Parts Manual
Model
TL642
S/N TBK00100 & After
P/N 31200255
Revised
November 15, 2010
EFFECTIVITY PAGE
31200255 TL642 i
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 November 15, 2010 - J - Revised Manual
TABLE OF CONTENTS
FIGURE NO.
TITLE
PAGE NO.
31200255 TL642 iii
SECTION 1 –
FRAME & ATTACHING PARTS . . . 1-1
1-1 Frame Shrouding & Trim . . . 1-2 1-2 Axle Mounting . . . 1-10 1-3 Outrigger Mounting, (if equipped) . . . 1-12
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 3-9 48” Side Shift Carriage . . . 3-18
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 Engine Assembly . . . 4-8 4-4 Cat Engine . . . 4-12 4-5 Fuel Tank & Lines . . . 4-16 4-6 Radiator Assembly . . . 4-18 4-7 Air Cleaner and Installation . . . 4-22 4-8 Exhaust Installation . . . 4-26 4-9 Transmission - ZF Transmission . . . 4-30 4-10 ZF Transmission - Converter & Input . . . 4-32 4-11 ZF Transmission - Gearbox Housing . . . 4-34 4-12 ZF Transmission - Reversing Gear . . . 4-36
TABLE OF CONTENTS
FIGURE NO.
TITLE
PAGE NO.
4-13 ZF Transmission - Reverse Gear Group . . . 4-38 4-14 ZF Transmission - 1st Shaft Group . . . 4-40 4-15 ZF Transmission - 2nd Shaft Group . . . 4-42 4-16 ZF Transmission - 3rd Shaft Group . . . 4-44 4-17 ZF Transmission - 4th Shaft Group . . . 4-46 4-18 ZF Transmission - Power Take-Off . . . 4-48 4-19 ZF Transmission - Control Unit & Pressure Regulator . . . 4-50 4-20 ZF Transmission - Gearshift System . . . 4-52 4-21 ZF Transmission - Oil Pump, Filter & Dipstick . . . 4-54 4-22 ZF Transmission - Transfer Box . . . 4-56
SECTION 5 –
DRIVE TRAIN . . . 5-1
5-1 Front Axle Assembly . . . 5-2 5-2 Front Axle . . . 5-6 5-3 Front Axle Housing Assembly . . . 5-8 5-4 Front Steering Components . . . 5-10 5-5 Front Gear Components . . . 5-12 5-6 Front Differential . . . 5-14 5-7 Front Double Joint . . . 5-16 5-8 Front Brakes . . . 5-18 5-9 Front Wheel Hub . . . 5-20 5-10 Front Reduction Gears . . . 5-22 5-11 Rear Axle Assembly . . . 5-24 5-12 Rear Axle . . . 5-26 5-13 Rear Axle Housing Assembly . . . 5-28 5-14 Rear Steering Components . . . 5-30 5-15 Rear Gear Components . . . 5-32 5-16 Rear Differential . . . 5-34 5-17 Rear Double Joint . . . 5-36 5-18 Rear Brakes . . . 5-38 5-19 Rear Wheel Hub . . . 5-42 5-20 Rear Reduction Gears . . . 5-44 5-21 Drive Shaft Assembly . . . 5-46 5-22 Tires & Rims . . . 5-48
SECTION 6 –
CAB . . . 6-1
6-1 Cab Assembly . . . 6-2 6-2 Cab . . . 6-10 6-3 Suspension Seat . . . 6-14 6-4 Instrument Panel . . . 6-16 6-5 Heating Components . . . 6-20 6-6 Cab Air Conditioning . . . 6-24TABLE OF CONTENTS
FIGURE NO.
TITLE
PAGE NO.
31200255 TL642 v
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 . . . 8-6 8-3 Steer Select Valve . . . 8-12 8-4 Service/Parking . . . 8-14 8-5 Joystick Circuit . . . 8-16 8-6 Lift Cylinder . . . 8-18 8-7 Extend/Retract . . . 8-20 8-8 Tilt & Tilt Compensating Cylinder . . . 8-22 8-9 Auxiliary Hydraulics . . . 8-24 8-10 Sway Cylinder . . . 8-26 8-11 Outrigger Controller, (if equipped) . . . 8-28 8-12 Outrigger Cylinders, (if equipped) . . . 8-30
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 . . . 9-30 9-10 Priority Valve . . . 9-34 9-11 Steer Select Valve . . . 9-36 9-12 Quick Coupler Cylinder . . . 9-38 9-13 Outrigger Cylinder, (if equipped) . . . 9-40 9-14 Outrigger Control Valve, (if equipped) . . . 9-42 9-15 Swing Carriage Cylinder . . . 9-44 9-16 Side Shift Carriage Cylinder . . . 9-46TABLE OF CONTENTS
FIGURE NO.
TITLE
PAGE NO.
SECTION 10 –
ELECTRICAL . . . 10-1
10-1 Battery & Cables . . . 10-2 10-2 Battery Disconnect Option . . . 10-4 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 10-9 Chassis Harness . . . 10-20
SECTION 11 –
DECALS . . . 11-1
11-1 Cab & Frame Decals . . . 11-2 11-2 Boom Decals . . . 11-10
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 Arctic Package . . . 12-36 12-14 Top Cab Glass Shield . . . 12-40 12-15 Front Cab Glass Shield . . . 12-42 12-16 Hydraulic Cooler Bypass Install . . . 12-44 12-17 Beacon Light Mount w/AC . . . 12-46
SECTION 13 –
RECOMMENDED SPARE PARTS . . . 13-1
SECTION 14 – PART NUMBER INDEX . . . 14-1
SMCS CODES - TELEHANDLER
vii
1350 ENGINE COOLING SYSTEM
1351 RADIATOR & OIL COOLER 1353 RADIATOR
1354 EXPANSION TANK 1360 FAN GUARD
1374 HYDRAULIC OIL COOLER
1375 TORQUE CONVERTER / TRANSMISSION OIL COOLER
1380 COOLANT HOSE / LINES 1381 RADIATOR AND GUARD 1382 RADIATOR CAP
1384 ENGINE COOLANT HEATER 1386 HYDRAULIC FAN MOTOR 1387 HYDRAULIC FAN PUMP 1395 ENGINE COOLANT 1400 ELECTRICAL SYSTEM 1401 BATTERY 1402 BATTERY CABLE 1408 WIRING HARNESS 1416 START SWITCH
1417 FUSE / CIRCUIT BREAKER PANEL 1428 BACKUP LIGHT(S)
1429 LIGHT(S)
1430 DIRECTIONAL LIGHT 1431 BEACON LIGHT(S) 1432 STOP /LIGHT / TAILLIGHT 1434 CAB LIGHT
1434 FLOODLIGHT
OTHER ENGINE COMPONENTS
1801 ENGINE SOUND SUPPRESSION 1802 REFRIGERANT COMPRESSOR 1805 REFRIGERANT CONDENSER
1807 AIR CONDITIONER COMPRESSOR DRIVE 1808 AIR CONDITIONER LINES
1810 RADIATOR & REFRIGERANT CONDENSER 1812 HEATER / HOSE LINES
1813 RADIATOR HOSE
3000 TRANSMISSION & DRIVE LINE
3013 AXLE ARRANGEMENT 3020 DRIVE & STEERING AXLE 3061 TRANSMISSION GEARS 3063 TRANSMISSION SHAFT 3064 TRANSMISSION CASE 3065 TRANSMISSION CONTROL 3066 TRANSMISSION OIL PUMP 3067 TRANSMISSION OIL FILTER 3068 TRANSMISSION OIL FILTER BASE 3075 TRANSMISSION OUTPUT GEARS 3080 TRANSMISSION OIL
3081 TRANSMISSION OIL LEVEL 3082 TRANSMISSION MOUNT
3100 TORQUE CONVERTER, TORQUE DIVIDER, RETARDER
3101 TORQUE CONVERTER
3115 TORQUE CONVERTER/TRANSMISSION SCAVENGE PUMP
3133 TORQUE CONVERTER RELIEF VALVE 3139 MODULATING VALVE
3141 TORQUE CONVERTER SPEED SENSOR
3030 POWER SHIFT / HYDROSTATIC TRANSMISSION
3063 TRANSMISSION SHAFT 3064 TRANSMISSION CASE
3065 HYDROSTATIC CONTROL LINKAGE (EXTERNAL) 3066 POWER SHIFT TRANSMISSION OIL PUMP 3067 HYDROSTATIC TRANSMISSION OIL FILTER 3073 HYDROSTATIC MAIN CONTROL VALVE 3151 TRANSMISSION GOVERNOR
3154 TRANSMISSION LINES/HOSES 3155 TRANSMISSION CLUTCH
3157 TRANSMISSION SELECTOR VALVE 3159 TRANSFER GEARS
3160 TRANSMISSION PLANETARY
3167 TRANSMISSION HYDRAULIC CONTROL 3168 TRANSMISSION ELECTRONIC CONTROL 3174 SHIFT SOLENOID
SMCS CODES - TELEHANDLER
3181 TRANSMISSION NEUTRALIZER CONTROL VALVE 3182 TRANSMISSION LUBRICATION RELIEF VALVE 3184 TRANSMISSION OIL COOLER BYPASS VALVE 3186 TRANSMISSION PLANET CARRIER
3187 TRANSMISSION CARRIER THRUST DISC/PLATE 3190 TRANSMISSION CLUTCH PLATE
3191 TRANSMISSION NEUTRALIZER
3194 TRANSMISSION TEMPERATURE SENSOR 3202 TRANSMISSION FLOW CONTROL VALVE 3203 DRIVE PUMP
3204 CHARGE PUMP
3205 SERVO CONTROL VALVE 3206 MANIFOLD/METERING VALVE 3207 SERVO CYLINDER
3210 HIGH PRESSURE RELIEF VALVE 3213 CHARGE & MAIN RELIEF VALVE 3214 SYNCHRONIZING VALVE
3215 POWER UNIT CONTROL LINKAGE
3216 TRANSMISSION UNDERSPEED/OVERSPEEDVALVE 3219 TRANSMISSION PILOT OVERSPEED VALVE
3220 TRAVEL SPEED CONTROL VALVE 3221 HYDROSTATIC POWER CASE 3222 PUMP HEAD
3223 TRANSMISSION UNDERSPEED OVERRIDE VALVE 3225 TRAVEL ELECTRONIC CONTROL
3226 DOWNSHIFT INHIBITOR
3250 DRIVE LINE/DRIVE AXLE
3251 UNIVERSAL JOINT 3252 FLEXIBLE COUPLING 3253 DRIVE SHAFT 3254 DRIVE LINE PINION 3256 BEVEL GEAR/SHAFT
3257 BEVEL GEAR SHAFT BEARING 3258 DIFFERENTIAL
3259 AXLE SHAFT
3260 AXLE HOUSING ASSEMBLY 3263 LIMITED SLIP DIFFERENTIAL 3267 DRIVE SHAFT SUPPORT
3269 PINION HOUSING
3274 CONSTANT VELOCITY UNIVERSAL JOINT 3275 DRIVE LINE BRAKE
3276 DRIVE LINE BRAKE DISC 3278 DRIVE AXLE
3281 BEVEL GEAR CASE 3282 AXLE
3283 DIFFERENTIAL CASE 3284 DIFFERENTIAL CARRIER
4000 DRIVE TRAIN
4004 BRAKE & AXLE
4005 STEERING & BRAKING SYSTEM
4050 FINAL DRIVE
4051 FINAL DRIVE & WHEEL 4052 FINAL DRIVE SEAL
4053 DRIVE AXLE HUB/GEAR ASSEMBLY 4054 FINAL DRIVE HUB
4055 FINAL DRIVE GEARS 4056 FINAL DRIVE - DRIVE SHAFT 4057 FINAL DRIVE PINION FLANGE 4059 FINAL DRIVE CASE/BORE
4084 FINAL DRIVE PLANETARY CARRIERS, HUB & RING GEAR
4091 FINAL DRIVE PINION
4092 PLANETARY FINAL DRIVE CARRIER
4093 FINAL DRIVE PLANETARY CARRIER THRUST SURFACE
4094 FINAL DRIVE PINION & FLANGE
4200 WHEEL & TIRE
4201 WHEEL 4202 RIM & TIRE 4203 TIRE
4208 WHEEL ASSEMBLY 4209 WHEEL RIM
4210 WHEEL STUD/BOLT/NUT 4220 MUD GUARD
SMCS CODES - TELEHANDLER
ix
4250 BRAKING SYSTEM
4251 SERVICE BRAKE 4255 BRAKE DISC
4256 BRAKE CALIPER, HEAD ASSEMBLY 4257 BRAKE LINES
4258 BRAKE MASTER CYLINDER 4262 BRAKE ACTUATOR
4265 SERVICE BRAKE CONTROL VALVE 4267 PARKING BRAKE
4269 SERVICE BRAKE CONTROL 4273 FRICTION PADS
4282 PARKING/SECONDARY BRAKE CONTROL VALVE 4284 PARKING BRAKE CONTROL
4291 BRAKE HYDRAULIC RESERVOIR
4300 STEERING SYSTEM 4301 STEERING GEAR 4303 STEERING CYLINDER 4307 STEERING VALVE 4309 STEERING WHEEL 430S STEERING SENSOR 4310 STEERING COLUMN
4312 STEERING METERING PUMP 4313 STEERING AXLE
4314 KINGPIN 4318 TIE ROD
4321 STEERING KNUCKLE 4322 STEERING RELIEF VALVE 4329 TIE ROD END
4338 ADJUSTABLE STEERING COLUMN
4349 STEERING SELECTOR & PRESSURE CONTROL VALVE
4350 HYDROSTATIC DRIVE
4351 HYDRAULIC PROPEL/DRIVE MOTOR 4352 DRIVE CONTROL VALVE
4267 HYDROSTATIC DRIVE PARKING BRAKE 4354 BRAKE RELEASE PUMP
4355 HYDROSTATIC DRIVE GEAR REDUCER 4356 BRAKE & SHIFT VALVE
5000 IMPLEMENT CONTROLS
5001 IMPLEMENT CONTROL LOCK 5002 HYDRAULIC & FUEL TANK 5004 RIDE CONTROL SYSTEM 5005 AUXILIARY HYDRAULIC CIRCUIT
5050 HYDRAULIC SYSTEM
5051 HYDRAULIC CONTROL VALVE 5056 HYDRAULIC TANK
5057 HYDRAULIC HOSES/LINES 5059 PILOT CONTROL VALVE 505C PISTON CYLINDER 5063 IMPLEMENT CONTROL 5068 HYDRAULIC OIL FILTER 5069 MAIN SYSTEM RELIEF VALVE 506P IMPLEMENT PRIORITY VALVE 5070 PISTON PUMP
5071 HYDRAULIC OIL COOLER BYPASS VALVE 5072 PILOT SYSTEM RELIEF VALVE
5084 IMPLEMENT PUMP 5086 COMPENSATOR VALVE
5093 HYDRAULIC FILTER BYPASS VALVE 5095 HYDRAULIC OIL
509T HYDRAULIC OIL TEMPERATURE SENSOR
5100 LIFT, TILT, TIP & OTHER CONTROLS
5102 LIFT/HOIST CYLINDER 5103 LIFT CYLINDER TRUNNION 5104 TILT CYLINDER
5106 TIP CYLINDER
5116 ATTACHMENT CYLINDER 5130 LOCK VALVE
5141 HITCH LIFT CYLINDER 5144 FRAME LEVEL VALVE 5486 EXTENSION CYLINDER
SMCS CODES - TELEHANDLER
5700 IMPLEMENT ELECTRONIC CONTROLS
5701 IMPLEMENT ELECTRONIC CONTROL MODULE (PREPROGRAMMED)
5702 IMPLEMENT HYDRAULIC ELECTRONIC CONTROL 5705 JOYSTICK
5734 HYDRAULIC SYSTEM WIRING HARNESS 5735 FRAME LEVEL CONTROL
5800 OTHER CONTROLS
5804 SIDESHIFT CYLINDER 5811 LOAD CONTROL VALVE 5816 COMPENSATING CYLINDER 5823 FORK LEVEL CYLINDER
6400 MATERIAL HANDLING ATTACHMENTS
6402 STANDARD CARRIAGE 6404 LIFT CHAIN 6405 LIFT FORK 6408 ROTATING CARRIAGE 6409 WIDE CARRIAGE 6416 BALE CLAMP 6425 SIDESHIFT CARRIAGE 6459 LIFTING HOOK 6460 TELESCOPING BOOM 6461 MAN BASKET 7050 FRAME 7051 MAIN FRAME 7056 COUNTERWEIGHT
7059 FUEL TANK, SEAT & FRAME 7078 FRAME LEVEL CYLINDER
7100 HITCH 7105 FIXED DRAWBAR 7116 HITCH/TOW PIN 7150 GUARD 7151 CRANKCASE GUARD 7154 ENGINE GUARD 7165 CAB/CANOPY SCREEN 7170 RADIATOR GRILLE 7177 ROPS ROLL BAR 7192 WHEEL CHOCK 7200 SUSPENSION 7221 OUTRIGGER 7250 BODY 7251 HOOD 7252 FENDER 7253 PLATFORM/DECK 7257 BATTERY BOX/SUPPORT
7261 PLATFORM SOUND SUPPRESSION 7262 FIREWALL
7263 ENGINE ENCLOSURE
7264 ROPS MOUNT REAR SUPPORT 7265 FLOORPLATE
7266 ROPS MOUNT 7267 BODY PANEL 726A ACCESS PANEL 726M FLOORMAT 7272 RADIATOR ENCLOSURE/SHROUD 7273 COMPARTMENT DOOR 7276 MACHINE ENCLOSURE 7300 OPERATOR STATION 7301 CAB 7302 CANOPY 7304 CAB HEATER 7305 WINDSHIELD WIPER 7306 WINDSHIELD WASHER 7307 SEAT/ARM CUSHION 7308 CAB DOOR
7309 HEATER & AIR CONDITIONER 7310 WINDOW GLASS
7312 SEAT ASSEMBLY 7314 DASH
SMCS CODES - TELEHANDLER
xi
731S SEAT AIR COMPRESSOR 7320 AIR CONDITIONER 7321 SEAT FRAME
7322 AIR CONDITIONER RECEIVER/DRYER 7323 ROPS/FOPS CANOPY
7324 SUSPENSION SEAT 7325 ROPS/FOPS CAB 7327 SEAT BELT
7329 CAB LINER/SOUND SUPPRESSION 7330 CANOPY SOUND SUPPRESSION 7332 ELECTRIC SWITCH (MANUAL) 7338 RADIO
7340 WINDSHIELD 7342 CAB AIR FILTER
7400 PROTECTION DEVICES, ALARMS & INDICATORS
7402 WARNING HORN
7405 INSTRUCTION/WARNING PLATE/FILM 7406 BACK-UP ALARM
7407 ACTION ALARM
7420 LOW COOLANT TEMPERATURE ALARM 7421 LOW ENGINE OIL PRESSURE SHUTOFF 7431 WARNING/INDICATOR LIGHT
7450 GAUGES & INDICATORS
7451 INSTRUMENT PANEL/CONTROL PANEL 7452 AIR FILTER INDICATOR
7453 ENGINE COOLANT TEMPERATURE GAUGE 7455 ENGINE OIL PRESSURE GAUGE
7459 TRANSMISSION GEAR/SHIFT INDICATOR 7462 TACHOMETER
7463 SPEEDOMETER 7464 ODOMETER 7467 AMMETER
7470 COOLANT LEVEL GAUGE 7475 OIL FILTER INDICATOR
7477 TRANSMISSION/TORQUE CONVERTER TEMPERATURE GAUGE
7478 SERVICE METER 7479 SIGHT GAUGE
7480 ELECTRIC HOUR METER
7481 FUEL LEVEL GAUGE
7483 LOW FUEL LEVEL INDICATOR
7485 ENGINE LOW OIL PRESSURE INDICATOR 7486 PARKING BRAKE INDICATOR LIGHT 7488 HYDRAULIC OIL TEMPERATURE GAUGE 7490 ELECTRONIC MONITORING SYSTEM/PANEL 7493 GROUND SPEED SENSOR
7496 ALTERNATOR INDICATOR
7500 MAINTENANCE
7501 FIRST SERVICE INTERVAL 7502 SECOND SERVICCE INTERVAL 7503 THIRD SERVICE INTERVAL 7504 FOURTH SERVICE INTERVAL 7507 LIFT ARM SUPPORT
751B BATTERY CHARGER
7524 250 SERVICE HOUR MAINTENANCE 7525 500 SERVICE HOUR MAINTENANCE 7526 1000 SERVICE HOUR MAINTENANCE 7527 2000 SERVICE HOUR MAINTENANCE 7534 750 SERVICE HOUR MAINTENANCE 7542 SOS
7550 COMMON SUBJECTS
7551 BEARINGS 7552 GEARS
7553 FASTENERS, CONNECTORS & HARDWARE 7554 HOSES & LINES
7555 SEALS & GASKETS 7556 WIRE
7557 INFORMATION/IDENTIFICATION PLATES & TRANSFERS
7558 WEAR SLEEVES 7559 PAINTED SURFACES 755R RETAINER SYSTEM
7560 COMPARTMENT FLUID LEVEL 7561 DUO-CONE SEAL
7562 HYDRAULIC CYLINDERS
7569 TROUBLESHOOTING PROCEDURE 756P MAINTENANCE PARTS
SMCS CODES - TELEHANDLER
7571 SOS ENGINE PRODUCT INFORMATION
7573 SOS TRANSMISSION PRODUCT INFORMATION 7574 SOS DRIVE TRAIN PRODUCT INFORMATION 7575 SOS HYDRAULIC PRODUCT INFORMATION 7576 SOS OTHER PRODUCT INFORMATION 7577 SOS FLUID INFORMATION
7578 SOS FILTER INFORMATION 7579 FLUID
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
7771 SOS "URGENT" REPORTS 7851 FUEL FILTER INDICATOR 7856 STABILITY INDICATOR 7858 ANGLE INDICATOR
7859 ENGINE OIL TEMPERATURE GAUGE
7942 PERSONALITY MODULE - UPDATE ELECTRONIC COMPONENTS
7950 MISCELLANEOUS 79M4 OTHER ADJUSTMENTS
31200255 TL642
SECTION 1
FRAME & ATTACHING PARTS
Figure 1-1 Frame Shrouding & Trim
61 59 60 47 21 72 22 23 49 18 50 51 40 13 1415 26 55 24 25 40 41 18 20 63 1716 18 19 51 18 40 48 63 18 51 63 67 68 59 69 70 45 40 19 11 63 11 63 11 63 11 63 59 48 63 6 5 2 4 58 66 43 1 65 7 8 46 4 10 12 3 48 63 9 44 11 63 52 53 54 57 66 19 56 PAL0016 49 11 18 51 40 47 37 64
MACHINES EQUIPPED WITH OUTRIGGERS
Before S/N TBK01167 excluding
TBK01162
FRAME & ATTACHING PARTS
31200255 TL642 1-3
Figure 1-1 Frame Shrouding & Trim (Continued)
38 39 27 29 28 31 30 29 32 33 35 36 34 PAL1441 42 103 104 102 101 105 106 107 110 111 108 109 FRAME MOUNT WELDMENT CAB WALL UPPER CAB MOUNT FRAME MOUNT WELDMENT CAB MOUNT WELDMENT LOWER CAB
MOUNT SHOWN WITH WORK LIGHT
Before S/N TBK01167 excluding
TBK01162
FRAME & ATTACHING PARTS
Figure 1-1 Frame Shrouding & Trim
Item Part Number Qty. Description Rev.
1 1 ENGINE COVER, (includes items 2, 3, 4, 6, 7, 8, 9, 43, 44, 52, 53, 54, 57, 58, 65 & 66)
I
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
14 298-1586 1 LOCKWASHER, 5/16
15 298-7990 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
20 298-7897 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)
1 COUNTERWEIGHT, (with pintle hook)
24 298-7293 1 BACK-UP ALARM 25 298-8048 2 HEX NUT, 5/16-18 26 298-7991 2 HEX HD CAPSCREW, 5/16-18X3/4, GR5 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 31 298-7845 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
39 298-7840 4 WHIZ-LOCK BOLT, 3/8-16X1
40 303-4798 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
44 298-1579 6 LOCK NUT, 3/8-16
45 303-5003 1 TANK BRACKET
Before S/N TBK01167 excluding
TBK01162
FRAME & ATTACHING PARTS
31200255 TL642 1-5
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)
303-4864 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 LOCTITE, #242
64 297-7040 8 HEX HD CAPSCREW, 1/2-13X1-1/8, GR5
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 68 298-8011 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 LOCTITE, #271
315-3423 1 LH MIRROR INSTALLATION, (includes items 101 thru 111),
(Before S/N TBK00765)
B 323-1647 1 LH MIRROR INSTALLATION, (includes items 102, 103, 108 & 109),
(S/N TBK00765 & After)
A
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 2Y-6141 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
Figure 1-1 Frame Shrouding & Trim (Continued)
Item Part Number Qty. Description Rev.
Before S/N TBK01167 excluding
TBK01162
FRAME & ATTACHING PARTS
Figure 1-1 Frame Shrouding & Trim
6 604 605 608 609 605 601 602 603 1 404 404 401 402 406 403 405 2 4 25 604 607 964 962 960 961 959 501 726 728 731 829 831 830827 826 826 827 830 831 831 830 832 729 732 725 727 730 723 724 501 713 712 9 8 10 11 12 13 825 828 827 826
S/N TBK01167 & After including
TBK01162
FRAME & ATTACHING PARTS
31200255 TL642 1-7
Figure 1-1 Frame Shrouding & Trim
PAL1441 107 106 105 105 103 104 112 111 110 109 108 152 154 151 153 552 551 150
S/N TBK01167 & After including
TBK01162
FRAME & ATTACHING PARTS
Figure 1-1 Frame Shrouding & Trim
Item Part Number Qty. Description Rev.
364-5671 Ref ENGINE COVER INSTALL, (not available to order, see items 1 thru 29 for service)
F
1 364-5674 1 ENGINE COVER, (includes items 601 thru 609)
2 298-7365 10 WASHER, 3/8
4 297-7031 10 HEX HD CAPSCREW, 3/8-16X1, GR5
8 364-5679 1 LATCH MOUNT BRACKET
9 303-4751 4 SCREW, 3/8-16X1.5
10 364-5678 1 LATCH CATCH BRACKET
11 298-1360 2 SCREW, 3/8-16X1.25
12 298-7374 2 WASHER, 3/8
13 298-8049 2 HEX NUT, 3/8-16
15 298-7378 8 LOCK WASHER, 1/4
16 8 HEX HD CAPSCREW, 1/4-20X1.125, GR5
19 364-5698 Ref R.H. MIRROR INSTALL, (not available to order, see items 401 thru 406 for service)
20 Ref AIR FILTER INTAKE ADAPTER, (not shown), (see Figure 4-7 for details)
21 Ref FOAM SEAL, (not shown), (see Figure 4-7 for details)
22 Ref BAND CLAMP, (not shown), (see Figure 4-7 for details)
24 2 ENGINE HOOD SHIM
25 1 HOOD HINGE SUPPORT PLATE
26 367-3291 AR BULB SEAL
27 1 GAS STRUT REAR BRACKET
28 1 GAS STRUT FRONT BRACKET
29 1 HOOD HINGE MOUNT PLATE
364-5703 Ref CAB INSTALL, (not available to order, see items 103 thru 112 for service) D
103 309-6238 2 HEX HD CAPSCREW, 7/8-9X5, GR8 104 352-4588 2 WASHER 105 298-8581 4 SHOCK MOUNT 106 298-1746 2 REBOUND WASHER 107 298-8053 2 HEX NUT, 7/8-9 108 303-4744 4 HEX HD CAPSCREW, 3/4-10X3.75, GR8 109 298-1631 4 WASHER, 3/4 110 298-7030 4 CENTER MOUNT 111 298-1740 4 WASHER 112 298-8052 4 HEX NUT, 3/4-10
150 Ref CAB ASSY, (see Figure 6-1 for details)
151 297-7088 2 HEX HD CAPSCREW, M6X20, GR8.8
152 329-0046 1 RECTANGULAR MIRROR
153 2Y-6141 2 LOCK WASHER, M6
154 1 MIRROR ARM
304-2660 Ref PINTLE HOOK INSTALL W/ COUNTERWEIGHT, (not available to order, see items 201 thru 204 for service)
B
201 308-7035 1 COUNTERWEIGHT
202 299-0361 1 PINTLE HOOK
203 298-7922 4 HEX HD CAPSCREW, 1/213X1.75
S/N TBK01167 & After including
TBK01162
FRAME & ATTACHING PARTS
31200255 TL642 1-9
401 2 HEX HD CAPSCREW, 1/4-20x1.125, GR5
402 298-0549 2 HEX LOCK NUT, 1/4-20, GR2
403 298-0565 2 PLUG
404 298-7372 4 WASHER, 1/4
405 309-2991 1 MIRROR
406 364-5697 1 MIRROR BRACKET
501 1 FRAME WELDMENT, (with outrigger)
1 FRAME WELDMENT, (without outrigger)
502 360-6624 1 ENGINE POD
551 299-0402 1 CAB FENDER
552 298-7840 4 WHIZ-LOCK BOLT, 3/8-16X1
601 303-4836 1 COMPRESSION LATCH, (includes items 650 & 651)
303-4864 1 KEY
602 8T-4205 4 WASHER, 6MM
603 303-4779 4 HEX LOCK NUT, M6X1
604 298-7365 8 WASHER, 3/8
605 298-0570 8 BUTTON HD SCREW, 3/8-16X1
606 364-5685 2 GAS SPRING
607 364-5686 1 ENGINE COVER FRONT HINGE
608 364-5687 1 ENGINE COVER REAR HINGE
609 364-5688 1 ENGINE COVER SUPPORT BAR
650 303-4779 4 LOCKNUT 651 298-7363 4 LOCKWASHER 712 8 HEX HD CAPSCREW, 7/8-9X2.5, GR8 713 298-7395 8 WASHER, 7/8 723 298-7875 4 WASHER 724 298-7913 4 HEX HD CAPSCREW, 1/8X3.5 725 297-7011 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5 726 300-6074 1 HEX HD CAPSCREW, 5/16-18X1/2, GR5 727 298-7363 2 WASHER, 1/4 728 298-7379 1 LOCK WASHER, 5/16 729 298-7293 1 BACKUP ALARM
730 298-7900 2 HEX LOCK NUT
731 298-6870 1 HORN 732 367-4967 1 MOLDED RESISTOR 825 360-7796 1 FRONT COVER 826 298-1609 10 TINNERMAN NUT 827 298-7374 10 WASHER, 3/8 828 298-8034 4 BUTTON HD SCREW, 3/8-16X3/4
829 298-8140 1 MAIN VALVE COVER
830 298-7380 9 LOCKWASHER, 3/8
831 297-7032 9 HEX HD CAPSCREW, 3/8-16X1.25, GR5
832 1 VALVE COVER PANEL
959 298-1609 10 TINNERMAN NUT
960 298-7374 10 WASHER, 3/8
961 298-7380 13 LOCK WASHER
962 297-7032 10 HEX HD CAPSCREW, 3/8-16X1.25, GR5
NOTE: ITEM NUMBERS NOT LISTED ARE NOT USED ON THIS FIGURE
Figure 1-1 Frame Shrouding & Trim
Item Part Number Qty. Description Rev.
S/N TBK01167 & After including
TBK01162
FRAME & ATTACHING PARTS
Figure 1-2 Axle Mounting
1 2 3 34 2 3 5 34 PAL0020
FRAME & ATTACHING PARTS
31200255 TL642 1-11
Figure 1-2 Axle Mounting
Item Part Number Qty. Description Rev.
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
FRAME & ATTACHING PARTS
Figure 1-3 Outrigger Mounting, (if equipped)
12 6 13 7 5 5 4 12 10 8 3 2 11 9 14 15 16 15 16 15 16 15 16
FRAME & ATTACHING PARTS
31200255 TL642 1-13
Figure 1-3 Outrigger Mounting, (if equipped)
Item Part Number Qty. Description Rev.
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 2987-8429 2 OUTRIGGER CYLINDER PIN
7 298-8430 2 ARM PIN 8 298-8431 2 SHOE PIN 9 298-6849 2 KEEPER 10 297-7036 2 HEX HD CAPSCREW, 3/8-16X4-1/4, GR5 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
16 AR LOCTITE, #242
17 Ref HOSE ASSEMBLY, (not shown), (see Figure 8-12 for details)
FRAME & ATTACHING PARTS
31200255 TL642
SECTION 2
BOOM
BOOM
Figure 2-1 First Boom Section
10 19 1 9 18 20 2 12 21 3 22 4 13 5 14 15 6 16 7 17 8 1 1 11 24 25 27 26 PAL1191 28
Coat Anchor Bolt Threads on items 2 & 12 with Mystik XD2, (14404818). Tighten to collapse washers. Coat bores for item 8 with Never Seeze Lube, (14403323S).
BOOM
31200255 TL642 2-3
Figure 2-1 First Boom Section
Item Part Number Qty. Description Rev.
1 304-2658 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)
6 297-7029 2 HEX HD CAPSCREW, 3/8-16X3/4, GR5
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
14 297-7041 4 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5
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
21 298-1612 2 LUBE FITTING, STRAIGHT, 1/8
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
BOOM
Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)
11 5 10 9 8 19 7 18 2 3 2 1 13 12 14 15 5 16 17 6 2 21 4 20 5 PAL1170 SERVICE NOTES:
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 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, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.
BOOM
31200255 TL642 2-5
Figure 2-2 Bearing Pads, Spacers & Shims, (First Boom Section)
Item Part Number Qty. Description Rev.
1 Ref FIRST BOOM SECTION, (see Figure 2-1 for details)
2 298-1629 8 HARDENED WASHER, 1/2
3 297-7039 4 HEX HD CAPSCREW, 1/2-13X1, GR5
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 5 298-1628 16 HARDENED WASHER, 3/8 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 10 298-7015 1 MOUNT PLATE
11 8 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft)
297-7056 AR 3/8-24X3/4
297-7057 AR 3/8-24X7/8
298-8015 AR 3/8-24X1
12 4 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft)
298-8015 AR 3/8-24X1 298-8016 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 15 298-7073 4 BEARING PAD 16 297-7030 4 HEX HD CAPSCREW, 3/8-16X7/8, GR5 17 298-1732 2 SPACER 18 AR SHIM OPTIONS 298-1736 AR 2X8X.0598 298-1737 AR 2X8X.0359 19 298-7075 2 BEARING PAD
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
BOOM
Figure 2-3 Second Boom Section
1 10 16 9 18 5 10 21 2 11 22 3 12 4 13 14 7 15 6 1 11 20 20 23 19 19 8 17 9 24 PAL1150 25 26 NOTE:
FOR PART NUMBER AND MOUNTING HARDWARE OF ITEM 13 REFER TO FIGURE 2-1, ITEMS 13, 14, & 15.
BOOM
31200255 TL642 2-7
Figure 2-3 Second Boom Section
Item Part Number Qty. Description Rev.
1 303-8668 1 SECOND BOOM SECTION
2 298-6862 2 PUSH BEAM PIN
3 297-7047 2 HEX HD CAPSCREW, 1/2-13X3-5/8, GR5
4 298-7382 2 LOCKWASHER, 1/2
5 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
11 298-7318 4 RETAINING RING
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
18 298-8003 1 HEX HD CAPSCREW, 3/8-16X4, GR5
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
BOOM
Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)
3 17 7 2 3 4 22 24 1 10 11 12 13 23 22 16 3 10 19 2 25 5 26 22 18 8 9 3 21 20 14 15 27 6 9 8 PAL1180 SERVICE NOTES:
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, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.
BOOM
31200255 TL642 2-9
Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)
Item Part Number Qty. Description Rev.
1 Ref SECOND BOOM SECTION, (see Figure 2-3 for details)
2 8 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft)
297-7056 AR 3/8-24X3/4 297-7057 AR 3/8-24X7/8 298-8015 AR 3/8-24X1 3 298-1628 20 HARDENED WASHER, 3/8 4 298-7075 2 BEARING PAD 5 298-1732 2 SPACER 6 2 SHIM OPTIONS 298-1726 AR 2X8X.0598 298-1727 AR 2X8X.0359 7 298-6924 1 MOUNT PLATE 8 6 SHIM OPTIONS 298-1787 AR 2X4X.0598 298-1788 AR 2X4X.0359 9 298-1728 6 SPACER 10 298-7073 6 BEARING PAD
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
13 298-8209 2 BEARING PAD
14 299-0493 2 SPACER
298-1733 AR SPACER
15 298-1735 AR SHIM, 2X8X.0359
16 4 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft)
297-7060 AR 3/8-24X1-3/4
297-7061 AR 3/8-24X2
17 8 HEX HD CAPSCREW OPTIONS, GR5, (torque to 28-30 lb-ft)
298-8012 AR 3/8-24X1/2
298-8013 AR 3/8-24X5/8
297-7056 AR 3/8-24X3/4
18 298-1615 2 LUBE FITTING, 90 DEGREES, 1/4-28
19 298-7074 2 BEARING PAD 20 298-1730 2 SPACER 21 2 SHIM OPTIONS 298-1789 AR 2X4X.0598 298-1790 AR 2X4X.0359 22 298-1629 10 HARDENED WASHER, 1/2
23 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
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
25 298-8208 2 BEARING PAD
26 4 HEX HD CAPSCREW OPTIONS, GR5, (torque to 76-86 lb-ft)
298-8019 AR 1/2-20X3/4
298-8020 AR 1/2-20X7/8
BOOM
297-7069 AR 1/2-20X1-1/4
297-7070 AR 1/2-20X1-1/2
27 298-1729 2 SPACER
Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)
BOOM
31200255 TL642 2-11
Figure 2-4 Bearing Pads, Spacers and Shims, (Second Boom Section)
BOOM
Figure 2-5 Third Boom Section
1 13 12 1 11 8 7 3 3 3 4 2 9 10 5 6 11 11 14 PAL1121 101 102 103 104 SERVICE NOTES:
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, (14404818), to all bearing pad slide areas. 4. Use loctite, (0100011S), on all bolt threads.
BOOM
31200255 TL642 2-13
Figure 2-5 Third Boom Section
Item Part Number Qty. Description Rev.
1 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)
9 297-7060 2 HEX HD CAPSCREW, 3/8-24X1-3/4, GR5, (torque to 28-30 lb-ft)
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
13 297-7029 1 HEX HD CAPSCREW, 3/8-16X3/4, GR5
14 298-7380 1 LOCKWASHER, 3/8
340-4184 1 FRONT BOOM COVER INSTALLATION, (if equipped,) (not available to order, see items 101 thru 104 for service)
A
101 Ref CAT THREADLOCK
102 1 LANYARD CABLE
103 340-4180 1 COMPRESSION LATCH
104 340-4182 1 FRONT BOOM COVER
BOOM
Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section)
1 4 3 12 2 13 6 7 11 5 5 14 8 9 10 16 15 PAL1130 SERVICE NOTES:
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.
BOOM
31200255 TL642 2-15
Figure 2-6 Bearing Pads, Spacers and Shims, (Third Boom Section)
Item Part Number Qty. Description Rev.
1 Ref THIRD BOOM SECTION, (see Figure 2-5 for details)
2 298-7076 2 BEARING PAD 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
6 4 HEX HD CAPSCREW OPTIONS, (torque to 76-86 lb-ft)
297-7069 1/2-20X1-1/4, GR5
298-8021 1/2-20X1-1/2, GR5
7 4 HEX HD CAPSCREW OPTIONS, (torque to 28-30 lb-ft)
298-8013 3/8-24X5/8, GR5 297-7056 3/8-24X3/4, GR5 298-8014 3/8-24X7/8, GR5 8 298-1789 2 SHIM, 2X4X.0598 9 298-1730 2 SPACER 10 298-7074 2 BEARING PAD
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
12 298-8209 2 BEARING PAD
13 298-1629 4 HARDENED WASHER, 1/2
14 298-1731 2 SPACER
15 298-1615 2 LUBE FITTING, 45 DEGREES, 1/4-28
16 2 LUBE BOLT OPTIONS, (torque to 45-50 lb-ft)
298-1626 1/2-20X1-1/4
BOOM
Figure 2-7 Push Beam/Extend Chain & Roller Assembly
PAL1111 2 8 11 7 17 1 9 1915 8 21 8 16 7 20 104 102 103 105 312 1 5 6 14 10 22 4 18 13 12 203 203 202 3 101 3 101
NOTE: THE CHAIN CLEVIS ROD (item 4), ATTACHES TO THE STRONG BACK (item 3), IN FIGURE 2-1
NOTE: SEE FIGURE 2-5 FOR PUSH BEAM, CHAIN RETAINER & BEARING PADS.
NOTE: THE CLEVIS ROD (item 102), SEATS IN THE REAR OF THE THIRD BOOM SECTION, ILLUSTRATED IN FIGURE 2-5.
BOOM
31200255 TL642 2-17
Figure 2-7 Push Beam/Extend Chain & Roller Assembly
Item Part Number Qty. Description Rev.
300-6073 1 PUSH BEAM ASSY, (includes items 1 thru 22) B
1 AR LOCTITE, #242
2 AR LOCTITE, #545
3 304-3165 Ref LEAF CHAIN ASSY, (not available to order, see items 101 thru 105 for service)
C
4 305-3763 1 CHAIN CLEVIS ROD
5 297-7039 2 HEX HD CAPSCREW, 1/2-13X1, GR5
6 298-7382 2 LOCKWASHER, 1/2
7 AR NEVER SEEZ LUBE
8 AR MYSTIK TETRIMOLY GREASE
9 298-8062 1 HEX NUT, 1-3/8-12, (torque to 155-195 lb-ft)
10 298-7312 2 SNAP RING, 3/8
11 298-1612 1 LUBE FITTING, STRAIGHT, 1/8
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
105 AR ANTI SEEZE LUBE
202 303-5000 1 BUSHING
203 298-7032 2 SEAL
312 Ref ANCHOR PIN, (see Figure 2-5 for details)
BOOM
Figure 2-8 Quick Coupler Assembly
101 102 3 8 7 9 4 1 6 7 9 8 5 2 3 14 11 12 10 13 SERVICE NOTES:
BOOM
31200255 TL642 2-19
Figure 2-8 Quick Coupler Assembly
Item Part Number Qty. Description Rev.
304-3176 1 QUICK COUPLER INSTALLATION, (includes items 1 thru 14) C
1 303-4926 1 QUICK ATTACH COUPLER ASSY, (Before S/N TBK01134)
365-9208 QUICK ATTACH COUPLER ASSY, (S/N TBK01134 & After)
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 2 HARDENED WASHER, 1/2
9 AR CAT THREADLOCK
10 300-6103 1 DUST CAP
11 300-6078 1 QUICK DISCONNECT COUPLING, FEMALE
12 300-6084 1 DUST PLUG
13 300-6079 1 QUICK DISCONNECT COUPLING, MALE
14 300-6095 2 FITTING
101 Ref THIRD BOOM SECTION, (see Figure 2-5 for details)
102 Ref TILT CYLINDER, (see Figure 9-3 for details)
BOOM
Figure 2-9 Hydraulic Quick Coupler Assembly
104 101 103 106 108 109 106 107 110 8 12 15 2 13 4 9 1 14 8 10 12 15 11 21 15 17 18 20 19 102 105 102 105 105 111 19 S/N TBK01134 & After
BOOM
31200255 TL642 2-21
Figure 2-9 Hydraulic Quick Coupler Assembly
Item Part Number Qty. Description Rev.
304-2595 1 HYDRAULIC QUICK COUPLER ASSEMBLY, (Before S/N TBK01134), (includes items 1 thru 21)
E 365-9209 1 HYDRAULIC QUICK COUPLER ASSEMBLY, (S/N TBK01134 & After),
(includes items 1 thru 10 & 12 thru 21)
A
1 303-4926 1 QUICK COUPLER ASSEMBLY, (Before S/N TBK01134)
365-9208 1 QUICK COUPLER ASSEMBLY, (S/N TBK01134 & After)
2 298-8734 1 HEAD PIN ASSEMBLY
4 298-7228 1 CYLINDER COVER, (Before S/N TBK01134)
365-9207 1 CYLINDER COVER, (S/N TBK01134 & After)
5 298-7356 2 CONNECTOR
6 308-0608 2 DOWEL PIN
7 298-0407 2 QUICK ATTACH PIN
8 297-7039 2 HEX HD CAPSCREW, 1/2-13X1, GR5
9 298-1358 2 SERRATED HEX HD SCREW, 3/8-16X3/4
10 298-7057 1 WELDMENT PIN
11 299-6623 AR FLEX TRIM SHIELD, (Before S/N TBK01134)
12 2 HARDENED WASHER, 1/2
13 298-1612 2 GREASE FITTING, (straight), 1/8
14 299-1349 1 QUICK COUPLER VALVE ASSEMBLY, (includes items 101 thru 111) F
15 AR CAT THREADLOCK
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 ASSY, (Before S/N TBK01134)
365-9211 2 HOSE ASSY, (S/N TBK01134 & After)
20 297-7020 1 HEX HD CAPSCREW, 5/16-18X1-1/2, GR5
21 299-6624 AR FLEX TRIM SHIELD
101 334-3738 1 QUICK COUPLER VALVE
102 298-7355 2 CONNECTOR, (Before S/N TBK01134)
298-0471 1 CONNECTOR, (S/N TBK01134 & After)
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
111 309-6353 1 ELBOW, 90 DEGREES, (includes o-ring)
201 Ref QUICK COUPLER CYLINDER, (see Figure 9-12 for details)
202 299-0308 1 CHECK PILOT VALVE
299-0285 1 SEAL KIT
BOOM
31200255 TL642
SECTION 3
ATTACHMENTS
ATTACHMENTS
Figure 3-1 50” & 72” Carriage Assembly
1 4 2 3 5 6 1 4 2 3 5 6 PAL0730
ATTACHMENTS
31200255 TL642 3-3
Figure 3-1 50” & 72” Carriage Assembly
Item Part Number Qty. Description Rev.
301-9757 1 50” CARRIAGE ASSY, (includes items 1 thru 6) A
301-9758 1 72” CARRIAGE ASSY, (includes items 1 thru 6) A
1 303-4741 2 HEX HD CAPSCREW, 5/8-11X4, GR5
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)
ATTACHMENTS
Figure 3-2 Forks
ATTACHMENTS
31200255 TL642 3-5
Figure 3-2 Forks
Item Part Number Qty. Description Rev.
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 324-5262 2 60” LUMBER FORK, 2X7, 13,700 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.
ATTACHMENTS
Figure 3-3 Winch Installation
2 19 19 21 27 28 29 24 10 14 15 20 9 11 13 9 11 12 8 9 11 1 17 19 18 19 3 5 6 4 2 1 3 AUXILIAR Y LINE "UP/RIGHT" AUXILIAR Y LINE "DOWN/LEFT" 7 26 25 22 21 10 24 A A B B VIEW A-A
ATTACHMENTS
31200255 TL642 3-7
Figure 3-3 Winch Installation
Item Part Number Qty. Description Rev.
305-3768 1 WINCH INSTALLATION, (includes all items) A, 4
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
8 298-7918 2 HEX HD CAPSCREW, 5/8-11X2-3/4, GR8, (torque to 200-215 lb-ft)
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
12 298-7916 2 HEX HD CAPSCREW, 5/8-11X2-1/4, GR8, (torque to 200-215 lb-ft) 13 298-7919 2 HEX HD CAPSCREW, 5/8-11X2-1/2, GR8, (torque to 200-215 lb-ft)
14 298-7995 2 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5
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
21 350-0995 1 HOSE ASSY
22 298-0475 2 ELBOW, 90 DEGREES, (includes o-ring)
24 298-0474 2 ELBOW, 90 DEGREES, (includes o-ring)
25 303-4755 1 ELBOW, 90 DEGREES, (includes o-ring)
26 298-0497 1 SWIVEL NUT RUN TEE, 1/2 TUBE
27 303-4737 4 HEX HD CAPSCREW, 3/8-16X1-3/8, GR5
28 298-7365 4 FLAT WASHER, 3/8
29 298-8049 4 HEX NUT, 3/8-16
ATTACHMENTS
Figure 3-4 50” & 72” Side Tilt Carriage Assembly
3 9 10 16 17 1 5 2 11 4 21 23 18 24 22 12 13 14 6 15 3 7 8 2 5 11 4 19 20 21 23 18 24 22 14 6 15 3 7 8 FRONT VIEW OF CARRIAGE
ATTACHMENTS
31200255 TL642 3-9
Figure 3-4 50” & 72” Side Tilt Carriage Assembly
Item Part Number Qty. Description Rev.
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
1 297-7033 4 HEX HD CAPSCREW, 3/8-16X1-1/2, GR5
2 303-4741 2 HEX HD CAPSCREW, 5/8-11X4, GR5
3 297-7077 3 HEX HD CAPSCREW, 1/2-13X1-1/4, GR8
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
10 298-1612 1 LUBE FITTING, STRAIGHT, 1/8
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)
19 313-3349 2 HOSE ASSEMBLY
20 300-6078 1 QUICK DISCONNECT, (female)
21 300-6079 1 QUICK DISCONNECT, (male)
22 1 S/N PLATE
23 330-8325 2 CONNECTOR
ATTACHMENTS
Figure 3-5 Fork Clamp Installation
1 2
ATTACHMENTS
31200255 TL642 3-11
Figure 3-5 Fork Clamp Installation
Item Part Number Qty. Description Rev.
310-6250 1 FORK CLAMP INSTALLATION, (includes all items) A
1 310-6251 4 FORK CLAMP
ATTACHMENTS
Figure 3-6 Fork Mounted Platform
17 10 4 11 2 101 102 107 109 3 112 114 113 103 104 106 108 105 1 110 111 218 101 201 214 209 211 108 1 110 111 2 4 17 11 10 203 210 212 3 102 103 104 106
ATTACHMENTS
31200255 TL642 3-13
Figure 3-6 Fork Mounted Platform
Item Part Number Qty. Description Rev.
Ref FORK MOUNTED PLATFORM, (Before S/N TBK01108), (no longer available, see items 1 thru 17 for service; order 1001108938, 1001108939 or 1001108940 for replacement)
D
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),
(no longer available, order items 101 thru 114 for service, order 1001108938 for replacement)
B
340-8976 1 FORK MOUNTED PLATFORM, (S/N TBK01108 & After),
(includes items 2, 3, 101 thru 104, 106,108, 110,111 & 201 thru 218)
E
2 338-9997 1 MANUAL DECAL
3 335-8059 8 LANYARD ATTACH DECAL
4 338-9996 1 MANUAL DECAL
328-7293 1 MANUAL DECAL, (ISO)
328-7292 1 MANUAL DECAL, (FRENCH)
10 338-9999 1 MANUAL DECAL
328-7290 1 MANUAL DECAL, (ISO)
328-7288 1 MANUAL DECAL, (FRENCH)
11 339-0000 1 MANUAL DECAL
328-7291 1 MANUAL DECAL, (ISO)
328-7289 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
201 297-7010 4 HEX HD CAPSCREW, 1/4-20X5/8, GR5 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
ATTACHMENTS
Figure 3-7 Fork Mounted Hook
PAL3450 1 4 3 5 6 2 7
ATTACHMENTS
31200255 TL642 3-15
Figure 3-7 Fork Mounted Hook
Item Part Number Qty. Description Rev.
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
ATTACHMENTS
ATTACHMENTS
31200255 TL642 3-17
Figure 3-8 100 Degree Swing Carriage
Item Part Number Qty. Description Rev.
318-9222 1 100 DEGREE SWING CARRIAGE, (includes all items) D
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 Ref CYLINDER, (see Figure 9-15 for details)
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 27 362-2111 2 CONNECTOR
28 362-2109 1 FEMALE QUICK COUPLER
29 362-2110 1 MALE QUICK COUPLER
30 327-6325 1 WARNING DECAL, HIGH PRESSURE
31 362-2106 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
ATTACHMENTS
ATTACHMENTS
31200255 TL642 3-19
Figure 3-9 48” Side Shift Carriage
Item Part Number Qty. Description Rev.
314-8479 1 48” SIDE SHIFT CARRIAGE, (includes items 1 thru 29) C
1 362-2110 1 MALE QUICK COUPLER
2 362-2109 1 FEMALE QUICK COUPLER
3 362-2111 2 CONNECTOR
4 362-2119 2 HOSE ASSY
5 362-2104 2 BULKHEAD STRAIGHT CONNECTOR
6 362-2118 1 HOSE ASSY
7 362-2117 1 HOSE ASSY
8 327-6333 2 ELBOW, 90 DEGREES
9 Ref CYLINDER, (see Figure 9-16 for details)
10 327-6287 1 PIN
11 362-2122 1 PIN
12 362-2108 2 HEX HD CAPSCREW, 0.3X1
13 362-2116 1 RIGHT PIN RETAINER
14 362-2114 1 LEFT PIN RETAINER
15 362-2100 6 HEX HD CAPSCREW, 0.5X1.5
16 362-2115 1 SIDE SHIFT PIN
17 327-6277 1 FORK PIN 18 1 S/N PLATE 19 362-2112 1 REAR FRAME 20 362-2113 1 FRONT FRAME 21 327-6305 1 HOSE CLAMP 22 362-2101 1 HEX HD CAPSCREW, 0.31X1.75
23 327-6325 1 HI PRESSURE WARNING DECAL
24 362-2106 1 MADE IN USA DECAL
25 327-6328 2 PINCH POINT DANGER DECAL
26 362-2107 2 GREASE ZERK
27 362-2103 2 FLAT WASHER, 0.31
28 362-2102 3 LOCK WASHER, 0.31
ATTACHMENTS
31200255 TL642
SECTION 4
ENGINE & ATTACHING PARTS
Figure 4-1 Engine Assembly, L.H. View
209 210 243 226 251 278 279 209 244 275 280 112 102 104 107 109 1 105 301 322 325 327 306 6 408 315 305 201 227 264 280 211 217 277 216 237 258 207 233 276 280 226 231 278 279 280 3 4 305 252 219 224 239 235 208 202 226 280 214 215 250 251 260 205 232 280 101 110 111 103 106 109 108 403 413 412 414 405 402 246 212 203 218 234 254 501 502 503 115 116 117 SERVICE NOTES: VIEW A-A A A GLOW PLUG STARTER
Before S/N TBK01167 excluding
TBK01162
ENGINE & ATTACHING PARTS
31200255 TL642 4-3
Figure 4-1 Engine Assembly, L.H. View
Item Part Number Qty. Description Rev.
1 331-2460 1 ZF TRANSMISSION ASSEMBLY, (includes items 101 thru 117) B
3 Ref ENGINE, (see Figure 4-4 for details) B
4 300-6082 1 ENGINE ASSEMBLY, (includes items 201 thru 280 on Figure 4-1 and all items on Figure 4-2)
C
6 Ref RADIATOR ASSEMBLY, (see Figure 4-6 for details) C
101 AR LOCTITE, #242
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 4-9 for details)
106 298-7368 6 FLAT WASHER, 5/8
107 8T-4121 12 FLAT WASHER, 10mm
108 299-0271 1 TRANSMISSION BRACKET
109 AR LOCTITE, # 242
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 201 297-7011 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5 202 303-4742 2 HEX HD CAPSCREW, 5/16-18X1-1/4, GR8 203 303-4743 1 HEX HD CAPSCREW, 3/8-16X1-1/4, GR8 205 8T-4136 2 HEX HD CAPSCREW, 10-1.50X25mm, GR8.8 207 8T-4956 1 HEX HD CAPSCREW, 12-1.75X35mm, 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 232 298-7388 2 SPRING LOCKWASHER, 10mm 233 298-7389 1 SPRING LOCKWASHER, 12mm 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
