AIW 2010 Series Illustrated Parts Manual Parts & Service Call: 1-330-308-2727 Customer Support Call: 1-330-308-6766 Revised October 7, 2013 Part Number 990001-056
IMPORTANT SAFETY INFORMATION FOR PERSONS PERFORMING MAINTENANCE This Illustrated Parts Manual provides information that pertains to spare parts for the carrier manufactured by Kimble Custom Chassis. In performing maintenance on the vehicle, review and thoroughly understand the recommended and required maintenance procedures in component manuals, including but not limited to, parts books, owners manuals, operator s manuals, maintenance manuals and/or service manuals. These publications should be carefully checked for original equipment manufacturers recommended and required maintenance procedures and instructions as well as all applicable DANGER, WARNING and CAUTION notices. In addition to manufacturer supplied manuals or publications, be sure to also review and thoroughly understand all procedures, including but not limited to, safety procedures, required by the United States Occupational Safety and Health Administration (O.S.H.A) and those of any other governmental regulatory body that may pertain to the work intended on being performed. Finally review and understand any applicable maintenance procedures and safety practices recommended by Truck Manufacturers Association (www.truckmfgs.org), before beginning maintenance work. ORDERING GENUINE KIMBLE PARTS FOR YOUR CARRIER Original Kimble parts are designed to meet exacting requirements for each particular application. Imitation parts are not the same as Kimble original parts and in some cases, in addition to not lasting as long, they can cause safety hazards. Kimble parts are engineered with safety and longevity, imitations may expose associates to injury or worse. When ordering parts for your Kimble vehicle having your model and serial number will be helpful. If ordering a large component there may be a model and serial number on that component as well. This will ensure the identification of correct parts.
EFFECTIVITY PAGE September 17, 2012 - Original Issue Of Manual October 31, 2012 - B - Revised Figure 3-2 October 7, 2013 - C - Revised Figure 8-2 & 9-1, Removed Options 990001-056 AIW 2010 Series i
EFFECTIVITY PAGE -ii AIW 2010 Series 990001-056
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 FRAME & ATTACHING PARTS................................................ 1-1 1-1 Frame Assembly............................................................. 1-2 1-2 Front Bumper Assembly........................................................ 1-4 1-3 Cab Step Assembly........................................................... 1-6 1-4 Engine Enclosure & Deck Assembly.............................................. 1-8 1-5 Horn & Back-Up Alarm Assemblies............................................... 1-12 SECTION 2 ENGINE & ATTACHING PARTS............................................... 2-1 2-1 Powertrain Assembly.......................................................... 2-2 2-2 Radiator Assembly............................................................ 2-6 2-3 Air Cleaner Assembly.......................................................... 2-8 2-4 Exhaust Assembly............................................................ 2-10 SECTION 3 DRIVE TRAIN.............................................................. 3-1 3-1 Drivetrain Installation.......................................................... 3-2 3-2 Front Axle Assembly.......................................................... 3-4 3-3 Front Drive Steer Axle - Housing................................................. 3-6 3-4 Front Drive Steer Axle - Differential............................................... 3-10 3-5 Front Drive Steer Axle - Components............................................. 3-12 3-6 Front Drive Steer Axle - Brakes.................................................. 3-16 3-7 Rear Axle Assembly........................................................... 3-18 3-8 Rear Axle - Brake Assembly.................................................... 3-20 3-9 Driveshafts Assembly.......................................................... 3-22 3-10 PTO Installation.............................................................. 3-24 SECTION 4 CAB...................................................................... 4-1 4-1 Operators Cab Installation...................................................... 4-2 4-2 Door Assembly, LH........................................................... 4-4 4-3 Door Assembly, RH........................................................... 4-6 4-4 Seat Assembly............................................................... 4-8 4-5 Seat Components............................................................. 4-10 4-6 Cab Interior Installation........................................................ 4-12 4-7 Shifter Console Assembly...................................................... 4-16 4-8 Dash Panel Assembly......................................................... 4-18 4-9 Cab Overhead Installation...................................................... 4-22 4-10 Windshield & Wiper Assembly................................................... 4-24 4-11 HVAC Unit Assembly.......................................................... 4-26 990001-056 AIW 2010 Series iii
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 5 CONTROLS................................................................ 5-1 5-1 Steering Column Assembly..................................................... 5-2 5-2 Floor Control Installation....................................................... 5-4 5-3 Treadle Valve Piping Installation................................................. 5-6 SECTION 6 CIRCUITS.................................................................. 6-1 6-1 Power Steering Installation..................................................... 6-2 6-2 Steering Component Assembly.................................................. 6-4 6-3 Antilock Brake Installation...................................................... 6-6 6-4 Fuel System Installation........................................................ 6-8 6-5 HVAC Plumbing Installation..................................................... 6-10 6-6 DEF Plumbing Installation...................................................... 6-12 SECTION 7 AIR SYSTEM............................................................... 7-1 7-1 Air System Schematic......................................................... 7-2 SECTION 8 ELECTRICAL............................................................... 8-1 8-1 Battery Installation............................................................ 8-2 8-2 Battery Cable Assembly........................................................ 8-4 8-3 Power Distribution Manager..................................................... 8-6 8-4 Power Panel Wiring........................................................... 8-8 8-5 Engine Wiring................................................................ 8-10 8-6 Transmission Wiring........................................................... 8-14 8-7 Chassis Wiring............................................................... 8-16 8-8 Cab Wiring.................................................................. 8-18 8-9 Cab Dash Wiring............................................................. 8-20 8-10 Power Mirror Wiring........................................................... 8-22 8-11 Tail Light Wiring.............................................................. 8-24 SECTION 9 DECALS................................................................... 9-1 9-1 Decal Installation............................................................. 9-2 SECTION 10 RECOMMENDED SPARE PARTS.............................................. 10-1 SECTION 11 PART NUMBER INDEX............................................. 11-1 iv AIW 2010 Series 990001-056
SERVICE KITS Section Page No. Part No. Description 990001-056 AIW 2010 Series v
SERVICE KITS Section Page No. Part No. Description vi AIW 2010 Series 990001-056
SECTION 1 FRAME & ATTACHING PARTS 990001-056 AIW 2010 Series
FRAME & ATTACHING PARTS Figure 1-1 Frame Assembly 305 202 203 201 1 204 101 106 102 104 107 105 102 103 206 PD1300 1-2 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-1 Frame Assembly Item Part Number Qty. Description Rev. 1 500001-115 1 FRAME WELDMENT, (consult factory) 558-C00002 1 FRONT TOW DEVICE ASSY, (includes items 101 thru 104) 101 C21-62300-86 2 BOLT, 5/8-11 X 3, HCS, SS 102 200105-008 4 WASHER, FLAT, SAE, 5/8 DIA, THRU HARD, ZINC PL 103 C42-06213-80 2 NUT, 5/8-11, H, SV, PL 104 200180-660 2 HEX FLG HD CAP SCR, 5/8-18 X 2-1/2 LG, GR 8, ZINC 105 200001-112 2 NUT, HEX FLG, 5/8-18, STOVER, GR G, ZINC PL 106 300040-002 1 TOW HOOK UNION, RH 107 300040-001 1 TOW HOOK UNION, LH 201 Ref CAB INSTALLATION, (see Figure 4-1 for details) 202 Ref ENGINE INSTALLATION, (see Figure 2-1 for details) 203 Ref ENGINE ENCLOSURE, (see Figure 1-4 for details) 204 Ref DRIVETRAIN INSTALLATION, (see Figure 3-1 for details) 205 Ref REAR FENDER ASSY, (not equipped on this vehicle) 206 Ref FRONT BUMPER ASSY, (see Figure 1-2 for details) 990001-056 AIW 2010 Series 1-3
FRAME & ATTACHING PARTS Figure 1-2 Front Bumper Assembly 7 18 8 3 2 14 9 4 14 5 10 11 12 1 9 14 13 13 10 11 12 14 18 7 6 13 17 16 2 8 13 PD1310 15 3 1-4 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-2 Front Bumper Assembly Item Part Number Qty. Description Rev. 600019-008 1 FRONT BUMBER ASSY, (includes items 1 thru 18) 1 500012-025 1 WELDMENT, BUMPER, FRONT 2 700030-016 2 TURN SIGNAL PLATE 3 300028-004 2 LAMP, MARKER/TURN/REFLECTOR, AMBER, FRONT 4 700030-017 1 BACKER PLATE 5 300027-006 1 ASSY, HEADLAMP, CHROME, RH 6 300027-005 1 ASSY, HEADLAMP, CHROME, LH 7 300028-112 2 LAMP, MARKER, KIT, 2-1/2, AMBER 8 300028-933 2 REFLECTOR, 3, AMBER 9 700030-034 2 BRACKET, BUMPER MTG 10 200042-007 6 BOLT, CARRIAGE, 1/2-13 X 1 1/2 LG, STNL STL 11 200054-006 6 LOCK WSHR, SPLIT, MEDIUM, 1/2, ZINC PL 12 200105-006 6 WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL 13 200037-006 26 TRUSS HD MACH SCR, PHILLIPS, 10-32 X 3/4 LG, STNL STL 14 200052-001 26 NUT, HEX, NYLOK, 10-32, ZINC PL 15 200039-009 4 HEX HD CAP SCR, 3/8-16 X 3/4 LG, GR 5, ZINC PL 16 200049-001 4 NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL 17 200108-001 4 WSHR, FLAT, 1/4, 18-8 STNL STL 18 300028-917 2 LAMP, GROMMET, 2-1/2 990001-056 AIW 2010 Series 1-5
300180-055 FRAME & ATTACHING PARTS Figure 1-3 Cab Step Assembly 5 23 17 FIRE EXTINGUISHER HERE 18 21 4 22 11 9 10 9 6 7 2 5 23 4 22 21 19 6 7 25 1 26 3 20 8 15 13 3 19 20 13 15 20 12 14 16 24 16 PD1320 14 1-6 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-3 Cab Step Assembly Item Part Number Qty. Description Rev. 600107-017 1 CAB STEP ACCESS ASSY, (includes items 1 thru 26) 1 500022-011 1 WELDMENT, STEP 2 500022-012 1 WELDMENT, STEP 3 700030-015 2 BRACE, BUMPER 4 700066-446 2 PLATE, STEP MTG 5 700066-447 2 PLATE, STEP MTG 6 300028-401 2 LAMP, STEP, 2-1/2, CLEAR, GRMT MNT 7 300028-801 2 LAMP, GROMMET, KIT W/PIGTAIL, 2-1/2 8 100057-006 2 STAIRTREAD, 1X1/8 BAR, 8-9/16W X 21 11/16 LG 9 300197-006 2 LATCH, LEVER COMPRESSION 10 700066-445 1 PLATE, LATCH, STEP CONSOLE 11 300092-001 1 FIRE EXTINGUISHER, 2-1/2 LB, CLASS AB&C 12 100057-004 2 STAIR, GRIP STRUT, 7 X 2 X 22 LG 13 700066-010 4 PLATE, STEP MOUNT 14 700066-011 4 PLATE, STEP COVER 15 700066-411 4 PLATE, STRAP, STEP 16 700066-012 4 STEP SUPPORT 17 300092-101 1 ROAD KIT TRIANGLE REFLECTORS 18 300180-055 1 DECAL, FIRE EXTINGUISHER HERE 19 200180-304 18 HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL 20 200001-105 38 NUT, HEX FLG, 3/8-16, STOVER, GR G, ZINC PL 21 200037-008 8 TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1 LG, STNL STL 22 200108-001 8 WSHR, FLAT, 1/4, 18-8 STNL STL 23 200049-001 8 NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL 24 200180-306 12 HEX FLG HD CAP SCR, 3/8-16 X 1-1/2 LG, GR 8, ZINC PL 25 200180-506 4 HEX FLG HD CAP SCR, 1/2-13 X 1-1/2 LG, GR 8, ZINC 26 200001-109 4 NUT, HEX FLG, 1/2-13, STOVER, GR G, ZINC PL 990001-056 AIW 2010 Series 1-7
FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly 28 20 19 45 35 3 4 21 29 25 45 35 35 45 23 1 22 46 33 37 40 41 36 44 34 2 32 21 26 32 28 PD1330 1-8 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) 49 5 38 27 24 48 38 43 38 7 30 30 39 31 10 47 18 15 30 47 12 14 17 45 35 9 16 11 8 44 34 13 34 44 6 PD1340 990001-056 AIW 2010 Series 1-9
FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev. 600005-012 1 ENGINE ENCLOSURE & DECK ASSY, (includes items 1 thru 49) 1 500055-141 1 WELDMENT, TOP PANEL 2 500055-142 1 WELDMENT, PANEL, LH 3 500055-143 1 WELDMENT, PANEL, RH 4 500055-144 1 WELDMENT, REAR PANEL 5 500045-115 1 WELD, FENDER EXTENSION 6 500045-116 1 WELD, LH FENDER 7 500045-117 1 WELD, RH FENDER 8 500045-033 1 LH FENDER EXTENSION 9 500045-135 1 WELDMENT, FENDER SUPPORT, LH REAR 10 500045-136 1 WELDMENT, FENDER SUPPORT, RH REAR 11 500045-137 1 WELDMENT, FENDER SUPPORT, LH CENTER 12 500045-138 1 WELDMENT, FENDER SUPPORT, RH CENTER 13 500045-139 1 WELDMENT, FENDER SUPPORT, LH FRONT 14 500045-140 1 WELDMENT, FENDER SUPPORT, RH FRONT 15 500046-036 1 WELDMENT, BATTERY TRAY 16 700121-132 1 LH FENDER TRIM 17 700125-033 1 RH FENDER TRIM 18 700125-022 1 PLATE, FUEL FILTER MTG 19 700134-125 2 LH ROLL-UP SHUTTER MTG 20 700134-126 2 RH ROLL-UP SHUTTER MTG 21 700134-127 2 ENGINE ENCLOSURE GRILLE 22 700134-356 2 BAFFLE, RUBBER 23 700134-357 1 BAFFLE, RUBBER 24 700496-005 2 RETAINING STRIP, 25 300028-204 1 LIGHT, ENGINE ENCLOSURE 26 300077-001 1 ASSY, RESERVOIR & PUMP 27 300125-002 2 MUD-FLAP, BLACK 28 300168-200 2 ROLL-UP SHUTTER 29 700114-101 2 TRIM, DRIP EDGE, ROOF 30 200001-105 16 NUT, HEX, FLG, STOVER, 3/8-16 31 200001-109 12 NUT, HEX, FLG, STOVER, 1/2-13 32 200037-006 32 TRUSS HD SCR, 10-32 X 3/4 LG, SS 33 200037-009 19 TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 3/4 LG, STNL STL 34 200039-102 24 HEX HD CAP SCR, 1/4-20 X 1 LG, STNL STL 35 200039-236 59 HEX HD CAP SCREW, 3/8-16 X 1.0 LG, 18-8 SS 36 200049-001 4 NUT, HEX, LOCKING, NYLOK, 1/4-20, GR 2, ZINC PL 37 200055-001 19 WSHR, FLAT, 1/4 ID X 1-1/4 OD 38 200055-114 12 WSHR, FLAT, 15/16 ID X 3-7/8 OD X 1/4 THK 39 200055-122 12 WSHR, FLAT, 1/2 X 1-3/4 OD 40 200065-003 4 STANCHION, CHROME, GRABHANDLE 41 200065-005 2 TUBE, GRABHANDLE, 24 LG 42 200069-004 16 PLUG, PIPE, 2-1/2 NPT, MAGNETIC 43 200080-102 12 ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID 44 200108-001 24 WSHR, FLAT, 1/4, 18-8 STNL STL 45 200108-003 47 WSHR, FLAT, 3/8, 18-8 STNL STL 46 200143-007 18 SCR, SELF DRILL, S.S., PAN HD, #8 X 3/4 47 200180-304 8 HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL 1-10 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev. 48 200180-305 8 HEX FLG HD CAP SCR, 3/8-16 X 1-1/4 LG, GR 8, ZINC PL 49 200180-509 12 HEX FLG HD CAP SCR, 1/2-13 X 2-1/4 LG, GR 8, ZINC PL 990001-056 AIW 2010 Series 1-11
FRAME & ATTACHING PARTS Figure 1-5 Horn & Back-Up Alarm Assemblies 2 3 4 1 5 PD1350 1-12 AIW 2010 Series 990001-056
FRAME & ATTACHING PARTS Figure 1-4 Engine Enclosure & Deck Assembly (Continued) Item Part Number Qty. Description Rev. 726-C00001 1 ELECTRIC HORN ASSY, (includes items 1 thru 4) 1 300070-004 1 ELECTRIC HORN 2 200108-001 2 WASHER, 1/4, 18-8 3 200054-001 2 LOCKWASHER, 1/4 4 200039-101 2 HEX HD CAPSCREW, 1/4-20X3/4 5 300069-005 1 ALARM, BACK-UP, BOLT-ON, 12 VDC 990001-056 AIW 2010 Series 1-13
FRAME & ATTACHING PARTS This Page Intentionally Left Blank 1-14 AIW 2010 Series 990001-056
SECTION 2 ENGINE & ATTACHING PARTS 990001-056 AIW 2010 Series
ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly 2 18 10 26 7 27 22 32 32 32 21 35 11 29 19 30 30 3 29 28 29 31 30 60 63 62 64 32 30 20 33 34 PD1370 25 23 32 30 24 2-2 AIW 2010 Series 990001-056
ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) 68 69 15 54 16 14 51 68 69 53 5 6 7 1 17 15 4 51 8 70 9 66 67 13 12 48 45 47 49 45 47 44 7 46 ATTACHES TO AIR COMPRESSOR 39 52 50 50 38 36 37 58 57 55 56 59 60 FRONT OF ENGINE 41 43 42 41 40 65 RH SIDE OF ENGINE PD1360 990001-056 AIW 2010 Series 2-3
ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) Item Part Number Qty. Description Rev. 600018-006 1 ENGINE SUPPORT ASSY, (includes items 1 thru 70) 1 300005-024 1 ENGINE, ISX11.9-450SV, 2010 EPA/CARB, WITH BRAKE 2 300128-030 1 BELT, FAN 3 700091-290 1 CLAMP MOUNT 4 300074-011 1 COMPRESSOR, REFRIGERANT, R134a, 155 CC 5 200151-011 2 FTG, SERVICE 1-14 FEM #8 ML 6 200039-211 4 HEX HD CAP SCR, M8-1.25 X 100MM LG, GR 8.8, ZINC PL 7 200105-010 12 WSHR, FLAT, SAE, 3/8 DIA, GR 8, ZINC PL 8 300128-033 1 BELT, FREON DRIVE, 2010 ISX11.9, 6PK, 61.12 LG 9 300112-006 1 ALTERNATOR, 220 AMP, 12 VDC, PAD MNT 10 200039-221 4 HEX HD CAP SCR, M10-1.5 X 100MM LG, GR 10.9 11 200105-006 6 WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL 12 200180-607 3 HEX FLG HD CAP SCR, 5/8-11 X 1-3/4 LG, GR 8, ZINC 13 300155-007 1 STARTER, CUMMINS 14 300151-028 1 TRANSMISSION, ALLISON, 4500RDS, TC-541, ISX 11.9 15 200039-204 12 HEX HD CAP SCR, M16-2 X 40MM LG, GR 10.9, ZINC PL 16 200180-406 12 HEX FLG HD CAP SCR, 7/16-14 X 1-1/2 LG, GR 8, ZINC PL 17 300121-102 1 PTO 18 300054-122 1 CLUTCH, FAN 19 300054-033 1 FAN, SUCTION, 36 DIA. X 9 BLADE, 2.5625 PILOT 20 500049-008 1 FAN RING 21 500049-009 1 FAN RING MOUNT WELD 22 500049-010 1 FAN RING MOUNT 23 500049-011 1 FAN, RH, SHROUD MOUNT 24 500049-012 1 FAN, LH, SHROUD MOUNT 25 300054-123 1 FAN SEAL 26 200106-003 6 NUT, HEX, 3/8-16, GR C, ZINC PL 27 200039-203 4 HEX FLG HD CAP SCR, M10-1.5 X 40MM LG, GR 10.9 ZINC PL 28 Ref AIR LINE 29 200012-101 3 ADAPTER, STR, 1/8 NPT X -4 AB TUBE, BRASS 30 200180-304 9 HEX FLG HD CAP SCR, 3/8-16 X 1 LG, GR 8, ZINC PL 31 300054-109 1 VALVE, SOLENOID, PNEUMATIC, FAN CLUTCH 32 200001-105 9 NUT, HEX FLG, 3/8-16, STOVER, GR G, ZINC PL 33 200183-406 6 HEX HD CAP SCR, M10-1.5 X 30 MM LG, GR 10.9, ZINC PL 34 200055-111 4 WSHR, FLAT, SAE, 7/16, THRU HARD, ZINC PL 35 200183-557 2 HEX HD CAP SCR, M12-1.25 X 35MM LG, GR 10.9, ZINC PL 36 200019-001 1 ADAPTER, ELBOW, 90 DEG, -8 SAE O-RING X -8 JIC 37 200113-603 1 ADAPTER, ELBOW, 90 DEG, -12 SAE O-RING X -16 JIC 38 200046-003 1 GASKET, PUMP, SAE 39 300062-013 1 PUMP, POWER STEERING, 28CC 40 200025-209 1 ADAPTER, BUSHING, 3/4 NPT X 1/2 FEMALE NPT, BRASS 41 200118-201 3 ADAPTER, STR, M27-2.0 DIN O-RING X 3/4 FEMALE NPT 42 200061-003 2 VALVE, NEEDLE, 90 DEG, 3/8 NPT X 5/8 HOSE BEAD, BRASS 43 200011-007 2 ADAPTER, BUSHING, 3/4 NPT X 3/8 FEMALE NPT 44 300109-001 1 GOVERNOR, AIR, 105 PSI, 1/8 NPT 45 200012-001 2 ADAPTER, STR, 1/8 NPT X -4 JIC 46 200039-212 2 HEX HD CAP SCR, M8-1.25 X 70MM LG, GR. 8.8, ZINC PL 47 200030-406 2 HOSE END, STR, -4 JIC FEMALE SWIVEL X -4 PUSHLOK BRASS 48 200028-005 2 PLUG, PIPE, HEX SOCKET, 1/8 NPT 2-4 AIW 2010 Series 990001-056
ENGINE & ATTACHING PARTS Figure 2-1 Powertrain Assembly (Continued) Item Part Number Qty. Description Rev. 49 300110-001 1 VENT, AIR 50 200080-141 2 ISOLATOR, RUBBER 51 200080-140 2 ISOLATOR, RUBBER 52 700128-441 1 BRACKET, FORMED, CHARGE AIR MTG 53 500011-067 1 WELDMENT, REAR ENG, MTG, LH 54 500011-068 1 WELDMENT, REAR ENG, MTG, RH 55 200022-018 1 ADAPTER, ELBOW, 90 DEG, 1/2 NPT X 5/8 HOSE BARB, BRASS 56 200118-202 1 ADAPTER, STR, M33-2.0 DIN O-RING X 3/4 FEMALE NPT 57 200021-003 1 ADAPTER, ELBOW, 90 DEG, STREET, 3/4 NPT 58 200022-003 1 ADAPTER, STR, 3/4 NPT X 3/4 HOSE BARB, BRASS 59 200022-010 1 ADAPTER, STR, 1/4 NPT X -4 HOSE BARB, BRASS 60 200029-109 2 ADAPTER, STR, M12-1.5 DIN O-RING X 1/4 FEMALE NPT 62 200089-202 1 ADAPTER, TEE, BRANCH, 1/4 NPT, BRASS 63 200012-208 1 ADAPTER, ELBOW, 45 DEG, 1/4 NPT X -4 AB TUBE, BRASS 64 200012-102 1 ADAPTER, STR, 1/4 NPT X -4 AB TUBE, BRASS 65 200022-013 1 ADAPTER, ELBOW, 45 DEG, 1/2 NPT X 5/8 HOSE BARB, BRASS 66 200183-709 2 HEX HD CAP SCR, M16-2 X 45MM LG, GR 10.9, ZINC PL 67 200055-106 2 WASHER, FLAT, SPL, 5/8 X 2-1/4 OD X 1/8 THK 68 200183-912 2 HEX HD CAP SCR, M20-2.5 X 60MM LG, GR 10.9, ZINC PL 69 200086-003 2 WASHER, FLAT, HEAVY, 7/8 70 700128-445 1 BRACKET, CONNECTOR, TRANSMISSION MTD 101 300072-009 1 DIPSTICK 102 300072-010 1 DIPSTICK TUBE 990001-056 AIW 2010 Series 2-5
ENGINE & ATTACHING PARTS Figure 2-2 Radiator Assembly 22 22 23 22 22 9 8 10 6 5 6 22 22 11 21 4 3 25 24 4 19 17 19 1 19 17 19 12 13 7 12 7 20 13 16 4 3 4 4 3 4 14 19 18 19 19 18 19 19 17 2 20 19 4 3 4 15 PD1380 2-6 AIW 2010 Series 990001-056
ENGINE & ATTACHING PARTS Figure 2-2 Radiator Assembly Item Part Number Qty. Description Rev. 680107-003 1 COOLING SYSTEM ASSY, (includes items 1 thru 25) 1 700065-207 1 TUBE, CHARGE AIR, OUTLET 2 700065-206 1 TUBE, CHARGE AIR, INLET 3 200043-001 4 HUMP, AIR INTAKE, 4 ID X 7-1/2 LG, SILICONE 4 200004-101 8 CLAMP, HOSE, SPRING LOADED, 4 DIA, STNL STL 5 200080-102 2 ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID 6 C39-50175-02 4 WASHER, 1/2 X 1 3/4, FW, TYPE B, Z 7 200001-111 2 NUT, HEX FLG, 5/8-11, STOVER, GR G, ZINC PL 8 300037-216 1 ASSY, RDTR/CAC, AKG, ISX11.9 2010 9 300116-020 1 CONDENSER, A/C, WITH ELECTRIC FAN 10 700094-027 2 STAY ROD, 1/2-13 X 11.0 LG GR8 11 300056-008 1 SURGE TANK, 2010 ISX 11.9 12 200055-101 2 WSHR, FLAT, SPL, 5/8 X 2-1/2 OD 13 200080-139 2 RUBBER ISOLATOR MOUNT, TWO PIECE, 2.55 OD.657ID 14 700065-208 1 TUBE, RADIATOR, UPPER 15 700065-210 1 TUBE, RADIATOR, LOWER 16 700065-209 1 TUBE, RADIATOR, LOWER 17 300166-123 3 HOSE, COOLANT, 2-1/2 DIA X 6 LG 18 700065-070 2 HOSE, COOLANT, 2-1/2 DIA X 4 LG 19 200004-009 10 CLAMP, HOSE, CONSTANT TENSION, 2-1/4 THRU 3-1/8 DIA 20 200004-250 2 CLAMP, GUILLOTINE, 2-1/2 DIA 21 300058-026 1 SENSOR, COOLANT LEVEL, CUMMINS 22 200106-005 16 NUT, HEX, 1/2-13, GR 8, ZINC PL 23 200105-006 4 WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL 24 200039-003 4 HEX HD CAP SCR, 5/16-18 X 3/4 LG, GR 5, ZINC PL 25 200054-004 4 LOCK WSHR, SPLIT, MEDIUM, 5/16, ZINC PL 990001-056 AIW 2010 Series 2-7
ENGINE & ATTACHING PARTS Figure 2-3 Air Cleaner Assembly 1 2 10 3 11 10 10 13 7 10 8 10 10 5 4 12 9 8 14 PD1390 2-8 AIW 2010 Series 990001-056
ENGINE & ATTACHING PARTS Figure 2-3 Air Cleaner Assembly Item Part Number Qty. Description Rev. 680019-005 1 AIR INTAKE INSTALLATION, (includes items 1 thru 14) 1 300100-001 1 HOOD, INTAKE, AIR CLNR, RAM AIR, 7 ID INLET 2 300101-007 1 AIR CLNR, 800CFM @ 5.5 IN 3 300101-109 1 MTG BAND, AIR CLNR, 7 DIA 4 300043-003 1 GAUGE, AIR RESTRICTION, 25 IN 5 500024-011 1 WELDMENT, INTAKE, TUBE 6 700065-204 1 TUBE, AIR CEANER 7 700065-205 1 TUBE, AIR CLEANER INLET 8 200004-201 2 CLAMP, T-BAR, 5 DIA, STNL STL 9 200004-203 1 CLAMP, T-BAR, 6 DIA, STNL STL 10 200004-204 6 CLAMP, T-BAR, 7 DIA, STNL STL 11 200043-004 1 HUMP, AIR INTAKE, 7 ID 12 200043-013 1 ELBOW, AIR INTAKE, 90 DEG, 7 ID 13 200043-018 1 HUMP, REDUCER, AIR INTAKE, 7 ID X 5 ID 14 200043-030 1 ELBOW, 90 DEGREE, 4 DIA TO 5 DIA 990001-056 AIW 2010 Series 2-9
ENGINE & ATTACHING PARTS Figure 2-4 Exhaust Assembly 110 109 109 111 3 5 3 1 3 7 4 3 110 102 112 101 106 107 6 103 107 106 2 2 104 106 107 107 106 6 105 0 113 114 108 PD1400 2-10 AIW 2010 Series 990001-056
ENGINE & ATTACHING PARTS Figure 2-4 Exhaust Assembly Item Part Number Qty. Description Rev. 680025-005 1 DPF INSTALLATION, (includes item 1 thru 7) 1 700094-028 2 STAY ROD, 1/2-13 X 8 LG 2 200001-111 8 NUT, HEX FLG, 5/8-11, STOVER, GR G, ZINC PL 3 200106-005 16 NUT, HEX, 1/2-13, GR 8, ZINC PL 4 200080-102 2 ISOLATOR, MTG, RUBBER, 1-3/4 OD X 17/32 ID 5 200105-006 4 WSHR, FLAT, SAE, 1/2 DIA, THRU HARDENED, ZINC PL 6 200180-609 8 HEX FLG HD CAP SCR, 5/8-18 X 1-1/2 LG, GR 8, ZINC PL 7 C39-50175-02 4 WASHER, 1/2 X 1 3/4, FW, TYPE B, Z 600105-011 1 DPF ASSY, (includes items 101 thru 114) 101 500036-229 1 WELDMENT, EXHAUST MTG 102 300104-407 1 SCR, CUMMINS ISX, 2010 103 300104-408 2 ELBOW, 90 DEG. INSULATED, CUMMINS ISX, 2010 104 300104-411 1 DECOMP REACTOR, SCR, CUMMINS ISX, 2010 105 300104-406 1 DPF, CUMMINS ISX, 2010 106 300104-410 4 GASKET, SCR, 5 SPHERICAL MARMON 107 300104-409 4 CLAMP, SCR, 5 SPHERICAL MARMON 108 700098-168 1 TUBE, EXHAUST, ISX 11.9 109 500034-042 4 WELD, EXHAUST STRAP 110 700503-024 4 SPACER, EXHAUST STRAP 111 200095-713 1 STACK PIPE, EXHAUST, CURVED, 5 OD x 24 LG, CHROME 112 200004-231 1 CLAMP, EXHAUST, WIDE BAND, 5 DIA, STNL STL, BRIGHT 113 300104-415 1 GASKET, SCR, 5 STD MARMON 114 300104-414 1 CLAMP, SCR, 5 STD MARMON 990001-056 AIW 2010 Series 2-11
ENGINE & ATTACHING PARTS This Page Intentionally Left Blank 2-12 AIW 2010 Series 990001-056
SECTION 3 DRIVE TRAIN 990001-056 AIW 2010 Series
DRIVE TRAIN Figure 3-1 Drivetrain Installation 5 4 3 105 103 101 PD1410 1 2 104 102 101 3-2 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-1 Drivetrain Installation Item Part Number Qty. Description Rev. 1 Ref FRONT AXLE SUSPENSION, (see Figure 3-2 for details) 2 Ref FRONT AXLE ASSY, (see Figure 3-2 for details) 3 Ref REAR AXLE ASSY, (see Figure 3-7 for details) 4 Ref DRIVESHAFTS, (see Figure 3-9 for details) 680068-002 1 FRONT WHEEL ASSY, (includes items 101 & 105) 101 300130-058 8 TIRE, 425/65R22.5 102 300148-115 4 WHEEL, 22.5 X 13.00, 6.12 INSET, HUB PILOT, ALUM, POLISHED 103 300148-116 4 WHEEL, 22.5 X 12.25, 0.56 OFFSET, HUB PILOT, ALUM, POLISHED 104 300148-011 4 INSULATOR, WHEEL, 10-HOLE, 335MM BC, 22MM DIA STUD 105 300148-008 4 INSULATOR, WHEEL, 10-HOLE 990001-056 AIW 2010 Series 3-3
DRIVE TRAIN Figure 3-2 Front Axle Assembly 207 9 10 1 11 12 7 201 203 202 107 102 105 101 106 102 105 103 103 104 204 205 206 6 104 2 8 8 5 107 102 105 101 3 103 104 PD1420 106 102 105 103 4 104 3-4 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-2 Front Axle Assembly Item Part Number Qty. Description Rev. 600017-027 1 FRONT AXLE ASSY, (includes items 1 thru 12) 1 300144-032 1 KIT, SUSPENSION, LEAF SPRING, TANDEM 2 300142-033 1 AXLE, STEER, TUBULAR, 24k, 34.75 SPRING CENTER 3 300147-037 1 AXLE, MH MT22H, 5.38 RATIO, NO SPRING PADS, 11.96 STEER ARM 4 500005-136 1 WELDMENT, SHOCK MOUNT, LH 5 500005-137 1 WELDMENT, SHOCK MOUNT, RH 6 500005-135 2 WELDMENT, SHOCK MOUNTING 7 300144-132 2 SPACER, SPRING, 2 IN 8 300144-237 4 U-BOLT, 6-3/8 ID X 19-1/2 LG X 7/8-14, GR 8 9 200040-101 8 NUT, HEX, 7/8-14, GR 8 10 700017-074 2 PLATE, STOP SPACER 11 700017-071 2 STOP PLATE 12 200086-003 8 WSHR, FLAT, HEAVY, 7/8 680103-008 1 FRONT AXLE SHOCK INSTALLATION, (includes items 101 thru 107) 101 300055-001 4 SHOCK, FRONT 102 200090-001 8 WSHR, SHOCK, 3/4 103 200090-002 8 WSHR, SHOCK, 1 104 200001-114 8 NUT, HEX FLG, 3/4-16, STOVER, GR G, ZINC PL 105 700017-007 8 SLEEVE, SHOCK ABSORBER MNT 106 200039-019 2 HEX HD CAP SCR, 3/4-16 X 5 LG, GR 8, ZINC PL 107 200181-768 6 HEX HD CAP SCR, 3/4-16 X 4-1/2 LG, GR 8, ZINC PL 680103-009 1 AXLE STOP INSTALL, (includes items 201 thru 207) 201 200001-112 12 NUT, HEX FLG, 5/8-18, STOVER, GR G, ZINC PL 202 200180-657 12 HEX FLG HD CAP SCR, 5/8-18 X 1-3/4 LG, GR 8, ZINC 203 500005-138 4 WELDMENT, TIMBREN STOP 204 300103-004 4 SPRING, HOLLOW RUBBER, TIMBREN 205 200055-003 4 WSHR, FLAT, 1/2 ID X 1-1/4 OD 206 200106-018 4 NUT, HEX, 1/2-13 PLAIN 207 700017-071 2 STOP PLATE 990001-056 AIW 2010 Series 3-5
DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing 3 54 52 49 45 47 46 2 3 1 62 63 51 61 52 51 60 48 59 50 38 43 43 42 41 38 37 36 6 35 7 58 14 56 34 33 23 24 4 101 5 8 9 72 10 12 71 69 70 11 15 18 68 67 66 62 63 64 55 16 65 17 19 20 58 57 44 38 43 34 21 39 41 42 25 27 28 38 26 22 30 36 37 40 31 31 32 29 PD0380 3-6 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing Item Part Number Qty. Description Rev. 1 HOUSING ASSY, (includes items 1 thru 75) 1 900002-001 1 AXLE HOUSING 2 900002-002 1 VENT EXTENSION 3 900002-003 3 VENT 4 900002-004 1 FILL PLUG 5 900002-005 1 DRAIN PLUG, MAGNETIC 6 900002-006 36 SPECIAL HEX BOLT 7 900002-007 2 DOWEL PIN 8 900002-008 2 SNAP RING 9 900002-009 2 ROLLER BEARING, AXLE SHAFT, INNER 10 900002-010 2 OIL SEAL, AXLE SHAFT, INNER 11 900002-011 2 SEAL HOLDER 12 900002-012 2 FELT WIPER 13 900002-013 1 YOKE HOUSING, LH 900002-014 1 YOKE HOUSING, RH, (not shown) 14 900002-015 AR TRUNNION SHIM, 1.00 MM 900002-016 AR TRUNNION SHIM, 1.20 MM 900002-017 AR TRUNNION SHIM, 0.40 MM 900002-018 AR TRUNNION SHIM, 0.60 MM 900002-019 AR TRUNNION SHIM, 1.40 MM 15 900002-020 4 LOCK PIN 16 900002-021 4 HEX NUT, M16X1.5 17 900002-022 2 BEARING CASE, UPPER 18 900002-023 2 O-RING 19 900002-024 2 THRUST DISK 20 900002-025 2 BEARING CASE, LOWER 21 900002-026 1 KNUCKLE SPINDLE ASSY, LH 900002-027 1 KNUCKLE SPINDLE ASSY, RH 24 900002-028 2 ABS SENSOR, (Wabco) 900002-029 2 SENSOR SPRING CLIP 25 900002-030 4 SPECIAL HEX BOLT 26 900002-031 4 DOWEL PIN 27 900002-032 2 WEAR SLEEVE HUB SEAL 28 900002-033 2 DUST SHIELD 29 900002-034 12 HEX BOLT, M8X16 30 900002-035 12 LOCKWASHER, M8 31 900002-036 4 WHEEL BEARING NUT 32 900002-037 2 WHEEL BEARING LOCK RING 33 900002-038 4 OIL SEAL, TRUNNION PIN 34 900002-039 4 TRUNNION PIN BUSHING 35 900002-040 2 TRUNNION PIN, UPPER (short) 36 900002-041 4 TRUNNION PIN COVER 37 900002-042 4 SNAP RING 38 900002-043 4 GREASE FITTING, 45 DEGREES 39 900002-044 2 TRUNNION PIN, LOWER, (long) 40 900002-045 2 ADAPTER 41 900002-046 4 TRUNNION COVER GASKET 42 900002-047 4 TRUNNION COVER 43 900002-048 12 BOLT, M8X20-1.25 990001-056 AIW 2010 Series 3-7
DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing (Continued) Item Part Number Qty. Description Rev. 44 900002-036 12 LOCKWASHER, M8 45 900002-050 2 ADAPTER FITTING 46 900002-051 2 ELBOW FITTING, VENT 47 900002-052 2 JAM NUT 48 900002-053 4 LOCKWASHER, M8 49 900002-054 4 HEX BOLT, M10X25 50 900002-055 1 BRACKET VENT, LH 900002-056 1 BRACKET VENT, RH, (not shown) 51 900002-057 4 RETAINING RING 52 900002-058 4 UNION NUT 53 900002-059 1 TUBE VENT, LH, (includes items 51 & 52) 900002-060 1 TUBE VENT, RH 54 900002-061 2 PIPE FITTING 55 900002-062 2 BOLT, M20X60-1.5 56 900002-063 2 BOLT, TURN STOP, M20X47-1.5 900002-064 2 BOLT, TURN STOP, M20X80-1.5 57 900002-065 2 SPECIAL HEX NUT 58 900002-066 4 DOWEL PIN 59 900002-067 4 STEERING ARM STUD 60 900002-068 1 BRAKE CHAMBER BRACKET, LH 900002-069 1 BRAKE CHAMBER BRACKET, RH 61 900002-070 1 STEERING ARM, LH 62 900002-071 1 STEERING ARM, RH, (not shown) 63 900002-072 AR LOCK WIRE 64 900002-073 8 CASTLE NUT 900002-074 1 TIE ROD ARM, LH 900002-075 1 TIE ROD ARM, LH, (0000, 11, 06) 900002-076 1 TIE ROD ARM, RH, (not shown) 900002-077 1 TIE ROD ARM, RH, (0000, 11, 06), (not shown) 65 900002-078 4 STUD TIE ROD ARM 900002-079 4 STUD TIE ROD ARM, (0000, 11, 06) 66 900002-080 2 ROLLER BEARING, AXLE SHAFT, OUTER 67 900002-081 2 SNAP RING 68 900002-082 2 OIL SEAL, AXLE SHAFT, OUTER 69 900002-083 2 DUST SHIELD, AXLE SHAFT 70 900002-084 2 FELT 71 900002-085 8 LOCKWASHER, M6 72 900002-086 8 HEX BOLT, M6X12 73 900002-087 2 THRUST BEARING KIT, (includes items 17 thru 20) 74 900002-088 2 O-RING 75 900002-089 2 SEAL HOLDER ASSY, (includes items 10, 11 & 12) 3-8 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-3 Front Drive Steer Axle - Housing (Continued) Item Part Number Qty. Description Rev. 990001-056 AIW 2010 Series 3-9
DRIVE TRAIN Figure 3-4 Front Drive Steer Axle - Differential 20 19 22 23 13 24 11 21 14 18 17 12 16 25 26 10 9 9 15 5 1 8 6 4 3 6 7 1 2 101 105 104 109 102 103 105 106 107 PD0410 108 3-10 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-4 Front Drive Steer Axle - Differential Item Part Number Qty. Description Rev. 1 DIFFERENTIAL ASSY, (includes items 1 thru 26) 1 900002-115 1 DIFFERENTIAL CASE HALVES ASSY 2 900002-116 12 SPECIAL HEX BOLT 3 900002-117 2 SPECIAL WASHER 4 900002-118 2 OIL BAFFLE PLATE 5 900002-119 1 DIFFERENTIAL CROSS 6 900002-120 1 NEST SET 7 900002-121 4 WASHER, DIFFERENTIAL PINION GEAR 8 900002-122 2 WASHER, DIFFERENTIAL SIDE GEAR 9 900002-123 1 RING & GEAR PINION 10 900002-124 16 FLANGED RING GEAR BOLT 11 900002-125 1 BEARING CAGE ASSY 12 900002-126 1 OIL BAFFLE PLATE 13 900002-127 12 SPECIAL FLANGED BOLT 14 900002-128 AR SHIM, 1.0 MM 900002-129 AR SHIM,.50 MM 900002-130 AR SHIM,.30 MM 900002-131 AR SHIM,.25 MM 900002-132 AR SHIM,.20 MM 15 900002-133 1 PINION BEARING, INNER 16 900002-134 1 PINION BEARING, OUTER 17 900002-135 1 COVER 18 900002-136 1 OIL SEAL KIT, PINION 19 900002-048 8 HEX BOLT, M8X22 20 900002-035 8 LOCKWASHER, M8 21 900002-138 1 COMPANION FLANGE, 1610 SERIES 900002-139 1 COMPANION FLANGE, 1610 SERIES 22 900002-140 1 PINION LOCKNUT 900002-141 1 PINION CASTLE NUT 23 900001-997 1 COTTER PIN 24 900002-143 1 SPECIAL WASHER 25 900002-144 1 DISTANCE SLEEVE 1 DIFFERENTIAL CARRIER HOUSING ASSY, (includes items 101 thru 109) 101 900002-146 1 DIFFERENTIAL CARRIER HOUSING 102 900002-147 14 FLANGED BOLT 103 900002-148 1 DIFFERENTIAL SIDE BEARING ASSY 104 900002-149 1 DIFFERENTIAL SIDE BEARING ASSY 105 900002-150 2 BEARING ADJUSTER 106 900002-151 2 LOCK PLATE 107 900002-152 2 LOCK PLATE 108 900002-034 4 HEX BOLT, M8X15, GR10.9 109 900002-153 14 LOCKWASHER, (nord-lock) 990001-056 AIW 2010 Series 3-11
DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components 7 6 9 18 19 20 17 2 1 3 5 4 3 8 11 14 15 16 21 22 12 13 PLANETARY 104 105 103 106 107 101 108 109 110 111 112 102 WHEEL HUB, BRAKE DRUM PD0400 3-12 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components (Continued) 209 203 212 208 210 209 209 207 206 211 209 212 212 210 211 212 204 209 209 207 208 AXLE SHAFT ASSY 306 304 302 303 TIE ROD 307 PD0390 990001-056 AIW 2010 Series 3-13
DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components Item Part Number Qty. Description Rev. 1 PLANETARY ASSY, (includes items 1 thru 25) 1 900002-090 10 PLANET GEAR PIN 2 900002-091 10 STEEL BALL 3 900002-092 20 DISTANCE PLATE 4 900002-093 10 ROLLER BEARING ASSY 5 900002-094 10 PLANET GEAR 6 900002-005 2 MAGNETIC DRAIN PLUG 7 900002-004 2 FILL PLUG 8 900002-095 10 HEX BOLT, M10X20 9 900002-096 2 END COVER 10 900002-097 2 PLANET GEAR CARRIER HUB PILOT 11 900002-098 2 PLANETARY RING GEAR 12 900002-099 2 RING GEAR SUPPORT HUB 13 900002-100 2 RETAINING RING 14 900002-101 2 SNAP RING 15 900002-102 2 SPACER 16 900002-103 2 SUN GEAR 17 900002-104 12 HEX BOLT, M10X30 18 900002-105 2 SNAP RING 19 900002-106 AR SHIM, 0.25 MM 900002-107 AR SHIM, 0.50 MM 900002-108 AR SHIM, 2.00 MM 20 900002-109 2 FRICTION DISK 21 900002-110 2 DISTANCE RING 22 900002-111 2 FRICTION DISK 23 900002-112 2 PLANET GEAR CARRIER ASSY 24 900002-113 2 PLANET GEAR KIT 25 900002-114 2 SUN GEAR/FRICTION DISK KIT 1 WHEEL HUB & BRAKE DRUM ASSY, (includes items 101 thru 112) 101 900001-978 2 HUB ASSY 102 900001-979 20 WHEEL STUD HUB PILOT 103 900001-980 20 FLANGE WHEEL NUT 104 900001-981 4 HEX BOLT, M10X40 105 900001-982 2 BRAKE DRUM 106 900001-983 2 WHEEL BEARING CONE, (outer) 107 900001-984 2 WHEEL BEARING CUP, (outer) 108 900001-985 2 WHEEL BEARING CUP, (inner) 109 900001-986 2 WHEEL BEARING CONE, (inner) 111 900001-987 2 EXCITER RING 112 900001-988 2 HUB SEAL 900001-049 1 BEARING KIT HUB, (includes items 106 thru 109) 1 AXLE SHAFT ASSY, (includes items 201 thru 213) 201 900001-998 1 AXLE SHAFT, SHORT SPLINE 900001-999 1 AXLE SHAFT LONG SPLINE 202 NSS DOUBLE CARDAN STEERING JOINT 3-14 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-5 Front Drive Steer Axle - Components (Continued) Item Part Number Qty. Description Rev. 203 NSS OUTER AXLE SHAFT 204 NSS INNER AXLE SHAFT 205 NSS COUPLE HOUSING 206 NSS CROSS SHAFT 207 NSS BEARING CUP ASSY 208 NSS SNAP RING 209 NSS BEARING CUP PLUG 210 NSS AXLE SHAFT PIN 211 NSS AXLE PIN SET SCREW 212 NSS BEARING CUP ASSY TIE ROD ASSY, (includes items 301 thru 308) 301 900001-989 1 TIE ROD 302 900001-990 1 BALL STUD ASSY, RH 900001-991 1 BALL STUD ASSY, LH 303 900001-992 4 SPECIAL HEX BOLT 304 900001-993 4 CASTLE NUT, M16X1.5 305 900001-994 4 COTTER PIN, 1/8X1-1/2 306 900001-995 1 TIE ROD 307 900001-996 2 CASTLE NUT 308 900001-997 2 COTTER PIN, 1/4X2 990001-056 AIW 2010 Series 3-15
DRIVE TRAIN Figure 3-6 Front Drive Steer Axle - Brakes 4 1 3 27 5 13 12 7 21 23 22 6 8 7 14 15 16 25 2 10 9 11 8 26 18 24 20 17 19 PD0340 3-16 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-6 Front Drive Steer Axle - Brakes Item Part Number Qty. Description Rev. 1 BRAKE ASSY, FRONT DRIVE STEER, (includes items 1 thru 27) 1 900002-154 4 BRAKE SHOE ASSY 2 900002-155 2 BRAKE SHOE RETURN SPRING 3 900002-156 4 RETURN SPRING, SHORT 4 900002-157 4 PIN, SPRING SUPPORT 5 900002-158 4 BRAKE SHOE ROLLER 6 900002-159 4 BRAKE SHOE PIN 7 900002-160 4 BUSHING 8 900002-161 4 OIL SEAL 9 900002-162 2 GREASE FITTING 10 900002-163 1 SPANNER HOUSING ASSY, LH, (includes items 7, 8 & 9) 900002-164 1 SPANNER HOUSING ASSY, RH, (includes items 7, 8 & 9) 11 900002-165 8 SPECIAL HEX BOLT 12 900002-166 2 SPECIAL WASHER 13 900002-167 1 CAM SHAFT, LH 900002-168 1 CAM SHAFT, RH 14 900002-169 2 SPACER 15 900002-170 AR SHIM,.50 MM 16 900002-171 1 AUTOMATIC SLACK ADJUSTER, LH 900002-172 1 AUTOMATIC SLACK ADJUSTER, RH 17 900002-173 2 SPACER 18 900002-174 2 WEAR INDICATION DISK 19 900002-175 2 SNAP RING 20 900002-176 4 SNAP RING 21 900002-177 1 BUMPER ASSY, LH 900002-178 1 BUMPER ASSY, RH 22 900002-179 4 BOLT, M8X14-1.25 23 900002-035 4 LOCKWASHER, M8 24 900002-180 2 GREASE FITTING, 1/8 900002-181 2 GREASE FITTING, M8X1.00 25 900002-182 2 BUSHING 26 900002-183 1 CAP, AUTOMATIC SLACK ADJUSTER, LH 900002-184 1 CAP, AUTOMATIC SLACK ADJUSTER, RH 900002-034 2 BOLT, M8X16-1.25 900002-185 2 BOLT, M6X20-1.00 27 900002-186 4 ROLLER SPRING, (optional) 900002-187 2 BRAKE SPRING & ROLLER KIT, (includes items 2, 3, 5, 6 & 27) 990001-056 AIW 2010 Series 3-17
DRIVE TRAIN Figure 3-7 Rear Axle Assembly 3 101 102 103 104 105 106 107 2 1 PD1430 3-18 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-7 Rear Axle Assembly Item Part Number Qty. Description Rev. 600017-026 1 REAR AXLE ASSY, (includes items 1 thru 3) 1 680072-008 1 FRONT REAR AXLE 2 680072-009 1 REAR REAR AXLE 3 300144-125 1 SUSPENSION KIT, 46K TANDEM ASSY, (includes items 101 thru 107) 101 900001-323 2 TORQUE ROD FRAME BRACKET 102 900002-412 2 TORQUE ROD ASSY 103 900002-386 2 TORQUE ROD ASSY 104 900001-314 8 THRUST WASHER 105 900001-312 2 BEAM CENTER SLEEVE 106 900001-954 1 BEAM END MOUNITNG HARDWARE 107 900002-413 2 EQUALIZER BEAM ASSY, 54 990001-056 AIW 2010 Series 3-19
DRIVE TRAIN Figure 3-8 Rear Axle - Brake Assembly PD1260 3-20 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-8 Rear Axle - Brake Assembly Item Part Number Qty. Description Rev. 900002-417 1 BRAKE ASSY, FORWARD/REAR AXLE LH, (includes items 1 thru 23) 900002-418 1 BRAKE ASSY, FORWARD/REAR AXLE RH, (includes items 1 thru 23) 900002-419 1 BRAKE ASSY, REAR/REAR AXLE LH, (includes items 1 thru 23) 900002-420 1 BRAKE ASSY, REAR/REAR AXLE RH, (includes items 1 thru 23) 1 900002-416 1 SPIDER & PIN ASSY 2 900001-028 1 GUSSET BRACKET ASSY, FORWARD/REAR AXLE LH 900001-029 1 GUSSET BRACKET ASSY, FORWARD/REAR AXLE RH 900001-490 1 GUSSET BRACKET ASSY, REAR/REAR AXLE LH 900001-489 1 GUSSET BRACKET ASSY, REAR/REAR AXLE RH 3 900001-829 2 GREASE SEAL 4 900001-830 2 CAMSHAFT BUSHING 5 900001-834 1 GREASE FITTING 6 900001-944 2 SHOE & LINING ASSY 7 900001-031 1 CAMSHAFT, FORWARD/REAR AXLE LH, CCW 900001-483 1 CAMSHAFT, FORWARD/REAR AXLE RH, CW 900001-483 1 CAMSHAFT, REAR/REAR AXLE LH, CW 900001-031 1 CAMSHAFT, REAR/REAR AXLE RH, CCW 8 900001-033 1 SLACK ADJUSTER 9 900001-485 1 SLACK ANCHOR BRACKET 900001-475 1 HARDWARE ASSY, (includes items 10 thru 16) 10 900001-811 AR CAMSHAFT SHIM WASHER,.030 11 900001-812 AR CAMSHAFT SHIM WASHER,.060 12 900001-813 4 BRACKET MOUNTING CAPSCREW 13 900001-814 1 SLACK ADJUSTER INNER WASHER 14 900001-761 4 BRACKET MOUNTING LOCKWASHER 15 900001-815 1 CAMSHAFT RETAINER SNAP RING 16 900001-827 1 CAM HEAD WASHER 900001-486 1 ROLLER & SPRING ASSY, (includes items 17 thru 20) 17 900001-794 2 CAM ROLLER 18 900002-373 2 ROLLER RETAINER 19 900002-374 1 SHOE RETURN SPRING 20 900001-797 2 SHOE RETAINER SPRING 900001-945 1 DUSTSHIELD ASSY, (includes items 21 thru 23) 21 900002-375 1 DUSTSHIELD 22 900001-791 4 DUSTSHIELD SCREW 23 900001-792 4 PLUG 990001-056 AIW 2010 Series 3-21
DRIVE TRAIN Figure 3-9 Driveshafts Assembly REAR-REAR AXLE 5 FRONT-REAR AXLE 1 6 5 2 TRANSMISSION 4 9 3 8 10 2 7 FRONT AXLE 10 PD1440 3-22 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-9 Driveshafts Assembly Item Part Number Qty. Description Rev. 680106-013 1 DRIVESHAFT ASSY, (includes items 1 thru 10) 1 300117-307 1 DRIVESHAFT, 1710, HALF RND, 20 LG 2 300117-317 2 DRIVESHAFT, 1710, HALF RND, 52.5 LG 3 300117-417 1 COUPLESHAFT, 1710, HALF RND, 57.25 LG 4 300117-503 1 JACKSHAFT, 1710, 57.2, HALF ROUND 5 300118-307 2 DRIVESHAFT, 1810, HALF RND, 43.75 LG 6 300118-503 1 JACKSHAFT, 1810, 46.5 7 500056-026 1 WELDMENT, DRIVESHAFT SUPPORT 8 500056-027 1 WELDMENT, CENTER BEARING SUPPORT 9 500056-028 1 WELDMENT, CENTER BEARING SUPPORT 10 700056-071 2 PLATE, BENT, CENTER BEARING 990001-056 AIW 2010 Series 3-23
DRIVE TRAIN Figure 3-10 PTO Installation 101 3 102 2 PD1610 1 3-24 AIW 2010 Series 990001-056
DRIVE TRAIN Figure 3-10 PTO Installation Item Part Number Qty. Description Rev. 605-C00142 1 PTO MOUNTING ASSY, (includes items 1 thru 3) 1 200001-109 4 NUT, HEX FLG, 1/2-13, STOVER, GR G, ZINC PL 2 200180-506 4 HEX FLG HD CAP SCR, 1/2-13 X 1-1/2 LG, GR 8, ZINC PL 3 500056-029 1 WELDMENT, PUMP SUPPORT 101 Ref TANDEM PTO PUMP, (see final stage manufacturer) 102 Ref PTO MOUNTING FLANGE, (see final stage manufacturer) 990001-056 AIW 2010 Series 3-25
DRIVE TRAIN This Page Intentionally Left Blank 3-26 AIW 2010 Series 990001-056
SECTION 4 CAB 990001-056 AIW 2010 Series
CAB Figure 4-1 Operators Cab Installation 13 101 102 1 202 15 10 202 203 11 12 201 10 2 14 7 3 9 8 9 6 5 203 16 PD1450 4-2 AIW 2010 Series 990001-056
CAB Figure 4-1 Operators Cab Installation Item Part Number Qty. Description Rev. 680114-001 1 CAB ASSY, (includes items 1 thru 16) 1 300028-931 5 LAMP, CLEARANCE, CAB, AMBER 2 700072-022 1 FRONT GRILL 3 700071-002 1 BRKT, MTG, HORN, AIR 4 700044-004 8 PLATE, WEB 5 300070-003 1 HORN, AIR, BLACK 6 200001-005 4 NUT, HEX FLG, 5/8-18, STOVER, GR G, BLK PHOS 7 200039-176 4 HEX HD CAP SCR, 5/8-18 X 5-1/2 LG, GR 8, ZINC PL 8 200080-104 4 ISOLATOR, MTG, RUBBER, 700 LB 9 200105-008 4 WSHR, FLAT, SAE, 5/8 DIA, THRU HARD, ZINC PL 10 200065-003 4 STANCHION, CHROME, GRABHANDLE 11 200065-004 2 TUBE, GRABHANDLE, 36 LG 12 700114-097 1 TRIM, DRIP EDGE, LH 13 700114-098 1 TRIM, DRIP EDGE, RH 14 700114-099 1 TRIM, DRIP EDGE, DOOR LH 15 700114-100 1 TRIM, DRIP EDGE, DOOR RH 16 200143-007 18 SCR, SELF DRILL, SS, PAN HD, #8 X 3/4 680023-005 1 SPOTLIGHT INSTALLATION, (includes items 101 thru 102) 101 300084-002 2 LAMP, SPOT, REMOTE CONTROL, GO LIGHT 102 200035-006 8 INSERT, THREADED, 10-32, ALUM 201 200156-003 12 HEX SOC BUTTON HD CAP SCR, 10-32 X 3/4 LG, STNL STL 202 300087-312 2 MIRROR, LOOKDOWN 203 300087-313 1 MIRROR KIT, CONVEX 990001-056 AIW 2010 Series 4-3
CAB Figure 4-2 Door Assembly, LH 199 185 184 185 108 126 127 128 182 183 129 124 107 191 196 192 125 197 195 186 121 1 101 106 192 105 118 112 103 192 193 114 109 194 111 194 194 116 122 102 113 119 189 198 185 123 117 190 120 192 187 188 104 193 110 188 115 PD1460 4-4 AIW 2010 Series 990001-056
CAB Figure 4-2 Door Assembly, LH Item Part Number Qty. Description Rev. 680200-001 1 DOOR ASSY, LH, (includes items 101 thru 199) 101 600014-001 1 DOOR WELDMENT, LH 102 200045-110 1 PULL DOOR HANDLE 103 200045-111 1 INSIDE DOOR HANDLE, LH 104 450400-086 1 REGULATOR BRACKET, LH 105 200045-009 1 ROTORY LATCH, LH 106 200065-402 1 GRAB HANDLE 107 300197-004 2 FOOTMAN LOOP 108 300087-308 1 REMOTE HEATED MIRROR, LH 109 200045-327 1 INTERIOR LOCK ROD, LH 110 450400-088 2 REGULATOR BRACKET SHIM 111 700015-054 1 ROTARY LATCH ADAPTER 112 200045-329 1 EXTERIOR LOCK ROD 113 200045-328 1 EXTERIOR LATCH ROD, LH 114 200045-326 1 INTERIOR LATCH ROD, LH 115 450400-089 1 REGULATOR MOUNTING BRACKET 116 300067-005 1 ROLL DOWN WINDOW, LH 117 200080-001 1 RUBBER BUMPER 118 450400-091 1 DOOR KICK PANEL, LH 119 100042-006 1 RUBBER TRIM 120 100041-019 1 RUBBER BULB SEAL 121 100041-027 1 RUBBER-D, 160 122 100041-027 1 RUBBER-D, 19 123 100041-031 1 RUBBER-D, 36 124 200047-019 1 GROMMET 125 300197-003 2 CHECK STRAP 126 200189011 2 POWER WINDOW SWITCH 127 450400-104 1 PLATE, SWITCH MOUNT 128 450400-102 1 CHANNEL, WINDOW 129 200157-003 4 FLAT SOCKET HEAD CAP SCREW, 10-32 X 3/4 LG, BLACK OXIDE 182 200054-001 3 LOCK WSHR, SPLIT, MEDIUM, 1/4, STNL STL 183 200050-001 3 NUT, HEX, THIN, 1/4-20 18-8 STNL STL 184 200037-032 3 TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1-1/4 LG, STNL STL 185 200108-001 7 WASHER, 1/4 186 200037-008 27 PAN HD SCREW, 1/4-20X1 187 200108-005 6 WASHER, #10, 18-8 188 200037-006 10 PAN HD SCREW, #10-32X3/4, 18-8 189 200039-103 1 HEX HD CAPSCREW, 1/4-20X1-1/4, 18-8 190 200049-001 1 LOCKNUT, 1/4-20, GR2 191 200048-050 4 PAN SCREW, M6-1X25MM 192 200052-001 14 LOCKNUT, #10-32 193 200107-001 6 WASHER, EXTERNAL TOOTH, #10 194 200037-003 6 PAN HD SCREW, #10-32X1/2, 18-8 195 200038-202 4 PAN HD SCREW, 1/4-20X1 196 200037-002 2 PAN HD SCREW, 1/4-20X1/2, 18-8 197 200036-004 4 OVAL HD MACHINE SCREW, 10-32X3/4 198 200055-001 1 WASHER 199 200037-009 4 PAN HD SCREW, 1/4-20X3/4, 18-8 APPLY BLUE LOCTITE TO ALL BOLTS & NUTS USING LOCKNUTS 990001-056 AIW 2010 Series 4-5
CAB Figure 4-3 Door Assembly, RH 184 185 115 182 183 129 127 125 128 1 101 185 199 124 126 197 117 192 103 191 104 113 105 195 118 119 106 107 102 186 109 108 111 120 123 185 198 189 122 114 190 121 187 112 188 110 193 116 188 PD1470 4-6 AIW 2010 Series 990001-056
CAB Figure 4-3 Door Assembly, RH Item Part Number Qty. Description Rev. 1 680200-002 1 DOOR ASSY, RH, (includes items 101 thru 199) 101 600014-002 1 DOOR WELDMENT, RH 102 200045-008 1 ROTORY LATCH, RH 103 200045-112 1 INSIDE DOOR HANDLE, RH 104 200045-110 1 PULL DOOR HANDLE 105 200045-330 1 INTERIOR LATCH ROD, RH 106 200045-331 1 INTERIOR LOCK ROD, RH 107 700015-054 1 ROTARY LATCH ADAPTER 108 200045-332 1 EXTERIOR LATCH ROD, RH 109 200045-329 1 EXTERIOR LOCK ROD 110 450400-087 1 REGULATOR BRACKET, RH 111 300067-006 1 ROLL DOWN WINDOW, RH 112 450400-090 1 REGULATOR MOUNTING ANGLE. RH 113 200065-402 1 GRAB HANDLE 114 200080-001 1 RUBBER BUMPER 115 300087-307 1 REMOTE HEATED MIRROR, RH 116 450400-088 2 REGULATOR BRACKET SHIM 117 300197-004 2 FOOTMAN LOOP 118 450400-092 1 DOOR KICK PANEL, RH 119 100041-027 1 RUBBER-D, 160 120 100041-027 1 RUBBER-D, 19 121 100041-031 1 RUBBER-D, 36 122 100041-019 1 RUBBER BULB SEAL 123 100042-006 1 RUBBER TRIM 124 200047-019 1 GROMMET 125 200189-011 1 POWER WINDOW SWITCH 126 300197-003 2 CHECK STRAP 127 450400-105 1 PLATE, SWITCH MOUNT 128 200157-003 4 FLAT SOCKET HEAD CAP SCREW, 10-32 X 3/4 LG, BLACK OXIDE 129 450400-102 1 CHANNEL, WINDOW 182 200054-001 3 LOCK WSHR, SPLIT, MEDIUM, 1/4, STNL STL 183 200050-001 3 NUT, HEX, THIN, 1/4-20 18-8 STNL STL 184 200037-032 3 TRUSS HD MACH SCR, PHILLIPS, 1/4-20 X 1-1/4 LG, STNL STL 185 200108-001 7 WASHER, 1/4 186 200037-008 27 PAN HD SCREW, 1/4-20X1 187 200108-005 6 WASHER, #10, 18-8 188 200037-006 10 PAN HD SCREW, #10-32X3/4, 18-8 189 200039-103 1 HEX HD CAPSCREW, 1/4-20X1-1/4, 18-8 190 200049-001 1 LOCKNUT, 1/4-20, GR2 191 200048-050 4 PAN SCREW, M6-1X25MM 192 200052-001 14 LOCKNUT, #10-32 193 200107-001 6 WASHER, EXTERNAL TOOTH, #10 194 200037-003 6 PAN HD SCREW, #10-32X1/2, 18-8 195 200038-202 4 PAN HD SCREW, 1/4-20X1 196 200037-002 2 PAN HD SCREW, 1/4-20X1/2, 18-8 197 200036-004 4 OVAL HD MACHINE SCREW, 10-32X3/4 198 200055-001 1 WASHER 199 200037-009 4 PAN HD SCREW, 1/4-20X3/4, 18-8 APPLY BLUE LOCTITE TO ALL BOLTS & NUTS USING LOCKNUTS 990001-056 AIW 2010 Series 4-7
CAB Figure 4-4 Seat Assembly 10 7 5 9 11 7 5 7 6 6 7 3 4 1 1 1 1 2 9 2 7 10 3 4 PD1480 4-8 AIW 2010 Series 990001-056
CAB Figure 4-4 Seat Assembly Item Part Number Qty. Description Rev. 600107-027 1 DRIVER SEAT ASSY, (includes items 1 thru 11) 1 200105-012 16 WSHR, FLAT, SAE, 5/16 DIA, GR 8, ZINC PL 2 200049-002 8 NUT, HEX, LOCKING, NYLOK, 5/16-18, GR 2, ZINC PL 3 200039-118 4 HEX HD CAP SCR, 5/8-18 X 5 LG, GR 8, ZINC PL 4 200039-004 4 HEX HD CAP SCR, 5/16-18 X 1 LG, GR 5, ZINC PL 5 300041-011 2 SEAT, AIR RIDE, HI-BACK, VINYL, PACIFIC GRAY 6 300086-002 2 ARM REST, SEAT GRAY, KIT, 2 EACH 7 300081-002 2 SEAT BELT, 3-PT SHOULDER, RH, BK 8 200106-001 14 NUT, HEX, 7/16-20, ZINC PL 9 200054-002 14 LOCK WSHR, SPLIT, MEDIUM, 7/16, ZINC PL 10 200039-015 10 HEX HD CAP SCR, 7/16-20 X 1-1/2 LG, GR 8, ZINC PL 11 700231 2 SPACER, TUBE SEATBELT BUCKLE 990001-056 AIW 2010 Series 4-9
CAB Figure 4-5 Seat Components 17 14 12 6 19 38 25 39 6 24 8 3 7 4 5 10 3 27 10 8 4 26 5 7 9 6 22 20 18 9 2 6 13 23 28 2 6 PD0290 6 4-10 AIW 2010 Series 990001-056
CAB Figure 4-5 Seat Components Item Part Number Qty. Description Rev. 900001-961 1 SUSPENSION HARDWARE KIT, (includes items 2 thru 10) 2 2 RUBBER BUMPER 3 2 SPACER ROLLER 4 6 MULTILUBE BEARING 5 4 BEARING BLOCK 6 6 CAPSCREW, M8X1.25 7 2 SHOULDER BOLT, M7X1.25 8 4 SLIDE BLOCK 9 2 STOP BLOCK ASSY 10 3 LOCKNUT, M8X1.25 900001-962 1 AIR VALVE KIT, (includes items 12 thru 15) 12 1 CLAMP CABLE 13 1 NYLON TUBING, 1/4 14 1 SCREW 15 1 PNEUMATIC VALVE 900001-963 1 STANDARD DAMPER KIT, (includes items 18 thru 21) 18 2 MULTILUBE BEARING 19 2 WASHER 20 2 PUSH-ON FASTENER 21 1 DAMPER 900001-964 1 AIR SPRING KIT, (includes items 22 thru 24) 22 1 AIR SPRING ASSY 23 1 NYLON TUBING, 1/4 24 1 FLAT HEAD SCREW, M8 25 900001-965 1 UPPER PLATE ASSY 26 900001-966 1 INNER LEVER ASSY 27 900001-967 1 OUTER LEVER ASSY 28 900001-968 1 BASE WELDMENT ASSY 900001-969 1 ICP BRACKETS KIT, (includes items 38 & 39) 38 4 CAPSCREW, M8X12MM 39 2 SEAT BELT BRACKET 101 900001-970 1 SEAT FOAM, (not shown) 102 900001-971 1 HIGH BACK FOAM, (not shown) 103 900001-972 1 LOW BACK FOAM, (not shown) 104 900001-973 1 SEAT COVER, (not shown) 105 900001-974 1 HIGH BACK COVER, (not shown) 106 900001-975 1 MID BACK COVER, (not shown) 107 900001-976 1 MID BACK FOAM, (not shown) 108 900001-977 1 LOW BACK COVER, (not shown) 1 990001-056 AIW 2010 Series 4-11
CAB Figure 4-6 Cab Interior Installation 102 101 102 101 5 10 4 5 3 PD1490 4-12 AIW 2010 Series 990001-056
CAB Figure 4-6 Cab Interior Installation (Continued) 6 2 8 9 2 7 11 12 1 9 8 16 14 13 17 16 1 15 17 13 PD1500 990001-056 AIW 2010 Series 4-13