Parts Manual. Model 502. Compact Excavator. Serial Number AA01022 to AA Form No Revision B July 2007

Transcription

1 Model 502 Form Revision B July 2007 Compact Excavator Serial Number AA01022 to AA01890 Parts Manual 2007 Gehl Company All Rights Reserved. Printed in USA

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

3 Introduction... i Table of Contents...1 Decal Locations...3 Undercarriage, Rubber Track...8 Undercarriage, Steel Track...9 Supporting Roller...11 Track Tensioner, Rubber Track...12 Track Tensioner, Rubber & Steel Tracks..13 Bottom Roller...14 Dozer Blade...15 Chassis...16 Chassis Covers...17 Chassis Lubrication...18 Rear Plate...19 Counterweight...20 Engine Hood...21 Valve Cover...22 Hose Cover...23 Hydraulic Tank Cover...24 Boom...25 Dipper Arm...26 Connecting Link...27 Cab Mounting...28 Cab (Cont.)...29 Cab (Cont.)...30 Cab (Cont.)...31 CAB (Cont.)...33 Cab (Cont.)...34 Wiring Harness...35 Front Window...36 Cab Windows...37 Cab Sliding Window...38 Cab Door...39 Cab Isolation Mats...40 Heater...41 Operator s Seat...42 Diesel Engine...43 Engine Mounts...44 Cylinder Head...45 Cylinder Block...46 Seal Crankshaft...47 Oil Pan...48 Camshaft...49 Crankshaft & Pistons...50 Oil Lubrication System...51 Cooling System...52 Fuel Injection System...53 TABLE OF CONTENTS Fuel Tank...54 fuel tank...54 Fuel System...55 Throttle Assembly...56 Cooling System...57 Air Intake System...58 Exhaust System...59 Hydraulic Pump Drive...60 Hydraulic Tank...61 Oil Cooler...62 Drive Motor...63 Swivel Joint...64 Hydraulic Pump External Parts...65 Hydraulic Pump Internal Parts...66 Swivel Drive...67 Valve Block Valve Block Pilot Oil Supply Unit...70 Valve Block...71 Manifold Block...72 Reversing Valve...73 Hand Levers...74 Dozer Blade Valve...75 Pilot Valve Travel...76 Auxiliary Hydraulics Pilot Valve /3 Valve (Option)...78 Solenoid Valve (Option)...79 ISO/SAE Pattern Valve (Option)...80 Boom Cylinder...81 Dipper Arm Cylinder...82 Bucket Cylinder...83 Swivel Cylinder...84 Dozer Blade Cylinder...85 Hydraulic Pump Hose Installation...86 Oil Cooler Hose Installation...87 Turntable Drive Unit Hose Installation...88 Travel Motor Hose Installation...89 Valve Hose Installation...90 Pilot Oil Supply Hose Installation...91 Swivel Cylinder Hose Installation...92 Dozer Blade Cylinder Hose Installation...93 Boom Hose Installation...94 Hand Levers Hose Installation...95 ISO/SAE Valve Hose Installation (Option)96 Pilot Pressure Hose Installation...97 Electrical Auxiliary Hose Installation (Option) 98 Printed in U.S.A /BP0707

4 Engine Wire Harness Left Console Wire Harness Right Console Wire Harness Relay Box Relay Box Installation Chassis Headlight Boom Headlight Battery Horn Tools Numerical Index TABLE OF CONTENTS /BP Printed in U.S.A

5 GENERAL INFORMATION Decal location information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations. To ensure proper selection of the correct replacement decals, compare all of the various closeup location drawings to your machine before starting to refinish the unit. Then circle each decal shown (applicable to your machine) while checking off its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal. NOTE:Refer to the SAFETY chapter of the Operator's Manual for the specific information provided on all of the various safety decals furnished in the decal kit(s). NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new decal. To apply, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth out the decal surface. CAUTION ALWAYS follow safety precautions on decals. Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE all applicable decals are affixed to your unit. DECAL LOCATIONS PAINT NOTICE Use this list to order paint for refinishing: qts. Construction Yellow (GEHL) qts. Light Gray (GEHL) qts. Dark Gray (GEHL) (12.8 oz. Spray Cans) Yellow (GEHL) (12.8 oz. Spray Cans) Dark Gray (GEHL) (12.8 oz. Spray Cans) Light Gray (GEHL) The decal kit for the Compact Excavator is listed below: Part Description & Quantity Diesel Fuel Hydraulic Oil Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING - Keep Away (2 places) WARNING - Read Manual WARNING - Rotating Fan Travel Left Travel Right WARNING - Mandatory Shutdown Manual Throttle WARNING - Avoid Injury (2 places) WARNING - Avoid Injury WARNING - Entanglement Hazard WARNING - Hot Surface (2 places) WARNING - Avoid Injury (2 places) Dozer Blade - Up/Down Right Joystick Control Left Joystick Control Control Pattern Left Graphic Right Graphic Engine Compartment Latch Hydraulics Compartment Latch GEHL GEHL (2 places) GEHL Protective Structure Lifting Capacity Warning - Hydraulic Reservoir Lubrication Printed in U.S.A /BP0707

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

7 DECAL LOCATIONS Overhead Panel Decals - positioning may vary by model and cabin style Printed in U.S.A /BP0707

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

9 DECAL LOCATIONS Printed in U.S.A /BP0707

10 502 - UNDERCARRIAGE, RUBBER TRACK UNDERCARRIAGE TRACK TENSIONER COMPLETE 2 (SN AA00674V and up) See page 12 for individual components TRACK TENSIONER COMPLETE 2 (SN AA00673V and before) See page 13 for individual components VALVE RING BOTTOM ROLLER 10 See page 14 for individual components SUPPORTING ROLLER 2 See page 11 for individual components TRAVELING GEAR SPROCKET RUBBER TRACK SWIVEL JOINT 1 See page 64 for individual components TURNTABLE SPROCKET GUARD LT SPROCKET GUARD RT COVER COVER COVER COVER LW SPRING B14 DIN SEAL KIT-TRACK TENSION CYLINDER PLUG GREASE ZERK (9mm HEX HEAD) PROTECTION CAP SHCS M X ZO HB M X 70 C10.9 ZO HLN INS M ZO SHCS M X ZO SHCS M X ZO FHCS M X 40 C10.9 ZO CS M X 30 C10.9 ZO SHCS M X ZO CS M X 20 C8.8 ZO CS M X 20 C8.8 ZO LW SPRING B14 DIN (SN AA04456 and before) WASHER (SN AA04457 and up) WASHER GR A15 DIN (SN AA04456 and before) WASHER/ROUND HI-TENS LOCKWASHER S WASHER WASHER GR A WASHER/NORD-LOCK NL WASHER SPRINGS TENSION ROLLER TENSION CYLINDER SHCS M X 20 C8.8 ZY SEAL (2.0M) /BP Printed in U.S.A

11 502 - UNDERCARRIAGE, STEEL TRACK UNDERCARRIAGE TRACK TENSIONER COMPLETE 2 See page 13 for individual components TENSION ROLLER RING BOTTOM ROLLER 10 See page 14 for individual components SUPPORTING ROLLER 2 See page 11 for individual components TRAVELING GEAR SPROCKET STEEL TRACK STEEL TRACK/RUBBERIZED TURNTABLE SPROCKET GUARD LT SPROCKET GUARD RT COVER COVER COVER COVER LW SPRING B14 DIN SEAL KIT/TRACK TENSION CYLINDER PLUG GREASE ZERK (9mm HEX HEAD) PROTECTION CAP SHCS M X ZO HB M X 70 C10.9 ZO HLN INS M Z SHCS M X ZO SHCS M X ZO FHCS M X ZO CS M X 30 C10.9 ZO SHCS M X ZO CS M X 25 C10.9 ZO CS M X 20 C8.8 ZO CS M X 25 C8.8 ZO 36 (SN AA04456 and before) WASHER (SN AA04457 and up) WASHER GR A15 DIN (SN AA04456 and before) WASHER/ROUND HI-TENS LOCKWASHER S WASHER WASHER GR A WASHER/NORD-LOCK NL WASHER SPRINGS SWIVEL JOINT 1 See page 64 for individual components TENSION CYLINDER 2 Printed in U.S.A /BP0707

12 502 - UNDERCARRIAGE, STEEL TRACK VALVE SHCS M X 20 C8.8 ZY CHAIN GUARD RT CHAIN GUARD LT WASHER CHAIN LINK STEEL PIN/MASTER STEEL PIN SEAL (2.0M) SEAL KIT /BP Printed in U.S.A

13 502 - SUPPORTING ROLLER SUPPORTING ROLLER LOCKWASHER S SET SCREW BEARING SEAL WASHER WASHER SHCS M5-0.8 X 16 C8.8 ZY 3 Printed in U.S.A /BP0707

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

15 502 - TRACK TENSIONER, RUBBER & STEEL TRACKS TRACK TENSIONER COMPLETE VALVE RING SHCS M X ZY WASHER/ROUND HI-TENS SPRING TENSION ROLLER TENSION CYLINDER SEAL KIT/TENSION CYLINDER SEAL KIT/TENSION ROLLER BUSHING BRACKET SHAFT PLUG SCREW WASHER 8 Printed in U.S.A /BP0707

16 502 - BOTTOM ROLLER BOTTOM ROLLER BUSHING SEAL KIT PLUG /BP Printed in U.S.A

17 502 - DOZER BLADE (5, 7, 8) x DOZER BLADE/PREASSEMBLED PIN PIN PIN BUSHING PIN/SPRING M8 X 80 ZO GREASE ZERK (9mm HEX HEAD) CAP BUSHING PIN SEAL BLADE CYLINDER COMPLETE See page 85 for individual components 1 Printed in U.S.A /BP0707

18 502 - CHASSIS * TURNING GEAR SWING BRACKET TURNTABLE SEAL (2.0M) BUSHING SWIVEL CYLINDER 1 See page 84 for individual components PIN PIN PIN/SPRING M8 x WASHER CAP O-RING HN SLTD M48-3 ZO PIN/SPRING M8 X 80 ZO HB M16-2 X 90 C10.9 ZY WASHER SCREW WASHER/NORD-LOCK NL CS M X 35 C10.9 ZO SCREW LOCKWASHER S WASHER GR A PIN BUSHING PIN SEAL PIN SEAL POP RIVET A4 x BRACKET SHCS M X 30 F8.8 ZY WASHER GR A REFLECTOR BRACKET/AIR INTAKE FILTER SCREW HEX NUT M WASHER GR A * Replaced by P/N for service /BP Printed in U.S.A

19 502 - CHASSIS COVERS COVER COVER COVER COVER COVER SHCS M X 20 C8.8 ZY WASHER WASHER GR A SEAL FOAM (7.0M) 7 Printed in U.S.A /BP0707

20 502 - CHASSIS LUBRICATION LUBRICATION ZERK BLOCK CS M6-1.0 X 30 C8.8 ZO LOCKWASHER S GREASE ZERK (7mm HEX HEAD) CAP SCREW JOINT LUBRICATION TUBE (1.0M) HP HOSE NUT WASHER SCREW JOINT ELBOW SET SCREW /BP Printed in U.S.A

21 502 - REAR PLATE REAR WALL COVER ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT SHCS M X 35 C10.9 ZY WASHER WASHER GR A SHCS M X 25 C8.8 ZY BRACKET HEX SCREW LOCKWASHER S LOCKWASHER S SCREW CAGE NUT M FHCS M5-0.8 X 16 C8.8 ZY ISOLATION MAT ISOLATION MAT WASHER 6 Printed in U.S.A /BP0707

22 502 - COUNTERWEIGHT COUNTERWEIGHT WASHER/ROUND HI-TENS SCREW BRACKET BRACKET SCREW LOCKWASHER S LW SPRING 6 DIN CS M X 25 C8.8 ZY WASHER WASHER GR A CABLE SCREW HN M6-1 C8 ZY CABLE LOCK COVER RETAINER REFLECTOR POP RIVET A4 X CS M X 45 C8.8 ZO WASHER WASHER /BP Printed in U.S.A

23 502 - ENGINE HOOD ENGINE HOOD ISOLATION MAT/HOOD HINGE PLATE HINGE BRACKET CS M X 30 C8.8 ZY WASHER WASHER PNEUMATIC SPRING HN M5-0.8 C8 ZY HANDLE FHCS M14-2 X 16 C8.8 ZY HN M4-0.7 C8 ZY LATCH WASHER CS M X 16 C8.8 ZY RUBBER EXTRUSION (2.65M) RUBBER EXTRUSION (1.3M) 1 Printed in U.S.A /BP0707

24 502 - VALVE COVER VALVE COVER SCREEN FRAME HINGE HINGE PNEUMATIC SPRING HLN INS M8 8 ZO D ISOLATION MAT ISOLATION MAT CS M X 30 C8.8 ZY WASHER WASHER HN M C8 ZO CAGE NUT M HANDLE FHCS M14-2 X 16 C8.8 ZY HEX NUT M4-0.7 C8 ZY LATCH CS M X 16 C8.8 ZY BRACKET HEX SCREW SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN BRACKET CABLE SCREW LN INS M6-1 C8 ZY CABLE LOCK WASHER 8.4 ST A2C BRACKET RUBBER STOP WASHER HN M16-1 C8 ZY FHCS M6-1 X 20 C8.8 ZY CAGE NUT M PLATE BRACKET /BP Printed in U.S.A

25 502 - HOSE COVER HOSE COVER (1.0m) ANTI-SLIDE STRIP (1.9M) RUBBER EXTRUSION (0.96M) WASHER WASHER 8.4 ST A2C CAGE NUT M BRACKET PLUG CS M X 25 C8.8 ZY 4 Printed in U.S.A /BP0707

26 502 - HYDRAULIC TANK COVER TANK COVER SHCS M X 20 F8.8 ZY LOCKWASHER S WASHER GR A BRACKET CAGE NUT M CS M X 25 C8.8 ZY SPACER WASHER GR A HEX SCREW SHCS M X 25 F8.8 ZY /BP Printed in U.S.A

27 502 - BOOM (15, 16) (8, 17, 18) x BOOM/PRE-ASSEMBLED TUBE TUBE TUBE TUBE HB M X 40 C8.8 ZY TUBE CLAMP PIN SEAL COVER HB M6-1 X 35 C8.8 ZY TUBE CLAMP COVER BUSHING TUBE GREASE ZERK (7mm HEX HEAD) CAP RING/SNAP SB BUSHING PIN WASHER HN SLTD M48-3 F8 ZY PIN/SPRING M8 x 80 ZO PIN SEAL LN INS MS-1.25 C8 ZY BOOM CYLINDER 1 See page 81 for individual components PIN PIN SHCS M X 90 C8.8 ZY 2 Printed in U.S.A /BP0707

28 502 - DIPPER ARM (5, 6, 7, 10, 11, 22, 23, 29) x PRE-ASSEMBLED DIPPER ARM/ 1 SHORT (1500mm) PRE-ASSEMBLED DIPPER ARM/ 1 LONG (1800mm) LN INS M C8 ZY SHCS M X 90 C8.8 ZY WASHER BUSHING SEAL HN SLTD M48-3 F8 ZY PIN/SPRING M8 X 80 ZO GREASE ZERK (7mm HEX HEAD) CAP SCREW JOINT SCREW JOINT COUPLER QUICK COUPLER COUPLER QUICK COUPLER PROTECTION CAP PROTECTION CAP PROTECTION CAP PROTECTION CAP BUSHING RING SNAP SB PIN PIN KIT/DIPPER ARM CYLINDER 1 See page 82 for individual components PIN LYNCH PIN PIN SEAL PIN /BP Printed in U.S.A

29 502 - CONNECTING LINK (6, 7) (5, 14, 20, 22) x CONNECTING LINK RT CONNECTING LINK LT ARTICULATING LINK ASY 1 (STANDARD = 380mm) ARTICULATING LINK ASY 1 (OPTIONAL = 330mm) BUSHING GREASE ZERK (7mm HEX HEAD) CAP PIN LYNCH PIN PIN PIN COVER LOCKWASHER S SHCS M X 30 F12.9 ZY PIN GASKET BUCKET CYLINDER 1 See page 83 for individual components PIN SHCS M X 90 C8.8 ZY LN INS M C8 ZY PIN BUSHING BUSHING LOCKWASHER SB60 4 Printed in U.S.A /BP0707

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

31 502 - CAB (CONT.) CAB SN AND UP COVER WIPER MOTOR WIPER ARM WIPER BLADE CLIPS WATER HOSE (1.9M) NOZZLE ASHTRAY SCREW PLUG DOME LIGHT BULB WINDSHIELD WASHER CS M6-1 X 12 C8.8 ZY PIN BRACKET PLATE WASHER MIRROR LT CS M6-1 X 16 C8.8 ZY WASHER COVER RADIO ANTENNA STORAGE BOX SPEAKER COVER SCREW EDGE PROTECTION (1.1M) LN INS M6-1 C8 ZY COVER COVER COVER SCREW COVER SCREW WASHER FRAME 1 Printed in U.S.A /BP0707

32 502 - CAB (CONT.) CAB SN AND BEFORE FRAME WIPER MOTOR WIPER ARM WIPER BLADE CLIP WATER HOSE (1.9M) NOZZLE ASHTRAY SCREW PLUG DOME LIGHT BULB WINDSHIELD WASHER CS M6-1 X 12 C8.8 ZY PIN BRACKET PLATE WASHER MIRROR LT CS M6-1 X 16 C8.8 ZY WASHER COVER RADIO ANTENNA STORAGE BOX SPEAKER COVER SCREW EDGE PROTECTION (1.1M) LN INS M6-1 C8 ZY COVER COVER COVER SCREW COVER SCREW WASHER /BP Printed in U.S.A

33 502 - CAB (CONT.) CAB SN AND UP HOSE PROFILE (2.4M) RUBBER PROFILE (4.6M) RUBBER PROFILE (1.7M) RUBBER BUFFER SCREW WASHER WASHER HN M5-0.8 C8 ZY SCREW LOCK LOCK SCREW CS M6-1 X 30 C8.8 ZY CS M6-1 X 50 C8.8 ZY WASHER DOOR LOCK WASHER BRACKET COVER RUBBER SEAL BAR HANDLE RUBBER BUFFER 1 Printed in U.S.A /BP0707

34 502 - CAB (CONT.) CAB SN AND BEFORE HOSE PROFILE (2.4M) RUBBER PROFILE (4.6M) RUBBER PROFILE (1.7M) RUBBER BUFFER SCREW WASHER WASHER HN M5-0.8 C8 ZY SCREW LOCK (FRONT LT, REAR RT) LOCK (FRONT RT, REAR LT) SCREW SCREW NUT CS M6-1 X 30 C8.8 ZY CS M6-1 X 50 C8.8 ZY WASHER DOOR LOCK WASHER BRACKET COVER RUBBER SEAL BAR HANDLE RUBBER BUFFER SCREW /BP Printed in U.S.A

35 502 - CAB (CONT.) CAB SN AND UP SHIELD PAN HEAD TAP SCREW GUTTER BRACKET RT BRACKET LT SCREW BRACKET BRACKET CS M X 25 C8.8 ZY CS M X 16 C8.8 ZY WASHER GR A8.4 ZO DIN HN M C8 ZY PLATE SCREW LN INS M C8 ZY NOZZLE SCREW BRACKET WASHER LN INS M6-1 C8 ZY 4 Printed in U.S.A /BP0707

36 502 - CAB (CONT.) CAB SN AND BEFORE SHIELD PAN HEAD TAP SCREW GUTTER SCREW BRACKET SCREW BRACKET BRACKET CS M X 25 C8.8 ZY CS M X 16 C8.8 ZY WASHER GR A8.4 ZO DIN HN M C8 ZY COVER SCREW LN INS M C8 ZY NOZZLE /BP Printed in U.S.A

37 502 - WIRING HARNESS WIRING HARNESS/MAIN WIRING HARNESS/SECONDARY STRAP 2 Printed in U.S.A /BP0707

38 502 - FRONT WINDOW FRONT WINDOW FRONT WINDOW TINTED WINDOW FRAME/LOWER WINDOW FRAME/UPPER SCREW FHCS M X 20 C8.8 ZY WASHER RUBBER WASHER RUBBER WASHER WASHER GR A8.4 ZO DIN HEX NUT/DOMED CAP M PVC WASHER EDGE PROTECTION (1.0M) SUN VISOR COMPLETE SCREW RUBBER PLUG PVC WASHER /BP Printed in U.S.A

39 502 - CAB WINDOWS FRONT WINDOW/TOP FRONT WINDOW/LOWER PVC WASHER RUBBER WASHER RUBBER WASHER HANDLE WASHER HN M C8 ZY RUBBER PROFILE (1.75M) SIDEPANE LT SIDEPANE LT TINTED UPPER SIDEPANE RUBBER PROFILE (1.3M) REAR WINDOW RUBBER PROFILE (0.87M) 1 Printed in U.S.A /BP0707

40 502 - CAB SLIDING WINDOW SLIDING WINDOW COMPLETE WINDOW/SLIDING WINDOW/STATIONARY LOCK /BP Printed in U.S.A

41 502 - CAB DOOR CAB DOOR COMPLETE DOOR FRAME LOCK W/O KEYS SCREW LN INS M C8 ZY HANDLE KEYS W/O LOCK COVER TIE RUBBER PROFILE (4.40M) DOOR ISOLATION DOOR WINDOW LOWER DOOR PANE NUT LOCK CS M6-1 x 20 C8.8 ZY WASHER LN INS M6-1 C8 ZY COVER DOOR ISOLATION 1 Printed in U.S.A /BP0707

42 502 - CAB ISOLATION MATS RUBBER FLOOR MAT/BACK 1 (CAB SN and up) RUBBER FLOOR MAT/BACK 1 (CAB SN and before) RUBBER FLOOR MAT/FRONT 1 (CAB SN and up) RUBBER FLOOR MAT/FRONT 1 (CAB SN and before) ISOLATION MAT/RT FRONT ISOLATION MAT/RT BACK ISOLATION MAT LT ISOLATION MAT/SEAT ISOLATION MAT/REAR ISOLATION MAT/ROOF VELCRO STRAP 25mm (13.0M) VELCRO STRAP 50mm (7.0M) /BP Printed in U.S.A

43 502 - HEATER CAB HEATER CAB HEATER BRACKET WASHER SEAL FOAM (0.7M) SHCS M X 16 C8.8 ZY WASHER WASHER 8.4 ST A2C CAGE NUT M CS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN SUPERFLEX HOSE (0.8M) STRAP HEATER HOSE (0.46M) HEATER HOSE (0.6M) HOSE CLAMP HOSE COVER UNION NUT A1 12VERZ WASHER REDUCTION JOINT SCREW JOINT NOZZLE ANGLE HP HOSE SCREW JOINT SCREW JOINT BALL VALVE SCREW JOINT FITTING SCREW JOINT 1 Printed in U.S.A /BP0707

44 502 - OPERATOR S SEAT HN M C8 ZY OPERATOR SEAT (CLOTH) HEX SCREW WASHER WASHER CAGE NUT M CONTROL LEVER CONSOLE CONTROL LEVER CONSOLE PLUG SHCS M X 30 C8.8 ZY PIN SPRING LOCKWASHER HB M X 120 C8.8 ZY WASHER TUBE KNOB D40mm WASHER GR A LN INS M C8 ZY COVER COVER COVER LN INS M C8 ZY CLIP-ON NUT FHCS M X 16 C8.8 ZY TUBE PIN PIN PIN PIN ARMREST ARMREST SEATBELT SHCS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A MICROSWITCH BRACKET SCREW/PAN HEAD TAP NECK SUPPORT CUSHION SEAT UPHOLSTERY /BP Printed in U.S.A

45 502 - DIESEL ENGINE DIESEL ENGINE (4TNE88-ENSW) GASKET SET (4TNE88-ENSW) V-BELT ENGINE OIL FILTER SENDER/OIL PRESSURE SWITCH/THERMOSTAT (110 C) SEAL SOLENOID STOP STARTER ALTERNATOR O-RING COOLING FAN 1 Printed in U.S.A /BP0707

46 502 - ENGINE MOUNTS ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE MOUNTING BRACKET SHCS M X 25 F8.8 ZY LOCKWASHER S WASHER GR A HYDRO SUSPENSION HEX SCREW WASHER WASHER CS M X 35 C10.9 ZY WASHER EXTERNAL TOOTH LOCKWASHER WASHER 8.4 ST A2C CORD /BP Printed in U.S.A

47 502 - CYLINDER HEAD CYLINDER HEAD (4TNE88-ENSW) CYLINDER HEAD (4TNE88-NSW) VALVE PLUG INTAKE VALVE EXHAUST VALVE STUD BOLT HEAT SHIELD SEAL RING SEAL SEAL KIT SPRING SPACER CLAMP VALVE CAP BEARING SUPPORT VALVE COVER HEADNUT O-RING GASKET/HEAD COVER VENTING HOSE OIL COVER O-RING SEAL SCREEN GUIDE 4 Printed in U.S.A /BP0707

48 502 - CYLINDER BLOCK GASKET/CYLINDER HEAD CYLINDER HEAD SCREW COVER PLUG BUSHING PLUG AXIAL BEARING AXIAL BEARING (OS=0.25) MAIN BEARING SET MAIN BEARING SET (US=0.25) /BP Printed in U.S.A

49 502 - SEAL CRANKSHAFT GEARBOX W/SHAFT SEAL SHAFT SEAL O-RING SCREW GASKET INJECTION PUMP SCREW OIL FILLER PIPE O-RING OIL COVER FLYWHEEL HOUSING PIPE LINE O-RING STUD BOLT NUT O-RING COVER SEAL FITTING PIN RUBBER PLUG 1 Printed in U.S.A /BP0707

50 502 - OIL PAN OIL PAN ASY OIL DRAIN PLUG O-RING SCREW SCREW SCREW /BP Printed in U.S.A

51 502 - CAMSHAFT CAMSHAFT ASY LIFTER PUSH ROD SLIDE BEARING GEAR (4TNE88-NSR/W) GEAR (4TNE88-ENSR/W) FLANGE (4TNE88-ENSR/W) SCREW (4TNE88-ENSR/W) SPRING RING HEXAGON NUT GEAR 1 Printed in U.S.A /BP0707

52 502 - CRANKSHAFT & PISTONS CRANKSHAFT ASY GEAR FITTING KEY CYLINDER PIN PULLEY FLYWHEEL PISTON (4TNE88-NSR/W) PISTON (4TNE88-NSR/W OS=0.25) PISTON (4TNE88-ENSR/W) PISTON (4TNE88-ENSR/W OS=0.25) PIN LOCK RING CONNECTING ROD BUSHING SCREW BEARING CONNECTING ROD BEARING 4 (US=0.25) SEAL SHAFT SEAL PISTON RING PISTON RING (OS=0.25) /BP Printed in U.S.A

53 502 - OIL LUBRICATION SYSTEM OIL DIPSTICK OIL DIPSTICK TUBE SENDER/OIL PRESSURE OIL SUMP GASKET OIL SUMP LUBRICATION OIL PUMP VALVE O-RING FILTER BASE GASKET FILTER BRACKET NUT ENGINE OIL FILTER SCREW SEAL RING (4TNE88-NSR/W) SEAL RING (4TNE88-ENSR/W) BANJO BOLT SEAL ENGINE OIL PIPE 1 Printed in U.S.A /BP0707

54 502 - COOLING SYSTEM WATER PUMP PUMP GASKET (4TNE88-NSR/W) PUMP GASKET (4TNE88-ENSR/W) THERMOSTAT GASKET THERMOSTAT GASKET SEAL SWITCH/THERMOSTAT (110 C) PLUG THERMOSTAT GASKET THERMOSTAT UPPER THERMOSTAT GASKET COOLANT HOSE HOSE CLAMP V-BELT BELT PULLEY FAN SPACER COOLING FAN DRAIN COCK COMPLETE DRAIN COCK THERMOSTAT HOUSING /BP Printed in U.S.A

55 502 - FUEL INJECTION SYSTEM INJECTION PUMP (4TNE88-NSW) INJECTION PUMP (4TNE88-ENSW) INJECTION NOZZLE 4 (4TNE88-NSW) INJECTION NOZZLE 4 (4TNE88-ENSW) NOZZLE INSERT (4TNE88-NSW) NOZZLE INSERT (4TNE88-ENSW) NUT NOZZLE SPRING NOZZLE SPRING SEAT PIN STOP PLATE ADJUSTING WASHER CLAMP INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) INJECTION LINE (4TNE88-NSW) INJECTION LINE (4TNE88-ENSW) HOSE PIPE ASY/FUEL OIL OIL LEAK LINE HOSE RING PIECE CAP NON-RETURN VALVE SEAL RING (4TNE88-NSW) SEAL RING (4TNE88-ENSW) CLAMP CLAMP 12 2 Printed in U.S.A /BP0707

56 502 - FUEL TANK DIESEL TANK FUEL STRAINER TANK CAP/PLASTIC W/O KEYS 1 * TANK CAP/METAL SCREW WASHER WASHER GR A13 DIN BRACKET PLUG SCREW JOINT SCREW JOINT TRANSMITTER SCREW LOCKWASHER S WASHER GR A4.3 ZO DIN TUBE SCREW MOUNT HOSE CLAMP SHCS M X 25 C8.8 ZY WASHER GR A SCREW JOINT 12L HP HOSE SCREW JOINT PLUG UNION NUT AI 12 VERZ KEYS/METAL CAP KEYS/PLASTIC CAP 2 * Replaced by P/N for service /BP Printed in U.S.A

57 502 - FUEL SYSTEM BRACKET CS M X 20 C8.8 ZY LOCKWASHER S WASHER GR A FUEL FILTER COMPLETE FUEL FILTER ELEMENT HB M X 70 C8.8 ZY WASHER WASHER TUBE TUBE BRAIDED HOSE GEN NW6 (1.0M) HOSE CLAMP O-RING WATER SEPARATOR COMPLETE WATER TRAP SCREEN O-RING FILTER HOUSING GASKET PUMP ASY/FUEL FEED PACKING 1 Printed in U.S.A /BP0707

58 502 - THROTTLE ASSEMBLY CABLE LEVER KNOB BRAKE DISC WASHER WASHER CS M X 25 C8.8 ZY WASHER BALL AND SOCKET LN INS M6-1 C8 ZY SHCS M5-0.8 X 16 C8.8 ZY WASHER WASHER GR A8.4 ZO DIN BRACKET SPRING BRACKET WASHER WASHER HEX SCREW BRACKET /BP Printed in U.S.A

59 502 - COOLING SYSTEM BRACKET BRACKET SCREW WASHER/ROUND HI-TENS NUT AIR GUIDING PLATE AIR GUIDING PLATE AIR GUIDING PLATE SEALING TAPE (2.04M) RADIATOR RADIATOR CAP HEX SCREW WASHER WASHER 8.4 ST A2C CAGE NUT M SCREW BRAIDED HOSE GEN NW8 (1.0M) SCREW HEX HD TAP B5.5 X RUBBER PROFILE (0.3M) HOSE PROFILE (2.0M) RUBBER EXTRUSION (1.0M) EXPANSION CONTAINER HOSE CLAMP BRAIDED HOSE GEN NW6 (0.5M) FAN PROTECTOR WASHER LN INS M C8 ZY SUB-TANK BRACKET COLLAR RADIATOR HOSE/UPPER RADIATOR HOSE/LOWER CLAMP 38 4 Printed in U.S.A /BP0707

60 502 - AIR INTAKE SYSTEM AIR FILTER ASY CS M X 25 C8.8 ZY WASHER WASHER LN INS M6-1 C8 ZY DUST VALVE DUST CAP CLAMP ASY AIR FILTER ELEMENT/INNER AIR FILTER ELEMENT/OUTER AIR FILTER NUT DIRT INDICATOR AIR INLET HOSE AIR INLET HOSE INLET MUFFLER HOSE CLAMP WASHER GR A6.4 ZO DIN SUCTION HOSE COLLAR AIR HEATER GASKET GASKET INTAKE MANIFOLD BAFFLE /BP Printed in U.S.A

61 502 - EXHAUST SYSTEM MUFFLER SUPPORT-RT MUFFLER SUPPORT-LT SCREW COLLAR MUFFLER COLLAR CS M X 30 C8.8 ZY WASHER WASHER EXHAUST PIPE/MANIFOLD HEX SCREW GASKET HN M C8 ZY EXHAUST PIPE/MUFFLER CLAMP ASY EXHAUST BRACKET CS M X 25 C8.8 ZY EXHAUST MANIFOLD GASKET/EXHAUST MANIFOLD STUD BOLT NUT STUD BOLT 4 Printed in U.S.A /BP0707

62 502 - HYDRAULIC PUMP DRIVE COUPLER COMPLETE PUMP BRACKET PLUG WASHER GR A SHCS HS M X 30 F8.8 ZY WASHER LOCKWASHER S WASHER GR A SHCS M X 30 C8.8 ZY /BP Printed in U.S.A

63 502 - HYDRAULIC TANK HYDRAULIC OIL TANK COVER O-RING REDUCTION JOINT SEAL FILTER SHCS M X 20 C8.8 ZY WASHER WASHER ISOLATION MAT SCREW JOINT ANGLE SCREW LOCKWASHER S WASHER GR A HYDRAULIC OIL FILTER COMPLETE HYDRAULIC FILTER ELEMENT SEAL SCREW PRESSURE SWITCH HP HOSE WASHER WASHER GR A13 DIN SCREW SCREW JOINT PLUG UNION NUT AI 12VERZ SCREW JOINT HYDRAULIC OIL STRAINER SCREW JOINT SCREW JOINT NON-RETURN VALVE SCREW JOINT OIL LEVEL GLASS REDUCTION JOINT SCREW JOINT 12L PLATE SCREW COVER SCREW WASHER GR A4.3 ZO DIN LOCKWASHER S O-RING 1 Printed in U.S.A /BP0707

64 502 - OIL COOLER HYDRAULIC OIL COOLER SCREW WASHER WASHER SCREW JOINT TEE SCREW JOINT ANGLE WASHER UNION NUT AI 22VERZ TUBE NON-RETURN VALVE /BP Printed in U.S.A

65 502 - DRIVE MOTOR DRIVE MOTOR COMPLETE SCREW JOINT SCREW JOINT O-RING SCREW SEAL KIT/HYDRAULIC MOTOR SEAL KIT/TRANSMISSION LOCK RING LOCK SCREW COVER 2 Printed in U.S.A /BP0707

66 502 - SWIVEL JOINT SWIVEL JOINT SCREW JOINT SCREW JOINT 12L SCREW JOINT ANGLE TEE TEE FITTING SEAL KIT COMPLETE/SWIVEL JOINT /BP Printed in U.S.A

67 502 - HYDRAULIC PUMP EXTERNAL PARTS HYDRAULIC PUMP COMPLETE SCREW JOINT SCREW JOINT HYDRAULIC PUMP GEAR PUMP SUCTION FLANGE O-RING SHCS M X 30 F8.8 ZY LOCKWASHER S SEAL KIT/HYDRAULIC PUMP O-RING O-RING 1 Printed in U.S.A /BP0707

68 502 - HYDRAULIC PUMP INTERNAL PARTS DRIVE UNIT SWASH PLATE SCREW SCREW BEARING BEARING GEAR PUMP O-RING O-RING O-RING CONTROL HOUSING ROTARY SHAFT SEAL /BP Printed in U.S.A

69 502 - SWIVEL DRIVE KIT/TURNING GEAR HYDRAULIC MOTOR 1 3 * TURNING GEAR SCREW JOINT 12L ANGLE SCREW JOINT PLUG UNION NUT A1 12VERZ SCREW JOINT SCREW JOINT SCREW JOINT HP HOSE SCREW JOINT TEE ANGLE PINION/SWIVEL DRIVE O-RING O-RING GASKET/SWIVEL DRIVE GEAR BRAKE VALVE MANDREL BRAKE VALVE O-RING SEAL KIT BRAKE DISC BRAKE DISC 2 * Replaced by P/N for service. Printed in U.S.A /BP0707

70 502 - VALVE BLOCK CONTROL VALVE SHCS M X 25 F8.8 ZY LOCKWASHER S SCREW JOINT FITTING TEE SCREW JOINT SCREW JOINT CORK WASHER LN INS M C8 ZY O-RING CONNECTOR SCREW JOINT ELBOW ANGLE REDUCTION JOINT TEE TEST PORT SCREW JOINT SCREW JOINT ELBOW SCREW JOINT REDUCTION JOINT BALL VALVE SCREW JOINT SCREW JOINT /BP Printed in U.S.A

71 502 - VALVE BLOCK SECTION BUCKET SECTION BOOM SECTION DRIVE RT SECTION SECTION DRIVE LT SECTION BUCKET STICK SECTION ADJUSTING SECTION ADDITIONAL HYDRAULICS SECTION DRIVE STRAIGHT SECTION SLEW SECTION DOZER BLADE SECTION TURN SECTION IN SECTION MANDREL PRESSURE RELIEF VALVE SEAL KIT TIE ROD NUT MANDREL (OPTION) VALVE CAP VALVE CAP O-RING SCREW VALVE CAP VALVE CAP VALVE CAP 1 Printed in U.S.A /BP0707

72 502 - PILOT OIL SUPPLY UNIT * PILOT OIL SUPPLY UNIT SEAL ACCUMULATOR SHCS M X 20 C8.8 ZY WASHER WASHER 8.4 ST A2C SCREW JOINT FITTING TEE TEE TEST PORT PLATE PLUG SOLENOID SWITCH SOLENOID PILOT VALVE 2 * Replaced by P/N for service /BP Printed in U.S.A

73 502 - VALVE BLOCK CONTROL VALVE SCREW LOCKWASHER S WASHER SCREW JOINT PLUG FITTING 1 Printed in U.S.A /BP0707

74 502 - MANIFOLD BLOCK DISTRIBUTION BLOCK SHCS M X 25 F8.8 ZY LOCKWASHER S WASHER GR A CONSOLE SCREW JOINT ELBOW ANGLE SCREW JOINT /BP Printed in U.S.A

75 502 - REVERSING VALVE REVERSING VALVE COMPLETE SCREW JOINT SCREW JOINT SHCS M6-1 X 50 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN HN M C8 ZO PLUG 1 Printed in U.S.A /BP0707

76 502 - HAND LEVERS PILOT VALVE PILOT VALVE SCREW JOINT SHCS M6-1 X 20 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN SEAL KIT SEAL KIT UNIVERSAL JOINT HANDLE BELLOWS HANDLE (OPTION) RUBBER CAP SET /BP Printed in U.S.A

77 502 - DOZER BLADE VALVE CONTROL LEVER HEX SCREW WASHER WASHER CAGE NUT M SEAL FOR TAPPET SCREW JOINT DOZER BLADE LEVER PEDAL WASHER SHCS M X 35 C10.9 ZY KNOB SET SCREW 1 Printed in U.S.A /BP0707

78 502 - PILOT VALVE TRAVEL CONTROL LEVER HEX SCREW WASHER WASHER CAGE NUT M SWITCH SCREW JOINT TEE TRAVELING HAND LEVER LT TRAVELING HAND LEVER RT SEAL FOR TAPPET WASHER SHCS M X 35 C10.9 ZY KNOB W/RED SWITCH SET SCREW TEE PEDAL FITTING KNOB /BP Printed in U.S.A

79 502 - AUXILIARY HYDRAULICS PILOT VALVE CONTROL VALVE HEX SCREW WASHER WASHER CAGE NUT M SCREW JOINT TEE FITTING SEAL/TAPPET 1 Printed in U.S.A /BP0707

80 502-4/3 VALVE (OPTION) /3 VALVE SCREW JOINT LN INS M6-1 C8 ZY SCREW LOCKWASHER S WASHER GR A6.4 ZO DIN SOLENOID /BP Printed in U.S.A

81 502 - SOLENOID VALVE (OPTION) SOLENOID VALVE BRACKET SCREW JOINT BRACKET SCREW LOCKWASHER S SHCS M6-1 X 25 C8.8 ZY WASHER GR A6.4 ZO DIN LN INS M6-1 C8 ZY CS M6-1 X 20 C8.8 ZY WASHER 4 Printed in U.S.A /BP0707

82 502 - ISO/SAE PATTERN VALVE (OPTION) G ISO/SAE VALVE CS M6-1 X 50 C8.8 ZY LOCKWASHER S WASHER GR A6.4 ZO DIN SCREW JOINT FITTING /BP Printed in U.S.A