Parts Manual 503Z. Compact Excavator. Beginning Serial Number: AC Form No Revision F Mar. 2008

Transcription

1 503Z Form Revision F Mar Compact Excavator Beginning Serial Number: AC02471 Parts Manual 2008 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 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 Newtonmeters 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 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 inclusions 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, nuts, and bolts are Grade 8.8, cadmium or zinc plated. NOTE:The following abbreviations may be used herein: ASSD...Assembled 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 LN...Lock Nut LT...Left LW...Lock Washer M...Meter or Meters MM/mm...Millimeter NPT...National Pipe Thread 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 TABLE OF CONTENTS Introduction... Inside Front Cover Table of Contents...1 Decal Locations...6 Diesel Engine...8 Engine Mounts...10 Cylinder Head, Valve Cover...12 Cylinder Block...13 Seal - Crankshaft...14 Oil Pan...16 Camshaft...18 Crankshaft, Piston...20 Lubrication...22 Cooling System...24 Fuel Injection System...26 Intake Manifold...28 Engine Air Filter...30 Exhaust Components...33 Fuel Tank...34 Fuel Supply...36 Throttle Lever (Cab)...38 Throttle Lever (Canopy)...39 Auto-Idle (Option)...40 Auto-Idle Installation (Option)...41 Hydraulic Pump Drive...42 Radiator...43 Oil Cooler...46 Hydraulic Oil Tank...48 Hydraulic Pump...50 Hydraulic Pump Assembly...52 Turntable Drive Unit Installation...53 Turntable Drive Unit...55 Drive Motor Installation...56 Drive Motor...57 Control Valve Fittings...58 Control Valve Assembly...60 Swivel Joint...61 Joysticks...62 Travel Pilot Valve...64 Auxiliary Hydraulics Pilot Valve...65 Dozer Blade Valve...66 Selection Valve...67 Proportional Valve (Option) /3 Valve (Option) /2 Valve (Option)...70 ISO/SAE Valve...71 Valve Block...72 Distribution Block...73 Hydraulic Pump Installation...74 Proportional Control (Option)...76 Boom Installation...77 Boom Cylinder...78 Dipper Arm Installation...80 Dipper Arm Cylinder...81 Bucket Installation...82 Bucket Cylinder...83 Boom Offset Cylinder Installation...84 Boom Offset Cylinder...85 Dozer Blade Installation...86 Dozer Blade Cylinder...87 Auxiliary Hydraulics Installation...88 ISO/SAE Valve Installation...90 Pilot Pressure Hoses...91 Hydraulic Tank Hoses...92 Dashboard (Cab)...94 Dashboard (Canopy)...96 Radio (Option)...97 Battery...98 Relay Box Horn Work Light Work Light - Rear (Option) Work Lights - Front (Option) Wire Harness - Chassis, Engine Wire Harness - Switch Wire Harness - Armrest Wire Harness - Work Light - Front (Option) Wire Harness - Work Light - Rear (Option) Wire Harness - Auto-Idle (Option) Printed in U.S.A /FP0308

4 TABLE OF CONTENTS Wire Harness - Proportional Control (Option) Chassis Rubber Track Steel Track (Option) Undercarriage, Rubber Track Undercarriage, Steel Track (Option) Track Tensioner, Rubber Track Track Tensioner, Steel Track (Option) Dozer Blade Lubrication Counterweight Counterweight (Option) Hood Tank Cover Partition Wall Chassis Cover Isolation Mats Boom Dipper Arm - Short Dipper Arm - Long (Option) Undercarriage Cover Cab Mounting Cab Frame Cab Frame Canopy Frame Cab Door Windshield Cab Windows Cab Trim Mirrors Rotating Beacon (Option) Operator s Seat Heater Air Conditioning Installation (Option) Air Conditioning (Option) Air Conditioning Compressor (Option) Tools Alphabetical Index Numerical Index /FP Printed in U.S.A

5 TABLE OF CONTENTS NOTES Printed in U.S.A /FP0308

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 If there is a decal on a part that is to be replaced, be sure that the decal is applied to the replacement part. 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 the machine. 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 model 503Z Compact Excavator is listed below: Part Description & Quantity Decal Kit - 503Z Decal/Diesel Fuel Decal/Hydraulic Oil Decal/Arrow (2 places) Decal/Lift Point(4 places) Decal/Tiedown Point (4 places) Decal/Warning Keep Away (2 places) Decal/Warning Read Manual Decal/Warning Rotating Fan (2 places) Decal/Travel Left Decal/Travel Right Decal/Warning Mandatory Shutdown Decal/Throttle Speed Decal/Warning Avoid Injury (2 places) Decal/Warning Avoid Injury Decal/Warning Entanglement Hazard Decal/Warning Hot Surface Decal/Warning Avoid Injury Decal/Zero Tail Decal/503Z (2 places) Decal SAE/ISO Control Decal/Dozer Blade Up/Down Decal/Warning Avoid Injury Decal/Controls SAE/ISO Lt Decal/Controls SAE/ISO Rt Decal/Lift Capacity Lube Chart Decal/Gehl 3.75 x (white) Decal/Gehl 3.75 x Decal/Gehl 4.75 X (2 Places) Reflector (2 places) /FP Printed in U.S.A

7 DECAL LOCATIONS Both Sides Both Sides Printed in U.S.A /FP0308

8 DECAL LOCATIONS The decal listing has been repeated for your convenience Part Description & Quantity Decal Kit - 503Z Decal/Diesel Fuel Decal/Hydraulic Oil Decal/Arrow (2 places) Decal/Lift Point(4 places) Decal/Tiedown Point (4 places) Decal/Warning Keep Away (2 places) Decal/Warning Read Manuall Decal/Warning Rotating Fan (2 places) Decal/Travel Left Decal/Travel Right Decal/Warning Mandatory Shutdown Decal/Throttle Speed Decal/Warning Avoid Injury (2 places) Decal/Warning Avoid Injury Part Description & Quantity Decal/Warning Entanglement Hazard Decal/Warning Hot Surface Decal/Warning Avoid Injury Decal/Zero Tail Decal/503Z (2 places) Decal SAE/ISO Control Decal/Dozer Blade Up/Down Decal/Warning Avoid Injury Decal/Controls SAE/ISO Lt Decal/Controls SAE/ISO Rt Decal/Lift Capacity Lube Chart Decal/Gehl 3.75 x (white) Decal/Gehl 3.75 x Decal/Gehl 4.75 X (2 places) Reflector (2 places) /FP Printed in U.S.A

9 DECAL LOCATIONS Overhead Panel Decals - positioning may vary by model and cabin style Printed in U.S.A /FP0308

10 503Z - DIESEL ENGINE (SN AH00579 AND UP) SEAL KIT BASIC ENGINE V-BELT (NON A/C)* STARTER ALTERNATOR ALTERNATOR BRACKET RADIATOR FAN 1 * For A/C Belt, see page /FP Printed in U.S.A

11 503Z - DIESEL ENGINE (SN AC AD07125) SEAL KIT BASIC ENGINE V-BELT (NON A/C)* 1 (SN AD04629 and up) V-BELT (NON A/C)* (SN AD04628 and before) ALTERNATOR ALTERNATOR BRACKET RADIATOR FAN STARTER 1 * For A/C Belt, see page 169. Printed in U.S.A /FP0308

12 503Z - ENGINE MOUNTS (SN AH00579 AND UP) ENGINE MOUNT-FRONT ENGINE MOUNT-FRONT ENGINE MOUNT-REAR ENGINE MOUNT-REAR THROTTLE CABLE BRACKET SHCS M X25 F8.8 ZY DIN LOCKWASHER S WASHER/GR A GROUND CABLE HEX SCREW LOCKWASHER WASHER CS M10-1.5X35 C8.8 ZY WASHER/GR A 15 DIN WASHER CS M10-1.5X16 C8.8 ZY DIN MOTOR MOUNT WASHER/GR A 8.4 ZO DIN /FP Printed in U.S.A

13 503Z - ENGINE MOUNTS (SN AC AD07125) ENGINE MOUNT-FRONT ENGINE MOUNT-REAR 1 (SN AD04651 and up) ENGINE MOUNT-REAR 1 (SN AD04650 and before) ENGINE MOUNT-REAR ENGINE MOUNT-FRONT SHCS M X ZO LOCKWASHER S SPACER GROUND CABLE HEX SCREW LOCKWASHER FLATWASHER CS M10-1.5X35 C8.8 ZY WASHER/GR A 15 DIN WASHER CS M X16 C8.8 ZO MOTOR MOUNT 4 Printed in U.S.A /FP0308

14 503Z - CYLINDER HEAD, VALVE COVER , CYLINDER HEAD CYLINDER HEAD 1 (SN AC AD07125) GUIDE VALVE PLUG INTAKE VALVE INTAKE VALVE 4 (SN AC AD07125) EXHAUST VALVE SPRING SPACER CLAMP CAP SEAL KIT SEAL KIT SHIELD SEAL RING SHAFT VALVE COVER SPRING DIAPHRAM VALVE COVER SEAL FILLER CAP O-RING HEADNUT O-RING GLOW PLUG CABLE CONNECTION /FP Printed in U.S.A

15 503Z - CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD SCREW COVER PLUG BUSHING PLUG AXIAL BEARING AXIAL BEARING (OS=0.25) MAIN BEARING SET MAIN BEARING SET (US=0.25) SCREW PLUG 1 Printed in U.S.A /FP0308

16 503Z - SEAL - CRANKSHAFT (SN AH00579 AND UP) GEARBOX SHAFT SEAL SCREW SEAL RING SHAFT SEAL FITTING PIN STUD BOLT FILLER CAP PIPELINE O-RING RUBBER PLUG FLYWHEEL HOUSING COVER O-RING SCREW O-RING SCREW HEXAGON NUT O-RING OIL FILLER PIPE /FP Printed in U.S.A

17 503Z - SEAL - CRANKSHAFT (SN AC AD07125) GEARBOX SHAFT SEAL COVER VALVE SPRING PLUG STUD BOLT FILLER CAP PIPELINE O-RING GEAR GEAR SCREW O-RING SCREW O-RING SCREW HEXAGON NUT O-RING OIL FILLER PIPE COVER FLYWHEEL HOUSING RUBBER PLUG FITTING PIN SHAFT SEAL 1 Printed in U.S.A /FP0308

18 503Z - OIL PAN (SN AC02514 AND UP) OIL PAN ASSEMBLY PLUG/OIL DRAIN O-RING SCREW M8X16 PLATED SCREW SCREW DRAIN COUPLER HOSE CLAMP DRAIN COUPLING FLEXIBLE TUBE (0.5M) DRAIN KIT /FP Printed in U.S.A

19 503Z - OIL PAN (SN AC02513 AND BEFORE) OIL PAN ASSEMBLY OIL DRAIN PLUG O-RING HEX SCREW SCREW HEX SCREW DRAIN COUPLER DRAIN COUPLING HOSE CLAMP FLEXIBLE TUBE (0.5M) DRAIN KIT 1 Printed in U.S.A /FP0308

20 503Z - CAMSHAFT (SN AH00579 AND UP) CAMSHAFT ASSEMBLY LIFTER PUSH ROD BRACKET GEAR GEAR SCREW FLANGE SPRING RING NUT /FP Printed in U.S.A

21 503Z - CAMSHAFT (SN AC AD07125) CAMSHAFT ASSEMBLY LIFTER PUSH ROD BRACKET GEAR GEAR SCREW FLANGE SPRING RING NUT 1 Printed in U.S.A /FP0308

22 503Z - CRANKSHAFT, PISTON (SN AH00579 AND UP) CRANK SHAFT GEAR FITTING KEY SPRING PIN BELT PULLEY RING GEAR PISTON PISTON (OS=0.25) CONN. ROD BEARING CONN. ROD BEARING (US=0.25) PISTON RING SET PISTON RING SET (OS=0.25) SCREW PIN LOCK RING CONNECTING ROD BUSHING /FP Printed in U.S.A

23 503Z - CRANKSHAFT, PISTON (SN AC AD07125) CRANK SHAFT GEAR FITTING KEY SPRING PIN BELT PULLEY 1 (SN AD04629 and up) BELT PULLEY 1 (SN AD04628 and before) SCREW PISTON PISTON (OS=0.25) BEARING BEARING (US=0.25) PISTON RING SET PISTON RING SET (OS=0.25) RING GEAR PIN LOCK RING CONNECTING ROD BUSHING 4 Printed in U.S.A /FP0308

24 503Z - LUBRICATION (SN AH00579 AND UP) DIPSTICK DIPSTICK TUBE SENDER/OIL PRESSURE OIL SUMP GASKET OIL SUMP SEAL RING FILTER HOUSING ASSY FILTER BASE GASKET ENGINE OIL FILTER BANJO BOLT PIPE LINE BANJO BOLT SEAL RING SCREW JOINT LUBRICATION OIL PUMP SEAL /FP Printed in U.S.A

25 503Z - LUBRICATION (SN AC AD07125) DIPSTICK DIPSTICK TUBE SENDER/OIL PRESSURE OIL SUMP GASKET OIL SUMP SEAL RING FILTER HOUSING ASSY FILTER BASE GASKET ENGINE OIL FILTER BANJO BOLT PIPE LINE BANJO BOLT SEAL RING SCREW JOINT 1 Printed in U.S.A /FP0308

26 503Z - COOLING SYSTEM (SN AH00579 AND UP) See page 43 for individual radiator components WATER PUMP WATER PUMP GASKET WATER PUMP SEAL O-RING GASKET THERMOSTAT THERMOSTAT GASKET THERMOSTAT GASKET/UPPER PLUG SEAL PIPE LINE PIPE LINE TEMPERATURE SENSOR BELT PULLEY V-BELT (NON A/C)* RADIATOR FAN FAN SPACER THERMOSTAT HOUSING DRAIN VALVE 1 * For A/C Belt, see page /FP Printed in U.S.A

27 503Z - COOLING SYSTEM (SN AC AD07125) See page 44 for individual radiator components WATER PUMP WATER PUMP GASKET WATER PUMP SEAL O-RING GASKET/THERMOSTAT THERMOSTAT GASKET/THERMOSTAT GASKET/THERMOSTAT PLUG SEAL RING PIPE LINE PIPE LINE SENSOR/THERMOSTAT 110 C THERMOSTAT HOUSING BELT PULLEY 1 (SN AD04629 and up) BELT PULLEY 1 (SN AD04628 and before) RADIATOR FAN EXPANSION TANK ASSY BRACKET/SUB-TANK FUEL LINE (0.40M) CLAMP TEMPERATURE SENSOR FAN SPACER V-BELT (NON A/C)* 1 (SN AD04629 and up) V-BELT (NON A/C)* (SN AD04628 and before) 1 * For A/C Belt, see page 169. Printed in U.S.A /FP0308

28 503Z - FUEL INJECTION SYSTEM (SN AH00579 AND UP) INJECTION PUMP INJECTION NOZZLE NOZZLE NUT SPRING - NOZZLE SEAT- NOZZLE SPRING PLATE - STOP PIN ADJUSTING WASHER CLAMP CLAMP INJECTION LINE INJECTION LINE INJECTION LINE INJECTION LINE TUBE BLEED LINE SOLENOID/STOP /FP Printed in U.S.A

29 503Z - FUEL INJECTION SYSTEM (SN AC AD07125) INJECTION PUMP INJECTION NOZZLE NOZZLE NUT SPRING NOZZLE SEAT-NOZZLE SPRING PLATE-STOP PIN ADJUSTING WASHER CLAMP CLAMP INJECTION LINE INJECTION LINE INJECTION LINE INJECTION LINE TUBE BLEED LINE SOLENOID/STOP 1 Printed in U.S.A /FP0308

30 503Z - INTAKE MANIFOLD (SN AH00579 AND UP) INTAKE MANIFOLD BREATHER INTAKE MANIFOLD GASKET INTAKE FLANGE GASKET /FP Printed in U.S.A

31 503Z - INTAKE MANIFOLD (SN AC AD07125) INTAKE MANIFOLD BREATHER INTAKE MANIFOLD GASKET INTAKE FLANGE GASKET 1 Printed in U.S.A /FP0308

32 503Z - ENGINE AIR FILTER (SN AH00579 AND UP) AIR FILTER COMPLETE AIR FILTER - INNER COVER DUST VALVE HOSE AIR SUCTION AIR FILTER - OUTER COLLAR CS M8-1.25X30 C8.8 ZY DIN LN INS M C8 ZY DIN WASHER 8.4 ST A2C DIRT INDICATOR AIR INTAKE HOSE HOSE CLAMP LATCH /FP Printed in U.S.A

33 503Z - ENGINE AIR FILTER (SN AD AD07125) AIR FILTER - OUTER AIR FILTER - INNER COVER DUST VALVE HOSE AIR SUCTION AIR FILTER COMPLETE COLLAR CS M8-1.25X30 C8.8 ZY DIN LN INS M C8 ZY DIN WASHER 8.4 ST A2C DIRT INDICATOR AIR INTAKE HOSE HOSE CLAMP 4 Printed in U.S.A /FP0308

34 503Z - ENGINE AIR FILTER (SN AD04628 AND BEFORE) AIR FILTER - OUTER AIR FILTER - INNER COVER DUST VALVE MUFFLER/INLET AIR FILTER - COMPLETE COLLAR HEX SCREW LN INS M C8 ZY WASHER/GR A 8.4 ZO DIRT INDICATOR HOSE/AIR INTAKE HOSE CLAMP HOSE/AIR INTAKE /FP Printed in U.S.A

35 503Z - EXHAUST COMPONENTS , EXHAUST MANIFOLD EXHAUST MANIFOLD GASKET HEXAGON NUT STUD BOLT SCREW STUD BOLT GASKET MUFFLER SCREW EXHAUST PIPE 1 (SN AD04907 and up) EXHAUST PIPE 1 (SN AD04906 and before) LOCKWASHER FLATWASHER ISOLATION MAT/EXHAUST HOSE CLAMP HN M C8 ZY 4 Printed in U.S.A /FP0308

36 503Z - FUEL TANK , (SN AC02651 AND UP) FUEL TANK KIT 1 (Includes 11 and 15-19) FUEL LEVEL SENDER W/GASKET SHCS M5-0.8 X ZO LOCKWASHER S WASHER/GR A 5.3 ZO DIN SCREW WASHER WASHER/GR A 13 DIN PLUG SCREW JOINT HEX HEAD SOCKET PIPE PLUG PLUG FUEL STRAINER TANK CAP/PLASTIC W/O KEYS SHIM MM AR SHIM MM AR SHIM MM AR SHIM MM AR RUBBER EXTRUSION (1.5M) 1 (SN AC02811 and up) BRACKET 1 (SN AC03168 and before) SINK SCREW 2 (SN AC03168 and before) LN INS M L8 ZY 2 (SN AC03168 and before) HEX SCREW 2 (SN AC03168 and before) SPACER (SN AC03168 and before) KEYS (W/O LOCK) /FP Printed in U.S.A

37 503Z - FUEL TANK (SN AC02650 AND BEFORE) FUEL TANK KIT 1 (Includes 11 and from page 34) FUEL LEVEL SENDER W/GASKET 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 PLUG FUEL STRAINER TANK CAP/PLASTIC W/O KEYS KEYS (W/O LOCK) BRACKET SINK SCREW LN INS M L8 ZY HEX SCREW SPACER 2 Printed in U.S.A /FP0308

38 503Z - FUEL SUPPLY (SN AH00579 AND UP) FUEL LINE FUEL LINE FUEL LINE (0.6M) FUEL LINE (1.6M) WATER SEPARATOR FILTER GASKET/FILTER HOUSING HOSE CLAMP FUEL FILTER FUEL PUMP HB M8-1.25X70 C8.8 ZY LOCKWASHER WASHER BRACKET/FUEL FILTER WASHER/GR A 10.5 ZO SCREW JOINT O-RING SCREW LOCKWASHER S WASHER FUEL LINE DIESEL COOLER CS M10-1.5X35 C8.8 ZY WASHER/GR A HN M F8 ZY DIN NUT /FP Printed in U.S.A

39 503Z - FUEL SUPPLY (SN AC AD07125) FUEL LINE (3.0M) FUEL LINE FUEL LINE (0.6M) FUEL LINE (1.6M) WATER SEPARATOR 1 (Includes 6) FILTER GASKET/FILTER HOUSING HOSE CLAMP FUEL FILTER FUEL PUMP HB M8-1.2 X 70 C 8.8 ZO LOCKWASHER FLATWASHER BRACKET/FUEL FILTER PIPE PIPE ASSY/FUEL OIL O-RING SCREW LOCKWASHER S WASHER 1 Printed in U.S.A /FP0308

40 503Z - THROTTLE LEVER (CAB) THROTTLE CABLE G THROTTLE LEVER KNOB SHCS M6-1X25 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN BRACKET /FP Printed in U.S.A

41 503Z - THROTTLE LEVER (CANOPY) THROTTLE CABLE THROTTLE LEVER - COMPLETE KNOB SHCS M6-1X25 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN THROTTLE LEVER BRACKET CLUTCH DISC PLUG HEX NUT SHCS M5-0.8X10 C8.8 ZY LOCKWASHER S WASHER/GR A 5.3 ZO DIN BRACKET 1 Printed in U.S.A /FP0308

42 503Z - AUTO-IDLE (OPTION) CYLINDER SCREW JOINT HN M6-1 C8 ZY DIN CLEVIS PLATE CS M6-1X12 C8.8 ZY DIN LN INS M6-1 C8 ZY DIN JOINT CS M8-1.25X25 C8.8 ZY DIN HN M C8 ZY DIN WASHER LN INS M C8 ZY DIN BRACKET CS M6-1X20 C8.8 ZY DIN WASHER GR A6.4 ZO DIN LOCKWASHER S HEX SCREW LOCKWASHER /FP Printed in U.S.A

43 503Z - AUTO-IDLE INSTALLATION (OPTION) HP HOSE HP HOSE HP HOSE º FITTING TEE 2 6 * AUTO IDLE RETROFIT KIT 1 * To be provided at a later time. Printed in U.S.A /FP0308

44 503Z - HYDRAULIC PUMP DRIVE COUPLER COMPLETE PUMP BRACKET PLUG SHCS M X ZO WASHER SCREW LOCKWASHER S WASHER/GR A /FP Printed in U.S.A

45 503Z - RADIATOR (SN AH00579 AND UP) RADIATOR CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A RADIATOR CAP RADIATOR HOSE W/O AC CLAMP RADIATOR HOSE CLAMP RADIATOR SHROUD CAGE NUT SCREW RING CS M8-1.25X25 C8.8 ZY DIN LOCKWASHER WASHER 8.4 ST A2C NUT/CAGE M PROTECTING SCREEN HN M6-1 C8 ZY DIN WASHER GR A6.4 ZO DIN LOCKWASHER S WASHER/GR A 10.5 ZO CS M10-1.5X25 C8.8 ZY NUT/CAGE M RESERVOIR CS M8-1.25X16 C8.8 ZY DIN BRACKET/SUB-TANK COLLAR HOSE CLAMP FUEL LINE (0.6M) 1 Printed in U.S.A /FP0308

46 503Z - RADIATOR (SN AD AD07125) RADIATOR RADIATOR BRACKET SHCS M X30 F8.8 ZY DIN LOCKWASHER S WASHER/GR A CROSS BAR LOCKWASHER HEX SCREW WASHER 8.4 ST A2C LN INS M C8 ZY DIN CS M8-1.25X35 C8.8 ZY DIN AIR GUIDE PLATE RADIATOR HOSE W/O AC CLAMP CLAMP RADIATOR HOSE DRAIN SCREW RUBBER BUFFER PROTECTING SCREEN RADIATOR CAP PLATE PLATE PLATE PLATE PLUG SPACER RADIATOR HOSE - A/C (See page 167) /FP Printed in U.S.A

47 503Z - RADIATOR (SN AD04628 AND BEFORE) RADIATOR BRACKET/RADIATOR SHCS M X30 F8.8 ZY DIN LOCKWASHER S WASHER/GR A CROSS BAR LOCKWASHER HEX SCREW WASHER 8.4 ST A2C LN INS M C8 ZY DIN CS M8-1.25X35 C8.8 ZY DIN AIR GUIDE PLATE RADIATOR HOSE W/O AC CLAMP CLAMP RADIATOR HOSE DRAIN SCREW RUBBER BUFFER PROTECTING SCREEN RADIATOR CAP PLATE PLATE PLATE PLATE PLUG SPACER (SN AC03732 and up) RADIATOR HOSE - A/C (See page 167) 1 Printed in U.S.A /FP0308

48 503Z - OIL COOLER (SN AH00579 AND UP) OIL COOLER CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A SCREW JOINT /FP Printed in U.S.A

49 503Z - OIL COOLER (SN AC AD07125) OIL COOLER SCREW CONNECTION SHCS M8-1.25X20 C8.8 ZY LOCKWASHER FLATWASHER 4 Printed in U.S.A /FP0308

50 503Z - HYDRAULIC OIL TANK (SN AH00579 AND UP) HYDRAULIC TANK SCREW WASHER WASHER/GR A 13 DIN PLUG SCREW COVER PLATE O-RING SHCS M8-1.25X20 C8.8 ZY DIN LOCKWASHER WASHER CAGE NUT RETURN FILTER SCREW JOINT MANIFOLD NON RETURN VALVE PRESSURE SWITCH SCREW LOCKWASHER S WASHER/GR A G BREATHER FILLER CAP HYDRAULIC OIL ELEMENT OIL TANK CAP PIPE LINE (0.40M) WASHER/GR A 10.5 ZO CS M10-1.5X25 C8.8 ZY SCREW JOINT SCREW JOINT SCREW JOINT 12L SCREW JOINT º FITTING TEE O-RING HYDRAULIC OIL FILTER ELEMENT SEAL KIT SCREW JOINT ANGLE SCREW JOINT SHIM MM AR SHIM MM AR SHIM MM AR SHIM MM AR DECAL MARKING DECAL MARKING /FP Printed in U.S.A

51 503Z - HYDRAULIC OIL TANK (SN AC AD07125) HYDRAULIC TANK SCREW WASHER WASHER/GR A 13 DIN PLUG SCREW COVER PLATE O-RING SHCS M8-1.25X20 C8.8 ZY DIN LOCKWASHER FLATWASHER CAGE NUT RETURN FILTER SCREW JOINT MANIFOLD NON RETURN VALVE PRESSURE SWITCH SCREW LOCKWASHER S WASHER/GR A G BREATHER FILLER CAP OIL TANK CAP 1 (SN AD04680 and up) OIL TANK CAP 1 (SN AD04679 and before) HEX SCREW LOCKWASHER S WASHER/GR A 5.3 ZO DIN SCREW JOINT SCREW JOINT SCREW JOINT 12L SCREW JOINT º FITTING ELBOW O-RING HYDRAULIC OIL FILTER ELEMENT SEAL KIT SCREW JOINT ANGLE SCREW JOINT SHIM MM AR SHIM MM AR SHIM MM AR SHIM MM AR DECAL MARKING 1 (SN AC02925 and up) DECAL MARKING 1 (SN AC02925 and up) CS M X 25 C8.8 ZY WASHER/GR. A 10.5 ZO PIPE LINE (0.40 M) HYDRAULIC OIL ELEMENT 1 (SN AD04680 and up) HYDRAULIC OIL ELEMENT (SN AD04679 and before) 1 Printed in U.S.A /FP0308

52 503Z - HYDRAULIC PUMP EXTERNAL COMPONENTS (SN AH00579 AND UP) HYDRAULIC PUMP SCREW JOINT SCREW JOINT SCREW JOINT O-RING ADAPTOR SUCTION FLANGE ACCUMULATOR LOCKWASHER S SHCS M X25 F8.8 ZY DIN TEE TEST CONNECTION 8 L A3C ELBOW TEST PORT /FP Printed in U.S.A

53 503Z - HYDRAULIC PUMP EXTERNAL COMPONENTS (SN AC AD07125) HYDRAULIC PUMP HYDRAULIC PUMP SCREW JOINT SCREW JOINT SCREW JOINT O-RING ADAPTER SUCTION FLANGE ACCUMULATOR LOCKWASHER S SHCS M X ZO TEE TEST CONNECTION 8 L A3C ELBOW (SN AC03368 and up) TEST PORT (SN AC03368 and up) ELBOW REDUCTION JOINT 3 (SN AC03367 and before) TEST PORT 3 Printed in U.S.A /FP0308

54 503Z - HYDRAULIC PUMP INTERNAL COMPONENTS DRIVE UNIT SWASH PLATE SCREW SCREW BEARING BEARING GEAR PUMP O-RING O-RING O-RING CONTROL HOUSING ROTARY SHAFT SEAL VALVE G SOLENOID SWITCH G SOLENOID SWITCH SCREW HYDRAULIC PUMP SEAL KIT O-RING O-RING /FP Printed in U.S.A

55 503Z - TURNTABLE DRIVE UNIT INSTALLATION (SN AH00579 AND UP) 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 /FP0308

56 503Z - TURNTABLE DRIVE UNIT INSTALLATION (SN AC AD07125) HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE /FP Printed in U.S.A

57 503Z - TURNTABLE DRIVE UNIT SWIVEL DRIVE SHCS M X ZO WASHER/NORD-LOCK NL SCREW CONNECTION TEE º FITTING SCREW JOINT º FITTING SCREW JOINT SCREW JOINT TORQUE MOTOR SEAL KIT SEAL KIT SHOCK VALVE ANTICAVITATION VALVE KIT BRAKE ASSY TIMER VALVE 1 Printed in U.S.A /FP0308

58 503Z - 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 HP HOSE HP HOSE /FP Printed in U.S.A

59 503Z - DRIVE MOTOR DRIVE MOTOR COMPLETE SCREW JOINT SCREW JOINT TRAVEL MOTOR SEAL KIT DRIVE MOTOR SEAL BEARING O-RING PLUG LOCK RING BRAKE VALVE CONTROL PLUNGER ANTICAVITATION VALVE ENGINE BRAKE KIT SEAL RING 2 Printed in U.S.A /FP0308

60 503Z - CONTROL VALVE FITTINGS (SN AH00579 AND UP) CONTROL BLOCK FASTEN PLATE FASTEN PLATE (OPTION) LN INS M C8 ZY DIN WASHER CS M10X LOCKWASHER S WASHER/GR A FASTEN PLATE SCREW JOINT SCREW JOINT FITTING SCREW CONNECTION SCREW JOINT SCREW JOINT SCREW JOINT TEE SCREW JOINT SEAL KIT/CONTROL VALVE PRESSURE SWITCH (OPTION) RUBBER BUFFER O-RING (OPTION) SCREW JOINT SCREW JOINT RUBBER METAL BUFFER PLUG /FP Printed in U.S.A

61 503Z - CONTROL VALVE FITTINGS (SN AC AD07125) CONTROL BLOCK FASTEN PLATE RUBBER METAL BUFFER HLN INST M C8 ZO WASHER CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A FASTEN PLATE SCREW JOINT SCREW JOINT º FITTING SCREW CONNECTION SCREW JOINT SCREW JOINT SCREW JOINT TEE SCREW JOINT SEAL KIT CONTROL VALVE RUBBER BUFFER 2 (SN AC02943 and up) RUBBER BUFFER 2 (SN AC02942 and before) SCREW JOINT 2 (SN AC03330 and before) SCREW JOINT 1 (SN AC03331 and up) SCREW JOINT (SN AC03331 and up) 1 Printed in U.S.A /FP0308

62 503Z - CONTROL VALVE ASSEMBLY BUCKET SEGMENT LIFTING BOOM SEGMENT SEGMENT (LEFT) INPUT SEGMENT SEGMENT (RIGHT) SEGMENT SUPPL. HYDRAULIC SEGMENT EXIT SEGMENT SEGMENT DOZER BLADE SEGMENT ROTARY SEGMENT AUXILIARY SEGMENT PRESSURE RELIEF VALVE MAIN PRESSURE LIMITER MAIN PRESSURE LIMITER VALVE CAP SCREW O-RING VALVE CAP VALVE CAP VALVE CAP VALVE CAP VALVE CAP TIE ROD NUT SHUT OFF VALVE NON RETURN VALVE /FP Printed in U.S.A

63 503Z - SWIVEL JOINT SWIVEL JOINT II G SCREW JOINT SCREW JOINT SCREW JOINT º FITTING ELBOW TEE º FITTING SCREW JOINT SEAL KIT (For 1 only) CS M10-1.5X30 C10.9 ZY DIN WASHER 4 Printed in U.S.A /FP0308

64 503Z - JOYSTICKS (SN AD05132 AND UP) 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 CONTROL RESTRICTOR RESTRICTOR RUBBER CAP SET BELLOWS JOYSTICK KIT/JOYSTICK LT/PROPORTIONAL KIT/JOYSTICK RT /FP Printed in U.S.A

65 503Z - JOYSTICKS (SN AD05131 AND BEFORE) VALVE UNIVERSAL JOINT SCREW JOINT SHCS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A 6.4 ZO DIN PILOT VALVE SEAL KIT RUBBER CAP SET RESTRICTOR PILOT CONTROL RESTRICTOR SCREW JOINT 4 (SN AC02873 and before) RESTRICTOR 4 (SN AC02874 and up) BELLOWS JOYSTICK KIT/JOYSTICK LT/PROPORTIONAL KIT/JOYSTICK RT 1 Printed in U.S.A /FP0308

66 503Z - TRAVEL PILOT VALVE TRAVEL PILOT VALVE COMPLETE RUBBER BELLOWS SEAL KIT LT/RT SEAL KIT SCREW JOINT SCREW HEX SCREW LOCKWASHER FLATWASHER SHCS M X ZO G TRAVEL JOYSTICK LT G TRAVEL JOYSTICK RT KNOB SET SCREW PILOT CONTROL RESTRICTOR LOCKWASHER S WASHER/GR A SCREW º FITTING TEE KIT/PEDAL PLATE /FP Printed in U.S.A

67 503Z - AUXILIARY HYDRAULICS PILOT VALVE CONTROL VALVE HEX SCREW LOCKWASHER FLATWASHER º FITTING SCREW JOINT ELBOW PLUNGER KIT 1 Printed in U.S.A /FP0308

68 503Z - DOZER BLADE VALVE DOZER BLADE VALVE COMPLETE CS M8-1.25X25 C8.8 ZY DIN LOCKWASHER FLATWASHER º FITTING PLUNGER KIT SCREW JOINT DOZER BLADE LEVER PEDAL WASHER SHCS M X35 C10.9 ZY DIN KNOB /FP Printed in U.S.A

69 503Z - SELECTION VALVE REVERSING VALVE COMPLETE SCREW JOINT WASHER GR A6.4 ZO DIN SCREW JOINT CS M6-1.00X50 C8.8 ZO LOCKWASHER S SEAL KIT NUT COIL SOLENOID ASSY 1 Printed in U.S.A /FP0308

70 503Z - PROPORTIONAL VALVE (OPTION) (SN AD04690 AND UP) PROPORTIONAL VALVE SOLENOID SCREW JOINT º FITTING CS M6-1X45 C8.8 ZY DIN LOCKWASHER S WASHER GR A6.4 ZO DIN /FP Printed in U.S.A

71 503Z - 4/3 VALVE (OPTION) (SN AD04689 AND BEFORE) /3 VALVE SCREW JOINT TEE CS M6-1X45 C8.8 ZY DIN LOCKWASHER S WASHER GR A6.4 ZO DIN SOLENOID 2 Printed in U.S.A /FP0308

72 503Z - 3/2 VALVE (OPTION) SOLENOID VALVE 1 (Includes 6) SCREW JOINT SCREW LOCKWASHER S WASHER SOLENOID /FP Printed in U.S.A

73 503Z - ISO/SAE VALVE G ISO/SAE VALVE SCREW JOINT º FITTING HEX SCREW LOCKWASHER S WASHER/GR A 5.3 ZO DIN TEE 1 Printed in U.S.A /FP0308

74 503Z - VALVE BLOCK VALVE BLOCK SCREW JOINT SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN /FP Printed in U.S.A

75 503Z - DISTRIBUTION BLOCK DISTRIBUTION BLOCK SCREW JOINT SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN º FITTING 2 Printed in U.S.A /FP0308

76 503Z - HYDRAULIC PUMP INSTALLATION (SN AC03368 AND UP) HP HOSE HP HOSE HP HOSE HP HOSE SUCTION HOSE HOSE CLAMP ELBOW TEST PORT /FP Printed in U.S.A

77 503Z - HYDRAULIC PUMP INSTALLATION (SN AC03367 AND BEFORE) HP HOSE HP HOSE HP HOSE HP HOSE SUCTION HOSE HOSE CLAMP ELBOW REDUCTION JOINT TEST CONNECTION 8 L A3C 3 Printed in U.S.A /FP0308

78 503Z - PROPORTIONAL CONTROL (OPTION) HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE TEE PROPORTIONAL CONTROL DECAL /FP Printed in U.S.A

79 503Z - BOOM INSTALLATION HP HOSE HP HOSE HP HOSE SCREW JOINT HP HOSE HP HOSE 1 Printed in U.S.A /FP0308

80 503Z - BOOM CYLINDER (SN AC04085 AND UP) BOOM CYLINDER CYLINDER SEAL KIT PISTON ROD GUIDE BUSHING PISTON SET SCREW G SCREW JOINT HYDRAULIC PIPE SCREW JOINT CLAMP CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A GUIDE PROTECTING RAIL NUT WASHER/GR A CLAMP FHSCS M8-1.25X20 C8.8 ZY DIN SHOCK ABSORBER STEEL BUSHING /FP Printed in U.S.A

81 503Z - BOOM CYLINDER (SN AC04084 AND BEFORE) REPAIR SET - BOOM CYLINDER CYLINDER SEAL KIT PISTON ROD GUIDE BUSHING PISTON SET SCREW G SCREW JOINT HYDRAULIC PIPE SCREW JOINT CLAMP CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A GUIDE PROTECTING RAIL NUT WASHER/GR A COLLAR STEEL BUSHING SHOCK ABSORBER 1 Printed in U.S.A /FP0308

82 503Z - DIPPER ARM INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT HP HOSE PIPE LINE /FP Printed in U.S.A

83 503Z - DIPPER ARM CYLINDER DIPPER ARM CYLINDER SEAL KIT CYLINDER HEAD GLAND PISTON ROD PISTON SET SCREW STEEL BUSHING SCREW JOINT BRACKET/HOSE CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A Printed in U.S.A /FP0308

84 503Z - BUCKET INSTALLATION , HP HOSE HP HOSE HP HOSE (SHORT DIPPER ARM) HP HOSE (LONG DIPPER ARM) HP HOSE SCREW JOINT HP HOSE HP HOSE PIPE LINE (SN AC04073 and up) PIPE LINE (SN AC04072 and before) PIPE LINE (SN AC04073 and up) PIPE LINE (SN AC04072 and before) /FP Printed in U.S.A

85 503Z - BUCKET CYLINDER BUCKET CYLINDER CYLINDER SEAL KIT GUIDE BUSHING PISTON ROD PISTON SET SCREW STEEL BUSHING BRACKET/HOSE CS M10-1.5X20 C8.8 ZY DIN LOCKWASHER S WASHER/GR A SCREW JOINT 2 Printed in U.S.A /FP0308

86 503Z - BOOM OFFSET CYLINDER INSTALLATION HP HOSE (SN AC03331 and up) HP HOSE (SN AC03330 and before) HP HOSE (SN AC03331 and up) HP HOSE (SN AC03330 and before) HP HOSE HP HOSE HP HOSE HP HOSE /FP Printed in U.S.A

87 503Z - BOOM OFFSET CYLINDER BOOM OFFSET CYLINDER PIN SEAL PISTON ROD PISTON DRIVE MOTOR COMPLETE SEAL KIT SET SCREW BUSHING CAP GREASE ZERK-9MM HEX HEAD HEXAGON NUT DAMPING SCREW JOINT (SN AC03331 and up) SCREW JOINT (SN AC03330 and before) SCREW JOINT (SN AC03331 and up) SCREW JOINT (SN AC03330 and before) º FITTING (SN AC03331 and up) º FITTING (SN AC03330 and before) Printed in U.S.A /FP0308

88 503Z - DOZER BLADE INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE /FP Printed in U.S.A

89 503Z - DOZER BLADE CYLINDER DOZER BLADE CYLINDER 1 COMPLETE SHIELD SHCS M X ZO LOCKWASHER S WASHER/GR A GREASE ZERK-9MM HEX HEAD CAP SCREW JOINT PISTON ROD PISTON GLAND SET SCREW SEAL KIT RESTRICTOR 1 Printed in U.S.A /FP0308

90 503Z - AUXILIARY HYDRAULICS INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE 1 7 * HP HOSE 2 9 * HP HOSE LOCK SCREW CONNECTION LOCK SCREW CONNECTION LOCKING CAP PLUG HYDRAULIC PIPE 2 (SN AC04073 and up) HYDRAULIC PIPE (SN AC04072 and before) HYDRAULIC PIPE 1 (SN AC04073 and up) HYDRAULIC PIPE 1 (SN AC04072 and before) COUPLING/FEMALE A13 BG CAP COUPLING/FEMALE A17 3/ CAP COUPLING/MALE A13 BG CAP CABLE HOSE 1 (SN AC02780 and up) COUPLING KIT 1 *See the following page for proper hose identification /FP Printed in U.S.A

91 503Z - AUXILIARY HYDRAULICS INSTALLATION Use the following tables to determine proper hose identification. LONG DIPPER ARM Position Hose Length Part Description A HP HOSE A HP HOSE B HP HOSE B HP HOSE SHORT DIPPER ARM A HP HOSE B HP HOSE B HP HOSE A - Pressure Hose B - Return Hose Printed in U.S.A /FP0308

92 503Z - ISO/SAE VALVE INSTALLATION HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE HP HOSE SCREW JOINT PLUG NUT /FP Printed in U.S.A