gehl 4640e power2 parts manual

SL4640ESL4640E (EU)Power2(SN 312901 and Up)

SL5240ESL5240E (EU)Power2(SN 432501 and Up)

Skid-Steer Loaders

Form No.50950011

PAR

TS

MA

NU

AL

Revision C11/12

IntroductionFor your safety and continued proper operation,use only genuine GEHL service parts. When or-dering service parts, specify the correct part num-ber, full description, quantity required, the unitmodel number and serial number.The model and serial number decal for this unit islocated on the left chassis upright. Right andLeft are determined from a position sitting onthe seat and facing forward.Manitou Americas, Inc. reserves the right to makechanges or improvements in the design or con-struction of any part of the unit without incurringthe obligation to install such changes on any previ-ously delivered units.NOTE:Purchase equivalent, quality tires for yourloader. Contact your dealer for replacement tireinformation.NOTE:Replacement batteries are not provided bythe GEHL Company. For battery specificationssee Electrical-Chassis chapter. ALL REPLACE-MENT BATTERIES MUST BE PURCHASEDLOCALLY.Refer to the abbreviations table located on thispage for the various fastener descriptions. Stan-dard attaching hardware torque values are alsoprovided on the inside back cover. If a part re-quires lubrication or a nonstandard torque val-ue, it will be specified behind the part numberdescription in parenthesis.Items shown in the parts list that do not have partnumbers are shown for reference purposes onlyand are NOT available for purchase.Dimensions are in inches unless otherwise speci-fied.

NOTE:The following abbreviations and symbolsmay be used herein:A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AmpereAR . . . . . . . . . . . . . . . . . . . . . . . . . . As RequiredASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSYAUX. . . . . . . . . . . . . . . . . . . . . . . . . . . AuxiliaryCCA. . . . . . . . . . . . . . Cold Cranking AmperageCYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CylinderDH . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual HandDJS. . . . . . . . . . . . . . . . . . . . . . . . . Dual JoystickFL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FlareFOPS . . . . . . Falling Object Protective StructureGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GaugeHEX. . . . . . . . . . . . . . . . . . . . . . . . . . . .HexagonH/F . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand/FootHF . . . . . . . . . . . . . . . . . . . . . . . . . . . High-FlowHYD. . . . . . . . . . . . . . . . . . . . . . . . . . . HydraulicJIC . . . . . . . . . . . . . . . . . Joint Industrial CouncilkW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KilowattLBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PoundsM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MeterMM (mm) . . . . . . . . . . . . . . . . . . . . . MillimeterNA . . . . . . . . . . . . . . . . . . . . Naturally AspiratedN/A . . . . . . . . . . . . . . . . . . . . . . .Not ApplicableNEG. . . . . . . . . . . . . . . . . . . . . . . . . . . .NegativeNm . . . . . . . . . . . . . . . . . . . . . . . .Newton meterNO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NumberNPT . . . . . . . . . . . . . . . . . . National Pipe ThreadNSS . . . . . . . . . . . . . . . . . . . Not Sold SeparatelyP-A-T . . . . . . . . . . . . . . . . . . . . . . Power-A-TachPN . . . . . . . . . . . . . . . . . . . . . . . . . .Part NumberPOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PositivePSI . . . . . . . . . . . . . . . . . Pounds per Square InchQTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . QuantityREF . . . . . . . . . . . . . . . . . . . . . . . . . . . ReferenceREQ'D.. . . . . . . . . . . . . . . . . . . . . . . . . .RequiredROPS . . . . . . . . . .Roll Over Protective StructureRPM. . . . . . . . . . . . . . . . Revolutions Per MinuteSAE . . . . . . . . Society of Automotive EngineersSN . . . . . . . . . . . . . . . . . . . . . . . . Serial NumberSQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SquareST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .StraightTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-BarTB/JS . . . . . . . . . . . . . . . . . . . . . . T-Bar/JoystickTURBO . . . . . . . . . . . . . . . . . . . . . TurbochargerV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt

GEHL is a registered trademark of Manitou Americas, Inc.

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TABLE OF CONTENTS

SECTION A: MAIN LOADER COMPONENTChassis and Control Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Rear Grille and Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13ROPS/FOPS Structure/Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Restraint Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Seat and Seat Belt Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Attachment Bracket (and Power-A-Tach ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Wheel Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Air Cleaner/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Radiator/Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Hydrostatics with Drive Motors (including Brake Release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Hydraulics - Chassis (Power-A-Tach, Cold Weather Power-A-Tach and Hydraglide). . . . . 65Hydraulics - Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Hydraulics - Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Controls - Wheel Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Controls - Lift/Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Controls - Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Controls - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Electrical - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Electrical - ROPS/FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Electrical - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Electrical - Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Electrical - Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Four-Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Sound Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

SECTION B: HYDRAULIC COMPONENTSLift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Drive Motors with Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Tandem Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Gear Pump - Double. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Self-Leveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Solenoid Valves - Lift, Tilt and Power-A-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Solenoid Valves - Brake and Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Main Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Proportional Valves - Two and Four Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Hydraglide Ride Control Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Pump - Cold-Weather Power-A-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

(continued on next page)

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TABLE OF CONTENTS

SECTION C: FILTER LISTING, KITS AND ACCESSORIESFilter Listing, Analysis Kits and Other Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 22650850096 4640 Heater/Defroster Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22750850104 5240 Heater/Defroster Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229811288 Horn Kit (5240) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231810469 Crossmember Auxiliary Tube Kit for 4640 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232811337 Crossmember Auxiliary Tube Kit for 5240 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . 233810404 and 810838 DJS Back-up Alarm Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234810401 Horn Kit (4640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235806894 Rearview Mirror Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235810412 Front Door Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Seat Belt Kits - 2" 810424 and 3" 810425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Seat Kits - Suspension 810422 and Standard 810423. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237810413 Side Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23850850113 Pre-Cleaner Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239805803 Strobe Light Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239810415 Counterweight Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240810421 Dual Flasher Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240810561 Impact-Resistant Front Door Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241810834 Single-Point Lift Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242810494 Interior Console Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242810897 Radio, AM-FM-WB Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243810945 Four-Point Lift Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244811226 14-Pin Connector for Auxiliary Attachments Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24550850099 (4640) / 50850102 (5240) Power-A-Tach Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24650850110 HVAC (5240 Service Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25050850107 Two-Speed Parking Brake Release Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25450850106 Single-Speed Parking Brake Release Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255811655 Rear Wiper Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25650850100 4640 Power-A-Tach Cold Weather Option Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25750850068 5240 Power-A-Tach Cold Weather Option Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

SECTION D: SCHEMATICSElectrical Schematic - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Electrical Schematic - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Electrical Schematic - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Hydrostatic/Hydraulic Schematic - Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Hydrostatic/Hydraulic Schematic - Non-Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Electrical Schematic - 14-Pin Auxiliary Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268Electrical Schematic - HVAC (5240) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Electrical Schematic - Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270Electrical Schematic - Power-A-Tach Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271Electrical Schematic - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274O-Ring Table, Coupling & Adapter Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Torque Specifications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

PRINTED IN USA 50950011/CP1112 1

SECTION A: MAIN LOADER COMPONENTSChassis and Control Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Rear Grille and Engine Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13ROPS/FOPS Structure/Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Restraint Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Seat and Seat Belt Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Attachment Bracket (and Power-A-Tach ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Wheel Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Air Cleaner/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Radiator/Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Hydrostatics with Drive Motors (including Brake Release). . . . . . . . . . . . . . . . . . . . . . . 55Hydraulics - Chassis (Power-A-Tach, Cold Weather Power-A-Tach, Hydraglide) 65Hydraulics - Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Hydraulics - Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Controls - Wheel Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Controls - Lift/Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Controls - Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Controls - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Electrical - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Electrical - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Electrical - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Electrical - Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Electrical - Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Four-Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Sound Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174SE

CT

ION

A: M

AIN

LO

AD

ER

CO

MPO

NE

NT

S

1 50950011/CP1112 PRINTED IN USA

35

11

10

15

1

14

34

9

416

5

18

1319

13

13

1727

13

28

21

20

22

25

23

23

24

24

NOTES:

1. APPLY HI-TACK GASKET ADHESIVE2. APPLY OIL-RESISTANT RTV

NOTE 2

NOTE 2

NOTE 1

NOTE 2

33

3

3

2 8

29

328

832

32

30

30

33

3

33

3631

35

3

3

3 36

30

32 33

6

6

6

7

12

26

3

7

3837

7

EARLIERMODELS

CHASSIS

400689

4640 Models


Ref. Part QuantityNo. No. Description 4640

1 072343 GASKET/FUEL SENDER 12 081380 SCREW/CAP FL LOCK 5/16 X 3/4 53 092164 SCREW/CAP FL LOCK 1/2 X 1-1/4 144 127342 CAP/HYDRAULIC RESERVOIR 15 128591 BREATHER/HYDRAULIC RESERVOIR 16 131522 PLUG MORB12 47 131529 a PLUG MORB08 58 131842 NUT/SPIRALOCK 5/16 89 132050 STRAINER/FUEL FILL 1

132051 CAP/FUEL FILL 1650702 SCREW/MACHINE PAN HEAD #6 X 3/8 2

10 132298 c WASHER/SEAL 211 134345 COVER/TOEPLATE 112 134756 SIGHT PORT/OIL LEVEL 113 134853 b NUT/SPIRALOCK 1/2-13 214 136013 FUEL SENSOR/VDO 115 140376 BELLYPAN/FRONT 116 192243 COVER/HYDRAULIC RESERVOIR 117 193018 PLATE/CROSSMEMBER 118 193051 COVER/UNDER SEAT RIGHT 119 193052 COVER/UNDER SEAT LEFT 120 193081 FENDER/LEFT 121 193091 FENDER/RIGHT 122 194273 PLATE/COVER 123 194547 COVER/CHAINCASE 224 195138 SCREW/TAPPING HEX WASHER HEAD THREAD ROLL 3/8 X 3/4 2825 240924 BELLYPAN/REAR 126 241053 COVER/ACCESS 127 275001 CHASSIS 128 275883 FILLER/ROPS RIGHT 129 275884 FILLER/ROPS LEFT 130 650486 SCREW/CAP 5/16 X 3/4 431 650494 c SCREW/CAP 1/2 X 1 232 650495 SCREW/CAP 1/2 X 1-1/4 633 651042 SCREW/MACHINE HEX WASHER HEAD FL 3/8 X 1 1034 651312 SCREW/MACHINE PHILLIPS HEAD #10 X 1/2 535 651648 SCREW/CAP THREAD FORMING TAP/R 5/16 X 3/4 336 654046 c WASHER/FLAT 7/16 237 070648 NUT/LOCK SERRATED FLANGE 5/16 238 50350514 BRACKET/AIR CLEANER 1a) Two additional plugs (#7) added to front of chassis, removing items #10, #31, and #36. SN 312975 and Up, and earlier SNs: 312928, 312929, 312942, 312950, 312952, 312963, 312964 and 312972.

b) Four locknuts (#13) removed at crossmember plate (#17). Design change added weld nuts to welded bracket on chassis. Check your unit for your con-figuration.

c) SN 312974 and Before (see exemptions in note a)

CHASSIS


6

3

3

NOTES:

1. APPLY HI-TACK GASKET ADHESIVE2. APPLY OIL-RESISTANT RTV

20

6

16

3

11

5

33

4

9

34

14

1

33

24

25

21

21

103631

3

25

24

17

30

30

18

32

3213

13

13

13

8

8

32

32

6

3

15

6

35

12

222

NOTE 2

NOTE 2

NOTE 2

19

2

2

23

3

26

333

3

NOTE 1

276

28

29

7

37

38

7

EARLIERMODELS

CHASSIS

410568

5240 Models



1 072343 GASKET/FUEL SENDER 12 081380 SCREW/CAP FL LOCK 5/16 X 3/4 53 092164 SCREW/CAP FL LOCK 1/2 X 1-1/4 144 127342 CAP/HYDRAULIC RESERVOIR 15 128591 BREATHER/HYDRAULIC RESERVOIR 16 131522 PLUG MORB12 57 131529 a PLUG MORB08 38 131842 NUT/SPIRALOCK 5/16 89 132050 STRAINER/FUEL FILL 1

132051 CAP/FUEL FILL 1650702 SCREW/MACHINE PAN HEAD #6 X 3/8 2

10 132298 c WASHER/SEAL 211 134345 COVER/TOEPLATE 112 134756 SIGHT PORT/OIL LEVEL 113 134853 b NUT/SPIRALOCK 1/2-13 214 136013 FUEL SENSOR/VDO 115 192243 COVER/HYDRAULIC RESERVOIR 116 193018 PLATE/CROSSMEMBER 117 193051 COVER/UNDER SEAT RIGHT 118 193052 COVER/UNDER SEAT LEFT 119 193081 FENDER/LEFT 120 193091 FENDER/RIGHT 121 193459 BELLYPAN 222 194273 PLATE/COVER 123 194513 SPACER/SOLENOID LIFT 124 194547 COVER/CHAINCASE 225 195138 SCREW/TAPPING HEX WASHER HEAD THREAD ROLL 3/8 X 3/4 2826 241053 COVER/ACCESS 127 244468 CHASSIS 128 275883 FILLER/ROPS RIGHT 129 275884 FILLER/ROPS LEFT 130 650486 SCREW/CAP 5/16 X 3/4 431 650494 c SCREW/CAP 1/2 X 1 232 650495 SCREW/CAP 1/2 X 1-1/4 633 651042 SCREW/MACHINE HEX WASHER HEAD FL 3/8 X 1 1034 651312 SCREW/MACHINE PHILLIPS HEAD #10 X 1/2 535 651648 SCREW/CAP THREAD FORMING TAP/R 5/16 X 3/4 336 654046 c WASHER/FLAT 7/16 237 070648 NUT/LOCK SERRATED FLANGE 5/16 238 50350466 BRACKET/AIR CLEANER 1a) Two additional plugs (#7) added to front of chassis, removing items #10, #31, and #36. SN 432617 and Up, and earlier SNs: 432610 and 432612.

b) Four locknuts (#13) removed at crossmember plate (#16). Design change added weld nuts to welded bracket on chassis. SN 432617 and Up

c) SN 432616 and Before (see two exemptions in note a)

CHASSIS


3

14

2

13

13

1

10

4

13

15

11

9

5

6

6

CONNECTS BETWEEN RIGHT CONTROLHANDLE AND CHASSIS HARNESS

7

7

12

8

CHASSIS

Covers - T-Bar and Dual Hand Controls

410623


Ref. Part QuantityNo. No. Description T-Bar/Dual Hand

1 134852 NUT/SPIRALOCK 3/8 22 190203 SUPPORT/BOOT BEZEL 83 190400 SPACER 34 190457 COVER/BOOT 25 193676 PAD/SOUND 16 193706 LATCH/SWELL 47 194271 STRIP/FOAM 1/4 X 1-12 X 15-51/64 28 241082 FLOOR ASSY/FRONT 19 241131 HARNESS/WIRE 110 275774 COVER/CONTROL 111 275875 PANEL/COVER RIGHT 112 275885 PANEL/COVER LEFT 113 651041 SCREW/MACHINE HEX WASHER HEAD 3/8 X 3/4 414 651651 SCREW/TAPPING TORX DRIVE PAN HEAD #10 X 1 815 L70486 SCREW/TRUSS TORX DRIVE 1/4 X 1 3

CHASSIS


2

1

13

12

14

11

3

8

10

5

9

5

4

CONNECTS BETWEEN RIGHT CONTROLHANDLE AND CHASSIS HARNESS

CONNECTS TO FOOT THROTTLECONNECTOR OF CHASSIS HARNESS

6

6

7

CHASSIS

Covers - Hand/Foot Controls

410624


Ref. Part QuantityNo. No. Description Hand/Foot

1 190203 SUPPORT/BOOT BEZEL 82 190400 SPACER 33 190457 COVER/BOOT 24 193677 PAD/SOUND 15 193706 LATCH/SWELL 46 194271 STRIP/FOAM 1/4 X 1-12 X 15-51/64 27 195557 PLUG/HARNESS 18 241131 HARNESS/WIRE 19 275875 PANEL/COVER RIGHT 110 275885 PANEL/COVER LEFT 111 275923 COVER/CONTROL 112 651041 SCREW/MACHINE HEX WASHER HEAD 3/8 X 3/4 213 651651 SCREW/TAPPING TORX DRIVE PAN HEAD #10 X 1 814 L70486 SCREW/TRUSS TORX DRIVE 1/4 X 1 3

CHASSIS


3

5

12

13

2

12

114

8

6

10

7

7

9 14

1

6

CHASSIS

Covers - T-Bar/Joystick Controls

400742


Ref. Part QuantityNo. No. Description T-Bar/Joystick

1 134852 NUT/SPIRALOCK 3/8 22 190203 SUPPORT/BOOT BEZEL 43 190400 SPACER 34 190457 COVER/BOOT 15 193680 SOUND PAD/HEEL 16 193706 LATCH/SWELL 47 194271 STRIP/FOAM 1/4 X 1-12 X 15-51/64 28 241082 ASSY/FRONT FLOOR 19 275875 PANEL/COVER RIGHT 110 275885 PANEL/COVER LEFT 111 275925 COVER/CONTROL 112 651041 SCREW/MACHINE HEX WASHER HEAD 3/8 X 3/4 413 651651 SCREW/TAPPING TORX DRIVE PAN HEAD #10 X 1 414 L70486 SCREW/TRUSS TORX DRIVE 1/4 X 1 3

CHASSIS


2

3

10

10

11 9

1 10

6

5

5

8

74

4

CHASSIS

Covers - Dual Joystick Controls

400743


Ref. Part QuantityNo. No. Description Dual Joystick

1 134852 NUT/SPIRALOCK 3/8 22 190400 SPACER 33 193685 SOUND PAD/HEEL 14 193706 LATCH/SWELL 45 194271 STRIP/FOAM 1/4 X 1-12 X 15-51/64 26 241082 FLOOR ASSY/FRONT 17 275875 PANEL/COVER RIGHT 18 275885 PANEL/COVER LEFT 19 275927 COVER/CONTROL 110 651041 SCREW/MACHINE HEX WASHER HEAD 3/8 X 3/4 411 L70486 SCREW/TRUSS TORX DRIVE 1/4 X 1 3

CHASSIS


STORE STOP PININ LOWER PIVOT

20

2638

17

39

9

30

12

7

1

41

1211

11

20

25

17

38

19

4

3

840

35

39

39

9

18

24 34

32

27

14

5 939

39

145

36

31

22

21

15

6

24014

14

40

10

23

7

TO FLANGE ON BATTERY BRACKET

TO BRACKET ONINNER FRAME

TO ROPS PIVOT BRACKETSON FRAME

FASTEN TO SIDEPANEL OF ROPS

TO THREADED BOSSON RIGHT INNER FRAME

28

29

28

37

33

13 16

REAR GRILLE AND ENGINE COVER

400690

4640 Models



1 064260 NUT/HEX WHIZLOCK 5/16 12 067847 NUT/HEX LOCK 3/8 13 068034 NUT/HEX LOCK 1/2 14 070648 NUT/SERRATED LOCK 5/16 15 081378 SCREW/CAP LOCKING 1/2 X 1-1/2 26 114665 SPRING/COMPRESSION 17 122485 STUD/BALL 28 128015 WASHER/FLAT 1-1/32 19 131913 BUMPER 310 131940 BUSHING 111 132293 SPRING/GAS 112 132493 CLIP/GAS SPRING 213 134588 NUT/SPIRALOCK 1/4 1014 134853 NUT/SPIRALOCK 1/2 415 136251 CLIP/RETAINING 116 137797 NUT/SERRATED FLANGE #10 217 140282 SEAL/BULB 218 184023 HANDLE/GRAB 119 184664 PIN/LOCK 120 184668 SEAL/EDGE 221 189832 ASSY/LATCH ROD 122 189833 LATCH/MOUNT 123 190045 LATCH/REAR GRILLE 124 191826 PLUG/HOLE 125 194681 ASSY/COVER LEFT 126 194688 ASSY/COVER RIGHT 127 240966 BUMPER 128 244863 SEAL/FOAM 229 245065 SEAL/FOAM 130 275006 COVER/ENGINE 131 275627 PLATE/SPACER 132 275641 GRILLE/REAR 133 50300169 SCREEN 134 650548 SCREW/MACHINE ROUND HEAD SLTD #10 X 1/2 235 650585 SCREW/CAP 1/2 X 2 136 650834 BOLT/CARRIAGE 1/2 X 1-1/2 237 651307 SCREW/MACHINE PAN HEAD CROSS-RECESSED 1/4 X 1/2 1038 651308 SCREW/PHILLIPS PAN HEAD 1/4 X 3/4 639 653034 NUT/HEX JAM 5/16 640 654009 WASHER/FLAT 1/2 341 654024 WASHER/LOCK 5/16 1



STORE STOP PININ LOWER PIVOT

6

10

16 40 12

22 39

2

9

35

3516

38

38

11

19

38

38

11

13

7

7TO THREADED BOSS LOCATED ON LEFT INNER FRAME

FASTEN TOSIDE PANELOF ROPS

1818

23

21

37

37

37

37

37

37

24

21

34

3

20

2

30

29

TO ROPS PIVOT BRACKETSON FRAME

33

4

27

3811

25

55

1616

42 42

311

14

14

28

32

41

8

BUMPERS CONNECT TOTABS ON THE CHASSIS

17

39

36

28

26

1515

40


410598

5240 Models



1 064260 NUT/HEX WHIZLOCK 5/16 12 067847 NUT/HEX LOCK 3/8 23 068034 NUT/HEX LOCK 1/2 14 070648 NUT/SERRATED LOCK 5/16 15 081378 SCREW/CAP LOCKING 1/2 X 1-1/2 26 114665 SPRING/COMPRESSION 17 122485 STUD/BALL 28 128015 WASHER/FLAT 1-1/32 19 131797 MOUNT/LATCH 110 131799 ASSY/LATCH ROD 111 131913 BUMPER 312 131940 BUSHING 113 132293 SPRING/GAS 114 132493 CLIP/GAS SPRING 215 134588 NUT/SPIRALOCK 1/4 916 134853 NUT/SPIRALOCK 1/2 417 137797 NUT/SERRATED FLANGE #10 218 140282 SEAL/BULB 219 184023 HANDLE/GRAB 120 184664 PIN/LOCK 121 184668 SEAL/EDGE 222 186709 LATCH/REAR GRILLE 123 194681 ASSY/COVER LEFT 124 194688 ASSY/COVER RIGHT 125 240966 BUMPER 126 241160 SCREEN 127 244817 GRILLE/REAR 128 244833 COVER/ENGINE 129 244863 SEAL/FOAM 230 244995 ROD/HANDLE 131 245065 SEAL/FOAM 132 650548 SCREW/MACHINE ROUND HEAD SLTD #10 X 1/2 233 650553 PIN/COTTER EPCS 1/8 X 3/4 134 650585 SCREW/CAP 1/2 X 2 135 650834 BOLT/CARRIAGE 1/2 X 1-1/2 236 651307 SCREW/MACHINE PAN HEAD CROSS-RECESSED 1/4 X 1/2 937 651308 SCREW/PHILLIPS PAN HEAD 1/4 X 3/4 638 653034 NUT/HEX JAM 5/16 539 654004 WASHER/FLAT 5/16 240 654009 WASHER/FLAT 1/2 241 654024 WASHER/LOCK 5/16 142 654049 WASHER/FLAT 3/8 2



39

6

2

30

19 18

239

6

14

32

5

401

31

17

7

128

38

3729

3

21

20

35

25

25

36

23

4

4

35

30

15

22

3535

99

11

9

10 35 35

9

3434

91613

99

13

34

34

9

28

33

33

28

2435

26

27

27

APPLY LOCTITE 680 (703285) TOPN 072490 WHEN INSTALLING

ROPS/FOPS STRUCTURE

190596


Ref. PartNo. No. Description Quantity

1 064260 NUT/HEX WHIZLOCK 5/16 22 067823 NUT/LOCK NYLON INSERT 5/8 23 071706 NUT/LOCK 1/2 14 072490 ISOLATOR/ROPS 25 077794 SPRING/TORSION 16 131945 BUSHING 27 132166 TAG/RIP CORD 18 132294 RING 19 134588 NUT/SPIRALOCK 1/4 810 137488 COVER/BOOK BOX 111 137532 HINGE/PIANO 112 139132 WINDOW/REAR STATIONARY 113 139505 CHANNEL/WIRE HARNESS 214 139987 PIN 115 140224 WINDOW/SKYLIGHT 116 140369 GROMMET/SLOT HOLE PLUG 117 170-35072 SPRING/GAS ASSIST 2

192087 SPRING/GAS HEAVY DUTY 218 183172 WEATHERSTRIP/WINDOW 119 183174 RIPCORD/WEATHERSTRIP 120 187671 SUPPORT/ROPS 121 187678 SPACER/TUBE 122 189477 ROPS/FOPS 123 190562 HEADLINER/MOLDED CARPET 124 191734 COVER/WIRE 125 191826 PLUG/HOLE 1/2 626 192182 PLUG/RUBBER 127 195522 SCREW/SEM 1/4 X 1-1/8 1128 480-27676 WASHER/FLAT 41/64 229 650448 SCREW/CAP 1/4 X 3/4 230 650499 SCREW/CAP 5/8 X 5-1/2 231 650568 SCREW/CAP 5/16 X 2 232 650585 SCREW/CAP 1/2 X 2 133 650647 SCREW/CAP 5/8 X 2 234 650771 BOLT/CARRIAGE 1/4 X 1/2 435 651308 SCREW/PHILLIPS PAN HEAD 1/4 X 3/4 1036 651672 SCREW/MACHINE PHILLIPS PAN HEAD 1/4 X 1-1/8 237 654002 WASHER/FLAT 1/4 238 654009 WASHER/FLAT 1/2 139 654012 WASHER/FLAT 5/8 240 655006 PIN/COTTER 1

ROPS/FOPS STRUCTURE


120

25

4

1

23

9

18

10

26

10

24

27

8

1

1

3

4

5

7

4

46 10

4

4

26

1

4

410

6

4

8

12

4

142

9

2319

2

13

21

21 5

24

11

25

20

1

107

27

3

4

15

22

22

16

20

2017

RESTRAINT BAR

140672



1 067950 RING/EXTERNAL RETAINING 62 070648 NUT/SERRATED LOCK 5/16 23 078942 SPRING/COMPRESSION 24 128316 BUSHING/PIVOT 125 131913 BUMPER 26 137035 PIN/PIVOT 27 137036 PIN/PIVOT GROOVED 28 137043 ROD/SPRING GUIDE 29 137061 NUT/HEX NYLON INSERT #4 410 137337 CLIP/RETAINING 611 139009 ASSY/PIVOT BRACKET 112 139010 BRACKET/PIVOT 113 139013 ASSY/PIVOT BRACKET 114 139014 ASSY/PIVOT BRACKET 115 183121 COVER/RIGHT/RESTRAINT BAR 116 183122 COVER/LEFT/RESTRAINT BAR 117 192450 BAR/RESTRAINT W/PAD 118 193156 SWITCH/PROXIMITY 119 193157 MAGNET/SWITCH ACTUATOR 120 650487 SCREW/CAP 5/16 X 1 421 650573 BOLT/CARRIAGE 5/16 X 1 222 651308 SCREW/PHILLIPS PAN HEAD 1/4 X 3/4 223 651529 WASHER/FLAT #4 424 653034 NUT/HEX JAM 5/16 225 654002 WASHER/FLAT 1/4 226 654004 WASHER/FLAT 5/16 227 654049 WASHER/FLAT 3/8 4

RESTRAINT BAR


2

1

1

1

1

3

4 5

5

4

2

1

1

1

1

SEATS - STANDARD AND SUSPENSION

183056_183057

Standard Seat

Suspension Seat


Ref. Part QuantityNo. No. Description Standard Seat

1 137836 NUT/HEX WHIZLOCK M8 42 184017 SEAT/STANDARD 1

184034 SWITCH/SEAT STANDARD 1184036 RAIL/SLIDE (SET) 1

3 184892 BRACKET/SEAT BELT 14 650630 SCREW/CAP 7/16 X 1 25 654046 WASHER/FLAT 7/16 2

Ref. Part QuantityNo. No. Description Suspension Seat

1 137836 NUT/HEX WHIZLOCK M8 42 184016 SEAT/SUSPENSION 1

184022 SWITCH/SEAT SUSPENSION 1184036 RAIL/SLIDE (SET) 1

SEATS - STANDARD AND SUSPENSION


5

552

4

4

4

DETAIL A

A

4

5

24

3

3

1

1

11

SEATS - SEAT BELT OPTION

183287_183289


Ref. Part QuantityNo. No. Description 2 Seat Belt 3 Seat Belt

1 081371 NUT/HEX LOCK 7/16 3 32 184007 TAB/RETRACTOR MOUNT 1 13 420-36086 ASSY/ SEAT BELT 2" 1 -

420-36087 ASSY/SEAT BELT 3" - 14 650630 SCREW/CAP 7/16 X 1 3 35 654046 WASHER/FLAT 7/16 3 3

SEATS - SEAT BELT OPTION


SEATS - THREE-POINT RESTRAINT SEAT BELT OPTION

243308_243309

DETAIL B

B

REMOVE RETRACTORCOVER TO INSTALLCAPSCREW & WASHER

OUTER FACEOF ROPSSIDE PANEL

5

C

5 6

5

62

5 6

5

6

2

6

D

DETAIL D

DETAIL C

EXTEND AND ASSEMBLED-RING AS SHOWN

EXTEND AND ASSEMBLED-RING AS SHOWN

5

6 3

1

1

1

1

1

1

4


3-Point Restraint SystemRef. Part Quantity QuantityNo. No. Description 2" Seat Belt 3" Seat Belt

1 081371 NUT/HEX LOCK 7/16 5 52 184007 TAB/RETRACTOR MOUNT 1 13 186834 SPACER 1 14 243284 a RESTRAINT ASSEMBLY/2 THREE-POINT 1 -

243289 a RESTRAINT ASSEMBLY/3 THREE-POINT - 15 650630 SCREW/CAP 7/16 X 1 5 56 654046 WASHER/FLAT 7/16 5 5a) Restraint assemblies includes all associated hardware, except PN 184007.

SEATS - THREE-POINT RESTRAINT SEAT BELT OPTION


16

1

22

102

5

7

921

4

8

17NOTE 3

NOTE 1

NOTE 1

NOTE 4

NOTE 4

NOTE 5NOTE 5

NOTES:

1. DO NOT OVERTIGHTEN2. APPLY LOCTITE 2423. ADDITIONAL SHIMS MAY BE USED TO INSURE CONTACT BETWEEN SHIMS AND CHASSIS STOP BLOCKS.4. 220 FT-LBS5. ADD SHIMS 136765 AND 136766 AS REQUIRED TO ACHIEVE A GAP BETWEEN THE LIFT ARMS AND THE ALL-TACH FROM O.OOO" TO 0.060" WIDE.

19

15

15

3

20

11

1314

18 12

12

18

14

1311

20

NOTE 5

NOTE 5

NOTE 2

23

6

23

6

LIFT ARM

410023

4640 Models



1 067847 NUT/HEX LOCK 3/8 22 074860 STEM/RUBBER 13 081377 SCREW/CAP HEX FLANGE LOCKING 3/8 X 1-1/4 44 079209 NUT/HEX 3/4 15 087854 PAD/ARM BRACE 16 128181 CAP/GREASE 2

194982 C-CLIP 27 243045 ARM/SAFETY 18 131201 STEP 19 131785 PIN/QUICK RELEASE 110 132289 RIVET/BLIND 111 135773 WASHER/FLAT HARDENED 5/8 212 136601 NUT/SPIRALOCK 5/8 213 136765 SHIM 2.03 ID .06 THK 214 136766 SHIM 2.03 ID .13 THK 215 188983 PIN/GREASELESS 2

134523 a PIN/GREASEABLE 216 193042 LIFT ARM 1

088101 BUSHING (AT HITCH ATTACHMENT) 2139734 BUSHING (LIFT ARM PIVOT) 4

17 193069 SHIM 218 240258 PIN/ALL-TACH PIVOT 219 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 620 570002 FITTING/GREASE 221 650483 SCREW/CAP 3/4 X 5-1/2 122 650818 SCREW/CAP 3/8 X 3 223 651634 SCREW/CAP 5/8 X 7 2a) Pin that takes a grease zerk (PN 570002) and requires lubricating grease for maintenance.

LIFT ARM


NOTES

1. DO NOT OVERTIGHTEN

2. APPLY LOCTITE 242

3. ADDITIONAL SHIMS MAY BE USED TO INSURE CONTACT BETWEEN SHIMS AND CHASSIS STOP BLOCKS.

4. 220 FT-LBS

5. ADD SHIMS 136765 AND 136766 AS REQUIRED TO ACHIEVE A GAP BETWEEN THE LIFT ARMS AND THE ALL-TACH FROM O.OOO" TO 0.060" WIDE.

17

15

15

1

22

10

9

2

5

7

4

21 NOTE 1

NOTE 1

16

3

1413

20

819

NOTE 3

NOTE 4

NOTE 4

NOTE 5NOTE 5

1413

NOTE 5NOTE 5NOTE 5

NOTE 5

2011

11

1812

12

18

NOTE 2

6

23

23

6

LIFT ARM

410038

5240 Models



1 067847 NUT/HEX LOCK 3/8 22 074860 STEM/RUBBER 13 081377 SCREW/CAP HEX FLANGE LOCKING 3/8 X 1-1/4 44 079209 NUT/HEX 3/4 15 087854 PAD/ARM BRACE 16 128181 CAP/GREASE 2

194982 C-CLIP 27 243045 ARM/SAFETY 18 131201 STEP 19 131785 PIN/QUICK RELEASE 110 132289 RIVET/BLIND 111 135773 WASHER/FLAT HARDENED 5/8 212 136601 NUT/SPIRALOCK 5/8 213 136765 SHIM 2.03 ID .06 THK 214 136766 SHIM 2.03 ID .13 THK 215 188983 PIN/GREASELESS 2

134523 a PIN/GREASEABLE 216 193069 SHIM 217 195400 LIFT ARM 1

088101 BUSHING (AT HITCH ATTACHMENT) 2139734 BUSHING (LIFT ARM PIVOT) 4

18 240258 PIN/ALL-TACH PIVOT 219 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 620 570002 FITTING/GREASE 221 650483 SCREW/CAP 3/4 X 5-1/2 122 650818 SCREW/CAP 3/8 X 3 223 651634 SCREW/CAP 5/8 X 7 2a) Pin that takes a grease zerk (PN 570002) and requires lubricating grease for maintenance.

LIFT ARM


17

2

10

521

20

67

3 4

8

1

11

15

9

16

LEFT

RIGHT12

NOTES : 1)USE LOCTITE 242 2)TORQUE TO 100 FT-LB

NOTES 1 & 2

NOTE 1

NOTES 1 & 2

13

14

18

18

19

18

ATTACHMENT BRACKET

184954

All-Tach 4640E Models: SN 313600 and Up5240E Models: SN 433432 and Up

Also includes the following SNs:4640E Models: 313585-313587, 313597-313598, 313590-3135915240E Models: 433409-433412, 433414-433417, 433421-433430



1 062756 PIN/SPRING 22 071706 NUT/LOCK 1/2 23 123554 SPRING/COMPRESSION 4-1/2 24 134594 ROD/PUSH 25 134707 SPRING/COMPRESSION 26 183570 PLATE/LATCH LINK 27 183574 ADAPTOR/PUSH ROD 28 183575 PIN/LATCH 29 50352450 WELDMENT/ALL-TACH 110 184059 HANDLE 211 184320 WASHER/BEVEL 212 184338 RING/RETAINING 1-1/8 213 420-18757 GRIPS 214 50300892 SCREW/SHOULDER 3/4 X 2 215 50300915 WASHER/FLAT 25/32 216 50352435 LINK/LATCH RIGHT 117 50352436 LINK/LATCH LEFT 118 570002 FITTING/GREASE 1/8 PTF 419 650585 SCREW/CAP 1/2 X 2 220 651542 SCREW/CAP 1/2 X 2-3/4 221 654009 WASHER/FLAT 1/2 2

ATTACHMENT BRACKET


7

3

13

622

16

21

910

4 5

11

2

14

1

12

8

LEFT

RIGHT

15

NOTES :

1) USE LOCTITE 242 2) TORQUE TO 100 FT-LB

NOTES 1 & 2

NOTE 1

NOTES 1 & 2

18

17

19

19

20

ATTACHMENT BRACKET

184954

All-Tach 4640E Models: SN 313599 and Before5240E Models: SN 433431 and Before

Excludes the following SNs:4640E Models: 313585-313587, 313597-313598, 313590-3135915240E Models: 433409-433412, 433414-433417, 433421-433430



1 057557 WASHER/FLAT 17/32 22 062756 PIN/SPRING 23 071706 NUT/LOCK 1/2 24 123554 SPRING/COMPRESSION 4-1/2 25 134594 ROD/PUSH 26 134707 SPRING/COMPRESSION 27 183568 LINK/LATCH LEFT 18 183569 LINK/LATCH RIGHT 19 183570 PLATE/LATCH LINK 210 183574 ADAPTOR/PUSH ROD 211 183575 PIN/LATCH 212 194948 ASSEMBLY/MULTI-TACH 1

183703 WELDMENT/MULTI-TACH 113 184059 HANDLE 214 184320 WASHER/BEVEL 215 184338 RING/RETAINING 1-1/8 216 188862 SPACER 217 310-32678 SCREW/CAP SOCKET HEAD 1/2 X 2-3/4 218 420-18757 GRIPS 219 570002 FITTING/GREASE 220 650585 SCREW/CAP 1/2 X 2 221 651542 SCREW/CAP 1/2 X 2-3/4 222 654009 WASHER/FLAT 1/2 2

ATTACHMENT BRACKET


27

42

24

27

42

20

47

21

4

4

31

30

24

INNER TUBE

OUTER TUBE

TO OUTER TUBETO INNER TUBE

28

29

26

45

25

33

3

ROUTE HOSESTHROUGH SLEEVE

ROUTE HOSESTHROUGH GUIDE

15ROUTE HOSES THROUGH SLEEVE

3737

445

6

5

9

22

34

352

18

4811

17

3843

8

3933

16

23

3219

33

ALL-TACH ASSEMBLY BREAKDOWN

VIEW

41

ROUTE HOSES THROUGH GUIDE

14

1

10

13

46

12

736

40

40

40

ATTACHMENT BRACKET

5240 Models - Power-A-Tach

50450108

SN 433432 and Up

Also includes the following SNs:433409-433412, 433414-433417, 433421-433430



1 062756 PIN/SPRING 22 071706 NUT/LOCK 1/2 23 075196 CLAMP/HOSE 1-1/2 X 13/32 HOLE 14 079026 FITTING/45 MJ06-MAORB06 25 079098 PLATE/TWIN COVER 26 079126 CLAMP/TUBE 5/8 17 090666 NUT/LOCK FLANGE SERRATED 3/8 28 123554 SPRING/COMPRESSION 4-1/2 29 131842 NUT/SPIRALOCK 5/16 110 134594 ROD/PUSH 211 134707 SPRING/COMPRESSION 212 183570 PLATE/LATCH LINK 213 183574 ADAPTOR/PUSH ROD 214 183575 PIN/LATCH 215 50352450 WELDMENT/ALL-TACH 116 184151 BRACKET/COVER SUPPORT 217 184319 FLAG 218 184320 WASHER/BEVEL 219 184481 DECAL/POWER-A-TACH 120 190068 CYLINDER/HYD POWER F-A-T 1

50250278 KIT/SEAL (FOR 190068 CYLINDER) 121 190711 ROD/EXTENSION 122 191395 SLEEVE/PROTECTIVE 26.00 123 192224 COVER/FRONT 124 192493 CLAMP/DUAL TUBE 3/8 X 43/64 225 192500 CLAMP/DUAL TUBE 3/8 226 192508 TUBE CLAMP/PLATE 227 192510 TUBE CLAMP/PLATE 228 193794 HOSE/MEDIUM PRESSURE 3/8 X 38 129 193795 HOSE/MEDIUM PRESSURE 3/8 X 33-1/2 130 194255 POWER TUBE/OUTSIDE HYDRAULIC 131 194256 POWER TUBE/INSIDE HYDRAULIC 132 195036 COVER/BACK 133 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 534 50300892 SCREW/SHOULDER 3/4 X 2 235 50300915 WASHER/FLAT 25/32 236 50350848 GUIDE/HOSE 137 50351147 HOSE/MEDIUM PRESSURE 3/8 X 50 238 50352435 LINK/LATCH RIGHT 139 50352436 LINK/LATCH LEFT 140 570002 FITTING/GREASE 1/8 PTF 441 650490 SCREW/CAP 3/8 X 1 242 650568 SCREW/CAP 5/16 X 2 243 650585 SCREW/CAP 1/2 X 2 244 650725 SCREW/CAP 5/16 X 2-1/4 145 650987 SCREW/TAPPING HEX WASHER HEAD THREAD CUTTING 3/8 X 1-1/2 246 651542 SCREW/CAP 1/2 X 2-3/4 247 653048 NUT/HEX JAM 5/8 148 654009 WASHER/FLAT 1/2 2

ATTACHMENT BRACKET


31

42

28

31

42

24

47

25

5

35

34

381

3

21

4812

20

1443

9

13

37

19

27

3622

37

28

INNER TUBE

OUTER TUBE

TO OUTER TUBETO INNER TUBE


VIEW

41

33

30

45

29

37

4




17

2

11

16

46

15

23

18

6

26

839

5

32

4040

446

7

10

ATTACHMENT BRACKET

5240 Models - Power-A-Tach

50450108

SN 433431 and Before

Excludes the following SNs:433409-433412, 433414-433417, 433421-433430



1 057557 WASHER/FLAT 17/32 22 062756 PIN/SPRING 23 071706 NUT/LOCK 1/2 24 075196 CLAMP/HOSE 1-1/2 X 13/32 HOLE 15 079026 FITTING/45 MJ06-MAORB06 26 079098 PLATE/TWIN COVER 27 079126 CLAMP/TUBE 5/8 18 090666 NUT/LOCK FLANGE SERRATED 3/8 29 123554 SPRING/COMPRESSION 4-1/2 210 131842 NUT/SPIRALOCK 5/16 111 134594 ROD/PUSH 212 134707 SPRING/COMPRESSION 213 183568 LINK/LATCH LEFT 114 183569 LINK/LATCH RIGHT 115 183570 PLATE/LATCH LINK 216 183574 ADAPTOR/PUSH ROD 217 183575 PIN/LATCH 218 183703 WELDMENT/ALL-TACH 119 184151 BRACKET/COVER SUPPORT 220 184319 FLAG 221 184320 WASHER/BEVEL 222 184481 DECAL/POWER-A-TACH 123 188862 SPACER 224 190068 CYLINDER/POWER 1

50250278 KIT/SEAL (FOR 190068 CYLINDER) 125 190711 ROD/EXTENSION 126 191395 SLEEVE/PROTECTIVE 26.00 127 192224 COVER/FRONT 128 192493 CLAMP/DUAL TUBE 3/8 X 43/64 229 192500 CLAMP/DUAL TUBE 3/8 230 192508 TUBE CLAMP/PLATE 231 192510 TUBE CLAMP/PLATE 232 193789 PLATE/ALL-TACH 133 193795 HOSE/MEDIUM PRESSURE 3/8 X 33-1/2 134 194255 POWER TUBE/OUTSIDE HYDRAULIC 135 194256 POWER TUBE/INSIDE HYDRAULIC 136 195036 COVER/BACK 137 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 538 310-32678 SCREW/CAP SOCKET HEAD 1/2 X 2-3/4 239 50350848 a GUIDE/HOSE 140 50351147 HOSE/MEDIUM PRESSURE 3/8 X 50 241 650490 SCREW/CAP 3/8 X 1 242 650568 SCREW/CAP 5/16 X 2 243 650585 SCREW/CAP 1/2 X 2 244 650725 SCREW/CAP 5/16 X 2-1/4 145 650987 SCREW/TAPPING HEX WASHER HEAD THREAD CUTTING 3/8 X 1-1/2 246 651542 SCREW/CAP 1/2 X 2-3/4 247 653048 NUT/HEX JAM 5/8 148 654009 WASHER/FLAT 1/2 2a) 50350848 replaced 193789. 193789 used 075196 hose clamp, 076588 HFS screw and 090666 locknut.

ATTACHMENT BRACKET


27

42

24

27

42

20

47

21

4

31

30

35

218

4811

17

3843

8

39

34

16

23

3219

34

24

INNER TUBE

OUTER TUBE

TO OUTER TUBE

TO INNER TUBE


VIEW

29

26

45

25

34

3




14

1

10

13

46

12

15ROUTE HOSES THROUGH SLEEVE

6

5

44

22

7 37

41

36

40

40

40

4

28

33

33

9

5

ATTACHMENT BRACKET

410116

4640 Models - Power-A-Tach SN 313600 and Up

Also includes the following SNs:313585-313587, 313597-313598, 313590-313591



1 062756 PIN/SPRING 22 071706 NUT/LOCK 1/2 23 075196 CLAMP/HOSE 1-1/2 X 13/32 HOLE 14 079026 FITTING/45 MJ06-MAORB06 25 079098 PLATE/TWIN COVER 26 079126 CLAMP/TUBE 5/8 17 090666 NUT/LOCK FLANGE SERRATED 3/8 28 123554 SPRING/COMPRESSION 4-1/2 29 131842 NUT/SPIRALOCK 5/16 110 134594 ROD/PUSH 211 134707 SPRING/COMPRESSION 212 183570 PLATE/LATCH LINK 213 183574 ADAPTOR/PUSH ROD 214 183575 PIN/LATCH 215 50352450 WELDMENT/ALL-TACH 116 184151 BRACKET/COVER SUPPORT 217 184319 FLAG 218 184320 WASHER/BEVEL 219 184481 DECAL/POWER-A-TACH 120 190068 CYLINDER/POWER 1

50250278 KIT/SEAL (FOR 190068 CYLINDER) 121 190711 ROD/EXTENSION 122 191395 SLEEVE/PROTECTIVE 26.00 123 192224 COVER/FRONT 124 192493 CLAMP/DUAL TUBE 3/8 X 43/64 225 192500 CLAMP/DUAL TUBE 3/8 226 192508 TUBE CLAMP/PLATE 227 192510 TUBE CLAMP/PLATE 228 193794 HOSE/MEDIUM PRESSURE 3/8 X 38 129 193795 HOSE/MEDIUM PRESSURE 3/8 X 33-1/2 130 194310 POWER TUBE/OUTSIDE HYDRAULIC 131 194311 POWER TUBE/INSIDE HYDRAULIC 132 195036 COVER/BACK 133 195114 HOSE/MEDIUM PRESSURE 3/8 X 57 234 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 535 50300892 SCREW/SHOULDER 3/4 X 2 236 50300915 WASHER/FLAT 25/32 237 50350848 GUIDE/HOSE 138 50352435 LINK/LATCH RIGHT 139 50352436 LINK/LATCH LEFT 140 570002 FITTING/GREASE 1/8 PTF 441 650490 SCREW/CAP 3/8 X 1 242 650568 SCREW/CAP 5/16 X 2 243 650585 SCREW/CAP 1/2 X 2 244 650725 SCREW/CAP 5/16 X 2-1/4 145 650987 SCREW/TAPPING HEX WASHER HEAD THREAD CUTTING 3/8 X 1-1/2 246 651542 SCREW/CAP 1/2 X 2-3/4 247 653048 NUT/HEX JAM 5/8 148 654009 WASHER/FLAT 1/2 2

ATTACHMENT BRACKET


31

42

28

31

42

24

47

25

5

35

34

39

1

321

4812

20

1443

9

13

38

19

27

3622

38

28

INNER TUBE

OUTER TUBE

TO OUTER TUBE

TO INNER TUBE


VIEW

33

30

45

29

38

4

ROUTE HOSES

THROUGH SLEEVE



17

2

11

16

46

15

23

18

10

6

7

6

44

26

8 40

41

5

32

37

37

ATTACHMENT BRACKET

410116

4640 Models - Power-A-Tach SN 313599 and Before

Excludes the following SNs:313585-313587, 313597-313598, 313590-313591



1 057557 WASHER/FLAT 17/32 22 062756 PIN/SPRING 23 071706 NUT/LOCK 1/2 24 075196 CLAMP/HOSE 1-1/2 X 13/32 HOLE 15 079026 FITTING/45 MJ06-MAORB06 26 079098 PLATE/TWIN COVER 27 079126 CLAMP/TUBE 5/8 18 090666 NUT/LOCK FLANGE SERRATED 3/8 29 123554 SPRING/COMPRESSION 4-1/2 210 131842 NUT/SPIRALOCK 5/16 111 134594 ROD/PUSH 212 134707 SPRING/COMPRESSION 213 183568 LINK/LATCH LEFT 114 183569 LINK/LATCH RIGHT 115 183570 PLATE/LATCH LINK 216 183574 ADAPTOR/PUSH ROD 217 183575 PIN/LATCH 218 194948 ASSEMBLY/ALL-TACH 1

183703 WELDMENT/ALL-TACH 119 184151 BRACKET/COVER SUPPORT 220 184319 FLAG 221 184320 WASHER/BEVEL 222 184481 DECAL/POWER-A-TACH 123 188862 SPACER 224 190068 CYLINDER/POWER 1

50250278 KIT/SEAL (FOR 190068 CYLINDER) 125 190711 ROD/EXTENSION 126 191395 SLEEVE/PROTECTIVE 26.00 127 192224 COVER/FRONT 128 192493 CLAMP/DUAL TUBE 3/8 X 43/64 229 192500 CLAMP/DUAL TUBE 3/8 230 192508 TUBE CLAMP/PLATE 231 192510 TUBE CLAMP/PLATE 232 193794 HOSE/MEDIUM PRESSURE 3/8 X 38 133 193795 HOSE/MEDIUM PRESSURE 3/8 X 33-1/2 134 194310 POWER TUBE/OUTSIDE HYDRAULIC 135 194311 POWER TUBE/INSIDE HYDRAULIC 136 195036 COVER/BACK 137 195114 HOSE/MEDIUM PRESSURE 3/8 X 57 238 310-32411 SCREW/SELF-TAPPING 3/8 X 3/4 539 310-32678 SCREW/CAP SOCKET HEAD 1/2 X 2-3/4 240 50350848 a GUIDE/HOSE 141 650490 SCREW/CAP 3/8 X 1 242 650568 SCREW/CAP 5/16 X 2 243 650585 SCREW/CAP 1/2 X 2 244 650725 SCREW/CAP 5/16 X 2-1/4 145 650987 SCREW/TAPPING HEX WASHER HEAD THREAD CUTTING 3/8 X 1-1/2 246 651542 SCREW/CAP 1/2 X 2-3/4 247 653048 NUT/HEX JAM 5/8 148 654009 WASHER/FLAT 1/2 2a) 50350848 replaced 193789. 193789 used 075196 hose clamp, 076588 HFS screw and 090666 locknut.

ATTACHMENT BRACKET


2

2

3

6

6

5

3

4

4

3

52

1

1

TORQUE TO 280 FT-LBS(LUBED HARDWARE)

3

4

4

TORQUE TO180 FT-LBS

5

5

6

1

1

2

6

FRONT

WHEEL DRIVES

138658_138663_139589

1314

156

7

98

10

1211

3

Note: All special washers are used 'as required'

4

ASSEMBLY NOTES:

1) PRESS OUTSIDE BEARING CUP INTO CASTING(6000 lbs)2) PRESS OUTER SEAL INTO CASTING(500 lbs)3) PRESS INNER BEARING CUP INTO CASTING(6000 lbs)4) PACK BEARING WITH LITHIUM GREASE5) PRESS BEARING CONE ONTO AXLE(6000 lbs)6) ASSEMBLE AXLE INTO HOUSING7) PACK BEARING WITH LITHIUM GREASE8) PRESS BEARING ONTO AXLE AND INTO CASTING(6000 lbs)9) INSTALL RETAINING RING10) MEASURE GAP BETWEEN BEARING AND SNAP RING11) REMOVE RETAINING RING12) INSTALL SPECIAL WASHER OF APPROPRIATE THICKNESS13) INSTALL RETAINING RING AND REMOVE PRESSURE

5

2

1

1

2

Axle Assembly194761


Ref. Part QuantityNo. No. Description 4640 5240

1 079152 NUT/WHEEL 32 322 131609 NUT/SPIRALOCK 1/2 32 323 134503 CHAIN #80 X 66 4 2

134504 CHAIN #80 X 74 - 24 137072 BOLT/CARRIAGE 3/4 X 2 32 325 194761 ASSY/AXLE 4 4

137915 BOLT/WHEEL 32 326 651564 WASHER/FLAT HARDENED 3/4 32 327 138296 SPROCKET #80-40T / SINGLE-SPEED (NOT SHOWN) 4 4

139302 SPROCKET #80-37T / TWO-SPEED (NOT SHOWN) 4 4

Ref. Part QuantityNo. No. Description 194761 Axle Assy

1 010-28854 CUP/BEARING 22 010-32401 CONE/BEARING 23 138759 HOUSING/AXLE/MACHINED 14 139587 ASSEMBLY/AXLE W/ STUDS 15 183784 SEAL/AXLE 16 350-32539 RETAINING RING/EXTERNAL 17 350-32542 O-RING 369 N70 18 400-32513 WASHER/SPECIAL .254 AR9 400-32514 WASHER/SPECIAL .250 AR10 400-32515 WASHER/SPECIAL .246 AR11 400-32521 WASHER/SPECIAL .234 AR12 400-32522 WASHER/SPECIAL .230 AR13 400-32523 WASHER/SPECIAL .226 AR14 400-32555 WASHER/SPECIAL .238 AR15 400-32556 WASHER/SPECIAL .242 AR

WHEEL DRIVES


1

1

7

37

36

84

19

18

20

44

32

40

46

38

21

3 6

1633

33

44

20 2816

35

35

1745

23

5 24 26

22

30

14

25

12

52

11

11

29

52

1215

3149

12

25

34

47

47

52

12

1512

25

1114

30

11

52

12

25

1013

NOTE 6

NOTE 1

NOTES 1 & 4

NOTES 1 & 4

NOTES 1 & 4

NOTES 1 & 4

NOTES 1 & 4

NOTES 1 & 3

NOTES 1 & 8

NOTES 1 & 5

NOTES 1 & 5

NOTES 1 & 5

41

27

39

NOTES:1) APPLY LOCTITE 242 OR EQUIVALENT2) APPLY PIPE THREAD SEALANT3) TORQUE TO 28 FT-LBS4) TORQUE TO 39 FT-LBS5) TORQUE TO 110 FT-LBS6) COUPLER PLATE INSTALLATION A)DO NOT APPLY LUBRICATION/GREASE B)LEADING EDGE OF COUPLER HUB TO BE POSITIONED .39"-.42" FROM PUMP SURFACE C)TORQUE (2) SET SCREWS TO 25 FT-LBS EACH

7) SERVICE ASSY 1863088) TORQUE TO 47 FT-LBS9) SERVICE PART 5035009410) RE-USE WASHER SUPPLIED WITH ENGINE OIL DRAIN PLUG11) REMOVE LIFT HOOK FROM FLYWHEEL END OF ENGINE AND DISCARD.

NOTE 7

TO FUELPUMP

TO LEFT INNERFRAME

TANK SUPPLY NOTE 2

TANK RETURN NOTE 2

ATTACH TOBATTERY TRAY

ATTACH TO AIR CLEANERSUPPORT ON LEFT FRAME

51 NOTE 9

43

50

39

41

42

42

DETAIL A

A

92

48

ROUTE OIL COOLERHOSE THROUGH CLAMP

NOTE 1

NOTE 11

ENGINE

400732

4640 Models



1 054626 FITTINGSTRAIGHT MJ08-MORB08 22 058805 CLAMP/HOSE 1-1/8 X 13/32 HOLE 13 062023 CLAMP/HOSE #05 94 067761 FITTING/90 MJ10-MAORB10 15 071246 NUT/LOCK INST M10 16 071401 NUT/HEX LOCK 1/4 27 072580 FITTING/STRAIGHT MJ10-MORB10 18 088442 FITTING/90 MJ08-FJS08 19 096511 SPACER 3/8 LONG 110 131842 NUT/SPIRALOCK 5/16 111 132707 WASHER/FLAT 3/8 HT 1612 135427 WASHER 813 136226 CLAMP/HOSE 3/4 X 13/32 HOLE 114 137063 ISOLATOR 215 189640 ISOLATOR 216 191735 VALVE/FUEL SHUT OFF 90 217 193569 BRACKET/ALTERNATOR 118 193971 MOUNT/FILTER 119 194068 ADAPTER/FILTER 1

191651 O-RING 230 N70 120 210-19470 NUT/LOCK SERRATED FLANGE 5/16 521 240021 HOSE ASSY/OIL DRAIN 1

131529 PLUG MORB08 122 241459 ALTERNATOR 95 A 123 241562 SPACER/ALTERNATOR 124 241563 SPACER/ALTERNATOR 125 241590 BOLT/CARRIAGE 5/8 X 4-1/2 426 241932 SPACER/ALTERNATOR 127 243129 ENGINE/4TNV98-ZNMS2 128 243432 SEPARATOR-FILTER/FUEL-WATER 1

245005 ELEMENT/FILTER/FUEL 129 244358 MOUNT/ENGINE (FW END) 130 244362 MOUNT/ENGINE 231 244365 COUPLER/FLEX 132 244465 ASSY/DIPSTICK 133 244955 HOSE/FUEL 5/16 X 8 334 245012 HOUSING/FLYWHEEL 135 275743 HOSE/FUEL 236 50352316 HOSE 5/8 X 26 137 50352312 HOSE 1/2 X 26 138 50350227 BRACKET/DIPSTICK 139 612604 WASHER/FLAT M8 240 650486 SCREW/CAP 5/16 X 3/4 141 651394 SCREW/CAP M10 X 25 MM 842 651395 SCREW/CAP M10 X 30 MM 843 651773 SCREW/CAP M10 X 60 MM 244 651799 SCREW/CAP 5/16 X 1 545 656002 SCREW/CAP M8 X 35 MM 146 656006 SCREW/CAP M10 X 20 MM 147 656045 SCREW/CAP SOCK HEAD M10 X 30 MM 948 656105 SCREW/CAP M8 X 25 MM 149 656141 SCREW/CAP SOCKET HEAD M10 X 25 MM 850 656154 SCREW/CAP M8 X 45 MM 151 656173 SCREW/CAP M10 X 130 MM 152 L50081 NUT/HEX 5/8 4

ENGINE


ENGINE

410546

5240 Models

19

24

NOTE #7

43

55

52

57

37

31

12

17

3560

12

2711

51

33

101348 46 3854

22

41

40

21

266

1

39

49

44

23

25

18

18

15

3

15

3

3

NOTE #1 & #5

NOTE #3

CONNECT TO PORTINSIDE OF CHASSIS

FRONT FUELTANK PORT NOTE #2

REAR FUELTANK PORT NOTE #2 NOTE

#1 & #4

NOTE#1 & #4

92 56

ENGINE OIL COOLER REAR HOSE

8

USE EXISTING YANMAR FUEL HOSES

60

12

11

50

36

14

12

31

2920

58

47

53

528

3032

59

DETAIL A

44

7

3

41

3

3

42

18

25

34

26

21

49

NOTE#1 & #5

NOTE #3

REAR FUEL TANK PORT NOTE #2

45

19

24

33

16

47

3

41

RPM LOW IDLE, NO LOAD

2500

NOTES:

1. APPLY LOCTITE 242 OR EQUIVALENT2. PIPE THREAD SEALANT3. 110 FT-LBS.4. 47 FT-LBS5. 28 FT-LBS6. RE-USE WASHER SUPPLIED WITH ENGINE OIL DRAIN PLUG7. COUPLER PLATE INSTALLATION A. DO NOT APPLY LUBRICATION /GREASE B. LEADING EDGE OF COUPLER GUB TO BE POSITIONED FROM .39"-.42" PUMP SURFACE C. TORQUE (2) SET SCREWS TO 20 FT-LBS EACH

SPEED SETTING

RPM HIGH, NO LOAD (EU ONLY)

GOVERNED ENGINE SPEED SPECIFICATIONS

102500 RPM

10

RPM

2500

100010

RPM10

HIGH IDLE, NO LOAD

TOLERANCE

*THE MAXIMUM RPM UNDER LOAD WHEN THE GOVERNOR IS AT ITS FASTEST SETTING(OPEN)

MANUFACTURER'S RATING*

8. REMOVE LIFT HOOK FROM FLYWHEEL END OF ENGINE AND DISCARD.

NOTE #8



1 054626 FITTINGSTRAIGHT MJ08-MORB08 22 058805 CLAMP/HOSE 1-1/8 X 13/32 HOLE 13 062023 CLAMP/HOSE #05 94 067761 FITTING/90 MJ10-MAORB10 15 071246 NUT/LOCK INST M10 16 072580 FITTING/STRAIGHT SAE10 X JIC10 17 076588 SCREW/CAP FL LOCK 3/8 X 3/4 28 088442 FITTING/90 MJ08-FJS08 19 096511 SPACER 3/8 LONG 110 131842 NUT/SPIRALOCK 5/16 111 132707 WASHER/FLAT 3/8 HT 1612 135427 WASHER 813 136226 CLAMP/HOSE 3/4 X 13/32 HOLE 114 137063 ISOLATOR 215 184296 HOSE/FUEL 5/16 X 25 216 186308 PUMP ASSY/FUEL FEED 117 189640 ISOLATOR 218 191735 VALVE/FUEL SHUT OFF 90 219 193024 FILTER/FUEL 1 MICRON 120 193569 BRACKET/ALTERNATOR 121 193971 MOUNT/FILTER 122 194068 ADAPTER/FILTER 1

191651 O-RING 230 N70 123 194166 CLAMP/HOSE 5/8 X 7/16 HOLE 124 195568 FILTER/ENGINE OIL 125 210-19469 NUT/LOCK SERRATED FLANGE 1/4 426 210-19470 NUT/LOCK SERRATED FLANGE 5/16 227 240021 HOSE ASSY/OIL DRAIN 1

131529 PLUG MORB08 128 241459 ALTERNATOR 95 A 129 241562 SPACER/ALTERNATOR 130 241563 SPACER/ALTERNATOR 131 241590 BOLT/CARRIAGE 5/8 X 4-1/2 432 241932 SPACER/ALTERNATOR 133 243129 ENGINE/4TNV98-ZNMS2 134 243432 SEPARATOR-FILTER/FUEL-WATER 1

245005 ELEMENT/FILTER/FUEL 135 244358 MOUNT/ENGINE (FW END) 136 244362 MOUNT/ENGINE 237 244365 COUPLER/FLEX 138 244465 ASSY/DIPSTICK 139 50352310 HOSE 5/8 X 34.50 140 50352309 HOSE 1/2 X 35 141 244955 HOSE/FUEL 5/16 X 8 242 244957 HOSE/FUEL 5/16 X 3 143 245012 HOUSING/FLYWHEEL 144 245033 BRACKET/PREFILTER/ASSY 145 50350094 BELT/ALTERNATOR 146 50350227 BRACKET/DIPSTICK 147 612604 WASHER/FLAT M8 248 650486 SCREW/CAP 5/16 X 3/4 149 650577 SCREW/CAP 5/16 X 1-1/2 250 651394 SCREW/CAP M10 X 25 MM 851 651395 SCREW/CAP M10 X 30 MM 852 651773 SCREW/CAP M10 X 60 MM 253 656002 SCREW/CAP M8 X 35 MM 154 656006 SCREW/CAP M10 X 20 MM 155 656045 SCREW/CAP SOCK HEAD M10 X 30 MM 956 656105 SCREW/CAP M8 X 25 MM 157 656141 SCREW/CAP SOCKET HEAD M10 X 25 MM 858 656154 SCREW/CAP M8 X 45 MM 159 656173 SCREW/CAP M10 X 130 MM 160 L50081 NUT/HEX 5/8 4

ENGINE


11

7

2

3

148

16

10

13

6

11

4

9

5

171

15

18

12

19INSTALL EXHAUST GASKETSUPPLIED WITH ENGINE

AIR CLEANER AND EXHAUST

410544



1 070648 NUT/SERRATED LOCK 5/16 22 076589 SCREW/CAP FL LOCK 3/8 X 1 43 078931 CLAMP/MUFFLER 2.00 14 087849 CLAMP/HOSE #52 15 183998 CLAMP/AIR CLEANER 16 184099 ELBOW/90 WITH INDICATOR TAP 17 184278 COUPLING/INTAKE HOSE 18 184605 CLAMP/T-BOLT 3-1/2 19 186014 ASSY/AIR CLEANER 1

184146 ELEMENT/PRIMARY FILTER 1184195 ELEMENT/SECONDARY FILTER 1187725 VALVE/EVACUATOR 1187726 END CAP/AIR CLEANER 1

10 186906 CLAMP/T-BOLT 3.00 111 187581 CLAMP/HOSE #44 212 191451 INDICATOR/RESTRICTION 113 192848 DIFFUSER/SOUND 114 274982 COUPLER/FLEX 115 274983 MUFFLER 116 275012 HOSE/INTAKE 117 650745 BOLT/CARRIAGE 5/16 X 1-1/4 218 656048 NUT/HEX M8 419 656110 WASHER/LOCK M8 4

AIR CLEANER AND EXHAUST


1929

6

6

6

35

35

5

5

26

25

14

28

35 35

5

5

6

6

6

22

13

3

6

21

18

6

23

11

9

6

10

7

12

16

6

61

3246

86

830

333

37

8

31

6

20

9

NOTE:1) APPLY LOCTITE 242 OR EQUIVALENT

NOTE 1

3638

27

2

2

2

2

34

4

15 32

RADIATOR/COOLER

400685

4640 Models



1 055005 FITTING/90 MJ12-MAORB12 12 061946 CLAMP/HOSE #24 43 062023 CLAMP/HOSE #05 34 070634 NUT/SERRATED LOCK 1/4 25 070856 NUT/LOCK LARGE SERRATED FLANGE 3/8 46 076588 SCREW/CAP LOCKING 3/8 X 3/4 157 095955 CLAMP/HOSE #10 18 128007 CLAMP/HOSE 5/8 X 13/32 HOLE 39 135385 SEAL/SHROUD 210 189286 HOSE/MEDIUM PRESSURE 3/4 X 34 111 189335 ADAPTER/12FQLH-12MB 112 193736 FITTING/90 HB12-MAORB12 113 194574 HOSE/COOLANT DRAIN 114 194584 SEAL/BULB 24-1/4 115 210-19470 NUT/LOCK SERRATED FLANGE 5/16 216 242290 HOSE 3/4 X 22 LOL W/ NYLON SLEEVE 118 245039 COOLER 1

184541 CAP/COOLER 1129346 COCK/DRAIN MP04 1

19 245043 SHROUD 120 245047 COVER/SHROUD 121 245065 SEAL/FOAM 122 245103 HOSE/RAD/LOWER 123 245104 HOSE/RAD/UPPER 124 184941 HOSE /FUEL 5/16 X 42 125 245239 FAN/1Z/6BLADE/25PITCH 126 273038 SPACER/FAN 127 274987 BOTTLE/OVERFLOW 128 275009 BRACKET/LEFT COOLER MOUNT 129 275013 BRACKET/RIGHT COOLER MOUNT 130 275588 BRACKET/OVERFLOW BOTTLE 131 50350012 SEAL/SHROUD 23-1/4 132 650486 SCREW/CAP 5/16 X 3/4 233 650542 SCREW/CAP 1/4 X 1/2 134 650758 BOLT/CARRIAGE 1/4 X 3/4 235 650786 BOLT/CARRIAGE 3/8 X 1-1/4 436 651776 SCREW/CAP SOCKET HEAD M10 X 55 MM 437 654002 WASHER/FLAT 1/4 138 656133 WASHER/FLAT M10 4

RADIATOR/COOLER


10

16

26

32

39

33

11

12

2

23 2

13

3

22

24

2

28

1

21

19

2934

15

36

25

8

3

3

92

9

7

1837

30

5

4

31

6

14

20

5

37

6

6

TO HYDRAULIC OIL FILTER

NOTE 1

NOTE:1. APPLY LOCTITE 242 OR EQUIVALENT

27

LONGER LEG LENGTH

LONGER LEG LENGTH

3538

8

6

MOUNTING PLATEIN REAR DOOR

RADIATOR/COOLER

410594

5240 Models



1 055005 FITTING/90 MJ12-MAORB12 12 061946 CLAMP/HOSE #24 43 062023 CLAMP/HOSE #05 34 070634 NUT/SERRATED LOCK 1/4 25 070856 NUT/LOCK LARGE SERRATED FLANGE 3/8 46 076588 SCREW/CAP FL LOCK 3/8 X 3/4 157 095955 CLAMP/HOSE #10 18 128007 CLAMP/HOSE 5/8 X 13/32 HOLE 39 135385 SEAL/SHROUD 210 189286 HOSE/MEDIUM PRESSURE 3/4 X 34 111 189335 ADAPTER/12FQLH-12MB 112 193736 FITTING/90 HB12-MAORB12 113 194574 HOSE/COOLANT DRAIN 114 194584 SEAL/BULB 24-1/4 115 210-19470 NUT/LOCK SERRATED FLANGE 5/16 216 242290 HOSE 3/4 X 22 LOL W/ NYLON SLEEVE 118 244964 BRACKET/LEFT COOLER MOUNT 119 245039 COOLER 1

129346 COCK/DRAIN MP04 1184541 CAP/COOLER 1

20 245043 SHROUD 121 245047 COVER/SHROUD 122 245065 SEAL/FOAM 123 245103 HOSE/RADIATOR/LOWER 124 245104 HOSE/RADIATOR/UPPER 125 184941 HOSE/FUEL 5/16 X 42 126 245239 FAN/1Z/6BLADE/25PITCH 127 274987 BOTTLE/OVERFLOW 128 275013 BRACKET/RIGHT COOLER MOUNT 129 275588 BRACKET/OVERFLOW BOTTLE 130 400-20715 WASHER 231 50350012 SEAL/SHROUD 23-1/4 132 50350097 SPACER/FAN 133 50657005 SCREW/CAP SOCKET HEAD M10 X 60 MM 434 650486 SCREW/CAP 5/16 X 3/4 235 650542 SCREW/CAP 1/4 X 1/2 136 650758 BOLT/CARRIAGE 1/4 X 3/4 237 650786 BOLT/CARRIAGE 3/8 X 1-1/4 438 654002 WASHER/FLAT 1/4 139 656133 WASHER/FLAT M10 4

RADIATOR/COOLER


12

9

10

46

13

1

19

143

22

4

16

143

42

42

4819

32

31

7

37

4737

34

E

E

F

H

J

J

K

K

H

G

G

APPLY LOCTITE 242TORQUE TO 55 FT-LBS

DRIVE MOTOR PORT REFERENCE

SINGLE SPEED (STANDARD) WITHOUT SHUTTLES

MAIN IN -10 ORB (B,D)

MAIN OUT -10 ORB (A,C)

CASE FLUSH-DRAIN -8 ORB

BRAKE -6 ORB (H,J)

DRAIN -8 ORB (K,L)

DRAIN -8 ORB

23

24

M

N

20

M

5

F

33N

25

4

21

18

15

1

26

17

2

27

28

43

39

O

13

38

38

38

41

29

29

29

29

A

B C

D

D

C

B

A

L

35

11 4

44

45

36

306

6

8

40

48L

O

HYDROSTATIC SYSTEM WITH DRIVE MOTORS

410026

Single-SpeedT-Bar, Hand/Foot, Dual Hand and

T-Bar/Joystick Controls


Ref. Part QuantityNo. No. Description Single-Speed

1 054626 c FITTING/STRAIGHT MJ08-MORB08 2054626 b FITTING/STRAIGHT MJ08-MORB08 4

2 054820 FITTING/TEE MJ06-MAORB06-MJ06 13 068938 FITTING/90 MJ06-MAORB06 24 076879 CAP FJ08 35 076880 FITTING/45 MJ08-MAORB08 16 080556 CAP FJ06 37 087393 FITTING/TEE MJ06-MJ06-MJ06 18 095601 ADAPTER/90 40RM-4JICM 19 114742 FITTING/TEE MJ08-MAORB08-MJ08 110 121684 FITTING/90 MJ12-MAORB16 111 122340 FITTING/TEE MJ08-MJ08-MAORB08 112 122641 TUBE/CHARGE 113 131493 FITTING/STRAIGHT MFS10-MORB12 414 131529 PLUG MORB08 215 131683 HOSE/MEDIUM PRESSURE 3/4 X 68 116 132049 SWITCH/TEMPERATURE 117 134588 NUT/SPIRALOCK 1/4 218 134966 WASHER/FLAT HARDENED 1/2 219 135773 WASHER/FLAT HARDENED 5/8 1220 136104 HOSE/MEDIUM PRESSURE 3/8 X 30 121 139438 SCREW/CAP LOCK FL 3/8 X 5/8 122 183390 HOSE/MEDIUM PRESSURE 1/2 X 26 1

055896 O-RING 123 184102 a VALVE/SOLENOID 124 184378 PLATE/SPACER 125 184946 MANIFOLD/HYDRAULIC RETURN 126 186913 a PUMP/TANDEM 2.48 SERVO 127 186929 TUBE ASSY/BRAKE VALVE 128 187348 HOSE/MEDIUM PRESSURE 1/4 X 17 129 189967 FITTING/STRAIGHT MFS10-MORB10 4

135124 O-RING 016 V90 AR055898 O-RING 910 N90 AR

30 193169 PORT/TEST 9/16 UNF 131 193226 TUBE ASSY/BRAKE RIGHT 132 193227 TUBE ASSY/BRAKE LEFT 133 193627 HOSE/MANIFOLD 134 193715 HOSE/MEDIUM PRESSURE 3/8 X 13-1/2 135 193745 FITTING/45 HB12-MAORB12 136 195032 CLAMP/HOSE 20-32 MM 137 195146 CROSS/TEE 238 195177 HOSE/HIGH PRESSURE 5/8 X 23-/34 339 230-32753 FITTING/TEE MJ04-MJ04-MAORB04 140 240355 HOSE/MEDIUM PRESSURE 1/2 X 26 141 240900 HOSE/HIGH PRESSURE 5/8 X 24-3/4 142 245279 ac MOTOR/SINGLE-SPEED 2

194032 ab MOTOR/SINGLE-SPEED 243 50351134 TUBE/TANDEM PUMP 144 50351392 c TUBE ASSY/MOTOR DRAIN LEFT 1

245284 b TUBE ASSY/MOTOR DRAIN LEFT 145 50351393 c TUBE ASSY/MOTOR DRAIN RIGHT 1

245283 b TUBE ASSY/MOTOR DRAIN RIGHT 146 650453 SCREW/CAP 1/2 X 1-1/2 247 650706 SCREW/CAP 1/4 X 2 248 651620 SCREW/CAP M16 X 30MM 12a) For breakdown see Section B of this manual.b) 4640 Models: SN 313599 and Before (see exemptions in note c). 5240 Models: SN 433437 and Before (see exemptions in note c).c) 4640 Models: SN 313600 and Up, plus 313585-313587 and 313597-313598. 5240 Models: SN 433438 and Up, plus 433414, 433426 and 433436.



1

42

44

13

10

4

16

40

5

11

37

104

39

39

4413

27

26

7

31

4331

F

H

J

J

K

K

H

L

G


DRIVE MOTOR PORT REFERENCESINGLE SPEED (STANDARD) WITHOUT SHUTTLES


MAIN OUT -10 ORB (A,C)

CASE FLUSH-DRAIN -8 ORB

BRAKE -6 ORB (H,J)

DRAIN -8 ORB (K,L)

DRAIN -8 ORB

17

18

M

14

M19

5

15

45

12

2

20

21

21

21

21

D

C

B

A

23

6

8

24

3

22

F

G

36

CD

A

B

38

34 35

3332

E

E

L

25

6

6

38

38

NOTE 1. REMOVE (4) CAPS AND TURN EACH SPEED ADJUSTMENT SCREW CLOCKWISE (APPROXIMATELY 1 FULL TURN)

MAX WHEEL SPEED TO BE 90 RPM 2 MAX DIFFERENCE OF 3 RPM BETWEEN LEFT & RIGHT SIDE

9

9

NOTE 1

NOTE 1

28

29

30

TANK

41


410027

Single-SpeedDual Joystick Controls


Ref. Part QuantityNo. No. Description Single-Speed DJS

1 054626 c FITTING/STRAIGHT MJ08-MORB08 2054626 b FITTING/STRAIGHT MJ08-MORB08 4

2 054820 FITTING/TEE MJ06-MAORB06-MJ06 13 055981 FITTING/TEE MJ06-MJ06-MAORB06 14 068938 FITTING/90 MJ06-MAORB06 25 076879 CAP FJ08 26 080556 CAP FJ06 47 087393 FITTING/TEE MJ06-MJ06-MJ06 18 121773 FITTING/45 MJ12-MAORB16 19 131493 FITTING/STRAIGHT MFS10-MORB12 410 131529 PLUG MORB08 211 132049 SWITCH/TEMPERATURE 112 134588 NUT/SPIRALOCK 1/4 213 135773 WASHER/FLAT HARDENED 5/8 1214 136104 HOSE/MEDIUM PRESSURE 3/8 X 30 115 139438 SCREW/CAP LOCK FL 3/8 X 5/8 116 183390 HOSE/MEDIUM PRESSURE 1/2 X 26 1

055896 O-RING 117 184102 a VALVE/SOLENOID 118 184378 PLATE/SPACER 119 184946 MANIFOLD/HYDRAULIC RETURN 120 186929 TUBE ASSY/BRAKE VALVE 121 189967 FITTING/STRAIGHT MFS10-MORB10 4

135124 O-RING 016 V90 AR055898 O-RING 910 N90 AR

22 190539 TUBE/CHARGE 123 191229 HOSE/MEDIUM PRESSURE 3/8 X 21-1/2 124 191854 HOSE/MEDIUM PRESSURE 3/4 X 63-1/2 125 193169 PORT/TEST 9/16 UNF 126 193226 TUBE ASSY/BRAKE RIGHT 127 193227 TUBE ASSY/BRAKE LEFT 128 193627 HOSE/MANIFOLD 129 193745 FITTING/45 HB12-MAORB12 130 195032 CLAMP/HOSE 20-32 MM 131 195146 CROSS/TEE 232 195458 HOSE/HIGH PRESSURE 5/8 X 27-1/4 133 195459 HOSE/HIGH PRESSURE 5/8 X 22-1/2 134 195460 HOSE/HIGH PRESSURE 5/8 X 27-5/8 135 195461 HOSE/HIGH PRESSURE 5/8 X 21-1/4 136 240591 FITTING/Y MJ08-MJ08-MAORB12 137 241253 HOSE/MEDIUM PRESSURE 1/2 X 17-1/2 1

055896 O-RING 908 N90 138 245149 a PUMP/TANDEM 139 245279 ac MOTOR/SINGLE-SPEED 2

194032 ab MOTOR/SINGLE-SPEED 240 50351392 c TUBE ASSY/MOTOR DRAIN LEFT 1

245284 b TUBE ASSY/MOTOR DRAIN LEFT 141 50351393 c TUBE ASSY/MOTOR DRAIN RIGHT 1

245283 b TUBE ASSY/MOTOR DRAIN RIGHT 142 650453 SCREW/CAP 1/2 X 1-1/2 243 650706 SCREW/CAP 1/4 X 2 244 651620 SCREW/CAP SOCKET HEAD M16 X 30MM 1245 P471548 WASHER/FLAT HARDENED 1/2 2a) For breakdown see Section B of this manual.b) 4640 Models: SN 313599 and Before (see exemptions in note c). 5240 Models: SN 433437 and Before (see exemptions in note c).c) 4640 Models: SN 313600 and Up, plus 313585-313587 and 313597-313598. 5240 Models: SN 433438 and Up, plus 433414, 433426 and 433436.



E

EG

J

HL

M

9

12 14 46

17

13

41

19

47

41

37

36

35

4818

43

45

7

15

4818

13

10

7

43




MAIN OUT -12 ORB (A,C)BRAKE -08 ORB (H,L)

CASE FLUSH-DRAIN -10 ORB (G)

2-SPEED -08 ORB (J,K)

3

21

22

16

H

J

K

L

31

38

N

2

38F

34

N

F

M

24

20

5

4426

8

K

O

O

G

33

32

4

27

125

29

30

13

13

40

AD

D

C

B

A

42B

40

C

115

39

28

6

6


410021

Two-SpeedT-Bar, Hand/Foot, Dual Hand and

T-Bar/Joystick Controls


Ref. Part QuantityNo. No. Description Two-Speed

1 054626 FITTING/STRAIGHT MJ08-MORB08 12 054816 FITTING/90 MJ08-MAORB08 13 054820 FITTING/TEE MJ06-MAORB06-MJ06 24 072806 FITTING/TEE MJ06-FJS06-MJ06 15 076879 CAP FJ08 26 080556 CAP FJ06 37 089099 FITTING/STRAIGHT MJ08-MORB10 28 095601 ADAPTER/90 40RM-4JICM 19 114742 FITTING/TEE MJ08-MAORB08-MJ08 110 121684 FITTING/90 MJ12-MAORB16 111 122340 FITTING/TEE MJ08-MJ08-MAORB08 112 122641 TUBE/CHARGE 113 131493 FITTING/STRAIGHT MFS10-MORB12 814 131683 HOSE/MEDIUM PRESSURE 3/4 X 68 115 132049 SWITCH/TEMPERATURE 116 134588 NUT/SPIRALOCK 1/4 217 134966 WASHER/FLAT HARDENED 1/2 218 135773 WASHER/FLAT HARDENED 5/8 1219 136104 HOSE/MEDIUM PRESSURE 3/8 X 30 120 139438 SCREW/CAP LOCK FL 3/8 X 5/8 121 183978 a MANIFOLD/VALVE 122 184378 PLATE/SPACER 123 184499 HOSE/MEDIUM PRESSURE 1/2 X 22 124 184946 MANIFOLD/HYDRAULIC RETURN 125 186913 a PUMP/TANDEM 2.48 SERVO 126 50351134 TUBE/TANDEM PUMP 127 187348 HOSE/MEDIUM PRESSURE 1/4 X 17 128 193169 PORT/TEST 9/16 UNF 129 193247 TUBE ASSY/TWO-SPEED MOTOR RIGHT 130 193248 TUBE ASSY/MOTOR BRAKE RIGHT 131 193249 TUBE ASSY/TWO-SPEED MOTOR LEFT 132 193270 TUBE ASSY/MOTOR BRAKE LEFT 133 193563 TUBE/DRAIN 134 193627 HOSE/MANIFOLD 135 193672 a MOTOR/TWO-SPEED RIGHT 136 193673 a MOTOR/TWO-SPEED LEFT 137 193715 HOSE/MEDIUM PRESSURE 3/8 X 13-1/2 138 193745 FITTING/45 HB12-MAORB12 139 195032 CLAMP/HOSE 20-32 MM 140 195118 HOSE/HIGH PRESSURE 5/8 X 21-7/8 341 195146 CROSS/TEE 242 195457 HOSE/HIGH PRESSURE 5/8 X 21-7/8 143 230-24749 FITTING/STRAIGHT MJ06-MORB08 444 230-32753 FITTING/TEE MJ04-MJ04-MAORB04 145 240107 TUBE ASSY/MOTOR DRAIN RIGHT 146 650453 SCREW/CAP 1/2 X 1-1/2 247 650706 SCREW/CAP 1/4 X 2 248 651620 SCREW/CAP M16 X 30MM 12a) For breakdown see Section B of this manual.



G

J

H

L

M

46

37

14

4437

31

30

4513

38

39

7

11

4513

738

APPLY LOCTITE 242 &TORQUE TO 55 FT-LBSBOTH 650453 BOLTS


MAIN OUT -12 ORB (A,C)BRAKE -08 ORB (H,L)

CASE FLUSH-DRAIN -10 ORB (G)

2-SPEED -08 ORB (J,K)

2

16

17

12

H

J

K

L

26

F

M

19

15

5

K

G

28

27

4 25

24

10

10D

C

B

A

21

36

9

F

E

E

A

B

CD

1

20

8

22 3

42

10

4135

34

18

6

43

6

6

23

41

10

38

NOTE 1. REMOVE (4) CAPS AND TURN EACH SPEED ADJUSTMENT SCREW CLOCKWISE (APPROXIMATELY 1 FULL TURN) MAX WHEEL SPEED TO BE 90 RPM 2 MAX DIFFERENCE OF 3 RPM BETWEEN LEFT & RIGHT SIDE

40

NOTE 1

NOTE 1

29

33

32

TANK



410028

Two-SpeedDual Joystick Controls


Ref. Part QuantityNo. No. Description Two-Speed DJS

1 054626 FITTING/STRAIGHT MJ08-MORB08 22 054820 FITTING/TEE MJ06-MAORB06-MJ06 23 055981 FITTING/TEE MJ06-MJ06-MAORB06 14 072806 FITTING/TEE MJ06-FJS06-MJ06 15 076879 CAP FJ08 16 080556 CAP FJ06 47 089099 FITTING/STRAIGHT MJ08-MORB10 28 121773 FITTING/45 MJ12-MAORB16 19 121775 FITTING/90 MJ08-MAORB12 110 131493 FITTING/STRAIGHT MFS10-MORB12 611 132049 SWITCH/TEMPERATURE 112 134588 NUT/SPIRALOCK 1/4 213 135773 WASHER/FLAT HARDENED 5/8 1214 136104 HOSE/MEDIUM PRESSURE 3/8 X 30 115 139438 SCREW/CAP LOCK FL 3/8 X 5/8 116 183978 a MANIFOLD/VALVE 117 184378 PLATE/SPACER 118 184499 HOSE/MEDIUM PRESSURE 1/2 X 22 119 184946 MANIFOLD/HYDRAULIC RETURN 120 190539 TUBE/CHARGE 121 191229 HOSE/MEDIUM PRESSURE 3/8 X 21-1/2 122 191854 HOSE/MEDIUM PRESSURE 3/4 X 63-1/2 123 193169 PORT/TEST 9/16 UNF 124 193247 TUBE ASSY/TWO-SPEED MOTOR RIGHT 125 193248 TUBE ASSY/MOTOR BRAKE RIGHT 126 193249 TUBE ASSY/TWO-SPEED MOTOR LEFT 127 193270 TUBE ASSY/MOTOR BRAKE LEFT 128 193563 TUBE/DRAIN 129 193627 HOSE/MANIFOLD 130 193672 a MOTOR/TWO-SPEED RIGHT 131 193673 a MOTOR/TWO-SPEED LEFT 132 193745 FITTING/45 HB12-MAORB12 133 195032 CLAMP/HOSE 20-32 MM 134 195120 HOSE/HIGH PRESSURE 5/8 X 21 135 195121 HOSE/HIGH PRESSURE 5/8 X 23-7/8 136 195122 HOSE/HIGH PRESSURE 5/8 X 21-3/4 137 195146 CROSS/TEE 238 230-24749 FITTING/STRAIGHT MJ06-MORB08 439 240107 TUBE ASSY/MOTOR DRAIN RIGHT 140 241505 HOSE/HIGH PRESSURE 5/8 X 21-5/8 141 241526 FITTING/90 MFS10-MAORB12 242 245149 a PUMP/TANDEM 143 650453 SCREW/CAP 1/2 X 1-1/2 244 650706 SCREW/CAP 1/4 X 2 245 651620 SCREW/CAP M16 X 30MM 1246 P471548 WASHER/FLAT HARDENED 1/2 2a) For breakdown see Section B of this manual.



15

14

6

16

12

5

TO LEFT DRIVE MOTOR BRAKE FITTING

TO RIGHT DRIVE MOTOR BRAKE FITTING

NOTES:1. 272760 TO BE LOCATED NEAR 2731552. 055981 TO BE INSTALLED INTO LEFT PORT OF MANIFOLD VALVE.3. DECAL 184215 TO BE LOCATED ON RH INNER FILLER PANEL.

18

1719

4

23

3

2028

9

1

23

25

7

11

13

24

10

8

21

22

NOTE 2

2627

NOTE 3


50440025_400745

Brake Release AssemblyTwo-Speed Models

12

10

TO LEFT DRIVE MOTOR BRAKE FITTING

TO RIGHT DRIVE MOTOR BRAKE FITTING

NOTES:

1. 272760 TO BE LOCATED NEAR 2731552. 055981 TO BE INSTALLED INTO 1841023. 184215 DECAL TO BE LOCATED ON RH INNER FILLER PANEL

13

15

4

6

5

14

9

18

8

20

11

173

16

724

3

2

21

19

1

NOTE 2

22

23

NOTE 3

Brake Release AssemblySingle-Speed Models


Ref. Part QuantityNo. No. Description Single-Speed

1 055981 FITTING/TEE MJ06-MJ06-MAORB06 12 064260 NUT/HEX WHIZLOCK 5/16 23 068938 FITTING/90 MJ06-MAORB06 24 071722 RIVET/BLIND 25 137959 BOLT/CARRIAGE 1/4 X 1-1/2 26 184215 DECAL/JACK 17 191330 SPACER 0.5 X 0.334 X 1.0 28 194271 STRIP/FOAM0.25 X 1.5 X 15.8 19 194309 CLAMP/TUBE TWIN 3/8 210 195147 ACOUSTIC PAD/FRONT LEFT SEAT 111 210-32184 NUT/CENTERLOCK FLANGE 1/4 212 242775 COVER/UNDER SEAT LEFT 113 272730 TUBE/HANDLE 114 272760 DECAL/PARK BRAKE RELEASE 115 273076 HANDLE HOLDER CLIP 216 273155 a PUMP/PARK BRAKE 117 50300144 TUBE/HYDRAULIC BRAKE RELEASE IN 118 50300145 TUBE/HYDRAULIC BRAKE RELEASE OUT 119 50300146 HOSE/MEDIUM PRESSURE 3/8 X 18-1/2 120 50300159 COVER/LEFT FRONT W/ BRAKE RELEASE 121 50300236 HOSE/MEDIUM PRESSURE 3/8 X 26 122 50350823 FILLER/ROPS RIGHT 123 50350824 FILLER/ROPS LEFT 124 650741 SCREW/CAP 5/16 X 3-1/4 2a) For breakdown see Section B of this manual.

Ref. Part QuantityNo. No. Description Two-Speed

1 055981 FITTING/TEE MJ06-MJ06-MAORB06 12 064260 NUT/HEX WHIZLOCK 5/16 23 068938 FITTING/90 MJ06-MAORB06 24 071722 RIVET/BLIND 25 080556 CAP FJ06 16 087393 FITTING/TEE MJ06-MJ06-MJ06 17 137959 BOLT/CARRIAGE 1/4 X 1-1/2 28 184215 DECAL/JACK 19 191330 SPACER 0.5 X 0.334 X 1.0 210 194271 STRIP/FOAM0.25 X 1.5 X 15.8 111 194309 CLAMP/TUBE TWIN 3/8 212 195147 ACOUSTIC PAD/FRONT LEFT SEAT 113 210-32184 NUT/CENTERLOCK FLANGE 1/4 214 242165 TUBE/BRAKE LEFT MOTOR 115 242391 TUBE/BRAKE RIGHT MOTOR 116 242775 COVER/UNDER SEAT LEFT 117 272730 TUBE/HANDLE 118 272760 DECAL/PARK BRAKE RELEASE 119 273076 HANDLE HOLDER CLIP 220 273155 a PUMP/PARK BRAKE 121 50300144 TUBE/HYDRAULIC BRAKE RELEASE IN 122 50300145 TUBE/HYDRAULIC BRAKE RELEASE OUT 123 50300146 HOSE/MEDIUM PRESSURE 3/8 X 18-1/2 124 50300159 COVER/LEFT FRONT W/ BRAKE RELEASE 125 50300236 HOSE/MEDIUM PRESSURE 3/8 X 26 126 50350823 FILLER/ROPS RIGHT 127 50350824 FILLER/ROPS LEFT 128 650741 SCREW/CAP 5/16 X 3-1/4 2a) For breakdown see Section B of this manual.



12

13

23

18

15

12

46

14

13

39

42

22

29

3826

25

30

33

34

27

36

36

35

10

12

12

12

12

21

19

30

21

LIFT-LOCK SOLENOIDTILT-LOCK SOLENOID

31

48

SELF-LEVELING VALVE DETAIL

MAIN CONTROL VALVE

14

REFERENCE TUBE ASSEMBLY SEQUENCE

1. 194503 5. 1945302. 194506 6. 1945313. 194529 7. 2421734. 194504 8. 272799

13

37

16

38

52

52

INSERT FITTING INTOMAIN CONTROL VALVEON UPPER R.H. SIDE

5

7

24

7

44

5

9

24

20

46

5

17

3

4745

50

11

1

19

44

3

492

51

32

7

28

40

4135

40

4

8

10

10

6

43

HYDRAULICS - CHASSIS

400691

4640 Models



1 055005 FITTING/90 MJ12-MAORB12 12 057557 WASHER/FLAT 17/32 13 064260 NUT/HEX WHIZLOCK 5/16 34 067460 FITTING/TEE MJ10-MJ10-FJS10 15 067761 FITTING/90 MJ10-MAORB10 36 071401 NUT/HEX LOCK 1/4 27 072580 FITTING/STRAIGHT MJ10-MORB10 88 072587 FITTING/STRAIGHT MJ12-MORB12 19 072807 FITTING/TEE MJ10-MAORB10-MJ10 110 076879 CAP FJ08 411 079092 FITTING/TEE MJ12-MAORB12-MJ12 112 079098 PLATE/TWIN COVER 613 079126 CLAMP/TUBE 5/8 314 088904 CLAMP/TUBE 1/2 215 095619 CLAMP/HOSE 1-1/4 X 13/32 HOLE 116 131838 ASSY/FILTER 1

240336 ASSY/FILTER INDICATOR 1074830 FILTER/OIL 1

17 131842 NUT/SPIRALOCK 5/16 218 134852 NUT/SPIRALOCK 3/8 119 135331 STRAP 120 135367 a VALVE/SELF LEVEL 121 184101 a VALVE/SOLENOID 222 186207 CLAMP/TUBE 1-1/4 123 186254 PLATE/TUBE CLAMP 124 191249 FITTING/TEE MJ08-MJ08-MAORB10 225 193212 TUBE 3/4 OD X 13/32 ID 226 193518 HOSE/SUCTION JOINT 127 194503 TUBE/LIFT 128 194504 TUBE/TILT 129 194506 TUBE/LIFT 130 194513 SPACER/SOLENOID LIFT 131 194528 BRACKET/HARNESS 132 194529 TUBE/TILT SOLENOID 133 194530 TUBE/TILT 134 194531 TUBE/TILT 135 194648 TUBE/LIFT CROSSOVER 136 195112 CLAMP/T-BOLT 1-5/8 237 242173 TUBE/HYDRAULIC FILTER 138 272799 TUBE/TILT 139 274958 TUBE/AUXILIARY 140 274977 TUBE/AUXILIARY 141 274979 TUBE/LIFT CROSSOVER 142 275021 TUBE/SUCTION 143 50350205 BRACKET/FILTER 144 50657028 SCREW/CAP 1/4 X 4-1/4 245 650490 SCREW/CAP 3/8 X 1 246 650547 SCREW/CAP 5/16 X 3-1/2 347 650733 SCREW/CAP 5/16 X 2-1/2 148 650741 SCREW/CAP 5/16 X 3-1/4 149 650773 BOLT/CARRIAGE 3/8 X 1-1/2 150 651041 SCREW/MACHINE HEX WASHER HEAD 3/8 X 3/4 451 651089 SCREW/CAP 1/4 X 3 252 654004 WASHER/FLAT 5/16 2a) For breakdown see Section B of this manual.

HYDRAULICS - CHASSIS


11

12

51

22

2

49

17

14

11

47

48

43

18

20

13

12

21

28

40

5

23

8

25

24

16

3

29

45

32

33

26 27

34

34

5

31

45

9

11

11

11

6

6

SELF-LEVELING VALVE DETAIL

23

19

45

5

8

5

TILT-LOCK SOLENOID

3

5

1843

6

2020

29

6

23

LIFT-LOCK SOLENOID

REFERENCE TUBE ASSEMBLY SEQUENCE

1. 194503 5. 1945302. 194506 6. 1945313. 194529 7. 2725954. 194504

gehl 4640e power2 parts manual

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