Compact Excavator. Beginning Serial Number: AC Form No Revision C 07/06 PARTS MANUAL

Transcription

1 603 Compact Excavator Beginning Serial Number: AC02472 Form Revision C 07/06 PARTS MANUAL

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 cabin. ''Right'' and ''left'' are determined from a position sitting on the 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 the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. Metric torque values shown in the illustrations are in Newton-meters and can be 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 > XXXXX) - indicates Serial Numbers up to and including XXXXX. 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 ASSY...Assembly CB...Carriage Bolt CP...Cotter Pin CS...Cap Screw (Hexagon Head) FHCS...Flat Head Cap Screw GR...Grade HB...Hex Bolt HLN...Hex Lock Nut HN...Hex Nut HP...High Pressure INS...Insert LN...Lock Nut LT...Left LW...Lock Washer M...Metric MM/mm...Millimeter OS...Oversize RT...Right SHCS...Socket Head Cap Screw SLTD...Slotted SN...Serial Number or Slotted Nut MM/mm...Millimeter US...Undersize (SN YYYYY >) - indicates Serial Numbers YYYYY and after.

3 Introduction... i Table of Contents...1 Decal Locations...4 Diesel Engine...9 Engine Mounting...10 Cylinder Head, Valve Cover...11 Cylinder Block...12 Seal - Crankshaft...13 Oil Pan...14 Camshaft...16 Crankshaft...17 Lube Oil System...18 Cooling System...19 Fuel Injection System...20 Intake Manifold...21 Exhaust...22 Engine Air Filter...23 Diesel Tank...25 Fuel Supply...27 Throttle...28 Hydraulic Pump Drive...29 Radiator...30 Turntable Drive Unit Installation...31 Turntable Drive Unit...32 Drive Motor Installation...33 Drive Motor...34 Swivel Joint...35 Hydraulic Oil Tank...36 Hydraulic Pump...38 Hydraulic Pump Assembly...39 Control Valve Control Valve Joysticks...42 Control Valve Travelling...44 Control Valve for Auxiliary Hydraulics...45 Dozer Blade Valve...46 Selection Valve /3 Valve (Option)...48 ISO/SAE...49 Valve Block...50 Distribution Block...51 Hydraulic Pump Installation...52 Lifting Boom Installation...54 Boom Cylinder...55 Dipper Arm Installation...57 Dipper Arm Cylinder...58 Bucket Installation (Short Dipper Arm)...59 Bucket Installation (Long Dipper Arm)...60 TABLE OF CONTENTS Bucket Cylinder...61 Swivel Cylinder Installation...62 Boom Offset (Swivel) Cylinder...63 Dozer Blade Installation...64 Dozer Blade Cylinder...65 Auxiliary Hydraulics Installation...66 ISO/SEA Valve Installation (Option)...67 Pilot Pressure Hoses...68 Hydraulic Tank Hoses...69 Battery...70 Dashboard...71 Radio (Option)...73 Relay Box...74 Horn...75 Work Headlight...76 Cab Headlight, Front (Option)...77 Cab Work Light, Rear (Option)...79 Wire Harness Chassis/Engine...80 Wire Harness Chassis/Engine...81 Wire Harness Armrest...82 Wire Harness Switch...83 Wire Harness Headlight...85 Cab Wire Harness...86 Rubber Track...87 Steel Track (Option)...88 Undercarriage, Rubber Track...89 Undercarriage, Steel Track (Option)...90 Track Tensioner, Rubber Track...91 Track Tensioner, Steel Track (Option)...93 Dozer Blade...94 Chassis...95 Lubrication...96 Counterweight...97 Counterweight Option...98 Hood...99 Tank Cover Partition Wall Isolation Mat Chassis Cover Undercarriage Cover Boom Dipper Arm - Short Dipper Arm - Long Cab Mounting Cab Frame Cab Frame Cab Door Windshield Printed in U.S.A /CP0706

4 Cab Windows Cab Trim Cab Harnesses Rotating Beacon (Option) Operator s Seat Mirrors Heater Air Conditioning (Option) Air Conditioning Compressor (Option) Air Conditioning Installation (Option) Tool Set Index Torque Specifications TABLE OF CONTENTS /CP Printed in U.S.A

5 TABLE OF CONTENTS NOTES Printed in U.S.A /CP0706

6 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 WARNING - To Avoid Injury SAE/ISO Control LH Controls SAE/ISO RH Controls SAE/ISO Reflector (2 Places) Lube Chart GEHL (3 places) GEHL Decal/Controls SAE/ISO Lt Decal/Controls SAE/ISO Rt Lift Capacity /CP Printed in U.S.A

7 DECAL LOCATIONS Both Sides Both Sides (except item 21) Printed in U.S.A /CP0706

8 DECAL LOCATIONS 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) Part Description & Quantity WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface (2 places) WARNING - Avoid Injury (2 places) Dozer Blade - Up/Down WARNING - To Avoid Injury SAE/ISO Control LH Controls SAE/ISO RH Controls SAE/ISO Reflector (2 Places) (???this is obsolete) Lube Chart GEHL (3 places) GEHL Decal/Controls SAE/ISO Lt Decal/Controls SAE/ISO Rt Lift Capacity ( ) /CP Printed in U.S.A

9 DECAL LOCATIONS Overhead Decals - positioning may vary Printed in U.S.A /CP0706

10 DECAL LOCATIONS NOTES /CP Printed in U.S.A

11 603 - DIESEL ENGINE BASE ENGINE RADIATOR FAN (SN > AD04628) RADIATOR FAN (SN AD04629 >) STARTER ALTERNATOR CLAMP BAR/ALTERNATOR 1 ADJUSTING GASKET/SEAL KIT WASHER V-BELT WASHER SPACER (SN AD04629 >) CS M6-1X16 C8.8 ZY LOCKWASHER S WASHER GR. A6.4 ZO DIN HB M8-1.25X80 C8.8 ZY 4 Printed in U.S.A /CP0706

12 603 - ENGINE MOUNTING ENGINE MOUNT-FRONT ENGINE MOUNT-REAR 1 (SN > AD04633) ENGINE MOUNT-REAR (SN AD >) ENGINE MOUNT-REAR ENGINE MOUNT-FRONT SHCS M X ZO LOCKWASHER S WASHER/GR A CORD CS M X16 C8.8 ZO CS M10-1.5x20 C8.8 ZY EDGED DISC CS M X35 C10.9 ZO CS M X20 C8.8 ZY WASHER/GR A 13 DIN MOTOR MOUNT /CP Printed in U.S.A

13 603 - CYLINDER HEAD, VALVE COVER CYLINDER HEAD VALVE CAP VALVE VALVE PLUG EXHAUST VALVE SPRING SPACER SEAL VALVE SHAFT SEAL VALVE BRIDGE VALVE WEDGE VALVE SEAL RING O-RING SHAFT SHIELD OIL COOLER VALVE COVER DIAPHRAGM SPRING VALVE COVER SEAL HEADNUT O-RING SEAL RING 1 Printed in U.S.A /CP0706

14 603 - CYLINDER BLOCK CYLINDER HEAD GASKET PLUG PLUG SCREW BUSHING PLUG MAIN BEARING SET AXIAL BEARING SCREW MAIN BEARING SET (US=0.25) AXIAL BEARING (OS=0.25) /CP Printed in U.S.A

15 603 - SEAL - CRANKSHAFT FLYWHEEL HOUSING FITTING PIN ROTARY SHAFT SEAL GEARBOX ROTARY SHAFT SEAL OIL PUMP O-RING O-RING O-RING OIL COVERQ FILLER PIPE O-RING O-RING GASKET INJECTION PUMP 1 Printed in U.S.A /CP0706

16 603 - OIL PAN (SN AC02491 >) OIL SUMP PLUG/DRAIN SEAL SCREW DRAIN COUPLING HOSE CLAMP DRAIN COUPLING FLEXIBLE TUBE (0.5 M) DRAIN KIT /CP Printed in U.S.A

17 603 - OIL PAN (SN > AC02490) OIL SUMP PLUG/DRAIN SEAL SCREW DRAIN COUPLING HOSE CLAMP DRAIN COUPLING FLEXIBLE TUBE (0.50) DRAIN KIT 1 Printed in U.S.A /CP0706

18 603 - CAMSHAFT CAMSHAFT LIFTER PUSH ROD BRACKET GEAR SCREW GEAR FLANGE SPRING RING NUT /CP Printed in U.S.A

19 603 - CRANKSHAFT CRANK SHAFT GEAR PIN FITTING KEY BELT PULLEY O-RING FLYWHEEL PISTON PISTON RING SET (OS=0.25) PIN LOCK RING CONNECTING ROD BUSHING SCREW CONNECTING ROD BEARING BEARING (US=0.25) PISTON PISTON RING SET (OS=0.25) 4 Printed in U.S.A /CP0706

20 603 - LUBE OIL SYSTEM OIL DIPSTICK PIPE LINE ENGINE OIL FILTER O-RING TUBE SENDER/OIL PRESSURE PIPE LINE BANJO BOLT SEAL RING SCREW JOINT /CP Printed in U.S.A

21 603 - COOLING SYSTEM WATER PUMP GASKET/WATER PUMP V-BELT (NON A/C) V-BELT (A/C) BELT PULLEY SEAL GASKET/THERMOSTAT GASKET/THERMOSTAT GASKET/THERMOSTAT THERMOSTAT ENGINE GASKET SEAL HOSE HOSE TEMPERATURE SENSOR FAN SPACER 1 Printed in U.S.A /CP0706

22 603 - FUEL INJECTION SYSTEM INJECTION PUMP INJECTION NOZZLE NOZZLE NUT SPRING - NOZZLE SEAT - NOZZLE SPRING PLATE - STOP PIN ADJUSTING WASHER RUBBER SLEEVE CLAMP CLAMP CLAMP BRACKET PIPE LINE PIPE LINE PIPE LINE PIPE LINE SOLENOID/STOP /CP Printed in U.S.A

23 603 - INTAKE MANIFOLD INTAKE MANIFOLD INTAKE MANIFOLD GASKET ENGINE GASKET PREHEATER 1 Printed in U.S.A /CP0706

24 603 - EXHAUST EXHAUST MANIFOLD EXHAUST MANIFOLD GASKET HEXAGON NUT STUD BOLT SCREW STUD BOLT GASKET EXHAUST HEX SCREW EXHAUST PIPE HN M C8 ZY WASHER SPACER EXHAUST ISOLATION MAT HOSE CLAMP /CP Printed in U.S.A

25 603 - ENGINE AIR FILTER (SN AD04629 >) AIR FILTER COMPLETE 1 (INCLUDES ITEMS 3, 4-7) BRACKET CAP AIR FILTER INNER AIR FILTER OUTER AIR FILTER CONSOLE HOSE AIR INTAKE HOSE AIR INSTAKE DIRT INDICATOR HOSE CLAMP HB M8-1.2 X 45 C 8.8 ZO WASHER 8.4 ST A2C HLN INS M8 8 ZO D CS M X30 C10.9 ZO LOCKWASHER S HOSE CLAMP WASHER/GR A Printed in U.S.A /CP0706

26 603 - ENGINE AIR FILTER (SN > AD04628) AIR FILTER COMPLETE 1 (INCLUDES ITEMS 2-3) AIR FILTER (INCLUDES ITEMS 4-7) BRACKET CAP AIR FILTER INNER AIR FILTER OUTER RING AIR FILTER CONSOLE HOSE AIR INTAKE HOSE AIR INTAKE DIRT INDICATOR HOSE CLAMP HB M8-1.2 X 45 C 8.8 ZO WASHER 8.4 ST A2C HLN INS M8 8 ZO D CS M X30 C10.9 ZO LOCKWASHER S WASHER/GR A REDUCTION PIECE (SN AC02776 >) HOSE CLAMP /CP Printed in U.S.A

27 603 - DIESEL TANK (SN AC02651 >) FUEL TANK FUEL LEVEL SENDER SHCS M5-0.8 X ZO RING/SNAP S WASHER/GR A 5.3 ZO DIN SCREW WASHER WASHER/GR A 13 DIN PLUG SCREW JOINT SOCKET HEAD PIPE PLUG SCREW FUEL STRAINER TANK COVER W/KEYS SHIM (0.5MM) SHIM (1.0MM) SHIM (2.0MM) SHIM (3.0MM) RUBBER PROFILE (1.3M) 1 (SN AC02811 >) BRACKET (SN > AC03168) SINK SCREW LN INS M C8 ZY HEX SCREW SPACER KEYS 1 Printed in U.S.A /CP0706

28 603 - DIESEL TANK (SN > AC02650) FUEL TANK FUEL TRANSMITTER SHCS M5-0.8 X ZO RING/SNAP S WASHER/GR A 5.3 ZO DIN SCREW WASHER WASHER/GR A 13 DIN PLUG SCREW JOINT SCREW SCREW FUEL STRAINER TANK COVER W/KEYS KEYS BRACKET (SN > AC03168) SINK SCREW LN INS M C8 ZY HEX SCREW SPACER /CP Printed in U.S.A

29 603 - FUEL SUPPLY BRAIDED HOSE (0.3M) FUEL LINE BRAIDED HOSE (0.6M) BRAIDED HOSE (1.6M) WATER SEPARATOR ELEMENT GASKET/FILTER HOUSING HOSE CLAMP FUEL FILTER FUEL PUMP HB M8-1.2 X 70 C 8.8 ZO WASHER WASHER BRACKET/DIESEL FILTER HOSE HOSE O-RING TUBE SEAL KIT BLEED LINE HOSE SLEEVE SEAL RING 1 Printed in U.S.A /CP0706

30 603 - THROTTLE THROTTLE CABLE G LEVER KNOB SHCS M6-1 X ZO LOCKWASHER S WASHER GR A6.4 ZO DIN /CP Printed in U.S.A

31 603 - HYDRAULIC PUMP DRIVE COUPLER PUMP CARRIER PLUG SHCS M X ZO WASHER CS M X30 C8.8 ZO LOCKWASHER S WASHER/GR A Printed in U.S.A /CP0706

32 603 - RADIATOR RADIATOR SCREW JOINT HOSE CLAMP PRESHAPED TUBE RADIATOR HOSE RADIATOR SUPPORT RESERVOIR FAN GUARD (SN > AD04628) FAN GUARD (SN AD04629 >) RUBBER METAL BUFFER WASHER RUBBER PROFILE (1.5M) CS M X30 C10.9 ZO LOCKWASHER S WASHER/GR A 10.5 ZO SCREW WASHER/GR A5.3 ZO DIN CLAMP STRAP HLN INST M C8 ZO SPACER (SN AC03594 >) SYNTHETIC HOSE (0.7M) RADIATOR SHROUD (SN AD04629 >) COVER PLATE (SN AD04629 >) HEX SCREW WASHER WASHER 8.4 ST A2C CS M6-1X16 C8.8 ZY WASHER G. A6.4ZO DIN HN M C8 ZO RUBBER PROFILE. 3.0 M 1 ( ) RADIATOR CAP LOCKWASHER S WASHER WASHER/GR A 10.5 ZO (SN > AC3593) /CP Printed in U.S.A

33 603 - TURNTABLE DRIVE UNIT INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE 1 Printed in U.S.A /CP0706

34 603 - TURNTABLE DRIVE UNIT SWIVEL DRIVE SHCS M X ZO WASHER/NORD-LOCK NL SCREW CONNECTION TEE ANGLE SCREW JOINT ANGLE SCREW JOINT SCREW JOINT SWIVEL MOTOR SEAL KIT SEAL KIT SHOCK VALVE ANTICAVIT VALVE KIT BRAKE ASSY TIMER VALVE /CP Printed in U.S.A

35 603 - DRIVE MOTOR INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE 1 Printed in U.S.A /CP0706

36 603 - DRIVE MOTOR DRIVE MOTOR COMPLETE SCREW JOINT SCREW JOINT DRIVE MOTOR SEAL KIT DRIVE MOTOR SEAL BEARING O-RING PLUG LOCK RING BRAKE VALVE CONTROL PLUNGER ANTICAVITATION VALVE ENGINE BRAKE KIT /CP Printed in U.S.A

37 603 - SWIVEL JOINT SWIVEL JOINT II SCREW JOINT SCREW JOINT 12L SCREW JOINT FITTING ELBOW TEE FITTING SCREW JOINT SEAL KIT CS M X30 C10.9 ZO WASHER FITTING 2 Printed in U.S.A /CP0706

38 603 - HYDRAULIC OIL TANK HYDRAULIC TANK SCREW WASHER WASHER/GR A 13 DIN PLUG HOSE CONNECTION COVER PLATE O-RING SHCS M8-1.2 X ZO WASHER WASHER CAGE NUT RETURN FILTER SCREW JOINT MANIFOLD NON RETURN VALVE PRESSURE SWITCH SCREW LOCKWASHER S WASHER/GR A G BREATHER SCREW JOINT OIL TANK CAP (SN > AC14679) OIL TANK CAP (SN AC14680 >) CS M5-0.80X10 C8.8 ZO LOCKWASHER S WASHER/GR A 5.3 ZO DIN SCREW JOINT SCREW JOINT SCREW JOINT SCREW JOINT FITTING ELBOW O-RING HYDRAULIC OIL FILTER SEAL SCREW JOINT ANGLE SCREW JOINT PIPE LINE (0.4M) PLUG NUT SHIM (0.5MM) SHIM (1.0MM) SHIM (2.0MM) SHIM (3.0MM) DECAL /CP Printed in U.S.A

39 603 - HYDRAULIC OIL TANK DECAL CS M10-1.5X25 GC8.8 ZY WASHER/GR A 10.5 ZO ELBOW HYDRAULIC OIL FILTER (SN > AC14679) HYDRAULIC OIL FILTER (SN AC14680 >) 1 1 Printed in U.S.A /CP0706

40 603 - HYDRAULIC PUMP HYDRAULIC PUMP SCREW JOINT SCREW JOINT SCREW JOINT O-RING ADAPTER O-RING ACCUMULATOR SUCTION FLANGE G SCREW WASHER SUCTION FLANGE SHCS M X ZO LOCKWASHER S ELBOW (SN AD03368 >) G TEST PORT (SN AD03368 >) TEE TEST PORT ELBOW (SN > AC03367) REDUCTION JOINT (SN > AC03367) TEST PORT (SN > AC03367) GEAR PUMP G SOLENOID SWITCH G SOLENOID SWITCH SCREW SEAL KIT HYDRAULIC PUMP VALVE /CP Printed in U.S.A

41 603 - HYDRAULIC PUMP ASSEMBLY DRIVE UNIT SWASH PLATE SCREW SCREW BEARING BEARING GEAR PUMP O-RING O-RING O-RING CONTROL HOUSING BEARING VALVE G SOLENOID SWITCH G SOLENOID SWITCH SCREW ROTARY SHAFT SEAL HYDRAULIC PUMP SEAL KIT 1 Printed in U.S.A /CP0706

42 603 - CONTROL VALVE CONTROL BLOCK (SN > AC03886) CONTROL BLOCK (SN AC03887 >) SCREW JOINT SCREW JOINT (SN > AC02927) SCREW JOINT ANGLE SCREW CONNECTION SCREW JOINT SCREW JOINT TEE FITTING ELBOW SEAL KIT CONTROL VALVE FASTEN PLATE RUBBER METAL BUFFER WASHER LN INS M C8 ZY CS M X 20 C8.8 ZY LOCKWASHER WASHER GR A ANGLE BRACKET RUBBER METAL BUFFER 2 (SN > AC02927) RUBBER BUFFER (SN AC02928 >) SCREW JOINT (SN AC02928 >) SCREW JOINT (SN > AC03330) SCREW JOINT (SN AC03331 >) SCREW JOINT (SN AC03331 >) SCREW JOINT /CP Printed in U.S.A

43 603 - CONTROL VALVE BUCKET SEGMENT LIFTING BOOM SEGMENT SEGMENT (LEFT) INPUT SEGMENT SEGMENT (RIGHT) LIFTING BOOM SEGMENT BUCKET SEGMENT SUPPL. HYDRAULIC SEGMENT EXIT SEGMENT SEGMENT DOZER BLADE SEGMENT ROTARY SEGMENT AUXILIARY SEGMENT PRESSURE LIMITING VALVE MAIN PRESSURE LIMITER MAIN PRESSURE LIMITER NUT TIE ROD VALVE CAP SCREW O-RING VALVE CAP VALVE CAP VALVE CAP VALVE CAP VALVE CAP LOADKEEPING VALVE SCREW SHOCKCARTRIDGE RETROFIT KIT 1 Printed in U.S.A /CP0706

44 603 - JOYSTICKS (SN AD05132 >) VALVE UNIVERSAL JOINT SCREW JOINT SHCS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A 6.4 ZO DIN PLUNGER KIT PLUNGER KIT RESTRICTOR PILOT FILTER RESTRICTOR RUBBER CAP SET BELLOWS JOYSTICK JOYSTICK JOYSTICK /CP Printed in U.S.A

45 603 - JOYSTICKS (SN > AD05131) VALVE UNIVERSAL JOINT SCREW JOINT SHCS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A 6.4 ZO DIN PILOT VALVE RUBBER CAP SET RESTRICTOR (SN > AC02644) RESTRICTOR (SN AC02645 >) CONTROL RESTRICTOR SCREW JOINT (SN > AC02908) RESTRICTOR (SN AC02909 >) RESTRICTOR (SN > AC02679) RESTRICTOR (SN AC02680 >) NON-RETURN VALVE (SN AC02645 >) BELLOWS JOYSTICK JOYSTICK JOYSTICK 1 Printed in U.S.A /CP0706

46 603 - CONTROL VALVE TRAVELLING TRAVEL PILOT VALVE COMPLETE RUBBER BELLOWS PLUNGER KITS LT/RT DUMPING PLUNGERS SCREW JOINT SCREW HEX SCREW WASHER WASHER SHCS M X ZO G LEFT JOYSTICK G RIGHT JOYSTICK KNOB SCREW MOUNT CONTROL RESTRICTOR RING/SNAP S WASHER/GR A SCREW ANGLE TEE KIT/PEDAL PLATE /CP Printed in U.S.A

47 603 - CONTROL VALVE FOR AUXILIARY HYDRAULICS CONTROL VALVE HEX SCREW WASHER WASHER ANGLE SCREW JOINT FITTING SEAL FOR TAPPET 1 Printed in U.S.A /CP0706

48 603 - DOZER BLADE VALVE CONTROL LEVER CS M8-1.25X25 C8.8 ZO WASHER WASHER FITTING SEAL FOR TAPPET SCREW JOINT DOZER BLADE LEVER PEDAL WASHER SHCS M X ZO KNOB /CP Printed in U.S.A

49 603 - SELECTION VALVE REVERSING VALVE COMPLETE SCREW JOINT WASHER GR A6.4 ZO DIN SCREW JOINT CS M6-1.00X50 C8.8 ZO LOCKWASHER S NUT COIL SOLENOID ASSEMBLY SEAL KIT 1 Printed in U.S.A /CP0706

50 603-4/3 VALVE (OPTION) /3 VALVE SCREW JOINT ELBOW SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN SOLENOID /CP Printed in U.S.A

51 603 - ISO/SAE G ISO/SAE VALVE SCREW JOINT FITTING HEX SCREW LOCKWASHER S WASHER/GR A 5.3 ZO DIN TEE 1 Printed in U.S.A /CP0706

52 603 - VALVE BLOCK VALVE BLOCK SCREW JOINT SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN /CP Printed in U.S.A

53 603 - DISTRIBUTION BLOCK DISTRIBUTION BLOCK SCREW JOINT SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN FITTING 1 Printed in U.S.A /CP0706

54 603 - HYDRAULIC PUMP INSTALLATION (SN AC03368 >) HP HOSE HP HOSE HP HOSE HOSE CLAMP SUCTION HOSE HOSE CLAMP SUCTION HOSE ELBOW G TEST PORT /CP Printed in U.S.A

55 603 - HYDRAULIC PUMP INSTALLATION (SN > AC03367) HOSE KIT HP HOSE HOSE CLAMP SUCTION HOSE HOSE CLAMP SUCTION HOSE ELBOW REDUCTION JOINT G TEST PORT 3 Printed in U.S.A /CP0706

56 603 - LIFTING BOOM INSTALLATION HP HOSE HP HOSE HP HOSE SCREW JOINT HP HOSE HP HOSE HP HOSE HP HOSE /CP Printed in U.S.A

57 603 - BOOM CYLINDER (SN AC04192 >) BOOM CYLINDER CYLINDER SEAL KIT PISTON ROD GUIDE BUSHING PISTON SET SCREW SCREW JOINT HYDRAULIC PIPE SCREW JOINT CLAMP CS M X20 C8.8 ZO RING/SNAP S WASHER/GR A GUIDE PROTECTING RAIL HEXAGON NUT WASHER/GR A CLAMP FHSCS M8-1.25X20 C8.8ZY BUSHING PIN SEAL DAMPING VALVE 1 Printed in U.S.A /CP0706

58 603 - BOOM CYLINDER (SN > AC004191) BOOM CYLINDER CYLINDER SEAL KIT PISTON ROD GUIDE BUSHING PISTON SET SCREW SCREW JOINT HYDRAULIC PIPE SCREW JOINT CLAMP CS M X20 C8.8 ZO RING/SNAP S WASHER/GR A GUIDE PROTECTING RAIL HEXAGON NUT WASHER/GR A CLAMP DAMPING VALVE BUSHING PIN SEAL /CP Printed in U.S.A

59 603 - DIPPER ARM INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT SHAFT NUT HYDRAULIC PIPE 2 Printed in U.S.A /CP0706

60 603 - DIPPER ARM CYLINDER DIPPER ARM CYLINDER SEAL KIT GUIDE BUSHING PISTON ROD PISTON SET SCREW BUSHING SCREW JOINT BRACKET HOSE CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A PIN SEAL /CP Printed in U.S.A

61 603 - BUCKET INSTALLATION (SHORT DIPPER ARM) HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT HP HOSE HP HOSE HYDRAULIC PIPE HYDRAULIC PIPE 1 Printed in U.S.A /CP0706

62 603 - BUCKET INSTALLATION (LONG DIPPER ARM) HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT HP HOSE HP HOSE HYDRAULIC PIPE HYDRAULIC PIPE /CP Printed in U.S.A

63 603 - BUCKET CYLINDER BUCKET CYLINDER SEAL KIT GUIDE BUSHING PISTON ROD PISTON SET SCREW STEEL BUSHING BRACKET HOSE CS M10-1.5X20 C8.8 ZY WASHER LOCKWASHER S SCREW JOINT 2 Printed in U.S.A /CP0706

64 603 - SWIVEL CYLINDER INSTALLATION HP HOSE (SN > AC03330) HP HOSE (SN > AC03330) HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE (SN AC03331 >) HP HOSE (SN AC03331 >) /CP Printed in U.S.A

65 603 - BOOM OFFSET (SWIVEL) CYLINDER BOOM OFFSET CYLINDER SCREW JOINT (SN > AC03330) PISTON ROD PISTON GLAND SEAL KIT SET SCREW FITTING (SN > AC03330) CAP GREASE ZERK HEXAGON NUT DAMPING SCREW JOINT (SN AC03331 >) SCREW JOINT (SN AC03331 >) SCREW JOINT (SN AC03331 >) BUSHING PIN SEAL 4 Printed in U.S.A /CP0706

66 603 - DOZER BLADE INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE /CP Printed in U.S.A

67 603 - DOZER BLADE CYLINDER DOZER BLADE CYLINDER GUARD SHCS M X ZO LOCKWASHER S WASHER/GR A GREASE ZERK CAP SCREW JOINT PISTON ROD PISTON PISTON SET SCREW SEAL KIT RESTRICTOR 1 Printed in U.S.A /CP0706

68 603 - AUXILIARY HYDRAULICS INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE LOCK SCREW CONNECTION LOCK SCREW CONNECTION HYDRAULIC PIPE HYDRAULIC PIPE CAP QUICK LOCK COUPLING CAP QUICK LOCK COUPLING CAP QUICK LOCK COUPLING CAP CABLE HOSE (SN AC02776 >) /CP Printed in U.S.A

69 603 - ISO/SEA VALVE INSTALLATION (OPTION) HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT PLUG NUT 1 Printed in U.S.A /CP0706

70 603 - PILOT PRESSURE HOSES HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE /CP Printed in U.S.A

71 603 - HYDRAULIC TANK HOSES HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE 2 Printed in U.S.A /CP0706

72 603 - BATTERY * BATTERY SCREW WASHER 8.4 ST A2C HLN INST M C8 ZO SWITCH BATTERY CABLE - LONG POS CABLE GROUND CAP BATTERY CABLE - SHORT POS CS M6-1.00X20 C8.8 ZO WASHER GR A6.4 ZO DIN HLN INST M C8 ZO 2 * Purchase locally. Group size 49; 680 CCA /CP Printed in U.S.A

73 603 - DASHBOARD (SN AC02890 >) INSTRUMENT CLUSTER TEMPERATURE GAUGE CIGARETTE LIGHTER PRE-HEATING START SWITCH VENTILATION FAN SYMBOL KEY FUSE BOX COVER/FUSE BOX FUSE 10 A FUSE 15 A FRAME FRAME BULB SWITCH HIGH-SPEED SYMBOL WINDSHEILD SWITCH WIPER SYMBOL WORK LIGHT SYMBOL BLANK ROCKER SWITCH - 2 POSITION 1 Printed in U.S.A /CP0706

74 603 - DASHBOARD (SN > AC02889) INSTRUMENT CLUSTER TEMPERATURE GAUGE CIGARETTE LIGHTER PRE-HEATING START SWITCH VENTILATOR FAN SYMBOL KEYS FUSE BOX COVER/FUSE BOX FUSE 10 A FUSE 15 A FRAME FRAME BULB SWITCH HIGH-SPEED SYMBOL WINDSHIELD WIPER SWITCH WIPER SYMBOL WORK LIGHT SYMBOL BLANK ROCK SWITCH - 2 POSITION /CP Printed in U.S.A

75 603 - RADIO (OPTION) RADIO FRAME ANTENNA SPEAKER LOUD SPEAKER COVER SCREW RUBBER BUFFER NUT DISTANCE FRAME 1 Printed in U.S.A /CP0706

76 603 - RELAY BOX HOUSING BRACKET RELAY RELAY RELAY DIODE RELAY RELAY 15A CS M5-0.80X10 C8.8 ZO LOCKWASHER S WASHER /CP Printed in U.S.A

77 603 - HORN HORN CS M8-1.25X16 C8.8 ZO WASHER WASHER 1 Printed in U.S.A /CP0706

78 603 - WORK HEADLIGHT WORK LIGHT COMPLETE (SN AC03289 >) WORK LIGHT COMPLETE (SN > AC03288) HALOGEN LAMP /CP Printed in U.S.A

79 603 - CAB HEADLIGHT, FRONT (OPTION) (CAB SN >) WORK LIGHT COMPLETE HALOGEN LAMP ROCKER SWITCH - 2 POSITION WORK LIGHT SYMBOL CABLE HEADLIGHT BRACKET LEFT HEADLIGHT BRACKET RIGHT WASHER/GR A 8.4 ZO DIN CS M6-1X12 C8.8 ZY COVER FRONT CABIN HEADLIGHT KIT 1 Printed in U.S.A /CP0706

80 603 - CAB HEADLIGHT, FRONT (OPTION) (CAB SN > 50946) WORK LIGHT COMPLETE HALOGEN LAMP ROCKER SWITCH - 2 POSITION WORK LIGHT SYMBOL CABLE HEADLIGHT BRACKET LEFT HEADLIGHT BRACKET RIGHT HLN INST M C8 ZO WASHER/GR A 8.4 ZO DIN HEX SCREW COVER /CP Printed in U.S.A

81 603 - CAB WORK LIGHT, REAR (OPTION) WORK LIGHT COMPLETE HALOGEN LAMP ROCKER SWITCH - 2 POSITION WORK LIGHT SYMBOL REAR CABIN WORK LIGHT KIT 1 Printed in U.S.A /CP0706

82 603 - WIRE HARNESS CHASSIS/ENGINE (SN AC04795 >) WIRING HARNESS ENGINE FUSE 30A FUSE 50A /CP Printed in U.S.A

83 603 - WIRE HARNESS CHASSIS/ENGINE (SN > AC04794) WIRING HARNESS ENGINE FUSE 30A FUSE 50A 1 Printed in U.S.A /CP0706

84 603 - WIRE HARNESS ARMREST WIRING HARNESS CABIN /CP Printed in U.S.A

85 603 - WIRE HARNESS SWITCH (SN AC02890 >) WIRING HARNESS SWITCH SIGNAL 1 Printed in U.S.A /CP0706

86 603 - WIRE HARNESS SWITCH (SN > AC02889) WIRING HARNESS SWITCH /CP Printed in U.S.A

87 603 - WIRE HARNESS HEADLIGHT WIRING HARNESS LIGHTING 1 Printed in U.S.A /CP0706

88 603 - CAB WIRE HARNESS WIRING HARNESS CABIN CABLE CLIP CABLE SLEEVE WINDSHEILD HARNESS /CP Printed in U.S.A

89 603 - RUBBER TRACK RUBBER TRACK 2 Printed in U.S.A /CP0706

90 603 - STEEL TRACK (OPTION) STEEL TRACK SCREW NUT STEEL TRACK TRACK LINK TRACK LINK TRACK LINK TRACK LINK BUSHING TRACK ELEMENT PIN TRACK ELEMENT PIN FLOOR PLATE /CP Printed in U.S.A

91 603 - UNDERCARRIAGE, RUBBER TRACK DRIVE ASSY TURNTABLE DRIVE UNIT COMPLETE (SEE PAGE 34 FOR INDIVIDUAL COMPO- NENTS) SPROCKET SHCS M X ZO WASHER HB M X 90 C 10.9 ZO GREASE ZERK CAP SWIVEL JOINT II (SEE PAGE 35 FOR 1 INDIVIDUAL COMPONENTS) CS M X30 C10.9 ZO WASHER BOTTOM ROLLER SCREW WASHER/NORD-LOCK NL SEAL KIT TOP ROLLER HB M X 70 C 10.9 ZO HLN INS M ZO PLUG BRACKET ADAPTER PLATE CS M X30 C10.9 ZO WASHER/NORD-LOCK NL SPACER GASKET/SLEWING GEAR (2.8 M) 1 Printed in U.S.A /CP0706

92 603 - UNDERCARRIAGE, STEEL TRACK (OPTION) DRIVE ASSY TURNTABLE DRIVE UNIT COMPLETE (SEE PAGE 34 FOR INDIVIDUAL COMPO- NENTS) SPROCKET SHCS M X ZO WASHER HB M X 90 C 10.9 ZO GREASE ZERK CAP SWIVEL JOINT II (SEE PAGE 35 FOR 1 INDIVIDUAL COMPONENTS) CS M X30 C10.9 ZO WASHER BOTTOM ROLLER SCREW WASHER/NORD-LOCK NL SEAL KIT TOP ROLLER HB M X 70 C 10.9 ZO HLN INS M ZO PLUG BRACKET ADAPTER PLATE TRACK GUARD SHCS M X ZO WASHER TRACK GUARD GASKET/SLEWING GEAR (2.8 M) CS M X30 C10.9 ZO WASHER/NORD-LOCK NL SPACER /CP Printed in U.S.A

93 603 - TRACK TENSIONER, RUBBER TRACK (SN AC03713 >) TRACK TENSIONER COMPLETE VALVE SCREW SEAL SHCS M X ZO WASHER/ROUND HI-TENS SPRINGS TENSION ROLLER TENSION CYLINDER SEAL KIT O-RING BUSHING BRACKET SHAFT PLUG SCREW WASHER 8 Printed in U.S.A /CP0706

94 603 - TRACK TENSIONER, RUBBER TRACK (SN > AC03712) TRACK TENSIONER COMPLETE VALVE SCREW SEAL SHCS M X ZO WASHER/ROUND HI-TENS SPRINGS TENSION ROLLER TENSION CYLINDER SEAL KIT O-RING BUSHING BRACKET SHAFT PLUG SCREW WASHER /CP Printed in U.S.A

95 603 - TRACK TENSIONER, STEEL TRACK (OPTION) TRACK TENSIONER COMPLETE VALVE RING SHCS M X ZO WASHER/ROUND HI-TENS SPRINGS TENSION WHEEL TENSION CYLINDER SEAL KIT O-RING BUSHING BRACKET SHAFT PLUG SCREW WASHER 8 Printed in U.S.A /CP0706

96 603 - DOZER BLADE PRE-ASSEMBLED DOZER BLADE 1 (INCLUDES ITEMS 5, 6, 7, 8) PIN PIN PIN SEAL BUSHING SEAL GREASE ZERK CAP BUSHING DOZER BLADE CYLINDER (SEE PAGE 65 FOR INDIVIDUAL COMPO- NENTS) NUT SHCS M X ZO /CP Printed in U.S.A

97 603 - CHASSIS CHASSIS TURNTABLE HB M X 90 C 10.9 ZO WASHER HLN INST M C8 ZO O-RING SWIVEL DRIVE (SEE PAGE 32 FOR 1 INDIVIDUAL COMPONENTS) SHCS M X ZO WASHER/NORD-LOCK NL BOOM OFFSET CYLINDER (SEE PAGE 63 FOR INDIVIDUAL COMPO- NENTS) SWIVEL CONSOLE PIN COTTER PIN PIN HEX SCREW PIN BRACKET FOR AXLE CS M X30 C10.9 ZO WASHER WASHER/GR A STEEL BUSHING SHIM (0.5 MM) SHIM (1.0 MM) SHIM (1.5 MM) SHIM (2.0 MM) 1 Printed in U.S.A /CP0706

98 603 - LUBRICATION LUBRICATION ZERK BLOCK CS M6-1.0X30 C8.8 ZO LOCKWASHER S GREASE ZERK CAP SCREW JOINT LUBRICATION TUBE (2.0 M) LUBRICATION TUBE (1.2 M) NUT WASHER ELBOW SCREW MOUNT PLUG SLEEVE (SN AC04159 >) /CP Printed in U.S.A

99 603 - COUNTERWEIGHT COUNTERWEIGHT HEX SCREW WASHER/ROUND HI-TENS PLUG COVER CS M20-2.5X70 C8.8 ZY REFLECTOR POP RIVET A4 X HEX SCREW 1 Printed in U.S.A /CP0706

100 603 - COUNTERWEIGHT OPTION COUNTERWEIGHT CS M X 0 C8.8 ZO WASHER/ROUND HI-TENS /CP Printed in U.S.A

101 603 - HOOD (SN AD04629 >) HOOD HINGE ANGLE BRACKET WASHER/GR A HLN INST M C8 ZO ANGLE PLATE CS M8-1.25X30 C8.8 ZO WASHER WASHER EXHAUST COVER CS M10-1.5X20 C8.8 ZY LOCKWASHER S NUT/CAGE M PRESSURE STUD SOCKET LOCKING WEDGE HEX SCREW LOCK GAS STRUT HLN INST M C8 ZO RUBBER PROFILE (3.5 M) KEY ISOLATION MAT (SN AC02780 >) SPACER 2 Printed in U.S.A /CP0706

102 603 - HOOD (SN > AD04628) HOOD HINGE ANGLE BRACKET WASHER/GR A HLN INST M C8 ZO ANGLE PLATE CS M8-1.25X30 C8.8 ZO WASHER WASHER EXHAUST COVER CS M10-1.5X20 C8.8 ZY LOCKWASHER S NUT/CAGE M PRESSURE STUD SOCKET LOCKING WEDGE HEX SCREW LOCK GAS STRUT HLN INST M C8 ZO RUBBER PROFILE (3.5 M) KEY BRACKET (SN AC02776 >) COVER PLATE 1 (SN AC02886 > AC03658) SPACER /CP Printed in U.S.A

103 603 - TANK COVER TANK COVER ( ) BRACKET BRACKET CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A 10.5 ZO NUT/CAGE M SHCS M X ZO 3 Printed in U.S.A /CP0706

104 603 - PARTITION WALL (SN AD04629 >) SEPARATING PLATE CLAMP COVER COVER ANGLE BRACKET BRACKET PROFILE CLAMP PLATE RUBBER PROFILE (2.0 M) CS M10-1.5X20 C8.8 ZY WASHER WASHER 8.4 ST A2C CS M X30 C10.9 ZO RING/SNAP S WASHER RUBBER PROFILE (1.0 M) /CP Printed in U.S.A

105 603 - PARTITION WALL (SN > AD04628) SEPARATING PLATE CLAMP COVER COVER ANGLE BRACKET BRACKET PROFILE CLAMP PLATE RUBBER PROFILE (2.0 M) CS M10-1.5X20 C8.8 ZY WASHER WASHER 8.4 ST A2C CS M X30 C10.9 ZO RING/SNAP S WASHER 5 Printed in U.S.A /CP0706

106 603 - ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT OIL TANK ISOLATION MAT ISOLATION MAT COOLER COATING CLAMP ISOLATION MAT (SN AC02776 >) ISOLATION MAT (SN AC02776 >) ISOLATION MAT (SN AC02776 >) ISOLATION MAT 1 (SN AC02776 AC03658) ISOLATION MAT (SN AD04629 >) /CP Printed in U.S.A

107 603 - CHASSIS COVER (SN AD04629 >) CHASSIS COVER RADIATOR DRAIN COVER CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A PLUG COVER 1 Printed in U.S.A /CP0706

108 603 - CHASSIS COVER (SN > AD04628) CHASSIS COVER (SN AC02491 >) RADIATOR DRAIN COVER CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A ENGINE COVER COVER (SN > AC02490) /CP Printed in U.S.A

109 603 - UNDERCARRIAGE COVER COVER SCREW WASHER WASHER/GR A COVER LEFT COVER RIGHT 1 Printed in U.S.A /CP0706

110 603 - BOOM (SN AC02660 >) BOOM CAP COVER SEAL HLN INST M C8 ZO CLAMP CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A BUSHING PIN SCREW HLN INST M C8 ZO PIN SEAL CLAMP (SN > AC05384) CLAMP (SN AC05585 >) COVER PLATE (SN > AC05384) CS M8-1.25X55 C8.8 ZO 6 (SN > AC05384) SCREW (SN AC03553 >) WASHER PIN HEXAGON HEAD SCREW PIN BRACKET HOSE DIPPER ARM CYLINDER (SEE PAGE 58 FOR INDIVIDUAL COMPO- NENTS) PIN CLAMP COVER SCREW CS M6-1.00X45 C8.8 ZO CLAMP BODY COVER CS M8-1.25X45 C8.8 ZO TUBE CLAMP SHIM (0.5 MM) SHIM (1.0 MM) SHIM (1.5 MM) SHIM (2.0 MM) COTTER PIN /CP Printed in U.S.A