Telehander

Parts Manual
Model
TL642
S/N TBK00100 & After
P/N 31200255
Revised
September 18, 2009
EFFECTIVITY PAGE
October 20, 2006 - A - Original Issue of Manual

November 9, 2006 - B - Revised Manual
February 23, 2007 - C - Revised Manual
June 29, 2007 - D - Revised Manual
November 1, 2007 - E - Revised Manual
April 25, 2008 - F - Revised Manual
October 24, 2008 - G - Revised Manual
February 6, 2009 - H - Revised Manual
September 18, 2009 - I - Revised Manual
31200255 TL642 i
EFFECTIVITY PAGE
-ii TL642 31200255

TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 –
FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1 Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 Outrigger Mounting, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
SECTION 2 –
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Bearing Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4 Bearing Pads, Spacers and Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-5 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-6 Bearing Pads, Spacers and Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-7 Push Beam/Extend Chain & Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-8 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-9 Hydraulic Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
SECTION 3 –
ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1 50” & 72” Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-4 50” & 72” Side Tilt Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5 Fork Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-6 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-7 Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-8 100 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
SECTION 4 –
ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 Engine Assembly, L.H. View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Engine Assembly, R.H. View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 Cat Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-5 Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-6 Air Cleaner and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-7 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-8 Transmission - ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-9 ZF Transmission - Converter & Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-10 ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-11 ZF Transmission - Reversing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-12 ZF Transmission - Reverse Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-13 ZF Transmission - 1st Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
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4-14 ZF Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4-15 ZF Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-16 ZF Transmission - 4th Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-17 ZF Transmission - Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-18 ZF Transmission - Control Unit & Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-19 ZF Transmission - Gearshift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4-20 ZF Transmission - Oil Pump, Filter & Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4-21 ZF Transmission - Transfer Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
SECTION 5 –
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Front Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 Front Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5 Front Gear Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6 Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 Front Double Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-8 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-9 Front Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-10 Front Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-11 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-12 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-13 Rear Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-14 Rear Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-15 Rear Gear Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-16 Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-17 Rear Double Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-18 Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5-19 Rear Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-20 Rear Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-21 Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-22 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
SECTION 6 –
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-4 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-5 Heating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-6 Cab Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-7 Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
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SECTION 7 –
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-4 Boom Joystick w/Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-5 Hydraulic Controller - Outrigger, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
SECTION 8 –
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-3 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8-4 Service/Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8-5 Joystick Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8-6 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8-7 Extend/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8-8 Tilt & Tilt Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8-9 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8-10 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8-11 Outrigger Controller, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8-12 Outrigger Cylinders, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
SECTION 9 –
HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9-2 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9-3 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9-5 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9-6 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9-7 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9-8 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9-9 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9-10 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9-11 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9-12 Quick Coupler Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9-13 Outrigger Cylinder, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9-14 Outrigger Control Valve, (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
SECTION 10 –
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10-1 Battery & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10-2 Battery Disconnect Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
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TABLE OF CONTENTS
10-3 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-4 Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10-5 Auxiliary Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10-6 Tilt Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10-7 A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10-8 Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
SECTION 11 –
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11-1 Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
SECTION 12 –
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1 Block Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12-2 8” Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12-3 Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
12-4 Pressure Reducer Valve - 1360 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12-5 Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
12-6 Fender Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
12-7 Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
12-8 Beacon Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24
12-9 Road Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
12-10 Boom Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
12-11 Skylight Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
12-12 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
12-13 Top Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
12-14 Front Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-38
12-15 Hydraulic Cooler Bypass Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
12-16 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42
12-17 Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
SECTION 13 –
RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
vi TL642 31200255
SMCS CODES - TELEHANDLER
1350 ENGINE COOLING SYSTEM 3000 TRANSMISSION & DRIVE LINE

1351 RADIATOR & OIL COOLER 3013 AXLE ARRANGEMENT
1353 RADIATOR 3020 DRIVE & STEERING AXLE
1354 EXPANSION TANK 3061 TRANSMISSION GEARS
1360 FAN GUARD 3063 TRANSMISSION SHAFT
1374 HYDRAULIC OIL COOLER 3064 TRANSMISSION CASE
1375 TORQUE CONVERTER / TRANSMISSION OIL 3065 TRANSMISSION CONTROL
COOLER
3066 TRANSMISSION OIL PUMP
1380 COOLANT HOSE / LINES
3067 TRANSMISSION OIL FILTER
1381 RADIATOR AND GUARD
3068 TRANSMISSION OIL FILTER BASE
1382 RADIATOR CAP
3075 TRANSMISSION OUTPUT GEARS
1384 ENGINE COOLANT HEATER
3080 TRANSMISSION OIL
1386 HYDRAULIC FAN MOTOR
3081 TRANSMISSION OIL LEVEL
1387 HYDRAULIC FAN PUMP
3082 TRANSMISSION MOUNT
1395 ENGINE COOLANT
3100 TORQUE CONVERTER, TORQUE DIVIDER,

1400 ELECTRICAL SYSTEM RETARDER
1401 BATTERY 3101 TORQUE CONVERTER
1402 BATTERY CABLE 3115 TORQUE CONVERTER/TRANSMISSION SCAVENGE
PUMP
1408 WIRING HARNESS
3133 TORQUE CONVERTER RELIEF VALVE
1416 START SWITCH
3139 MODULATING VALVE
1417 FUSE / CIRCUIT BREAKER PANEL
3141 TORQUE CONVERTER SPEED SENSOR
1428 BACKUP LIGHT(S)
1429 LIGHT(S)
3030 POWER SHIFT / HYDROSTATIC TRANSMISSION
1430 DIRECTIONAL LIGHT
3063 TRANSMISSION SHAFT
1431 BEACON LIGHT(S)
3064 TRANSMISSION CASE
1432 STOP /LIGHT / TAILLIGHT
3065 HYDROSTATIC CONTROL LINKAGE (EXTERNAL)
1434 CAB LIGHT
3066 POWER SHIFT TRANSMISSION OIL PUMP
1434 FLOODLIGHT
3067 HYDROSTATIC TRANSMISSION OIL FILTER
3073 HYDROSTATIC MAIN CONTROL VALVE
OTHER ENGINE COMPONENTS
3151 TRANSMISSION GOVERNOR
1801 ENGINE SOUND SUPPRESSION
3154 TRANSMISSION LINES/HOSES
1802 REFRIGERANT COMPRESSOR
3155 TRANSMISSION CLUTCH
1805 REFRIGERANT CONDENSER
3157 TRANSMISSION SELECTOR VALVE
1807 AIR CONDITIONER COMPRESSOR DRIVE
3159 TRANSFER GEARS
1808 AIR CONDITIONER LINES
3160 TRANSMISSION PLANETARY
1810 RADIATOR & REFRIGERANT CONDENSER
3167 TRANSMISSION HYDRAULIC CONTROL
1812 HEATER / HOSE LINES
3168 TRANSMISSION ELECTRONIC CONTROL
1813 RADIATOR HOSE
3174 SHIFT SOLENOID
3175 TRANSMISSION SPEED SENSOR
vii
3181 TRANSMISSION NEUTRALIZER CONTROL VALVE 3269 PINION HOUSING
3182 TRANSMISSION LUBRICATION RELIEF VALVE 3274 CONSTANT VELOCITY UNIVERSAL JOINT
3184 TRANSMISSION OIL COOLER BYPASS VALVE 3275 DRIVE LINE BRAKE
3186 TRANSMISSION PLANET CARRIER 3276 DRIVE LINE BRAKE DISC
3187 TRANSMISSION CARRIER THRUST DISC/PLATE 3278 DRIVE AXLE
3190 TRANSMISSION CLUTCH PLATE 3281 BEVEL GEAR CASE
3191 TRANSMISSION NEUTRALIZER 3282 AXLE
3194 TRANSMISSION TEMPERATURE SENSOR 3283 DIFFERENTIAL CASE
3202 TRANSMISSION FLOW CONTROL VALVE 3284 DIFFERENTIAL CARRIER
3203 DRIVE PUMP
3204 CHARGE PUMP 4000 DRIVE TRAIN
3205 SERVO CONTROL VALVE 4004 BRAKE & AXLE
3206 MANIFOLD/METERING VALVE 4005 STEERING & BRAKING SYSTEM
3207 SERVO CYLINDER
3210 HIGH PRESSURE RELIEF VALVE 4050 FINAL DRIVE
3213 CHARGE & MAIN RELIEF VALVE 4051 FINAL DRIVE & WHEEL
3214 SYNCHRONIZING VALVE 4052 FINAL DRIVE SEAL
3215 POWER UNIT CONTROL LINKAGE 4053 DRIVE AXLE HUB/GEAR ASSEMBLY
3216 TRANSMISSION UNDERSPEED/OVERSPEEDVALVE 4054 FINAL DRIVE HUB
3219 TRANSMISSION PILOT OVERSPEED VALVE 4055 FINAL DRIVE GEARS
3220 TRAVEL SPEED CONTROL VALVE 4056 FINAL DRIVE - DRIVE SHAFT
3221 HYDROSTATIC POWER CASE 4057 FINAL DRIVE PINION FLANGE
3222 PUMP HEAD 4059 FINAL DRIVE CASE/BORE
3223 TRANSMISSION UNDERSPEED OVERRIDE VALVE 4084 FINAL DRIVE PLANETARY CARRIERS, HUB & RING
GEAR
3225 TRAVEL ELECTRONIC CONTROL
4091 FINAL DRIVE PINION
3226 DOWNSHIFT INHIBITOR
4092 PLANETARY FINAL DRIVE CARRIER
4093 FINAL DRIVE PLANETARY CARRIER THRUST
3250 DRIVE LINE/DRIVE AXLE
SURFACE
3251 UNIVERSAL JOINT
4094 FINAL DRIVE PINION & FLANGE
3252 FLEXIBLE COUPLING
3253 DRIVE SHAFT
4200 WHEEL & TIRE
3254 DRIVE LINE PINION
4201 WHEEL
3256 BEVEL GEAR/SHAFT
4202 RIM & TIRE
3257 BEVEL GEAR SHAFT BEARING
4203 TIRE
3258 DIFFERENTIAL
4208 WHEEL ASSEMBLY
3259 AXLE SHAFT
4209 WHEEL RIM
3260 AXLE HOUSING ASSEMBLY
4210 WHEEL STUD/BOLT/NUT
3263 LIMITED SLIP DIFFERENTIAL
4220 MUD GUARD
3267 DRIVE SHAFT SUPPORT
4233 STEER TIRE, PNEUMATIC
3268 AXLE HOUSING SUPPORT/TRUNNION
viii
4250 BRAKING SYSTEM 5000 IMPLEMENT CONTROLS
4251 SERVICE BRAKE 5001 IMPLEMENT CONTROL LOCK
4255 BRAKE DISC 5002 HYDRAULIC & FUEL TANK
4256 BRAKE CALIPER, HEAD ASSEMBLY 5004 RIDE CONTROL SYSTEM
4257 BRAKE LINES 5005 AUXILIARY HYDRAULIC CIRCUIT
4258 BRAKE MASTER CYLINDER
4262 BRAKE ACTUATOR 5050 HYDRAULIC SYSTEM
4265 SERVICE BRAKE CONTROL VALVE 5051 HYDRAULIC CONTROL VALVE
4267 PARKING BRAKE 5056 HYDRAULIC TANK
4269 SERVICE BRAKE CONTROL 5057 HYDRAULIC HOSES/LINES
4273 FRICTION PADS 5059 PILOT CONTROL VALVE
4282 PARKING/SECONDARY BRAKE CONTROL VALVE 505C PISTON CYLINDER
4284 PARKING BRAKE CONTROL 5063 IMPLEMENT CONTROL
4291 BRAKE HYDRAULIC RESERVOIR 5068 HYDRAULIC OIL FILTER
5069 MAIN SYSTEM RELIEF VALVE
4300 STEERING SYSTEM 506P IMPLEMENT PRIORITY VALVE
4301 STEERING GEAR 5070 PISTON PUMP
4303 STEERING CYLINDER 5071 HYDRAULIC OIL COOLER BYPASS VALVE
4307 STEERING VALVE 5072 PILOT SYSTEM RELIEF VALVE
4309 STEERING WHEEL 5084 IMPLEMENT PUMP
430S STEERING SENSOR 5086 COMPENSATOR VALVE
4310 STEERING COLUMN 5093 HYDRAULIC FILTER BYPASS VALVE
4312 STEERING METERING PUMP 5095 HYDRAULIC OIL
4313 STEERING AXLE 509T HYDRAULIC OIL TEMPERATURE SENSOR
4314 KINGPIN
4318 TIE ROD 5100 LIFT, TILT, TIP & OTHER CONTROLS
4321 STEERING KNUCKLE 5102 LIFT/HOIST CYLINDER
4322 STEERING RELIEF VALVE 5103 LIFT CYLINDER TRUNNION
4329 TIE ROD END 5104 TILT CYLINDER
4338 ADJUSTABLE STEERING COLUMN 5106 TIP CYLINDER
4349 STEERING SELECTOR & PRESSURE CONTROL 5116 ATTACHMENT CYLINDER
VALVE
5130 LOCK VALVE
5141 HITCH LIFT CYLINDER
4350 HYDROSTATIC DRIVE
5144 FRAME LEVEL VALVE
4351 HYDRAULIC PROPEL/DRIVE MOTOR
5486 EXTENSION CYLINDER
4352 DRIVE CONTROL VALVE
4267 HYDROSTATIC DRIVE PARKING BRAKE
4354 BRAKE RELEASE PUMP
4355 HYDROSTATIC DRIVE GEAR REDUCER
4356 BRAKE & SHIFT VALVE
ix
5700 IMPLEMENT ELECTRONIC CONTROLS 7165 CAB/CANOPY SCREEN
5701 IMPLEMENT ELECTRONIC CONTROL MODULE 7170 RADIATOR GRILLE
(PREPROGRAMMED)
7177 ROPS ROLL BAR
5702 IMPLEMENT HYDRAULIC ELECTRONIC CONTROL
7192 WHEEL CHOCK
5705 JOYSTICK
5734 HYDRAULIC SYSTEM WIRING HARNESS
7200 SUSPENSION
5735 FRAME LEVEL CONTROL
7221 OUTRIGGER
5800 OTHER CONTROLS

7250 BODY
5804 SIDESHIFT CYLINDER
7251 HOOD
5811 LOAD CONTROL VALVE
7252 FENDER
5816 COMPENSATING CYLINDER
7253 PLATFORM/DECK
5823 FORK LEVEL CYLINDER
7257 BATTERY BOX/SUPPORT
7261 PLATFORM SOUND SUPPRESSION
6400 MATERIAL HANDLING ATTACHMENTS
7262 FIREWALL
6402 STANDARD CARRIAGE
7263 ENGINE ENCLOSURE
6404 LIFT CHAIN
7264 ROPS MOUNT REAR SUPPORT
6405 LIFT FORK
7265 FLOORPLATE
6408 ROTATING CARRIAGE
7266 ROPS MOUNT
6409 WIDE CARRIAGE
7267 BODY PANEL
6416 BALE CLAMP
726A ACCESS PANEL
6425 SIDESHIFT CARRIAGE
726M FLOORMAT
6459 LIFTING HOOK
7272 RADIATOR ENCLOSURE/SHROUD
6460 TELESCOPING BOOM
7273 COMPARTMENT DOOR
6461 MAN BASKET
7276 MACHINE ENCLOSURE
7050 FRAME
7300 OPERATOR STATION
7051 MAIN FRAME
7301 CAB
7056 COUNTERWEIGHT
7302 CANOPY
7059 FUEL TANK, SEAT & FRAME
7304 CAB HEATER
7078 FRAME LEVEL CYLINDER
7305 WINDSHIELD WIPER
7306 WINDSHIELD WASHER
7100 HITCH
7307 SEAT/ARM CUSHION
7105 FIXED DRAWBAR
7308 CAB DOOR
7116 HITCH/TOW PIN
7309 HEATER & AIR CONDITIONER
7310 WINDOW GLASS
7150 GUARD
7312 SEAT ASSEMBLY
7151 CRANKCASE GUARD
7314 DASH
7154 ENGINE GUARD
7316 CAB AIR FAN
7155 RADIATOR GUARD
7319 MIRROR
7159 OVERHEAD GUARD
x
731S SEAT AIR COMPRESSOR 7481 FUEL LEVEL GAUGE
7320 AIR CONDITIONER 7483 LOW FUEL LEVEL INDICATOR
7321 SEAT FRAME 7485 ENGINE LOW OIL PRESSURE INDICATOR
7322 AIR CONDITIONER RECEIVER/DRYER 7486 PARKING BRAKE INDICATOR LIGHT
7323 ROPS/FOPS CANOPY 7488 HYDRAULIC OIL TEMPERATURE GAUGE
7324 SUSPENSION SEAT 7490 ELECTRONIC MONITORING SYSTEM/PANEL
7325 ROPS/FOPS CAB 7493 GROUND SPEED SENSOR
7327 SEAT BELT 7496 ALTERNATOR INDICATOR
7329 CAB LINER/SOUND SUPPRESSION
7330 CANOPY SOUND SUPPRESSION 7500 MAINTENANCE
7332 ELECTRIC SWITCH (MANUAL) 7501 FIRST SERVICE INTERVAL
7338 RADIO 7502 SECOND SERVICCE INTERVAL
7340 WINDSHIELD 7503 THIRD SERVICE INTERVAL
7342 CAB AIR FILTER 7504 FOURTH SERVICE INTERVAL
7507 LIFT ARM SUPPORT
7400 PROTECTION DEVICES, ALARMS & INDICATORS 751B BATTERY CHARGER
7402 WARNING HORN 7524 250 SERVICE HOUR MAINTENANCE
7405 INSTRUCTION/WARNING PLATE/FILM 7525 500 SERVICE HOUR MAINTENANCE
7406 BACK-UP ALARM 7526 1000 SERVICE HOUR MAINTENANCE
7407 ACTION ALARM 7527 2000 SERVICE HOUR MAINTENANCE
7420 LOW COOLANT TEMPERATURE ALARM 7534 750 SERVICE HOUR MAINTENANCE
7421 LOW ENGINE OIL PRESSURE SHUTOFF 7542 SOS
7431 WARNING/INDICATOR LIGHT
7550 COMMON SUBJECTS
7450 GAUGES & INDICATORS 7551 BEARINGS
7451 INSTRUMENT PANEL/CONTROL PANEL 7552 GEARS
7452 AIR FILTER INDICATOR 7553 FASTENERS, CONNECTORS & HARDWARE
7453 ENGINE COOLANT TEMPERATURE GAUGE 7554 HOSES & LINES
7455 ENGINE OIL PRESSURE GAUGE 7555 SEALS & GASKETS
7459 TRANSMISSION GEAR/SHIFT INDICATOR 7556 WIRE
7462 TACHOMETER 7557 INFORMATION/IDENTIFICATION PLATES &
TRANSFERS
7463 SPEEDOMETER
7558 WEAR SLEEVES
7464 ODOMETER
7559 PAINTED SURFACES
7467 AMMETER
755R RETAINER SYSTEM
7470 COOLANT LEVEL GAUGE
7560 COMPARTMENT FLUID LEVEL
7475 OIL FILTER INDICATOR
7561 DUO-CONE SEAL
7477 TRANSMISSION/TORQUE CONVERTER
TEMPERATURE GAUGE 7562 HYDRAULIC CYLINDERS
7478 SERVICE METER 7569 TROUBLESHOOTING PROCEDURE
7479 SIGHT GAUGE 756P MAINTENANCE PARTS
7480 ELECTRIC HOUR METER 7570 PRODUCT UPDATE PROGRAM
xi
7571 SOS ENGINE PRODUCT INFORMATION 7771 SOS "URGENT" REPORTS
7573 SOS TRANSMISSION PRODUCT INFORMATION 7851 FUEL FILTER INDICATOR
7574 SOS DRIVE TRAIN PRODUCT INFORMATION 7856 STABILITY INDICATOR
7575 SOS HYDRAULIC PRODUCT INFORMATION 7858 ANGLE INDICATOR
7576 SOS OTHER PRODUCT INFORMATION 7859 ENGINE OIL TEMPERATURE GAUGE
7577 SOS FLUID INFORMATION 7942 PERSONALITY MODULE - UPDATE ELECTRONIC
COMPONENTS
7578 SOS FILTER INFORMATION
7950 MISCELLANEOUS
7579 FLUID
79M4 OTHER ADJUSTMENTS
7581 PAINTING & LUBRICATION
7588 PRE-DELIVERY INSPECTION
7589 PRE-DELIVERY WARRANTY
7590 DELIVERY
7591 FIRST REVISIT
7592 SECOND REVISIT
7593 USER ACCEPTANCE/FIELD FOLLOW
7594 CONTRACT FIELD FOLLOW RECORDS
7595 GENERAL OVERHAUL (NO FAILURE)
7600 MACHINE ELECTRONIC CONTROLS & DATA

MANAGEMENT SYSTEMS
7606 PRODUCT LINK SYSTEM
7610 PROGRAMMABLE CONTROL
7620 SOFTWARE
7630 INTERLOCK ELECTRONIC CONTROL MODULE
7631 MACHINE SECURITY SYSTEM
7700 SERVICE CLAIM CATEGORIES
7714 ROLL OVER PROTECTION STRUCTURE
DECERTIFIED
7715 ROLL OVER PROTECTION STRUCTURE
RECERTIFIED
7729 HEUI ACTUATION (OIL)
7730 REPAIR PROCEDURE (RP) PROGRAM
7750 DEFECTIVE PARTS STOCK
7751 PRODUCT IMPROVEMENT PROGRAM (PIP)
7752 PARTS STOCK CLAIM
7754 REMANUFACTURED COMPONENT
7755 PRODUCT SUPPORT PROGRAM (PSP)
7756 SERVICE ENGINEERING REQUESTED WORK
7760 INFORMATION RECORD ONLY
7762 DELIVERY DATE/SERVICE FEE
7770 SOS GENERAL INFORMATION
xii
SECTION 1
FRAME & ATTACHING PARTS
31200255 TL642
Figure 1-1 Frame Shrouding & Trim
48
63
46 11
9 63
8 44 12 19 49
10 11
3
2 18
4 5 51
6 43 40
4 58
66
1
7 56 65
52
53 47
54
57
66
MACHINES EQUIPPED WITH OUTRIGGERS
48
63
18 49
48
18 63 15
14
51
50
11
18 63 13
40 51 40
11 11 41 19
63 63 40
51 18 47
40 61 59
11 61
63 70
26
63
55 67
20 16
24 63 60
17
69
25 59 59 18
68 19
21
72
22
37
64
23 PAL0015
1-2 TL642 31200255

Figure 1-1 Frame Shrouding & Trim (Continued)
39
38
42 105
106
FRAME 107
MOUNT
WELDMENT 110
CAB 111
27 WALL
104
30
32 CAB
MOUNT
33 WELDMENT
31
28
29 29 34 108
FRAME 109
MOUNT
UPPER WELDMENT
CAB 35 36 103
MOUNT
101
LOWER
CAB 102
MOUNT SHOWN WITH
WORK LIGHT
PAL1441
31200255 TL642 1-3

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.
1 298-1535 1 ENGINE COVER, (includes items 2, 3, 4, 6, 7, 8, 9, 43, 44, 52, 53, 54, I
57, 58, 65 & 66)
2 303-8660 14 HEX HD CAPSCREW, 8X3/4
3 1 PROP BRACKETS
4 303-8567 2 PROP CLIPS
5 298-8777 1 MIRROR MOUNT BACK PLATE
6 303-8661 1 GAS PROP
7 303-4981 2 BALL STUD, (13mm)
8 303-8659 1 HINGE, 36”
9 6 SOCKET BUTTON HD CAPSCREW, 3/8-16X1-1/4
10 299-0330 1 MIRROR
11 297-7032 15 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5
12 298-8612 1 MIRROR BRACKET WELDMENT
13 298-6870 1 HORN
14 298-7379 1 LOCKWASHER, 5/16
15 300-6074 1 HEX HD CAPSCREW, 5/16-18X1/2, GR5
16 298-8205 1 LATCH BRACKET
17 298-8124 1 LATCH MOUNTING BRACKET
18 298-7374 12 FLAT WASHER, 3/8
19 298-8049 5 HEX NUT, 3/8-16
20 303-4751 4 WHIZ-LOCK SCREW, 3/8-16X1-1/2
21 298-7913 4 HEX HD CAPSCREW, 1/8X3-1/2
22 298-7875 4 WASHER
23 303-4989 1 COUNTERWEIGHT, (no pintle hook)
308-7035 1 COUNTERWEIGHT, (with pintle hook)
24 298-7293 1 BACK-UP ALARM
25 298-8048 2 HEX NUT, 5/16-18
27 298-1746 2 REBOUND WASHER
28 298-8053 2 HEX NUT, 7/8-9
29 298-8581 4 SHOCK MOUNT
30 298-1750 2 HARDENED WASHER
31 309-6238 2 HEX HD CAPSCREW, 7/8-9X5
32 303-4744 4 HEX HD CAPSCREW, 3/4-10X3-3/4
33 298-7976 4 HARDWASHER, 13/16
34 298-7030 4 CAB ISOLATOR MOUNT
35 298-1740 4 TAIL WASHER
36 298-8052 4 HEX LOCKNUT, 3/4-10
37 298-8119 1 OIL PAN COVER
38 299-0402 1 CAB FENDER
39 300-6075 4 WHIZ-LOCK BOLT, 3/8-16X1
40 298-7380 15 LOCKWASHER, 3/8
41 298-8126 1 PLATE VALVE COVER
42 Ref CAB ASSY, (see Figure 6-1 for details)
43 298-0551 1 WHIZ-LOK NUT, 5/16-18
44 298-0541 6 LOCK NUT, 3/8-16
45 300-6113 1 TANK BRACKET
46 298-1628 6 FLAT WASHER, 3/8
47 303-5007 1 FRAME WELDMENT, (no outriggers)
1-4 TL642 31200255

Figure 1-1 Frame Shrouding & Trim (Continued)

310-8443 1 FRAME WELDMENT, (with outriggers)
48 298-8034 10 SOCKET BUTTON HD CAPSCREW, 3/8-16X3/4
49 298-8267 1 FRONT COVER, (no outriggers)
303-4890 1 FRONT COVER, (with outriggers)
50 298-8140 1 COVER MAIN VALVE
51 298-1609 8 NUT
52 303-4836 1 LATCH, (includes items 53 & 54)
5P-8500 1 KEY
53 303-4779 4 LOCKNUT
54 298-7363 4 LOCKWASHER
55 298-7373 2 FLAT WASHER, 5/16
56 298-0551 1 HEX NUT, 5/16-18
57 304-3805 1 PERFERATED SCREEN
58 304-3177 1 EXHAUST SCREEN KIT
59 298-7976 16 HARDENED WASHER, 3/4
60 303-4966 1 ENGINE POD WELDMENT
61 297-7084 18 HEX HD CAPSCREW, 3/4-10X2
63 AR CAT THREADLOCK
65 303-8654 13’ BULB SEAL
66 304-2618 1 ADHESIVE KIT, (includes 3 tubes and applicator),
(enough to do exhaust screen kit)
67 298-1360 2 WHIZ-LOCK CAPSCREW, .375-16X1.25
68 297-7054 4 HEX HD CAPSCREW, 3/4-10X4.5, GR5
69 298-8052 4 HEX NUT, 3/4-10
70 299-0387 60” TRIM-LOK
71 8T-7008 3 HEX HD CAPSCREW, 3/8-16X3, GR5
72 AR CAT HIGH STRENGTH THREADLOCK
315-3423 1 LH MIRROR INSTALLATION, (includes items 101 thru 111), B
(Before S/N TBK00765)
323-1647 1 LH MIRROR INSTALLATION, (includes items 102, 103, 108 & 109), A
(S/N TBK00765 & After)
101 315-3422 1 MIRROR BRACKET
102 317-0088 1 MIRROR MOUNT ARM ASSY
103 317-0089 1 MIRROR HEAD
104 317-0090 A/R DOUBLE SIDED TAPE
105 315-3424 1 BOLT, 1/2-13
106 298-7375 1 FLAT WASHER, 1/2
107 298-7382 1 LOCKWASHER, 1/2
108 8T-4970 2 HEX HEAD CAP SCREW, M6X1X14mm GR8.8
109 303-4787 2 LOCKWASHER, M6
110 298-8050 1 HEX NUT, 1/2-13
111 298-1755 1 SPACER
NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE
31200255 TL642 1-5

Figure 1-2 Axle Mounting
4
3
3
4 2
3
3
2 PAL0020
1-6 TL642 31200255

Figure 1-2 Axle Mounting

1 Ref FRONT AXLE ASSY, (see Figure 5-1 for details)
2 298-1751 8 HEX HD CAPSCREW, 3/4-10X5, GR8, (loctite & torque to 340-365 lb-ft)
3 298-1631 16 HARDENED FLAT WASHER, 3/4
4 298-8052 8 HEX NUT, 3/4-10
5 Ref REAR AXLE ASSY, (see Figure 5-11 for details)
31200255 TL642 1-7

Figure 1-3 Outrigger Mounting, (if equipped)
12
13
15
16
5
15
16 7
5
14
11 4
8 12 15
16
15 10
16
PAL3390
1-8 TL642 31200255

Figure 1-3 Outrigger Mounting, (if equipped)

345-2161 1 OUTRIGGER ASSEMBLY, (includes all items) C
2 299-0277 2 ARM WELDMENT
3 299-0278 2 OUTRIGGER SHOE
4 Ref OUTRIGGER CYLINDER & VALVE, (see Figure 9-13 for details)
5 298-6891 4 BUSHING
6 298-8429 2 OUTRIGGER CYLINDER PIN
7 298-8430 2 ARM PIN
8 298-8431 2 SHOE PIN
9 298-6849 2 KEEPER
11 297-7039 4 HEX HD CAPSCREW, 1/2-13X1, GR5
12 298-0541 4 HEX LOCKNUT, 3/8-16
13 298-0574 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8
14 298-7382 4 LOCKWASHER, 1/2
15 298-1612 4 LUBE FITTING, STRAIGHT, 1/8
17 Ref HOSE ASSEMBLY, (not shown), (see Figure 8-12 for details)
31200255 TL642 1-9

This Page Intentionally Left Blank
1-10 TL642 31200255

SECTION 2
BOOM
31200255 TL642
BOOM
Figure 2-1 First Boom Section
27
5 26
4 7
3
1
2
8
28
22 9
1 21
10 24
20
11
12 1 25
19
18
Coat Anchor Bolt Threads on items 2 & 12 with Mystik XD2,

(14404818). Tighten to collapse washers.
16 13
15 Coat bores for item 8 with Never Seeze Lube, (14403323S).
17
14 PAL1191
2-2 TL642 31200255

BOOM
Figure 2-1 First Boom Section

1 300-6115 1 FIRST BOOM SECTION
2 Ref CHAIN CLEVIS ROD, (see Figure 2-7, item 4 for details)
3 298-8578 1 STRONG BACK
4 298-1786 8 SPRING WASHER, 7/8
5 298-1754 2 HEAVY HEX NUT, 7/8-14, (torque to 100-110 lb-ft)
7 331-3810 1 REAR COVER
8 Ref EXTEND/RETRACT CYLINDER PIN, (see Figure 9-2 for details)
9 298-7368 8 FLAT WASHER, 5/8
10 298-8009 8 HEX HD CAPSCREW, 5/8-11X1-1/2, GR5, (torque to 140-155 lb-ft)
11 298-7027 1 BOOM PIVOT PIN
12 Ref CHAIN ANCHOR, (see Figure 2-3, item 12 for details)
13 298-6922 1 ANCHOR PLATE
15 298-7367 4 FLAT WASHER, 1/2
16 298-8063 1 HEX JAM NUT, 5/8-18, (torque to 100-110 lb-ft)
17 Ref SECOND BOOM SECTION, (see Figure 2-3 for details)
18 298-8059 1 HEX NUT, 5/8-18
19 298-1781 8 SPRING WASHER, 5/8
20 298-7031 2 BOOM PIVOT BUSHING
22 Ref PUSH BEAM ASSY, (see Figure 2-7 for details)
24 298-7925 1 HEX HD CAPSCREW, 5/8-11X6
25 298-8070 1 HEX NUT, 5/8-11
26 298-7380 2 SPRING LOCKWASHER, 3/8
27 298-7374 2 FLAT WASHER, 3/8
28 331-1596 2 HEX HD FLANGE SCREW, 3/8-16X1-1/4, GR5
31200255 TL642 2-3

BOOM
Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)
16
5
13
14
11 15
5
12
10
5
9
8
19
1
7 17
18 2
2
2 3
SERVICE NOTES:
21 4
1. Add bearing pad shims & spacers as required to shim boom to
within 1/16” of a tight fit. Whenever a shim is used with a pad, a
spacer must be inserted between pad & shim. No pads shall sit
PAL1170 20 directly on slotted surface of shims.
2. The length of pad bolts depend on the amount of shims used.

Bolt cannot exceed past chamfer on bearing pad.
3. Add grease, (Cat Advanced 3Moly - NLGL Grade 2), to all bearing
pad slide areas.
4. Use Cat Threadlock on all bolt threads.
2-4 TL642 31200255

BOOM
Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)
1 Ref FIRST BOOM SECTION, (see Figure 2-1 for details)
4 4 HEX HD CAPSCREW OPTIONS, GR5, (torque to 76-86 lb-ft)
297-7069 AR 1/2-20X1-1/4
297-7070 AR 1/2-20X1-1/2
6 298-8208 2 BEARING PAD
7 298-7014 1 MOUNT PLATE
8 298-1729 2 SPACER
9 2 SHIM OPTIONS
298-1726 AR 2X8X.0598
298-1727 AR 2X8X.0359
297-7056 AR 3/8-24X3/4
297-7057 AR 3/8-24X7/8
298-8015 AR 3/8-24X1
298-8015 AR 3/8-24X1
297-7058 AR 3/8-24X1-1/4
13 4 SHIM OPTIONS
298-1787 AR 2X4X.0598
298-1788 AR 2X4X.0359
14 298-1728 4 SPACER
17 298-1732 2 SPACER
18 AR SHIM OPTIONS
298-1736 AR 2X8X.0598
298-1737 AR 2X8X.0359
20 298-1613 2 LUBE FITTING, STRAIGHT, 1/4-28
21 2 LUBE BOLT OPTIONS, (torque to 45-50 lb-ft)
298-1626 AR 1/2-20X1-1/4
298-1689 AR 1/2-20X1-1/2
31200255 TL642 2-5

BOOM
Figure 2-3 Second Boom Section
3
2 24
4
5
21
20
22 19
20
23
19
18 6
17 7
9
10
16 11 8
15
1
14 9
25
26
13
12 10 11
PAL1150
NOTE:
FOR PART NUMBER AND MOUNTING
HARDWARE OF ITEM 13 REFER TO
FIGURE 2-1, ITEMS 13, 14, & 15.
2-6 TL642 31200255

BOOM
Figure 2-3 Second Boom Section

1 300-6116 1 SECOND BOOM SECTION
2 298-6862 2 PUSH BEAM PIN
4 298-7382 2 LOCKWASHER, 1/2
5 299-6658 1 HOSE RETAINER, (includes the following items)
298-7011 1 L.H. HOSE RETAINER
298-7067 1 PAD
298-8030 4 SOCKET FLAT HD CAPSCREW, #10-24X5/8
298-8067 4 HEX NUT, #10-24
6 298-7023 1 RETRACTION SHEAVE PIN
7 298-1612 1 LUBE FITTING - STRAIGHT, 1/8
8 298-6830 1 RETAINING RING
9 299-0853 1 LEAF CHAIN 643
10 298-7108 2 ANCHOR PIN
12 303-4929 1 CHAIN ANCHOR
13 Ref ANCHOR PLATE, (see Figure 2-1, item 13 for details)
14 Ref THIRD BOOM SECTION, (see Figure 2-5 for details)
15 Ref LEAF CHAIN 866, (see Figure 2-7, item 101 for details)
16 Ref CLEVIS 866-634, (see Figure 2-7, item 102 for details)
17 298-7380 1 LOCKWASHER, 3/8
19 298-1741 AR THRUST WASHER
298-1742 AR THRUST WASHER
20 298-8576 2 SEAL
21 298-7069 1 RETRACT ROLLER ASSY, (includes items 20 & 22)
22 303-5001 1 BUSHING
23 298-7246 1 HOSE SHEAVE
24 298-7375 2 FLAT WASHER, 1/2
25 300-6071 1 CHAIN INSTALLATION, (includes items 9 thru 12 & item 26) C
26 AR CAT THREAD LUBRICANT
31200255 TL642 2-7

BOOM
Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)
11
8 9 10 13
12
14
17
3 15
7 2
22
25 23
5 18
22
3 16
6 26
3
27
4 8 9
22
2
24 1
3
21
20 10
SERVICE NOTES: 19
PAL1180
1. Add bearing pad shims & spacers as required to shim boom to within 1/16” of
a tight fit. Whenever a shim is used with a pad, a spacer must be inserted
between the pad & shim. No pads shall sit directly on slotted surface of shims.
2. The length of pad bolts depend on the amount of shims used. Bolt cannot
extend past chamfer on bearing pad.
3. Add grease, (Cat Advanced 3Moly - NLGL Grade 2), to all bearing pad slide
areas.
2-8 TL642 31200255

BOOM
1 Ref SECOND BOOM SECTION, (see Figure 2-3 for details)
297-7056 AR 3/8-24X3/4
297-7057 AR 3/8-24X7/8
298-8015 AR 3/8-24X1
5 298-1732 2 SPACER
6 2 SHIM OPTIONS
298-1726 AR 2X8X.0598
298-1727 AR 2X8X.0359
8 6 SHIM OPTIONS
298-1787 AR 2X4X.0598
298-1788 AR 2X4X.0359
9 298-1728 6 SPACER
11 297-7038 4 HEX HD CAPSCREW, 1/2-13X7/8, GR5, (torque to 76-86 lb-ft)
12 298-7367 4 FLAT WASHER, 1/2
14 299-0493 2 SPACER
298-1733 AR SPACER
15 298-1735 AR SHIM, 2X8X.0359
297-7060 AR 3/8-24X1-3/4
297-7061 AR 3/8-24X2
298-8012 AR 3/8-24X1/2
297-7055 AR 3/8-24X5/8
297-7056 AR 3/8-24X3/4
18 298-1615 2 LUBE FITTING, 90 DEGREES, 1/4-28
20 298-1730 2 SPACER
21 2 SHIM OPTIONS
298-1789 AR 2X4X.0598
298-1790 AR 2X4X.0359
298-1626 AR 1/2-20X1-1/4
298-1689 AR 1/2-20X1-1/2
24 4 HEX HD CAPSCREW OPTIONS, (torque to 76-86 lb-ft)
299-7118 AR 1/2-20X5/8
297-7066 AR 1/2-20X3/4
297-7067 AR 1/2-20X7/8
297-7066 AR 1/2-20X3/4
297-7067 AR 1/2-20X7/8
297-7068 AR 1/2-20X1
31200255 TL642 2-9

BOOM
297-7069 AR 1/2-20X1-1/4
297-7070 AR 1/2-20X1-1/2
27 298-1729 2 SPACER
2-10 TL642 31200255

BOOM
31200255 TL642 2-11

BOOM
Figure 2-5 Third Boom Section
11
10
9
3
4
3
7 11
2 3 5
14 8
13
12
1
11
SERVICE NOTES:
areas.
PAL1120
2-12 TL642 31200255

BOOM
Figure 2-5 Third Boom Section

1 298-8718 1 THIRD BOOM SECTION
2 297-7030 2 HEX HD CAPSCREW, 3/8-16X7/8, GR5, (torque to 28-30 lb-ft)
3 298-7365 6 FLAT WASHER, 3/8
4 298-7016 1 GUIDE BAR
5 298-8579 1 PUSH BEAM BEARING PAD
6 299-0401 1 CHAIN RETAINER
7 303-4743 2 HEX HD CAPSCREW, 3/8-16X1-1/4, (torque to 25-30 lb-ft)
8 Ref CLEVIS 866-634, (see Figure 2-7, item 102 for details)
10 Ref PUSH BEAM ASSY, (see Figure 2-7 for details)
11 Ref LEAF CHAIN 866, (see Figure 2-7, item 101 for details)
12 298-7063 1 ANCHOR PIN
14 298-7380 1 LOCKWASHER, 3/8
31200255 TL642 2-13

BOOM
Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section)
12
16
1
15
13
11
14
2 8
9
10 PAL1130
SERVICE NOTES:
areas.
2-14 TL642 31200255

BOOM
Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section)
3 298-1733 2 SPACER
4 2 SHIM OPTIONS
298-1734 AR 2X8X.0598
298-1735 AR 2X8X.0359
5 298-1628 8 FLAT WASHER, 3/8
297-7069 1/2-20X1-1/4, GR5
297-7070 1/2-20X1-1/2, GR5
297-7055 3/8-24X5/8, GR5
297-7056 3/8-24X3/4, GR5
297-7057 3/8-24X7/8, GR5
8 298-1789 2 SHIM, 2X4X.0598
9 298-1730 2 SPACER
11 4 SOCKET BUTTON HD CAPSCREW OPTIONS, (torque to 28-30 lb-ft)
298-8037 3/8-24X1
298-8038 3/8-24X1-1/4
14 298-1731 2 SPACER
15 298-1615 2 LUBE FITTING, 45 DEGREES, 1/4-28
298-1626 1/2-20X1-1/4
298-1689 1/2-20X1-1/2
31200255 TL642 2-15

BOOM
Figure 2-7 Push Beam/Extend Chain & Roller Assembly
NOTE: THE CHAIN CLEVIS ROD (item 4),

ATTACHES TO THE STRONG BACK
(item 3), IN FIGURE 2-1
7
4
8
NOTE: SEE FIGURE 2-5 FOR PUSH 16
BEAM, CHAIN RETAINER &
BEARING PADS. 10 20
3
101 22 312
8 103
21 105
102
104
3
15 101
1 19
NOTE: THE CLEVIS ROD (item 102), SEATS IN
9 1
THE REAR OF THE THIRD BOOM
SECTION, ILLUSTRATED IN FIGURE 2-5.
5
14
6
13 12
203
18
202 2
203 8
11
7
17 PAL1111
2-16 TL642 31200255

BOOM
Figure 2-7 Push Beam/Extend Chain & Roller Assembly

300-6073 1 PUSH BEAM ASSY, (includes items 1 thru 22) B
1 AR CAT THREADLOCK
2 AR LOCTITE, #545
3 304-3165 1 LEAF CHAIN ASSY, (includes items 101 thru 105) C
4 305-3763 1 CHAIN CLEVIS ROD
6 298-7382 2 LOCKWASHER, 1/2
8 AR CAT ADVANCED #MOLY - NLGI GRADE 2
9 298-8062 1 HEX NUT, 1-3/8-12, (torque to 155-195 lb-ft)
10 298-7312 2 SNAP RING, 3/8
12 298-1650 1 SHIM
13 298-1651 1 SHIM
14 298-6920 1 KEEPER
15 298-6921 1 TAB WASHER
16 Ref EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details)
17 298-7022 1 EXTEND SHEAVE PIN
18 298-7028 1 CHAIN ROLLER ASSY, (includes items 202 & 203)
19 298-1739 1 HARD WASHER
20 298-8257 13’ UHMW TAPE, (order by the ft.)
21 298-8767 1 PUSH BEAM WELDMENT
22 298-7106 1 ANCHOR PIN
101 298-8583 1 LEAF CHAIN, 866
102 303-4935 1 CLEVIS, 866-634
103 298-7107 1 ANCHOR PIN
104 298-7312 2 SNAP RING, 3/8
202 303-5000 1 BUSHING
203 298-7032 2 SEAL
312 Ref ANCHOR PIN, (see Figure 2-5 for details)
31200255 TL642 2-17

BOOM
Figure 2-8 Quick Coupler Assembly
7 6
9
101
8
5
102
3 1
8
7
9
PAL1250
SERVICE NOTES:
Use Cat Threadlock on all bolt threads
2-18 TL642 31200255

BOOM
Figure 2-8 Quick Coupler Assembly

299-1284 1 QUICK COUPLER INSTALLATION, (includes items 1 thru 9) B
1 298-8736 1 QUICK COUPLER ASSY
2 298-8734 1 HEAD PIN ASSY
3 298-8724 1 PIN ASSY
4 299-0305 1 PIN
5 298-7057 1 PIN WELDMENT
6 298-1612 2 GREASE FITTING, STRAIGHT
7 297-7039 2 HEX HD CAPSCREW, 1/2-13X1
8 298-7375 2 FLAT WASHER, 1/2
9 AR CAT THREADLOCK
102 Ref TILT CYLINDER, (see Figure 9-3 for details)
31200255 TL642 2-19

BOOM
Figure 2-9 Hydraulic Quick Coupler Assembly
14
102
105
19
2
13
8
12
15
15
8 17
9 10 11 18
1 12 20
4 15 21
103 101
104
106
108
109
106
107
110
16 6
5 202 201 7
PAL1200
2-20 TL642 31200255

BOOM
Figure 2-9 Hydraulic Quick Coupler Assembly

299-1285 1 HYDRAULIC QUICK COUPLER ASSEMBLY, (includes items 1 thru 21) E
1 298-8736 1 QUICK COUPLER ASSEMBLY
2 298-8734 1 HEAD PIN ASSEMBLY
4 298-7228 1 CYLINDER COVER
5 298-7356 2 CONNECTOR
6 298-0408 2 DOWEL PIN
7 298-0407 2 QUICK ATTACH PIN
9 298-1358 2 SERRATED WASHER HD SCREW, (whiz-lock), 3/8-16X3/4
10 298-7057 1 WELDMENT PIN
11 299-6623 AR FLEX TRIM SHIELD
12 298-7375 2 FLAT WASHER, 1/2
13 298-1612 2 GREASE FITTING, (straight), 1/8
14 299-1349 1 QUICK COUPLER VALVE ASSEMBLY, (includes items 101 thru 110) D
16 299-1351 1 QUICK COUPLER CYLINDER ASSEMBLY, (includes items 201 thru 202) B
17 298-7437 1 CLAMP SET
18 299-6644 1 COVER PLATE
19 298-0413 2 HOSE ASSEMBLY
21 299-6624 AR FLEX TRIM SHIELD
101 299-1349 1 QUICK COUPLER VALVE
102 298-7355 2 CONNECTOR
103 298-0466 2 CONNECTOR
104 298-0414 2 SWIVEL ADAPTER
105 298-0416 2 STRAIGHT THREAD REDUCER/EXPANDER
106 300-6095 2 ELBOW, 90 DEGREES
107 300-6078 1 QUICK DISCONNECT COUPLING, FEMALE
108 300-6079 1 QUICK DISCONNECT COUPLING, MALE
109 300-6103 1 DUST CAP
110 300-6084 1 DUST PLUG
201 Ref QUICK COUPLER CYLINDER, (see Figure 9-12 for details)
202 299-0308 1 CHECK PILOT VALVE
299-0285 1 SEAL KIT
31200255 TL642 2-21

BOOM
2-22 TL642 31200255

SECTION 3
ATTACHMENTS
31200255 TL642
ATTACHMENTS
Figure 3-1 50” & 72” Carriage Assembly
1 3
4
5
1 3
4 5
2
PAL0730
3-2 TL642 31200255

ATTACHMENTS
Figure 3-1 50” & 72” Carriage Assembly

301-9757 1 50” CARRIAGE ASSY, (includes items 1 thru 6) A
301-9758 1 72” CARRIAGE ASSY, (includes items 1 thru 6) A
2 303-4782 2 LOCKNUT, 5/8
3 303-4957 1 FORK PIN, (50” carriage)
303-4958 1 FORK PIN, (72” carriage)
4 303-4988 2 COLLAR
5 305-3783 1 50” CARRIAGE WELDMENT
305-3784 1 72” CARRIAGE WELDMENT
6 305-3785 1 50” CARRIAGE SERIAL NO. PLATE
305-3786 1 72” CARRIAGE SERIAL NO. PLATE
101 Ref FORK, (see Figure 3-2 for details)
31200255 TL642 3-3

ATTACHMENTS
Figure 3-2 Forks
PAL1210
3-4 TL642 31200255

ATTACHMENTS
Figure 3-2 Forks

301-9752 2 48” CUBING FORK, 2X2, 3,880 lbs. A
301-9755 2 48” PALLET FORK, 2.36X4, 10,950 lbs. A
301-9753 2 48” PALLET FORK, 2.36X5, 13,700 lbs. A
301-9754 2 60” LUMBER FORK, 2.36X6, 16,300 lbs. A
301-9756 2 60” LUMBER FORK, 1-3/4X7, 10,800 lbs. A
311-2854 2 DUAL TAPER FORKS, 2X6X72, 11,300 lbs. A
NOTE:
FORKS RATED LESS THAN THE ATTACHMENT OR MACHINE’S CAPACITY
DECREASE CAPACITY OF THE ATTACHMENT OR MACHINE TO THAT OF
THE FORKS. FORKS RATED MORE THAN THE ATTACHMENT OR
MACHINE’S CAPACITY DO NOT INCREASE ATTACHMENT OR MACHINE’S
CAPACITY.
NOTE:
PLEASE CONSULT THE JLG PARTS DEPARTMENT TO DETERMINE THE
CORRECT FORKS APPLICABLE TO YOUR SPECIFIC CARRIAGE
ASSEMBLY AND APPLICATION.
31200255 TL642 3-5

ATTACHMENTS
Figure 3-3 Winch Installation
1 9
8 11
9 12
11 9
11
13
20
B B
A
3
17 10
19 14
21 15
5 19
27
28 24
18 29
6 19 19
2
4
A VIEW A-A
7
AUXILIARY LINE
AUXILIARY LINE
"DOWN/LEFT"
"UP/RIGHT"
10 25 26 24
21
22
20 PAL0740
VIEW B-B
3-6 TL642 31200255

ATTACHMENTS
Figure 3-3 Winch Installation

305-3768 1 WINCH INSTALLATION, (includes all items) A, 3
1 303-4999 1 WINCH MOUNTING PLATE
2 303-4898 1 WINCH HOOK STOWAGE
3 Ref WINCH W/MOTOR, (see Figures 12-2 & 12-3 for details)
4 299-0362 1 HOOK & BALL
5 298-7055 1 CABLE
6 298-6832 1 WIRE ROPE CLIP, 7/16
7 298-1660 1 CAUTION DECAL
9 298-1630 6 HARDENED WASHER
10 Ref PRESSURE REDUCER VALVE, 1360 PSI, (see Figure 12-4 for details)
11 298-8051 6 HEX NUT, 5/8-11
15 298-7379 2 FLAT WASHER, 5/16
17 300-6078 1 FEMALE QUICK DISCONNECT
18 300-6079 1 MALE QUICK DISCONNECT
19 304-2581 2 HOSE ASSY
20 304-2582 1 HOSE ASSY
21 304-2583 1 HOSE ASSY
22 298-0475 2 ELBOW, 90 DEGREES, (includes o-ring)
26 298-0497 1 SWIVEL NUT RUN TEE, 1/2 TUBE
28 298-7365 4 FLAT WASHER, 3/8
29 298-8049 4 HEX NUT, 3/8-16
31200255 TL642 3-7

ATTACHMENTS
Figure 3-4 50” & 72” Side Tilt Carriage Assembly
22
15
18
24
5
11
14
2
3
7
8
23
21
19
20 12
13
3
9
10
FRONT VIEW
22 16 OF CARRIAGE
17
15 4
18
24
2
11
5
14
3
7
8
23
21
19
20 PAL3220
3-8 TL642 31200255

ATTACHMENTS
Figure 3-4 50” & 72” Side Tilt Carriage Assembly

309-4315 1 50” SIDE TILT CARRIAGE ASSEMBLY, (includes items 1 thru 24) D
309-4316 1 72” SIDE TILT CARRIAGE ASSEMBLY, (includes items 1 thru 24) D
4 309-4320 1 50” CARRIAGE
309-4321 1 72” CARRIAGE
5 303-4782 2 NYLON COLLAR LOCKNUT, 5/8-11
6 303-4957 1 FORK PIN, (50” carriage)
303-4958 1 FORK PIN, (72” carriage)
7 309-4322 2 CYLINDER PIN
8 309-4323 2 KEEPER, 1/2
9 298-7392 1 FLAT WASHER, 1/2
11 303-4988 2 FORK COLLAR
12 309-4311 2 WEAR PAD ASSEMBLY
13 309-4312 2 SHIM
14 309-4313 1 CARRIAGE PIVOT BASE
15 309-4317 1 HYDRAULIC CYLINDER
16 309-4318 1 BEARING
17 309-4319 1 PIN
18 298-7358 2 CONNECTOR, (includes o-ring)
20 300-6078 1 QUICK DISCONNECT, (female)
21 300-6079 1 QUICK DISCONNECT, (male)
22 1 S/N PLATE
23 330-8325 2 CONNECTOR
31200255 TL642 3-9

ATTACHMENTS
Figure 3-5 Fork Clamp Installation
PAL3210
3-10 TL642 31200255

ATTACHMENTS
Figure 3-5 Fork Clamp Installation

310-6250 1 FORK CLAMP INSTALLATION, (includes all items) A
1 310-6251 4 FORK CLAMP
2 4 HEX HD CAPSCREW, 5/8-18X1-1/2
31200255 TL642 3-11

ATTACHMENTS
Figure 3-6 Fork Mounted Platform
101
102
107
1 109
110
111
11
4 114
17
2 10
112
113
3
105
103
108
104
106
101
201
214
1 209
110
111
11 4
17
203 2 218
210
212
3
10
102
211 103
108
104
106
PAL3231
3-12 TL642 31200255

ATTACHMENTS
Figure 3-6 Fork Mounted Platform

Ref FORK MOUNTED PLATFORM, (Before S/N TBK01108), (no longer available, D
see items 1 thru 17 for service; order 343-9736, 343-9737 or 343-9738 for
replacement)
343-9736 1 FORK MOUNTED PLATFORM,(includes items 1, 4 thru 17) A
343-9737 1 FORK MOUNTED PLATFORM, (ISO), (includes items 1, 4 thru 17) A
343-9738 1 FORK MOUNTED PLATFORM, (FRENCH), (includes items 1, 4 thru 17) A
1 1 FORK MOUNTED PLATFORM, (Before S/N TBK01108), B
(no longer available, order items 101 thru 114 for service, order 343-9736 for
replacement)
340-8976 1 FORK MOUNTED PLATFORM, (S/N TBK01108 & After), E
(includes items 2, 3, 101 thru 104, 106,108, 110,111 & 201 thru 218)
2 338-9997 1 MANUAL DECAL
3 335-8059 8 LANYARD ATTACH DECAL
328-7293 1 MANUAL DECAL, (ISO)
328-7292 1 MANUAL DECAL, (FRENCH)
17 1 S/N PLATE
101 304-2566 1 MANUAL STORAGE BOX
102 4 RIVNUT, 1/4-20
103 335-8066 2 HINGE
104 336-2804 1 LATCH
105 335-8078 21 PLUG
106 335-8080 20 RIVET
107 298-7372 4 WASHER, 1/4
108 335-8098 1 GATE
109 4 WHIZ LOCK SCREW, 1/4-20X0.5
110 339-0003 1 WORK PLATFORM GATE, (Before S/N TBK01108)
340-8975 1 WORK PLATFORM GATE, (S/N TBK01108 & After)
111 339-0004 1 PLATFORM BASE, (Before S/N TBK01108)
340-8974 1 PLATFORM BASE, (S/N TBK01108 & After)
112 327-6271 2 SUPPORT PIN
113 2 SAFETY SNAP PIN W/LANYARD
114 2 LYNCH PIN W/LANYARD, 3/16
203 340-8977 2 LANYARD CABLE, 6 in
209 298-0548 4 HEX NUT, 1/4-20, GR2
210 340-8978 2 PIN
211 335-8077 10 PLUG
212 4 RING
214 298-7363 8 WASHER, 1/4
218 340-8979 2 HITCH PIN
NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE.
31200255 TL642 3-13

ATTACHMENTS
Figure 3-7 Fork Mounted Hook
7
4
PAL3450
3-14 TL642 31200255

ATTACHMENTS
Figure 3-7 Fork Mounted Hook

321-0556 1 FORK MOUNTED HOOK, (includes all items) A
1 327-6270 1 FORK MOUNTED HOOK WELDMENT
2 327-6335 1 HOOK
3 327-6317 2 COTTER PIN
4 327-6271 2 PIN WELDMENT
5 327-6272 1 SPRING BUSHING
6 327-6318 1 CHAIN SHACKLE
7 1 SERIAL NUMBER PLATE
31200255 TL642 3-15

ATTACHMENTS
Figure 3-8 100 Degree Swing Carriage
3-16 TL642 31200255

ATTACHMENTS
Figure 3-8 100 Degree Swing Carriage

318-9222 1 100 DEGREE SWING CARRIAGE, (includes all items) A
1 1 SWING CARRIAGE
2 1 SWING WELDMENT
3 1 FORK PIN
4 327-6320 2 FORK PIN RETAINER
5 327-6329 4 LOCKWASHER, 1/2
6 327-6321 4 HEX HD CAPSCREW, 1/2X1-1/4
7 1 SWING POST
8 327-6327 2 LUBE FITTING, 1/8
9 2 BEARING
10 2 THRUST WASHER
11 327-6326 1 CASTLE NUT
12 327-6323 1 COTTER PIN
13 5 HEX HD CAPSCREW, 3/4-3
14 5 HEX LOCKNUT, 3/4-16
15 2 CYLINDER
16 2 SPACER
17 4 LOCKING PIN
18 4 FLAT WASHER, 3/8
19 327-6330 4 LOCKWASHER, 3/8
20 4 HEX HD CAPSCREW, 3/8X1
21 327-6324 2 ELBOW, 90 DEGREES
22 327-6333 2 ELBOW, 90 DEGREES
23 327-6273 2 HOSE ASSY
24 2 HOSE ASSY
25 327-6274 2 RUN TEE
26 2 HOSE ASSY
27 2 CONNECTOR
28 1 FEMALE QUICK COUPLER
29 1 MALE QUICK COUPLER
30 327-6325 1 WARNING DECAL, HIGH PRESSURE
31 1 MADE IN USA DECAL
32 327-6328 2 PINCH POINT DECAL
33 1 S/N PLATE
34 2 STOP BLOCK
35 4 HEX HD CAPSCREW, 3/4X2-1/4, GR8
4 LOCKWASHER, 3/4
31200255 TL642 3-17

ATTACHMENTS
3-18 TL642 31200255

SECTION 4
ENGINE & ATTACHING PARTS
31200255 TL642
Figure 4-1 Engine Assembly, L.H. View
A A
209
244 210
275 243 112
6 280
1
105
260 205
232 306
280
315
305
251 250 301

322
325
226 327
209 102
251 408
278 104
279 402 107
109 305
405
414
412
413
403
201
227
264 277
3 216
280 4
101
110 237
111 258
103
106
109 115
108
116
117
219 STARTER
202 208 224 239
226 235
280 211 226 207
214 217 231 233
215 278 276
279 501 280
252 502
280
503
GLOW PLUG
VIEW A-A 246
212
203
218
234
SERVICE NOTES: 254
1) Use Cat Threadlock on all bolt threads. 280
213
253 PAL1012
4-2 TL642 31200255

Figure 4-1 Engine Assembly, L.H. View

1 331-2460 1 ZF TRANSMISSION ASSEMBLY, (includes items 101 thru 117) B
3 Ref ENGINE, (see Figure 4-3 for details) B
4 300-6082 1 ENGINE ASSEMBLY, (includes items 201 thru 280 on Figure 4-1 and all items C
on Figure 4-2)
6 Ref RADIATOR ASSEMBLY, (see Figure 4-5 for details) C
102 8T-4136 4 HEX HD CAPSCREW, 10-1.50X25mm, GR8.8, (torque to 26-29 lb-ft)
103 303-8559 6 HEX HD CAPSCREW, 16-2.00X45mm, GR8.8, (torque to 125-140 lb-ft)
104 297-7098 12 HEX HD CAPSCREW, 10-1.50X35mm, GR10.9, (torque to 53-58 lb-ft)
105 Ref ZF TRANSMISSION, (see Figure 4-8 for details)
106 298-7368 6 FLAT WASHER, 5/8
107 8T-4121 12 FLAT WASHER, 10mm
108 299-0271 1 TRANSMISSION BRACKET
110 298-8410 1 FITTING
111 298-8412 1 TRANSMISSION TEMPERATURE SENSOR
112 Ref TRANSMISSION HARNESS, (see Figure 10-4 for details)
115 331-2385 1 OIL DRAIN VALVE
116 341-2966 1 HOSE
117 303-8599 1 CLAMP
205 8T-4136 2 HEX HD CAPSCREW, 10-1.50X25mm, GR8.8
208 304-2567 1 ELECTRIC RELAY BRACKET
209 299-0309 4 BAND CLAMP
210 298-1633 1 LAMP CLAMP
211 303-4769 1 HOSE FITTING
212 298-0516 1 FITTING
213 298-0517 1 FITTING TEE
214 303-4951 1 FUSE HOLDER
215 303-4952 1 FUSE, 50 AMP
216 298-0532 AR FUEL LINE
217 303-4953 1 HOSE
218 303-4774 1 HEX LOCKNUT, 3/8-16, GR2
219 303-4776 2 HEX LOCKNUT, 3MM-1/2
224 303-4785 2 POSI-DRIVE MACHINE SCREW, 3MM-.5X16
226 298-7364 4 FLAT WASHER, 5/16
227 298-7378 2 LOCKWASHER, 1/4
231 298-7387 2 SPRING LOCKWASHER, 8mm
234 303-4789 2 WASHER, 3/8
235 303-4790 5 RIPPBOLT, 6-36X10mm
237 303-4753 1 LOCKWASHER, .500
239 299-0326 2 RELAY
243 299-0378 1 FUEL STRAINER
244 298-1666 1 SUPPORT CLAMP
31200255 TL642 4-3

Figure 4-1 Engine Assembly, L.H. View (Continued)

246 299-0390 1 OIL PRESSURE SENSOR
250 298-8732 1 R.H. ENGINE MOUNT
251 298-8733 1 L.H. ENGINE MOUNT
252 Ref RELAY, (Fuel Pump), (see Figure 10-3 for details)
253 298-0402 1 OIL PRESSURE SENDER
254 303-4821 1 MOUNT PLATE BRACKET
258 303-4826 1 CAB GROUND CABLE
260 298-0419 1 TURBO INTAKE BRACKET
264 298-0425 1 THROTTLE INTAKE BRACKET
301 AR DIELECTRIC GREASE
305 298-0467 5 CONNECTOR
306 Ref IMPLEMENT PUMP, (see Figure 9-7 for details)
315 303-4758 1 ELBOW, 90 DEGREES
325 298-7392 3 WASHER, 1/2
327 298-7890 1 O-RING, (located between pump and transmission)
403 298-0559 4 HEX LOCKNUT, 1/2-13
405 298-7375 4 FLAT WASHER, 1/2
408 Ref BATTERY, (see Figure 10-1 for details)
412 298-8379 4 ENGINE MOUNT SHIM
413 298-8380 4 ENGINE MOUNT WASHER
414 298-8435 4 ENGINE MOUNT RUBBER
310-8508 1 OIL DRAIN INSTALLATION, (includes items 501 thru 503) B

501 303-8599 1 CLAMP
503 341-1835 1 HOSE
4-4 TL642 31200255

Figure 4-1 Engine Assembly, L.H. View (Continued)

31200255 TL642 4-5

Figure 4-2 Engine Assembly, R.H. View
70 20
21
29
76 30
71
57
55
56 4
31
7 85
33
67
32
85
6 84 86
5
28
66
45
62
5
32
85
86
63
HEAT SHIELD
SHOWN TRANSPARENT
FOR CLARITY
PAL1022
SERVICE NOTES:
1) Use Cat Threadlock on all bolt threads.
4-6 TL642 31200255

Figure 4-2 Engine Assembly, R.H. View

300-6082 1 ENGINE ASSEMBLY, (includes items 201 thru 280 on Figure 4-1 & all items on F
Figure 4-2)
4 8T-4908 1 HEX HD CAPSCREW, 8X25, GR8.8
20 303-4777 1 HEX NUT, M5X0.8
21 5C-2890 1 HEX NUT, M6X1
28 8T-4121 3 FLAT WASHER, 10mm
45 303-4827 1 ENGINE TEMPERATURE SENSOR
55 Ref NEGATIVE BATTERY CABLE, (see Figure 10-1 for details)
57 Ref POSITIVE BATTERY CABLE, (see Figure 10-1 for details)
61 Ref EXHAUST INSTALLATION, (see Figure 4-7 for details)
62 302-0581 1 OUTLET ADAPTER
63 299-0303 1 ELBOW
66 298-8737 1 MOUNTING BRACKET
67 298-8738 1 HEAT SHIELD
71 Ref AIR CLEANER INSTALLATION, (see Figure 4-6 for details)
84 8T-4186 2 HEX HD CAPSCREW, M10X40
85 298-7365 7 FLAT WASHER, 3/8
86 8T-4133 4 HEX NUT, M10X1.5
31200255 TL642 4-7

Figure 4-3 Cat Engine
PAL0980
4-8 TL642 31200255

Figure 4-3 Cat Engine

284-4636 1 CAT ENGINE - 3054C, 99HP, (includes all items), (Before S/N TBK01051) E
268-0867 1 SHORT BLOCK
1R-1804 1 FUEL FILTER KIT
130-1161 1 DIPSTICK
124-7702 1 DIPSTICK TUBE
7W-2326 1 OIL FILTER
268-3633 1 STARTER MOTOR, (Before S/N TBK01051)
303-4891 1 ALTERNATOR, (Before S/N TBK01051)
254-2267 1 THERMOSTAT
9L-0895 1 FAN BELT
103-5916 1 FAN
330-3035 1 CAT ENGINE, 99HP, (includes all items), (S/N TBK01051 & After)
268-0867 1 SHORT BLOCK
1R-1804 1 FUEL FILTER KIT
130-1161 1 DIPSTICK
124-7702 1 DIPSTICK TUBE
7W-2326 1 OIL FILTER
329-0290 1 STARTER MOTOR, (S/N TBK01051 & After)
339-7766 1 ALTERNATOR, (S/N TBK01051 & After)
254-2267 1 THERMOSTAT
9L-0895 1 FAN BELT
103-5916 1 FAN
FOR ADDITIONAL ENGINE INFORMATION REFER TO THE FOLLOWING:

SEBU7655 OPERATION AND MAINTENANCE MANUAL (O&MM)
RENR2437 SPECIFICATIONS MANUAL (SPEC)
RENR2438 SYSTEMS OPERATION TEST AND ADJUST (SOTA)
RENR2433 DISASSEMBLY & ASSEMBLY (D&A)
31200255 TL642 4-9

Figure 4-4 Fuel Tank & Lines
8 1
4 3
9
7
308
319 320
316 6
321
320
319
310 204 201

402 401 202
7
402 401 203 201 SUCTION LINE, PAL0581
(from R.H. side
RETURN LINE, of engine)
(from L.H. side
NOTE: USE LOCTITE 30512 #1 GASKET of engine)
SEALANT ON ALL PIPE TREADS;
EXCEPT FILLER CAP, OR AS
NOTED.
4-10 TL642 31200255

Figure 4-4 Fuel Tank & Lines

299-1340 1 FUEL TANK ASSY, (includes items 1 thru 9) F, 3
1 298-1540 1 FILLER NECK
2 298-7224 1 LOCKING FUEL TANK CAP
3 AR LOCTITE, 30512 #1 GASKET SEALANT
4 298-7243 1 FUEL TANK HOOD
6 298-7251 1 FUEL TANK
7 298-7254 1 FUEL GAUGE HARNESS
8 298-8042 5 WHIZ-LOK BOLT, 5/16-18X5/8
9 310-7936 1 FUEL LEVEL SENDER
201 304-3797 2 ELBOW, 90 DEGREES
202 304-3810 1 HOSE BARB
203 304-2652 1 HOSE BARB
204 303-4805 1 HEX SOCKET PIPE PLUG, 1/2
308 299-0400 1 FUEL TANK HOLD DOWN
310 298-8250 1 FUEL TANK STRAP WELDMENT
319 298-7374 5 FLAT WASHER, 3/8
320 298-7380 5 LOCKWASHER, 3/8
401 298-7980 2 HOSE CLAMP
402 Ref FUEL LINE, (see Figure 4-1 for details)
31200255 TL642 4-11

Figure 4-5 Radiator Assembly
S/N TBK00795 S/N BEFORE

& AFTER TBK00795
4
14
10 23
28
20
101
102
14
11
229
18 9
16
228
303 18 6
304 22 3
11 4
302 1
21 11 S/N BEFORE
TBK00795
7
29 10
13
11
3
30 26
S/N TBK00795
& AFTER
301
14 12
17
10 19 15
25
27
PAL0151
14
4-12 TL642 31200255

Figure 4-5 Radiator Assembly

299-1350 1 RADIATOR ASSY, (includes items 1 thru 30) D
3 298-0468 1 CONNECTOR, (includes o-ring) S/N BEFORE TBK 00795
298-0468 2 CONNECTOR, (includes o-ring) S/N TBK00795 & AFTER
4 298-0476 2 ELBOW, 90 DEGREE, (includes o-ring) S/N BEFORE TBK 00795
298-0476 1 ELBOW, 90 DEGREE, (includes o-ring) S/N TBK 00795 & AFTER
5 298-0477 1 ELBOW, 90 DEGREES
6 298-7364 2 FLAT WASHER, 5/16
7 298-7373 1 FLAT WASHER, 5/16
9 298-7992 2 HEX HD CAPSCREW, 5/16-18X7/8
10 300-6075 10 WHIZ LOCK SCREW, 5/16-18X5/8
11 298-7841 7 WHIZ LOCK NUT, 5/16-18
12 299-0353 2 MOUNTING PAD
13 298-7297 1 DRAIN COCK
14 298-7981 4 HOSE CLAMP
15 298-0541 2 LOCKNUT, 3/8-16
16 298-6833 AR GASKA-TAPE
17 3P-8517 2 FLAT WASHER, REBOUND
18 299-0373 2 SHOCK MOUNT
19 298-1674 4 BAR CLAMP
20 298-8580 1 RADIATOR, (includes items 101 & 102)
21 298-8118 1 RADIATOR BRACKET
22 298-8121 2 AIR DAM BRACKET
23 298-8598 1 HYDRAULIC OIL COOLER
25 298-8605 1 RUBBER AIR DAM
27 298-0421 1 LOWER RADIATOR HOSE
28 298-0423 1 UPPER RADIATOR HOSE
30 298-8739 1 RADIATOR FAN SHROUD
101 299-0912 1 RADIATOR CAP
102 38” OVERFLOW HOSE
228 298-7364 1 FLAT WASHER, 5/16
331-0795 1 FAN GUARD INSTALLATION, W/O A/C, (includes items 301 thru 304) A
301 298-8603 1 FAN GUARD
302 297-7030 3 HEX HD CAPSCREW, 3/8-16x7/8, GR5
303 298-7374 3 FLAT WASHER, 3/8
304 298-7380 3 LOCKWASHER, 3/8
31200255 TL642 4-13

Figure 4-6 Air Cleaner and Installation
506
102 507
4
7 8 6
9 5
203 201
101
202
3
204
1 2
103
503
502
504
506
507
505 515
305 638
659
304
305
647
672
PAL0671 671
4-14 TL642 31200255

Figure 4-6 Air Cleaner and Installation

299-1345 1 AIR CLEANER ASSY, (includes items 1 thru 9) A, 2
1 299-1344 1 AIR FILTER ASSY, (includes items 101 thru 103) D
3 298-7854 1 BAND CLAMP
4 298-8243 1 MOUNTING BRACKET
5 298-7364 4 FLAT WASHER, 5/16
6 298-7841 4 WHIZ-LOCKNUT, 5/16-18
8 298-7379 4 LOCKWASHER, 5/16
9 AR CAT THREADLOCK
101 299-7099 1 SERVICE INDICATOR
102 299-0352 1 AIR INLET HOOD, (includes clamp)
103 298-8729 1 AIR CLEANER, (includes items 201 thru 204) B, 2
201 206-5234 1 ELEMENT, (outer)
202 206-5235 1 ELEMENT, (inner)
203 298-8728 1 COVER ASSY
299-0842 1 VACTUATOR
204 298-0435 2 MOUNTING BAND
304 298-7037 1 STRAIGHT HUMP
305 298-1696 2 BAND CLAMP
502 298-8143 1 AIR INTAKE TUBE
503 298-1697 1 BAND CLAMP
504 298-8122 1 INTAKE SUPPORT BRACKET
505 298-0530 2 CLAMP
507 298-7380 4 LOCKWASHER, 3/8
515 298-7374 2 FLAT WASHER, 3/8
638 298-0530 1 MUFFLER CLAMP
647 298-1696 1 BAND CLAMP
659 298-0418 1 AIR INTAKE TUBE
671 298-7229 1 AIR INTAKE ELBOW
672 298-7343 1 BAND CLAMP
31200255 TL642 4-15

Figure 4-7 Exhaust Installation
6 7 5
168
7
4 132
7 105
15
16
202 161
201 7
149
148
165 148
138
PAL0691
4-16 TL642 31200255

Figure 4-7 Exhaust Installation

4 298-8156 1 MUFFLER TUBE
5 299-0392 1 MUFFLER
6 298-7066 1 TAIL PIPE
16 298-7374 4 FLAT WASHER, 3/8
105 8T-4136 3 HEX HD CAPSCREW, 10X25
132 298-7388 3 LOCKWASHER, 10mm
148 298-1758 2 CLAMP PIPE
149 298-8145 1 FLEX TUBE
161 298-0422 1 EXHAUST TUBE
165 298-0426 1 MUFFLER TUBE
168 299-0304 1 METAL GASKET
325-1345 1 MUFFLER COVER INSTALLATION, (inccludes items 210 & 202) A

201 325-1351 1 MUFFLER COVER
202 325-1352 2 WORM CLAMP
NOTE: ITEM NUMBERS NOT LISTED AARE NOT USED ON THIS FIGURE
31200255 TL642 4-17

Figure 4-8 Transmission - ZF Transmission
13 1
11
12
3
4
11
10
5
6
7
8
PAL1750
4-18 TL642 31200255

Figure 4-8 Transmission - ZF Transmission

299-0321 1 ZF THREE SPEED TRANSMISSION, (includes all items) A
299-0479 1 SEAL KIT, (includes all seals required for rebuild)
1 Ref TORQUE CONVERTER & INPUT, (see Figure 4-9 for details)
2 Ref GEARBOX HOUSING, (see Figure 4-10 for details)
3 Ref FORWARD GEAR GROUP, (see Figure 4-11 for details)
4 Ref REVERSE GEAR GROUP, (see Figure 4-12 for details)
5 Ref 1ST SHAFT GROUP, (see Figure 4-13 for details)
6 Ref 2ND SHAFT GROUP, (see Figure 4-14 for details)
7 Ref 3RD SHAFT GROUP, (see Figure 4-15 for details)
8 Ref 4TH SHAFT GROUP, (see Figure 4-16 for details)
9 Ref POWER TAKE-OFF, (see Figure 4-17 for details)
10 Ref CONTROL UNIT & PRESSURE REGULATOR, (see Figure 4-18 for details)
11 Ref GEARSHIFT SYSTEM, (see Figure 4-19 for details)
12 Ref OIL PUMP, FILTER & DIPSTICK, (see Figure 4-20 for details)
13 Ref TRANSFER BOX, (see Figure 4-21 for details)
31200255 TL642 4-19

Figure 4-9 ZF Transmission - Converter & Input
4-20 TL642 31200255

Figure 4-9 ZF Transmission - Converter & Input

1 298-7410 4 HEX HD CAPSCREW, M10X16, GR8.8
2 298-7411 8 WASHER
3 299-0899 2 DIAPHRAGM
4 299-0918 1 CONVERTER
5 299-0638 1 STATOR SHAFT
6 299-0592 1 BEARING BUSHING
7 299-0637 1 TURBINE SHAFT
8 N/S 2 CAPSCREW, M8X16, GR8.8
9 N/S 2 SHACKLE
11 299-0639 1 PISTON RING
12 299-0593 1 BALL BEARING
31200255 TL642 4-21

Figure 4-10 ZF Transmission - Gearbox Housing
4-22 TL642 31200255

Figure 4-10 ZF Transmission - Gearbox Housing

1 298-7257 1 PIPE
3 298-7881 8 O-RING
4 298-7256 1 PIPE
5 298-7258 1 PIPE
6 298-7239 7 PLUG
7 298-7876 7 O-RING
8 N/S 1 ORIFICE
9 N/S 1 HOUSING
10 298-7237 1 BRACKET
11 N/S 6 HEX HD CAPSCREW, M10X50, GR8.8
12 N/S 1 PLUG
13 298-7235 4 PIN
15 298-7349 5 HEX HD CAPSCREW
16 299-7091 1 SCREEN SHEET
19 298-7259 1 SUCTION TUBE
20 298-7346 2 O-RING
21 298-7260 1 PIPE
22 N/S 1 HOUSING
23 N/S 2 O-RING
24 N/S 1 HOUSING
25 N/S 6 CAPSCREW, M10X30,GR8.8
26 299-0896 1 BREATHER
27 N/S 4 GROOVED STUD, 3X5
28 N/S 1 TYPE PLATE
29 299-0469 1 SHAFT SEAL
31200255 TL642 4-23

Figure 4-11 ZF Transmission - Reversing Gear
4-24 TL642 31200255

Figure 4-11 ZF Transmission - Reversing Gear

2 299-0598 1 ROLLER BEARING
3 299-0640 1 COUPLING
4 299-0841 1 PISTON
5 299-0594 7 CUP SPRING
6 299-0599 1 SUPPORT SHIM
9 299-0641 11 FRICTION DISC
10 299-0642 11 STATIC DISC
11 298-7412 1 END SHIM
12 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
13 299-0605 1 DISC CARRIER
14 298-0444 AR RETAINING RING, 3.20
298-0445 AR RETAINING RING, 3.10
31200255 TL642 4-25

Figure 4-12 ZF Transmission - Reverse Gear Group
4-26 TL642 31200255

Figure 4-12 ZF Transmission - Reverse Gear Group

3 299-0644 1 COUPLING
4 299-0841 1 PISTON
5 299-0594 7 CUP SPRING
6 299-0599 1 SUPPORT SHIM
9 299-0642 11 STATIC DISC
10 298-7412 1 END SHIM
11 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
14 298-0444 AR RETAINING RING, 3.20
31200255 TL642 4-27

Figure 4-13 ZF Transmission - 1st Shaft Group
4-28 TL642 31200255

Figure 4-13 ZF Transmission - 1st Shaft Group

3 298-7238 1 COUPLING
4 299-0841 1 PISTON
5 299-0594 5 CUP SPRING
6 298-7348 1 SHIM
10 298-7412 1 END SHIM
11 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
12 299-6620 2 ROLLER CAGE
14 304-2621 1 OUTER RING
15 304-2622 1 INNER RING
31200255 TL642 4-29

Figure 4-14 ZF Transmission - 2nd Shaft Group
4-30 TL642 31200255

Figure 4-14 ZF Transmission - 2nd Shaft Group

3 299-0645 1 COUPLING
4 299-0841 1 PISTON
5 299-0594 5 CUP SPRING
6 298-7348 1 SHIM
10 298-7412 1 END SHIM
11 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
14 304-2621 1 OUTER RING
15 304-2622 1 INNER RING
31200255 TL642 4-31

Figure 4-15 ZF Transmission - 3rd Shaft Group
4-32 TL642 31200255

Figure 4-15 ZF Transmission - 3rd Shaft Group

1 1 ROLLER BEARING ASSY
321-5023 1 OUTER BEARING RING
321-5024 1 INNER BEARING RING
2 1 ROLLER BEARING ASSY
321-5021 1 BEARING RING
321-5022 1 BEARING ROLLER CAGE
4 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
5 298-7412 1 END SHIM
9 298-7413 1 WASHER
10 299-0647 7 CUP SPRING
11 299-0841 1 PISTON
12 299-0646 1 COUPLING
14 299-0643 2 PISTON BEARING
31200255 TL642 4-33

Figure 4-16 ZF Transmission - 4th Shaft Group
4-34 TL642 31200255

Figure 4-16 ZF Transmission - 4th Shaft Group

3 299-0651 1 COUPLING
4 299-0841 1 PISTON
5 299-0594 5 CUP SPRING
6 298-7348 1 SHIM
10 298-7412 1 END SHIM
11 298-0439 AR SNAP RING, 4.0
304-2633 AR SNAP RING, 3.75
298-0440 AR SNAP RING, 3.5
304-2632 AR SNAP RING, 3.25
298-0441 AR SNAP RING, 3.0
304-2635 AR SNAP RING, 2.75
298-0442 AR SNAP RING, 2.5
304-2634 AR SNAP RING, 2.25
298-0443 AR SNAP RING, 2.0
31200255 TL642 4-35

Figure 4-17 ZF Transmission - Power Take-Off
4-36 TL642 31200255

Figure 4-17 ZF Transmission - Power Take-Off

1 299-0468 1 SHAFT SEAL
2 331-0104 1 HOUSING
3 298-7235 2 CYLINDRICAL PIN
6 299-0655 1 GASKET
8 299-0652 1 SHAFT
11 299-0654 1 SHAFT
31200255 TL642 4-37

Figure 4-18 ZF Transmission - Control Unit & Pressure Regulator
4-38 TL642 31200255

Figure 4-18 ZF Transmission - Control Unit & Pressure Regulator

1 299-0658 1 VALVE
2 Ref HOUSING, (see Figure 4-10 for details)
3 299-0840 3 SOLENOID VALVE
5 N/S 4 BRACKET
6 299-0660 1 COMPRESSED SPRING
7 299-0659 1 PISTON
8 299-0656 1 GASKET
9 299-6635 1 PLATE
10 298-7415 46 HEX HD CAPSCREW
11 299-7092 1 INTERMEDIATE SHEET
13 299-0897 1 BALL
14 Ref VALVE HOUSING, (see Figure 4-19 for details)
15 298-7344 16 WASHER
31200255 TL642 4-39

Figure 4-19 ZF Transmission - Gearshift System
4-40 TL642 31200255

Figure 4-19 ZF Transmission - Gearshift System

1 298-0456 2 HEX HD CAPSCREW, M6X25,GR10.9
2 298-7351 6 WASHER
4 299-0919 1 COVER
5 299-0662 1 GASKET
6 298-7417 1 SPACER
7 299-0606 1 VALVE ASSY, (includes items 8 thru 11)
8 2 SNAP RING
9 2 SPRING SLEEVE
10 2 COMPRESSED SPRING
11 1 PISTON
12 299-0663 1 PISTON
13 298-0451 AR WASHER, 2.0
298-0452 AR WASHER, 1.0
298-0453 AR WASHER, 0.5
298-0454 AR WASHER, 0.3
298-0455 AR WASHER, 0.2
16 299-6636 1 SLEEVE
17 299-0661 1 CONTROL PISTON
20 N/S 2 BRACKET
21 298-7239 2 PLUG, M10
22 298-7876 2 O-RING
23 N/S 2 PLUG, M24
24 304-2605 2 O-RING
26 299-0898 2 BALL
27 348-2862 1 VALVE HOUSING
28 299-6621 1 ORIFICE
31200255 TL642 4-41

Figure 4-20 ZF Transmission - Oil Pump, Filter & Dipstick
4-42 TL642 31200255

Figure 4-20 ZF Transmission - Oil Pump, Filter & Dipstick

1 298-7239 2 PLUG, M10X1
2 298-7876 2 O-RING
5 298-7418 4 CAPSCREW, M12X80, GR10.9
6 299-0920 1 PUMP
1 O-RING, (located between two halves of oil pump)
7 298-7261 3 O-RING
8 298-7352 1 O-RING
9 299-0900 1 FILTER
10 299-0359 1 DIPSTICK
11 335-3833 1 DIPSTICK TUBE
12 298-7347 2 CAPSCREW, M8X16, GR8.8
13 298-7346 1 O-RING
14 Ref O-RING, (see Figure 4-1 for details)
15 344-7016 1 O-RING, (located between oil pump and transmission)
31200255 TL642 4-43

Figure 4-21 ZF Transmission - Transfer Box
4-44 TL642 31200255

Figure 4-21 ZF Transmission - Transfer Box

315-2004 1 TRANSFER BOX, (includes all items)
2 N/S 2 TAB WASHER
3 298-7350 2 WASHER
4 303-8568 2 FLANGE
6 299-0470 3 SHAFT SEAL
7 298-7235 2 CYLINDRICAL PIN
9 303-8561 2 PLUG
10 304-2596 4 STUD, 3X5
11 N/S 1 PLATE
12 299-0591 1 BREATHER
14 N/S 1 HOUSING
16 304-2631 1 OUTPUT SHAFT
17 4 TAPERED ROLLER BEARING
311-9612 1 CUP
311-9613 1 CONE
19 304-2617 1 IDLER GEAR
20 1 INPUT SHAFT
314-7795 1 INPUT GEAR
314-7798 1 SEAL
21 N/S 1 HOUSING
22 304-2615 1 HEX NUT, M16
23 304-2614 1 SLEEVE
31200255 TL642 4-45

4-46 TL642 31200255

SECTION 5
DRIVE TRAIN
31200255 TL642
DRIVE TRAIN
Figure 5-1 Front Axle Assembly
12
1
9
7
8 101
6
13
7
9
2
10
14
15
11
14
15
16
11
3
4
204
205
202
201
203
202
201
203
PAL0182
5-2 TL642 31200255

DRIVE TRAIN
Figure 5-1 Front Axle Assembly

299-1338 1 FRONT AXLE ASSY, (includes items 1 thru 101) C, 5
1 Ref FRONT AXLE, (see Figure 5-2 for details)
2 298-8783 1 SWAY LUG ASSY, (if equipped), (includes item 101)
3 298-8127 2 RETAINING PLATE, (if equipped)
4 298-1632 8 HARDENED WASHER, 1, (if equipped)
5 298-1793 4 HEX HD CAPSCREW, 1-8X9, GR8, (if equipped)
6 298-0498 1 SWIVEL NUT BRANCH TEE, 3/8 TUBE
8 298-0507 1 SWIVEL NUT ELBOW
9 2 HOSE ASSY 5
10 298-1394 1 HOSE ASSY 4
12 298-1397 1 HOSE ASSY
13 298-0496 1 SWIVEL NUT RUN TEE
14 298-7249 AR NYLON SLEEVE
15 298-0496 3 TY-WRAP
16 325-8143 1 HOSE ASSY C,4
101 298-6865 2 BUSHING, (if equipped)
331-0804 1 HOIST LUGS INSTALL, (if equipped), C

(includes items 201 thru 205 & items 101 thru 104 on Figure 5-11)
201 298-1632 11 WASHER
202 298-8127 4 RETAINER PLATE
203 298-1793 8 HEX HD CAPSCREW, 1X8X9
AR CAT THREADLOCK
204 331-0803 1 AXLE HOIST LUG
205 1 LIFT LUG SWAY PIVOT BEARING BRACKET
31200255 TL642 5-3

DRIVE TRAIN
Figure 5-2 Front Axle
2
3
6
1
5
7
8
PAL0190
5-4 TL642 31200255

DRIVE TRAIN
Figure 5-2 Front Axle

298-8138 1 FRONT AXLE, (includes all items)
1 Ref AXLE HOUSING ASSY, (see Figure 5-3 for details)
2 Ref STEERING COMPONENTS, (see Figure 5-4 for details)
3 Ref BEVEL GEAR SET, (see Figure 5-5 for details)
4 Ref DIFFERENTIAL, (see Figure 5-6 for details)
5 Ref DOUBLE JOINT, (see Figure 5-7 for details)
6 Ref BRAKES, (see Figure 5-8 for details)
7 Ref WHEEL HUB, (see Figure 5-9 for details)
8 Ref REDUCTION GEARS, (see Figure 5-10 for details)
31200255 TL642 5-5

DRIVE TRAIN
Figure 5-3 Front Axle Housing Assembly
5-6 TL642 31200255

DRIVE TRAIN
Figure 5-3 Front Axle Housing Assembly

1 298-1799 5 O-RING
2 Ref COVER, (see Figure 5-8 for details)
3 298-8178 8 STUD
4 304-4581 1 INTERMEDIATE COVER
5 299-0790 1 HOUSING
6 299-7161 1 PLUG
7 299-7134 1 VENT
8 299-0821 1 CIRCLIP
9 299-7170 5 PLUG
10 304-2241 3 MAGNET PLUG
11 299-7103 2 PLUG
12 298-1857 2 GREASE FITTING
13 299-0196 2 THRUST BUSHING
14 299-0197 4 REDUCTION BUSHING
15 299-0793 1 SUPPORT ASSY, REAR, (includes items 11 thru 14)
299-0794 1 SUPPORT ASSY, FRONT, (includes items 11 thru 14)
16 299-0199 2 AXLE CASE
17 304-3231 32 WASHER
18 298-8179 24 STUD
19 298-1853 2 NUT
20 304-3230 2 BOLT
21 298-1854 32 NUT
31200255 TL642 5-7

DRIVE TRAIN
Figure 5-4 Front Steering Components
5-8 TL642 31200255

DRIVE TRAIN
Figure 5-4 Front Steering Components

299-0796 1 STEERING CASE ASSY, L.H., (includes item 17)
299-0795 1 STEERING CASE ASSY, R.H., (includes item 16)
4 299-7136 2 TIE ROD, (includes hex nut)
5 298-1800 4 CYLINDER BOLT
6 299-0808 1 CYLINDER
304-2620 1 SEAL KIT
7 299-7137 2 COVER
8 298-1865 24 BOLT
9 299-7103 2 PLUG
11 299-0228 2 PIVOT PIN, (includes item 10)
12 298-1860 2 SHIM
298-1861 2 SHIM
298-1862 2 SHIM
14 303-8572 4 DUST EXCLUDER
15 303-8570 2 OUTER RACE
16 299-0201 1 STEERING CASE, L.H.
17 299-0202 1 STEERING CASE, R.H.
18 299-0223 2 BEARING
19 303-8571 2 PIVOT PIN, (includes items 10, 14 & 18)
20 4 NUT
21 4 BOLT
305-5426 4 STEERING ADJUST BOLT KIT, (includes items 20 & 21)
299-0253 1 NUT & COTTER PIN KIT
31200255 TL642 5-9

DRIVE TRAIN
Figure 5-5 Front Gear Components
5-10 TL642 31200255

DRIVE TRAIN
Figure 5-5 Front Gear Components

1 298-1801 1 NUT
2 298-1802 1 O-RING
3 299-7138 1 FLANGE
4 299-7139 1 COVERPLATE
5 299-0508 1 SEAL
6 298-1803 1 RING NUT
7 304-2603 2 TAPER ROLLER BEARING
8 298-1804 1 SHIM
298-1805 1 SHIM
298-1806 1 SHIM
298-1807 1 SHIM
9 298-1808 1 SPACER
10 298-1809 1 SHIM
298-1810 1 SHIM
298-1811 1 SHIM
298-1812 1 SHIM
11 298-8181 1 BEVEL GEAR SET
31200255 TL642 5-11

DRIVE TRAIN
Figure 5-6 Front Differential
5-12 TL642 31200255

DRIVE TRAIN
Figure 5-6 Front Differential

2 298-1813 2 RING NUT
4 298-1865 12 BOLT
5 Ref BEVEL GEAR, (see Figure 5-5 for details)
6 304-2265 1 CLUTCH DISC KIT
7 304-2264 1 DIFFERENTIAL CARRIER
8 299-0788 4 DIFFERENTIAL PINION
9 299-0511 2 DIFFERENTIAL SIDE GEAR
10 304-3220 4 CIRCLIP
11 304-3221 4 CIRCLIP
12 299-0789 4 PIN
13 298-1814 4 FRICTION WASHER
304-2243 1 DIFFERENTIAL KIT, (includes items 6 thru 13)
31200255 TL642 5-13

DRIVE TRAIN
Figure 5-7 Front Double Joint
5-14 TL642 31200255

DRIVE TRAIN
Figure 5-7 Front Double Joint

1 299-0827 2 CIRCLIP
2 299-0821 2 CIRCLIP
4 299-0520 2 SEAL
5 299-0236 2 REDUCTION BUSHING, (includes items 2, 3, 4 & 6)
6 298-1877 2 O-RING
7 299-7140 2 JOINT
8 303-8573 2 SEAL
1 CROSS KIT, (includes cross for double joint, circlips & needle bearings)
31200255 TL642 5-15

DRIVE TRAIN
Figure 5-8 Front Brakes
5-16 TL642 31200255

DRIVE TRAIN
Figure 5-8 Front Brakes

1 298-1815 2 SPACER
2 298-8186 4 SPRING
3 298-8187 2 PISTON
4 298-1816 2 O-RING
5 298-1883 4 O-RING
6 299-7165 4 BACK-UP RING
7 299-7103 4 PLUG
8 298-7873 4 BLEEDING BOLT
9 298-1878 4 BOLT
10 298-1879 4 SEAL WASHER
12 298-1817 2 O-RING
13 299-7141 2 BACK-UP RING
14 298-8188 2 PISTON
15 298-8189 2 INTERMEDIATE BRAKE DISC
16 299-0241 6 SPRING
17 6 ADJUSTING BOLT, (Before Axle S/N HITA-725998), (298-1818 is no longer
available; order qty. 6 of 298-7430 for replacement)
298-7430 6 ADJUSTING BOLT, (Axle S/N HITA-725998 & After)
18 299-0240 6 SPRING
19 298-1881 6 ADJUSTING BOLT
20 298-8191 8 BRAKE DISC
22 298-1819 2 SPACER
23 298-1820 2 SHIM
298-1821 2 SHIM
298-1822 2 SHIM
25 298-7867 4 NUT
26 304-2244 4 BOLT
31200255 TL642 5-17

DRIVE TRAIN
Figure 5-9 Front Wheel Hub
5-18 TL642 31200255

DRIVE TRAIN
Figure 5-9 Front Wheel Hub

1 303-8574 2 SEAL
2 298-8193 4 BEARING
3 298-7274 20 WHEEL STUD
4 299-6639 2 WHEEL HUB
6 298-8297 2 O-RING
7 298-8194 2 CIRCLIP
8 298-8195 2 RING GEAR
9 298-8196 2 RING GEAR SUPPORT
10 298-8197 2 LOCKING PLATE
11 298-8198 20 STUD
12 298-1825 20 NUT
31200255 TL642 5-19

DRIVE TRAIN
Figure 5-10 Front Reduction Gears
5-20 TL642 31200255

DRIVE TRAIN
Figure 5-10 Front Reduction Gears

1 299-0205 8 CIRCLIP
2 299-0206 8 PLANETARY GEAR
3 299-0207 8 BEARING
4 299-0797 2 PLANETARY GEAR CARRIER
6 299-7170 4 PLUG
7 298-8300 4 COUNTERSUNK BOLT
350-8580 2 PLANETARY CARRIER KIT, (includes items 1 thru 4 and items 7, 8 & 9
on Figure 5-9)
299-0813 2 RING GEAR SUPPORT, (includes items 7, 8 & 9 on Figure 5-9)
31200255 TL642 5-21

DRIVE TRAIN
Figure 5-11 Rear Axle Assembly
2 4
5
6
5
104
104
101
102
103
101
102
PAL0281
103
5-22 TL642 31200255

DRIVE TRAIN
Figure 5-11 Rear Axle Assembly

299-1337 1 REAR AXLE ASSY, (includes items 1 thru 6) B, 5
1 Ref REAR AXLE, (see Figure 5-12 for details)
2 298-1610 2 ADAPTER, M14 3
3 1 HOSE ASSY 5
4 298-0498 1 SWIVEL NUT BRANCH TEE, 3/8 TUBE
5 298-0474 2 ELBOW, 90 DEGREES, (includes o-ring) 3
6 298-1394 2 HOSE ASSY
331-0804 1 HOIST LUGS INSTALL, (if equipped), C

(includes items 101 thru 104 & items 201 thru 205 on Figure 5-1)
101 298-1632 12 WASHER
102 298-8127 4 RETAINER PLATE
103 298-1793 8 HEX HEAD CAPSCREW, 1-8X9
AR CAT THREADLOCK
104 331-0803 2 AXLE HOIST LUG
31200255 TL642 5-23

DRIVE TRAIN
Figure 5-12 Rear Axle
2
3
6
1
5
7
8
PAL0290
5-24 TL642 31200255

DRIVE TRAIN
Figure 5-12 Rear Axle

298-8139 1 REAR AXLE, (includes all items), (Before S/N TBK01105) B
331-3989 1 REAR AXLE, (includes all items), (S/N TBK01105 & After) A
1 Ref AXLE HOUSING ASSY, (see Figure 5-13 for details)
3 Ref BEVEL GEAR SET, (see Figure 5-15 for details)
4 Ref DIFFERENTIAL, (see Figure 5-16 for details)
5 Ref DOUBLE JOINT, (see Figure 5-17 for details)
6 Ref REAR BRAKES, (see Figure 5-18 for details)
7 Ref WHEEL HUB, (see Figure 5-19 for details)
8 Ref REDUCTION GEARS, (see Figure 5-20 for details)
31200255 TL642 5-25

DRIVE TRAIN
Figure 5-13 Rear Axle Housing Assembly
18
S/N TBK01105 & AFTER
5-26 TL642 31200255

DRIVE TRAIN
Figure 5-13 Rear Axle Housing Assembly

1 298-1799 5 O-RING, (Before S/N TBK01105)
298-1799 3 O-RING, (S/N TBK01105 & After)
2 Ref COVER, (see Figure 5-18 for details), (Before S/N TBK01105)
3 298-8178 8 STUD
5 299-0790 1 HOUSING
6 299-7161 1 PLUG
7 299-7134 1 VENT
8 299-0821 1 CIRCLIP
9 299-7170 3 PLUG
10 304-2241 3 MAGNET PLUG, (Before S/N TBK01105)
299-0195 3 MAGNET PLUG, (S/N TBK01105 & After)
11 299-7103 2 PLUG
14 299-0197 4 REDUCTION BUSHING
15 299-0793 1 FRONT SUPPORT ASSY, (includes items 11 thru 14)
299-0794 1 REAR SUPPORT ASSY, (includes items 11 thru 14)
16 299-0199 2 AXLE CASE, (Before S/N TBK01105)
350-8568 2 AXLE CASE, (S/N TBK01105 & After)
17 304-3231 32 WASHER, (Before S/N TBK01105)
18 298-8179 24 STUD, (Before S/N TBK01105)
350-8569 32 BOLT, (S/N TBK01105 & After)
19 298-1853 2 NUT
20 304-3230 2 BOLT
21 298-1854 32 NUT, (Before S/N TBK01105)
31200255 TL642 5-27

DRIVE TRAIN
Figure 5-14 Rear Steering Components
5-28 TL642 31200255

DRIVE TRAIN
Figure 5-14 Rear Steering Components

4 299-7136 2 TIE ROD, (includes hex nut)
6 299-0808 1 CYLINDER
304-2620 1 SEAL KIT
7 299-7137 2 COVER
8 298-1865 24 BOLT
9 299-7103 2 PLUG
11 299-0228 2 PIVOT PIN, (includes item 10)
12 298-1860 2 SHIM
298-1861 2 SHIM
298-1862 2 SHIM
14 303-8572 4 DUST EXCLUDER
15 303-8570 2 BUSHING
16 299-0795 1 STEERING CASE ASSY, L.H., (includes thrust bushing 299-0227)
17 299-0796 1 STEERING CASE ASSY, R.H., (includes thrust bushing 299-0227)
18 299-0223 2 BEARING
19 303-8571 2 PIVOT PIN, (includes items 10, 14 & 18)
20 298-7868 4 NUT
21 298-1863 4 BOLT
305-5426 4 STEERING ADJUST BOLT KIT, (includes items 20 & 21)
31200255 TL642 5-29

DRIVE TRAIN
Figure 5-15 Rear Gear Components
5-30 TL642 31200255

DRIVE TRAIN
Figure 5-15 Rear Gear Components

1 298-1801 1 NUT
2 298-1802 1 O-RING
3 299-7138 1 FLANGE, (Before S/N TBK01105)
350-8570 1 FLANGE, (S/N TBK01105 & After)
4 299-7139 1 COVERPLATE
5 299-0508 1 SEAL
6 298-1803 1 RING NUT
7 304-2603 2 TAPER ROLLER BEARING
8 298-1804 1 SHIM
298-1805 1 SHIM
298-1806 1 SHIM
298-1807 1 SHIM
9 298-1808 1 SPACER
10 298-1809 1 SHIM
298-1810 1 SHIM
298-1811 1 SHIM
298-1812 1 SHIM
11 298-8200 1 BEVEL GEAR SET
31200255 TL642 5-31

DRIVE TRAIN
Figure 5-16 Rear Differential
5-32 TL642 31200255

DRIVE TRAIN
Figure 5-16 Rear Differential

3 298-1813 2 RING NUT
5 298-1865 12 BOLT
6 Ref BEVEL GEAR, (see Figure 5-15 for details)
7 2 FRICTION WASHER
8 2 DIFFERENTIAL SIDE GEAR
9 4 CIRCLIP
10 304-3221 4 CIRCLIP, (Before axle S/N IITA769001)
11 4 PIN
12 4 FRICTION WASHER
13 4 DIFFERENTIAL PINION
14 1 DIFFERENTIAL CARRIER
350-8571 1 DIFFERENTIAL ASSY, (includes items 7, 8, 9 & 11 thru 14)
31200255 TL642 5-33

DRIVE TRAIN
Figure 5-17 Rear Double Joint
5-34 TL642 31200255

DRIVE TRAIN
Figure 5-17 Rear Double Joint

1 299-0827 2 CIRCLIP
2 299-0821 2 CIRCLIP
4 299-0520 2 SEAL
5 299-0236 2 REDUCTION BUSHING, (includes items 2, 3, 4 & 6)
6 298-1877 2 O-RING
7 299-7140 2 JOINT, (Before S/N TBK01105)
350-8572 2 JOINT, (S/N TBK01105 & After)
8 303-8573 2 SEAL
31200255 TL642 5-35

Before S/N TBK01105
DRIVE TRAIN
Figure 5-18 Rear Brakes
5-36 TL642 31200255

Before S/N TBK01105
DRIVE TRAIN

1 304-3225 2 SPACER
3 298-1883 2 O-RING
4 299-7103 2 PLUG
6 298-1878 2 BOLT
9 298-1817 2 O-RING
10 299-7141 2 BACK-UP RING
11 304-3819 2 PISTON
13 299-0241 6 SPRING
14 6 ADJUSTING BOLT, (Before Axle S/N HITA-726032), (298-1818 is no longer
available; order qty. 6 of 298-7430 for replacement)
298-7430 6 ADJUSTING BOLT, (Axle S/N HITA-726032 & After)
15 299-0240 6 SPRING
17 298-8191 8 BRAKE DISC
19 298-1819 2 SPACER
31200255 TL642 5-37

DRIVE TRAIN
10
2
3
17
6
7 16
12
9
8 11
18
5
13
PY3780
5-38 TL642 31200255

DRIVE TRAIN

1 298-8191 8 BRAKE DISC
3 299-0241 6 TUBE
4 350-8575 2 PISTON
5 299-0240 6 SPRING
7 350-8577 2 O-RING
9 350-8579 2 O-RING
12 299-7103 2 PLUG
13 350-2524 2 PILOT BOLT
14 350-8574 2 PISTON KIT, (includes items 3, 4 & 6 thru 9)
17 298-1878 2 BOLT
31200255 TL642 5-39

DRIVE TRAIN
Figure 5-19 Rear Wheel Hub
5-40 TL642 31200255

DRIVE TRAIN
Figure 5-19 Rear Wheel Hub

1 303-8574 2 SEAL
2 298-8193 4 BEARING
3 298-7274 20 WHEEL STUD
4 299-6639 2 WHEEL HUB
6 298-8297 2 O-RING
7 298-8194 2 CIRCLIP
8 298-8195 2 RING GEAR
9 298-8196 2 RING GEAR SUPPORT
10 298-8197 2 LOCKING PLATE
11 298-8198 20 STUD
12 298-1825 20 NUT
31200255 TL642 5-41

DRIVE TRAIN
Figure 5-20 Rear Reduction Gears
5-42 TL642 31200255

DRIVE TRAIN
Figure 5-20 Rear Reduction Gears

1 299-0205 8 CIRCLIP
2 299-0206 8 PLANETARY GEAR
3 299-0207 8 BEARING
4 299-0797 2 PLANETARY GEAR CARRIER
6 299-7170 4 PLUG
7 298-8300 4 COUNTERSUNK BOLT
350-8580 2 PLANETARY CARRIER KIT, (includes items 1 thru 4 and items 7, 8 & 9
on Figure 5-19)
299-0813 2 RING GEAR SUPPORT, (includes items 7, 8 & 9 on Figure 5-19)
31200255 TL642 5-43

DRIVE TRAIN
Figure 5-21 Drive Shaft Assembly
2 6
2 7
PAL0380
5-44 TL642 31200255

DRIVE TRAIN
Figure 5-21 Drive Shaft Assembly

1 299-0317 1 DRIVESHAFT, (front), (includes item 2)
2 303-8584 4 UNIVERSAL JOINT KIT
3 299-0316 1 DRIVESHAFT, (rear), (includes item 2)
4 Ref FLANGE, (see Figure 5-15 for details)
6 298-8599 8 BEARING STRAP
7 298-1791 16 STRAP BOLT
31200255 TL642 5-45

DRIVE TRAIN
Figure 5-22 Tires & Rims
TREAD PATTERNS MAY VARY
8 5
7
11
9 12
3
10
1 PAL3580
6
5-46 TL642 31200255

DRIVE TRAIN
Figure 5-22 Tires & Rims

4520368 1 TIRE SET, 13.00-24 BIAS A
91405035 2 R.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, (includes items 1 thru 3) H
91405036 2 L.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, (includes items 1 thru 3) H
4520369 1 TIRE SET, 13.0-24 BIAS, ROCK TREAD A
91535017 4 TIRE & WHEEL ASSY, 13.00-24 BIAS, ROCK TREAD, (includes items 2, 3 & B
5)
4520455 1 TIRE SET, 15.50-25 BIAS A
91475031 2 R.H. TIRE & WHEEL ASSY, 15.5-25 BIAS, (includes items 2, 6 & 10) C
91475032 2 L.H. TIRE & WHEEL ASSY, 15.5-25 BIAS, (includes items 2, 6 & 10) C
4520458 1 TIRE SET, 13.0-24 BIAS A
4520451 4 TIRE & WHEEL ASSY, 15.5-25 BIAS, ROCK TREAD, (includes items 2, A
7&10)
4520374 1 TIRE SET, 13.0-24 RADIAL A
91515056 4 TIRE & WHEEL ASSY, 13.0-24 RADIAL, (includes items 2, 3 & 8) B
4520461 1 TIRE SET, 13.0-24 RADIAL A
4520453 4 TIRE & WHEEL ASSY, 15.5-25, RADIAL, (includes items 2, 9 & 10) A
4520370 1 TIRE SET, 13.0-24 BIAS, FOAM FILLED A
91475054 2 R.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, FOAM FILLED, 542#, D
(includes items 1 thru 3)
91475055 2 L.H. TIRE & WHEEL ASSY, 13.0-24 BIAS, FOAM FILLED, 542#, D
(includes items 1 thru 3)
4520375 1 TIRE SET, 13.0-24 RADIAL, FOAM FILLED A
91475093 4 TIRE & WHEEL ASSY, 13.0-24 RADIAL, FOAM FILLED, 542#, E
(includes items 2, 3 and 8)
4520371 1 TIRE SET, 13.0-24 BIAS, ROCK TREAD, FOAM FILLED A
91535019 4 TIRE & WHEEL ASSY, 13.0-24 BIAS, ROCK TREAD, FOAM FILLED, 542#, D
(includes items 2, 3 & 5)
4520459 1 TIRE SET, 15.5-25, FOAM FILLED A
91475105 4 TIRE & WHEEL ASSY, 15.5-25, ROCK TREAD, FOAM FILLED, 600# B
4520449 2 R.H. TIRE & WHEEL ASSY, 15.5-25, FOAM FILLED, G-2, A
4520450 2 L.H. TIRE & WHEEL ASSY, 15.5-25, FOAM FILLED, G-2, A
91515066 4 TIRE & WHEEL ASSY, 15.5-25, RADIAL, FOAM FILLED, 600# D
4520645 1 SOLID TIRE SET, 13.0-24, (includes items 11 & 12) A
1 8780031 1 TIRE, 13.0-24 BIAS, DIRECTIONAL
2 298-7311 1 VALVE STEM
3 298-8780 1 WHEEL, 24X9
4 298-1744 10 LUG NUT
5 8780045 1 TIRE, 13.0-24 BIAS, ROCK TREAD, NON-DIRECTIONAL
6 8780036 1 TIRE, 15.5-25 BIAS, DIRECTIONAL
7 8780050 1 TIRE, 15.5-25 BIAS, ROCK TREAD, NON-DIRECTIONAL
8 8780264 1 TIRE, 13.0-24 RADIAL, NON-DIRECTIONAL
9 8780048 1 TIRE, 15.5-25 RADIAL, L-2
10 298-8781 1 WHEEL, 25X13
11 4520646 1 R.H. SOLID TIRE & WHEEL ASSY B
12 4520647 1 L.H. SOLID TIRE & WHEEL ASSY B
31200255 TL642 5-47

DRIVE TRAIN
5-48 TL642 31200255

SECTION 6
CAB
31200255 TL642
CAB
Figure 6-1 Cab Assembly
41
14 4
66
67
4
13 14
17
2
7
65
54 53 62
12 63
52 64
6
27
28 30 27
CLAMP MOUNT
BEHIND SEAT
29 28
26
27 3 45
28 32 49 33
61 41
68
69
28
34 35 36
56 59 39 34
25
60 40 72
41
101 42 28
112 43 55
37 56
57 16
58 104 38
9 106
10 15 113
31 102 MACHINES EQUIPPED
42 105 WITH
107 OUTRIGGERS
107 108 106
108 109
110 111
18 4
19 24
20
A A 23
21
22 VIEW A-A
50
51
48
50 11
70 14
71 38 PAL2082
SIDE VIEW OF CAB
6-2 TL642 31200255

CAB
Figure 6-1 Cab Assembly

Ref OPEN CAB ASSY, (includes items 1 thru 61)
Ref ENCLOSED CAB ASSY, (includes items 1 thru 67)
1 Ref CAB WELDMENT, (see Figure 6-2 for details)
2 344-7161 1 ACCESS COVER PLATE
3 298-8041 2 MACHINE HD SCREW, 1/4-20X5/8
4 298-7372 11 FLAT WASHER, 1/4
5 298-7079 1 TILT ON JOYSTICK CAB HARNESS, (not shown)
6 298-1770 2 SELF-TAPPING SCREW, #6X1/2
7 1 VENT COVER PLATE
8 298-8152 1 JOYSTICK ENGINE HARNESS, (not shown)
9 298-8141 1 CABLE
10 305-2028 1 LH BRACKET
11 298-1772 2 FENDER WASHER
12 298-0552 4 LOCKNUT, 5/16-18
13 Ref SUSPENSION SEAT, (see Figure 6-3 for details)
15 Ref BRAKE PEDAL ASSY, (see Figure 7-3 for details)
16 Ref ACCELERATOR PEDAL ASSY, (see Figure 7-1 for details)
17 304-2566 1 MANUAL STORAGE BOX
18 298-1738 1 DASH CLAMP
19 298-1359 2 SCREW, 3/8-16X1
21 298-1643 2 FENDER WASHER, 5/16
23 298-8761 1 DASH BRACE
25 298-8608 1 DASH, (open cab)
298-8609 1 DASH, (enclosed cab)
26 1 LH VERTICAL DASH PANEL
27 6V-7978 16 FLAT HD CAPSCREW, #10-24X1
28 298-7880 12 TINNERMAN NUT, #10-24
29 Ref INSTRUMENT PANEL, (see Figure 6-4 for details)
31 309-6321 3 HEX HD CAPSCREW, 1/4-20X2-1/2
32 299-0395 2 LOAD CHART BRACKET
33 Ref BOOM JOYSTICK w/TILT, (see Figure 7-4 for details)
34 298-7105 1 CONTROL PANEL, (no outriggers)
303-4865 1 CONTROL PANEL, (with outriggers)
35 298-8644 1 RH HORZ CONTROL ASSY
36 298-8149 1 CABLE
37 298-7039 1 LH VERTICAL CONTROL ASSY
38 350-2520 1 RH CONSOLE
39 315-5502 1 RH SWAY BRACKET
40 297-7014 3 HEX HD CAPSCREW, 1/4-20X2
41 298-7378 6 LOCKWASHER, 1/4
42 298-8047 6 HEX NUT, 1/4-20
45 298-8043 4 PAN HD SCREW, 6-32X1/2, (self tap)
48 299-0369 AR TRIM-LOK
31200255 TL642 6-3

CAB
Figure 6-1 Cab Assembly (Continued)

49 298-7017 1 MOUNTING PLATE
51 298-7373 1 FLAT WASHER, 5/16
52 298-1362 1 FLOOR MAT
53 298-7364 4 FLAT WASHER, 5/16
55 298-8133 1 COVER PANEL
56 298-7101 10 SELF TAPPING SCREW, 10X3/4
58 298-7367 2 FLAT WASHER, 1/2
60 298-7379 3 FLAT WASHER, 5/16
61 298-7286 1 RHEOSTAT TILT SWITCH
62 298-1770 2 SELF TAP SCREW, #6
64 298-7362 2 FLAT WASHER, #10
65 Ref HEATING COMPONENTS, (see Figure 6-5 for details)
66 298-7295 1 WASHER FLUID BOTTLE
67 298-7292 AR WASHER FLUID HOSE
68 298-7372 4 FLAT WASHER, 1/4
71 298-7438 2 CLAMP SET
72 Ref OUTRIGGER CONTROLLER, (see Figure 8-11 for details)
101 334-3559 1 LOWER CONSOLE, RH
102 334-3558 1 LOWER CONSOLE MOUNTING BRACKET
104 297-7009 2 SOCKET BUTTON HD CAPSCREW, 1/4-20X1
106 298-7363 2 FLAT WASHER, 1/4
107 298-7372 4 FLAT WASHER, WIDE, 1/4
108 298-7378 3 LOCKWASHER, 1/4
109 298-8047 1 HEAVY HEX NUT, 1/4-20
111 298-7050 1 HEATER PLENUM
112 299-6623 14” TRIM LOC, 3/16
113 334-3560 1 RETAINING NUT, .25-20
222 298-8047 1 HEAVY HEX NUT, 1/2-20
314-6130 1 CAB ENCLOSURE KIT, (includes items 4, 14, 41, 62 thru 66, A, 1
107 thru 111 & 222)
Ref CAB ENCLOSURE, (see Figure 6-2 for details)
6-4 TL642 31200255

CAB
Figure 6-1 Cab Assembly (Continued)

31200255 TL642 6-5

CAB
Figure 6-2 Cab
NOTE: APPLY LOCTITE, ITEM 68, TO

ALL HARDWARE THAT REQUIRE
LOCKNUTS.
6-6 TL642 31200255

CAB
Figure 6-2 Cab (Continued)
NOTE: APPLY LOCTITE, ITEM 68, TO

ALL HARDWARE THAT REQUIRE
LOCKNUTS.
31200255 TL642 6-7

CAB
Figure 6-2 Cab

299-7148 1 OPEN CAB, (includes items 1 thru 11)
298-7225 1 ENCLOSED CAB, (includes items 1 thru 66)
308-6651 1 CAB ENCLOSURE, (includes items 14, 16 thru 18, 24 thru 26, 31 & 32)
1 303-8618 1 RH WINDOW w/ BORDER
2 320-0534 AR URETHANE
3 304-2656 AR ACTIVATOR
4 303-8579 13 SETTING BLOCK
5 N/S 1 SERIAL TAG, (open cab)
N/S 1 SERIAL TAG, (enclosed cab)
6 303-8619 1 REAR WINDOW
8 303-8612 1 ROPS WARNING DECAL
10 304-3181 1 PLUG, (open cab)
303-8615 1 SPACER, (enclosed cab)
11 303-8585 3 PLUG, (open cab)
303-8592 2 SCREW, 1/4-28X3/4, (enclosed cab)
12 303-8591 1 WET ARM ADAPTER
13 303-8596 1 ADAPTER KIT
14 304-3799 1 WIPER SYSTEM ASSY
15 303-8593 1 WET ARM KIT
16 303-8594 1 WIPER ARM
17 303-8595 1 WIPER BLADE, 28”
18 303-8625 1 FRONT WINDOW
19 303-8628 2 PLUG, 1-1/4
20 AR CLEAR SEALANT
21 303-8624 1 SKY LIGHT WINDOW
22 303-8627 1 HEADLINER
23 303-8630 3 RIVET, 1/8
24 303-8632 1 EXIT HAMMER w/ CABLE
25 303-8631 1 EMERGENCY EXIT DECAL
26 303-4978 1 LH SIDE REAR WINDOW
27 303-8626 1 FOAM, LH SIDE PANEL
28 303-8634 1 HEX BOLT, 3/8-16X6-1/2
29 303-8590 2 HEX BOLT, 3/8-16X4-1/2
30 303-8635 3 HEX NUT, 3/8-16
31 304-2638 1 LOWER DOOR ASSY, (includes items 44 thru 66 & items 68 and 69)
32 304-2639 1 UPPER DOOR ASSY, (includes items 2, 3, 38 thru 43 & item 68)
33 303-8597 1 DOOR STRAP
34 303-8613 1 HEX BOLT, 3/8-16X7/8
35 303-8629 2 WASHER
36 303-8582 1 STRIKER
37 303-8633 1 DOOR HOLD-OPEN, FEMALE
38 303-8581 11’ BULB SEAL
39 304-2301 2 HEX BOLT, 5/16-18X5/8
40 303-8614 2 WASHER
41 303-8649 1 SLAM LATCH
42 303-8667 1 DOOR HOLD-OPEN, MALE
43 303-8648 1 UPPER DOOR GLASS
44 304-2300 2 FLAT HD SCREW, 1/4-20X1-1/4
45 303-8642 1 GRAB HANDLE
6-8 TL642 31200255

CAB
Figure 6-2 Cab (Continued)

46 303-8578 3 SCREW, M6X1X12
47 303-8638 1 PLASTIC DOOR COVER
48 303-8587 6 WHIZ-LOCK SCREW, #10-24X0.5
49 303-8588 1 INSIDE HANDLE ASSY, LH
50 303-8641 1 RELEASE LEVER, RH WINDOW/LH DOOR
51 303-8643 1 SOCKET HD SCREW, #8-32X1.12
52 303-8644 1 NUT, #8-32
53 303-8640 6 LOCKNUT, #10-24
54 303-8646 1 SLAM LATCH STIFFENER
55 303-8645 1 SLAM LATCH, LH
56 304-2645 2 RIVNUT, 1/4-20
57 303-8647 1 LOWER DOOR DRIVE BAR WELDMENT
58 304-2649 4 HEX SCREW, 1/4-20X3/4
59 304-3800 1 PADDLE LATCH, LH
5P-8500 1 KEY
60 303-8581 8’ BULB SEAL
61 303-8583 1 CAM LATCH, RH
62 303-8636 1 EXTERIOR RELEASE DOOR ROD
63 303-8586 3 ROD END RETAINER CLIP
64 303-8637 1 INTERIOR RELEASE DOOR ROD
65 303-8639 1 FOAM, LOWER DOOR
67 304-4580 1 SERIAL TAG, (cab enclosure kit)
68 AR LOCTITE
69 304-2640 AR BLACK VINYL TAPE, 2”
70 304-3798 1 SEAT RISER WELDMENT
71 304-2648 4 FLAT WASHER, 3/8
73 304-2637 4 LOCKWASHER, 3/8
74 303-8589 1 WIPER ARM DRIVE
75 303-8611 1 WIPER PIVOT SHAFT, 2”
31200255 TL642 6-9

CAB
Figure 6-3 Suspension Seat
5
1
2 3 4
6
7
10 PAL0700
6-10 TL642 31200255

CAB
Figure 6-3 Suspension Seat

298-8722 1 SUSPENSION SEAT, (includes all items) C
1 299-0927 1 ARMREST ASSY RH KIT, (includes items 2 & 3)
2 1 ARMREST, MOLDED KIT
3 1 ARMREST STOP ASSY
4 304-2626 1 BACK CUSHION KIT
5 299-0925 1 BACK PANEL KIT
6 299-0928 1 SEAT BELT KIT
298-8669 1 SEAT BELT, 3 IN., (California Only), (not included with 298-8722)
7 299-6637 1 TETHER KIT
8 299-0924 1 SEAT CUSHION KIT
9 299-0922 1 KNOB KIT
10 299-0921 1 SLIDE KIT
31200255 TL642 6-11

CAB
Figure 6-4 Instrument Panel
BAT-1
7
1
18
HR MTR
2
6 8
3 HORN
4 FUL GAG
5 ST RLY
6 BAT-2
7 SP-1
WIRE DESIGNATION
PIN DESIGNATION
8 SP-2
9 ALT EXC
10 SP-3
11 STR AW
12 STR CRB
13 TRANS-B
14 TRANS-A
15 TRANS-C
16 TRANS-D
11 9
17 TRANS-E
18 18
18 REV AL
15 1
17 DEUTSCH 8 PIN
RECEPTACLE
1 SHFT PWR 1
WIRING SPECIFICATIONS 2 TRANS-A
WIRE DESIGNATION
PIN DESIGNATION
KEY KEY KEY
WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE 3 SHIFT-B
DESIGNATION COLOR/STRIPE
KEY GAGE DESIGNATION COLOR/STRIPE GAGE DESIGNATION COLOR/STRIPE GAGE
ALT EXC VIOLET/RED 16 INST GND BLACK 16 SHFT PWR 1 ORANGE/RED 16
BACK LT YELLOW/ORANGE 16 KEY ACC ORANGE/GRAY 16 SHFT PWR 2 ORANGE/BLACK 16 4 SHIFT STRT
BRK SOL BLUE/TAN 16 KEY STRT RED/BROWN 16 GP SW WHITE/BLUE 16
BRK SW RED/TAN 14 KEY PWR RED 12 SHIFT-B VIOLET/TAN 16
BAT-1 RED 8 OIL GAG BLUE/BROWN 16 GP SIG WHITE/GREEN 16
5 TRANS-C
BAT-2 RED 12 PS IGN ORANGE/DK GREEN 16 SHIFT STRT RED/WHITE 16
BR SW PWR ORANGE/BLUE 16 PB LT GND BLACK 16 TR LT BLUE/WHITE 16
6 TRANS-E
CLT TMP BLUE/VIOLET 16 REV AL BLUE 16 TR LT SW BLUE/WHITE 16
FUL GAG BLUE/BLACK 16 STOP LT YELLOW/RED 12 TRANS-A VIOLET/WHITE 16
GND-1 BLACK 8 ST RLY VIOLET/ORANGE 16 TRANS-B VIOLET/TAN 16 7 TRANS-D
GND-2 BLACK 12 SP-1 GRAY/ORANGE 12 TRANS-C VIOLET/GRAY 16
GAG PWR ORANGE/TAN 16 SP-2 GRAY/YELLOW 12 TRANS-D VIOLET/DK GREEN 16 13 8 SHFT PWR 2
14
HMTR GND BLACK 16 SP-3 GRAY/BLUE 16 TRANS-E VIOLET/BLUE 16
HR MTR BLUE/RED 16 STR AW VIOLET/LT GREEN 16 WORK LT YELLOW/BLUE 12
HORN
HRN PWR
ORANGE/YELLOW
ORANGE/VIOLET
16
16
STR CRB
STR PWR
VIOLET/YELLOW
ORANGE/WHITE
16
16
16
1
1
SPARE_BAT SL_SWA WL_SWA W/W_SW

SPARE_BAT
OPT_PWR
FAN/HTR
LIGHTS
GAUGES
RELAYS
STEER
HORN
30A
10A
15A
25A
10A
10A
10A
25A
25A
25A
KEY
W/W
1 GND-1
GND3
GND2
GND1
OPT3
OPT2
OPT1
BACK LT
FAN_SW
2
HTR_SW
OPT2
OPT1
OPT3
WL2
15A
15A
10A
ACC LIGHTS W/W FAN/HTR

SL_SWB
WL_SWB
3 PLUG
4 PLUG 5 OPT AUX_ELEC2 AUX_ELEC1 WARN_LT_CK REV_ALARM
SPARE_COIL GND85 SW1-87A SW2-86 SW2-87A SW1-86
5 PLUG
6 WORK LT
GND-2
WIRE DESIGNATION
7
PIN DESIGNATION
8 STOP LT
9 PS IGN
10 OIL GAG
11 CLT TMP
12
12 PRK SOL
13 TR LT SW
14 GP SW
2 10
15 GP SIG
3
16 PLUG
PLUG
17 3
N
CO
T
BA
ST
PLUG
C
18
AC
L
RE
4
NOTE: BLACK PLASTIC PANEL NOT AVAILABLE FOR
SERVICE. MUST ORDER COMPLETE INSTRUMENT
PANEL, 298-7222, FOR REPLACEMENT. PAL2240
6-12 TL642 31200255

CAB
Figure 6-4 Instrument Panel

1 298-7222 1 INSTRUMENT PANEL, (includes all items)
3 299-7132 2 STRAIN RELIEF, 90 DEGREES
5 299-0325 AR RELAY
6 299-0363 1 HOURMETER
7 303-8662 1 PARK BRAKE SWITCH, (includes item 18)
8 320-8390 1 4 IN 1 GAUGE
9 304-2613 1 HORN SWITCH, (includes item 18)
10 333-2415 1 IGNITION SWITCH
5P-8500 1 KEY
11 298-7048 1 STEER SELECT SWITCH, (includes item 18)
12 346-2984 1 RECEPTACLE
13 298-7093 1 SMALL GAUGE BRACKET
14 298-7092 1 LARGE GAUGE BRACKET
15 304-2641 1 PRE HEAT SWITCH, (includes item 17)
16 299-0860 4 BULB
17 304-2642 1 ACTUATOR
18 304-2612 3 ACTUATOR
31200255 TL642 6-13

CAB
Figure 6-5 Heating Components
LOW
HSW BAT
HSW
MED
HSW
HIG 31
HSW NOT USED
32
33 5
34 36 18
39 35
40
423 20
19
20 HOSE VIEW
524
12
38 19
6
15
16 11 13 14
21
22
23
17 24
RETURN 3 21
VIEW OF RH CONSOLE
TO SHOW HEATER VALVE MTG SUPPLY 25
26 RETURN
27
601 SUPPLY
602
201 203
17
208
207
202
201
17
PAL2112
6-14 TL642 31200255

CAB
Figure 6-5 Heating Components (Continued)
SW1-86 SW2-87A SW2-86 SW1-87A GND85 SPARE_COIL
REV_ALARM WARN_LT_CK AUX_ELEC1 AUX_ELEC2 OPT
F
E
D C
WL_SWB
SL_SWB
A B
FAN/HTR W/W LIGHTS ACC
OPT1
OPT2
OPT3
10A
15A
15A
HTR_SW
WL2
OPT1
OPT2
OPT3
328
GND1
GND2
GND3
SPARE_BAT
OPT_PWR
GAUGES
FAN/HTR
RELAYS
LIGHTS
STEER
HORN
W/W
10A
25A
25A
25A
25A
10A
10A
KEY
15A
10A
30A
W/W_SW WL_SWA SL_SWA SPARE_BAT
111
12+
OIL FUEL
LT GND TEMP
104
GND HSW
BAT HSW
BAT WSW
F
E
D
C
HIG WSW
B
A
LOW WSW BAT HSW

GND HSW
WAS WSW PAR WSW
PAR WSW 102 WAS WSW
LOW WSW
BAT WSW HIG WSW
FAN WIRING
HIG HWS
MED HWS
LOW HWS HIG HWS
BAT FAN
GND HWS MED HSW
LOW HWS
GND FAN
PAR
HIGH
GND HWS 109
WSW
3 1 WSW 103 112
LOW 2 B W WAS 113
WSW WSW
BAT WEATHER PACK CONNECTOR
WSW WIRING CHART
"A" GND FAN
"B" BAT FAN
BAT HSW
GND HSW GND HSW
BAT HSW
101 PAR WSW
WAS WSW
LOW WSW
PAR WSW HIG WSW
HIG WSW
LOW WSW
GND FAN
A B
BAT FAN
WAS WSW PAL2101
31200255 TL642 6-15

CAB
Figure 6-5 Heating Components

3 298-7041 1 HEATER UNIT, (includes items 601 & 602)
5 299-0333 2 AIR DIFFUSER VENT
6 298-7102 1 RECTANGULAR VENT
7 298-7077 2 3-WAY CONNECTOR
11 298-7098 1 HEATER CONTROL CABLE
12 298-8584 1 HEATER CONTROL PANEL
13 298-7285 1 HEATER SWITCH
14 299-0331 1 ROTARY CONTROL
15 298-7277 1 KNOB
16 298-7296 1 HOT WATER VALVE
17 298-7290 2 HEATER HOSE
18 298-7262 AR DUCT HOSE, 2”
19 298-7263 AR AIR HOSE, 2-1/2”
20 298-7931 18 HOSE CLAMP
21 298-7977 4 HOSE CLAMP
22 298-7834 1 CLAMP HALVES SET
26 298-7372 4 FLAT WASHER, 1/4
27 298-7378 4 LOCKWASHER, 1/4
31 298-8590 1 DEFROST FAN
32 298-7013 1 FAN BASE PLATE
33 298-6843 1 RUBBER GROMMET
34 298-8022 4 SOCKET HD CAPSCREW, #10-24X3/4, GR8
35 298-7844 4 WHIZ-LOCK NUT, 10-24
36 298-8589 2 VENT REDUCER
38 299-6646 1 KNOB
39 298-7102 2 RECTANGULAR VENT
40 298-1770 2 SELF TAP SCREW, #6
101 298-7051 1 WIPER/HEATER HARNESS
102 298-7052 1 WIPER/WASHER HARNESS
103 298-7053 1 HEATER HARNESS
104 298-7283 1 WIPER/WASHER SWITCH
109 299-0341 1 SHROUD CONN
111 298-7896 2 FUSE
112 298-7282 2 MALE PIN TERMINAL
113 299-0346 2 CABLE SEAL
304-2565 1 HEATER ENGINE PARTS, (includes items 201 thru 208) E

201 303-8599 2 GEAR CLAMP
202 303-8600 1 HOSE BARB
203 299-0328 1 COOLANT RESTRICTER ORAFICE
205 298-7290 1 HOSE, 5/8
206 AR CAT WICKING SEALANT
207 298-1633 1 LOOP CLAMP
208 303-8601 1 ELBOW, 90 DEGREES
328 299-0325 1 RELAY
423 298-6833 AR WEATHER STRIP TAPE
6-16 TL642 31200255

CAB
Figure 6-5 Heating Components (Continued)

524 303-4807 2 VENT WELDMENT
601 1 HEATER FAN MOTOR, (Before S/N )(no longer available, order 70023012 first
602 299-0972 2 HEATER FAN WHEEL
299-6616 1 OPEN CAB HEATER, (includes items 3, 6, 11 thru 17, 19 thru 27, 38, 101 thru
103, 111, 201 thru 208, 328 & 524)
31200255 TL642 6-17

CAB
Figure 6-6 Cab Air Conditioning
STARTER
110
113
114
GROUND
TO
CIRCUIT BOARD COMPRESSOR
ON DASH
C
A/ E
111
SI
D
112
E R
AT
HE E
105
D
SI
106
107
104 108
109
3
4
14
19
2
18 7
21
201
202
203
204
22
27 11
3
4 24
14 3 1 3
4 25
5
14 14 26
PAL3434
6-18 TL642 31200255

CAB
Figure 6-6 Cab Air Conditioning

303-4893 1 AIR CONDITIONING ASSY, ENGINE PARTS, (includes items 1 thru 22) H
1 313-5257 1 A/C COMPRESSOR BRACKET
2 305-2023 1 ADJUSTMENT BRACKET
3 298-0555 8 NUT, 3/8-16 GR2
4 298-0573 7 SOCKET HEAD CAP SCREW, 3/8-16X1-1/2
5 7X-3359 1 SOCKET HEAD CAP SCREW, 3/8-16X1-1/4
6 1 A/C DRIVE PULLEY
7 322-9668 1 BRACKET, FRONT ADJUST
11 298-1633 1 P-CLAMP, 1-3/4” ID
14 298-7365 14 WASHER, 3/8
18 325-1433 1 A/C BELT SHIELD
19 298-7374 2 WASHER, 3/8
21 314-2893 1 A/C REFRIGERANT DECAL
22 309-6819 A/R A/C SHIM
304-3171 1 AIR CONDITIONING ASSY, (includes items 101 thru 114) F

101 Ref AIR CONDINTIONING KIT, , (see Figure 6-7 for details)
104 298-7846 1 HALF CLAMP SET
105 298-7834 1 CLAMP HALVES
106 298-7835 1 STACK BOLT
107 298-7837 1 SAFETY WASHER
108 299-0949 1 COVER PLATE
110 Ref A/C WIRE HARNESS, (see Figure 10-7 for details)
111 299-0327 1 RELAY
113 298-1359 1 SCREW, 3/8-16X1
114 303-4795 1 WHIZ-LOCK NUT, 3/8-16
331-0101 1 FAN GUARD INSTALLATION, W/ A/C, (includes items 201 thru 204) A
201 311-0660 1 FAN GUARD
202 297-7030 3 HEX HD CAPSCREW, 3/8-16X7/8, GR 5
203 298-7374 3 FLAT WASHER, 3/8
204 298-7380 3 LOCK WASHER, 3/8
31200255 TL642 6-19

CAB
Figure 6-7 Air Conditioning Components
215
214
201
216
204
203
218 204
206 207
213 217
205
209
211
212 208
210
104
112 103
202
104
102
114 106
113 107
108
110 105
110
101
111
109 PAL3650
6-20 TL642 31200255

CAB
Figure 6-7 Air Conditioning Components (Continued)
2 302
STARTER
GROUND
3
TO
CIRCUIT BOARD 303 4
ON DASH
COMPRESSOR
6
5
C
A/ E
D
SI
ER
AT
HE E
301 SI
D
401
402
PAL3660
31200255 TL642 6-21

CAB

313-5260 1 AIR CONDITIONING KIT, (includes items 1 thru 6) D
1 318-9229 1 EVAPORATOR/HEATER UNIT, (includes items 101 thru 121
299-7178 1 POWER HEAD ONLY, (includes items 101 thru 105, 109 and 110)
2 318-9231 1 CONDENSOR, (includes items 201 thru 225)
3 318-9230 1 HOSE KIT, (includes items 301 thru 303)
4 318-9232 1 COMPRESSOR KIT, (includes items 401 thru 405)
5 1 THERMOSTAT SWITCH
6 1 A/C SWITCH
101 1 CASE TOP
102 1 CASE BOTTOM
103 298-7095 1 BLOWER MOTOR
104 299-0972 1 BLOWER WHEEL
105 1 HEATER/COOLER COIL
106 299-7182 1 VALVE
107 1 BULB CLAMP
108 318-9246 1 O-RING, #8
109 1 3 HOLE TOP
110 2 LEG
111 299-7179 1 THERMOSTAT
112 318-9233 2 HEATER HOSE
113 2 HEATER SPLICE
114 4 WORM GEAR CLAMP
115 1 AIR RESTRICTER, (not illustrated)
116 298-8317 1 METRO SWITCH, (not illustrated)
117 318-9234 1 12 VOLT RELAY, (not illustrated)
118 3’ DRAIN HOSE, 3/8, (not illustrated)
119 1 DRAIN ELBOW, 3/8, (not illustrated)
120 1 DRAIN TEE, 3/8, (not illustrated)
121 298-7278 1 PRESSURE SWITCH, (not illustrated)
201 318-9237 1 CASE TOP
202 1 CASE BOTTOM
203 318-9238 1 OVERHEAD CONDENSER COIL
204 2 MOUNTING BRACKET
205 298-8313 1 TUBE ASSY
206 299-7180 1 DRIER
207 1 DRIER MOUNT
208 1 O-RING
209 1 HOSE CLAMP
210 318-9239 1 TUBE ASSY
211 318-9240 1 TUBE ASSY
212 4 HOSE CLAMP
213 3 CUSHION CLAMP
214 1 HOLE PLUG
215 299-7184 2 CONDENSER FAN
216 318-9241 1 HARNESS PIGTAIL
217 1 O-RING, #8
218 2’ CLOSED CELL FOAM
219 318-9242 4 WELL NUT, (not illustrated)
220 8 NYLON INSERT NUT, 1/4-20, (not illustrated)
6-22 TL642 31200255

CAB

221 318-9243 1 RELAY, (not illustrated)
222 4 HEX HD CAPSCREW, 3/8-16X3, (not illustrated)
223 318-9244 1 HARNESS, (not illustrated)
224 4 FLAT WASHER, 3/8, (not illustrated)
225 4 LOCKWASHER, 3/8, (not illustrated)
301 318-9235 1 HOSE ASSY
302 298-8314 1 HOSE ASSY
303 318-9236 1 HOSE ASSY
401 318-9228 1 COMPRESSOR
402 299-7181 1 BELT
403 318-9245 2 O-RING, #6, (not illustrated)
31200255 TL642 6-23

CAB
6-24 TL642 31200255

SECTION 7
CONTROLS
31200255 TL642
CONTROLS
Figure 7-1 Accelerator Pedal Assembly
11
1 201
121 119
18 114
19 14
6
202
203
3
9
10 7
16 17
8
1
12
21 22
20 23 4
5
15
13
PAL0520
7-2 TL642 31200255

CONTROLS
Figure 7-1 Accelerator Pedal Assembly

299-6669 1 ACCELERATOR PEDAL ASSY, (includes items 1 thru 23) C
1 298-8790 1 ACCELERATOR PEDAL BRACKET
2 298-8593 1 ACCELERATOR PEDAL ARM
3 298-8592 1 ACCELERATOR BELL CRANK
4 298-7010 1 PEDAL
5 298-7275 1 PEDAL PAD
6 298-7064 1 FLANGE BUSHING
7 298-1753 1 FLAT WASHER
8 298-7250 1 EXTENSION SPRING
9 298-7065 1 STUD, #10-32X1-1/4
10 298-7071 2 BALL JOINT, 1/4-28
11 298-8031 1 SOCKET HD SHOULDER SCREW, 3/8X5/8
12 298-8774 1 PIVOT PIN
14 298-8164 1 ACCELERATOR CABLE, (includes items 201 thru 203)
15 298-1581 1 LOCKNUT, 1/4-20
16 298-8049 1 HEX NUT, 3/8-16
17 298-0573 1 SOCKET HD CAPSCREW, 3/8-16X1-1/2
18 298-1634 1 WAVE WASHER
19 298-7365 1 FLAT WASHER, 3/8
21 298-7379 1 LOCKWASHER, 5/16
22 298-7364 1 FLAT WASHER, 5/16
23 298-6852 2 BUSHING
119 298-7379 2 LOCKWASHER, 5/16
121 298-7373 2 FLAT WASHER, 5/16
201 304-2297 1 U-BOLT
202 304-4572 1 SADDLE
203 304-2298 2 HEX NUT
31200255 TL642 7-3

CONTROLS
Figure 7-2 Steering Column & Attaching Parts
401
402
305
201
801 304
502
501
2
601
6 111
5
120
735
1
4
PAL0601
7-4 TL642 31200255

CONTROLS
Figure 7-2 Steering Column & Attaching Parts

299-1339 1 STEERING CONTROL ASSY, (includes items 1 thru 6) A, 1
1 298-8745 1 STEERING CONTROL UNIT
303-8610 1 STEERING CONTROL UNIT SEAL KIT
2 298-8637 1 STEERING COLUMN, (includes item 201)
5 298-7380 2 LOCKWASHER, 3/8
120 298-7380 2 LOCKWASHER, 3/8
201 298-1683 1 STEERING WHEEL NUT, (torque to 29-34 lb-ft)
304 299-0562 1 SHIFTER, 4-SPEED, (includes items 501 & 502)
305 299-0560 1 STEERING WHEEL, (includes items 401 & 402)
401 299-0913 1 CENTER CAP
402 299-6632 1 SPINNER KNOB, (includes items 6 & 7)
501 2 HEX HD CAPSCREW, (torque to 30-35 lb-ft)
502 1 CLAMP SET
601 298-0403 1 SHIFTER ADAPTER HARNESS
735 Ref INSTRUMENT PANEL HARNESS, (see Figure 10-3 for details)
801 Ref SHIFTER DECAL, (see Figure 11-1 for details)
31200255 TL642 7-5

CONTROLS
Figure 7-3 Brake Pedal Assembly
13
17
1
13
17 17
11
15
10
16 14
4 7
19
6
5
121 3
119
114
PAL3032
7-6 TL642 31200255

CONTROLS
Figure 7-3 Brake Pedal Assembly

307-9870 1 POWER BRAKE ASSY, (includes items 1 thru 19) C
1 Ref POWER BRAKE VALVE, (see Figure 9-9 for details)
2 305-2026 1 BRAKE BRACKET
3 305-2025 1 BRAKE PEDAL
4 299-0208 1 PIVOT PIN
6 298-7380 1 LOCKWASHER, 3/8
7 8T-4195 4 HEX HD CAPSCREW,10-1.50X30mm, GR8.8
10 298-0522 1 CONNECTOR
11 300-6104 1 CONNECTOR
13 298-0507 2 ELBOW, 90 DEGREES, (swivel nut)
14 300-6099 1 FITTING REDUCER
15 298-8280 2 ACTUATOR
16 298-8244 1 TIE BAR
17 298-1610 3 CONNECTOR
19 AR CAT MOLYBDENUM PASTE
119 298-7379 4 LOCKWASHER, 5/16
121 298-7373 4 FLAT WASHER, 5/16
31200255 TL642 7-7

CONTROLS
Figure 7-4 Boom Joystick w/Tilt
1
16
2
3
17
18
18
5
2&4
1&3
4 3
9
2
1 4
19 6
13 11
12
7
10
15
14
PAL1080
NOTE: THE BOSCH REXROTH CORPORATION JOYSTICK

HANDLE SWITCH IS NOT A FIELD SERVICEABLE
COMPONENT. ANY ATTEMPT BY NON-FACTORY
AUTHORIZED PERSONNEL TO REPAIR OR REPLACE
THE SWITCH WILL VOID THE WARRANTY AND CAN
RESULT IN A JOYSTICK MALFUNCTION.
7-8 TL642 31200255

CONTROLS
Figure 7-4 Boom Joystick w/Tilt

298-8585 1 BOOM JOYSTICK W/TILT, (includes all items) A
1 299-0970 1 HANDLE W/ WIRE & CONNECTOR
2 299-0966 1 BENT LEVER KIT, (includes items 3 & 4)
3 1 SPRING PIN
4 1 HEX NUT
5 299-0954 1 BOOT
6 299-0953 1 CARDAN KIT, (includes item 7)
7 AR SHIM
8 298-7082 1 RETAINING PLATE
9 299-0967 1 UPPER BODY, (includes item 10)
10 1 LOWER BODY
11 1 O-RING
12 2 DOWEL PIN
13 1 O-RING
14 1 SCREW ASSY
15 1 O-RING
16 299-0960 4 PLUNGER & GUIDE KIT
17 299-7122 4 REGULATING UNIT
18 299-0209 1 SPRING, (ports 1 & 3), (pack of two)
299-0210 1 SPRING, (ports 2 & 4), (pack of two)
19 299-0834 1 GROMMET W/CABLE TIE KIT
299-0498 AR SEAL KIT, (includes items 11 thru 15)
31200255 TL642 7-9

CONTROLS
Figure 7-5 Hydraulic Controller - Outrigger, (if equipped)
4 3
7
6
8
7
10
9
1
10
PAL2020
7-10 TL642 31200255

CONTROLS
Figure 7-5 Hydraulic Controller - Outrigger, (if equipped)

299-0558 2 HYDRAULIC CONTROLLER - OUTRIGGER, (includes all items) A
1 299-0559 1 HYDRAULIC CONTROLLER, (includes one each of items 3 thru 8)
2 299-0917 1 HYDRAULIC CONTROLLER, (includes one each of items 3 thru 8)
3 299-7144 2 GRIP
4 299-0976 2 RUBBER BOOT
5 299-0915 2 LEVER OPERATION KIT
6 299-0960 2 PLUNGER KIT
7 299-0916 2 REGULATING UNIT KIT
8 299-0210 2 RETURN SPRING
9 299-0635 2 O-RING
10 299-0636 1 BOLT & NUT KIT
31200255 TL642 7-11

CONTROLS
7-12 TL642 31200255

SECTION 8
HYDRAULIC CIRCUITS
31200255 TL642
HYDRAULIC CIRCUITS
Figure 8-1 Priority Valve
4
25
20
6 7
5
29 1
28 27
26 15 30 4
16 9
19
13
TO
HYDRAULIC 8
TANK
31 4
TO JOYSTICK ASSY,
(see Figure 8-5) 11
21
23
2
24
FROM 17
HYDRAULIC
PUMP
22 18
20
PAL0680
8-2 TL642 31200255

HYDRAULIC CIRCUITS

1 Ref PRIORITY VALVE, (see Figure 9-10 for details)
2 298-1384 1 HOSE ASSY
4 298-6868 3 TEST COUPLING
15 298-1378 1 HOSE ASSY
16 298-1404 1 TUBE ASSY
17 298-0410 1 HOSE ASSY
18 Ref STEERING CONTROL ASSY, (see Figure 7-2 for details)
19 298-1403 1 TUBE ASSY
20 298-1379 1 HOSE ASSY
22 298-1405 1 TUBE ASSY
24 Ref MAIN CONTROL VALVE, (see Figure 9-6 for details)
26 298-7983 1 CLAMP SET
29 298-0496 1 SWIVEL NUT RUN TEE
30 303-4770 1 CONNECTOR
31 298-0489 1 ELBOW, 90 DEGREES
31200255 TL642 8-3

Before S/N TBK00795
HYDRAULIC CIRCUITS
Figure 8-2 Dump Circuit
16
2
17
15 20
1
12 25
13 17
14 29
18
1
TO TRANSMISSION
FROM
5 PRIORITY
4 VALVE 19
2
3 23
22
21
28
6 7 9
11
26
FROM
BOOM
JOYSTICK
10
27
PAL1350
8-4 TL642 31200255

Before S/N TBK00795
HYDRAULIC CIRCUITS

1 298-0411 1 HOSE ASSY
2 298-0412 1 HOSE ASSY
3 299-0355 2 SPLIT CLAMP HALF
4 297-7076 4 HEX HD CAPSCREW, 7/16-14X1-1/2
5 298-7381 4 LOCKWASHER, 7/16
6 298-7360 1 O-RING
7 298-0409 1 HOSE ASSY
8 Ref OIL COOLER, (see Figure 4-5 for details)
9 Ref HYDRAULIC RESERVOIR ASSY, (see Figure 9-8 for details)
10 298-1381 1 HOSE ASSY
11 298-1367 1 HOSE ASSY
13 299-0947 3 PLATE COVER
14 298-7435 3 CLAMP SET
15 304-2576 1 HOSE ASSY
16 Ref ELBOW, (see Figure 4-5 for details)
18 Ref CONNECTOR, (see Figure 4-5 for details)
19 304-2575 1 HOSE ASSY
20 298-1411 1 TUBE ASSY
22 304-2600 1 ELBOW, 90 DEGREE, (swivel nut)
27 Ref BRAKE ASSY, (see Figure 7-3 for details)
28 Ref HOSE ASSY, (see Figure 8-5 for details)
31200255 TL642 8-5

HYDRAULIC CIRCUITS
16
17
34
15 20
12 25
18
13
14 35 18
33
32
TO TRANSMISSION
FROM PRIORITY
5 VALVE 19
4 30 1 29
3 30 23
2 22
21
6 9
7 11
26
28
FROM BOOM
JOYSTICK
10
27
PAL4740
8-6 TL642 31200255

HYDRAULIC CIRCUITS

1 324-7404 1 HOSE ASSY
2 324-7403 1 HOSE ASSY
3 299-0355 2 SPLIT CLAMP HALF
4 297-7076 4 HEX HD CAPSCREW, 7/16-14X1-1/2
5 298-7381 4 LOCKWASHER, 7/16
6 298-7360 1 O-RING
7 298-0409 1 HOSE ASSY
8 Ref OIL COOLER, (see Figure 4-5 for details)
9 Ref HYDRAULIC RESERVOIR ASSY, (see Figure 9-8 for details)
10 298-1381 1 HOSE ASSY
11 298-1367 1 HOSE ASSY
13 299-0949 2 TWIN PLATE COVER
14 298-7436 2 TWIN CLAMP
15 304-2576 1 HOSE ASSY
18 Ref CONNECTOR, (see Figure 4-5 for details)
19 304-2575 1 HOSE ASSY
20 298-1411 1 TUBE ASSY
22 304-2600 1 ELBOW, 90 DEGREE, (swivel nut)
23 298-0468 1 CONNECTOR, (includes o-ring),
30 298-0467 2 ADAPTER,(includes o-ring)
32 324-7385 1 TUBE
33 324-7388 1 TUBE
34 324-7389 1 TUBE
35 324-7390 1 TUBE
31200255 TL642 8-7

HYDRAULIC CIRCUITS
Figure 8-3 Steer Select Valve
11
2
REAR AXLE
11
2
9
10
19
5 20
6 21
13
5 6
13
15
16
17
3 6
13
2
8
1
4 22 14
20 7
2
21
1
FRONT AXLE 18
12
PAL0511
8-8 TL642 31200255

HYDRAULIC CIRCUITS

2 298-0502 4 BULKHEAD UNION, 3/4-16X1/2, TUBE
3 324-7401 1 HOSE ASSY
4 324-7402 1 HOSE ASSY
6 303-4802 4 CONNECTOR, (includes item 13)
8 Ref STEER SELECT VALVE, (see Figure 9-11 for details)
9 324-7398 1 HOSE ASSY
10 324-7399 1 HOSE ASSY
12 298-1371 2 HOSE ASSY
13 298-1596 4 O-RING
14 303-8602 2 O-RING
16 298-7379 4 LOCKWASHER, 5/16
17 298-7364 4 FLAT WASHER, 5/16
19 298-7834 1 CLAMP
20 299-0949 2 COVER
22 298-7892 1 CLAMP
31200255 TL642 8-9

HYDRAULIC CIRCUITS
Figure 8-4 Service/Parking
22
24
21
19
18
23
17
15
9
14
10 2
3 4
11 13
10 11
6 7 8
1 5
12
16
2 3 4 PAL0430
8-10 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-4 Service/Parking

1 Ref FRONT AXLE ASSY, (see Figure 5-1 for details)
2 298-7839 2 CLAMP
5 298-1398 1 HOSE ASSY
6 298-7833 1 CLAMP SET
7 298-7372 1 FLAT WASHER, 1/4
9 298-7838 4 CLAMP SET
11 298-7439 4 HEX HD CAPSCREW, 5/16-18X1-3/8
12 298-1395 1 HOSE ASSY
13 298-1378 1 HOSE ASSY
14 298-1406 1 PARK BRAKE TUBE
15 315-6549 1 SERVICE BRAKE TUBE, (supply)
18 Ref PRIORITY VALVE, (see Figure 9-10 for details)
19 298-0492 1 RUN TEE, (includes o-ring)
21 298-0498 1 SWIVEL NUT BRANCH TEE
22 298-6868 1 TEST COUPLING
24 298-0525 1 HYDRAULIC FITTING
31200255 TL642 8-11

HYDRAULIC CIRCUITS
Figure 8-5 Joystick Circuit
WITH
OUTRIGGERS
TO
OUTRIGGER
16
CONTROLLER,
(see Figure 8-11)
1
2
7
15
9 6
11
2
12 2
13
14 TO HYDRAULIC WITHOUT
RESERVOIR, OUTRIGGERS
(see Figure 8-2)
4
9 5
10 10
FROM
6 OUTRIGGER
CONTROLLER,
FROM
4 PRIORITY VALVE,
(see Figure 8-11)
(see Figure 8-1)
7
8 17
9
WITHOUT
OUTRIGGERS
PAL2491
WITH
OUTRIGGERS
8-12 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-5 Joystick Circuit

4 298-1373 1 HOSE ASSY
5 298-1372 1 HOSE ASSY
6 298-1374 1 HOSE ASSY
7 298-1375 1 HOSE ASSY
8 298-1387 1 HOSE ASSY
9 298-1366 1 HOSE ASSY, (no outriggers)
303-4880 2 HOSE ASSY, (with outriggers)
11 Ref BOOM JOYSTICK, (see Figure 7-4 for details)
13 298-7378 4 LOCKWASHER, 1/4
14 298-7372 4 FLATWASHER, 1/4
15 298-0489 1 ELBOW, 90 DEGREE, LONG
16 Ref SWIVEL NUT RUN TEE, (with outriggers), (see Figure 8-11 for details)
17 Ref RUN TEE, (with outriggers), (see Figure 8-11 for details)
31200255 TL642 8-13

HYDRAULIC CIRCUITS
Figure 8-6 Lift Cylinder
15
14
16
13
12
2
2
3
11
10
19
20
7
17
19 18
4
7
5
6 PAL0410
8-14 TL642 31200255

HYDRAULIC CIRCUITS

1 Ref LIFT CYLINDER, (see Figure 9-1 for details)
2 298-1423 2 HYDRAULIC SWIVEL
3 298-1389 2 HOSE ASSY
4 325-8144 1 TUBE ASSY
5 324-7406 1 TUBE ASSY
9 298-7437 1 CLAMP SET
11 298-7439 1 HEX HD CAPSCREW, 5/16-18X1-3/8
12 Ref MALE ELBOW, (see Figure 9-1 for details)
13 298-7298 2 HOSE ASSY
14 298-7305 AR TY-WRAP
15 298-1597 2 MALE CONNECTOR, 1/8X3/16 TUBE
16 298-1612 2 LUBE FITTING, STRAIGHT 1/8
17 298-1792 1 SPECIAL TUBE CLAMP
18 297-7014 3 HEX HD CAPSCREW, 1/2-20X2
19 298-7372 6 FLAT WASHER, 1/4
20 298-1581 3 HEX LOCKNUT, 1/4-20
31200255 TL642 8-15

HYDRAULIC CIRCUITS
Figure 8-7 Extend/Retract
8
2
10
7
6
9
11
10
9
11
SEE FIGURE 8-6 FOR

CLAMP DETAILS
1 12
2
4 PAL0420
8-16 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-7 Extend/Retract

4 323-4208 1 TUBE ASSY
5 325-8140 1 TUBE ASSY
6 Ref EXTEND/RETRACT CYLINDER, (see Figure 9-2 for details)
7 324-7383 1 TUBE ASSY
8 324-7384 1 TUBE ASSY
9 298-1388 2 HOSE ASSY
10 298-1657 2 CLAMP
11 298-7249 36” NYLON SLEEVE
12 Ref TUBE CLAMP, (see Figure 8-6 for details)
8-17 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-8 Tilt & Tilt Compensating Cylinder
26
16
17
27
30
22
15
23
19 15
25
28 18
29 24
20
31
31 21
32
32 10
14
221
121 11
33 120
125
13
119 229
125 128 8
118
34
117
7
123 9
125 8
6
122
5
4
313
312 2
123
1 PAL1140
8-18 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-8 Tilt & Tilt Compensating Cylinder

4 298-1414 1 TUBE ASSY
5 325-8141 1 TUBE ASSY
6 298-1386 1 HOSE ASSY
7 298-1385 1 HOSE ASSY
8 298-0497 2 SWIVEL NUT RUN TEE, 1/2 TUBE
10 Ref COMPENSATING CYLINDER, (see Figure 9-4 for details)
13 298-1369 1 HOSE ASSY
14 298-1368 1 HOSE ASSY
15 298-1656 2 CLAMP
16 298-1472 1 TUBE ASSY
17 298-1471 1 TUBE ASSY
19 298-7438 3 CLAMP SET
20 298-7439 3 HEX HD CAPSCREW, 5/16X1-3/8
21 298-0519 2 FITTING, 90 DEGREES
22 298-0504 2 BULKHEAD FITTING, 90 DEGREES
23 303-4912 1 HOSE BRACKET
25 298-7365 2 FLAT WASHER, 3/8
26 298-1465 2 HOSE ASSY
27 298-8716 1 HOSE RETAINER
28 298-7380 2 LOCKWASHER, 3/8
29 298-8049 2 HEX NUT, 3/8-16
30 298-0501 2 BULKHEAD UNION, 9/16-18X3/8, TUBE
31 298-1466 2 HOSE ASSY
32 299-0471 2 ELBOW, 90 DEGREES
33 Ref TILT CYLINDER, (see Figure 9-3 for details)
299-0780 2 SOLENOID
118 298-8023 2 SOCKET HD CAPSCREW, 1/4-20X2-1/2, GR8
119 298-7378 2 WASHER, 1/4
120 298-8047 2 HEAVY HEX NUT, 1/4-20
125 298-7357 4 CONNECTOR
128 298-0507 1 ELBOW, 90 DEGREES
221 Ref SWIVEL NUT BRANCH TEE, (see Figure 8-5 for details)
229 Ref SWIVEL NUT RUN TEE, (see Figure 8-1 for details)
312 298-0489 1 ELBOW, 90 DEGREES
313 298-7358 1 CONNECTOR
8-19 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-9 Auxiliary Hydraulics
302
105
104
102
129
114 101
103
202
201
112
115 110 127
123 124
127
107
125
113 106
126
111
410
412
119 411
413
116
48
414 414
47
49
130 130
46
45
44
1
43
8
42 PAL0441
8-20 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-9 Auxiliary Hydraulics

8 298-0464 2 STRAIGHT THREAD CONNECTOR, (includes o-ring)
42 298-1407 1 TUBE ASSY
43 298-1408 1 TUBE ASSY
44 324-7391 1 TUBE ASSY
45 324-7392 1 TUBE ASSY
46 298-7438 1 CLAMP
48 298-7439 1 HEX BOLT, 5/16X1-3/8
49 324-7405 2 HOSE ASSY
299-1286 1 AUX HYDRAULICS ASSY, (includes items 101 thru 202) D, 8

101 298-7024 1 RETRACT SHEAVE PIN
102 298-1742 1 THRUST WASHER
104 298-7246 1 HOSE SHEAVE PULLY
105 299-6659 1 HOSE RETAINER ASSY, (includes the following items)
298-7012 1 HOSE RETAINER, R.H.
298-7067 1 PAD
298-8030 4 SOCKET FLAT HD CAPSCREW, #10-24X5/8
298-8067 4 HEX NUT, #10-24
107 298-7365 2 FLAT WASHER, 3/8
110 298-0504 2 BULKHEAD FITTING, 90 DEGREES, (includes o-ring)
111 298-0519 2 ELBOW, 90 DEGREES
112 298-8760 1 HOSE RETAINER
113 298-8049 2 HEX NUT, 3/8-16
114 298-1465 1 HOSE ASSY
115 298-0501 2 BULKHEAD UNION
116 298-1467 1 HOSE ASSY
119 298-1468 1 HOSE ASSY
123 300-6094 1 HOSE BRACKET
124 298-7438 3 CLAMP
125 299-6644 3 COVER PLATE
126 298-7439 3 HEX BOLT, 5/16X1-3/8
127 298-1656 2 HOSE CLAMP
129 298-1741 1 THRUST WASHER
130 298-0506 2 BULKHEAD FITTING
201 298-1473 1 HYDRAULIC TUBE
302 Ref PIN, (see Figure 2-3 for details)
410 300-6103 1 DUST CAP
411 300-6078 1 FEMALE QUICK DISCONNECT
412 300-6084 1 DUST PLUG
413 300-6079 1 MALE QUICK DISCONNECT
414 300-6095 2 ELBOW, 90 DEGREES
8-21 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-10 Sway Cylinder
3 8
2 5
16
17
6 10
13
1 14 121
7 15 9 12
202
PAL1331
8-22 TL642 31200255

HYDRAULIC CIRCUITS

1 Ref SWAY CYLINDER, (see Figure 9-5 for details)
2 298-8157 1 SWAY CYLINDER VALVE
5 298-1383 2 HOSE ASSY
6 298-1415 1 TUBE ASSY
7 298-1416 1 TUBE ASSY
13 298-7833 3 CLAMP SET
14 298-7372 3 FLAT WASHER, 1/4
17 298-7378 3 LOCKWASHER, 1/4
121 299-0383 1 ADAPTER BONNET
202 Ref CABLE, (see Figure 6-1 for details)
31200255 TL642 8-23

HYDRAULIC CIRCUITS
Figure 8-11 Outrigger Controller, (if equipped)
6
TO
JOYSTICK, 4 7
FROM ( see Figure 8-5) 4
JOYSTICK,
(see Figure 8-5) 3 5
15 11
14 8
TO
HYDRAULIC
RESERVOIR,
9
(see Figure 8-2)
FROM
1 PRIORITY
VALVE, 13 10
(see Figure 8-1) 12
18
11
11 16
13
17 16
PAL3330
8-24 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-11 Outrigger Controller, (if equipped)

1 Ref HOSE ASSEMBLY, (see Figure 8-5 for details)
2 298-0498 1 SWIVEL NUT BRACH TEE, (includes o-ring)
3 298-0489 1 ELBOW, 90 DEGREES, (long)
5 298-0493 1 RUN TEE, (includes o-ring)
6 Ref OUTRIGGER CONTROLLER, (see Figure 7-5 for details)
8 303-4866 1 CONTROLLER BRACKET
9 298-7363 4 FLAT WASHER, 1/4
10 298-0549 4 HEX LOCKNUT, 1/4-20
13 298-7364 6 FLAT WASHER, 5/16
17 Ref OUTRIGGER CONTROL VALVE, (see Figure 9-14 for details)
31200255 TL642 8-25

HYDRAULIC CIRCUITS
Figure 8-12 Outrigger Cylinders, (if equipped)
TO
FIGURE 8-2 1
2
3
10 4
8
FROM
FIGURE 8-1
18 13
17
8
7
19 22 16 11 12
10 6
24
15 17 7
20 5
23 6
16 18
14
21 19
20
21
PAL3350
8-26 TL642 31200255

HYDRAULIC CIRCUITS
Figure 8-12 Outrigger Cylinders, (if equipped)

3 323-5627 1 UNION TEE
11 Ref OUTRIGGER CONTROL VALVE, (see Figure 8-12 for details)
12 298-0465 2 CONNECTOR
16 298-7438 4 CLAMP SET
21 Ref OUTRIGGER CYLINDER, (see Figure 9-13 for details)
31200255 TL642 8-27

HYDRAULIC CIRCUITS
8-28 TL642 31200255

SECTION 9
HYDRAULIC COMPONENTS
31200255 TL642
S/N TBK00100 thru TBK00774
24
4
5
2
3
23 1
25
6
26
9
10
9
7
8
28
27 1
11
19
18
17
16
15
13
14
20
21
22
22
12
29
23
30
28
27 PAL0450
9-2 TL642 31200255


298-8115 1 LIFT CYLINDER, (includes items 1 thru 24) B
1 303-8620 1 CASE ASSY
2 303-8621 1 VALVE BLOCK ASSY, (includes item 3)
3 298-7087 1 VALVE, (torque to 44 lb-ft)
299-0499 1 SEAL KIT
4 304-2281 4 CAPSCREW, (torque to 10-12 lb-ft)
6 298-1646 1 LOCKNUT
7 299-0863 1 PISTON ASSY, (includes items 8 thru 11)
8 299-0864 1 PISTON
9 2 WEAR RING
10 1 CAP SEAL
11 1 O-RING
12 298-1663 1 SET SCREW
13 299-0187 1 HEAD ASSY, (includes items 14 thru 20)
14 304-2282 1 HEAD
15 1 O-RING
16 1 ROD SEAL
17 1 STEP SEAL
18 1 WEAR RING
19 1 U-CUP
20 1 CANNED WIPER
21 298-7407 1 O-RING
22 299-0188 1 SHAFT ASSY
23 304-2299 4 BUSHING
25 298-8167 1 LOWER LIFT CYLINDER PIN
26 298-8131 1 KEEPER PLATE
28 298-7392 2 HARD WASHER, 1/2
29 337-7993 1 UPPER LIFT CYLINDER PIN
30 298-1598 2 MALE ELBOW, 90 DEGREES, 3/6X1/8 TUBE
299-0501 1 SEAL KIT, (includes items 9 thru 11 & 15 thru 20)
31200255 TL642 9-3

17 18
14
14
15
18
115
19
110
113
111
13
9
7
8 9
3 22
2
21 1
10 2
9
10
4
6
20
18
18 14
208
207
205 PW0070
9-4 TL642 31200255


325-0035 1 LIFT CYLINDER, (includes items 1 thru 22), (S/N TBK00775 thru TBK00984) B
331-3800 1 LIFT CYLINDER, (includes items 1 thru 22), (S/N TBK00985 & After) A
1 1 O-RING
2 2 BACK-UP
3 1 O-RING
4 1 SEAL
5 1 SEAL
6 1 WIPER
7 1 SEAL
8 1 SEAL
9 2 WEAR RING
10 2 WEAR RING
12 341-4075 2 SET SCREW
13 341-4076 1 SELF TAPPING SCREW
14 4 LUBE FITTING
15 1 PORT PLUG
17 298-7087 1 VALVE
18 341-4078 4 BUSHING
19 1 TUBE ASSY, (no longer available; replace with both 70021957 head and
70021958 tube assy), (S/N TBK00775 thru TBK00984)
341-4081 1 TUBE ASSY, (S/N TBK00985 & After)
20 341-4074 1 ROD ASSY
21 1 HEAD, (no longer available; replace with both 70021957 head and 70021958
tube assy), (S/N TBK00775 thru TBK00984)
341-4082 1 HEAD, (S/N TBK00985 & After)
22 341-4079 1 PISTON
113 298-7392 1 HARD WASHER, 1/2
115 298-8167 1 LIFT CYLINDER PIN
207 298-7392 1 HARD WASHER, 1/2
208 337-7993 1 LIFT CYLINDER PIN
341-4080 1 SEAL KIT, (includes items 1 thru 10)
31200255 TL642 9-5

Figure 9-2 Extend/Retract Cylinder
1
2
21
3
4
5
20 4
1
19 6
18
17 7
16
8
15
14 13
12
11
10
9
PAL1530
9-6 TL642 31200255


298-7018 1 EXTEND/RETRACT CYLINDER, (includes all items except item 20 & 21) G
1 299-0855 1 CASE ASSY
2 298-7087 1 VALVE, (torque to 40-45 lb-ft)
299-0499 1 SEAL KIT
3 298-1647 1 LOCK NUT, (torque to 600-650 lb-ft)
4 2 WEAR RING
5 1 PISTON SEAL
6 313-2472 1 PISTON ASSY, (includes items 4, 5 and 7)
7 1 O-RING
8 304-2272 1 SPACER
9 304-2273 1 SHAFT
10 298-1766 1 SET SCREW, (torque to 11 lb-ft)
11 1 CANNED WIPER
12 313-2473 1 HEAD ASSY, (includes items 11, 13 thru 18), (torque to 100 lb-ft)
13 1 O-RING
14 1 U-CUP
15 1 STEP SEAL
16 1 WEAR RING
17 1 BACKUP
18 1 O-RING
19 303-8655 1 WEAR BAND
21 298-7026 1 EXTEND/RETRACT CYLINDER PIN
313-2471 1 SEAL KIT, (includes items 4, 5, 7, 11 & 13 thru 18)
31200255 TL642 9-7

15
16
18
105
136
106
12
9
6
9
21
23
2
3
4
20 1
10
8
5
7
17
22
13
19
PW0090
9-8 TL642 31200255


325-0033 1 CROWD CYLINDER, (includes items 1 thru 23) B
1 1 O-RING
2 1 O-RING
3 1 BACK-UP RING
4 1 O-RING
5 1 SEAL
6 1 SEAL
7 1 WIPER
8 1 SEAL
9 2 WEAR RING
10 2 WEAR RING
12 341-4085 1 LOCKNUT
13 341-4086 2 SET SCREW
15 341-4087 3 PORT PLUG
16 298-7087 1 COUNTERBALANCE VALVE
17 341-4088 1 WEAR PAD
18 341-4083 1 TUBE ASSY
19 341-4084 1 ROD
20 341-4091 1 HEAD
21 341-4092 1 PISTON
22 341-4089 1 COLLAR
23 341-4090 1 SPACER
136 AR CAT MOLYBDENUM PASTE
31200255 TL642 9-9

Figure 9-3 Tilt Cylinder
25
7 2
117 103
3
4
19
3
105
5
6
19
18
17
15
14
13
16 12
11
10
8
8 7
9
PAL1160
26
9-10 TL642 31200255


298-7019 1 TILT CYLINDER, (includes items 1 thru 21) J
1 298-7087 1 VALVE, (torque to 45-50 lb-ft)
299-0499 1 SEAL KIT
3 2 WEAR RING
4 1 PISTON SEAL
5 304-2284 1 PISTON
6 1 O-RING
8 299-0858 1 SHAFT ASSY
9 298-1663 1 SET SCREW, (torque to 11 lb-ft)
10 1 CANNED WIPER
11 299-0856 1 HEAD, (torque to 200 lb-ft)
12 1 O-RING
13 1 U-CUP SEAL
14 1 STEP SEAL
15 1 WEAR RING
16 1 BACKUP
17 1 U-CUP
19 299-0857 1 CASE ASSY
20 299-0861 2 BUSHING, (manganese phosphate coating)
103 298-8782 1 TILT CYLINDER PIN
117 298-7392 1 WASHER, 1/2
299-0495 1 SEAL KIT, (includes items 3, 4, 6, 10 & 12 thru 17)
31200255 TL642 9-11

16
17
14
17
19
13 11
9
403
4
9
417 22
405
1
12
7
2
21
8
6
3
5
13
20
18 PAL4780
9-12 TL642 31200255


325-0034 1 TILT CYLINDER, (includes items 1 thru 22) A
1 1 O-RING
2 1 O-RING
3 1 SEAL
4 1 SEAL
5 1 WIPER
6 1 SEAL
7 1 SEAL
8 1 WEAR RING
9 2 WEAR RING
11 341-4085 1 LOCKNUT
13 3 LUBE FITTING
14 341-4077 1 PORT PLUG
16 298-7087 1 COUNTERBALANCE VALVE
17 341-4096 2 BUSHING
18 341-4097 1 BUSHING
19 341-4094 1 TUBE ASSY
20 341-4095 1 ROD ASSY
21 341-4098 1 HEAD
22 341-4099 1 PISTON
417 298-7392 1 WASHER, 1/2
31200255 TL642 9-13

Figure 9-4 Compensating Cylinder
23 1
22
2
3
4
3
20 5
21 1
6
16
15
14
13
17
12
11
25
7
10
24 8
18
20 19
21 PAL1360
9-14 TL642 31200255

Figure 9-4 Compensating Cylinder

298-8114 1 COMPENSATING CYLINDER, (includes items 1 thru 17)
1 304-2251 1 CASE ASSY
3 2 WEAR RING
4 1 PISTON SEAL
5 304-2253 1 PISTON ASSY
6 1 O-RING
7 1 SHAFT ASSY
8 1 GREASE FITTING
9 2 GREASE FITTING
10 1 SET SCREW
11 1 CANNED WIPER
13 1 U-CUP SEAL
14 1 STEP SEAL
15 1 WEAR RING
16 1 U-CUP
17 1 O-RING
18 298-8287 1 PIN
20 298-7392 2 HARD WASHER, 1/2
22 298-8782 1 PIN
25 1 SQUARE RING
304-2627 1 SEAL KIT

304-2257 1 SEAL KIT, PISTON END, (includes items 3, 4 & 6)
304-2258 1 SEAL KIT, ROD END, (includes items 11, 13 thru 17)
31200255 TL642 9-15

16 19
1
107 4
105 3
5
1
6
15
14
13 12
11
9
10
8
7
16
106
107
9-16 TL642 31200255


298-8137 1 SWAY CYLINDER, (includes items 1 thru 16) D
1 298-8201 1 CASE ASSY
3 2 WEAR RING
4 1 PISTON SEAL
5 304-2292 1 PISTON
6 1 O-RING
8 304-3227 1 SHAFT ASSY
9 298-1663 1 SET SCREW
10 1 CANNED WIPER
12 1 O-RING
13 1 U-CUP SEAL
14 1 STEP SEAL
15 1 U-CUP SEAL
16 299-0861 3 BUSHING
105 298-7035 1 SWAY CYLINDER PIN
106 298-7034 1 SWAY PIN
299-0496 1 SEAL KIT (includes items 3, 4, 6, 10 & 12 thru 15)
31200255 TL642 9-17

15
14
11
15
105
13
107 16
12
9
4
9
18 1
5
2
19
8
6
8
3
7
14
17
106
15
107 PY2041
9-18 TL642 31200255


325-0036 1 SWAY CYLINDER, (includes items 1 thru 19) A
1 1 O-RING
2 1 O-RING
3 1 SEAL
4 1 SEAL
5 1 SEAL
6 1 SEAL
7 1 WIPER
8 2 WEAR RING
9 2 WEAR RING
11 2 O-RING
12 341-4085 1 LOCKNUT
14 3 LUBE FITTING
15 3 BUSHING
16 1 TUBE ASSY
17 1 ROD ASSY
18 1 PISTON
19 1 HEAD
1 SEAL KIT, (includes items 1 thru 9)
31200255 TL642 9-19

Figure 9-6 Main Control Valve
9-20 TL642 31200255

Figure 9-6 Main Control Valve

298-1365 1 MAIN CONTROL VALVE, (no outrigger), (includes items 1 thru 51 & 56) C
310-8321 1 MAIN CONTROL VALVE, (with outrigger), (includes items 1 thru 51 & item 56) A
1 304-2270 1 INLET COVER ASSY, (includes item 2)
2 329-9751 1 MAIN RELIEF, 4000PSI, (includes items 3, 4 & 5)
3 1 O-RING
4 1 BACKUP RING
5 1 O-RING
6 304-2294 1 VALVE SECTION ASSY, (Lift), (includes one each of items 13 & 25
and two of item 7)
7 303-8609 5 LOAD CHECK PLUG, (includes items 8 thru 12)
8 10 O-RING
9 10 BACKUP RING
10 10 O-RING
11 10 BACKUP RING
12 10 O-RING
13 304-4564 3 HYDRAULIC REMOTE POSITIONER, (includes items 14 thru 24)
14 24 HEX HD CAPSCREW, 1/4-20X3
15 24 LOCKWASHER, 1/4
16 6 BEARING PLATE
17 6 BONNET
18 6 SEAL
19 3 SPOOL POSITIONER
20 3 WASHER
21 3 SPRING, (large)
22 3 SPRING, (small)
23 3 STOP SLEEVE
24 3 STOP COLLAR
25 316-9020 3 HYDRAULIC REMOTE POSITIONER, (includes items 14 thru 18)
26 304-2295 1 VALVE SECTION ASSY, (Crowd), (includes one each of items 7, 13, 25 & 56)
27 329-9754 2 RELIEF CARTRIDGE, 4300 PSI, (includes items 8 thru 12)
28 304-3228 1 VALVE SECTION ASSY, (Tilt), (includes one each of items 13 & 25 and two
of item 27)
29 303-8623 1 VALVE SECTION ASSY, (Sway), (includes one each of items 30 & 41 and two
each of 7 & 37)
30 303-8605 2 SPOOL POSITIONER ASSY, (includes items 31 thru 36)
31 4 SCREW
32 4 WASHER
33 2 BONNET
34 2 SPOOL COLLAR
35 4 SPRING COLLAR
36 2 SPRING
37 303-8606 4 SPOOL SEAL KIT, (includes items 38 thru 40)
38 4 RETAINER
39 4 WASHER
40 4 SEAL
41 303-8607 2 SPOOL RETAINER, (includes items 42 & 43)
42 4 WASHER
43 4 SCREW
31200255 TL642 9-21

Figure 9-6 Main Control Valve (Continued)

44 304-2247 1 VALVE SECTION ASSY, (Aux), (includes one each of items 30 & 41 and two
each of 37 & 45)
46 304-2271 1 OUTLET COVER ASSY, (no outrigger), (includes item 47)
1 OUTLET COVER ASSY, (with outrigger), (includes items 47 & 55)
47 304-3813 1 PLUG, (no outrigger)
2 PLUG, (with outrigger)
48 3 HEX HD CAPSCREW
49 3 HEX NUT
50 7 O-RING
51 17 O-RING
52 3 CARRIAGE BOLT, 5/16-18X3
53 298-7373 3 FLAT WASHER, 5/16
54 3 HEX LOCKNUT, 5/16-18
55 1 PLUG
304-2248 1 VALVE SECTION SEAL KIT, (includes items 50 & 51)

304-2249 1 STUD KIT, (no outrigger, (includes items 48 & 49)
1 STUD KIT, (with outrigger), (includes items 48 & 49)
304-2269 1 MAIN RELIEF SEAL KIT, (includes items 3, 4 & 5)
304-2250 5 PLUG SEAL KIT, (includes items 8 thru 12)
9-22 TL642 31200255

Figure 9-6 Main Control Valve (Continued)

9-23 TL642 31200255

Figure 9-7 Implement Pump
15
5
7
10
13
12
9
2
6
3
10 7
9
12
13
11
14 1 PAL1460
9-24 TL642 31200255

Figure 9-7 Implement Pump

298-7247 1 IMPLEMENT PUMP, (includes all items) B
1 304-2630 1 SHAFT END COVER ASSY
2 304-3205 1 PORT END COVER ASSY
3 304-3206 1 GEAR HOUSING
4 304-2629 1 GEAR SHAFT SET
5 304-2335 4 CAPSCREW
6 304-2246 2 DRIVE SCREW
7 304-2651 4 DOWEL PIN
8 304-2628 1 NAME PLATE
9 298-7294 2 THRUST PLATE
10 2 O-RING
11 1 LIP SEAL
12 2 CHANNEL SEAL
13 2 BACK-UP SEAL
14 304-3807 1 SPLINE ADAPTER
15 304-3806 4 WASHER
31200255 TL642 9-25

Figure 9-8 Hydraulic Tank Assembly
509
510
26
516 21 28
29
30
16
1 17
10
3
118 9
8
7
134
119 13
12
2 27
609
24 23
25 PAL0401
9-26 TL642 31200255

Figure 9-8 Hydraulic Tank Assembly

299-6615 1 HYDRAULIC TANK ASSY, (includes items 1 thru 30) E, 7
1 303-4808 1 HYDRAULIC RESERVOIR
2 299-0376 1 FLUID LEVEL GAUGE, (includes mounting hardware)
3 298-1417 1 OIL FILTER
108-1153 1 FILTER ELEMENT (PTI TECH. #FSE-070-KC-B)
303-8617 1 BAR GAUGE
7 298-8588 1 FILLER CAP
8 298-8135 1 FILL TUBE
10 298-8587 1 TANK FILTER
12 298-0515 1 CONNECTOR
13 299-0379 TANK FILTER
16 305-2033 1 CONNECTOR
26 331-2386 1 ADAPTER
27 298-0518 1 MALE PIPE FITTING
29 341-2967 1 HOSE
30 303-8599 1 CLAMP
119 298-7367 3 FLAT WASHER, 1/2
134 298-7382 3 LOCKWASHER, 1/2
509 299-0310 1 BREATHER
510 298-1695 1 BULKHEAD
516 298-1370 1 BREATHER HOSE
609 304-2601 1 ELBOW, 45 DEGREES
31200255 TL642 9-27

Figure 9-9 Brake Valve
21 22
20
19
18 17
16
23
14 24
49
13
50
25
15
26 14
15
17 27
28
30
31 32 33
16
22 29
51 48
47
46 32
52
41 34
35
45 43 40
39
44 38
37
36
1
2
3
4
6
5
8
7 9
11
10 12 53
PAL3591
9-28 TL642 31200255

Figure 9-9 Brake Valve

344-1586 1 POWER BRAKE VALVE, (includes items 1 thru 52) B
1 304-3213 1 SCREW
2 299-0192 2 PIN
3 317-0601 2 SPRING
4 299-7131 2 WIPER
5 317-0602 1 COVER
6 299-7130 2 WIPER
7 317-0603 1 COVER
8 299-0191 2 QUAD RING
9 317-0604 2 PISTON
11 2 PIN
12 304-3211 2 SPRING
13 298-8175 1 BALL
14 304-3212 4 PLUG
15 298-1796 4 O-RING
16 298-1797 2 O-RING
17 299-0985 2 BACKUP RING
18 304-3214 1 DUMP PISTON
19 304-3215 1 DUMP SPOOL
20 317-0607 1 SPRING
21 304-3216 1 PLUG
22 298-8303 2 O-RING
23 317-0608 1 INLET SEAT
24 317-0609 1 O-RING
25 317-0610 1 RETAINER
26 317-0611 1 SPRING
27 299-0194 1 PISTON
28 299-0193 1 SEAT
29 317-0612 1 BALL
30 317-0613 1 SPRING
31 317-0614 1 SPRING
32 298-8302 3 O-RING
33 317-0615 1 PLUG
34 317-0616 2 NEEDLE ROLLER
35 317-0617 2 MAKE-UP CHECK
36 304-3209 2 PLUG
37 298-1794 2 O-RING
38 317-0618 2 SPRING
39 317-0619 2 SPRING GUIDE
40 317-0620 2 SPRING
41 317-0621 2 ORIFICE
43 317-0622 2 SPRING
44 317-0623 1 PLUG
45 317-0624 1 O-RING
46 317-0625 1 PLUG
47 317-0626 1 O-RING
48 317-0627 1 ORIFICE
49 317-0628 1 PLUG
31200255 TL642 9-29

Figure 9-9 Brake Valve (Continued)

50 317-0629 1 PLUG
51 1 HOUSING
52 2 SPOOL
53 2 POPPET
9-30 TL642 31200255

Figure 9-9 Brake Valve (Continued)

31200255 TL642 9-31

3
4
2
6 PAL2320
9-32 TL642 31200255


299-0322 1 PRIORITY VALVE ASSY, (includes items 1 thru 9) C
1 1 VALVE BODY
2 298-8170 1 CHECK VALVE CARTRIDGE
1 SEAL KIT
3 304-2260 1 COIL ASSY
1 SEAL KIT
5 304-2263 1 RELIEF VALVE CARTRIDGE
299-0505 1 SEAL KIT
6 304-3218 1 ORIFICE PLUG
7 304-2262 1 RELIEF VALVE CARTRIDGE
299-0505 1 SEAL KIT
8 303-8666 1 COMPENSATOR CARTRIDGE
1 SEAL KIT
9 304-2261 1 REDUCING VALVE CARTRIDGE
299-0506 1 SEAL KIT
107 298-7380 3 LOCKWASHER, 3/8
31200255 TL642 9-33

9
7 8
3
7
7
6
1
PAL1310
9-34 TL642 31200255


303-5004 1 STEER SELECT VALVE, (includes all items)
1 304-4579 1 STEERING MANIFOLD
2 303-8566 4 CAPSCREW
3 304-2657 1 STEERING CONTROL, (includes items 7 thru 9)
5 304-3208 4 CAPSCREW
6 304-3818 2 O-RING
7 303-8565 1 SEAL KIT
8 303-8658 2 SOLENOID
9 304-2646 2 HAND NUT
31200255 TL642 9-35

Figure 9-12 Quick Coupler Cylinder
11
13
14
12
10
8
PAL2840
9-36 TL642 31200255

Figure 9-12 Quick Coupler Cylinder

295-3419 1 QUICK COUPLER CYLINDER, (includes all items)
1 315-3678 1 CASE ASSEMBLY
6 315-3680 2 ROD ASSEMBLY
8 315-3679 2 HEAD ASSEMBLY
9 2 WIPER RING
10 2 SEAL
11 2 PISTON SEAL
12 2 O-RING
13 2 O-RING
14 2 BACKRING
31200255 TL642 9-37

Figure 9-13 Outrigger Cylinder, (if equipped)
26
24
25
27
21
22
22
23 19
28
17 20
20
1
2
3
4
18
5
6
4
7
2
9 8
10
11
12
13
14
15
16
17
18
PAL0850
9-38 TL642 31200255

Figure 9-13 Outrigger Cylinder, (if equipped)

299-1323 1 OUTRIGGER CYLINDER ASSY, (includes all items) A
1 298-6909 1 OUTRIGGER CYLINDER, (includes items 2 thru 18)
2 305-2106 1 BARREL, (includes item 18)
3 305-5459 1 LOCKNUT, (torque to 1300-1350 lb-ft)
4 2 WEAR RING
5 1 PISTON SEAL
6 305-2088 1 PISTON
7 1 O-RING
8 1 O-RING
9 1 BACK-UP RING
10 305-5431 1 CAPSCREW
11 305-2089 1 HEAD
12 1 WEAR RING
13 1 STEP SEAL
14 1 U-CUP
15 1 CANNED WIPER
16 305-2087 1 SHAFT ASSY, (includes item 18)
18 305-2090 2 BUSHING
19 298-6906 1 OUTRIGGER CYLINDER VALVE, (includes items 20 thru 23)
20 298-1645 2 O-RING
21 298-6844 1 THERMAL RELIEF VALVE
22 299-7116 2 VALVE SEAL KIT
23 299-0852 1 CHECK CARTRIDGE
25 2 O-RING
27 298-7380 3 LOCKWASHER, 3/8
28 299-0396 1 ORIFICE, (C2 port)
315-1126 1 SEAL KIT, (includes items 4, 5, 6, 8, 9, 10, 13, 14 & 15)
31200255 TL642 9-39

Figure 9-14 Outrigger Control Valve, (if equipped)
18
17
11 10 20
5 15
14
21
24 6
6 13
15 12
9
8
16
11
4 5
2
26 25
3 27
7
8 28
9
15
16 19 23
15 1
17
20
18 PAL3490
9-40 TL642 31200255

Figure 9-14 Outrigger Control Valve, (if equipped)

304-2573 1 OUTRIGGER CONTROL VALVE B
1 1 INLET COVER ASSY, (includes items 2 thru 5)
2 1 PLUG
3 3 SQUARE SEAL
4 9 O-RING
5 2 PLUG
6 2 VALVE SECTION ASSY, (Outriggers), (includes two of item 3, six of item 4
and items 7 thru 20)
7 2 SPOOL
8 4 O-RING
9 4 SEAL RETAINER
10 2 STRIPPER BOLT
11 4 WASHER
12 2 TUBE
13 2 SPRING
14 2 SPRING
15 8 O-RING
16 4 TUBE
17 4 END CAP
18 8 SOCKET HD CAPSCREW, 4-1/2
19 2 PLUG
20 4 PLUG
21 1 OUTLET COVER ASSY, (includes one of item 5)
22 4 STUD ASSY, (includes items 23 & 24)
23 8 HEX NUT
24 4 STUD
25 1 O-RING
26 1 BACK-UP RING
27 1 GASKET
28 1 O-RING
29 1 O-RING
299-0523 1 VALVE SECTION SEAL KIT, (includes items 3 & 4)

1 R/V SEAL KIT, (includes items 25 thru 27)
1 REMOTE SEAL KIT, (includes two of item 8 and four of item 15)
1 WORK VALVE SEAL KIT, (includes three of item 3, two of item 8, four of item 15,
item 28 and 29)
31200255 TL642 9-41

9-42 TL642 31200255

SECTION 10
ELECTRICAL
31200255 TL642
ELECTRICAL
Figure 10-1 Battery & Cables
157
156
6
7
156
10 173
157 6
174
155
174
7
PAL1450
10-2 TL642 31200255

ELECTRICAL
Figure 10-1 Battery & Cables

6 298-7841 2 WHIZ-LOK NUT, 5/16-18
7 298-6850 2 HOLD DOWN STUD, 5/16-18
8 175-4390 1 BATTERY, (12 volt, 1000 amps), TOP STUD,
3/8-16 UNC THREAD, BCI GROUP 31
10 298-6925 1 BATTERY HOLD DOWN
155 298-0404 1 NEGATIVE BATTERY CABLE, (battery to frame)
156 298-0405 1 NEGATIVE BATTERY CABLE, (frame to starter)
157 298-0406 1 POSITIVE BATTERY CABLE
173 303-4795 1 WHIZ-LOK NUT, 3/8-16
174 298-7853 2 TERMINAL NUT
31200255 TL642 10-3

ELECTRICAL
Figure 10-2 Battery Disconnect Option
EXISTING NUT, WASHER,

AND GROUND STUD.
155
156
1
3
2
4
PAL1490
10-4 TL642 31200255

ELECTRICAL
Figure 10-2 Battery Disconnect Option

304-2592 1 BATTERY DISCONNECT OPTION, (includes all items) A
1 303-4749 2 SCREW, 1/4-20X3/4
2 298-0549 2 HEX LOCKNUT, 1/4-20
3 298-7363 2 FLAT WASHER, 1/4
4 303-4828 1 BATTERY DISCONNECT SWITCH
304-4563 1 BATTERY DISCONNECT KEY
5 303-4829 1 BATTERY DISCONNECT BAR
6 303-4831 1 BATTERY DISCONNECT MOUNT
31200255 TL642 10-5

ELECTRICAL
Figure 10-3 Engine Harness
16
X16 20
21 15
22 16
B A
SP1 SP2 17
16 AWG "PS IGN" TO X2 "PS IGN" TO X21 16 AWG "BRK SOL" TO X5 16 AWG
16 AWG "BRK SOL" TO X2
16 AWG "PS IGN" TO X8 "PS IGN" TO X25 16 AWG "BRK SOL" TO X12 16 AWG
C
B
A
SPLICE INFORMATION
X15
X14
1
2 X5 14
18 14 15
3 19 15
4 X12 16
16
X1
A B
B A
DIODE
X13
X2
SP2 SP1
2
3
4 DIODE
5
6
X1
CONN WIRE
COLOR GAUGE TYPE TO X6
POS
1
DESIGNATION
BAT-1 RED 8 AWG GXL X19 X3 X4
2 HR MTR BLU/RED 16 AWG GXL X21
3
4
HORN
FUL GAG
ORA/YEL
BLU/BLK
16 AWG
16 AWG
GXL
GXL
X6
X13
7 7 9
5 ST RLY VIL/ORA 16 AWG GXL X9 8 8 10
6
7
BAT-2
SP-1
RED
GRY/ORA
12 AWG
12 AWG
GXL
GXL
X19
X14 28 28 11
8 SP-2 GRY/YEL 12 AWG GXL X14
9 ALT EXC VIL/RED 16 AWG GXL X27
10 SP-3 GRY/BLU 16 AWG GXL X14
11 STR AW VIL/GRN 16 AWG GXL X4
12 STR CRB VIL/YEL 16 AWG GXL X3 X10 X11
13 TRANS-B VIL/TAN 16 AWG GXL X5 X7 10 X9
14 TRANS-A VIL/WHT 16 AWG GXL X5
12
15
16
TRANS-C
TRANS-D
VIL/GRY
VIL/DGN
16 AWG
16 AWG
GXL
GXL
X5
X5 X8 13
17 TRANS-E VIL/BLU 16 AWG GXL X5
18 REV AL BLUE 16 AWG GXL X16 X5
CONN WIRE
COLOR GAUGE TYPE TO
POS DESIGNATION
X2 1 TRANS-A VIL/WHT 16 AWG GXL X1
CONN WIRE 2 TRANS-B VIL/TAN 16 AWG GXL X1
COLOR GAUGE TYPE TO
POS DESIGNATION 3 TRANS-C VIL/GRY 16 AWG GXL X1
1
2
GND-1
BACK LT
BLACK
YRL/ORN
8 AWG
16 AWG
GXL
GXL
X17
X15
4 TRANS-D VIL/DGN 16 AWG GXL X1 X9
5 TRANS-E VIL/BLU 16 AWG GXL X1 TERM WIRE
3 PLUG - - - - COLOR GAUGE TYPE TO
6 BRK SOL BLU/TAN 16 AWG GXL SP2 # DESIGNATION
4 PLUG - - - - 7 TR LT SW BLU/WHT 16 AWG GXL X2 1 ST RLY VIL/ORA 16 AWG GXL X1 X13
5 PLUG - - - - 8 GND-9 BLACK 16 AWG GXL X17 GND-6 BLACK 16 AWG GXL X10 CONN WIRE
2 COLOR GAUGE TYPE TO
6 WORK LT YEL/BLU 16 AWG GXL X15 POS DESIGNATION
9 GND-10 BLACK 16 AWG GXL X17 GND-6 BLACK 16 AWG GXL X8
7 GND-2 BLACK 12 AWG GXL X17 A FUL GAG BLU/BLK 16 AWG GXL X1
10 GND-11 BLACK 16 AWG GXL X17 3 START SOL RED/VIL 10 AWG GXL X18
8 STOP LT YEL/RED 16 AWG GXL X15 B GND-4 BLACK 16 AWG GXL X17
11 GND-12 BLACK 16 AWG GXL X17 4 ST RLY PWR ORANGE 10 AWG GXL X19
9 PS IGN ORN/DGN 16 AWG GXL SP1 12 GND-13 BLACK 16 AWG GXL X17
10
11
OIL GAG
CLT TMP
BLU/BRN
BLU/VIL
16 AWG
16 AWG
GXL
GXL
X20
X26 X10 X14
CONN WIRE
12
13
BRK SOL
TR LT SW
BLU/TAN
BLU/WHT
16 AWG
16 AWG
GXL
GXL
SP2
X5
X6 TERM
#
WIRE
DESIGNATION
COLOR GAUGE TYPE TO POS DESIGNATION
COLOR GAUGE TYPE TO
TERM WIRE - SP-1 GRY/ORA 12 AWG GXL X1

COLOR GAUGE TYPE TO 1 GP SIG WHT/GRN 16 AWG GXL X2
14 GP SW WHT/BLU 16 AWG GXL X21 # DESIGNATION - SP-2 GRY/YEL 12 AWG GXL X1
GND-6 BLACK 16 AWG GXL X17
15 GP SIG WHT/GRN 16 AWG GXL X10 1 HORN ORA/YEL 16 AWG GXL X1 2 - SP-3 GRY/BLU 16 AWG GXL X1
16 PLUG - - - -
3 GLOW PLG ORN/RED 8 AWG GXL X24
17 PLUG - - - -
18 PLUG - - - - X7 4 GP RLY ORN/BLU 8 AWG GXL X11 X15
CONN WIRE
CONN WIRE COLOR GAUGE TYPE TO
POS DESIGNATION
X3
POS DESIGNATION
COLOR GAUGE TYPE TO
X11 A BACK LT YRL/ORN 16 AWG GXL X2
A FP PWR RED/GRN 16 AWG GXL X11 TERM WIRE
COLOR GAUGE TYPE TO B STOP LT YEL/RED 16 AWG GXL X2
CONN WIRE B FP RLY WHT/GRN 16 AWG GXL X8 # DESIGNATION
COLOR GAUGE TYPE TO C WORK LT YEL/BLU 16 AWG GXL X2
POS DESIGNATION GP PWR RED/GRN 8 AWG GXL X19
1 STR CRB VIL/YEL 16 AWG GXL X1 1 D GND-16 BLK 16AWG GXL X17
FP PWR RED/GRN 16 AWG GXL X7
2 GND-7 BLACK 16 AWG GXL X17 X8 2 GP RLY ORN/BLU 8 AWG GXL X10 X16
CONN WIRE
POS DESIGNATION
COLOR GAUGE TYPE TO CONN WIRE
COLOR GAUGE TYPE TO
POS DESIGNATION
X4 1 (30)
2 (85)
FP RLY
GND-6
WHT/GRN
BLACK
16 AWG
16 AWG
GXL
GXL
X7
X9
X12 A REV AL BLUE 16 AWG GXL X1
CONN WIRE CONN WIRE B GND-5 BLACK 16 AWG GXL X17
COLOR GAUGE TYPE TO 3 (87A) - - - - - COLOR GAUGE TYPE TO
POS DESIGNATION POS DESIGNATION
1 STR AW VIL/GRN 16 AWG GXL X1 4 (87) FUEL PUMP WHT/VIL 16 AWG GXL X22 A BRK SOL BLU/TAN 16 AWG GXL SP2
5 (86) PS IGN ORN/DGN 16 AWG GXL SP1
2 GND-8 BLACK 16 AWG GXL X17 B GND-3 BLACK 16 AWG GXL X17 PAL1031
10-6 TL642 31200255

ELECTRICAL
Figure 10-3 Engine Harness (Continued)
GND POWER
MOLDED
TWO POSITION
CONNECTOR
TIE WRAP
MOLDED DIODE
16 DIODE
22 INSTALLATION
X21 24 (TYP) 3-PLCS
X20
25
32
X24 29
X26 X27
X28
X17
X23 X25
30 7
31 X22 8
28
X18
X19 X21
CONN WIRE
COLOR GAUGE TYPE TO
POS DESIGNATION
A HR MTR BLU/RED 16 AWG SXL X1
B PS IGN ORN/DGN 16 AWG SXL SP1
C GP SW WHT/BLU 16 AWG SXL X2
X17 X22
TERM WIRE CONN WIRE
COLOR GAUGE TYPE TO COLOR GAUGE TYPE TO
# DESIGNATION POS DESIGNATION
1 GND-1 BLACK 8 AWG GXL X2 1 FUEL PUMP WHT/VIL 16 AWG GXL X8
GND-3 BLACK 16 AWG GXL X12 2 GND-15 BLACK 16 AWG GXL X17
2
3
GND-5
GND-6
BLACK
BLACK
16 AWG
16 AWG
GXL X16
GXL X10
X23
GND-7 BLACK 16 AWG GXL X3 CONN WIRE
COLOR GAUGE TYPE TO
4 POS DESIGNATION
1 PS IGN ORN/DGN 16 AWG GXL X25
5 2 GND-14 BLACK 16 AWG GXL X17
6
GND-12 BLACK 16 AWG GXL X5 X24
GND-13 BLACK 16 AWG GXL X5 CONN WIRE
GND-14 BLACK 16 AWG GXL X23 POS DESIGNATION
GND-15 BLACK 16 AWG GXL X22 1 GLOW PLG ORN/RED 8 AWG GXL X10
8
9 GND-16 BLACK 16AWG GXL X15 X25
TERM WIRE
COLOR GAUGE TYPE TO
# DESIGNATION
X18 PS IGN ORN/DGN 16 AWG GXL SP1
TERM WIRE 1
COLOR GAUGE TYPE TO PS IGN ORN/DGN 16 AWG GXL X23
# DESIGNATION
1 START SOL RED/VIL 10 AWG GXL X9
X26
X19 TERM
#
WIRE
DESIGNATION
COLOR GAUGE TYPE TO
TERM WIRE 1 CLT TMP BLU/VIL 16 AWG GXL X2
COLOR GAUGE TYPE TO
# DESIGNATION
ALT BAT 1 RED/WHT 8 AWG GXL X28
1
ALT BAT 2 RED/WHT 8 AWG GXL X28 X27
BAT-1 RED 8 AWG GXL X1 TERM WIRE
BAT-2 RED 12 AWG GXL X1 # DESIGNATION
ST RLY PWR ORANGE 10 AWG GXL X9 1 ALT EXC VIL/RED 16 AWG GXL X1
3
GP PWR RED/GRN 8 AWG GXL X11
X28
X20 TERM WIRE
COLOR GAUGE TYPE TO
TERM WIRE # DESIGNATION
COLOR GAUGE TYPE TO ALT BAT 1 RED/WHT 8 AWG GXL X19
# DESIGNATION
1 OIL GAG BLU/BRN 16 AWG GXL X2
1
ALT BAT 2 RED/WHT 8 AWG GXL X19 PAL1041
31200255 TL642 10-7

ELECTRICAL
Figure 10-3 Engine Harness

298-0400 1 PERKINS ENGINE HARNESS, (includes all items) D
1 1 CONNECTOR
2 303-4983 2 NUT
4 303-8663 2 STRAIN RELIEF
5 1 CONNECTOR
6 1 PLUG
8 299-6641 3 TERMINAL
10 304-2650 2 TERMINAL
11 299-0944 1 COVER
12 299-0945 1 CONNECTOR
13 304-3822 1 RELAY, (Fuel Pump)
14 299-0340 2 CONNECTOR
15 299-0349 3 TERMINAL
16 299-0346 5 SEAL
17 305-2115 1 CONNECTOR
18 299-0908 1 CONNECTOR
19 299-7106 1 LOCK CONNECTOR
20 304-2610 1 CONNECTOR
21 304-2623 1 TPA
22 2 TERMINAL
24 299-6640 1 CONNECTOR
25 299-7096 1 TPA
28 304-2240 3 SEAL
29 334-4098 1 CONNECTOR
30 304-2606 1 CONNECTOR
31 305-5449 1 WEDGE
32 303-4997 1 DIODE
10-8 TL642 31200255

ELECTRICAL
Figure 10-3 Engine Harness (Continued)

31200255 TL642 10-9

ELECTRICAL
Figure 10-4 Transmission Harness
SP3 "GND-9" TO Y1 16 AWG

16 AWG "GND-9" TO X5
"GND-9" TO Y2 16 AWG
8 3
SP4 4
Y5
16 AWG "GND-11" TO X5
Y4
3
4
Y6
3
8 4
1
2
8 3
4
X5
Y2
SP3 SP4 5
6
7
X29
8 3
4
Y1
3
4
Y3
8
Y4
CONN WIRE
COLOR GAUGE TYPE TO
POS DESIGNATION
A TRANS-D VIL/DGN 16 AWG GXL X5
B GND-11 BLACK 16 AWG GXL SP4
GND POWER
MOLDED
TWO POSITION
Y5 Y1 TIE WRAP
CONNECTOR
CONN WIRE
POS DESIGNATION COLOR GAUGE TYPE TO
POS DESIGNATION
A TRANS-E VIL/BLU 16 AWG GXL X5 DIODE
A TRANS-A VIL/WHT 16 AWG GXL X5
B GND-11 BLACK 16 AWG GXL SP4 INSTALLATION
B GND-9 BLACK 16 AWG GXL SP3 (TYP) 6-PLCS
Y6 X5
CONN WIRE
Y2 CONN WIRE
COLOR GAUGE TYPE TO
COLOR GAUGE TYPE TO CONN WIRE POS DESIGNATION
POS DESIGNATION COLOR GAUGE TYPE TO 1 TRANS-A VIL/WHT 16 AWG GXL Y1
POS DESIGNATION
A BRK SOL BLU/TAN 16 AWG GXL X5
A TRANS-B VIL/TAN 16 AWG GXL X5 2 TRANS-B VIL/TAN 16 AWG GXL Y2
B GND-12 BLACK 16 AWG GXL X5
B GND-9 BLACK 16 AWG GXL SP3 3 TRANS-C VIL/GRY 16 AWG GXL Y3
4 TRANS-D VIL/DGN 16 AWG GXL Y4
5 TRANS-E VIL/BLU 16 AWG GXL Y5
6 BRK SOL BLU/TAN 16 AWG GXL Y6
7 TR LT SW BLU/WHT 16 AWG GXL X29
X29 Y3 8 GND-9 BLACK 16 AWG GXL SP3
CONN WIRE 9 GND-10 BLACK 16 AWG GXL Y3
POS DESIGNATION COLOR GAUGE TYPE TO 10 GND-11 BLACK 16 AWG GXL SP4
POS DESIGNATION
A TR LT SW BLU/WHT 16 AWG GXL X5
A TRANS-C VIL/GRY 16 AWG GXL X5 11 GND-12 BLACK 16 AWG GXL Y6
B GND-13 BLACK 16 AWG GXL X5
B GND-10 BLACK 16 AWG GXL X5 12 GND-13 BLACK 16 AWG GXL X29
PAL1050
10-10 TL642 31200255

ELECTRICAL
Figure 10-4 Transmission Harness

303-4752 1 TRANSMISSION HARNESS, (includes all items) A
2 304-2647 1 CONNECTOR LOCK
3 5 CONNECTOR
4 5 TERMINAL
6 1 TERMINAL
7 1 SEAL
8 303-4997 6 MOLDED DIODE
31200255 TL642 10-11

ELECTRICAL
Figure 10-5 Auxiliary Electrics
A
211
212 B
213
** unknown **
** unknown **
4
YES
GROUND(YELLOW)
3
9112-5077
12-5077
B
202
C 218
219
220
C 217
202
204
205
VIEW C-C 211
QC VALVE HARN. TO BOOM HARN
201 212
QC VALVE HARNESS
WIRE COLOR
WIRE
COLOR
WIRE
DESIGNATION 213
BLACK QC PWR
YELLOW
RED QC PWR
YELLOW NO CONN
BLUE QC GND
BROWN QC PWR QC PWR
ORANGE QC GND YELLOW YELLOW
PLUG EXTRA
F B
BLACK
A
E C
D
PLUG
202 QC GND
BROWN QC GND
BROWN
105 101
104
SPARE_BAT
OPT_PWR
FAN/HTR
GAUGES
RELAYS
LIGHTS
STEER
HORN
30A
10A
15A
25A
10A
10A
10A
25A
25A
25A
KEY
W/W
GND3
GND2
GND1
1 2
OPT3
OPT2
OPT1
FAN_SW
OIL
12+
B+ FUEL
HTR_SW
OPT3
OPT2
OPT1
WL2
15A
15A
10A
ACC LIGHTS W/W FAN/HTR +

SL_SWB
WL_SWB
D
GR
LT GND
G TEMP
OPT AUX_ELEC2 AUX_ELEC1 WARN_LT_CK REV_ALARM 4 3

BAT C
AC
BAT
ST
IGN
IGN
IGN QA
VALVE
202
103
VIEW A-A VIEW D-D
TIE WRAP TO
EXSISTING PACKARD METRI-PAK
DASH HARNESS CONNECTION #1
8 NO CONN.
7 GND
6
DESIGNATION
DESIGNATION
QC GND
TERMINAL #
WIRE
5 GND
4 QC GND
3 QC PWR
2 PWR
1 QC PWR
1
202
D
D
** unknown **
** unknown **
4
YES
VIEW B-B
1
9112-5077
PAL1481
10-12 TL642 31200255

ELECTRICAL
Figure 10-5 Auxiliary Electrics

299-1297 1 AUXILIARY ELECTRICS, (includes all items) E, 6
1 298-7047 1 AUXILIARY FRAME WIRING HARNESS
101 300-6092 1 DASH HARNESS
103 298-7221 1 CONDURA SWITCH
104 299-0325 1 RELAY
105 298-7848 1 FUSE, 10A
201 298-7070 1 TUBE WELD
202 298-7072 1 AUXILIARY WIRING HARNESS
205 298-7374 1 FLAT WASHER, 3/8
211 298-7839 3 CLAMP
212 299-6645 3 COVER PLATE
213 298-7440 6 HEX HD CAPSCREW, 1/4-20X1-3/8
217 298-0434 1 QUICK CHANGE HARNESS
218 298-7437 1 CLAMP
219 299-6644 1 COVER PLATE
31200255 TL642 10-13

ELECTRICAL
Figure 10-6 Tilt Electronics
TILT CYLINDER
14
5000
203
PSI

COMPENSATING
CYLINDER
15
WL_SWB
SL_SWB

OPT3
OPT1
OPT2
10A
15A
15A
HTR_SW
WL2
FAN_SW
-TILT PWR- RHEOSTAT TILT UP

OPT1
OPT3
OPT2
CONNECT TO TILT DWN

GND1
GND2
GND3
4300
PSI
OPT-2 RED WIRE
SPARE_BAT
OPT_PWR
GAUGES
FAN/HTR
RELAYS
4300
STEER
LIGHTS
HORN
W/W
KEY
PSI
25A
25A
25A
10A
10A
10A
25A
15A
10A
30A
YELLOW WIRE
W/W_SW WL_SWA SL_SWA SPARE_BAT 8 7
B
A
16 -TILT PWR 1- -TILT PWR-
MAIN CONTROL
CROWD VALVE TILT -TILT PWR 2-
SECTION
A
B
SOLENOID
VALVE
13 201
T
A
B
P -TILT UP- -TILT DWN-
TO 'BV'
ON PRIORITY
BLOCK
105
106
ROCKER SWITCH
ON JOYSTICK GND 15
RHEOSTAT GND 16
12
CONNECT TO
EXISTING
OPT-2 +
CAB GND.
LOCATION
12 VOLTS TILT UP TILT DWN
GND 16 GND 15
ELECTRIC/HYDRAULIC
SCHEMATIC
"T" "P"
202 PAL2230
10-14 TL642 31200255

ELECTRICAL
Figure 10-6 Tilt Electronics

7 298-7308 1 BULLET TRMINAL
8 299-0324 1 FULLY INSULATED BULLET RECEPTACLE
12 298-8152 1 HARNESS ASSEMBLY
13 298-7079 1 TILT HARNESS
14 299-0325 1 BOSCH RELAY
15 298-7849 1 FUSE, 15 AMP
16 298-7850 1 FUSE, 30 AMP
106 298-7385 1 STAR LOCK WASHER
201 Ref BOOM JOYSTICK w/TILT, (see Figure 7-4 for details)
202 Ref SOLENOID VALVE, (see Figure 8-8 for details)
203 Ref INSTRUMENT PANEL, (see Figure 6-4 for details)
31200255 TL642 10-15

ELECTRICAL
Figure 10-7 A/C Harness
GND
1
GND
RLY 87
2
3 H A
GND GND 4
RLY 85 AC SW GND 5
RLY 85 6
E B
RLY 30 RLY 87 FAN SW C
RLY 30 FAN SW C
PRS SW
AC SW
C
PRS SW RLY 85 PAL3460
WIRE CHART
WIRE WIRE WIRE WIRE END WIRE END WIRE END WIRE END WIRE END WIRE END WIRE END WIRE END
DESIGNATION COLOR/STRIPE GAGE G H REMARKS
A B C D E F
RLY 87 ORANGE 16 WEATHER PACK 1/4 FEMALE SPADE CONDENSOR TO RELAY
RLY 30 RED 16 1/4 FEMALE SPADE 1/4 FEMALE SPADE DASH CIRCUIT BOARD TO RELAY
RLY 85 BLUE 16 1/4 FEMALE SPADE 1/4 FEMALE SPADE WEATHER PACK RELAY TO PRESSURE SWITCH TO COMP. CLUTCH
PRS SW VIOLET 16 1/4 FEMALE SPADE 1/4 FEMALE SPADE PRESSURE SWITCH TO THERMOSTATIC SWITCH
AC SW YELLOW 16 1/4 FEMALE SPADE 1/4 FEMALE SPADE AC SWITCH TO THERMOSTATIC SWITCH
1/4 FEMALE SPADE
FAN SW C GREEN 16 AC SWITCH TO FAN C
1/4 FEMALE SPADE
GND BLACK 16 WEATHER PACK 1/4 FEMALE SPADE 1/4 FEMALE SPADE RING 3/8 SCREW RING 3/8 SCREW GROUND
10-16 TL642 31200255

ELECTRICAL
Figure 10-7 A/C Harness

298-8284 1 A/C HARNESS, (includes items 1 thru 6) E
1 299-0339 2 SHROUD
2 299-0349 2 TERMINAL
3 299-0346 2 CABLE SEAL
4 299-0341 2 SHROUD
5 298-7282 2 TERMINAL
6 299-0347 2 CABLE SEAL
31200255 TL642 10-17

ELECTRICAL
Figure 10-8 Cab Work Light Harness
5 1
4
2
3
PY1770
10-18 TL642 31200255

ELECTRICAL
Figure 10-8 Cab Work Light Harness

328-1548 1 CAB WORK LIGHT HARNESS, (includes all items)
1 303-4696 2 TERMINAL
2 303-4970 2 TERMINAL
3 334-5871 1 TERMINAL
4 323-7236 1 TERMINAL
5 298-7252 2 WIRE, 16 GA, BLACK
31200255 TL642 10-19

ELECTRICAL
10-20 TL642 31200255

SECTION 11
DECALS
31200255 TL642
DECALS
Figure 11-1 Cab & Frame Decals
23
7
19 1
2
3
4
5
6
7
17 39 18 8
VIEW D-D 4
5
VIEW E-E
VIEW F-F
E E
16 24 13
A B
VIEW B-B
14
8
A B
101
D
VIEW A-A
34
D
42
F
C 3
F
16
VIEW C-C C
31 20
20
21 21
33
28 32 30
PAL2313
OPEN CAB ENCLOSED CAB
11-2 TL642 31200255

DECALS
Figure 11-1 Cab & Frame Decals

305-3767 1 DECAL INSTALLATION, ENGLISH, (includes items 1 thru 42 on Figure 11-1 and 9
all items on Figure 11-2)
314-5304 1 DECAL INSTALLATION, ISO, (includes items 1 thru 42 on Figure 11-1 andall 1
items on Figure 11-2)
314-2351 1 DECAL INSTALLATION, FRENCH, (includes items 1 thru 42 on Figure 11-1 and 1
3 1 SERIAL NO. NAME PLATE
4 313-6241 1 LUBRICATION CHART DECAL
5 313-6242 1 MAINTENANCE CHART DECAL
7 314-6696 1 LOAD CHART BOOKLET, W/O OUTRIGGERS, ENGLISH UNIT G
314-6032 1 COVER, ENGLISH UNIT E
344-7172 1 STANDARD CARRIAGE, ENGLISH UNIT A
315-8700 1 SIDE TILT, ENGLISH UNIT A
314-6031 1 SIDE-SWING, ENGLISH UNIT A
314-6697 1 SIDE SHIFT, ENGLISH UNIT B
312-2615 1 TRUSS BOOM, ENGLISH UNIT A
313-4359 1 STANDARD BUCKETS, ENGLISH UNIT A
314-6030 1 MULTI-PURPOSE, ENGLISH UNIT A
339-9620 1 LIFTING HOOK, ENGLISH UNIT G
339-9609 1 LOAD CHART BOOKLET, W/O OUTRIGGERS, METRIC UNIT B
314-5306 1 COVER, METRIC UNIT A
314-5307 1 STANDARD CARRIAGE, METRIC UNIT A
314-5308 1 SIDE TILT, METRIC UNIT A
314-5309 1 SIDE SWING, METRIC UNIT A
314-5310 1 SIDE SHIFT, METRIC UNIT A
314-5311 1 TRUSS BOOM, METRIC UNIT A
314-5312 1 STANDARD BUCKET, METRIC UNIT A
1 MULTI-PURPOSE, METRIC UNIT A
339-9595 1 LIFTING HOOK, METRIC UNIT B
315-4601 1 LOAD CHART BOOKLET, W/OUTRIGGERS, ENGLISH UNIT B
315-4603 1 COVER, ENGLISH UNIT A
315-4609 1 SIDE SHIFT, ENGLISH UNIT A
339-9603 1 MULTI-PURPOSE, ENGLISH UNIT B
339-9594 1 LIFTING HOOK, ENGLISH UNIT B
315-4615 1 LOAD CHART BOOKLET, W/OUTRIGGERS, METRIC UNIT B
339-9604 1 MULTI-PURPOSE, METRIC UNIT B
339-9596 1 LIFTING HOOK, METRIC UNIT B
31200255 TL642 11-3

DECALS
Figure 11-1 Cab & Frame Decals (Continued)

321-2484 1 LOAD CHART BOOKLET, W/WINCH, ENGLISH UNIT A
321-2493 1 WINCH, ENGLISH UNIT A
321-2504 1 LOAD CHART BOOKLET, W/WINCH, METRIC UNIT A
321-2512 1 MULTI-PURPOSE, METRIC UNIT A
321-2513 1 WINCH, METRIC UNIT A
321-2494 1 LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, ENGLISH UNIT A
321-2503 1 WINCH, ENGLISH UNIT A
321-2514 1 LOAD CHART BOOKLET, W/OUTRIGGERS, W/WINCH, METRIC UNIT A
321-2522 1 MULTI-PURPOSE, METRIC UNIT A
321-2523 1 WINCH, METRIC UNIT A
8 303-4906 1 REAR PANEL CAT DECAL
13 298-8438 1 OIL LEVEL DEAL
14 303-4962 1 HYDRAULIC OIL DECAL
16 303-4963 4 TIE-DOWN DECAL
17 303-4946 1 TIP OVER DECAL, ENGLISH
314-5324 1 TIP OVER DECAL, ISO
314-2338 1 TIP OVER DECAL, FRENCH
18 303-4941 1 ELECTROCUTION HAZARD DECAL, ENGLISH
314-5321 1 ELECTROCUTION HAZARD DECAL, ISO
11-4 TL642 31200255

DECALS
Figure 11-1 Cab & Frame Decals (Continued)

314-2339 1 ELECTROCUTION HAZARD DECAL, FRENCH
19 303-4949 1 CRUSH HAZARD WARNING DECAL, ENGLISH
314-5315 1 CRUSH HAZARD WARNING DECAL, ISO
314-2340 1 CRUSH HAZARD WARNING DECAL, FRENCH
20 303-4948 1 NO RIDERS DECAL, ENGLISH
314-5316 1 NO RIDERS DECAL, ISO
314-2341 1 NO RIDERS DECAL, FRENCH
23 303-4939 1 BATTERY DECAL, ENGLISH
314-5318 1 BATTERY DECAL, ISO
314-2343 1 BATTERY DECAL, FRENCH
24 303-4942 1 ROTATING PARTS DECAL, ENGLISH
314-5322 1 ROTATING PARTS DECAL, ISO
314-2344 1 ROTATING PARTS DECAL, FRENCH
27 305-3791 1 DASH DECAL KIT, RH, (includes items 28 thru 33), ENGLISH
314-5317 1 DASH DECAL KIT, RH, (includes items 28 thru 33), ISO
314-2350 1 DASH DECAL KIT, RH, (includes items 28 thru 33), FRENCH
28 303-4950 1 TIP OVER DECAL, ENGLISH
314-5320 1 TIP OVER DECAL, ISO
314-2345 1 TIP OVER DECAL, FRENCH
30 303-4945 1 RUN OVER DECAL, ENGLISH
314-5327 1 RUN OVER DECAL, ISO
314-2346 1 RUN OVER DECAL, FRENCH
31 303-4944 1 READ MANUAL DECAL, ENGLISH
314-5323 1 READ MANUAL DECAL, ISO
314-2347 1 READ MANUAL DECAL, FRENCH
32 303-4947 1 MACHINE ROLL DECAL, ENGLISH
314-5325 1 MACHINE ROLL DECAL, ISO
314-2348 1 MACHINE ROLL DECAL, FRENCH
33 298-1844 1 BOOM OPERATION DECAL
34 303-4909 1 CAT IGNITION SWITCH DECAL
35 323-5609 1 WARNING ETHER STARTING DECAL, ISO
39 299-0354 1 TILT ANGLE GAUGE
42 303-4819 1 CAT LOGO DECAL
46 330-4923 1 NO ETHER DECAL
323-5609 1 NO ETHER DECAL
101 298-1694 1 SHIFTER DECAL
31200255 TL642 11-5

DECALS
Figure 11-2 Boom Decals
29
36
43 E E
44
45
29
80°
70°
60°
°
50
°
40
30°
20°
-10° 0° 10°
12 1
VIEW E-E
22
29
29
-10°
PAL2301
11-6 TL642 31200255

DECALS
Figure 11-2 Boom Decals

305-3767 1 DECAL INSTALLATION, ENGLISH, (includes items 1 thru 46 on Figure 11-1 and 6
314-5304 1 DECAL INSTALLATION, ISO, (includes items 1 thru 46 on Figure 11-1 andall 1
items on Figure 11-2)
314-2351 1 DECAL INSTALLATION, FRENCH, (includes items 1 thru 46 on Figure 11-1 and 1
1 303-4883 1 TL642 CAT LH BOOM DECAL
2 303-4884 1 TL642 CAT RH BOOM DECAL
12 298-0576 1 BOOM ANGLE DECAL
22 303-4940 1 CARRY PERSONNEL DECAL, ENGLISH
314-5319 1 CARRY PERSONNEL DECAL, ISO
314-2342 1 CARRY PERSONNEL DECAL, FRENCH
29 303-4943 5 PINCH POINT DECAL, ENGLISH
314-5326 5 PINCH POINT DECAL, ISO
314-2349 5 PINCH POINT DECAL, FRENCH
36 320-7883 1 PENDULUM
43 320-7882 1 SPACER
44 298-7365 1 WASHER, 3/8
45 309-6301 1 HEX LOCKNUT, 3/8-16
47 330-5286 2 GOOSENECK 6 DECAL
31200255 TL642 11-7

DECALS
11-8 TL642 31200255

SECTION 12
OPTIONS
31200255 TL642
OPTIONS
Figure 12-1 Block Heater Installation
PAL1260
12-2 TL642 31200255

OPTIONS
Figure 12-1 Block Heater Installation

299-6648 1 BLOCK HEATER INSTALLATION, (includes item 1) A
1 303-4841 1 BLOCK HEATER
31200255 TL642 12-3

OPTIONS
Figure 12-2 8” Winch
12-4 TL642 31200255

OPTIONS
Figure 12-2 8” Winch

298-8596 1 WINCH, 8” DRUM, (includes all items)
1 304-2302 1 GEAR CASE
2 304-4573 1 LOCK SET A
3 304-3182 1 LOCK SET B
4 304-4577 1 CABLE DRUM, 8”
5 1 BRAKE DRUM
6 304-2304 1 GEAR CASE COVER
7 304-4578 1 CABLE DRUM SHAFT, 8”
8 304-2305 1 WORM SHAFT, (includes item 10)
9 304-2306 1 WORM GEAR
10 1 WORM
11 304-4575 6 CABLE DRUM SHAFT KEY
12 304-3183 1 LOCK SEAT A BUSHING
13 304-2307 2 BUSHING
14 304-2308 4 STUD BOLT, 1/2X1-1/2
15 304-2309 2 COLLAR
16 1 BRAKE PLATE
17 1 BRAKE HOUSING
18 1 BRAKE DRUM
19 1 ADJUSTING BOLT
20 1 ADJUSTING NUT
21 1 SPRING SEAT
22 1 ROLLER
23 2 BRAKE LINING
24 1 BRAKE PLATE A
25 2 BRAKE PLATE B
26 1 FIXING PLATE
27 304-2318 1 OIL FILL PLUG
28 304-2319 1 BEARING SHIM
29 303-8650 2 BEARING HUB GASKET
30 304-2320 1 GEAR CASE GASKET
31 1 O-RING
32 304-2322 2 WASHER
33 304-2323 1 BUSHING
34 2 SEAL
35 304-2324 2 WORM SHAFT KEY
36 304-2325 1 WORM SHAFT KEY
37 1 SPRING
38 1 BRAKE DRUM SPRING
39 304-2266 1 MOTOR MOUNT ADAPTER
40 304-3812 1 COUPLER, WINCH SHAFT
42 303-8651 2 BEARING
43 2 V.C. TYPE LOCK RING
44 304-2328 1 OIL LEVEL PLUG
45 304-2329 1 OIL DRAIN PLUG
46 304-2267 1 COUPLER SPACER
47 303-8652 2 BEARING HUB
48 303-8653 2 OIL SEAL
49 8 CAP SCREW, 3/8X1-1/2
31200255 TL642 12-5

OPTIONS
Figure 12-2 8” Winch (Continued)

50 8 LOCK WASHER
52 5 NUT
53 304-3184 1 HEX HD CAPSCREW, 3/8X1
54 301-3185 1 LOCK WASHER
55 301-3186 1 HEX HD CAPSCREW, 3/8X1
56 1 BRAKE COVER GASKET
57 304-2334 2 OIL SEAL
58 304-3817 1 LOCK SEAT GASKET
320-4875 1 BRAKE LINING ASSY, (includes items 5, 16 thru 26, 31, 34, 37, 38, 43, 49, 50,
52 & 56)
12-6 TL642 31200255

OPTIONS
Figure 12-2 8” Winch (Continued)

31200255 TL642 12-7

OPTIONS
Figure 12-3 Winch Motor
12-8 TL642 31200255

OPTIONS
Figure 12-3 Winch Motor

303-8656 1 WINCH MOTOR, (includes all items)
1 304-3192 1 DUST SEAL
2 1 SPLIT WIRE RING
3 1 METAL BACKUP SHIM
4 1 HIGH PRESSURE SEAL
5 1 METAL BACKUP SHIM
6 1 TEFLON BACKUP SHIM
7 1 SHAFT SEAL
8 304-3193 1 BODY SEAL KIT
9 1 SEAL CARRIER
10 1 THRUST WASHER
11 304-3194 1 THRUST BEARING
12 304-3195 1 DRIVE LINK
13 304-3196 1 MID MOUNT WEAR PLATE
14 304-3197 1 ROTOR KIT
15 304-3198 1 DRIVE LINK PIN
16 304-3199 1 END COVER
17 304-3200 1 BOLT SET
18 304-3201 1 HOUSING
19 304-3202 1 COOLING PLUG
20 304-3203 1 SHAFT, (includes item 21)
21 304-3204 1 KEY

304-2268 1 SEAL KIT, (includes items 9 & 10)
31200255 TL642 12-9

OPTIONS
Figure 12-4 Pressure Reducer Valve - 1360 PSI
PAL1220
12-10 TL642 31200255

OPTIONS
Figure 12-4 Pressure Reducer Valve - 1360 PSI

298-7099 1 PRESSURE REDUCER VALVE, 1360 PSI, (includes all items)
1 304-3189 1 PRESSURE REDUCING CARTRIDGE
2 304-3188 1 CHECK CARTRIDGE
3 1 O-RING
4 1 O-RING
5 1 O-RING
304-3187 1 SEAL KIT, (includes items 3, 4 & 5)
31200255 TL642 12-11

OPTIONS
Figure 12-5 Pintle Hook Installation
1
2
3
4
PAL2170
12-12 TL642 31200255

OPTIONS
Figure 12-5 Pintle Hook Installation

304-2660 1 PINTLE HOOK INSTALLATION, (includes items 1 thru 4) B
1 Ref COUNTERWEIGHT, (see Figure 1-1 for details)
2 299-0361 1 PINTLE HOOK
3 298-7922 4 HEX HD CAPSCREW, 1/2-13X1-3/4
4 298-7382 4 LOCKWASHER, 1/2
31200255 TL642 12-13

OPTIONS
Figure 12-6 Fender Option
10 10 10
11 12 11
14
9
13
1
2
4
6
7
8
1
3
5
6
7
8
PAL0090
12-14 TL642 31200255

OPTIONS
Figure 12-6 Fender Option

299-6673 1 FENDER OPTION, (includes all items) A
1 298-8604 4 FENDER
2 298-8791 1 RIGHT REAR FENDER MOUNT
3 298-8792 1 LEFT REAR FENDER MOUNT
4 299-0544 1 LEFT FRONT FENDER MOUNT
5 299-0546 1 RIGHT FRONT FENDER MOUNT
6 298-8290 16 FENDER STUD
7 298-1849 16 HEX NUT, M12X1.25
8 298-7382 16 LOCKWASHER, 1/2
9 298-7373 24 FLAT WASHER, 5/16
10 300-6108 24 FLAT WASHER, 5/16
13 298-1578 24 HEX LOCKNUT, 5/16-18
14 298-0565 8 PLUG
31200255 TL642 12-15

Before S/N TBK00706
OPTIONS
Figure 12-7 Work Light Package
VIEW A-A
7
5 9
11 10
16
DOME LT
3
2
8 LIGHT-1
11
GND L
GND DL
13
1 1 14
4 4 A A
11 11
6
A
B
15 15 17
9
10
B
A
GND L
GND L1 LIGHT-2
WORK LT
STOP SW GND L
LIGHT SW
DOME LT
STOP LT
GND LT
IND LT
17
WORK LT
LIGHT-1
LIGHT SW
17
12
STOP LT
STOP SW
101
102
103
104
105
106
A
B
BACK-LT
STOP-LT 111 STOP SW
C WORK-LT/TAIL-LT
401 STOP LT
A MIRROR-LT 402
B GND
403
GND 2 404
111 405
108 406
B A
109 407
110
107
C
B
A
GND 1
114
STOPLIGHT SWITCH
MTG. ON BRAKE
TERMINAL A GREEN
TERMINAL B RED
ASSEMBLY
TERMINAL C BLACK
A BACK-LT
B STOP-LT
C TAIL-LT PAL3080
12-16 TL642 31200255

Before S/N TBK00706
OPTIONS
Figure 12-7 Work Light Package (Continued)
BACK-LT
STOP-LT
TAIL-LT 201
GND-1
GND-2
202 204
205
206
203
A
B
C
A
B
B
C
C
208
209
210
A BACK-LT
B STOP-LT
C WORK-LT/TAIL-LT
GND L1
LIGHT SW
REF: LIGHT HARNESS WORK LT IND LT
(9140-3305) LIGHT-1
GND L
LIGHT-2
301 302
B A
GND L
B A
DOME LT
12+
OIL FUEL
R
+
D
GR
GND DL
WORK
LIGHTS GND
F 80
QUARTZ
FUEL
OI
LT TEMP
E 0 W/W_SW
SPARE_BAT
240 16 SL_SWA WL_SWA
TEMP VOLTS
SPARE_BAT
OPT_PWR
0 0 0 0 0 0
GAUGES
RELAYS
FAN/HTR
LIGHTS
STEER
HORN
W/W
10A
25A
KEY
10A
25A
25A
30A
10A
15A
25A
10A
- +
100 10
BA C
T AC
303
BAT
4X4 ST
OFF
IG
OPT1
OPT3
OPT2
N N
15A
15A
10A
304
IG
RUN
ACC
IGN
START
IGNITION
4X2
MACHINE MUST BE OPT AUX_ELEC2 AUX_ELEC1 WARN_LT_CK REV_ALARM
IN NEUTRAL AND
PARK BRAKE ON
TO START
STOP LT
OTHER CONNECTORS
REMOVED FOR CLARITY
STOP SW
A MIRROR-LT
REF: ENGINE HARNESS B GND
(G6-42A 9147-3101) B A
(TF6-42 9150-3060)
A BACK-LT
A BACK-LT
B STOP-LT
B STOP-LT
C WORK-LT/TAIL-LT
C TAIL-LT
C
C
B
B
DASH PANEL
A
A
FRONT
WORK PARK
GND L1
FRONT
WORK REF: TAIL LIGHT HARNESS
LIGHT
(9140-3306)
WORK
LIGHT BRAKE
LIGHT LIGHT IND LT
(ON CAB) INDICATOR (ON CAB)
HOUR METER
DATCON
P/N 56458-10
OIL FUEL WORK LIGHT
12 UDC CARLING SWITCH
P/N V1D1S00BAZC00-000
1 2
PARK BRAKE 8 7
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 1 4 GND 12V
8 7
5
2
GND
1 4
6
3
G
TEMP 2 5
LIGHT SW
WORK LT
3 6
3
4 IN 1 GAGE
BEEDE
DEUTSCH P/N HD-36-24-18-PN
DEUTSCH P/N HD-34-24-18-SN
A B A B
STEER
LIGHT
HORN
LIGHT
LIGHT-2
LIGHT-1
GND L
IGNITION SWITCH STEER SELECT

GND L
POLLACK P/N 31-610 CARLING SWITCH

P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH 8 7
BAT ACC
P/N VJD1S00BAZC00-000
8 7 1 4 REV AL 18 REV AL
STRT TRANS-E 17 TRANS-E
1 4 2 5
TRANS-D 16 TRANS-D
2 5 3 6 TRANS-C 15 TRANS-C
IGN
TRANS-A 14 TRANS-A
3 6
TRANS-B 13 TRANS-B
STR CRB 12 STR CRB
STR AW 11 STR AW
SP-3 10 SP-3
ALT EXC 9 ALT EXC
TRANS
TEMP SP-2 8 SP-2
WARN
LIGHT SP-1 7 SP-1
6
FRONT
BAT-2 BAT-2
WORK
ST RLY 5 ST RLY LIGHT
FUL GAG 4 FUL GAG
HORN 3 HORN
HR MTR 2 HR MTR
MIRROR-LT
BAT-1 1 BAT-1
GND
CAB FIREWALL
GND L
GND L
A B
LIGHT SW LIGHT-2 18
17
GND L1 16
LIGHT SW
WORK LT
15
IND LT 14
MIRROR-LT
TR LT SW 13 TR LT SW
GND
12 REV AL
BRK SOL BRK SOL
CLT TMP 11 CLT TMP BACK-UP
GND 1 ALARM
SWI-86 SW2-87a SW2-86 SW1-87a GND 85 SPARE_COIL OIL GAG 10 OIL GAG
PS IGN 9 PS IGN
8 GND 2
STOP LT STOP LT
O
A P
GND-2 7 GND-2
GND-5
WORK LT 6 WORK LT WORK LT
B Q C
C R
5 GROUND
4 STOP LT (AT
D B
STARTER
S 3
E MOTOR)
D1 T BACK LT 2 BACK LT BACK LT A
GND-1 1 GND-1
10 OHM D5 (10A) (15A) (15A)
30W D2 D3 D4
R1 OPT-1 OPT-2 OPT-3
DEUTSCH P/N HD-36-24-18-SN
DEUTSCH P/N HD-34-24-18-PN
87 87 87 87 87
GND L1
OPT-1
OPT-2
OPT-3
87a 87a 87a 87a 87a

BACK LT
STOP LT
GND L
GND L
86 85 86 85 86 85 86 85 86 85
TAIL LT
30 REV 30 30 30 30
ALARM WARN AUX
F AUX ELEC2 OPT
LT CK ELEC1
G
GND1 GND2 GND3
SL
STOP LT
SWB
GND L A B C
WL U
SWB V
WL2 D7 D8 D9
LIGHT-1
D6
GND DL
87 87 87 87
HTR FAN 87a 87a 87a 87a

86 85 86 85 86 85 86 85
SW SW 30 30 30 30
BACK-UP STOP TAIL

H LIGHT
(GREEN)
LIGHT
(RED)
LIGHT
(BLACK)
W REAR TAIL LIGHT

ASSEMBLY
X
I
J
K
L
Y
M MOTOROLA (25A) (25A) (25A) GND

MR 752 (25A) (10A) (10A) (10A) (15A) (10A) (30A)
D10 FAN/HTR W/W LIGHTS RELAYS SPARE HORN
OR EQUIV GAGES STEER BAT KEY OPT_PWR AA
N
BAT
IND LT
WL_SWA SL_SWA GND DL

W/W_SW SPARE_BAT
DOME LT
DOME LT
DOME
WORK LT DOME LIGHT
LIGHT
STOP LT
STOP SW STOP SW SWITCH
ELECTRICAL SCHEMATIC PAL3090

STOPLT SW
31200255 TL642 12-17

Before S/N TBK00706
OPTIONS

299-6670 1 WORK LIGHT PACKAGE, (includes items 1 thru 304) E
1 299-0338 2 UTILITY FLOOD LIGHT
299-0849 2 BULB
2 298-0528 1 INTERIOR LIGHT
3 298-6911 1 MOUNTING UNIT
4 298-1773 2 MOUNTING BOLT
5 298-8045 2 SELF TAPPING SCREW, #8-32X3/8
6 299-0341 2 WEATHER PACK SHROUD
8 298-1583 3 LOCKWASHER, #8
10 299-0347 5 CABLE SEAL
12 298-7044 1 LIGHT HARNESS
13 298-1627 3 PAN HD SCREW, #8-32X3/8
14 298-8068 3 HEX NUT, #8
15 298-1755 2 SPACER
16 299-0850 1 GROMMET, RUBBER
17 298-8744 3 ECONOMY WIRING DUCT
18 AR CAT RTV SILICON SEALANT, (not shown)
101 298-6857 1 TAIL LIGHT HOUSING
102 298-6858 1 TAIL LIGHT BRACKET
103 299-6654 1 TAIL LIGHT ASSY, (includes items 401 thru 407)
105 298-1593 1 FLAT WASHER, 3/4
106 298-1587 1 LOCKWASHER, 3/4
107 298-8614 1 STOPLIGHT MOUNTING TAB
109 299-0347 3 CABLE SEAL
111 298-7045 1 TAIL LIGHT HARNESS
114 298-6866 1 STOPLIGHT SWITCH
201 299-0338 1 UTILITY FLOOD LIGHT
202 298-8128 1 FLOOD LIGHT BRACKET
205 299-0349 2 FEMALE PIN TERMINAL
206 299-0347 2 CABLE SEAL
209 298-8049 2 HEX NUT, 3/8-16
210 303-4798 2 LOCKWASHER, 3/8
301 298-8766 1 TOGGLE SWITCH
302 298-1761 1 WORK LIGHTS DECAL
303 298-7896 1 FUSE, 25 AMP
304 299-0325 1 RELAY
401 298-6860 1 TAIL LIGHT
402 298-7302 38” BLACK WIRE, 16 GA.
403 298-7303 38” GREEN WIRE, 16 GA.
12-18 TL642 31200255

Before S/N TBK00706
OPTIONS

404 298-7303 38” RED WIRE, 16 GA.
405 298-7306 3 BUTT CONNECTOR
406 298-7291 45” WIRE LOOM
407 298-6860 1 TAIL LIGHT
31200255 TL642 12-19

OPTIONS
11 301
1 302
12 6
23 303
305
201 304 306
202
15 203
15 204
205
15
15
307
A
308
4 309
14 13 310
A 23
8
17 16 26 27
5
7
28
F 80
QUARTZ FUEL OI
E 0
240 16
SPARE_BAT
TEMP
OPT_PWR
FAN/HTR
VOLTS
LIGHTS
GAUGES
RELAYS
STEER
0 0 0 0 0 0
HORN
30A
10A
15A
25A
10A
10A
10A
25A
25A
25A
KEY
W/W
- +
100 10
GND3
GND2
GND1
OPT3
OPT2
OPT1
4X4
FAN_SW
HTR_SW
OPT2
OPT1
OPT3
WL2
15A
15A
10A

SL_SWB
WL_SWB
4X2
OPT AUX_ELEC2 AUX_ELEC1 WARN_LT_CK REV_ALARM
3
2
7
VIEW A-A VIEW B-B
18
101
102 8
103
21 9
22 25
20 19
VIEW OF R.H. CONSOLE

10
24
B
1
4
B 6
9
14 PAL2714
12-20 TL642 31200255

OPTIONS
BEACON WORK LIGHT

SWITCH SWITCH
X3 X2
1
2
3
7
8
2
3
7
8
4
6
BEACON
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
BCN PWR
WORK LT
CAB LT
WORK LT PWR
CAB LT PWR
X7
BEACON 1 BEACON
2 BCN GND
X5
1 CAB LT CAB LT 1
REAR CAB CAB LT GND CAB LT GND
2 2
WORK LIGHT
FRONT CAB
X6 WORK LIGHTS
CAB LT 1
CAB LT GND 2
X4
"SL_SWA" ON CIRCUIT BOARD G6/G9 WORK LT PWR

PLUG 1 1 PLUG
"OPT1" ON CIRCUIT BOARD G6/G9 BCN PWR WORK LT PWR 2 2 WORK LT PWR
BCN PWR 3 3 BCN PWR
"GND1" ON CIRCUIT BOARD G6/G9 BCN GND PLUG 4 4 PLUG
BCN GND 5 5 BCN GND
"WL_SWA" ON CIRCUIT BOARD G6/G9 CAB LT PWR CAB LT PWR 6 6 CAB LT PWR
CAB LT GND 7 7 CAB LT GND
"GND3" ON CIRCUIT BOARD G6/G9 CAB LT GND WORK LT 8 8 WORK LT
"WL_SWB" ON CIRCUIT BOARD G6/G9 WORK LT
X1 X1
19 18
X2 (6 PLACES)
X3
X1
17
1 WORK LT WORK LT 1
REAR WORK LT GND LT GND
2 2
LIGHT
BOOM WORK
LIGHTS
WORK LT 1
LT GND 2
X4
WORK LT
LT GND
PLUG
PLUG
X2
C
A
D
B
REVERSE
WORK LT
LT GND
STOP LT
CURRENT
ENGINE HARNESS G6/G9 PAL2720
31200255 TL642 12-21

OPTIONS

305-3789 1 WORK LIGHT PACKAGE, (includes items 1 thru 28) E
2 2 HEX HD CAPSCREW, 1/2-13X1-3/4, GR5
3 304-2569 1 BOOM LIGHT MOUNTING BRACKET
4 298-0548 5 HEX NUT, 1/4-20
5 298-0557 2 HEX NUT, 1/2-13
6 298-7363 8 FLAT WASHER, 1/4
7 298-7367 4 FLAT WASHER, 1/2
8 315-2027 3 UTILITY FLOOD LIGHT, (includes items 101 thru 103) B
299-0849 3 BULB
9 298-7971 4 CLAMP
10 303-4914 1 BOOM WORK LIGHTS HARNESS
11 303-4924 2 FLOOD LIGHT ASSEMBLY, (includes items 201 thru 205) B
12 303-4961 2 KEEPER
13 303-4925 1 BEACON/FLOODLIGHT INSTALLATION, (includes items 301 thru 310) C
14 298-7378 5 LOCKWASHER, 1/4
15 298-7281 AR WIRING DUCT
16 304-4551 1 WORK LIGHTS SWITCH
17 304-4552 1 BEACON SWITCH
18 303-4915 1 WORK LIGHTS CAB HARNESS
19 303-4916 1 WORK LIGHTS HARNESS
20 303-4923 1 BACKUP LIGHT MOUNTING BRACKET
22 298-7369 1 WASHER, 3/4
23 AR CAT RTV SILICONE ADHESIVE SEALANT
24 317-5987 1 CLIP
26 299-0325 1 RELAY
27 1 FUSE
28 298-7382 2 LOCKWASHER, 1/2
101 303-4969 2 PIN TERMINAL
102 323-7236 1 2 POSITION TERMINAL
103 299-0338 1 UTILITY FLOOD LIGHT A, 1
299-0849 2 BULB
299-0849 1 BULB
204 298-1755 1 SPACER
205 298-1773 1 WORK LIGHT MOUNTING BOLT
301 304-2571 1 BEACON BRACKET
299-0849 1 BULB
305 299-0398 1 ROTATING BEACON
298-6910 1 BULB
306 303-4927 1 GROMMET
307 332-1348 3 INDENTED HEX HEAD MACHINE SCREW, #10-24X0.75
12-22 TL642 31200255

OPTIONS

308 298-0546 3 NUT, #10-24 GR2
309 5W-8686 3 WASHER, #10
310 298-7377 3 LOCKWASHER, #10
31200255 TL642 12-23

OPTIONS
Figure 12-8 Beacon Light Package
12 1
15 13 2
15 14 3
4
4 5
5 6
15 6
11 7
15
TO
BEACON
TO SWITCH
CIRCUIT IN
BOARD DASH
16
104
101
BEACON
F 80
QUARTZ FUEL OIL
E 0
240 16
TEMP VOLTS
0 0 0 0 0 0
- +
100 10
LOW ALT
BRAKE
FLUID
4X4
OFF
RUN
ACC
START
4X2 IGNITION
MACHINE MUST BE
IN NEUTRAL AND
PARK BRAKE ON
TO START
87 30
87A BATT
TERM 3 BEACON SW GND L1 RELAY PWR
TERM 2 BEACON-1 IND LT 86 85
LIGHT
AT
BEACON SWITCH
10 AMP 30 AMP
FUSE FUSE
12+
OIL FUEL
GND L1
+
IND LT
D
GR
BEACON-1
GND
BEACON
LT TEMP SWITCH
BEACON SW
2 3
GND L
BEACON
BA
T AC
C
ELECTRICAL (ON CAB)
SCHEMATIC
BAT
ST
IG
N
IG
N
(1001001046)
IGN

103
105
WL_SWB
SL_SWB

OPT1
OPT2
OPT3
10A
15A
15A
HTR_SW
WL2
FAN_SW
OPT3
OPT1
OPT2
GND1
GND2
GND3
SPARE_BAT
OPT_PWR
GAUGES
RELAYS
FAN/HTR
LIGHTS
STEER
HORN
W/W
GND L
KEY
10A
10A
25A
25A
15A
10A
10A
30A
25A
25A
W/W_SW WL_SWA SL_SWA SPARE_BAT
BEACON-1
106
TO BEACON PAL3100
A
B
12-24 TL642 31200255

OPTIONS
Figure 12-8 Beacon Light Package

299-6617 1 BEACON LIGHT PACKAGE, (includes all items) A, 2
1 299-0398 1 ROTATING BEACON
298-6910 1 BULB
2 298-8248 1 BEACON BRACKET
4 298-8039 3 ROUND HD MACHINE SCREW, #10-24X3/4
5 298-7377 3 LOCKWASHER, #10
6 298-8067 3 HEX NUT, #10-24
8 298-1588 2 FLAT WASHER, 1/4
9 298-7378 2 LOCKWASHER, 1/4
10 298-8047 2 HEX NUT, 1/4-20
12 299-0341 1 WEATHER PACK, (shroud)
13 298-7282 2 WEATHER PACK, (male pin terminal)
14 299-0346 2 WEATHER PACK, (cable seal)
15 298-7281 1 ECONOMY WIRING DUCT, 79”
16 298-7100 1 BEACON HARNESS
101 298-8766 1 TOGGLE SWITCH
103 299-0325 1 RELAY
104 298-1771 1 DECAL BEACON
105 298-7848 1 10 AMP FUSE
106 298-7850 1 30 AMP FUSE
31200255 TL642 12-25

OPTIONS
Figure 12-9 Road Lights Installation
24
9 25
9
4 4
8 8
10 23 10
14 14
16 16
VIEW A-A
1 4
4 8
8 10 A
10 14
16 16
2
5
9
1
USE EXISTING HARDWARE
TO MOUNT CLAMP ON
FAR SIDE OF FRAME.
ROUTE HARNESS THRU
THIS CLAMP
4
8
4 4 10
8 8 13
10 10 16
16 16
27 26
3
9
28
29
4
8
10
16
PAL3240
TAIL LIGHT VIEW
12-26 TL642 31200255

OPTIONS
Figure 12-9 Road Lights Installation (Continued)
12
VIEW OF STEERING COLUMN
22
15
7
11
21
20
LOWER DASH
HAZARD
LIGHTS
19
BEACON
LIGHT
WORK
LIGHTS
F 80
QUARTZ FUEL OI
E 0
240 16
TEMP VOLTS
0 0 0 0 0 0
- +
100 10
4X4
4X2
31 30
SPARE_BAT
OPT_PWR
GAUGES
FAN/HTR
RELAYS
HORN
STEER
LIGHTS
W/W
KEY
30A
10A
15A
25A
10A
10A
10A
25A
25A
25A
GND3
GND2
GND1
OPT3
OPT2
OPT1
FAN_SW
HTR_SW
OPT2
OPT1
OPT3
WL2
15A
15A
10A
WL_SWB
SL_SWB
OPT AUX_ELEC2 AUX_ELEC1 WARN_LT_CK REV_ALARM
CONNECT TO CURRENT
CHASSIS/BOOM HARNESS
CONNECT TO WORK LIGHT

BOOM HARNESS
1
6
17
18
USE BRAKE VALVE
TO ATTACH TAB
MOUNTING SCREW
PAL3250
31200255 TL642 12-27

OPTIONS
Figure 12-9 Road Lights Installation (Continued)
CURRENT
ENGINE HARNESS TL6/TL9
REVERSE
WORK LT
STOP LT
LT GND
X6 X7
C
C
A
A
D
D
B
B
REVERSE
PLUG
PLUG
PLUG
WORK LT
WORK LT
LT GND
LT GND
20 X2
X4 LOW
TAIL GND2 1
1 GND1 LO BEAM 2
PARK LT HI BEAM HIGH
2 3
BACK REVERSE PARK LT LEFT HEAD
3 4
LEFT TAIL LT TURN LT TURN LIGHT
4 5
LIGHT STOP LT PLUG SIDE
5 6
TURN PLUG
6
TURN
STOP
LO BEAM
RT TURN
LT TURN
HI BEAM
STOP LT
PARK LT
GND1
GND2
X1
LOW
1
2
3
7
8
4
TAIL GND2 1
GND1 LO BEAM
1
X1 2
GND1
HIGH
GND2
PARK LT HI BEAM
LO BEAM
RT TURN
HI BEAM
LT TURN
STOP LT
PARK LT
2 3
BACK REVERSE PARK LT RIGHT HEAD
3 4
RIGHT TAIL RT TURN RT TURN LIGHT
4 5
LIGHT STOP LT PLUG SIDE
5 6
TURN
6 PLUG
X5
15A BAT PWR 1
FLASH PWR
X3 TURN
STOP PLUG NC
2
X5 HI BEAM 3
HIGH HD
PLUG 4
NC
LO BEAM 5
LOW HD
PARK LT 6
SIDE LT
HEADLIGHT/TURN
PLUG 7
NC
SIGNAL SWITCH
15A OPT 2 8
LIGHT PWR
21 LT TURN
RT TURN
9
10
LEFT
RIGHT
FLASHER OUT 11
TURN PWR
PLUG 12
NC
EMPTY
FLASHER PWR X L
X
EMPTY P FLASHER FLASHER
FLASHER OUT L
EMPTY
X3 FLASHER
15A OPT 2 1
BRAKE PEDAL STOP LT FLASHER PWR 2
SWITCH 15A BAT PWR 15A BAT PWR 3
EMPTY 4
FLASHER OUT
X8 EMPTY
5
HAZARD SWITCH
6
LT TURN 7
RT TURN 8
EMPTY 9
GND1 10
X6
15A
FUSE
"GND2" ON CIRCUIT BOARD 15A OPT 2 15A OPT 2 A 15A OPT 2

TL6/TL9 15A OPT 2 GND GND2
"OPT2" ON CIRCUIT BOARD 15A OPT 2 GND
B X4
TL6/TL9
X1 15A BAT PWR SP BAT PWR "SPARE_BAT" ON CIRCUIT BOARD TL6/TL9;
X2 (2 PLACES) X2
GND1 "GND1" ON CIRCUIT BOARD TL6/TL9;
X7 (2 PLACES) PAL3260
12-28 TL642 31200255

OPTIONS
Figure 12-9 Road Lights Installation

305-3790 1 ROAD LIGHTS INSTALLATION, (includes all tiems) B
1 324-9527 4 CLAMP, 1/2
2 297-7044 2 HEX HD CAPSCREW, 1/2-13X2-1/4, GR5, (torque to 75 lb-ft)
3 303-4740 1 HEX HD CAPSCREW, 1/2-13X2-3/4, GR5, (torque to 80 lb-ft)
4 298-0546 27 HEX NUT, 10-24
5 298-0559 2 HEX LOCKNUT, 1/2-13
6 324-9528 2 TAP SCREW
7 303-4973 1 FASTON TERMINAL
8 298-7362 30 FLAT WASHER, #10
9 298-7375 7 FLAT WASHER, 1/2
10 298-7377 27 LOCKWASHER, #10
11 303-4979 1 CONNECT TERMINAL, MALE
12 303-4980 1 TURN SIGNAL SELECTOR
13 324-9529 2 REFLECTOR, RED
14 324-9530 4 REFLECTOR, YELLOW
15 298-7289 1 VARIABLE LOAD FLASHER
16 324-9531 27 SOCKET BUTTON HD CAPSCREW, #10-24X3/4
17 298-6866 1 STOPLIGHT SWITCH
18 298-8614 1 MOUNTING TAB
19 304-2594 1 SWITCH
20 303-4917 1 ROAD LIGHTS FRAME HARNESS
21 303-4918 1 ROAD LIGHTS CAB HARNESS
22 303-4922 1 ROAD LIGHTS HARNESS
23 315-5795 1 FRONT ROAD LIGHTS BRACKET
24 315-5797 1 FRONT ROAD LIGHTS, RH, (torque to 50 lb-ft)
346-2985 1 CONNECTOR
305-5467 1 LOCK CONNECTOR
25 315-5798 1 FRONT ROAD LIGHTS, LH, (torque to 50 lb-ft)
26 315-5799 1 TAIL LIGHT, RH
27 315-5800 1 TAIL LIGHT, LH
28 315-5802 1 TAIL LIGHT BRACKET
29 315-5806 2 TAIL LIGHT COVER
30 299-0325 1 RELAY
31 298-7896 1 FUSE, 25A
31200255 TL642 12-29

Before S/N TBK00706
OPTIONS
Figure 12-10 Boom Lights Installation
6 6
VIEW A-A
A
4
5
9
2 3
5
REPLACE EXISTING SCREW

7 AND USE EXISTING WASHER
11 TO MOUNT CLAMP
10
ROUTE WIRE HARNESS
THRU EXISTING CLAMPS
AS SHOWN
BOOM HARNESS ROUTING PAL3270
12-30 TL642 31200255

Before S/N TBK00706
OPTIONS
Figure 12-10 Boom Lights Installation

315-2025 1 BOOM LIGHTS INSTALLATION, (Includes all items) A
2 297-7033 2 HEX HD CAPSCREW, 3/8-16X1.5, GR5
3 315-2026 1 BOOM LIGHT MOUNTING BRACKET
4 298-8049 2 HEX NUT, 3/8-16 GR5
5 298-7365 2 FLAT WASHER, 1/4
6 315-2027 2 UTILITY FLOOD LIGHT B
303-4969 2 TERMINAL
323-7236 1 TERMINAL, RECEPTACLE
299-0338 1 FLOOD LIGHT A
299-0849 1 BULB
7 298-7971 1 CLAMP, 1/2
9 315-2023 1 WIRE, JUMPER HARNESS A
1 CONNECTOR
299-0349 2 TERMINAL
2 SEAL
299-0342 1 SHROUD
298-7282 1 TERMINAL
299-0346 1 SEAL
10 317-5987 1 CLIP TUBE .75”
31200255 TL642 12-31

OPTIONS
Figure 12-11 Skylight Wiper Assembly
103
101
104
107
109
108
105 102
106
107
2
3
4
5
PAL3330
12-32 TL642 31200255

OPTIONS
Figure 12-11 Skylight Wiper Assembly

314-8489 1 SKYLIGHT WIPER ASSY, (includes items 1 thru 5) B
1 A/R CAT THREADLOCK
2 343-7820 1 SKYLIGHT WIPER MOTOR ASSY, (includes items 101 thru 109)
3 A/R SEALANT
4 298-7281 53” WIRING DUCT
5 314-7754 1 WIPER MOTOR JUMPER HARNESS
304-2606 1 HOUSING
305-5449 1 LOCK
101 339-0837 1 FLAT WASHER, 1/4
102 339-1711 1 FLAT WASHER, 1/4
103 339-1712 1 NUT, #10-24
104 320-0525 1 WIPER ARM
105 320-0529 1 WIPER BLADE
106 339-1713 1 HEX BOLT, #10-24X3/4
107 339-1714 1 WIPER COVER
108 343-7819 1 WIPER MOTOR
109 325-1068 1 HARNESS
31200255 TL642 12-33

OPTIONS
Figure 12-12 Cold Weather Package
POWER CORD FROM

ENGINE BLOCK HEATER
5
ATTACH TO 6 1 4 3 2
ENGINE POD
115 201 107
FRAME
(NOT SHOWN PLUG END CONNECTS TO PLUG FROM ENGINE BLOCK HEATER
FOR CLARITY) OPERATOR SUPPLIED 120V
POWER SOURCE
PLUG FROM BATTERY HEATER
PAL3400
12-34 TL642 31200255

OPTIONS
Figure 12-12 Cold Weather Package

311-0680 1 COLD WEATHER PACKAGE, (includes items 1 thru 6) A
1 1 3-WAY EXTENSION CORD
2 345-1922 1 BATTERY HEATER DECAL
3 344-7176 1 ENGINE BLOCK HEATER DECAL
4 344-7179 1 HEATER CORD DECAL
5 346-2986 A/R 11” WIRE TIE
6 335-8093 6 CABLE TIE MOUNT TERMINAL
107 346-4742 2 HOLD DOWN STUD, 11-1/2
115 311-0684 1 BATTERY INSULATE
311-0685 1 BATTERY HEATER INSTALLATION, (includes item 201) A

201 311-0679 1 BATTERY HEATER
301 Ref BLOCK HEATER INSTALLATION, (not shown), (see Figure 12-1 for details)
31200255 TL642 12-35

OPTIONS
Figure 12-13 Top Cab Glass Shield
11
3 1
3 7 2
6 9 4
8 10 5
12
PY1270
12-36 TL642 31200255

OPTIONS
Figure 12-13 Top Cab Glass Shield

328-1546 1 TOP CAB GLASS SHIELD, (includes all items) A
1 297-7031 2 HEX HD CAPSCREW, 3/8-16X1
2 303-4774 2 HEX NUT, 3/8-16 GR8
3 303-4961 4 SHIM
4 298-7365 4 WASHER, 3/8
5 298-7380 2 LOCK WASHER, 3/8
6 298-7382 2 LOCK WASHER, 1/2
7 A/R CAT RTV SILICONE ADHESIVE SEALANT
8 298-8050 2 HEX NUT, 1/2-13
9 298-1755 2 SPACER
10 315-3424 2 BOLT, 1/2-13 HOLLOW
11 328-1545 1 SHIELD
12 Ref HARNESS, CAB WORK LIGHT, (see Figure 10-8 for details)
31200255 TL642 12-37

OPTIONS
Figure 12-14 Front Cab Glass Shield
1
3
5
9
1
6
7
10
PY1280
12-38 TL642 31200255

OPTIONS
Figure 12-14 Front Cab Glass Shield

328-1547 1 FRONT CAB GLASS SHIELD, (includes all items) A
1 303-4961 4 SHIM
2 317-0090 1 TAPE
3 298-7382 2 LOCK WASHER, 1/2
4 298-7840 4 WHIZ LOCK SCREW, 5/16-18X.625
5 298-8050 2 HEX NUT, 1/2-13
6 298-1755 2 SPACER
7 315-3424 2 BOLT, 1/2-13 HOLLOW
8 328-1544 1 SHIELD
9 Ref HARNESS, CAB WORK LIGHT, (see Figure 10-8 for details)
10 A/R CAT RTV SILICONE ADHESIVE SEALANT
31200255 TL642 12-39

OPTIONS
Figure 12-15 Hydraulic Cooler Bypass Install
11
10
6
9
5
PAL5020
12-40 TL642 31200255

OPTIONS
Figure 12-15 Hydraulic Cooler Bypass Install

340-0961 1 HYDRAULIC COOLER BYPASS INSTALL, (includes all items) A
5 298-0476 2 FITTING, 90 DEGREE, (includes o-ring)
6 309-6332 1 CHECK VALVE
7 340-0977 1 HYDRAULIC COOLER HOSE ASSY
8 340-0978 1 TANK RETURN HOSE ASSY
9 340-0979 1 HYDRAULIC BYPASS COOLER INLET TUBE
10 340-0985 1 BYPASS HOSE ASSY
11 340-0986 1 HYDRAULIC BYPASS COOLER OUTLET TUBE
31200255 TL642 12-41

OPTIONS
Figure 12-16 Air Conditioning
6
23
RADIATOR & FAN NOT SHOWN

FOR CLARITY
4
5 5
19 2 12 21
20 4
19
5
19
14
20
22
4
5
19
4
5
19 1
PY3840
12-42 TL642 31200255

OPTIONS
Figure 12-16 Air Conditioning

309-6823 1 AIR CONDITIONING, (includes all items) I
1 313-5257 1 COMPRESSOR BRACKET
2 305-2023 1 ADJUSTMENT BRACKET
3 322-9668 1 FRONT ADJUSTMENT BRACKET
4 298-0573 7 SOC HD CAPSCREW, 3/8-16X1-1/2
5 298-0555 8 HEX LOCK NUT, 3/8-16 GR2
6 313-5259 1 PULLEY
12 7X-3359 1 SOC HD CAPSCREW, 3/8-16X1-1/4
14 325-1433 1 COVER
19 298-7365 14 WASHER, 3/8
20 298-7374 2 WASHER, 3/8
21 298-1633 1 CLAMP, 1-3/4
22 314-2893 1 DECAL, A/C REFRIGERANT
23 309-6819 A/R SHIM
31200255 TL642 12-43

OPTIONS
302 501
2
303
STARTER
505
506
GROUND
401 COMPRESSOR
402
TO 114
CIRCUIT BOARD
ON DASH
503
504
502
1
609
608
S /C
E
A
ID
605
ID R
606
S TE
E
A
E
H
607
604
301
PAL5100
12-44 TL642 31200255

OPTIONS
215
214
201
216
204
203
218 204
206 207
213 217
205
209
211
212 208
210
104
103
202
104
102
106
107
108
110 105
110
101
111
PAL3651
31200255 TL642 12-45

OPTIONS

1 AIR CONDITIONING KIT, (includes all items)
1 350-2529 1 EVAPORATOR/HEATER UNIT, (includes items 101 thru 119)
2 350-2528 1 CONDENSOR, (includes items 201 thru 225)
101 1 CASE TOP
102 1 CASE BOTTOM
103 298-7095 1 BLOWER MOTOR
104 299-0972 1 BLOWER WHEEL
105 1 HEATER/COOLER COIL
106 299-7182 1 VALVE
107 1 BULB CLAMP
108 318-9246 1 O-RING, #8
110 2 LEG
111 299-7179 1 THERMOSTAT
112 4 WORM GEAR CLAMP, (not illustrated)
113 1 AIR RESTRICTER, (not illustrated)
114 298-8317 1 METRO SWITCH
115 1.5’ CORK TAPE, (not illustrated)
116 3’ DRAIN HOSE, 3/8, (not illustrated)
117 1 DRAIN ELBOW, 3/8, (not illustrated)
118 1 DRAIN TEE, 3/8, (not illustrated)
119 298-7278 1 PRESSURE SWITCH, (not illustrated)
201 318-9237 1 CASE TOP
202 1 CASE BOTTOM
203 318-9238 1 OVERHEAD CONDENSER COIL
204 2 MOUNTING BRACKET
205 298-8313 1 TUBE ASSY
206 299-7180 1 DRIER
207 1 DRIER MOUNT
208 318-9245 1 O-RING
209 1 HOSE CLAMP
210 318-9239 1 TUBE ASSY
211 318-9240 1 TUBE ASSY
212 4 HOSE CLAMP
213 3 CUSHION CLAMP
214 1 HOLE PLUG
215 299-7184 2 CONDENSER FAN
216 318-9241 1 HARNESS PIGTAIL
217 318-9246 1 O-RING, #8
218 2’ CLOSED CELL FOAM
219 318-9242 4 WELL NUT, (not illustrated)
220 8 NYLON INSERT NUT, 1/4-20, (not illustrated)
221 318-9243 1 RELAY, (not illustrated)
222 4 HEX HD CAPSCREW, 3/8-16X3, (not illustrated)
223 318-9244 1 HARNESS, (not illustrated)
224 4 FLAT WASHER, 3/8, (not illustrated)
225 4 LOCKWASHER, 3/8, (not illustrated)
301 350-2530 1 HOSE ASSY
302 350-2531 1 HOSE ASSY
303 350-2532 1 HOSE ASSY
12-46 TL642 31200255

OPTIONS

401 349-6876 1 COMPRESSOR
402 1 BELT
501 298-8285 1 A/C WIRING HARNESS
502 299-0327 1 RELAY
503 300-6074 1 HEX HD CAPSCREW, 5/16-18X1/2
504 298-6828 14 TIE WRAP
505 298-1359 1 SCREW, 3/8-16X1
506 303-4795 1 LOCK NUT, 3/8-16
604 298-7846 1 CLAMP SET
605 298-7834 1 CLAMP SET
606 298-7835 1 STACK BOLT
607 298-7837 1 SAFETY CLIP
608 299-0949 1 COVER PLATE
609 298-7995 1 HEX HD CAPSCREW, 5/16-18X1-3/4
31200255 TL642 12-47

OPTIONS
12-48 TL642 31200255

SECTION 13
RECOMMENDED SPARE PARTS
The following list will service fleets of machines (built to current production per date on the front cover) with repair
parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep
service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
Part Number Description Qty./Machine

BOOM ASSEMBLY
298-1466 Tilt Cyl Hose, (see Figure 8-8) 2
298-1465 Boom Hose, (see Figure 8-8) 2
298-7246 Hose Sheave, (see Figure 2-3) 1
298-7073 Bearing Pad, (see Section 2) 10
298-1787 Shim, .0598, (see Section 2) AR
299-0493 Spacer, .1875, (see Section 2) 2
298-8579 Bearing Pad, Push Beam, (see Figure 2-5) 1
298-8724 Quick Coupler Pin, (see Figure 2-8) 1
299-0305 Quick Release Pin, (see Figure 2-8) 1
ENGINE
298-7224 Fuel Tank Cap, (see Figure 4-4) 1
103-5916 Fan, (see Figure 4-3) 1
9L-0895 Alternator Belt, (see Section 4) 1
130-1161 Dipstick, (see Section 4) 1
DRIVE TRAIN
299-0562 FNR Shifter, 4-Speed, (see Figure 7-2) 1
298-8164 Accelerator Cable, (see Figure 7-1) 1
303-8573 Wheel End Seal, (see Section 5)
299-0227 Wheel End Bushing, (see Section 5) 4
303-8574 Wheel Hub Seal, (see Section 5) 4
303-8584 Universal Joint Kit, (see Figure 5-21) 2
4
31200255 TL642 13-1


HYDRAULIC SYSTEMS
298-8585 Boom Joystick Assy w/Tilt, (see Figure 7-4) 1
299-0970 Boom Joystick Handle Assy, (see Figure 7-4) 1
299-0501 Lift Cyl Seal Kit, (see Figure 9-1) 1
313-2471 Extend/Retract Cyl Seal Kit, (see Figure 9-2) 1
299-0495 Tilt Cyl Seal Kit, (see Figure 9-3) 1
304-2627 Comp Cyl Seal Kit, (see Figure 9-4) 1
299-0496 Sway Cyl Seal Kit, (see Figure 9-5) 1
108-1153 Hydraulic Filter Element, (see Figure 9-8) 1
299-0379 Tank Filter, (see Figure 9-8) 1
298-8587 Tank Filter, (see Figure 9-8) 1
299-0310 Breather, (see Figure 9-8) 1
299-0376 Fluid Level Gauge, (see Figure 9-8) 1
303-8617 Bar Gauge, (see Figure 9-8) 1
ELECTRICAL
303-4827 Engine Temp. Sensor, (see Figure 4-2) 1
298-8412 Transmission Temp Switch, (see Figure 4-2) 1
299-0390 Oil Press Sender, (see Figure 4-1) 1
310-7936 Fuel Level Sender, (see Figure 4-4) 1
299-0326 Starter Relay, (see Figure 4-1) 1
298-7293 Backup Alarm, (see Figure 1-1) 1
333-2415 Ignition Switch, (see Figure 6-4) 1
303-4891 Alternator, (see Figure 4-3) 1
268-3633 Starter, (see Figure 4-3) 1
298-6870 Horn, (see Figure 1-1) 1
268-3633 Starter, (see Figure 4-3), (Before S/N TBK01051)
329-0290 Starter, (see Figure 4-3), (S/N TBK01051 & After)
303-4891 Alternator, (see Figure 4-3), (Before S/N TBK01051)
339-7766 Alternator, (see Figure 4-3), (S/N TBK01051 & After)
MISC
1001008686 Key 1
304-4563 Battery Disconnect Key 1
31200247 Owner/Operator Manual 1
31200292 Service Manual 1
31200255 Parts Manual 1
13-2 TL642 31200255

31200255 TL642 13-3

13-4 TL642 31200255

SECTION 14 PART NUMBER INDEX
PART NUMBER INDEX
Part Number Page Part Number Page Part Number Page Part Number Page
103-5916 .......................... 4-9 297-7066.......................... 2-9 298-0462 ........................ 8-23 298-0573 ...................... 12-43
108-1153 ........................ 9-27 297-7067.......................... 2-9 298-0463 ......... 7-5, 8-3, 8-19 298-0574 .......................... 1-9
124-7702 .......................... 4-9 297-7068.......................... 2-9 298-0464 ...............8-19, 8-21 298-0576 ........................ 11-7
130-1161 .......................... 4-9 297-7069........ 2-5, 2-10, 2-15 298-0465 ........................ 8-27 298-1358 ........................ 2-21
175-4390 ........................ 10-3 297-7070........ 2-5, 2-10, 2-15 298-0466 ..... 2-21, 8-15, 8-17 298-1359 ................. 6-3, 6-19
1R-1804 ........................... 4-9 297-7076................... 8-5, 8-7 298-0467 ...................4-4, 8-7 298-1359 ...................... 12-47
206-5234 ........................ 4-15 297-7077.......................... 3-9 298-0468 . 4-13, 8-3, 8-5, 8-7, 298-1360 .......................... 1-5
206-5235 ........................ 4-15 297-7077 9-3, 9-5, 9-11, 9-13, 8-27 298-1362 .......................... 6-4
254-2267 .......................... 4-9 9-15 298-0469 .................8-3, 8-27 298-1365 ........................ 9-21
268-0867 .......................... 4-9 297-7081.......................... 3-7 298-0471 .......................... 7-5 298-1366 ........................ 8-13
268-3633 .......................... 4-9 297-7084.......................... 1-5 298-0473 ....... 8-3, 8-11, 8-13 298-1367 ................... 8-5, 8-7
284-4636 .......................... 4-9 297-7098.......................... 4-3 298-0473 ........................ 9-27 298-1368 ........................ 8-19
295-3419 ........................ 9-37 298-0400........................ 10-8 298-0474 3-7, 5-3, 5-23, 8-19 298-1369 ........................ 8-19
297-7008 .......................... 6-4 298-0402.......................... 4-4 298-0474 ........................ 9-27 298-1370 ........................ 9-27
297-7009 .......................... 6-4 298-0403.......................... 7-5 298-0475 .......................... 3-7 298-1371 .......................... 8-9
297-7010 .................3-13, 6-3 298-0404........................ 10-3 298-0476 ........................ 4-13 298-1372 ........................ 8-13
297-7011 .......................... 4-3 298-0405........................ 10-3 298-0476 ...................... 12-41 298-1373 ........................ 8-13
297-7012 . 6-3, 6-4, 7-3, 8-11, 298-0406........................ 10-3 298-0477 ........................ 4-13 298-1374 ........................ 8-13
8-13, 8-23, 8-25 298-0407........................ 2-21 298-0486 ........................ 9-27 298-1375 ........................ 8-13
297-7012 ...................... 12-25 298-0408........................ 2-21 298-04898-3, 8-13, 8-19, 8-25 298-1378 ................. 8-3, 8-11
297-7013 .................8-3, 8-11 298-0409................... 8-5, 8-7 298-0490 ........................ 8-19 298-1379 .......................... 8-3
297-7014 .................6-3, 8-15 298-0410.......................... 8-3 298-0492 ........................ 8-11 298-1380 ........................ 8-19
297-7016 .... 1-4, 6-3, 7-3, 8-9 298-0411.......................... 8-5 298-0493 ........................ 8-25 298-1381 ................... 8-5, 8-7
297-7017 .. 6-4, 7-3, 7-7, 8-25 298-0412.......................... 8-5 298-0496 ...................5-3, 8-3 298-1383 ........................ 8-23
297-7018 .................4-15, 6-4 298-0413........................ 2-21 298-0497 .................3-7, 8-19 298-1384 .......................... 8-3
297-7019 ........................ 8-27 298-0414........................ 2-21 298-04985-3, 5-23, 8-11, 8-25 298-1385 ........................ 8-19
297-7020 ........................ 2-21 298-0416........................ 2-21 298-0501 ...............8-19, 8-21 298-1386 ........................ 8-19
297-7021 3-7, 4-13, 6-3, 6-16, 298-0418........................ 4-15 298-0502 .......................... 8-9 298-1387 ........................ 8-13
6-19, 8-7, 8-9 298-0419.......................... 4-4 298-0504 ...............8-19, 8-21 298-1388 ........................ 8-17
297-7022 .......................... 8-5 298-0421........................ 4-13 298-0506 ........................ 8-21 298-1389 ........................ 8-15
297-7025 ........................ 8-25 298-0422........................ 4-17 298-0507 . 3-9, 5-3, 7-7, 8-19, 298-1394 ................. 5-3, 5-23
297-7029 2-3, 2-13, 4-15, 7-5 298-0423........................ 4-13 8-23, 8-25 298-1395 ........................ 8-11
297-7030 .......2-5, 2-13, 4-13, 298-0425.......................... 4-4 298-0515 ........................ 9-27 298-1397 .......................... 5-3
6-19, 8-19, 8-21 298-0426........................ 4-17 298-0516 .......................... 4-3 298-1398 ............... 8-11, 8-19
297-7030 ...................... 10-13 298-0434...................... 10-13 298-0517 .......................... 4-3 298-1403 ................. 8-3, 8-27
297-7031 ..........4-11, 7-5, 7-7 298-0435........................ 4-15 298-0518 ........................ 9-27 298-1404 .......................... 8-3
297-7031 12-22, 12-31, 12-37 298-0439..... 4-25, 4-27, 4-29, 298-0519 ...............8-19, 8-21 298-1405 .......................... 8-3
297-7032 .................1-4, 4-11 4-31, 4-33, 4-35 298-0522 .......................... 7-7 298-1406 ........................ 8-11
297-7032 ........................ 9-33 298-0440..... 4-25, 4-27, 4-29, 298-0525 ........................ 8-11 298-1407 ........................ 8-21
297-7033 .......................... 3-9 4-31, 4-33, 4-35 298-0526 ......... 4-4, 4-7, 4-13 298-1408 ........................ 8-21
297-7033 ...................... 12-31 298-0441..... 4-25, 4-27, 4-29, 298-0528 ...................... 12-18 298-1411 ................... 8-5, 8-7
297-7036 .......................... 1-9 4-31, 4-33, 4-35 298-0529 .......................... 6-4 298-1414 ........................ 8-19
297-7038 .......................... 2-9 298-0442..... 4-25, 4-27, 4-29, 298-0530 ...............4-15, 4-17 298-1415 ........................ 8-23
297-7039 1-9, 2-5, 2-17, 2-19, 4-31, 4-33, 4-35 298-0532 .......................... 4-3 298-1416 ........................ 8-23
2-21, 6-4 298-0443..... 4-25, 4-27, 4-29, 298-0541 ......... 1-4, 1-9, 4-13 298-1417 ........................ 9-27
297-7039 ........................ 9-27 4-31, 4-33, 4-35 298-0546 ...........12-23, 12-29 298-1418 ........................ 8-19
297-7040 .......................... 1-5 298-0444............... 4-25, 4-27 298-0548 ........................ 3-13 298-1423 ........................ 8-15
297-7041 .......................... 2-3 298-0445............... 4-25, 4-27 298-0548 ...................... 12-22 298-1465 ............... 8-19, 8-21
297-7044 ...................... 12-29 298-0446............... 4-25, 4-27 298-0549 ........................ 8-25 298-1466 ........................ 8-19
297-7047 .......................... 2-7 298-0447............... 4-25, 4-27 298-0549 ........................ 10-5 298-1467 ........................ 8-21
297-7048 .......................... 4-4 298-0448............... 4-25, 4-27 298-0551 ...................1-4, 1-5 298-1468 ........................ 8-21
297-7052 ...................... 12-22 298-0449............... 4-25, 4-27 298-0552 .......................... 6-3 298-1471 ........................ 8-19
297-7054 .......................... 1-5 298-0450............... 4-25, 4-27 298-0555 ........................ 6-19 298-1472 ........................ 8-19
297-7055 .................2-9, 2-15 298-0451........................ 4-41 298-0555 ...................... 12-43 298-1473 ........................ 8-21
297-7056 ..........2-5, 2-9, 2-15 298-0452........................ 4-41 298-0557 ...................... 12-22 298-1474 ........................ 8-21
297-7057 ..........2-5, 2-9, 2-15 298-0453........................ 4-41 298-0559 .......................... 4-4 298-1499 ........................ 8-27
297-7058 .......................... 2-5 298-0454........................ 4-41 298-0559 ...................... 12-29 298-1535 .......................... 1-4
297-7060 .................2-9, 2-13 298-0455........................ 4-41 298-0565 ...................... 12-15 298-1540 ........................ 4-11
297-7061 .......................... 2-9 298-0456........................ 4-41 298-0573 .................6-19, 7-3 298-1541 .......................... 4-9
31200255 TL642 14-1

PART NUMBER INDEX
298-1578 ...................... 12-15 298-1736 ..........................2-5 298-1844 ........................ 11-5 298-7028........................ 2-17
298-1581 ................. 7-3, 8-15 298-1737 ..........................2-5 298-1849 ...................... 12-15 298-7030.......................... 1-4
298-1583 ...................... 12-18 298-1738 ..........................6-3 298-1853 ................. 5-7, 5-27 298-7031.......................... 2-3
298-1587 ...................... 12-18 298-1739 ........................2-17 298-1854 ................. 5-7, 5-27 298-7032........................ 2-17
298-1588 ...................... 12-25 298-1740 ..........................1-4 298-1857 5-7, 5-9, 5-27, 5-29 298-7034............... 9-17, 9-19
298-1593 ...................... 12-18 298-1741 ................ 2-7, 8-21 298-1860 ................. 5-9, 5-29 298-7035............... 9-17, 9-19
298-1596 .......................... 8-9 298-1742 ................ 2-7, 8-21 298-1861 ................. 5-9, 5-29 298-7037........................ 4-15
298-1597 ........................ 8-15 298-1744 ........................5-47 298-1862 ................. 5-9, 5-29 298-7039.......................... 6-3
298-1598 .......................... 9-3 298-1746 ..........................1-4 298-1863 ........................ 5-29 298-7041........................ 6-16
298-1599 .......................... 8-3 298-1750 ..........................1-4 298-18655-9, 5-13, 5-29, 5-33 298-7044...................... 12-18
298-1606 .......................... 8-3 298-1751 ..........................1-7 298-1877 ............... 5-15, 5-35 298-7045...................... 12-18
298-1609 .......................... 1-5 298-1753 ..........................7-3 298-1878 ......5-17, 5-37, 5-39 298-7047...................... 10-13
298-1610 ..........5-3, 5-23, 7-7 298-1754 ..........................2-3 298-1879 ......5-17, 5-37, 5-39 298-7048........................ 6-13
298-1612 ..1-9, 2-3, 2-7, 2-17, 298-1755 ..........................1-5 298-1881 ......5-17, 5-37, 5-39 298-7050.......................... 6-4
2-19, 2-21, 3-9, 298-175512-18, 12-22, 12-37, 298-1883 ............... 5-17, 5-37 298-7051........................ 6-16
8-15 12-39 298-6828 ...................... 12-47 298-7052........................ 6-16
298-1613 .......................... 2-5 298-1758 ........................4-17 298-6830 ................. 2-7, 8-21 298-7053........................ 6-16
298-1615 ................. 2-9, 2-15 298-1761 ......................12-18 298-6831 ............... 9-17, 9-19 298-7055.......................... 3-7
298-1626 ..........2-5, 2-9, 2-15 298-1766 ..........................9-7 298-6832 .......................... 3-7 298-7057............... 2-19, 2-21
298-1627 ...................... 12-18 298-1770 ......... 6-3, 6-4, 6-16 298-6833 ............... 4-13, 6-16 298-7063........................ 2-13
298-1628 ...1-4, 2-5, 2-9, 2-15 298-1771 ......................12-25 298-6843 ........................ 6-16 298-7064.......................... 7-3
298-1629 ..........2-5, 2-9, 2-15 298-1772 ..........................6-3 298-6844 ........................ 9-39 298-7065.......................... 7-3
298-1630 .......................... 3-7 298-1773 .......... 12-18, 12-22 298-6849 .......................... 1-9 298-7066........................ 4-17
298-1631 .......................... 1-7 298-1781 ..........................2-3 298-6850 ........................ 10-3 298-7067................. 2-7, 8-21
298-1632 ................. 5-3, 5-23 298-1786 ..........................2-3 298-6852 .......................... 7-3 298-7068........................ 8-19
298-1633 ........4-3, 6-16, 6-19 298-1787 .................. 2-5, 2-9 298-6857 ...................... 12-18 298-7069.......................... 2-7
298-1633 ...................... 12-43 298-1788 .................. 2-5, 2-9 298-6858 ...................... 12-18 298-7070...................... 10-13
298-1634 .......................... 7-3 298-1789 ................ 2-9, 2-15 298-6860 ........... 12-18, 12-19 298-7071.......................... 7-3
298-1643 .......................... 6-3 298-1790 ..........................2-9 298-6862 .......................... 2-7 298-7072...................... 10-13
298-1645 ........................ 9-39 298-1791 ........................5-45 298-6865 .......................... 5-3 298-7073................... 2-5, 2-9
298-1646 .......................... 9-3 298-1792 ........................8-15 298-6866 ........... 12-18, 12-29 298-7074................. 2-9, 2-15
298-1647 ................. 9-7, 9-11 298-1793 ................ 5-3, 5-23 298-6868 ................. 8-3, 8-11 298-7075................... 2-5, 2-9
298-1650 ........................ 2-17 298-1794 ........................9-29 298-6870 .......................... 1-4 298-7076........................ 2-15
298-1651 ........................ 2-17 298-1796 ........................9-29 298-6891 .......................... 1-9 298-7077........................ 6-16
298-1656 ............... 8-19, 8-21 298-1797 ........................9-29 298-6906 ........................ 9-39 298-7079.......................... 6-3
298-1657 ........................ 8-17 298-1799 ................ 5-7, 5-27 298-6907 ........................ 6-13 298-7079...................... 10-15
298-1660 .......................... 3-7 298-1800 ................ 5-9, 5-29 298-6909 ........................ 9-39 298-7082.......................... 7-9
298-1663 ........9-3, 9-11, 9-17 298-1801 .............. 5-11, 5-31 298-6910 ........... 12-22, 12-25 298-7087....9-3, 9-5, 9-7, 9-9,
298-1666 .......................... 4-3 298-1802 .............. 5-11, 5-31 298-6911 ...................... 12-18 9-11, 9-13
298-1674 ........................ 4-13 298-1803 .............. 5-11, 5-31 298-6920 ........................ 2-17 298-7091........................ 6-13
298-1675 ........................ 9-17 298-1804 .............. 5-11, 5-31 298-6921 ........................ 2-17 298-7092........................ 6-13
298-1682 ........9-3, 9-11, 9-17 298-1805 .............. 5-11, 5-31 298-6922 .......................... 2-3 298-7093........................ 6-13
298-1683 .......................... 7-5 298-1806 .............. 5-11, 5-31 298-6924 .......................... 2-9 298-7095........................ 6-22
298-1684 ........................ 4-15 298-1807 .............. 5-11, 5-31 298-6925 ........................ 10-3 298-7095...................... 12-46
298-1689 ..........2-5, 2-9, 2-15 298-1808 .............. 5-11, 5-31 298-7010 .......................... 7-3 298-7098........................ 6-16
298-1694 ........................ 11-5 298-1809 .............. 5-11, 5-31 298-7011 .......................... 2-7 298-7099...................... 12-11
298-1695 ........................ 9-27 298-1810 .............. 5-11, 5-31 298-7012 ........................ 8-21 298-7100...................... 12-25
298-1696 ........................ 4-15 298-1811 .............. 5-11, 5-31 298-7013 ........................ 6-16 298-7101.......................... 6-4
298-1697 ........................ 4-15 298-1812 .............. 5-11, 5-31 298-7014 .......................... 2-5 298-7102........................ 6-16
298-1726 ................... 2-5, 2-9 298-1813 .............. 5-13, 5-33 298-7015 .......................... 2-5 298-7105.......................... 6-3
298-1727 ................... 2-5, 2-9 298-1814 ........................5-13 298-7016 ........................ 2-13 298-7106........................ 2-17
298-1728 ................... 2-5, 2-9 298-1815 ........................5-17 298-7017 .......................... 6-4 298-7107........................ 2-17
298-1729 ................. 2-5, 2-10 298-1816 ........................5-17 298-7018 .......................... 9-7 298-7108.......................... 2-7
298-1730 ................. 2-9, 2-15 298-1817 .............. 5-17, 5-37 298-7019 ........................ 9-11 298-7221...................... 10-13
298-1731 ........................ 2-15 298-1819 .............. 5-17, 5-37 298-7022 ........................ 2-17 298-7222............... 6-12, 6-13
298-1732 ................... 2-5, 2-9 298-1820 ........................5-17 298-7023 .......................... 2-7 298-7224........................ 4-11
298-1733 ................. 2-9, 2-15 298-1821 ........................5-17 298-7024 ........................ 8-21 298-7225.......................... 6-8
298-1734 ........................ 2-15 298-1822 ........................5-17 298-7026 ................... 9-7, 9-9 298-7228........................ 2-21
298-1735 ................. 2-9, 2-15 298-1825 .............. 5-19, 5-41 298-7027 .......................... 2-3 298-7229........................ 4-15
14-2 TL642 31200255

PART NUMBER INDEX
298-7233 ......4-29, 4-31, 4-35 298-7346............... 4-23, 4-43 298-7388 .. 4-3, 4-7, 4-17, 7-7 298-7896 ........... 12-18, 12-29
298-7234 ........................ 4-41 298-7347............... 4-23, 4-43 298-7389 ...................4-3, 4-7 298-7913 .......................... 1-4
298-7235 ......4-23, 4-37, 4-45 298-7348...... 4-29, 4-31, 4-35 298-7392 ...................3-9, 4-4 298-7918 .......................... 3-7
298-7237 ........................ 4-23 298-7349........................ 4-23 298-7392 9-3, 9-5, 9-11, 9-13, 298-7922 ...................... 12-13
298-7238 ........................ 4-29 298-7350........................ 4-45 9-15 298-7925 .......................... 2-3
298-7239 ......4-23, 4-41, 4-43 298-7351........................ 4-41 298-7407 .......................... 9-3 298-7926 .......................... 8-3
298-7240 ........................ 4-41 298-7352........................ 4-43 298-7410 ........................ 4-21 298-7931 ........................ 6-16
298-7241 ........................ 4-41 298-7354........................ 4-41 298-7411 ........................ 4-21 298-7971 ........... 12-22, 12-31
298-7243 ........................ 4-11 298-7355........................ 2-21 298-7412 .... 4-25, 4-27, 4-29, 298-7974 .......................... 4-4
298-7246 .................2-7, 8-21 298-7356........ 2-21, 8-3, 8-25 4-31, 4-33, 4-35 298-7976 ................... 1-4, 1-5
298-7247 ........................ 9-25 298-7357........................ 8-19 298-7413 ........................ 4-33 298-7977 ........................ 6-16
298-7249 .................5-3, 8-17 298-7358....... 3-9, 8-13, 8-19, 298-7414 ........................ 4-37 298-7980 ........................ 4-11
298-7250 .......................... 7-3 8-23, 8-27 298-7415 ........................ 4-39 298-7981 ........................ 4-13
298-7251 ........................ 4-11 298-7358............... 9-27, 9-39 298-7416 ........................ 4-39 298-7983 .......................... 8-3
298-7252 ...................... 10-19 298-7360................... 8-5, 8-7 298-7417 ........................ 4-41 298-7988 ........................ 8-23
298-7254 ........................ 4-11 298-7362.......................... 6-4 298-7418 ........................ 4-43 298-7992 ........................ 4-13
298-7256 ........................ 4-23 298-7362...................... 12-29 298-7419 ........................ 4-43 298-7995 ...................... 12-47
298-7257 ........................ 4-23 298-7363. 1-5, 3-13, 6-4, 8-25 298-7430 ...............5-17, 5-37 298-7997 ...................... 12-15
298-7258 ........................ 4-23 298-7363............. 10-5, 12-22 298-7435 .......................... 8-5 298-7998 ...................... 12-15
298-7259 ........................ 4-23 298-7364 4-3, 4-13, 4-15, 6-4, 298-7436 .......................... 8-7 298-8001 ...................... 12-18
298-7260 ........................ 4-23 7-3, 8-9, 8-25 298-7437 ...............2-21, 8-15 298-8002 ........................ 9-39
298-7261 ........................ 4-43 298-7365 2-13, 3-7, 4-7, 6-19, 298-7437 ...................... 10-13 298-8009 .......................... 2-3
298-7262 ........................ 6-16 7-3, 8-19, 8-21 298-74386-4, 8-19, 8-21, 8-27 298-8012 .......................... 2-9
298-7263 ........................ 6-16 298-7365. 11-7, 12-31, 12-37, 298-7439 .... 8-11, 8-15, 8-19, 298-8015 ................... 2-5, 2-9
298-7274 ...............5-19, 5-41 12-43 8-21 298-8022 ........................ 6-16
298-7275 .......................... 7-3 298-7367............ 2-3, 2-9, 6-4 298-7440 ...................... 10-13 298-8023 ........................ 8-19
298-7277 ........................ 6-16 298-7367............. 9-27, 12-22 298-7833 ...............8-11, 8-23 298-8030 ................. 2-7, 8-21
298-7278 ........................ 6-22 298-7368................... 2-3, 4-3 298-7834 ....... 6-16, 6-19, 8-9 298-8031 .......................... 7-3
298-7278 ...................... 12-46 298-7369...................... 12-22 298-7834 ...................... 12-47 298-8032 ........................ 6-16
298-7281 12-22, 12-25, 12-33 298-7372 3-13, 6-3, 6-4, 6-16, 298-7835 ........................ 6-19 298-8034 .......................... 1-5
298-7282 ........................ 6-16 8-11, 8-13, 8-15, 298-7835 ...................... 12-47 298-8037 ........................ 2-15
298-728210-17, 12-18, 12-25, 8-23 298-7837 ........................ 6-19 298-8038 ........................ 2-15
12-31 298-7373.. 1-5, 4-13, 6-4, 7-3, 298-7837 ...................... 12-47 298-8039 ...................... 12-25
298-7283 ........................ 6-16 7-7 298-7838 ........................ 8-11 298-8041 .......................... 6-3
298-7285 ........................ 6-16 298-7373............. 9-22, 12-15 298-7839 ........................ 8-11 298-8042 ........................ 4-11
298-7286 .......................... 6-4 298-7374 1-4, 2-3, 4-11, 4-13, 298-7839 ...................... 10-13 298-8043 .......................... 6-3
298-7289 ...................... 12-29 4-15, 4-17, 6-19 298-7840 ...................... 12-39 298-8045 ...................... 12-18
298-7290 ........................ 6-16 298-7374........... 10-13, 12-43 298-7841 ...............4-13, 4-15 298-8047 ..........6-3, 6-4, 8-19
298-7291 ...................... 12-19 298-7375 1-5, 2-7, 2-19, 2-21, 298-7841 ........................ 10-3 298-8047 ...................... 12-25
298-7292 .......................... 6-4 4-4 298-7844 ........................ 6-16 298-8048 .......................... 1-4
298-7293 .......................... 1-4 298-7375...................... 12-29 298-7846 ........................ 6-19 298-8049 ..1-4, 3-7, 7-3, 8-19,
298-7294 ........................ 9-25 298-7377 12-23, 12-25, 12-29 298-7846 ...................... 12-47 8-21
298-7295 .......................... 6-4 298-7378.. 4-3, 6-3, 6-4, 6-16, 298-7848 ...........10-13, 12-25 298-8049 ........... 12-18, 12-31
298-7296 ........................ 6-16 8-13, 8-19, 8-23 298-7849 ...................... 10-15 298-8050 .......................... 1-5
298-7297 ........................ 4-13 298-7378........... 12-22, 12-25 298-7850 ...........10-15, 12-25 298-8050 ........... 12-37, 12-39
298-7298 ........................ 8-15 298-7379.. 1-4, 3-7, 4-15, 6-4, 298-7853 ........................ 10-3 298-8051 .......................... 3-7
298-7302 ...................... 12-18 7-3, 7-7, 8-9 298-7854 ........................ 4-15 298-8052 ............ 1-4, 1-5, 1-7
298-7303 ...........12-18, 12-19 298-7380.. 1-4, 2-3, 2-7, 2-13, 298-7867 ........................ 5-17 298-8053 .......................... 1-4
298-7305 ........................ 8-15 4-11, 4-13, 4-15, 298-7868 ........................ 5-29 298-8059 .......................... 2-3
298-7306 ...................... 12-19 6-19, 7-5, 7-7, 298-7870 ........................ 5-17 298-8062 ........................ 2-17
298-7308 ...................... 10-15 8-19 298-7873 ..... 5-17, 5-37, 5-39 298-8063 .......................... 2-3
298-7310 .......................... 8-3 298-7380.... 9-33, 9-39, 12-37 298-7875 .......................... 1-4 298-8067 ................. 2-7, 8-21
298-7311 ........................ 5-47 298-7381................... 8-5, 8-7 298-7876 ..... 4-23, 4-41, 4-43 298-8067 ...................... 12-25
298-7312 ........................ 2-17 298-7382... 1-5, 1-9, 2-7, 2-17 298-7877 ..... 4-23, 4-37, 4-43 298-8068 ...................... 12-18
298-7314 ...................9-7, 9-9 298-7382. 9-27, 12-13, 12-15, 298-7880 .......................... 6-3 298-8070 .......................... 2-3
298-7318 .......................... 2-7 12-22, 12-37, 298-7881 ........................ 4-23 298-8114 ........................ 9-15
298-7343 ........................ 4-15 12-39 298-7890 .......................... 4-4 298-8115 .......................... 9-3
298-7344 ........................ 4-39 298-7385...................... 10-15 298-7892 .......................... 8-9 298-8118 ........................ 4-13
298-7345 ........................ 4-45 298-7387................... 4-3, 4-7 298-7896 ........................ 6-16 298-8119 .......................... 1-4
31200255 TL642 14-3

PART NUMBER INDEX
298-8121 ........................ 4-13 298-8300 .............. 5-21, 5-43 298-8745 .......................... 7-5 12-29
298-8122 ........................ 4-15 298-8302 ........................9-29 298-8760 ........................ 8-21 299-0326.......................... 4-3
298-8124 .......................... 1-4 298-8303 ........................9-29 298-8761 .......................... 6-3 299-0327........................ 6-19
298-8126 .......................... 1-4 298-8313 ........................6-22 298-8766 ........... 12-18, 12-25 299-0327...................... 12-47
298-8127 ................. 5-3, 5-23 298-8313 ......................12-46 298-8767 ........................ 2-17 299-0328........................ 6-16
298-8128 ...................... 12-18 298-8314 ........................6-23 298-8774 .......................... 7-3 299-0330.......................... 1-4
298-8131 ..........9-3, 9-5, 9-15 298-8317 ........................6-22 298-8777 .......................... 1-4 299-0331........................ 6-16
298-8133 .......................... 6-4 298-8317 ......................12-46 298-8780 ........................ 5-47 299-0333........................ 6-16
298-8135 ........................ 9-27 298-8379 ..........................4-4 298-8781 ........................ 5-47 299-0338 12-18, 12-22, 12-31
298-8137 ........................ 9-17 298-8380 ..........................4-4 298-8782 ......9-11, 9-13, 9-15 299-0339........... 10-17, 12-18
298-8138 .......................... 5-5 298-8410 ..........................4-3 298-8783 .......................... 5-3 299-0340........................ 10-8
298-8139 ........................ 5-25 298-8412 ..........................4-3 298-8789 ........................ 4-17 299-0341........................ 6-16
298-8140 .......................... 1-5 298-8429 ..........................1-9 298-8790 .......................... 7-3 299-0341 10-17, 12-18, 12-25
298-8141 .......................... 6-3 298-8430 ..........................1-9 298-8791 ...................... 12-15 299-0342........... 12-18, 12-31
298-8143 ........................ 4-15 298-8431 ..........................1-9 298-8792 ...................... 12-15 299-0346........................ 6-16
298-8145 ........................ 4-17 298-8435 ..........................4-4 299-0187 .......................... 9-3 299-0346. 10-8, 10-17, 12-25,
298-8149 .......................... 6-3 298-8438 ........................11-4 299-0188 .......................... 9-3 12-31
298-8152 .......................... 6-3 298-8576 ..........................2-7 299-0191 ........................ 9-29 299-0347........... 10-17, 12-18
298-8152 ...................... 10-15 298-8578 ..........................2-3 299-0192 ........................ 9-29 299-0349. 10-8, 10-17, 12-18,
298-8156 ........................ 4-17 298-8579 ........................2-13 299-0193 ........................ 9-29 12-31
298-8157 ........................ 8-23 298-8580 ........................4-13 299-0194 ........................ 9-29 299-0352........................ 4-15
298-8164 .......................... 7-3 298-8581 ..........................1-4 299-0195 ........................ 5-27 299-0353........................ 4-13
298-8167 ................... 9-3, 9-5 298-8583 ........................2-17 299-0196 ................. 5-7, 5-27 299-0354........................ 11-5
298-8170 ........................ 9-33 298-8584 ........................6-16 299-0197 ................. 5-7, 5-27 299-0355................... 8-5, 8-7
298-8170 ........................ 9-33 298-8585 ..........................7-9 299-0199 ................. 5-7, 5-27 299-0359........................ 4-43
298-8175 ........................ 9-29 298-8587 ........................9-27 299-0201 .......................... 5-9 299-0360...................... 12-25
298-8178 ................. 5-7, 5-27 298-8588 ........................9-27 299-0202 .......................... 5-9 299-0361...................... 12-13
298-8179 ................. 5-7, 5-27 298-8589 ........................6-16 299-0205 ............... 5-21, 5-43 299-0362.......................... 3-7
298-8181 ........................ 5-11 298-8590 ........................6-16 299-0206 ............... 5-21, 5-43 299-0363........................ 6-13
298-8182 ............... 5-13, 5-33 298-8592 ..........................7-3 299-0207 ............... 5-21, 5-43 299-0369.......................... 6-3
298-8186 ........................ 5-17 298-8593 ..........................7-3 299-0208 .......................... 7-7 299-0373........................ 4-13
298-8187 ........................ 5-17 298-8596 ........................12-5 299-0209 .......................... 7-9 299-0376........................ 9-27
298-8188 ........................ 5-17 298-8598 ........................4-13 299-0210 ................. 7-9, 7-11 299-0378.......................... 4-3
298-8189 ............... 5-17, 5-37 298-8599 ........................5-45 299-0223 ................. 5-9, 5-29 299-0379........................ 9-27
298-8191 ......5-17, 5-37, 5-39 298-8603 ........................4-13 299-0227 ......5-15, 5-29, 5-35 299-0383........................ 8-23
298-8192 ......5-17, 5-37, 5-39 298-8604 ......................12-15 299-0228 ................. 5-9, 5-29 299-0387.......................... 1-5
298-8193 ............... 5-19, 5-41 298-8605 ........................4-13 299-0235 ............... 5-15, 5-35 299-0390.......................... 4-4
298-8194 ............... 5-19, 5-41 298-8608 ..........................6-3 299-0236 ............... 5-15, 5-35 299-0392........................ 4-17
298-8195 ............... 5-19, 5-41 298-8609 ..........................6-3 299-0240 ......5-17, 5-37, 5-39 299-0395.......................... 6-3
298-8196 ............... 5-19, 5-41 298-8612 ..........................1-4 299-0241 ......5-17, 5-37, 5-39 299-0396........................ 9-39
298-8197 ............... 5-19, 5-41 298-8614 .......... 12-18, 12-29 299-0253 .......................... 5-9 299-0398........... 12-22, 12-25
298-8198 ............... 5-19, 5-41 298-8637 ..........................7-5 299-0271 .......................... 4-3 299-0400........................ 4-11
298-8200 ........................ 5-31 298-8644 ..........................6-3 299-0277 .......................... 1-9 299-0401........................ 2-13
298-8201 ........................ 9-17 298-8669 ........................6-11 299-0278 .......................... 1-9 299-0402.......................... 1-4
298-8205 .......................... 1-4 298-8716 ........................8-19 299-0285 ........................ 2-21 299-0468........................ 4-37
298-8208 ................... 2-5, 2-9 298-8718 ........................2-13 299-0303 .......................... 4-7 299-0469........................ 4-23
298-8209 ................. 2-9, 2-15 298-8722 ........................6-11 299-0304 ........................ 4-17 299-0470........................ 4-45
298-8243 ........................ 4-15 298-8724 ........................2-19 299-0305 ........................ 2-19 299-0471........................ 8-19
298-8244 .......................... 7-7 298-8728 ........................4-15 299-0308 ........................ 2-21 299-0479........................ 4-19
298-8248 ...................... 12-25 298-8729 ........................4-15 299-0309 .......................... 4-3 299-0493.......................... 2-9
298-8250 ........................ 4-11 298-8732 ..........................4-4 299-0310 ........................ 9-27 299-0495........................ 9-11
298-8257 ........................ 2-17 298-8733 ..........................4-4 299-0316 ........................ 5-45 299-0496........................ 9-17
298-8267 .......................... 1-5 298-8734 .............. 2-19, 2-21 299-0317 ........................ 5-45 299-0498.......................... 7-9
298-8280 .......................... 7-7 298-8736 .............. 2-19, 2-21 299-0321 ........................ 4-19 299-0499.......... 9-3, 9-7, 9-11
298-8284 ...................... 10-17 298-8737 ..........................4-7 299-0322 ........................ 9-33 299-0501.......................... 9-3
298-8285 ...................... 12-47 298-8738 ..........................4-7 299-0324 ...................... 10-15 299-0505........................ 9-33
298-8287 ........................ 9-15 298-8739 ........................4-13 299-0325 ............... 6-13, 6-16 299-0508............... 5-11, 5-31
298-8290 ...................... 12-15 298-8740 ..........................4-7 299-032510-13, 10-15, 12-18, 299-0511........................ 5-13
298-8297 ............... 5-19, 5-41 298-8744 ......................12-18 12-22, 12-25, 299-0520............... 5-15, 5-35
14-4 TL642 31200255

PART NUMBER INDEX
299-0523 ........................ 9-41 299-0793................. 5-7, 5-27 299-0966 .......................... 7-9 299-7118 .......................... 2-9
299-0544 ...................... 12-15 299-0794................. 5-7, 5-27 299-0967 .......................... 7-9 299-7122 .......................... 7-9
299-0546 ...................... 12-15 299-0795................. 5-9, 5-29 299-0970 .......................... 7-9 299-7130 ........................ 9-29
299-0558 ........................ 7-11 299-0796................. 5-9, 5-29 299-0972 ...............6-17, 6-22 299-7131 ........................ 9-29
299-0559 ........................ 7-11 299-0797............... 5-21, 5-43 299-0972 ...................... 12-46 299-7132 ........................ 6-13
299-0560 .......................... 7-5 299-0808................. 5-9, 5-29 299-0976 ........................ 7-11 299-7134 ................. 5-7, 5-27
299-0562 .......................... 7-5 299-0813............... 5-21, 5-43 299-0985 ........................ 9-29 299-7136 ................. 5-9, 5-29
299-0591 ........................ 4-45 299-08215-7, 5-15, 5-27, 5-35 299-1284 ........................ 2-19 299-7137 ................. 5-9, 5-29
299-0592 ........................ 4-21 299-0827............... 5-15, 5-35 299-1285 ........................ 2-21 299-7138 ............... 5-11, 5-31
299-0593 ........................ 4-21 299-0834.......................... 7-9 299-1286 ........................ 8-21 299-7139 ............... 5-11, 5-31
299-0594 .....4-25, 4-27, 4-29, 299-0835........................ 4-33 299-1297 ...................... 10-13 299-7140 ............... 5-15, 5-35
4-31, 4-35 299-0836........................ 4-21 299-1323 ........................ 9-39 299-7141 ............... 5-17, 5-37
299-0595 ........................ 4-29 299-0839............... 4-39, 4-41 299-1337 ........................ 5-23 299-7142 ........................ 5-17
299-0596 ...............4-29, 4-37 299-0840........................ 4-39 299-1338 .......................... 5-3 299-7144 ........................ 7-11
299-0597 ........................ 4-31 299-0841..... 4-25, 4-27, 4-29, 299-1339 .......................... 7-5 299-7148 .......................... 6-8
299-0598 .....4-25, 4-27, 4-31, 4-31, 4-33, 4-35 299-1340 ........................ 4-11 299-7161 ................. 5-7, 5-27
4-35 299-0842........................ 4-15 299-1344 ........................ 4-15 299-7165 ............... 5-17, 5-37
299-0599 ...............4-25, 4-27 299-0849 12-18, 12-22, 12-31 299-1345 ........................ 4-15 299-71705-7, 5-21, 5-27, 5-43
299-0600 ...............4-25, 4-27 299-0850........... 12-18, 12-25 299-1349 ........................ 2-21 299-7178 ........................ 6-22
299-0601 ........................ 4-33 299-0851........................ 9-11 299-1350 ........................ 4-13 299-7179 ........................ 6-22
299-0602 ...............4-25, 4-27 299-0852........................ 9-39 299-1351 ........................ 2-21 299-7179 ...................... 12-46
299-0603 ........................ 4-35 299-0853.......................... 2-7 299-6615 ........................ 9-27 299-7180 ........................ 6-22
299-0604 ......4-25, 4-27, 4-35 299-0855.......................... 9-7 299-6616 ........................ 6-17 299-7180 ...................... 12-46
299-0605 ...............4-25, 4-27 299-0856........................ 9-11 299-6617 ...................... 12-25 299-7181 ........................ 6-23
299-0606 ........................ 4-41 299-0857........................ 9-11 299-6620 ..... 4-29, 4-31, 4-35 299-7182 ........................ 6-22
299-0635 ........................ 7-11 299-0858........................ 9-11 299-6621 ........................ 4-41 299-7182 ...................... 12-46
299-0636 ........................ 7-11 299-0859........................ 9-11 299-6623 .................2-21, 6-4 299-7184 ........................ 6-22
299-0637 ........................ 4-21 299-0860........................ 6-13 299-6624 ........................ 2-21 299-7184 ...................... 12-46
299-0638 ........................ 4-21 299-0861............... 9-11, 9-17 299-6632 .......................... 7-5 300-6071 .......................... 2-7
299-0639 ........................ 4-21 299-0863.......................... 9-3 299-6635 ........................ 4-39 300-6073 ........................ 2-17
299-0640 ........................ 4-25 299-0864.......................... 9-3 299-6636 ........................ 4-41 300-6074 ................. 1-4, 6-19
299-0641 .....4-25, 4-27, 4-29, 299-0896........................ 4-23 299-6637 ........................ 6-11 300-6074 ........... 10-15, 12-47
4-31, 4-33, 4-35 299-0897........................ 4-39 299-6639 ...............5-19, 5-41 300-6075 ................. 1-4, 4-13
299-0642 .....4-25, 4-27, 4-29, 299-0898........................ 4-41 299-6640 ........................ 10-8 300-6078 .2-21, 3-7, 3-9, 8-21
4-31, 4-33, 4-35 299-0899........................ 4-21 299-6641 ........................ 10-8 300-6079 .2-21, 3-7, 3-9, 8-21
299-0643 .....4-25, 4-27, 4-29, 299-0900........................ 4-43 299-6644 ...... 2-21, 6-4, 8-11, 300-6082 ................... 4-3, 4-7
4-31, 4-33, 4-35 299-0908........................ 10-8 8-15, 8-19, 8-21, 300-6084 ............... 2-21, 8-21
299-0644 ........................ 4-27 299-0912........................ 4-13 8-27 300-6092 ...................... 10-13
299-0645 ........................ 4-31 299-0913.......................... 7-5 299-6644 ...................... 10-13 300-6094 ........................ 8-21
299-0646 ........................ 4-33 299-0915........................ 7-11 299-6645 ........................ 8-11 300-6095 ............... 2-21, 8-21
299-0647 ........................ 4-33 299-0916........................ 7-11 299-6645 ...................... 10-13 300-6099 .......................... 7-7
299-0650 ......4-33, 4-37, 4-45 299-0917........................ 7-11 299-6646 ........................ 6-16 300-6103 ............... 2-21, 8-21
299-0651 ........................ 4-35 299-0918........................ 4-21 299-6648 ........................ 12-3 300-6104 .......................... 7-7
299-0652 ........................ 4-37 299-0919........................ 4-41 299-6654 ...................... 12-18 300-6108 ...................... 12-15
299-0653 ........................ 4-37 299-0920........................ 4-43 299-6658 .......................... 2-7 300-6113 .......................... 1-4
299-0654 ........................ 4-37 299-0921........................ 6-11 299-6659 ........................ 8-21 300-6115 .......................... 2-3
299-0655 ........................ 4-37 299-0922........................ 6-11 299-6669 .......................... 7-3 300-6116 .......................... 2-7
299-0656 ........................ 4-39 299-0924........................ 6-11 299-6670 ...................... 12-18 301-3185 ........................ 12-6
299-0657 ........................ 4-39 299-0925........................ 6-11 299-6673 ...................... 12-15 301-3186 ........................ 12-6
299-0658 ........................ 4-39 299-0927........................ 6-11 299-7086 ........................ 4-45 301-9752 .......................... 3-5
299-0659 ........................ 4-39 299-0928........................ 6-11 299-7090 ........................ 4-23 301-9753 .......................... 3-5
299-0660 ........................ 4-39 299-0944........................ 10-8 299-7091 ........................ 4-23 301-9754 .......................... 3-5
299-0661 ........................ 4-41 299-0945........................ 10-8 299-7092 ........................ 4-39 301-9755 .......................... 3-5
299-0662 ........................ 4-41 299-0947.......................... 8-5 299-7096 ........................ 10-8 301-9756 .......................... 3-5
299-0663 ........................ 4-41 299-0949. 6-16, 6-19, 8-7, 8-9 299-7099 ........................ 4-15 301-9757 .......................... 3-3
299-0780 ........................ 8-19 299-0949...................... 12-47 299-7103 5-7, 5-9, 5-17, 5-27, 301-9758 .......................... 3-3
299-0788 ........................ 5-13 299-0953.......................... 7-9 5-29, 5-37, 5-39 302-0581 .......................... 4-7
299-0789 ........................ 5-13 299-0954.......................... 7-9 299-7106 ........................ 10-8 303-4696 ...................... 10-19
299-0790 .................5-7, 5-27 299-0960................. 7-9, 7-11 299-7116 ........................ 9-39 303-4735 ...................... 12-22
31200255 TL642 14-5

PART NUMBER INDEX
303-4737 .......................... 3-7 303-4898 ..........................3-7 303-8563 ............... 4-25, 4-27 303-8633.......................... 6-8
303-4738 .......................... 2-7 303-4906 ........................11-4 303-8565 ........................ 9-35 303-8634.......................... 6-8
303-4740 ...................... 12-29 303-4909 ........................11-5 303-8566 ........................ 9-35 303-8635.......................... 6-8
303-4741 ................... 3-3, 3-9 303-4912 ........................8-19 303-8567 .......................... 1-4 303-8636.......................... 6-9
303-4742 .......................... 4-3 303-4914 ......................12-22 303-8568 ........................ 4-45 303-8637.......................... 6-9
303-4743 ................. 2-13, 4-3 303-4915 ......................12-22 303-8570 ................. 5-9, 5-29 303-8638.......................... 6-9
303-4744 .......................... 1-4 303-4916 ......................12-22 303-8571 ................. 5-9, 5-29 303-8639.......................... 6-9
303-4749 ........................ 10-5 303-4917 ......................12-29 303-8572 ................. 5-9, 5-29 303-8640.......................... 6-9
303-4751 .......................... 1-4 303-4918 ......................12-29 303-8573 ............... 5-15, 5-35 303-8641.......................... 6-9
303-4752 ...................... 10-11 303-4922 ......................12-29 303-8574 ............... 5-19, 5-41 303-8642.......................... 6-8
303-4753 .......................... 4-3 303-4923 ......................12-22 303-8578 .......................... 6-9 303-8643.......................... 6-9
303-4754 ........................ 8-23 303-4924 ......................12-22 303-8579 .......................... 6-8 303-8644.......................... 6-9
303-4755 .......................... 3-7 303-4925 ......................12-22 303-8581 ................... 6-8, 6-9 303-8645.......................... 6-9
303-4756 ........................ 8-27 303-4927 ......................12-22 303-8582 .......................... 6-8 303-8646.......................... 6-9
303-4758 .......................... 4-4 303-4929 ..........................2-7 303-8583 .......................... 6-9 303-8647.......................... 6-9
303-4769 .......................... 4-3 303-4935 ........................2-17 303-8584 ........................ 5-45 303-8648.......................... 6-8
303-4770 .......................... 8-3 303-4939 ........................11-5 303-8585 .......................... 6-8 303-8649.......................... 6-8
303-4774 .......................... 4-3 303-4940 ........................11-7 303-8586 .......................... 6-9 303-8650........................ 12-5
303-4774 ...................... 12-37 303-4941 ........................11-4 303-8587 .......................... 6-9 303-8651........................ 12-5
303-4776 .......................... 4-3 303-4942 ........................11-5 303-8588 .......................... 6-9 303-8652........................ 12-5
303-4777 .......................... 4-7 303-4943 ........................11-7 303-8589 .......................... 6-9 303-8653........................ 12-5
303-4779 .......................... 1-5 303-4944 ........................11-5 303-8590 .......................... 6-8 303-8654.......................... 1-5
303-4782 ................... 3-3, 3-9 303-4945 ........................11-5 303-8591 .......................... 6-8 303-8655.......................... 9-7
303-4785 .......................... 4-3 303-4946 ........................11-4 303-8592 .......................... 6-8 303-8656........................ 12-9
303-4787 ................... 1-5, 4-7 303-4947 ........................11-5 303-8593 .......................... 6-8 303-8658........................ 9-35
303-4789 .......................... 4-3 303-4948 ........................11-5 303-8594 .......................... 6-8 303-8659.......................... 1-4
303-4790 .......................... 4-3 303-4949 ........................11-5 303-8595 .......................... 6-8 303-8660.......................... 1-4
303-4792 .......................... 4-4 303-4950 ........................11-5 303-8596 .......................... 6-8 303-8661.......................... 1-4
303-4795 ........................ 6-19 303-4951 ..........................4-3 303-8597 .......................... 6-8 303-8662........................ 6-13
303-4795 ............. 10-3, 12-47 303-4952 ..........................4-3 303-8599 ..........4-3, 4-4, 6-16 303-8663........................ 10-8
303-4798 ...................... 12-18 303-4953 ..........................4-3 303-8599 ........................ 9-27 303-8666........................ 9-33
303-4802 .......................... 8-9 303-4957 .................. 3-3, 3-9 303-8600 ........................ 6-16 303-8667.......................... 6-8
303-4803 .......................... 8-9 303-4958 .................. 3-3, 3-9 303-8601 ........................ 6-16 304-2240........................ 10-8
303-4804 .......................... 8-9 303-4961 12-22, 12-37, 12-39 303-8602 .......................... 8-9 304-2241................. 5-7, 5-27
303-4805 ........................ 4-11 303-4962 ........................11-4 303-8605 ........................ 9-21 304-2243........................ 5-13
303-4807 ........................ 6-17 303-4963 ........................11-4 303-8606 ........................ 9-21 304-2244........................ 5-17
303-4808 ........................ 9-27 303-4966 ..........................1-5 303-8607 ........................ 9-21 304-2246........................ 9-25
303-4819 ........................ 11-5 303-4969 .......... 12-22, 12-31 303-8609 ........................ 9-21 304-2247........................ 9-22
303-4821 .......................... 4-4 303-4970 ......................10-19 303-8610 .......................... 7-5 304-2248........................ 9-22
303-4826 .......................... 4-4 303-4971 ......................12-22 303-8611 .......................... 6-9 304-2249........................ 9-22
303-4827 .......................... 4-7 303-4972 ......................12-22 303-8612 .......................... 6-8 304-2250........................ 9-22
303-4828 ........................ 10-5 303-4973 ......................12-29 303-8613 .......................... 6-8 304-2251........................ 9-15
303-4829 ........................ 10-5 303-4978 ..........................6-8 303-8614 .......................... 6-8 304-2253........................ 9-15
303-4831 ........................ 10-5 303-4979 ......................12-29 303-8615 .......................... 6-8 304-2254........................ 9-15
303-4836 .......................... 1-5 303-4980 ......................12-29 303-8617 ........................ 9-27 304-2255........................ 9-15
303-4841 ........................ 12-3 303-4981 ..........................1-4 303-8618 .......................... 6-8 304-2256........................ 9-15
303-4865 .......................... 6-3 303-4982 ........................10-8 303-8619 .......................... 6-8 304-2257........................ 9-15
303-4866 ........................ 8-25 303-4983 ........................10-8 303-8620 .......................... 9-3 304-2258........................ 9-15
303-4875 ........................ 8-27 303-4988 .................. 3-3, 3-9 303-8621 .......................... 9-3 304-2259........................ 9-33
303-4876 ........................ 8-27 303-4989 ..........................1-4 303-8623 ........................ 9-21 304-2260........................ 9-33
303-4877 ........................ 8-27 303-4997 ............ 10-8, 10-11 303-8624 .......................... 6-8 304-2261........................ 9-33
303-4878 ........................ 8-27 303-4999 ..........................3-7 303-8625 .......................... 6-8 304-2262........................ 9-33
303-4879 ........................ 8-25 303-5000 ........................2-17 303-8626 .......................... 6-8 304-2263........................ 9-33
303-4880 ........................ 8-13 303-5001 ..........................2-7 303-8627 .......................... 6-8 304-2264........................ 5-13
303-4883 ........................ 11-7 303-5004 ........................9-35 303-8628 .......................... 6-8 304-2265........................ 5-13
303-4884 ........................ 11-7 303-5007 ..........................1-4 303-8629 .......................... 6-8 304-2266........................ 12-5
303-4890 .......................... 1-5 303-8559 ..........................4-3 303-8630 .......................... 6-8 304-2267........................ 12-5
303-4891 .......................... 4-9 303-8561 ........................4-45 303-8631 .......................... 6-8 304-2268........................ 12-9
303-4893 ........................ 6-19 303-8562 .............. 4-25, 4-27 303-8632 .......................... 6-8 304-2269........................ 9-22
14-6 TL642 31200255

PART NUMBER INDEX
304-2270 ........................ 9-21 304-2607...................... 10-11 304-3195 ........................ 12-9 304-4580 .......................... 6-9
304-2271 ........................ 9-22 304-2610........................ 10-8 304-3196 ........................ 12-9 304-4581 ................. 5-7, 5-27
304-2272 .......................... 9-7 304-2612........................ 6-13 304-3197 ........................ 12-9 305-2023 ........................ 6-19
304-2273 .......................... 9-7 304-2613........................ 6-13 304-3198 ........................ 12-9 305-2023 ...................... 12-43
304-2281 .......................... 9-3 304-2614........................ 4-45 304-3199 ........................ 12-9 305-2025 .......................... 7-7
304-2282 .......................... 9-3 304-2615........................ 4-45 304-3200 ........................ 12-9 305-2026 .......................... 7-7
304-2283 .......................... 9-3 304-2617........................ 4-45 304-3201 ........................ 12-9 305-2028 .......................... 6-3
304-2284 ........................ 9-11 304-2618.......................... 1-5 304-3202 ........................ 12-9 305-2032 ........................ 9-27
304-2292 ........................ 9-17 304-2620................. 5-9, 5-29 304-3203 ........................ 12-9 305-2033 ........................ 9-27
304-2294 ........................ 9-21 304-2621............... 4-29, 4-31 304-3204 ........................ 12-9 305-2087 ........................ 9-39
304-2295 ........................ 9-21 304-2622............... 4-29, 4-31 304-3205 ........................ 9-25 305-2088 ........................ 9-39
304-2297 .......................... 7-3 304-2623........................ 10-8 304-3206 ........................ 9-25 305-2089 ........................ 9-39
304-2298 .......................... 7-3 304-2626........................ 6-11 304-3207 ........................ 9-35 305-2090 ........................ 9-39
304-2299 .......................... 9-3 304-2627........................ 9-15 304-3208 ........................ 9-35 305-2106 ........................ 9-39
304-2300 .......................... 6-8 304-2628........................ 9-25 304-3209 ........................ 9-29 305-2110 ...................... 10-13
304-2301 .......................... 6-8 304-2629........................ 9-25 304-3211 ........................ 9-29 305-2115 ............. 10-8, 12-31
304-2302 ........................ 12-5 304-2630........................ 9-25 304-3212 ........................ 9-29 305-3763 ........................ 2-17
304-2304 ........................ 12-5 304-2631........................ 4-45 304-3213 ........................ 9-29 305-3767 ............... 11-3, 11-7
304-2305 ........................ 12-5 304-2632..... 4-25, 4-27, 4-29, 304-3214 ........................ 9-29 305-3768 .......................... 3-7
304-2306 ........................ 12-5 4-31, 4-33, 4-35 304-3215 ........................ 9-29 305-3783 .......................... 3-3
304-2307 ........................ 12-5 304-2633..... 4-25, 4-27, 4-29, 304-3216 ........................ 9-29 305-3784 .......................... 3-3
304-2308 ........................ 12-5 4-31, 4-33, 4-35 304-3218 ........................ 9-33 305-3785 .......................... 3-3
304-2309 ........................ 12-5 304-2634..... 4-25, 4-27, 4-29, 304-3220 ........................ 5-13 305-3786 .......................... 3-3
304-2318 ........................ 12-5 4-31, 4-33, 4-35 304-3221 ...............5-13, 5-33 305-3789 ...................... 12-22
304-2319 ........................ 12-5 304-2635..... 4-25, 4-27, 4-29, 304-3222 ...............5-13, 5-33 305-3790 ...................... 12-29
304-2320 ........................ 12-5 4-31, 4-33, 4-35 304-3225 ........................ 5-37 305-3791 ........................ 11-5
304-2322 ........................ 12-5 304-2636.......................... 6-9 304-3226 ........................ 5-37 305-5426 ................. 5-9, 5-29
304-2323 ........................ 12-5 304-2637.......................... 6-9 304-3227 ........................ 9-17 305-5431 ........................ 9-39
304-2324 ........................ 12-5 304-2638.......................... 6-8 304-3228 ........................ 9-21 305-5449 ............. 10-8, 12-33
304-2325 ........................ 12-5 304-2639.......................... 6-8 304-3229 ........................ 10-8 305-5454 ...................... 12-18
304-2328 ........................ 12-5 304-2640.......................... 6-9 304-3230 .................5-7, 5-27 305-5459 ............... 9-15, 9-39
304-2329 ........................ 12-5 304-2641........................ 6-13 304-3231 .................5-7, 5-27 305-5460 ........................ 9-39
304-2332 ........................ 12-6 304-2642........................ 6-13 304-3232 ...............5-13, 5-33 305-5467 ...................... 12-29
304-2334 ........................ 12-6 304-2645.......................... 6-9 304-3781 .......................... 3-7 305-6015 ........................ 9-37
304-2335 ........................ 9-25 304-2646........................ 9-35 304-3797 ........................ 4-11 307-9870 .......................... 7-7
304-2339 ........................ 9-25 304-2647...................... 10-11 304-3798 .......................... 6-9 308-6651 .......................... 6-8
304-2565 ........................ 6-16 304-2648.......................... 6-9 304-3799 .......................... 6-8 308-7035 .......................... 1-4
304-2566 .................3-13, 6-3 304-2649.......................... 6-9 304-3800 .......................... 6-9 309-4311 .......................... 3-9
304-2567 .......................... 4-3 304-2650........................ 10-8 304-3805 .......................... 1-5 309-4312 .......................... 3-9
304-2569 ...................... 12-22 304-2651........................ 9-25 304-3806 ........................ 9-25 309-4313 .......................... 3-9
304-2571 ...................... 12-22 304-2652........................ 4-11 304-3807 ........................ 9-25 309-4315 .......................... 3-9
304-2573 ........................ 9-41 304-2656.......................... 6-8 304-3810 ........................ 4-11 309-4316 .......................... 3-9
304-2575 ...................8-5, 8-7 304-2657........................ 9-35 304-3812 ........................ 12-5 309-4317 .......................... 3-9
304-2576 ...................8-5, 8-7 304-2660...................... 12-13 304-3813 ........................ 9-22 309-4318 .......................... 3-9
304-2581 .......................... 3-7 304-3165........................ 2-17 304-3817 ........................ 12-6 309-4319 .......................... 3-9
304-2582 .......................... 3-7 304-3171........................ 6-19 304-3818 ........................ 9-35 309-4320 .......................... 3-9
304-2583 .......................... 3-7 304-3177.......................... 1-5 304-3819 ........................ 5-37 309-4321 .......................... 3-9
304-2592 ........................ 10-5 304-3181.......................... 6-8 304-3820 ........................ 9-17 309-4322 .......................... 3-9
304-2594 ...................... 12-29 304-3182........................ 12-5 304-3822 ........................ 10-8 309-4323 .......................... 3-9
304-2596 ........................ 4-45 304-3183........................ 12-5 304-4551 ...................... 12-22 309-6238 .......................... 1-4
304-2597 ...............4-25, 4-27 304-3184........................ 12-6 304-4552 ...................... 12-22 309-6301 ........................ 11-7
304-2598 ...............4-25, 4-27 304-3187...................... 12-11 304-4563 ........................ 10-5 309-6321 ................... 6-3, 6-4
304-2599 ...............4-25, 4-27 304-3188...................... 12-11 304-4564 ........................ 9-21 309-6332 ...................... 12-41
304-2600 .. 8-3, 8-5, 8-7, 8-27 304-3189...................... 12-11 304-4572 .......................... 7-3 309-6819 ........................ 6-19
304-2601 ........................ 9-27 304-3190........................ 12-9 304-4573 ........................ 12-5 309-6819 ...................... 12-43
304-2603 ...............5-11, 5-31 304-3191........................ 12-9 304-4575 ........................ 12-5 309-6823 ...................... 12-43
304-2604 .......................... 4-7 304-3192........................ 12-9 304-4577 ........................ 12-5 310-6250 ........................ 3-11
304-2605 ........................ 4-41 304-3193........................ 12-9 304-4578 ........................ 12-5 310-6251 ........................ 3-11
304-2606 .............10-8, 12-33 304-3194........................ 12-9 304-4579 ........................ 9-35 310-7936 ........................ 4-11
31200255 TL642 14-7

PART NUMBER INDEX
310-8321 ........................ 9-21 314-5320 ........................11-5 317-0089 .......................... 1-5 318-9245........... 12-46, 12-47
310-8443 .......................... 1-5 314-5321 ........................11-4 317-0090 .......................... 1-5 318-9246............... 6-22, 6-23
310-8451 ........................ 8-27 314-5322 ........................11-5 317-0090 ...................... 12-39 318-9246........... 12-46, 12-47
310-8452 ........................ 8-27 314-5323 ........................11-5 317-0601 ........................ 9-29 318-9247........................ 6-23
310-8453 ........................ 8-27 314-5324 ........................11-4 317-0602 ........................ 9-29 318-9247...................... 12-47
310-8454 ........................ 8-27 314-5325 ........................11-5 317-0603 ........................ 9-29 320-0525...................... 12-33
310-8455 ........................ 8-27 314-5326 ........................11-7 317-0604 ........................ 9-29 320-0529...................... 12-33
310-8507 .......................... 4-4 314-5327 ........................11-5 317-0605 ........................ 9-29 320-0534.......................... 6-8
310-8507 ........................ 9-27 314-6030 ........................11-3 317-0607 ........................ 9-29 320-4875........................ 12-6
310-8508 .......................... 4-4 314-6031 ........................11-3 317-0608 ........................ 9-29 320-7882........................ 11-7
311-0660 ........................ 6-19 314-6032 ........................11-3 317-0609 ........................ 9-29 320-7883........................ 11-7
311-0679 ...................... 12-35 314-6130 ..........................6-4 317-0610 ........................ 9-29 320-8390........................ 6-13
311-0680 ...................... 12-35 314-6696 ........................11-3 317-0611 ........................ 9-29 321-0556........................ 3-15
311-0684 ...................... 12-35 314-6697 ........................11-3 317-0612 ........................ 9-29 321-2484........................ 11-4
311-0685 ...................... 12-35 314-7754 ......................12-33 317-0613 ........................ 9-29 321-2485........................ 11-4
311-2854 .......................... 3-5 314-7795 ........................4-45 317-0614 ........................ 9-29 321-2486........................ 11-4
311-9612 ........................ 4-45 314-7798 ........................4-45 317-0615 ........................ 9-29 321-2487........................ 11-4
311-9613 ........................ 4-45 314-8489 ......................12-33 317-0616 ........................ 9-29 321-2488........................ 11-4
312-2615 ........................ 11-3 315-1126 ........................9-39 317-0617 ........................ 9-29 321-2489........................ 11-4
313-2471 .......................... 9-7 315-2004 ........................4-45 317-0618 ........................ 9-29 321-2490........................ 11-4
313-2472 .......................... 9-7 315-2023 ......................12-31 317-0619 ........................ 9-29 321-2491........................ 11-4
313-2473 .......................... 9-7 315-2025 ......................12-31 317-0620 ........................ 9-29 321-2492........................ 11-4
313-3349 .......................... 3-9 315-2026 ......................12-31 317-0621 ........................ 9-29 321-2493........................ 11-4
313-4359 ........................ 11-3 315-2027 .......... 12-22, 12-31 317-0622 ........................ 9-29 321-2494........................ 11-4
313-5257 ........................ 6-19 315-3422 ..........................1-5 317-0623 ........................ 9-29 321-2495........................ 11-4
313-5257 ...................... 12-43 315-3423 ..........................1-5 317-0624 ........................ 9-29 321-2496........................ 11-4
313-5259 ...................... 12-43 315-3424 ..........................1-5 317-0625 ........................ 9-29 321-2497........................ 11-4
313-5260 ........................ 6-22 315-3424 .......... 12-37, 12-39 317-0626 ........................ 9-29 321-2498........................ 11-4
313-6241 ........................ 11-3 315-3678 ........................9-37 317-0627 ........................ 9-29 321-2499........................ 11-4
313-6242 ........................ 11-3 315-3679 ........................9-37 317-0628 ........................ 9-29 321-2500........................ 11-4
314-2338 ........................ 11-4 315-3680 ........................9-37 317-0629 ........................ 9-30 321-2501........................ 11-4
314-2339 ........................ 11-5 315-4601 ........................11-3 317-5987 ........... 12-22, 12-31 321-2502........................ 11-4
314-2340 ........................ 11-5 315-4603 ........................11-3 318-9222 ........................ 3-17 321-2503........................ 11-4
314-2341 ........................ 11-5 315-4605 ........................11-3 318-9228 ........................ 6-23 321-2504........................ 11-4
314-2342 ........................ 11-7 315-4606 ........................11-3 318-9229 ........................ 6-22 321-2505........................ 11-4
314-2343 ........................ 11-5 315-4607 ........................11-3 318-9230 ........................ 6-22 321-2506........................ 11-4
314-2344 ........................ 11-5 315-4609 ........................11-3 318-9231 ........................ 6-22 321-2507........................ 11-4
314-2345 ........................ 11-5 315-4610 ........................11-3 318-9232 ........................ 6-22 321-2508........................ 11-4
314-2346 ........................ 11-5 315-4611 ........................11-3 318-9233 ........................ 6-22 321-2509........................ 11-4
314-2347 ........................ 11-5 315-4615 ........................11-3 318-9234 ........................ 6-22 321-2510........................ 11-4
314-2348 ........................ 11-5 315-4617 ........................11-3 318-9235 ........................ 6-23 321-2511........................ 11-4
314-2349 ........................ 11-7 315-4618 ........................11-3 318-9236 ........................ 6-23 321-2512........................ 11-4
314-2350 ........................ 11-5 315-4619 ........................11-3 318-9237 ........................ 6-22 321-2513........................ 11-4
314-2351 ............... 11-3, 11-7 315-4621 ........................11-3 318-9237 ...................... 12-46 321-2514........................ 11-4
314-2893 ........................ 6-19 315-4622 ........................11-3 318-9238 ........................ 6-22 321-2515........................ 11-4
314-2893 ...................... 12-43 315-4623 ........................11-3 318-9238 ...................... 12-46 321-2516........................ 11-4
314-5304 ............... 11-3, 11-7 315-4625 ........................11-3 318-9239 ........................ 6-22 321-2517........................ 11-4
314-5306 ........................ 11-3 315-5502 ..........................6-3 318-9239 ...................... 12-46 321-2518........................ 11-4
314-5307 ........................ 11-3 315-5795 ......................12-29 318-9240 ........................ 6-22 321-2519........................ 11-4
314-5308 ........................ 11-3 315-5797 ......................12-29 318-9240 ...................... 12-46 321-2520........................ 11-4
314-5309 ........................ 11-3 315-5798 ......................12-29 318-9241 ........................ 6-22 321-2521........................ 11-4
314-5310 ........................ 11-3 315-5799 ......................12-29 318-9241 ...................... 12-46 321-2522........................ 11-4
314-5311 ........................ 11-3 315-5800 ......................12-29 318-9242 ........................ 6-22 321-2523........................ 11-4
314-5312 ........................ 11-3 315-5802 ......................12-29 318-9242 ...................... 12-46 321-5021........................ 4-33
314-5315 ........................ 11-5 315-5806 ......................12-29 318-9243 ........................ 6-23 321-5022........................ 4-33
314-5316 ........................ 11-5 315-6549 ........................8-11 318-9243 ...................... 12-46 321-5023........................ 4-33
314-5317 ........................ 11-5 315-8700 ........................11-3 318-9244 ........................ 6-23 321-5024........................ 4-33
314-5318 ........................ 11-5 316-9020 ........................9-21 318-9244 ...................... 12-46 322-9668........................ 6-19
314-5319 ........................ 11-7 317-0088 ..........................1-5 318-9245 ........................ 6-23 322-9668...................... 12-43
14-8 TL642 31200255

PART NUMBER INDEX
323-1647 .......................... 1-5 328-1544...................... 12-39 339-1712 ...................... 12-33 344-7016 ........................ 4-43
323-4208 ........................ 8-17 328-1545...................... 12-37 339-1713 ...................... 12-33 344-7161 .......................... 6-3
323-5609 ........................ 11-5 328-1546...................... 12-37 339-1714 ...................... 12-33 344-7163 ...................... 10-11
323-5627 ........................ 8-27 328-1547...................... 12-39 339-7766 .......................... 4-9 344-7172 ........................ 11-3
323-7236 10-19, 12-22, 12-31 328-1548...................... 10-19 339-9594 ........................ 11-3 344-7176 ...................... 12-35
324-7383 ........................ 8-17 328-7288........................ 3-13 339-9595 ........................ 11-3 344-7179 ...................... 12-35
324-7384 ........................ 8-17 328-7289........................ 3-13 339-9596 ........................ 11-3 345-1922 ...................... 12-35
324-7385 .......................... 8-7 328-7290........................ 3-13 339-9603 ........................ 11-3 345-2161 .......................... 1-9
324-7388 .......................... 8-7 328-7291........................ 3-13 339-9604 ........................ 11-3 346-2984 ........................ 6-13
324-7389 .......................... 8-7 328-7292........................ 3-13 339-9609 ........................ 11-3 346-2985 ...................... 12-29
324-7390 .......................... 8-7 328-7293........................ 3-13 339-9620 ........................ 11-3 346-2986 ...................... 12-35
324-7391 ........................ 8-21 329-0290.......................... 4-9 340-0961 ...................... 12-41 346-4742 ...................... 12-35
324-7392 ........................ 8-21 329-3482........................ 9-27 340-0977 ...................... 12-41 348-2862 ........................ 4-41
324-7398 .......................... 8-9 329-9751........................ 9-21 340-0978 ...................... 12-41 349-6876 ...................... 12-47
324-7399 .......................... 8-9 329-9753........................ 9-22 340-0979 ...................... 12-41 350-2520 .......................... 6-3
324-7401 .......................... 8-9 329-9754........................ 9-21 340-0985 ...................... 12-41 350-2524 ........................ 5-39
324-7402 .......................... 8-9 329-9755........................ 9-22 340-0986 ...................... 12-41 350-2528 ...................... 12-46
324-7403 .......................... 8-7 330-3035.......................... 4-9 340-8974 ........................ 3-13 350-2529 ...................... 12-46
324-7404 .......................... 8-7 330-4923........................ 11-5 340-8975 ........................ 3-13 350-2530 ...................... 12-46
324-7405 ........................ 8-21 330-5286........................ 11-7 340-8976 ........................ 3-13 350-2531 ...................... 12-46
324-7406 ........................ 8-15 330-8325.......................... 3-9 340-8977 ........................ 3-13 350-2532 ...................... 12-46
324-9527 ...................... 12-29 331-0101........................ 6-19 340-8978 ........................ 3-13 350-8568 ........................ 5-27
324-9528 ...................... 12-29 331-0104........................ 4-37 340-8979 ........................ 3-13 350-8569 ........................ 5-27
324-9529 ...................... 12-29 331-0795........................ 4-13 341-1835 .......................... 4-4 350-8570 ........................ 5-31
324-9530 ...................... 12-29 331-0803................. 5-3, 5-23 341-2966 .......................... 4-3 350-8571 ........................ 5-33
324-9531 ...................... 12-29 331-0804................. 5-3, 5-23 341-2967 ........................ 9-27 350-8572 ........................ 5-35
325-0033 .......................... 9-9 331-1596.......................... 2-3 341-4074 .......................... 9-5 350-8573 ........................ 5-39
325-0034 ........................ 9-13 331-2385.......................... 4-3 341-4075 .......................... 9-5 350-8574 ........................ 5-39
325-0035 .......................... 9-5 331-2386........................ 9-27 341-4076 ....... 9-5, 9-13, 9-19 350-8575 ........................ 5-39
325-0036 ........................ 9-19 331-2460.......................... 4-3 341-4077 ........................ 9-13 350-8576 ........................ 5-39
325-1068 ...................... 12-33 331-3800.......................... 9-5 341-4078 .......................... 9-5 350-8577 ........................ 5-39
325-1345 ........................ 4-17 331-3810.......................... 2-3 341-4079 .......................... 9-5 350-8578 ........................ 5-39
325-1351 ........................ 4-17 331-3989........................ 5-25 341-4080 .......................... 9-5 350-8579 ........................ 5-39
325-1352 ........................ 4-17 332-1348...................... 12-22 341-4081 .......................... 9-5 350-8580 ............... 5-21, 5-43
325-1433 ........................ 6-19 333-2415........................ 6-13 341-4082 .......................... 9-5 3P-8517 ......................... 4-13
325-1433 ...................... 12-43 334-3558.......................... 6-4 341-4083 .......................... 9-9 4520368 ......................... 5-47
325-8140 ........................ 8-17 334-3559.......................... 6-4 341-4084 .......................... 9-9 4520369 ......................... 5-47
325-8141 ........................ 8-19 334-3560.......................... 6-4 341-4085 ....... 9-9, 9-13, 9-19 4520370 ......................... 5-47
325-8143 .......................... 5-3 334-4097........................ 10-8 341-4086 .......................... 9-9 4520371 ......................... 5-47
325-8144 ........................ 8-15 334-4098........................ 10-8 341-4087 .......................... 9-9 4520374 ......................... 5-47
327-6270 ........................ 3-15 334-5871...................... 10-19 341-4088 .......................... 9-9 4520375 ......................... 5-47
327-6271 ...............3-13, 3-15 335-3833........................ 4-43 341-4089 .......................... 9-9 4520449 ......................... 5-47
327-6272 ........................ 3-15 335-8059........................ 3-13 341-4090 .......................... 9-9 4520450 ......................... 5-47
327-6273 ........................ 3-17 335-8066........................ 3-13 341-4091 .......................... 9-9 4520451 ......................... 5-47
327-6274 ........................ 3-17 335-8077........................ 3-13 341-4092 .......................... 9-9 4520453 ......................... 5-47
327-6317 ........................ 3-15 335-8078........................ 3-13 341-4093 .......................... 9-9 4520455 ......................... 5-47
327-6318 ........................ 3-15 335-8080........................ 3-13 341-4094 ........................ 9-13 4520456 ......................... 5-47
327-6320 ........................ 3-17 335-8093...................... 12-35 341-4095 ........................ 9-13 4520458 ......................... 5-47
327-6321 ........................ 3-17 335-8098........................ 3-13 341-4096 ........................ 9-13 4520459 ......................... 5-47
327-6323 ........................ 3-17 336-2804........................ 3-13 341-4097 ........................ 9-13 4520461 ......................... 5-47
327-6324 ........................ 3-17 337-7993................... 9-3, 9-5 341-4098 ........................ 9-13 4520462 ......................... 5-47
327-6325 ........................ 3-17 338-9997........................ 3-13 341-4099 ........................ 9-13 4520645 ......................... 5-47
327-6326 ........................ 3-17 338-9998........................ 3-13 341-4100 ........................ 9-13 4520646 ......................... 5-47
327-6327 ........................ 3-17 338-9999........................ 3-13 343-7819 ...................... 12-33 4520647 ......................... 5-47
327-6328 ........................ 3-17 339-0000........................ 3-13 343-7820 ...................... 12-33 5C-2890 ........................... 4-7
327-6329 ........................ 3-17 339-0003........................ 3-13 343-9736 ........................ 3-13 5P-8500 ........... 1-5, 6-9, 6-13
327-6330 ........................ 3-17 339-0004........................ 3-13 343-9737 ........................ 3-13 5W-8686 ...................... 12-23
327-6333 ........................ 3-17 339-0837...................... 12-33 343-9738 ........................ 3-13 6V-7978 ........................... 6-3
327-6335 ........................ 3-15 339-1711...................... 12-33 344-1586 ........................ 9-29 7W-2326 .......................... 4-9
31200255 TL642 14-9

PART NUMBER INDEX
7X-3359 ......................... 6-19
7X-3359 ....................... 12-43
8780031 ......................... 5-47
8780036 ......................... 5-47
8780045 ......................... 5-47
8780048 ......................... 5-47
8780050 ......................... 5-47
8780264 ......................... 5-47
8T-4121..................... 4-3, 4-7
8T-4133............................ 4-7
8T-4136............4-3, 4-7, 4-17
8T-4186............................ 4-7
8T-4189............................ 4-4
8T-4195............................ 7-7
8T-4196............................ 4-7
8T-4200............................ 4-4
8T-4908............................ 4-7
8T-4956.............. 4-3, 4-4, 4-7
8T-4970............................ 1-5
8T-7008............................ 1-5
91405035 ....................... 5-47
91405036 ....................... 5-47
91475031 ....................... 5-47
91475032 ....................... 5-47
91475054 ....................... 5-47
91475055 ....................... 5-47
91475093 ....................... 5-47
91475105 ....................... 5-47
91515056 ....................... 5-47
91515066 ....................... 5-47
91535017 ....................... 5-47
91535019 ....................... 5-47
9L-0895 ............................ 4-9
14-10 TL642 31200255

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762

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Parts Manual

October 20, 2006 - A - Original Issue of Manual

-ii TL642 31200255

31200255 TL642 iii

FIGURE NO. TITLE PAGE NO.

4-14 ZF Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

FIGURE NO. TITLE PAGE NO.

10-3 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

1350 ENGINE COOLING SYSTEM 3000 TRANSMISSION & DRIVE LINE

3100 TORQUE CONVERTER, TORQUE DIVIDER,

5800 OTHER CONTROLS

7600 MACHINE ELECTRONIC CONTROLS & DATA

Figure 1-1 Frame Shrouding & Trim

1-2 TL642 31200255

Figure 1-1 Frame Shrouding & Trim (Continued)

31200255 TL642 1-3

Figure 1-1 Frame Shrouding & Trim

1-4 TL642 31200255

Figure 1-1 Frame Shrouding & Trim (Continued)

31200255 TL642 1-5

Figure 1-2 Axle Mounting

1-6 TL642 31200255

Figure 1-2 Axle Mounting

31200255 TL642 1-7

Figure 1-3 Outrigger Mounting, (if equipped)

1-8 TL642 31200255

Figure 1-3 Outrigger Mounting, (if equipped)

31200255 TL642 1-9

This Page Intentionally Left Blank

1-10 TL642 31200255

Figure 2-1 First Boom Section

Coat Anchor Bolt Threads on items 2 & 12 with Mystik XD2,

2-2 TL642 31200255

Figure 2-1 First Boom Section

31200255 TL642 2-3

2. The length of pad bolts depend on the amount of shims used.

4. Use Cat Threadlock on all bolt threads.

2-4 TL642 31200255

31200255 TL642 2-5

Figure 2-3 Second Boom Section

2-6 TL642 31200255

Figure 2-3 Second Boom Section

31200255 TL642 2-7

4. Use Cat Threadlock on all bolt threads.

2-8 TL642 31200255

31200255 TL642 2-9

2-10 TL642 31200255

31200255 TL642 2-11

Figure 2-5 Third Boom Section

4. Use Cat Threadlock on all bolt threads.

2-12 TL642 31200255

Figure 2-5 Third Boom Section

31200255 TL642 2-13

4. Use Cat Threadlock on all bolt threads.

2-14 TL642 31200255

31200255 TL642 2-15

Figure 2-7 Push Beam/Extend Chain & Roller Assembly

NOTE: THE CHAIN CLEVIS ROD (item 4),

2-16 TL642 31200255

Figure 2-7 Push Beam/Extend Chain & Roller Assembly

31200255 TL642 2-17

Figure 2-8 Quick Coupler Assembly