLATE HINGE BRACKET CS M X 30 C8.8 ZY WASHER WASHER PNEUMATIC SPRING HN M5-0.8 C8 ZY HANDLE FHCS M14-2 X 16 C8.8 ZY HN M4-0.7 C8 ZY LATCH WASHER CS M X 16 C8.8 ZY RUBBER EXTRUSION (2.65M) RUBBER EXTRUSION (1.3M) /CP Printed in U.S.A

25 502 - VALVE COVER VALVE COVER SCREEN FRAME HLN INS M8 8 ZO D PNEUMATIC SPRING HINGE HINGE ISOLATION MAT PLATE CS M X 30 C8.8 ZY WASHER WASHER HN M C8 ZO CAGE NUT M HANDLE FHCS M14-2 X 16 C8.8 ZY HEX NUT M LATCH CS M X 16 C8.8 ZY BRACKET HEX SCREW SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN BRACKET CABLE/VALVE COVER RELEASE SCREW LN INS M6-1 C8 ZY CABLE LOCK WASHER 8.4 ST A2C BRACKET RUBBER STOP WASHER HN M16-1 C8 ZY FHCS M6-1 X 20 C8.8 ZY CAGE NUT M BELLOWS ISOLATION MAT ANGLE 1 (SN AB02253 and before) ANGLE 1 (SN AB02254 and up) BRACKET 1 Printed in U.S.A /CP0707

26 502 - HOSE COVER HOSE COVER (1.0m) ANTI-SLIDE STRIP (1.9M) RUBBER EXTRUSION (0.96M) WASHER WASHER 8.4 ST A2C CAGE NUT M BRACKET PLUG GREASE GUN BRACKET 1 (SN AB01264 and up) CS M X 25 C8.8 ZY 1 (SN AB01264 and up) HEX SCREW 1 (SN AB01263 and before) CS M X 25 C8.8 ZY /CP Printed in U.S.A

27 502 - HYDRAULIC TANK COVER TANK COVER SHCS M X 20 F8.8 ZY LOCKWASHER S WASHER GR A BRACKET CAGE NUT M CS M X 25 C8.8 ZY SPACER WASHER GR A HEX SCREW SHCS M X 25 F8.8 ZY 1 Printed in U.S.A /CP0707

28 502 - ISOLATION MATS ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT/REAR PLATE ISOLATION MAT/TANK ISOLATION MAT/REAR PLATE ISOLATION MAT/REAR PLATE /CP Printed in U.S.A

29 502 - TOOL CASE TOOL BOX BRACKET/TOOL BOX BRACKET/TOOL BOX CS M X 16 C8.8 ZY WASHER WASHER GR A LN INS M6-1 C8 ZY CS M6-1 X 16 C8.8 ZY CAGE NUT M WASHER 6 Printed in U.S.A /CP0707

30 502 - BOOM (15, 16) (8, 17, 18) x BOOM/PRE-ASSEMBLED TUBE TUBE TUBE TUBE HB M X 40 C8.8 ZY TUBE CLAMP PIN SEAL COVER HB M6-1 X 35 C8.8 ZY TUBE CLAMP COVER BUSHING TUBE GREASE ZERK (7mm HEX HEAD) CAP RING/SNAP SB BUSHING PIN WASHER HN SLTD M48-3 F8 ZY PIN/SPRING M8 x PIN SEAL LN INS MS-1.25 C8 ZY BOOM CYLINDER 1 (SN AB01490 and up) See page 92 for individual components BOOM CYLINDER 1 (SN AB01489 and before) See page 93 for individual components PIN PIN SHCS M X 90 C8.8 ZY /CP Printed in U.S.A

31 502 - DIPPER ARM (5, 6, 7, 10, 11, 22, 23, 29) x PRE-ASSEMBLED DIPPER ARM/ 1 SHORT (1500mm) PRE-ASSEMBLED DIPPER ARM/ 1 LONG (1800mm) LN INS M C8 ZY SHCS M X 90 C8.8 ZY WASHER BUSHING SEAL HN SLTD M48-3 F8 ZY PIN/SPRING M8 X 80 ZO GREASE ZERK (7mm HEX HEAD) CAP SCREW JOINT SCREW JOINT (SN AB and up) SCREW JOINT 2 (SN AB and before) COUPLER COUPLER (SN AB and up) QUICK COUPLER 1 (SN AB and before) COUPLER COUPLER (SN AB and up) QUICK COUPLER (SN AB and before) PROTECTION CAP PROTECTION CAP 1 (SN AB and up) PROTECTION CAP 1 (SN AB and before) PROTECTION CAP PROTECTION CAP 1 (SN AB and up) PROTECTION CAP 1 (SN AB and before) BUSHING RING SNAP SB PIN PIN KIT/DIPPER ARM CYLINDER 1 (SN AB01490 and up) See page 94 for individual components KIT/DIPPER ARM CYLINDER 1 (SN AB01489 and before) See page 95 for individual components PIN LYNCH PIN PIN SEAL PIN 1 Printed in U.S.A /CP0707

32 502 - CONNECTING LINK (6, 7) (5, 14, 20, 22) x CONNECTING LINK RT CONNECTING LINK LT ARTICULATING LINK ASY 1 (STANDARD = 380mm) ARTICULATING LINK ASY 1 (OPTIONAL = 330mm) BUSHING GREASE ZERK (7mm HEX HEAD) CAP PIN LYNCH PIN PIN PIN COVER LOCKWASHER S SHCS M X 30 F12.9 ZY PIN GASKET BUCKET CYLINDER 1 See page 96 for individual components PIN SHCS M X 90 C8.8 ZY LN INS M C8 ZY PIN BUSHING BUSHING LOCKWASHER SB /CP Printed in U.S.A

33 502 - CAB MOUNTING CUSHION HB M X 100 C8.8 ZY WASHER/ROUND HI-TENS CS M X 30 C8.8 ZY CS M X 25 C8.8 ZY WASHER GR A LOCKWASHER S SUPPORT PLATE SUPPORT PLATE WASHER GR A NUT HB M F8 ZY 4 Printed in U.S.A /CP0707

34 502 - CAB CAB SN AND UP CAB FRAME MIRROR PLUG PLUG PIN BRACKET PLATE WASHER G DOOR LOCK WIPER MOTOR COVER WIPER ARM WIPER BLADE CLIPS WATER HOSE (4.2M) RETROFIT KIT/RT MIRROR NOZZLE NON-RETURN VALVE DOME LIGHT BULB SCREW MIRROR LT CS M6-1 X 16 C8.8 ZY WASHER COVER RADIO (SN AB02743 and up) RADIO (SN AB02742 and before) FRAME ANTENNA SPEAKER NUT COVER COVER COVER HEAT SHRINK SLEEVE (0.05M) BRACKET COLLAR SHCS M CORD WASHER HEX SCREW WASHER WASHER MIRROR RT RETROFIT KIT/LT MIRROR /CP Printed in U.S.A

35 502 - CAB CAB SN AND BEFORE CAB FRAME 1 (SN AB01940 and up) CAB FRAME 1 (SN AB01939 and before) ASHTRAY 1 (CAB SN and before) PLUG PLUG PIN BRACKET PLATE WASHER G DOOR LOCK 1 (CAB SN ) DOOR LOCK 1 (CAB SN and before) WIPER MOTOR COVER/WIPER MOTOR WIPER ARM WIPER BLADE CLIPS WATER HOSE (0.6M) WATER HOSE (4.2M) NOZZLE NON-RETURN VALVE DOME LIGHT BULB SCREW MIRROR LT CS M6-1 X 16 C8.8 ZY WASHER COVER RADIO (SN AB02743 and up) RADIO (SN AB02742 and before) FRAME ANTENNA SPEAKER NUT COVER COVER COVER 1 (SN AB00989 and up) COVER 1 (SN AB00988 and before) CORD WASHER 1 Printed in U.S.A /CP0707

36 502 - CAB CAB SN AND BEFORE HEX SCREW WASHER WASHER HEAT SHRINK SLEEVE (0.05M) BRACKET MIRROR RT RETROFIT KIT/LT MIRROR RETROFIT KIT/RT MIRROR COLLAR 2 (SN AB01940 and up) SHCS M6 2 (SN AB01940 and up) MIRROR (SN AB01940 and up) /CP Printed in U.S.A

37 502 - CAB HOSE PROFILE (2.4M) RUBBER PROFILE (4.6M) RUBBER PROFILE (1.7M) LOCK 1 (FRONT LT, REAR RT) LOCK 1 (FRONT RT, REAR LT) SCREW BRACKET LT BRACKET RT CS M6-1 X 30 C8.8 ZY WASHER RESILIENT PAD RUBBER PLUG SCREW FASTENING STRAP 1 (CAB SN and before) LN INS M6-1 C8 ZY 2 (CAB SN and before) CIGARETTE LIGHTER VENT VENT WASHER ADHESIVE TAPE (0.4M) BRACKET 1 (SN AB00989 and up) BRACKET 1 (SN AB00988 and before) SCREW VENT PLATE CS M6-1 X 12 C8.8 ZY 2 Printed in U.S.A /CP0707

38 502 - CAB (CONT.) SN AB01951 AND UP SHIELD PAN HEAD TAP SCREW GUTTER BRACKET SCREW FOOT REST CS M X 16 C8.8 ZY WASHER GR A8.4 ZO DIN FOOT REST SCREW LN INS M C8 ZY ADHESIVE TAPE (0.8M) WASHER LN INS M6-1 C8 ZY FOAM STRIP (1.0M) EDGE PROTECTION (0.1M) SHEET METAL BRACKET /CP Printed in U.S.A

39 502 - CAB (CONT.) SN AB01950 AND BEFORE SHIELD PAN HEAD TAP SCREW GUTTER 1 (SN AB00989 and up) GUTTER 1 (SN AB00988 and before) BRACKET 1 (SN AB00989 and up) BRACKET 1 (SN AB00988 and before) SCREW FOOT REST CS M X 16 C8.8 ZY WASHER GR A8.4 ZO DIN FOOT REST SCREW LN INS M C8 ZY BRACKET ADHESIVE TAPE (0.8M) WASHER LN INS M6-1 C8 ZY FOAM STRIP (1.0M) EDGE PROTECTION (0.1M) 1 Printed in U.S.A /CP0707

40 502 - CAB INTERIOR COVER TRIM SN AB01951 AND UP FLOOR MAT COVER VALVE COVER COVER COVER COVER MAT/ROOF COVER MAT/REAR WALL COVER RIVET 11mm RIVET 20mm FLOOR MAT/PART /CP Printed in U.S.A

41 502 - CAB INTERIOR COVER TRIM SN AB01950 AND BEFORE FRONT COVER TRIM COVER VALVE COVER COVER COVER COVER MAT/ROOF COVER G MAT/REAR WALL COVER RIVET 11mm RIVET 20mm FLOOR MAT/PART FLOOR MAT/PART REAR COVER TRIM SCREW 8 Printed in U.S.A /CP0707

42 502 - MAIN WIRING HARNESS WIRING HARNESS/MAIN (SN AB01951 and up) WIRING HARNESS/MAIN (SN AB01950 and before) CABLE CLIP TUBING SLIT (0.2M) /CP Printed in U.S.A

43 502 - FRONT WINDOW FRONT WINDOW FRONT WINDOW TINTED WINDOW FRAME/LOWER WINDOW FRAME/UPPER SCREW FHCS M X 20 C8.8 ZY WASHER RUBBER WASHER RUBBER WASHER WASHER GR A8.4 ZO DIN HEX NUT/DOMED CAP M PVC WASHER EDGE PROTECTION (1.0M) SUN VISOR 1 (CAB SN LK-74 and up) SUN VISOR 1 (CAB SN LK-73 and before) SCREW BRACKET BRACKET SUN VISOR COMPLETE RUBBER PLUG PVC WASHER 2 Printed in U.S.A /CP0707

44 502 - CAB WINDOWS & FRONT WINDOW/TOP FRONT WINDOW/LOWER FRONT WINDOW/LOWER TINTED PVC WASHER RUBBER WASHER RUBBER WASHER NUT WASHER HN M C8 ZY RUBBER PROFILE (1.75M) SIDEPANE LT SIDEPANE LT TINTED UPPER SIDEPANE UPPER SIDEPANE TINTED RUBBER PROFILE (1.5M) REAR WINDOW 1 (SN AB01950 and before) REAR WINDOW 1 (SN AB01951 and up) REAR WINDOW TINTED 1 (SN AB01951 and up) FRONT WINDOW COMPLETE/ 1 LOWER RUBBER PROFILE (0.87M) /CP Printed in U.S.A

45 502 - CAB SLIDING WINDOW SLIDING WINDOW COMPLETE WINDOW/SLIDING WINDOW/SLIDING TINTED WINDOW/STATIONARY WINDOW/STATIONARY TINTED LOCK 1 Printed in U.S.A /CP0707

46 502 - CAB DOOR SN AB01951 AND UP CAB DOOR COMPLETE LOCK W/O KEYS SCREW LN INS M C8 ZY HANDLE SHIM SHIM KEYS W/O LOCK COVER RUBBER PROFILE (3.30M) DOOR WINDOW DOOR WINDOW TINTED LN INS M C8 ZY WASHER CS M6-1 x 20 C8.8 ZY WASHER FLAT HEAD SCREW LN INS M5-0.8 C8 ZY WASHER G DOOR LATCH G RUBBER WASHER STICKER DECAL /CP Printed in U.S.A

47 502 - CAB DOOR SN AB01950 AND BEFORE CAB DOOR COMPLETE 1 (SN AB00989 and up) CAB DOOR COMPLETE 1 (SN AB00988 and before) LOCK W/O KEYS SCREW LN INS M C8 ZY HANDLE SHIM SHIM KEYS W/O LOCK COVER RUBBER PROFILE (3.30M) DOOR WINDOW DOOR WINDOW TINTED LN INS M C8 ZY DOOR TRIM CS M6-1 x 20 C8.8 ZY WASHER FLAT HEAD SCREW LN INS M5-0.8 C8 ZY WASHER G DOOR LATCH RIVET 11mm STICKER DECAL WASHER G RUBBER WASHER 1 Printed in U.S.A /CP0707

48 502 - ROTATING BEACON (OPTION) LAMP COMPLETE LENS HALOGEN LIGHT BULB WASHER GR A8.4 ZO DIN LN INS M C8 ZY COVER LAMP ATTACHMENT RETROFIT KIT SHCS M5-0.8 X 20 C8.8 ZO BLIND RIVET NUT BRACKET SYMBOL/TURNING LIGHT LIGHT SWITCH /CP Printed in U.S.A

49 502 - HEATER CAB HEATER CAB HEATER BRACKET WASHER SEAL FOAM (0.7M) CS M X 16 C8.8 ZY WASHER WASHER 8.4 ST A2C CAGE NUT M CS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN SUPERFLEX HOSE (1.5M) STRAP HEATER HOSE (3.5M) HEATER HOSE (3.5M) HOSE CLAMP HOSE COVER UNION NUT A1 12VERZ WASHER ANGLE SCREW JOINT NOZZLE SUPERFLEX HOSE (1.5M) VALVE BOWDEN CONTROL KNOB CLIP RUBBER BUSHING REDUCTION JOINT CONNECTOR SCREW JOINT RUBBER BUSHING 1 Printed in U.S.A /CP0707

50 502 - OPERATOR S SEAT SN AB01951 AND UP PROFILE BUFFER/RUBBER-METAL FIXING PLATE OPERATOR SEAT (CLOTH) SEATBELT HEX SCREW WASHER WASHER LIMIT CONTROL LEVER CONSOLE ARMREST TUBE CONSOLE-RT CONSOLE-LT PLUG PLUG NUT SPRING NUT/HEX DOMED CAP M TUBE LN INS M C8 ZY LOCKWASHER HB M X 120 C8.8 ZY WASHER KNOB D40mm SHCS M X 30 C8.8 ZY PIN PIN PIN WASHER GR A LN INS M C8 ZY MICROSWITCH CAGE NUT M WASHER NUT WASHER 8.4 ST A2C LW M8 RZO HN M C8 ZY SHSS CP M X 12 C45H SCREW/C SUNK HD M5 X CS M X 16 C8.8 ZY ROUND HEAD SCREW BRACKET SCREW SHEET METAL SHCS M X 90 C8.8 ZY NECK SUPPORT CUSHION SEAT UPHOLSTERY CLIP-ON NUT /CP Printed in U.S.A

51 502 - OPERATOR S SEAT SN AB01950 AND BEFORE PROFILE BUFFER/RUBBER-METAL FIXING PLATE OPERATOR SEAT (CLOTH) SEATBELT HEX SCREW WASHER WASHER LIMIT CONTROL LEVER CONSOLE ARMREST HANDLE CONSOLE RT CONSOLE LT COVER PLUG NUT SPRING TUBE PIN NUT/HEX DOMED CAP M LOCKWASHER CS M6-1 X 12 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN SHCS M X 30 C8.8 ZY PIN PIN PIN WASHER GR A LN INS M C8 ZY MICROSWITCH CAGE NUT M WASHER NUT WASHER 8.4 ST A2C LW M8 RZO HN M C8 ZY SHSS CP M X 12 C45H SCREW/C SUNK HD M5 X CS M X 16 C8.8 ZY BRACKET NECK SUPPORT CUSHION SEAT UPHOLSTERY CLIP-ON NUT 8 Printed in U.S.A /CP0707

52 502 - BLOWER BLOWER BRACKET/STANDARD SEAT HARNESS WIRING SCREW LOCKWASHER S WASHER GR A4.3 ZO DIN SEAL FOAM (1.0M) KNOB ON-OFF SWITCH BLOWER LEVEL DECAL /CP Printed in U.S.A

53 502 - BLOWER MOUNTING KIT BLOWER MOUNTING CASE BRACKET BRACKET VENT KNOB M8 X BRACKET/CAB HEATING 1 Printed in U.S.A /CP0707

54 502 - DIESEL ENGINE DIESEL ENGINE (4TNE88-ENSW) GASKET SET (4TNE88-NSW) V-BELT ENGINE OIL FILTER SENDER/OIL PRESSURE SWITCH/THERMOSTAT (110 C) SEAL SOLENOID STOP STARTER ALTERNATOR O-RING COOLING FAN /CP Printed in U.S.A

55 502 - ENGINE MOUNTS ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET SHCS M X 25 F8.8 ZY LOCKWASHER S WASHER GR A HYDRO SUSPENSION HEX SCREW WASHER WASHER CS M X 35 C10.9 ZY WASHER EXTERNAL TOOTH LOCKWASHER WASHER 8.4 ST A2C CORD 1 Printed in U.S.A /CP0707

56 502 - CYLINDER HEAD CYLINDER HEAD (4TNE88-ENSW) CYLINDER HEAD (4TNE88-NSW) VALVE PLUG INTAKE VALVE EXHAUST VALVE STUD BOLT HEAT SHIELD SEAL RING SEAL SEAL KIT SPRING SPACER CLAMP VALVE CAP BEARING SUPPORT VALVE COVER HEADNUT O-RING GASKET/HEAD COVER VENTING HOSE OIL COVER O-RING SEAL SCREEN GUIDE /CP Printed in U.S.A

57 502 - CYLINDER BLOCK GASKET/CYLINDER HEAD CYLINDER HEAD SCREW COVER PLUG BUSHING PLUG AXIAL BEARING AXIAL BEARING (OS=0.25) MAIN BEARING SET MAIN BEARING SET (US=0.25) 5 Printed in U.S.A /CP0707

58 502 - SEAL CRANKSHAFT GEARBOX W/SHAFT SEAL SHAFT SEAL O-RING SCREW GASKET INJECTION PUMP SCREW OIL FILLER PIPE O-RING OIL COVER FLYWHEEL HOUSING PIPE LINE O-RING STUD BOLT NUT O-RING COVER SEAL FITTING PIN RUBBER PLUG /CP Printed in U.S.A

59 502 - OIL PAN OIL PAN ASY OIL DRAIN PLUG O-RING SCREW SCREW SCREW 2 Printed in U.S.A /CP0707

60 502 - CAMSHAFT CAMSHAFT ASY LIFTER PUSH ROD SLIDE BEARING GEAR (4TNE88-NSR/W) GEAR (4TNE88-ENSR/W) FLANGE (4TNE88-ENSR/W) SCREW (4TNE88-ENSR/W) SPRING RING HEXAGON NUT GEAR /CP Printed in U.S.A

61 502 - CRANKSHAFT & PISTONS CRANKSHAFT ASY GEAR FITTING KEY CYLINDER PIN PULLEY FLYWHEEL PISTON (4TNE88-NSR/W) PISTON (4TNE88-NSR/W OS=0.25) PISTON (4TNE88-ENSR/W) PISTON (4TNE88-ENSR/W OS=0.25) PIN LOCK RING CONNECTING ROD BUSHING SCREW BEARING CONNECTING ROD BEARING 4 (US=0.25) SEAL SHAFT SEAL PISTON RING PISTON RING (OS=0.25) 4 Printed in U.S.A /CP0707

62 502 - OIL LUBRICATION SYSTEM OIL DIPSTICK OIL DIPSTICK TUBE SENDER/OIL PRESSURE OIL SUMP GASKET OIL SUMP LUBRICATION OIL PUMP VALVE O-RING FILTER BASE GASKET FILTER BRACKET NUT ENGINE OIL FILTER SCREW SEAL RING (4TNE88-NSR/W) SEAL RING (4TNE88-ENSR/W) BANJO BOLT SEAL ENGINE OIL PIPE /CP Printed in U.S.A

63 502 - COOLING SYSTEM WATER PUMP PUMP GASKET (4TNE88-NSR/W) PUMP GASKET (4TNE88-ENSR/W) THERMOSTAT GASKET THERMOSTAT GASKET SEAL SWITCH/THERMOSTAT (110 C) PLUG THERMOSTAT GASKET THERMOSTAT UPPER THERMOSTAT GASKET COOLANT HOSE HOSE CLAMP V-BELT BELT PULLEY FAN SPACER COOLING FAN DRAIN COCK COMPLETE DRAIN COCK THERMOSTAT HOUSING 1 Printed in U.S.A /CP0707

64 502 - FUEL INJECTION SYSTEM INJECTION PUMP (4TNE88-NSW) INJECTION PUMP (4TNE88-ENSW) INJECTION NOZZLE 4 (4TNE88-NSW) INJECTION NOZZLE 4 (4TNE88-ENSW) NOZZLE INSERT (4TNE88-NSW) NOZZLE INSERT (4TNE88-ENSW) NUT NOZZLE SPRING NOZZLE SPRING SEAT PIN STOP PLATE ADJUSTING WASHER CLAMP INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) HOSE PIPE ASY/FUEL OIL OIL LEAK LINE HOSE RING PIECE CAP NON-RETURN VALVE SEAL RING (4TNE88-NSW) SEAL RING (4TNE88-ENSW) CLAMP CLAMP /CP Printed in U.S.A

65 502 - FUEL TANK DIESEL TANK FUEL STRAINER TANK CAP/PLASTIC W/O KEYS SCREW WASHER WASHER GR A13 DIN BRACKET PLUG SCREW JOINT SCREW JOINT TRANSMITTER SCREW LOCKWASHER S WASHER GR A4.3 ZO DIN TUBE SCREW MOUNT HOSE CLAMP SCREW WASHER GR A SCREW JOINT 12L HP HOSE SCREW JOINT PLUG UNION NUT AI 12 VERZ KEYS/PLASTIC CAP 2 Printed in U.S.A /CP0707

66 502 - FUEL SYSTEM BRACKET CS M X 20 C8.8 ZY LOCKWASHER S WASHER GR A FUEL FILTER COMPLETE FUEL FILTER ELEMENT HB M X 70 C8.8 ZY WASHER WASHER TUBE TUBE BRAIDED HOSE GEN NW6 (1.0M) HOSE CLAMP O-RING WATER SEPARATOR COMPLETE WATER TRAP SCREEN O-RING FILTER HOUSING GASKET PUMP ASY/FUEL FEED PACKING /CP Printed in U.S.A

67 502 - THROTTLE ASSEMBLY THROTTLE CABLE THROTTLE LEVER KNOB HEX SCREW SCREW WASHER BRACKET SPRING BRACKET WASHER WASHER 2 Printed in U.S.A /CP0707

68 502 - COOLING SYSTEM BRACKET BRACKET SCREW WASHER LN INS M C8 ZY AIR GUIDING PLATE AIR GUIDING PLATE AIR GUIDING PLATE SEALING TAPE (2.04M) RADIATOR RADIATOR CAP HEX SCREW WASHER WASHER 8.4 ST A2C CAGE NUT M SCREW PUMP SCREW HEX HD TAP B5.5 X RUBBER PROFILE (0.3M) HOSE PROFILE (2.0M) RUBBER EXTRUSION (1.0M) EXPANSION CONTAINER HOSE CLAMP BRAIDED HOSE GEN NW6 (0.5M) FAN PROTECTOR WASHER LN INS M C8 ZY SUB-TANK BRACKET WINDSHIELD WASHING TANK RADIATOR HOSE/UPPER RADIATOR HOSE/LOWER CLAMP COLLAR BRAIDED HOSE GEN NW8 (1.0M) CLAMP NUT SHCS M5-0.8 X 20 C8.8 ZY WASHER GR A5.3 ZO DIN /CP Printed in U.S.A

69 502 - AIR INTAKE SYSTEM AIR FILTER ASY CS M X 25 C8.8 ZY WASHER WASHER LN INS M6-1 C8 ZY DUST VALVE DUST CAP CLAMP ASY AIR FILTER ELEMENT/INNER AIR FILTER ELEMENT/OUTER AIR FILTER NUT DIRT INDICATOR AIR INLET HOSE AIR INLET HOSE INLET MUFFLER HOSE CLAMP WASHER GR A6.4 ZO DIN SUCTION HOSE COLLAR AIR HEATER GASKET GASKET INTAKE MANIFOLD BAFFLE 1 Printed in U.S.A /CP0707

70 502 - EXHAUST SYSTEM MUFFLER SUPPORT RT MUFFLER SUPPORT LT SCREW COLLAR MUFFLER COLLAR CS M X 30 C8.8 ZY WASHER WASHER EXHAUST PIPE/MANIFOLD HEX SCREW GASKET HN M C8 ZY EXHAUST PIPE/MUFFLER CLAMP ASY EXHAUST BRACKET CS M X 25 C8.8 ZY EXHAUST MANIFOLD GASKET/EXHAUST MANIFOLD STUD BOLT NUT STUD BOLT /CP Printed in U.S.A

71 502 - HYDRAULIC PUMP DRIVE COUPLER COMPLETE 1 (SN AB02342 and up) COUPLER COMPLETE 1 (SN AB02341 and before) PUMP BRACKET 1 (SN AB02342 and up) PLUG SHCS M X 30 C10.9 ZY WASHER SCREW LOCKWASHER S WASHER GR A SHCS HS M X 35 F10.9 ZY PUMP BRACKET (SN AB02341 and before) 1 Printed in U.S.A /CP0707

72 502 - HYDRAULIC TANK HYDRAULIC OIL TANK COVER O-RING REDUCTION JOINT SEAL FILTER SHCS M X 20 C8.8 ZY WASHER WASHER ISOLATION MAT SCREW JOINT ANGLE SCREW LOCKWASHER S WASHER GR A HYDRAULIC OIL FILTER COMPLETE HYDRAULIC FILTER ELEMENT SEAL SCREW PRESSURE SWITCH HP HOSE WASHER WASHER GR A13 DIN SCREW SCREW JOINT PLUG UNION NUT AI 12VERZ SCREW JOINT HYDRAULIC OIL STRAINER SCREW JOINT SCREW JOINT NON-RETURN VALVE SCREW JOINT OIL LEVEL GLASS REDUCTION JOINT SCREW JOINT 12L PLATE SCREW COVER SCREW WASHER GR A4.3 ZO DIN LOCKWASHER S O-RING /CP Printed in U.S.A