153 Compact Excavator

Transcription

1 153 Compact Excavator Form No Revision D Beginning Serial Number: AB00440 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. From this position, the cab is on the left and the hydraulic valve compartment is on the right. 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 provided on the inside back cover. Metric torque values shown in the illustrations are in Newton-meters and can be converted to Footpounds by multiplying by In the exploded view parts list, additional information may follow the Reference Number. Serial number breaks are indicated as follows: Unless otherwise specified, all cap screws or 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 RT - Right SHCS - Socket Head Cap Screw SLTD - Slotted SN - Serial Number or Slotted Nut (SN XXXXX) - indicates serial numbers up to and including XXXXX. (SN YYYYY ) - indicates serial numbers YYYYY and after.

3 TABLE OF CONTENTS Introduction Inside Front Cover Decal Locations Undercarriage, Rubber Track Rubber Track Undercarriage, Steel Track (Option) Steel Track (Option) Track Tension, Rubber Track Track Tensioner, Steel Track (Option) Dozer Blade Dozer Blade Extensions Chassis Chassis Cover Lubrication Counterweight Hood Seat Console Side Panels Seat Console Cover Isolation Mats Lifting Boom Dipper Arm Short Dipper Arm Long (Option) Connecting Link Covers Cabin Frame Canopy Frame Front Window Cabin Windows Cabin Harnesses Rotating Beacon Cabin Door Operator s Seat Diesel Engine (Tier 2 Engine) (SN AE00001 ) 40 Engine Mounts Heater Cylinder Head, Valve Cover Cylinder Block Seal, Crankshaft Oil Pan Camshaft Crankshaft, Piston Fuel Injection Equipment Exhaust System Fuel System Throttle Lever Air Intake System Cooling System Radiator Diesel Tank Lubrication Oil Cooler Diesel Engine (Tier 1 Engine) (SN AD00454 AD99999) Engine Mounts Heater Air Intake System Radiator Exhaust System Fuel System Oil Pan Throttle Lever Cylinder Block Camshaft Cylinder Head, Valve Cover Exhaust Manifold Intake Manifold Seal, Crankshaft Crankshaft, Piston Cooling System Fuel Injection System Seal Kit Diesel Tank Lubrication Oil Cooler Hydraulic Pump Hydraulic Pump Drive Hydraulic Oil Tank Drive Motor Control Valve Control Valve Swivel Joint Turntable Drive Unit Dozer Blade Valve Dozer Blade Valve - Disassembled ISO/SAE Valve Reversing Valve Joysticks Pilot Valve, Travel Auxiliary Hydraulics Boom Cylinder Dipper Arm Cylinder - Short Dipper Arm Cylinder - Long (Option) Bucket Cylinder Boom Offset Cylinder Telescopic Cylinder Dozer Blade Cylinder Oil Cooler Installation Printed in U.S.A /DP0306

4 Hydraulic Pump Installation Travel Gear Installation Boom Offset Cylinder Installation Turntable Drive Unit Installation Dozer Blade Installation Telescopic Cylinder Installation Travel Valve Installation Dipper Arm Installation - Short Dipper Arm Installation - Long Boom Installation Bucket Installation Auxiliary Function Installation Battery Installation Dashboard Engine Wire Harness Armrest Wire Harness Chassis Wire Harness Auxiliary Hydraulic Wire Harness (Option) Radio (Option) Relay Box Horn Work Light Cab Work Light (Option) Mirror (Option) Sun Visor (Option) Tool Kit Index Numerical Index Notes Hydraulic Fitting Data Torque Chart Inside Rear Cover /CP Printed in U.S.A.

5 INTENTIONALLY BLANK Printed in U.S.A /DP0306

6 DECAL LOCATIONS 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 shown decal (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. 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) Most of the decals are common to all units. Any differences are called out using asterisks. The decal kit for the model 153 Compact Excavator is listed below: Ref. Part No. No. Description & Quantity Decal Kit Diesel Fuel Hydraulic Oil Lubrication WARNING - Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan (2 places) Dozer Blade Travel - Left Travel - Right Right Joystick Control Left Joystick Control Lifting Capacity WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface WARNING - Avoid Injury (cabin models only) G Track Spread G Heater (cabin models only) G Swing Lock G Return Flow Control G ISO/SAE Valve G ROPS/FOPS G Cabin Support GEHL GEHL (2 places) (2 places) GEHL Decal/Reflector /DP Printed in U.S.A.

7 Both Sides Both Sides Printed in U.S.A /DP0306

8 The decal listing has been repeated for your convenience. Ref. Part No. No. Description & Quantity Decal Kit Diesel Fuel Hydraulic Oil Lubrication WARNING - Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan (2 places) Dozer Blade Travel - Left Travel - Right Right Joystick Control Left Joystick Control Lifting Capacity WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface WARNING - Avoid Injury (cabin models only) G Track Spread G Heater (cabin models only) G Swing Lock G Return Flow Control G ISO/SAE Valve G ROPS/FOPS G Cabin Support GEHL GEHL (2 places) (2 places) GEHL Decal/Reflector /DP Printed in U.S.A.

9 Printed in U.S.A /DP0306

10 The decal listing has been repeated for your convenience. Ref. Part No. No. Description & Quantity Decal Kit Diesel Fuel Hydraulic Oil Lubrication WARNING - Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan (2 places) Dozer Blade Travel - Left Travel - Right Right Joystick Control Left Joystick Control Lifting Capacity WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface WARNING - Avoid Injury (cabin models only) G Track Spread G Heater (cabin models only) G Swing Lock G Return Flow Control G ISO/SAE Valve G ROPS/FOPS G Cabin Support GEHL GEHL (2 places) (2 places) GEHL Decal/Reflector /DP Printed in U.S.A.

11 6 Both Sides Printed in U.S.A /DP0306

12 153 - UNDERCARRIAGE, RUBBER TRACK SNAP RING S FRAME/RIGHT FRAME/LEFT CYLINDER/TELESCOPIC See page 102 for individual components PROTECTION PIN SCREW WASHER/GR A 18 ZO DIN TRACK TENSIONER COMPLETE See page 14 for individual components VALVE ROLLER HLN INS M ZO SWIVEL JOINT See page 88 for individual components COVER COVER DRIVE MOTOR See page 85 for individual components SPROCKET G UNDERCARRIAGE TUBE TURNTABLE RING CS M14-2X50 C10.9 ZY CS M X40 C10.9 ZY SHCS M X ZO SCREW PIN/SPRING M SHCS M8-1.25X20 C8.8 ZY CS M10-1.5X20 C8.8 ZY WASHER/ROUND HI-TENS WASHER/GR A SEAL KIT G TENSION CYLINDER WASHER LOCKWASHER S WASHER LOCKWASHER S HN M16-2 C8 ZY /DP Printed in U.S.A.

13 RUBBER TRACK RUBBER TRACK Printed in U.S.A /DP0306

14 153 - UNDERCARRIAGE, STEEL TRACK (OPTION) G UNDERCARRIAGE FRAME RIGHT FRAME LEFT CYLINDER/TELESCOPIC See page 102 for individual components SHIELD PIN SCREW SNAP RING S TENSION WHEEL See page 15 for individual components VALVE BOTTOM ROLLER (STEEL TRACK) TUBE SWIVEL JOINT See page 88 for individual components COVER COVER DRIVE MOTOR See page 85 for individual components SPROCKET SEAL KIT WASHER/GR A 18 ZO DIN TURNTABLE RING CS M X 50 C10.9 ZO CS M X 40 C10.9 ZY SHCS M X ZO SCREW HLN INS M ZO SHCS M8-1.2 X ZO CS M X 20 C8.8 ZO WASHER/ROUND HI-TENS WASHER/GR A ROLLER COMPLETE SPRING ASSEMBLY WASHER LOCKWASHER S WASHER LOCKWASHER S HN M16-2 C8 ZY PIN/SPRING M /DP Printed in U.S.A.

15 STEEL TRACK (OPTION) STEEL TRACK Printed in U.S.A /DP0306

16 153 - TRACK TENSION, RUBBER TRACK TRACK TENSIONER COMPLETE G ROLLER COMPLETE G SPRING ASSEMBLY PISTON SEAL SEAL CYLINDER CS M X 35 C 10.9 ZO LW SPRING B10 DIN NUT COTTER PIN GUIDANCE SHAFT SCREW BEARING WASHER SEAL /DP Printed in U.S.A.

17 TRACK TENSION, STEEL TRACK (OPTION) TRACK TENSION ROLLER COMPLETE SPRING ASSEMBLY SEAL SEAL CS M X 35 C 10.9 ZO LW SPRING B10 DIN NUT COTTER PIN CONSOLE SEAL KIT SHAFT BUSHING PLUG ROLLER COMPLETE (INCLUDES ITEMS 13, 14, 15 & 16) Printed in U.S.A /DP0306

18 153 - DOZER BLADE DOZER BLADE PIN PIN/SPLIT 6.3 X 50 ZO D CAP G DOZER BLADE CYLINDER COMPLETE 1 See page 103 for individual components GREASE ZERK G SPACER PIN /DP Printed in U.S.A.

19 DOZER BLADE EXTENSIONS G DOZER BLADE EXTENSION RIGHT G DOZER BLADE EXTENSION LEFT G CONNECTOR Printed in U.S.A /DP0306

20 153 - CHASSIS CHASSIS O-RING WASHER/ROUND HI-TENS HB M12-1.7X 55 C 10.9 ZO BUSHING PIN GRUB SCREW SWING BRACKET G BOOM OFFSET CYLINDER See page 101 for individual components PIN PIN PIN/SPRING M8 X 70 D G LOCKING PISTON G LEVER G HEXAGON NUT WASHER KNOB D40MM WASHER G BRACKET SHCS M X ZO WASHER/NORD-LOCK NL SHCS M X ZO COLLAR COVER PLATE HB M8-1.2 X 40 C 8.8 ZO G HYDRAULIC MOTOR See page 89 for individual components HB M8-1.2 X 70 C 8.8 ZO HLN INS M ZO CAP GREASE ZERK WASHER WASHER/ROUND HI-TENS HLN INS M27-3 ZO G BRACKET /DP Printed in U.S.A.

21 CHASSIS COVER ENGINE COVER SEAL FOAM (0.50M) HEX SCREW WASHER WASHER NUT/CAGE M Printed in U.S.A /DP0306

22 153 - LUBRICATION WASHER NUT ELBOW G GREASE ZERK CAP SCREW JOINT G SCREW JOINT LUBRICATION TUBE - (0.9M) LUBRICATION TUBE (0.4M) /DP Printed in U.S.A.

23 COUNTERWEIGHT COUNTERWEIGHT G HEX HEAD SCREW WASHER G SUPPORT CS M10-1.5X16 C8.8 ZY LOCKWASHER S WASHER/GR A 10.5 ZO SHEET METAL WASHER BRACKET G BRACKET G MOUNTING LINK SCREW FCHC HS M8-1.2X GREASE GUN BRACKET CS M X 16 C8.8 ZO WASHER NUT/CAGE M NUT/CAGE M CS M8-1.25X35 C8.8 ZY LW M8 Z PHEOLL KB G SCREW WASHER/ROUND HI-TENS BRACKET Printed in U.S.A /DP0306

24 153 - HOOD HOOD WASHER HLN INS M ZO WASHER CS M X 30 C8.8 ZO ISOLATION MAT EDGE PROTECTION SECTION (1.3M) RUBBER SEAL - (2.0M) BRACKET BALL AND SOCKET FHSCS M5-0.8 X ZO CLAMP HLN INS M ZO HINGE G LOCK (W/O KEY) SCREW KEYS /DP Printed in U.S.A.

25 SEAT CONSOLE SEAT CONSOLE BOTTOM COVER LEFT G STORAGE BOX (CANOPY) SHCS M X ZO WASHER NUT/CAGE M LOCKWASHER S WASHER GR A6.4 ZO DIN HN M6-1.0 D934 Z F-Z0 PHEOL WASHER WASHER/GR A 8.4 ZO PVC EDGE PROTECTION (0.6M) EDGE PROTECTION SECTION (2.8M) KEYS G COVER PVC EDGE PROTECTION (0.6M) G HINGE FHSCS M5-0.8 X ZO G COVER-CABIN MODEL G LOCK (W/O KEY) CS M 6-1.0X16 C 8.8 ZO G COVER SHCS M5-0.8 X ZO WASHER CS M X 40 C 10.9 ZO NUT/HEX M D934 PC HEX SCREW BOTTOM COVER BOTTOM COVER WASHER G AIR GUIDING PLATE WASHER LOCKWASHER S RUBBER PROFILE - (0.30M) WASHER/GR A WASHER COVER COVER Printed in U.S.A /DP0306

26 153 - SIDE PANELS SIDE WALL LEFT SIDE WALL RIGHT EDGE PROTECTION SECTION (6.0M) G SCREW LOCKWASHER S WASHER/GR A SHCS M X ZO SHCS M X ZO NUT/CAGE M /DP Printed in U.S.A.

27 SEAT CONSOLE COVER G COVER G COVER RIVET 11MM RIVET 20MM Printed in U.S.A /DP0306

28 153 - ISOLATION MATS G ISOLATION MAT G ISOLATION MAT G ISOLATION MAT G LOCK/RIGHT G FOOT MAT G ISOLATION MAT RIGHT G ISOLATION MAT LEFT G ISOLATION MAT G ISOLATION MAT ISOLATION MAT ISOLATION MAT G ISOLATION MAT G ISOLATION MAT ISOLATION MAT /DP Printed in U.S.A.

29 LIFTING BOOM PRE-ASSEMBLED BOOM (INCLUDES ITEMS 12 & 13) BRACKET G LIFTING BOOM CYLINDER See page 97 for individual components HB M8-1.25X70 C8.8 ZY LN INS M C8 ZY G PIN DM=30 X G DIPPER ARM CYLINDER COVER CS M6-1X35 C8.8 ZY G PIN DM=36 X SCREW BUSHING RING/SNAP B45 D GREASE ZERK CAP TUBE TUBE TUBE TUBE TUBE G TUBE CLAMP G COVER CS M8-1.25X35 C8.8 ZY G TUBE CLAMP TUBE CLAMP G CLAMP CS M8-1.25X35 C8.8 ZY COVER TUBE CLAMP G PIN DM=30 X G RUBBER COVER HEX SCREW LOCKWASHER S WASHER WASHER 8.4 ST A2C Printed in U.S.A /DP0306

30 153 - DIPPER ARM, SHORT G PRE-ASSEMBLED SHORT DIPPER ARM 1 (INCLUDES ITEMS 3, 5 & 16) CAP RING/SNAP B38 D CAP BUSHING G BUSHING 30/40X HB M8-1.2 X 70 C 8.8 ZO HLN INS M ZO G PIN DIM=30X SCREW WASHER G SCREW GREASE ZERK G BLOCK G BLOCK BUSHING O-RING COUPLING/FEMALE A13 15L BG CAP COUPLING/MALE A13 15L BG /DP Printed in U.S.A.

31 DIPPER ARM, LONG (OPTION) G PRE-ASSEMBLED DIPPER ARM LONG 1 (INCLUDES ITEMS 3, 5 & 16) CAP RING/SNAP B38 D CAP BUSHING G BUSHING 30/40X HB M8-1.2 X 70 C 8.8 ZO HLN INS M ZO G PIN DIM=30X SCREW JOINT WASHER G SCREW GREASE ZERK G BLOCK G BLOCK BUSHING O-RING COUPLING/FEMALE A13 15L BG CAP COUPLING/MALE A13 15L BG Printed in U.S.A /DP0306

32 153 - CONNECTING LINK G PRE-ASSEMBLED CONNECTOR LINK. 1 (INCLUDES ITEMS 2, 3 & 4) RING/SNAP B38 D BUSHING BUSHING GREASE ZERK CAP CONNECTING LINK CONNECTING LINK G DIPPER CYLINDER See page 100 for individual components PIN HLN INS M27-3 ZO G PIN DIM=30X HB M8-1.2 X 70 C 8.8 ZO HLN INS M ZO PIN DM=32X COTTER PIN /DP Printed in U.S.A.

33 COVERS COVER CS M X 12 C8.8 ZO G COVER G COVER RIVET 11MM COVER DOME LIGHT BULB SCREW G COVER WASHER HLN INS M ZO CAP D=5MM WASHER COVER Printed in U.S.A /DP0306

34 153 - CABIN FRAME CABIN COMPLETE PLUG PLUG G RUBBER BUSHING PIN BRACKET PLATE WASHER RUBBER PROFILE - (3.90M) HOSE PROFILE (1.1M) ANTI-SLIDE STRIP 25MM (0.30M) G LOCK G LOCK-LEFT G LOCK-RIGHT BRACKET-LEFT BRACKET-RIGHT CS M6-1X30 C8.8 ZY WASHER RESILIENT PAD RUBBER PLUG SCREW G FOIL/LEFT G FOIL/RIGHT FOAM RUBBER BLACK 10X15MM (1.5M) SEAL - (0.80M) SEAL - (1.50M) G COLLAR SCREW WASHER G BRACKET RUBBER (3.00M) CS M5-0.8 X 16 C 8.8 ZO G LATCH POST EXTENSION G SCREW NUT/HEX M D934 PC8 F-ZO G RUBBER BUFFER RUBBER WASHER SHCS M X ZO WASHER WASHER/GR A 13 DIN SHCS M X ZO /DP Printed in U.S.A.

35 CANOPY FRAME CANOPY PLUG PLUG HOSE PROFILE (1.1M) G BRACKET EDGE PROTECTION (1.0M) ANTI-SLIDE STRIP 25MM (1.0M) STORAGE BOX RIVET 11MM G WINDOW SCREW G COVER WASHER HLN INS M ZO CAP D=5MM Printed in U.S.A /DP0306

36 153 - FRONT WINDOW G FRONT WINDOW G BRACKET FOAM STRIP (0.85M) BAR LOCK SCREW G WASHER DISTANCE ROLLER RUBBER WASHER WASHER/GR A 8.4 ZO DIN PVC-ROLLER G NUT MOTOR/WINDSHIELD WASHER G WIPER ARM G WIPER BLADE NOZZLE G RUBBER BUSHING WATER HOSE (1.40M) WATER HOSE (2.30M) NON RETURN VALVE CONNECTOR COVER SCREW NUT HN M C8 ZY CS M8-1.2 X 12 C 8.8 ZO RUBBER WASHER G PVC-PROFILE G BALL KNOB CATCH BOLT WASHER BRACKET/LEFT G WASHER NUT/HEX DOMED CAP M FHSCS M8-1.25X20 C8.8 ZY BRACKET/RIGHT DISTANCE ROLLER SPACER FRONT WINDOW TINTED WINDSHIELD WASHER RESERVOIR PUMP WASHTANK FASTEN PLATE HEX SCREW M6X A2C WASHER GR A6.4 ZO DIN LN INS M6-1 C8 ZY /DP Printed in U.S.A.

37 CABIN WINDOWS G SIDE PANE LEFT SIDE PANE LEFT TINTED (OPTION) G SIDE PANE RIGHT SIDE PANE RIGHT TINTED (OPTION) G REAR WINDOW REAR WINDOW TINTED (OPTION) G LOWER WINDSHIELD FRONT WINDSHIELD TINTED (OPTION) HOSE PROFILE (1.0M) PVC-WASHER RUBBER WASHER RUBBER WASHER PVC-WASHER G BALL KNOB SIDE PANE RIGHT SIDE PANE RIGHT TINTED (OPTION).. 1 Printed in U.S.A /DP0306

38 153 - CABIN HARNESSES G MAIN CABIN HARNESS G WINDSHIELD HARNESS TUBING SLIT (0.2M) /DP Printed in U.S.A.

39 ROTATING BEACON (OPTION) LAMP COMPLETE LENS HALOGEN LAMP WASHER/GR A 8.4 ZO DIN HLN INS M ZO COVER LAMP ATTACHMENT SCREW WASHER HLN INS M ZO BRACKET SYMBOL/TURNING LIGHT ARM LIGHT SWITCH Printed in U.S.A /DP0306

40 153 - CABIN DOOR CABIN DOOR LEFT COMPLETE CABIN DOOR RIGHT COMPLETE LOCK/LEFT TRAP LOCK/RT SCREW HLN INS M ZO G HANDLE G SHIM KEYS CS M X 12 C8.8 ZO G KEY BUTTON SEAL (6.60M) G DOOR WINDOW DOOR WINDOW TINTED (OPTION) G DOOR LOCK SEAL (7.60M) G COVER G COVER G RUBBER BUFFER RIVET 11MM G DOOR LOCK G SCREW WASHER /DP Printed in U.S.A.

41 OPERATOR S SEAT CONSOLE SUPPORT OPERATOR S SEAT (CLOTH) OPERATOR S SEAT (VINYL) SEAT BELT, 2 RETRACTABLE HIGH SPEED SYMBOL LN INS M C8 ZY HLN INS M ZO WASHER CONSOLE-CONTROL LEVERS LEFT ARMREST CONSOLE-CONTROL LEVERS RIGHT CONSOLE FOR DASHBOARD LEFT CONSOLE/INSTRUMENTS SCREW/C SUNK HD M5X NUT SWITCH/FAST SPEED SHCS M8-1.25X20 C8.8 ZY SHCS M8-1.25X16 C8.8 ZY WASHER BLANK MICROSWITCH WASHER NUT G BRACKET CS M X 16 C8.8 ZO LOCKWASHER S WASHER/GR A 10.5 ZO CS M X 25 C 8.8 ZO WASHER/GR A SPRING NUT/HEX DOMED CAP M TUBE SCREW SNAP RING G ELEVATION ADJUSTMENT HN M Z PHEOLL KB PLUG CIGARETTE LIGHTER TUBE KNOB/BALL D40MM W/HOLE WASHER HB M X 120 C 8.8 ZO HN M C8 ZY FLAT HEAD SCREW SHEET METAL SEAT UPHOLSTERY (CLOTH) SEAT UPHOLSTERY (VINYL) BACK CUSHION (CLOTH) BACK CUSHION (VINYL) SCREW Printed in U.S.A /DP0306

42 153 - DIESEL ENGINE (TIER 2 ENGINE) (SN AE00001 ) DIESEL ENGINE RADIATOR FAN FAN BELT STARTER ALTERNATOR CLAMP BAR/ALTERNATOR ADJUSTING SEAL KIT HOSE CLAMP CS M10-1.5X20 C8.8 ZY LOCKWASHER S WASHER/GR A /DP Printed in U.S.A.

43 ENGINE MOUNTS (TIER 2 ENGINE) (SN AE00001 ) ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT ENGINE MOUNT MOTOR MOUNT SUPPORT SHEET CS M10-1.5X25 C8.8 ZY LOCKWASHER S WASHER HEX SCREW WASHER SPACER CS M10-1.5X30 C10.9 ZY WASHER Printed in U.S.A /DP0306

44 153 - HEATER (TIER 2 ENGINE) (SN AE00001 ) CAB HEATER BRACKET HOSE CLAMP HEATER HOSE (0.9M) HEX SCREW HEATER HOSE (0.9M) SCREW JOINT WASHER/GR A 6.4 ZO TUBE SCREW JOINT SCREW JOINT BALL VALVE HOSE COVER NUT WASHER SCREW JOINT /DP Printed in U.S.A.

45 153 - CYLINDER HEAD, VALVE COVER (TIER 2 ENGINE) (SN AE00001 ) CYLINDER HEAD SEAL GUARD PLUG INTAKE VALVE EXHAUST VALVE VALVE CAP CLAMP SPACER SPRING VALVE STEM SEAL VALVE STEM SEAL VALVE GLOW PIN CABLE SHAFT VALVE COVER VALVE COVER SEAL OIL COVER O-RING SEAL DIAPHRAGM Printed in U.S.A /DP0306

46 153 - CYLINDER BLOCK (TIER 2 ENGINE) (SN AE00001 ) CYLINDER HEAD GASKET CYLINDER HEAD SCREW PLUG PLUG PLUG AXIAL BEARING (STANDARD) AXIAL BEARING (OS) MAIN BEARING SET (STANDARD) MAIN BEARING SET (OS) /DP Printed in U.S.A.

47 SEAL, CRANKSHAFT (TIER 2 ENGINE) (SN AE00001 ) GEARBOX SEAL COVER PLUG SPRING VALVE SCREW GEAR GEAR OIL COVER O-RING OIL FILLER PIPE SCREW SCREW SCREW O-RING O-RING O-RING HEXAGON NUT STUD BOLT TUBE FITTING PIN SEAL FLYWHEEL HOUSING RUBBER PLUG Printed in U.S.A /DP0306

48 153 - OIL PAN (TIER 2 ENGINE) (SN AE00001 ) OIL PAN ASSY SEAL RING LOCK SCREW SCREW SCREW SCREW SCREW /DP Printed in U.S.A.

49 CAMSHAFT (TIER 2 ENGINE) (SN AE00001 ) CAMSHAFT PLUNGER PUSH ROD GEAR BRACKET FLANGE GEAR SCREW SPRING RING HEXAGON NUT Printed in U.S.A /DP0306

50 153 - CRANKSHAFT, PISTON (TIER 2 ENGINE) (SN AE00001 ) CRANK SHAFT GEAR PARALLEL KEY BELT PULLEY FLYWHEEL CONNECTING ROD BUSHING BEARING BEARING SCREW PIN LOCK RING PISTON PISTON SET OF BACKUP RINGS SET OF BACKUP RINGS /DP Printed in U.S.A.

51 153 - FUEL INJECTION SYSTEM (TIER 2 ENGINE) (SN AE00001 ) INJECTION PUMP INJECTION NOZZLE NOZZLE TUBE SEAL RING HEX SCREW TUBE NON RETURN VALVE SEAL RING PIECE CLAMP INJECTION LINE INJECTION LINE INJECTION LINE Printed in U.S.A /DP0306

52 153 - EXHAUST SYSTEM (TIER 2 ENGINE) (SN AE00001 ) EXHAUST G SEAL EXHAUST PIPE SEAL EXHAUST PIPE EXHAUST BRACKET CLAMP EXHAUST BRACKET G ISOLATION MAT G HOSE CLAMP EXHAUST MANIFOLD GASKET STUD BOLT STUD BOLT SCREW HEXAGON NUT CLAMP HN M F8 ZY LOCKWASHER S WASHER/GR A HN M C8 ZY WASHER WASHER/GR A 8.4 ZO DIN WASHER HEX SCREW WASHER /DP Printed in U.S.A.

53 FUEL SYSTEM (TIER 2 ENGINE) (SN AE00001 ) FUEL FILTER ASSY FUEL FILTER ELEMENT HOSE CLAMP BRAIDED HOSE GCN NW6 (1.0M) FUEL PUMP BRAIDED HOSE GCN NW6 (0.9M) WATER SEPARATOR SCREEN/WATER TRAP O-RING BRACKET TUBE FILTER BRAIDED HOSE GCN NW6 (0.9M) BRAIDED HOSE GCN NW6 (0.7M) FITTING HB M8-1.25X80 C8.8 ZY WASHER SPACER G HEXAGON HEAD SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN Printed in U.S.A /DP0306

54 153 - THROTTLE LEVER (TIER 2 ENGINE) (SN AE00001 ) KNOB G THROTTLE LEVER CS M6-1X30 C8.8 ZY WASHER GR A6.4 ZO DIN HN M C8 ZO G CABLE /DP Printed in U.S.A.

55 AIR INTAKE SYSTEM (TIER 2 ENGINE) (SN AE00001 ) AIR FILTER ASSY. - COMPLETE AIR FILTER/OUTER AIR FILTER/INNER DIRT INDICATOR AIR FILTER BRACKET AIR INTAKE HOSE PROTECTING COVER SUPERFLEX (0.75M) CS M8-1.25X35 C8.8 ZY SPACER LN INS M C8 ZY FILTER COVER HOSE CLAMP Printed in U.S.A /DP0306

56 153 - COOLING SYSTEM (TIER 2 ENGINE) (SN AE00001 ) WATER PUMP WATER PUMP GASKET O-RING ENGINE GASKET THERMOSTAT HOUSING THERMOSTAT PLUG SEAL SWITCH/THERMOSTAT FAN BELT FAN SPACER VENTILATOR FAN /DP Printed in U.S.A.

57 RADIATOR (TIER 2 ENGINE) (SN AE00001 ) RADIATOR RADIATOR CAP METAL-RUBBER BUFFER HN M6-1 C8 ZY RUBBER BUFFER HOSE CLAMP HOSE BRACKET RUBBER SEAL CLAMP PLATE CLAMP PLATE PROTECTING SCREEN BRACKET BRACKET/SUB-TANK RESERVOIR COLLAR CS M6-1X20 C8.8 ZY LOCKWASHER S NUT/CAGE M HN M C8 ZO HOSE CLAMP LW SPRING 6 DIN CS M6-1X16 C8.8 ZY NUT/CAGE M BRAIDED HOSE GCN NW6 (0.4M) WASHER GR A6.4 ZO DIN NUT/CAGE M Printed in U.S.A /DP0306

58 153 - DIESEL TANK (TIER 2 ENGINE) (SN AE00001 ) FUEL TANK G DIESEL HOSE FILLER NECK HOSE CLAMP COLLAR STRAINER/FUEL TANK RUBBER BRACKET TANK COVER SHCS M5-0.8 X ZO LOCKWASHER S WASHER/GR A 5.3 ZO DIN SCREW JOINT WASHER/GR A 4.3 ZO DIN SHCS M X30 F8.8 ZY LOCKWASHER S WASHER PLUG SCREW JOINT STOP SOLENOID FUEL TRANSMITTER CS M4-X 16 C 8.8 ZO LOCKWASHER S CS M X 25 C 8.8 ZO WASHER WASHER/GR A G ISOLATION MAT FITTING HEX SCREW WASHER 8.4 ST A2C RUBBER EXTRUSION (0.7M) /DP Printed in U.S.A.

59 LUBRICATION (TIER 2 ENGINE) (SN AE00001 ) DIPSTICK DIPSTICK TUBE SENDER/OIL PRESSURE OIL FILTER PIPE LINE BANJO BOLT SEAL RING PIPE LINE O-RING SCREW JOINT Printed in U.S.A /DP0306

60 153 - OIL COOLER (TIER 2 ENGINE) (SN AE00001 ) G HYDRAULIC OIL COOLER G SCREW JOINT BRACKET CS M X 25 C 8.8 ZO CS M X 16 C8.8 ZO NUT/CAGE M CS M X 30 C8.8 ZO WASHER WASHER 8.4 ST A2C WASHER LOCKWASHER S WASHER/GR A NUT/CAGE M ANGLE /DP Printed in U.S.A.

61 ET DIESEL ENGINE (TIER 1 ENGINE) (SN AD00454 AD99999) G DIESEL ENGINE G VENTILATOR BELT/FAN OIL FILTER SWITCH/THERMOSTAT 110 DEG C PACKING SENDER/OIL PRESSURE SOLENOID STOP GASKET/CYLINDER HEAD GASKET/HOOD SUMP ASSY/LUB OIL See page 66 for individual components PLUG/OIL DRAIN WATER PUMP ASSEMBLY See page 75 for individual components GASKET/WATER PUMP THERMOSTAT GASKET INJECTION NOZZLE FUEL PUMP ASSEMBLY GASKET/FUEL PUMP GENERATOR REGULATOR INJECTION PUMP See pages 76 and 77 for individual components STARTER COUPLER/REGULATOR SEAL G SEAL KIT See page 78 for individual components G FAN SPACER SCREW Printed in U.S.A /DP0306

62 153 - ENGINE MOUNTS (TIER 1 ENGINE) ET (SN AD00454 AD99999) G ENGINE MOUNT PUMP SIDE G ENGINE MOUNT COOLER SIDE G ENGINE MOUNT PUMP SIDE G ENGINE MOUNT COOLER SIDE CS M X 25 C 8.8 ZO RING/SNAP S WASHER/GR A G SCREW WASHER WASHER SHCS M X ZO WASHER WASHER/GR A 13 DIN G VIBRATION MOUNT /DP Printed in U.S.A.

63 HEATER (TIER 1 ENGINE) (SN AD00454 AD99999) CAB HEATER BRACKET CLAMP HEATER HOSE (0.9M) SCREW/HEX HD TAP B5.5X HEATER HOSE (0.9M) SCREW JOINT WASHER CONNECTION PIECE G SCREW JOINT ANGLE BALL VALVE HOSE COVER NUT WASHER SCREW JOINT Printed in U.S.A /DP0306

64 153 - AIR INTAKE SYSTEM (TIER 1 ENGINE) ET (SN AD00454 AD99999) AIR CLEANER ASSY ELEMENT/AIR CLEANER INDICATOR WASHER WASHER CS M8-1.2 X 12 C 8.8 ZO SUCTION PIPE HOSE CLAMP PROTECTING COVER SUPERFLEX (1.0M) MUFFLER/INLET /DP Printed in U.S.A.

65 RADIATOR (TIER 1 ENGINE) (SN AD00454 AD99999) RADIATOR EDGE PROTECTION SECTION (0.4M) NUT/CAGE M CS M X 16 C8.8 ZO WASHER WASHER/GR A 8.4 ZO CS M X 12 C8.8 ZO LOCKWASHER S WASHER/GR A 6.4 ZO COVER BRACKET/SUB-TANK EXPANSION TANK ASSY RUBBER EXTRUSION (1.0M) SCREW LOCKWASHER S WASHER BRAIDED HOSE GCN NW6 (0.6M) CLAMP RADIATOR HOSE RADIATOR HOSE RUBBER EXTRUSION (0.9M) COLLAR HOSE CLAMP RUBBER EXTRUSION (0.35M) G RUBBER BUSHING RUBBER PROFILE (0.50M) G BRACKET CS M8-1.2 X 12 C 8.8 ZO WASHER LW M8 RZO HN M C8 ZY G VENTILATOR Printed in U.S.A /DP0306

66 153 - EXHAUST SYSTEM (TIER 1 ENGINE) ET (SN AD00454 AD99999) G TUBE G SEAL G MUFFLER GASKET G EXHAUST BRACKET G EXHAUST TUBE HN M C8 ZY G ISOLATION MAT WASHER WASHER/GR A 8.4 ZO COLLAR WASHER/GR A G HOSE COLLAR HN M F8 ZY /DP Printed in U.S.A.

67 ET FUEL SYSTEM (TIER 1 ENGINE) (SN AD00454 AD99999) FILTER HOUSING 3TNE74-NSR FUEL FILTER CLAMP G BRACKET CS M X 20 C8.8 ZO WASHER WASHER WATER SEPARATOR SCREEN/WATER TRAP HB M8-1.2 X 70 C 8.8 ZO HOSE CLAMP BRAIDED HOSE GCN NW6 (0.7M) G DIESEL SUCTION TUBE TUBE BRAIDED HOSE GCN NW6 (2.1M) BRAIDED HOSE GCN NW6 (0.9M) BRAIDED HOSE GCN NW6 (0.45M) CS M10-1.5X20 C8.8 ZY WASHER/GR A FILTER O-RING Printed in U.S.A /DP0306

68 153 - OIL PAN (TIER 1 ENGINE) (SN AD00454 AD99999) ET SUMP ASSY/LUB OIL INTERMEDIATE PIECE PLUG/DRAIN SEAL SCREW SCREW /DP Printed in U.S.A.

69 ET THROTTLE LEVER (TIER 1 ENGINE) (SN AD00454 AD99999) KNOB G HAND LEVER CS M6-1X30 C8.8 ZY G CABLE HN M ZO ALL METAL BRACKET CS M X 20 C8.8 ZO WASHER WASHER SPRING BRACKET WASHER GR A6.4 ZO DIN Printed in U.S.A /DP0306

70 153 - CYLINDER BLOCK (TIER 1 ENGINE) ET (SN AD00454 AD99999) CYLINDER HEAD SEAL SCREW BEARING WASHER PLUG PLUG PLUG PLUG PLUG SCREW CRANKSHAFT BEARING SCREW /DP Printed in U.S.A.

71 ET CAMSHAFT (TIER 1 ENGINE) (SN AD00454 AD99999) CAMSHAFT PUSH ROD PLUNGER CAMSHAFT BEARING SCREW TOOTHED GEAR TOOTHED GEAR PARALLEL KEY SCREW WASHER WASHER BUSHING FLANGE SHAFT BEARING BEARING SCREW SCREW BEARING SHAFT COMPLETE Printed in U.S.A /DP0306

72 153 - CYLINDER HEAD, VALVE COVER (TIER 1 ENGINE) ET (SN AD00454 AD99999) CYLINDER HEAD CONNECTING LINK SCREW SCREW CONNECTING LINK PLUG PLUG HOSE DOWEL PIN VALVE INLET VALVE GUIDE INJECTION NOZZLE SEAL VALVE SHAFT SEAL SPRING SPACER CLAMP CAP COVER PLATE SCREW SEAL GASKET/HOOD O-RING OIL COVER PLUG O-RING PLUG GLOW PIN GLOW PLUG CONNECTION ROCKER ARM SHAFT SHAFT SEAL /DP Printed in U.S.A.

73 ET EXHAUST MANIFOLD (TIER 1 ENGINE) (SN AD00454 AD99999) EXHAUST MANIFOLD GASKET STUD BOLT SCREW STUD BOLT NUT GASKET Printed in U.S.A /DP0306

74 153 - INTAKE MANIFOLD (TIER 1 ENGINE) ET (SN AD00454 AD99999) INTAKE MANIFOLD GASKET SCREW /DP Printed in U.S.A.

75 ET SEAL, CRANKSHAFT (TIER 1 ENGINE) (SN AD00454 AD99999) COVER O-RING SEAL OIL COVER TUBE COVER SCREW O-RING SCREW SCREW SCREW OIL FILLER PIPE GEAR BOX PLUG O-RING SCREW STUD BOLT CYLINDER PIN NUT SEAL COVER SEAL STUD BOLT NUT FLYWHEEL HOUSING SCREW SCREW RUBBER PLUG FITTING PIN HOUSING SEAL SCREW GRUB SCREW Printed in U.S.A /DP0306

76 153 - CRANKSHAFT, PISTON (TIER 1 ENGINE) ET (SN AD00454 AD99999) CRANKSHAFT FITTING PIN PARALLEL KEY GEAR CONNECTING ROD BELT DISC WASHER SCREW SET OF BACKUP RINGS WASHER PISTON PIN BUSHING CONNECTING ROD CAMP SCREW /DP Printed in U.S.A.

77 ET COOLING SYSTEM (TIER 1 ENGINE) (SN AD00454 AD99999) WATER PUMP ASSEMBLY DRAIN COCK DRAIN COCK COMPLETE SCREW SWITCH/THERMOSTAT 110 DEG C SEAL GASKET/WATER PUMP PLUG SEAL THERMOSTAT GASKET THERMOSTAT HOUSING SCREW CONNECTION BELT/FAN BELT DISC G VENTILATOR SCREW EXPANSION TANK ASSY COLLAR TUBE COLLAR PLUG BRACKET/SUB-TANK Printed in U.S.A /DP0306

78 153 - FUEL INJECTION SYSTEM (TIER 1 ENGINE) ET (SN AD00454 AD99999) INJECTION PUMP INJECTION NOZZLE O-RING ADJUSTING WASHER SPRING SEAT - NOZZLE SPRING WASHER INJECTION VALVE SCREW JOINT CONICAL NIPPLE SEAL PIPE INJECTION COUPLING CLAMP PIPE INJECTION COUPLING PIPE LUBRICATION NIPPLE PIPE COMPLETE CLAMP PIPE SCREW SEAL RING CLAMP SCREW HP TUBE HP TUBE HP TUBE /DP Printed in U.S.A.

79 ET FUEL INJECTION SYSTEM (TIER 1 ENGINE) (SN AD00454 AD99999) INJECTION PUMP HYDRAULIC PUMP ELEMENT NON RETURN VALVE CONICAL NIPPLE SPRING O-RING BRACKET RACK PINION BRACKET SCREW PIN GUIDE PIN PLATE PIN SCREW WASHER SPRING BRACKET WASHER KIT PLUNGER SCREW SEAL RING SCREW Printed in U.S.A /DP0306

80 153 - SEAL KIT (TIER 1 ENGINE) (SN AD00454 AD99999) ET G SEAL KIT CYLINDER HEAD SEAL SEAL O-RING SEAL VALVE SHAFT SEAL SEAL INJECTION NOZZLE SEAL FLANGE SEAL GASKET/HOOD SEAL SEAL SEAL GASKET SEAL GASKET/WATER PUMP GASKET GASKET/FUEL PUMP SEAL SEAL SEAL SEAL RING SEAL RING SEAL O-RING O-RING O-RING O-RING O-RING SEAL SEAL /DP Printed in U.S.A.

81 ET DIESEL TANK (TIER 1 ENGINE) (SN AD00454 AD99999) G FUEL TANK G DIESEL HOSE G FILLER NECK CLAMP COLLAR STRAINER/FUEL TANK RUBBER BRACKET TANK COVER SHCS M5-0.8 X ZO RING/SNAP S WASHER/GR A 5.3 ZO DIN SCREW JOINT WASHER/GR A 4.3 ZO DIN SCREW RING/SNAP S WASHER PLUG STOP SOLENOID G TRANSMITTER CS M4- X 16 C 8.8 ZO RING/SNAP S CS M X 25 C 8.8 ZO WASHER WASHER/GR A G ISOLATION MAT ANGLE CS M X 20 C8.8 ZO WASHER 8.4 ST A2C PLATE NUT/CAGE M RUBBER EXTRUSION (0.7M) CONICAL NIPPLE Printed in U.S.A /DP0306

82 153 - LUBRICATION (TIER 1 ENGINE) (SN AD00454 AD99999) ET DIPSTICK GUIDE O-RING TUBE SCREW SENDER/OIL PRESSURE OIL PUMP PRESSURE LIMITING VALVE O-RING SEAL HOUSING SCREW NUT OIL FILTER SEAL SCREW /DP Printed in U.S.A.

83 ET OIL COOLER (TIER 1 ENGINE) (SN AD00454 AD99999) G HYDRAULIC OIL COOLER G SCREW JOINT BRACKET CS M X 25 C 8.8 ZO CS M X 16 C8.8 ZO NUT/CAGE M CS M X 30 C8.8 ZO WASHER WASHER 8.4 ST A2C WASHER RING/SNAP S WASHER/GR A NUT/CAGE M Printed in U.S.A /DP0306

84 153 - HYDRAULIC PUMP PUMP/COMPLETE (INCLUDES 4, 5 & 6) G SOLENOID SWITCH G SOLENOID SWITCH G PILOT OIL SUPPLY UNIT G GEAR PUMP VARIABLE PUMP G SEAL KIT O-RING SCREW LOCKWASHER S G FLANGE SCREW JOINT SCREW JOINT SCREW JOINT ELBOW TEE TEST PORT SCREW JOINT SCREW O-RING O-RING O-RING /DP Printed in U.S.A.

85 HYDRAULIC PUMP DRIVE COUPLING PUMP CARRIER CS M10-1.5X30 C8.8 ZY LOCKWASHER S WASHER/GR A CS M X 35 C 8.8 ZO SHCS M X ZO WASHER Printed in U.S.A /DP0306

86 153 - HYDRAULIC OIL TANK HYDRAULIC OIL TANK G OIL LEVEL GLASS HYD OIL FILTER COMP G SCREW PLUG SHCS M X ZO LOCKWASHER S WASHER SCREW JOINT SCREW FITTING HYDRAULIC OIL FILTER WASHER/GR A SCREW JOINT TUBE G DISTRIBUTION PIECE SCREW JOINT BALL VALVE SCREW JOINT SEAL KIT/HYD FILTER G NON RETURN VALVE TUBE G BREATHER SCREW WASHER/GR A 10.5 ZO ELBOW COVER /DP Printed in U.S.A.

87 DRIVE MOTOR DRIVE UNIT COMPLETE G SCREW JOINT O-RING SCREW JOINT SCREW JOINT FITTING SEAL KIT (HYDRAULIC MOTOR) O-RING COVER PLUG LOCK RING BEARING DRIVE ASSY COVER VALVE SET CONTROL PLUNGER Printed in U.S.A /DP0306

88 153 - CONTROL VALVE CONTROL VALVE SCREW JOINT SCREW JOINT SCREW JOINT CORK WASHER SCREW JOINT SCREW JOINT ANGLE ANGLE ANGLE FITTING SCREW JOINT VALVE HLN INS M ZO SCREW JOINT WASHER SCREW JOINT WASHER WASHER/GR A G BRACKET BRACKET CS M10-1.5X20 C8.8 ZY LOCKWASHER S /DP Printed in U.S.A.

89 CONTROL VALVE G SECTION G SEGMENT G SEGMENT G SEGMENT G SEGMENT LEFT G INLET SECTION G SEGMENT RIGHT G SEGMENT G SEGMENT G SEGMENT G PRESSURE LIMITING VALVE G PRESSURE LIMITING VALVE G TIE ROD G SEAL KIT G VENT PLUG PILOT CONTROL CAP PILOT CONTROL CAP SEGMENT SEGMENT SEGMENT Printed in U.S.A /DP0306