Property of American Airlines Illustrated Parts · Section 1 GT-35 Tow T ractor (Deutz Tier 4i) B....

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Chapter 4GT-35 Tow Tractor (Deutz Tier 4i) Table of Contents

TABLE OF CONTENTS

SECTION 1: DESCRIPTION ...................................................................................................... 4-1-1A. Introduction ........................................................................................................... 4-1-1B. Using the Illustrated Parts List .............................................................................. 4-1-2

1. Figure and Index Number ......................................................................... 4-1-22. Part Number ............................................................................................. 4-1-33. Description and Quantity .......................................................................... 4-1-34. Effectivity .................................................................................................. 4-1-4

C. Ordering Spare Parts ............................................................................................ 4-1-4

SECTION 2: ILLUSTRATED PARTS LIST ................................................................................ 4-2-1Figure 2-1. Frame Assembly, Front View............................................................. 4-2-2Figure 2-2. Frame Assembly, Rear View ............................................................. 4-2-4Figure 2-3. Panels and Ballast Installation .......................................................... 4-2-6Figure 2-4. Decals Locations ................................................................................ 4-2-8Figure 2-5. Panels' Decals ................................................................................ 4-2-10Figure 2-6. Front Bumper Assembly .................................................................. 4-2-12Figure 2-7. Front Bumper Assembly (With Clearence Lights) ........................... 4-2-14Figure 2-8. Rear Bumper Assembly .................................................................. 4-2-16Figure 2-9. Traction Kit (Without Cab) ............................................................... 4-2-18Figure 2-10. Traction Kit (With Cab) ................................................................... 4-2-20Figure 2-11. Cab Installation .............................................................................. 4-2-22Figure 2-12. Cab With AC Installation ............................................................... 4-2-24Figure 2-13. AC Hoses Installation .................................................................... 4-2-26Figure 2-14. Cab Assembly ................................................................................ 4-2-28Figure 2-15. Cab Interior ................................................................................... 4-2-30Figure 2-16. Dome Light Installation (Cab With AC) ......................................... 4-2-32Figure 2-17. Wipers Assembly........................................................................... 4-2-34Figure 2-18. Passenger Door Assembly ............................................................ 4-2-36Figure 2-19. Driver Door Assembly ................................................................... 4-2-38Figure 2-20. Seats Installation ............................................................................ 4-2-40Figure 2-21. Instrument Panel Assembly ........................................................... 4-2-42Figure 2-22. Upper Instrument Panel Assembly ................................................ 4-2-46Figure 2-23. Accelerator Pedal Installation ........................................................ 4-2-48

CHAPTER 4. PARTS LIST

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Chapter 4Table of Contents GT-35 Tow Tractor (Deutz Tier 4i)

Figure 2-24. Brake Assembly ............................................................................ 4-2-49Figure 2-25. Steering Column Assembly ........................................................... 4-2-50Figure 2-26. Engine Installation ......................................................................... 4-2-52Figure 2-27. Engine Assembly ........................................................................... 4-2-54Figure 2-28. AC Compressor Installation ............................................................ 4-2-58Figure 2-29. Heater Assembly ............................................................................ 4-2-59Figure 2-30. Block Heater and Heater Assembly ............................................... 4-2-60Figure 2-31. AirIntake Assembly ......................................................................... 4-2-61Figure 2-32. Exhaust Assembly ......................................................................... 4-2-62Figure 2-32a. Exhaust Assembly, Tier 3 ............................................................ 4-2-63Figure 2-33. Exhaust (Rear Option) Assembly ................................................... 4-2-64Figure 2-34. Cooling System .............................................................................. 4-2-65Figure 2-35. Fuel System ................................................................................... 4-2-66Figure 2-36. Fuel Assembly (With Heater Option) .............................................. 4-2-68Figure 2-37. Heater Box Assembly ..................................................................... 4-2-70Figure 2-38. Transmission Installation ................................................................ 4-2-72Figure 2-39. Drive Shaft Installation ................................................................... 4-2-74Figure 2-40. Front Axle Assembly ...................................................................... 4-2-76Figure 2-41 Rear Axle Assembly ....................................................................... 4-2-78Figure 2-42. Hydraulic Assembly ....................................................................... 4-2-80Figure 2-42. Hydraulic Assembly (Cont'd) ......................................................... 4-2-82Figure 2-43. Hydraulic Assembly With Emergency Pump Option ..................... 4-2-84Figure 2-43. Hydraulic Assembly With Emergency Pump Option (Cont'd) ........ 4-2-86Figure 2-44. Hydraulic Manifold Assembly ........................................................ 4-2-88Figure 2-45. Emergency Steering Pump Assembly (Optional) ........................... 4-2-90Figure 2-46.Control Box Assembly ..................................................................... 4-2-92Figure 2-46.Control Box Assembly (Cont'd) ....................................................... 4-2-94Figure 2-47.Batteries Installation ........................................................................ 4-2-96Figure 2-48.Circuit Breakers Installation ............................................................ 4-2-98Figure 2-49.Horn Installation ............................................................................ 4-2-100

SECTION 3: NUMERICAL INDEX............................................................................................... 4-3-1

SECTION 4: ALPHABETICAL INDEX ........................................................................................ 4-4-1Pr

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Chapter 4GT-35 Tow Tractor (Deutz Tier 4i) Section 1

SECTION 1: DESCRIPTION

A. INTRODUCTION

The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement partsinformation as well as general part and assembly information necessary for maintenance of the TUGModel GT-35 Tow Tractor.

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Chapter 4Section 1 GT-35 Tow Tractor (Deutz Tier 4i)

B. USING THE ILLUSTRATED PARTS LIST

The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems whichcomprise the GT-35 Tow Tractor. Each IPL consists of a figure illustrating a group of related partsand a corresponding list identifying the parts by part number(s) and description. The quantity given inthe list is for the particular assembly shown in the illustration and is not necessarily the quantity for theentire unit.

1. Figure and Index NumberThe figure and index number refers to the figure on which the part is depicted. The indexnumber refers to the individual part shown on the illustration. See the following example forfurther explanation of the Figure and Index Number.

NOTE: Sample tables in this section are intended to illustrate tablestructure and format, and should not be used for reference of actual data.Refer to applicable figure for specific required part information.

Note

Fig &Ind

Tug PartNumber Description

51-1 12950649 Battery Rack51-2 T6-9011-235 Battery Group 31 C with Studs

51-3 G1-30284 Cable, Battery (+) to Battery Discon. Switch51-4 2MJ7 Cable, Jumper, 7", 2/0 Sealed51-5 12950655 Cover, Battery Rack51-6 7802 Double Type "U" BOP51-7 G1-30140-8 Cable, Battery, Ground51-8 284-4001 Heater, Blanket, 120V, 80W, 36'51-9 70018 Bolt, Battery Hold, J, Ø5/16-18NC x 8" Long51-10 G1-30285 Cable, Battery Disconnect Switch to Stud 151-11 728154C1 Switch, Battery Disconnect51-12 G1-30272 Bracket, Battery Disconnect Switch

51-13TA-50

12902827Decal, OFF/ONWasher, Flat, SAE THRU-Hard, 1" YZNut, Lock, Bolt Battery Hold51-14

Refers to the figure number, and theitem's number on that figure.

Figure and index number blank:This item is one of possibly many itemsdesignated by a single Figure and IndexNumber. The first item in such a group isassigned a number; the rest of theseitems are listed directly below.These items are generally similar infunction, but have different applicabilitiesor effectivities.

Battery Group 27 C with StudsT6-7001-205

51-

No index number: This item is related tothe components or system in theillustration, but is not actually shown. Incertain cases, such items are shown inother figures in section 4-2.

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2. Part NumberParts are identified by part numbers assigned by TUG or, in the case of fasteners and relatedmaterials, by industry standard specification. In a few instances, TUG part numbers are notavailable. See the following illustration for further explanation of Part Numbers.

3. Description and QuantityA description and quantity is provided for each part listed in the IPL. The quantity given forsubassemblies and subparts is the number of subassemblies/parts contained in the componentor system depicted by the associated illustration, not necessarily the entire vehicle.

Part number assigned by TUG

No TUG part number indicates that TUG has not assigneda part number to the part. It may also indicate that the partis not supplied separately from another part to which it isrelated.

Fig &Ind

Tug PartNumber Description

51-1 12950649 Battery Rack51-2 T6-9011-235 Battery Group 31 C with Studs

51-3 G1-30284 Cable, Battery (+) to Battery Discon. Switch51-4 2MJ7 Cable, Jumper, 7", 2/0 Sealed51-5 12950655 Cover, Battery Rack51-6 7802 Double Type "U" BOP51-7 G1-30140-8 Cable, Battery, Ground51-8 284-4001 Heater, Blanket, 120V, 80W, 36'51-9 70018 Bolt, Battery Hold, J, Ø5/16-18NC x 8" Long

51-10 G1-30285 Cable, Battery Disconnect Switch to Stud 151-11 728154C1 Switch, Battery Disconnect51-12 G1-30272 Bracket, Battery Disconnect Switch

51-13TA-50

12902827Decal, OFF/ONWasher, Flat, SAE THRU-Hard, 1" YZNut, Lock, Bolt Battery Hold51-14

Battery Group 27 C with StudsT6-7001-205

51-

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4. EffectivityThe effectivity of each item in the parts list is given in part or in whole in the “Effective”column of the IPL. Information concerning the effectivity of a particular part may also befound in the description column, the figure title or in notes located at the bottom of the IPLpage. Effectivity is usually (but not always) associated with the serial number.

C. ORDERING SPARE PARTS

To ensure that proper spares and replacement parts are obtained, it is recommended that all majorcomponents be procured directly from TUG. Use of parts not manufactured or supplied by TUG mayvoid the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.

Spare parts can be ordered directly from TUG by telephoning TUG SHOP at1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask forTUG SHOP when calling. FAX messages can be sent to 770-422-8730 (U.S.).

When ordering parts, please be prepared with TUG part numbers, part description, figure and indexnumber and the revision of the IPL page (located in the footer of each page, directly under each pagenumber).

TUG SHOP business hours are from 8:00 a.m. until 5:00 p.m. Eastern time, Monday through Friday.Answering machines are ready to receive calls after regular business hours. All calls received afterhours will be returned during the next regular business day.

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SECTION 2: ILLUSTRATED PARTS LIST

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Figure 2-1. Frame Assembly, Front View

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10 1112

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1718

19

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2627

2829

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Table 2-1. Frame Assembly, Front View

Fig & Ind

Tug Part Number Description Qty Effective

1- G35-30093 Frame Weldment, Tier 4I, GT35 1 1115 & Up1-1 G35-30093-7 Plate, Front Deck 2 "1-2 G35-30093-8 Bracket, Deck Plate Mounting 4 "1-3 G35-30093-3 Rail, Frame, RH Outer 1 "1-4 G35-30093-10 Plate, Ballast Compartment, Side 3 "1-5 12951122 Angle, Back Plate Support 4 "1-6 12970431-42 Bushing 4 "1-7 G35-30093-6 Plate, Rear Deck 2 "1-8 80729 Stud, Welded, 5/16 x 3/4 CFL 5 "1-9 12970431-55 Angle 2 "1-10 G35-30093-16 Plate, Fuel Tank 1 "1-11 12951370 Bar, Back Plate Mounting 1 "1-12 12970431-50 Bracket 1 "1-13 G35-30093-1 Bumper, Rear 1 "1-14 G35-30002-12 Ballast, Rear Bumper 2 "1-15 G35-30093-4 Rail, Frame, LH Outer 1 "1-16 G35-30093-32 Plate, Ballast Compartment, Side, LH 1 "1-17 12970431-44 Angle, Support 1 "1-18 G35-30002-3 Pad, Axle 2 "1-19 12970431-31 Gusset, Axle Mount 4 "1-20 G35-30093-31 Bracket, Battery Support 1 "1-21 G35-30093-9 Mount, Transmission, Frame - ZF 2 "1-22 G35-30093-22 Mount, Motor, Front 2 "1-23 G35-30093-2 Rail, Frame, LH Outer 1 "1-24 G35-30093-19 Plate, Seat 1 "1-25 G35-30093-25 Box, Heater, Center 1 "1-26 G35-30093-20 Plate, Floor 1 "1-27 G35-30093-23 Plate, Lower Front Bumper 1 "1-28 G35-30002-20 Box, Headlight 2 "1-29 G35-30093-30 Plate, Front Bumper 1 "1-30 G35-30002-22 Bracket, E-Stop 1 "1-31 G35-30093-24 Panel, Instrument Weldment 1 "1-32 G35-30093-18 Plate, Rear Seat 1 "1-33 G35-30093-17 Plate, Seat Back 1 "1-34 G35-10038-51 Gusset, Seat Plate 2 "1-35 G35-30093-27 Plate, Front Deck Lip 1 "

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Figure 2-2. Frame Assembly, Rear View

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Table 2-2. Frame Assembly, Rear View

Fig & Ind


2-1 G35-30093-1 Bumper, Rear 1 1115 & Up2-2 G35-30002-13 Plate, Tail Light 2 "2-3 G35-30093-16 Plate, Fuel Tank 1 "2-4 G35-30093-26 Gusset, Rear Axle, Outer 4 "2-5 12970431-48 Angle, Support 1 "2-6 12970431-36 Bracket, Tie-Down 4 "2-7 G35-30002-3 Pad, Axle 2 "2-8 G35-30002-11 Ballast, Rear Deck 2 "2-9 G35-30002-15 Angle, Ballast Support 8 "2-10 G35-30093-10 Plate, Ballast Compartment, Side 3 "2-11 G35-30093-11 Plate, Ballast Compartment, Floor 2 "2-12 G35-30093-22 Mount, Motor, Front, Weldment 2 "2-13 G35-30093-12 Crossmember, Midle 1 "2-14 G35-30093-15 Plate, Rear Crossmember 1 "2-15 G35-30093-13 Crossmember, Front Axle 2 "2-16 G35-30093-29 Support, Upper Front Ballast 2 "2-17 G35-10038-51 Gusset, Seat Plate 2 "2-18 G35-30093-25 Box, Heater, Center 1 "2-19 G35-30093-20 Plate, Floor 1 "2-20 G35-30093-21 Plate, Cab Bottom 1 "2-21 12970431-59 Gusset, Front Underside 2 "2-22 G35-30093-14 Plate, Front Crossmember 1 "2-23 G35-30093-9 Mount, Transmission, Frame - ZF 2 "2-24 G35-30093-4 Rail, Frame, LH Inner 1 "2-25 G35-30093-31 Bracket, Battery Support 1 "

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Figure 2-3. Panels and Ballast Installation

6

1

4

2

3

5

7

8910

13

14

16

15

17

18

12

19

21

22

12

18

27

24

25

11

20

23

26

2830

13

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35

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Chapter 4GT-35 Tow Tractor (Deutz Tier 4i ) Section 2

Table 2-3. Panels and Ballast Installation

Fig & Ind


3-1 12930793 Hitch, Assembly, W/Pin Holder 2 1115 & Up3-2 MR-1155-1 E-Stop Assembly 1 "3-3 G35-30040 Guard, Headlight-Opt 2 As Req'd3-4 G35-30059 Handle, E-Stop Guard- Opt 1 "3-5 C35-3025 Eheater, High Output (Cab)-Opt 1 "3-6 GH180C Handle, Chrome 2 1115 & Up3-7 G35-30103 Cover, Mount, Engine 1 "3-8 5867 Hinge, 5" Stamped Steel 4 "3-9 78383 Cylinder, Gas Assist 4 "3-10 A9008 Stud, For 78383, MFGR Gas 8 "3-11 A9002 Clip, For 78383, MFGR Gas 8 "3-12 12951386 Ballast, Small, Center Pockets-Opt (22,000) 2 As Req'd

G35-10046 Ballast, Central, Pockets - Opt (30,000) 2 "3-12 G35-30130 Ballast 35,000 - Opt 2 "3-13 G35-10047 Retainer, Ballast - Opt 6 "3-14 G35-30101 Plate, Ballast Cover 1 1115 & Up3-15 G35-30104 Mount, Rear Cover 1 "3-16 G35-30129 Cover, Ballast, W/Air Cleaner 1 "3-17 G35-30102 Cover, Engine 4I 1 "3-18 68-80-302-10 Bail Handle Latch, Series 80 2 "3-19 G35-30106 Door, Rear Access 1 "3-20 G35-30105 Cover, Fuel Tank 1 "3-21 G35-30111 Pipe, Exhaust, Doc Outlet 1 "

Fig & Ind


3-22 12980078 Tire & Wheel Assy, GT35A 4 1115 & Up2920199 Wheel, GT35 4 "12951858 Tire, Tubeless, 315/80R22.5 Load Range "J" 4 "G35-10081 Tire & Wheel Assy, Solid (Trelleborg)-Opt 4 As Req'd

3-23 M22 x 1.5 Nut, Lug, 22mm x 1.5 20 1115 & Up3-24 1-585809 Step, Folding, Malleable Iron 1 "3-25 8423 Cable, 3 Cond. 20 AWG, Shielded, 50' - Opt 1 As Req'd3-26 12941692 Mount, Phone Jack - Opt 1 "3-27 A14664 Phone, Jack - Opt 1 "3-28 A14663 Cover, Phone Jack, Spring -Opt 1 "3-29 G35-30090 Manifold, Hydraulic 1 1115 & Up3-30 G35-30093 Frame, Weldment, Tier 4I, GT35 1 "

G35-30139* Frame, Weldment 40# G35-4I -Opt 1 As Req'd3-31 5/16-18 x 3/4 Bolt, Flange Head Ø5/16-18x¾" Long - Opt 8 "3-32 14091 Bracket Fire Extinguisher-Opt 2 "3-33 IK2-E Fire Extinguisher - Doodley Tackaberry - Opt 2 "3-34 73040 Alarm, Back-Up - Opt 1 "3-35 12990669 Plate, Access, Brake Pedal 1 1115 & Up3-36 G1-30319 Cover, Fuel Cap Weldment - Opt 1 As Req'd3-37 G35-30127 Bracket, Air Filter, Deutz 3.6 1 1115 & Up3-38 G35-30125 Bracket, Air Deflector 2 "

*Opt. 40,000 # Ballast includes Frame (G35-30139) and 2 Ballasts 35,000 (G35-30130)

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Chapter 4Section 2 GT-35 Tow Tractor (Deutz Tier 4i )

Figure 2-4. Decals Locations

WELDING PROCEDURES TO PROTECT

TRANSMISSION AND ENGINE

ELECTRONIC CONTROLS.

WHEN W

ELDING IS REQUIRED ON TRACTOR, THE

FOLLOWING PROCEDURES ARE TO BE TAKEN TO

PROTECT THE ELECTRONIC CONTROL COMPONENTS:

1 . DISCONNECT THE WIRING HARNESS CONNECTORS

AT THE TRANSMISSION ELECTRONIC CONTROL UNIT.

2 . DISCONNECT ALL ENGINE ECM CONNECTORS.

3 . DISCONNECT THE POSITIVE AND NEGATIVE BATTERY

CONN ECTIO NS, AND ANY ELECTRONIC CONTROL

GROUND WIRES CON NECTED TO THE FRAME OR

CHASSIS.4 . COVER ELECTRONIC CONTROL COMPONENTS AND

WIRING TO PROTECT FROM HOT SPARKS, ETC..

5 . DO NOT CONNECT WELDING CABLES TO ELECTRONIC

CONTROL COMPONENTS.

IMPORTANT

P/N 12970494

WELDING CAUTION

T-W4

MANUAL RELEASE OF PARK BRAKE:

1. USE WHEEL CHOCKS TO PREVENT

UNWANTED MOVEMENT OF THE TRACTOR.

2. PUSH IN AND ROTATE KNOB ON HYDRAULIC

MANIFOLD CLOCKWISE

3. REMOVE HANDLE FROM HOLSTER AND

INSERT INTO HAND PUMP ON MANIFOLD

4. CYCLE PUMP WITH HANDLE UNTIL PARK

BRAKE RELEASES (USUALLY 2-4 PUMPS)

5. TO RETURN PARK BRAKE TO NORMAL

OPERATI ON, PUSH IN ON THE KNOB AND

ROTATE COUNTER-CLOCKWISE

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Table 2-4. Decals Locations

Fig & Ind


4-1 T-Y2 Decal, Emergency Stop 1 1115 & Up4-2 12970860 Decal, Phone Jack - Opt. 2 As Req-ed4-3 T-W4 Decal, Emergency Park Brake Release 1 1115 & Up4-4 AS-10172 Reflector, Stick-On, Amber 4 "4-5 T6-200-106 Safety Walk, 22" Wide, 10' Long 1 "4-6 12930133 Nameplate, Identification 1 "4-7 12970494 Decal, Welding Caution 1 "4-8 12990777 Decal, Explosion Hazard 1 "4-9 12970508 Decal, Trained Personnal Only 1 "4-10 12970518 Decal, Warning, Read Oper. Manual 1 "4-11 SW600 Decal, Warning, Pressurized 1 "4-12 12970420 Decal, Tire Pressure, 125 PSI 4 "4-13 660-ND-2283 Paper, Grit 70, 4" x 60' 1 "4-14 AS-10171 Reflector, Stick-On, Red 4 "4-15 T-A56 Decal, Ultra Low Sulfur Diesel 1 "4-16 12970423 Decal, Diesel, Fuel 1 "4-17 T-B5 Decal, 24V System 1 "4-18 SW7 Decal, Danger - Hot Exhaust 1 "

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Figure 2-5. Panels' Decals

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Table 2-5. Panels' Decals

Fig & Ind


5-1 G35-30102 Cover, Engine 4I 1 1115 & Up5-2 SW700 Decal, Warning, High Pressure 1 "5-3 12990777 Decal, Explosion Hazard 1 "5-4 TA-70 Decal, Service Information, Tier 4I 1 "5-5 12990611 Decal, Moving Part, Hazard 1 "5-6 SW2 Decal, Caution-Use Proper Tool 1 "5-7 G35-30106 Door, Rear Access 1 "5-8 12990610 Decal, Rotation, Drive Line 1 "5-9 SW500 Decal, Warning, Battery Hazard 1 "

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Figure 2-6. Front Bumper Assembly

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10 12

14 15

13




WHEN WELDING I S REQUIRED ON TRACTOR, THE

FOLLOWI NG PROCEDUR ES ARE TO BE TAKEN TO

PRO TECT TH E ELECTRONI C CONTROL COMPONENTS:

1. DI SC ONNECT THE WIR ING HARNESS CONNECTORS

AT THE TRANSMISSION ELECTRONIC CONTROL UNIT.

2. D ISCONNECT ALL ENGINE ECM CONNECTORS.

3. DISCO NNECT THE POSITIVE AND NEGATIVE BATTERY

CONNECTIO NS, AND AN Y ELECTRONIC CONTROL

G ROUND WI RES CONNECTED TO THE FRAME OR

CHASSIS.4. COVER ELECTR ONIC CO NTROL COMPONENTS AND


5. D O NOT CON NEC T WELDI NG CABLES TO ELECTRONIC

C ONTROL COMPONENTS.

IMPORTANT

P/N 12 97 04 94

WELDING CAUTION

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17

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Table 2-6. Front Bumper Assembly

Fig & Ind


6-1 G35-30093 Weldment, Frame, TIER 4I, GT35 1 1115 & Up6-2 G35-30016 Headlight, LED, R/H 1 "6-3 HRN-35D4I-110 Harness, Dash 1 "6-4 T6-9011-713 Headlidht LED, 9-36V (Front Hitch Light)-Opt 1 As Req'd6-5 12010293 Seal - Opt. 1 "6-6 12941692 Mount, Phone Jack - Opt. 1 "6-7 A14664 Jack, Phone - Opt. 1 "6-8 A14663 Cover, Phone Jack, Spring Loaded - Opt. 1 "6-9 G35-30017 Headlight, LED, L/H 1 1115 & Up6-10 G35-30040 Guard, Headlight - Opt 2 As Req'd6-11 8423 Cable, 3 Cond. 20AWG, Shielded - Opt. 1 "6-12 12970860 Decal, Phone Jack - Opt. 1 "6-13 G35-30057 Pedestal, Beacon w/o Cab 1 "6-14 G35-10036 Hook, Headphones, 4" - Opt. 1 "6-15 G1-30227 Beacon, Light, Led Amber, 12-24V - Opt. 1 "6-16 280951 Mirror, Rear View, Low Profile 2 1115 & Up6-17 86581 Bracket, Mirror 2 "

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Figure 2-7. Front Bumper Assembly (With Clearence Lights)

1

2

43

5

6

78

9

11

1012

14

15 16

13




WHEN WELDING I S REQ UIRED ON TRACTOR, THE

FOLLOWING PROCEDURES ARE TO BE TAKEN TO

PROTECT THE ELECTRONIC CONTROL COMPONENTS:

1. DISCON NEC T TH E WIRING HARNESS CONNECTORS

AT THE TRANSMISSI ON ELECTRONIC CONTROL UNIT.

2. DISCONN ECT ALL ENGINE ECM CONNECTORS.

3. DI SCO NNECT TH E POSITIVE AND NEGATIVE BATTERY

CONNECTIONS, AND ANY ELECTRONIC CONTROL

G ROUND WIRES CONNECTED TO THE FRAME OR

CHASSIS.4. COVER ELECTRONIC CONTROL COMPONENTS AND


5. DO NOT CONNECT WELDING CABLES TO ELECTRONIC

CONTROL COMPONENTS.

IMPORTANT

P/N 1 29 70 49 4

WELDING CAUTION

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Table 2-7. Front Bumper Assembly (With Clearence Lights)

Fig & Ind


7-1 G35-30093 Weldment, Frame, TIER 4I, GT35 1 1115 & Up7-2 G35-30016 Headlight, LED, R/H 1 "7-3 HRN-35D4I-110 Harness, Dash 1 "7-4 T6-9011-713 Headlidht LED, 9-36V (Front Hitch Light)-Opt 2 As Req'd7-5 12010293 Seal - Opt. 2 "7-6 12941692 Mount, Phone Jack - Opt. 1 "7-7 A14664 Jack, Phone - Opt. 1 "7-8 A14663 Cover, Phone Jack, Spring Loaded - Opt. 1 "7-9 G35-30017 Headlight, LED, L/H 1 1115 & Up7-10 G35-30040 Guard, Headlight - Opt 2 As Req'd7-11 8423 Cable, 3 Cond. 20AWG, Shielded - Opt. 1 "7-12 12970860 Decal, Phone Jack - Opt. 1 "7-13 ELE-10009 Light, Marker/ Clearance, Led 2 "7-14 G35-30057 Pedestal, Beacon w/o Cab 1 "7-15 G35-10036 Hook, Headphones, 4" - Opt. 1 "7-16 G1-30227 Beacon, Light, Led Amber, 12-24V - Opt. 1 "

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CD400


Figure 2-8. Rear Bumper Assembly

ULTR

A LOW

-SULFU

R

DIESE

L FUE

L ONL

YT- A

56

1514

1819

1

6

3

4

2

5

7

8

910

11 12

13

16

8

7

17

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4-2-17Orig

CD400


Table 2-8. Rear Bumper Assembly

Fig & Ind


8-1 G35-30093 Weldment, Frame, TIER 4I, GT35 1 1115 & Up8-2 G35-30011 Guard, Tail Light 2 "8-3 280951 Mirror, Rear View, Low Profile - Opt 1 As Req'd8-4 G50-10045 Bracket, Mirror, GT-50 - Opt 1 "8-5 12990777 Decal, Explosion Hazard 1 1115 & Up8-6 AS-10171 Reflector, Stick-On, Red 4 "8-7 MZ-10017 Light, Tail Stop/Backup, Led 2 "8-8 G35-30041 Guard, Tail Light - Opt 2 As Req'd8-9 12941692 Mount, Phone Jack - Opt. 1 "8-10 8423 Cable, 3 Cond. 20AWG, Shielded - Opt. 1 "8-11 A14664 Jack, Phone - Opt. 1 "8-12 A14663 Cover, Phone Jack, Spring Loaded - Opt. 1 "8-13 T6-9011-713 Headlight, Led, 9-36V (Hitch Light) - Opt 1 "8-14 G35-10088 Plug, Twist Lock - 30A, 250 VAC- Opt 1 "8-15 WP2 Cover, Receptacle, Waterproof - Opt 1 "8-16 12930793 Hitch Assembly, W/Pin Holder 1 1115 & Up8-17 T6-9011-713 Headlight, Led, 9-36V (Work Light) - Opt 1 As Req'd

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4-2-18Orig

CD400


Figure 2-9. Traction Kit (Without Cab)

4

3

2

1

5

6

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4-2-19Orig

CD400


Table 2-9. Traction Kit (Without Cab)

Fig & Ind


9- G35-30141 Traction Tread Kit, W/O Cab 1 1115 & Up9-1 G35-30141-1 Traction Tread, Driver Flooorboard 1 "9-2 G35-30141-2 Traction Tread, Cover, Electric 1 "9-3 G35-30141-3 Traction Tread, Passenger Flooorboard 1 "9-4 G35-30141-4 Traction Tread, Front, Top Deck 2 "9-5 G35-30141-5 Traction Tread, Middle Cover 1 "9-6 G35-30141-6 Traction Tread, Rear, Top Deck 2 "

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4-2-20Orig

CD400


Figure 2-10. Traction Kit (With Cab)

4

3

5

8

6

2

1

7

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4-2-21Orig

CD400


Table 2-10. Traction Kit (With Cab)

Fig & Ind


10- G35-30142 Traction Tread Kit, W/Cab 1 As Req'd10-1 G35-30141-2 Traction Tread, Cover, Electric 1 "10-2 G35-30142-1 Traction Tread, Driver Flooorboard 1 "10-3 G35-30142-2 Traction Tread, Driver Side Edge 1 "10-4 G35-30141-4 Traction Tread, Front, Top Deck 2 "10-5 G35-30141-6 Traction Tread, Rear, Top Deck 1 "10-6 G35-30141-5 Traction Tread, Middle Cover 1 "10-7 G35-30142-3 Traction Tread, Passenger Side Edge 1 "10-8 G35-30142-4 Traction Tread, Passenger Flooorboard 1 "

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4-2-22Orig

CD400


Figure 2-11. Cab Installation

1

2

3

4

6

5

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4-2-23Orig

CD400


Table 2-11. Cab Installation

Fig & Ind


11-1 OPT-CAB-212 Cab,W/Heater, GT35 Tier 4I 1 As Req'd11-2 280951 Mirror, Rearview, Low Profile 2 "11-3 C35-3031 Bracket, Mirror, Weldment 2 "11-4 T6-9011-713 Headlight, Led, 9-36V ( Work Light) 1 "11-5 T6-9011-713 Headlight, Led, 9-36V ( Hitch Light) 1 "11-6 G1-30227 Beacon, Light, Led Amber, 12-24V 1 "

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4-2-24Orig

CD400


Figure 2-12. Cab With AC Installation

12

5

3

4

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4-2-25Orig

CD400


Table 2-12. Cab With AC Installation

Fig & Ind


12-1 OPT-CAB-212 Cab, W/Heater, GT35 Tier 4I - Opt 1 As Req'dC35-3032K Kit, Cab WLDMT, 4I W/AC - Opt 1 "

12-2 T6-9011-606 Bracket, Mounting Light Post - Opt 1 "12-3 G1-30264 Post, Led Amber Beacon Light W/AC - Opt 1 "12-4 G1-30227 Light, Led Amber Beacon, 12-24V - Opt. 1 "12-5 G35-30143 Air Conditioning Unit and Installation(24V) - Opt. 1 "

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4-2-26Orig

CD400


Figure 2-13. AC Hoses Installation

2

1

3

4

5

6

7

8

9

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4-2-27Orig

CD400


Table 2-13. AC Hoses Installation

Fig & Ind


13-1 OPT-CAB-212 Cab, W/Heater GT35 Tier 4I - Opt 1 As Req'd13-2 C35-3030 Panel, Roof W/Window - Opt 1 "13-3 T6-9003-165 Gasket, Glass Window (By the foot) - Opt 4 "13-4 CMH-409 Glass, Roof, Laminated - Opt 1 "13-5 G35-30143-3 Hose, AC Discharge - Opt 1 "13-6 G35-30143 Air Conditioning Unit and Installation (24V) - Opt. 1 "13-7 G35-30143-2 Hose, AC Suction - Opt 1 "13-8 ------- P-Clamps - Opt 7 "13-9 G35-30103 Mount, Engine Cover 1 1115 & Up

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4-2-28Orig

CD400


Figure 2-14. Cab Assembly

4

23

5

6

1

9

21

8

6

1011

1514

12

13

1716

7

1918

20

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4-2-29Orig

CD400


Table 2-14. Cab Assembly

Fig & Ind


14-1 CMH-409 Glass, Roof, Laminated - Opt 1 As Req'd14-2 C35-3028K Door, Kit, RH 1 "14-3 C35-3027 Panel, Roof 1 "

C35-3030 Panel, Roof, W/ Window - Opt 1 "14-4 C35-3005 Glass, Front Windshield 1 "14-5 C35-3026K Cab, Kit, 4I 1 "

C35-3032K Cab, Kit, 4I W/AC 1 "14-6 T6-9003-165 Gasket, Glass Window (by the Foot) 36 "14-7 C35-3001-9 Panel, Windshield 1 "14-8 C35-3004 Glass, Front Lower Sight 1 "14-9 MG-1-320 Trim-Lok (price per Foot) 5 "14-10 CMA-127 Receiver, Hinge 4 "14-11 CMA-123 Hinge, R/H Door 2 "14-12 CMA-124 Hinge, L/H Door 2 "14-13 C35-3029K Door, Kit, LH 1 "14-14 5/16-18 x 1 Bolt, Flande Ø5/16-18 x 1" Long 11 "14-15 5/16 Washer, Flat, 5/16"ID 11 "14-16 C35-3018 Plate, Strike Bolt Cover 2 "14-17 T6-9003-303 Bolt, Striker 2 "14-18 C35-3034 Plate, Strike Bolt 2 "14-19 C35-3015 Panel, Insulation, Roof 1 "14-20 C35-3001-12 Panel, Rear 1 "14-21 C35-3012 Window, Sliding, Rear 1 "

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4-2-30Orig

CD400


Figure 2-15. Cab Interior

1

67

345

89

2

10

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4-2-31Orig

CD400


Table 2-15. Cab Interior

Fig & Ind


15-1 T6-9011-105 Fan, Cab 1 1115 & Up15-2 T6-7010-114 Switch, Toggle 1 "15-3 MZ-10033 Light, Led, Dome 1 "15-4 T-W17 Decal, Dome 1 "15-5 C35-3033 Bracket, Dome Light 1 "15-6 OPT-CAB-212 Cab, W/Heater GT35 Tier 4I - Opt 1 "15-7 920408C1 Mirror Assembly 1 "15-8 C35-3022 Motor, Wiper 100D 3 "15-9 G50-20403 Plate, Door Strap Clamp 4 "15-10 G1-20518 Strapping Material, Door 1.5' "

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4-2-32Orig

CD400


Figure 2-16. Dome Light Installation (Cab With AC)

1 2

5

4

6

7

3

8

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4-2-33Orig

CD400


Table 2-16. Dome Light Installation (Cab With AC)

Fig & Ind


16-1 C35-3032K Cab, Kit, WLDMNT 4I W/AC - Opt 1 As Req'd16-2 G35-30143 Air Conditioning Unit and Installation (24V) - Opt 1 "16-3 T6-7010-114 Switch, Toggle 1 "16-4 MR-1252 Switch, Wiper 1 "16-5 G35-3062 Switch, Dual Wiper/Washer 1 "16-6 C35-3024-1 Panel, Switch W/Dome Light, Upper - Opt 1 "16-7 MZ-10033 Light, LED Dome - Opt 1 "16-8 T-W17 Decal, Dome - Opt 1 "

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4-2-34Orig

CD400


Figure 2-17. Wipers Assembly

1

4

3

5

9

16

10

2

6

78

11

1213

14

9

15

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4-2-35Orig

CD400


Table 2-17. Wipers Assembly

Fig & Ind


17-1 C35-3026K Cab Kit, Weldment, 4I 1 As Req'd17-2 T6-9011-456 Tank, Washer Fluid 1 "17-3 T6-9003-120 Blade, Wiper, 16" Long 2 "17-4 T6-9003-122 Arm, Wiper, 15"-19" Long 2 "17-5 T6-9003-171 Grommet, Windshield 2 "17-6 T6-9003-211 Spacer, Grommet 2 "17-7 T6-9011-457 Nozzle, Windshield Washer 1 "17-8 MG-ND-857 Tee, Vacuum 3/16 x 3/16 x 3/16 117-9 TM1-1-6551 Fitting, Dual Wipers 2 "17-10 C35-3022 Motor, Wiper 100D 12V 3 "17-10 C35-3037 Motor, Wiper 100D 24V 3 "17-11 TM1-1-6550 Windshield Washer Kit, Wet Arm 1 "17-12 G35-30062 Switch, Dual Wiper (Windshield Wipers) 1 "17-13 MR-1252 Switch, Wiper (Rear Window Wiper) 1 "17-14 T6-9003-125 Blade, Wiper 1 "17-15 T6-9003-123 Arm, Wiper 1 "17-16 C35-3026 Panel, Rear 1 "

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4-2-36Orig

CD400


Figure 2-18. Passenger Door Assembly

1

3

2

4

6

5

7

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4-2-37Orig

CD400


Table 2-18. Passenger Door Assembly

Fig & Ind


18-1 C35-3028K Door Kit, R/H 1 As Req'd18-2 CMA-451 Window, R/H Double Slide 1 "18-3 C35-3007 Handle, Outside Door 1 "18-4 T6-9003-165 Gasket, Glass Window, 66" 1 "18-5 C35-3035 Glass, Lower Door, 4I 1 "18-6 C35-3009 Handle/Latch, Inner Door, R/H 1 "18-7 CMA-504 Strip, Seal - Door (Price/Foot) 14.5 "

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4-2-38Orig

CD400


Figure 2-19. Driver Door Assembly

1

3

2

4

6

5

7

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4-2-39Orig

CD400


Table 2-19. Driver Door Assembly

Fig & Ind


19-1 C35-3029K Door Kit, L/H 1 As Req'd19-2 CMA-450 Window, L/H Double Slide 1 "19-3 C35-3007 Handle, Outside Door 1 "19-4 T6-9003-165 Gasket, Glass Window, 66" 1 "19-5 C35-3035 Glass, Lower Door, 4I 1 "19-6 C35-3008 Handle/Latch, Inner Door, L/H 1 "19-7 CMA-504 Strip, Seal - Door (Price/Foot) 14.5 "

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4-2-40Orig

CD400


Figure 2-20. Seats Installation

1

5

32

4

46

7

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4-2-41Orig

CD400


Table 2-20. Seats Installation

Fig & Ind


20-1 WM127-14 Seat Assembly, with Slides 2 1115 & UpBLE-4-2712 Seat, Bucket, Ultraseat - Opt. 2 As Req'd

20-2 G35-30054 Mount, Headphone Hook - Opt 1 "20-3 T6-9011-456 Tank, Washer Fluid - Cab Opt 1 "20-4 660-6-0581-25 Belt, Safety (Non-Retractable) 2 1115 & Up

T6-9011-733 Belt, Seat, Flip Open, (Retractive) - Opt 1 As Req'd20-5 12960182 Bracket, Seat Belt 2 1115 & Up20-6 G35-10036 Hook, Headphones, 4" - Opt 1 As Req'd20-7 G35-30093 Frame Weldment, Tier 4I, GT35 1 1115 & Up

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4-2-42Rev 1

CD400


Figure 2-21. Instrument Panel Assembly

1

23

5

4

678

910

14 1918

16

17 21

2223

2526

2728

29

32

35

48

OPTIONAL

1

49

OPTIONAL

40

52

53

6

13

33

11

12

34

1520

23

24

37

38

3637

3940

42

31

43

44

45

4647

30

50

51

54

OPTIONAL

56

10

55

41

58

57

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4-2-43Rev 1

CD400


Table 2-21. Instrument Panel Assembly

Fig & Ind


21-1 G35-30093-24 Instrument Panel Weldment 1 1115 & Up21-2 G1-30222-1 Display, Dash, PV450LCD 1 "21-3 G1-30270 Terminal, OP, W/Lighted Buttons - Opt 1 As Req'd21-4 MH-ND-955 Switch, (HTR/DEF), 4 P os. Fan - Opt 1 "21-5 1TL156-3 Switch, Toggle, ON/OFF (Front Hitch Light) - Opt. 1 "21-6 1TL156-3 Switch, Toggle, ON/OFF (Rear Hitch/Work Light) - Opt. 1 "21-7* LE000307 Switch, Toggle, 4PDT, Maintained, ON-NONE-ON

(Parking Brake Switch)1 1115 & Up

21-8* G35-30097-1 Faceplate, Switch Panel 1 "21-9* G1-30106 Label, Toggle Switch Guard 1 "21-10* G1-30102-2 Display, Transmission 1 "21-11* G1-30105 Guard, Toggle Switch 1 "21-12* 014050 Light, Dash 1 "21-13* 67785 Bulb, 24V, T-3-1/4 1 "21-14 HRN-35D4I-110 Harness, Dash 1 "21-15 G1-30102-1 Shifter, VTS 3 1 "21-16 G1-30102-267 Cover, Shifter Push Button -Opt 1 As Req'd21-17* T6-9003-571 Plug, Button, Black ½" 1 1115 & Up21-18* G1-40109-18 Frame, Mounting 1 "21-19* ELE-10003 Light, Brake Warning/Park Brake, 24V 1 "21-20* ELE-10004 Light, Transmisson/Battery, 24V 1 "21-21* ELE-10001 Light, Glow Plug, Yellow, 24V Led 1 "21-22 HDP26-24-31SE Plug, P15, 24 Shell, 31 Cavity, Female 1 "21-23 HRN-35D4i-101 Harness, Control Box 1 "21-24 HDP24-24-31PE Receptacle, P15, 31 Cavity, Male 1 "21-25 HDP26-24-31PE Plug, P16, 24 Shell, 31 Cavity, Male 1 "21-26 HDP24-24-31SE Receptacle, P16, 31 Cavity, Female 1 "

* P/N G35-30097 Dash Panel Assembly includes items 7-13, 17-21, 27, and 30.

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4-2-44Rev 1

CD400


1

23

5

4

678

910

14 1918

16

17 21

2223

2526

2728

29

32

35

48

OPTIONAL

1

49

OPTIONAL

40

52

53

6

13

33

11

12

34

1520

23

24

37

38

3637

3940

42

31

43

44

45

4647

30

50

51

54

OPTIONAL

56

10

55

41

58

57

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4-2-45Rev 1

CD400


Table 2-21. Instrument Panel Assembly (Cont'd)

Fig & Ind Tug Part Number Description Qty Effective

21-27* ELE-10002 Light, Check Engine 1 1115 & Up21-28 12930905 Nameplate, Emergency Steering Pump - Opt 1 As Req'd21-29 T-A45 Sticker, Heater - Opt 1 "21-30* 012481 Switch, Toggle (Head Lights) 1 1115 & Up21-31 1TL156-3 Switch, Toggle, ON/OFF (Beacon) - Opt. 1 As Req'd21-32 76474 Switch, Toggle, 1 Pole, 2 Pos.(Emerg. Steer. Pump)-Opt 1 "21-33 T-A56D Decal, Dash, Ultra Low Sulfur 1 1115 & Up21-34 T-Y2 Decal, Emergency Stop - Opt 1 As Req'd21-35 T-B5 Decal, 24V System 1 1115 & Up21-36 T-W46 Decal, 2014 Emission Control 1 "21-37 12960001 Decal, Seat Belt 2 "21-38 MR-1155-1 E-Stop Assembly - Opt 1 As Req'd21-39 12970444 Decal, Park Brake Warning 1 1115 & Up21-40 G1-30148-7 Plug, Engine Diagnostic 1 "21-41 12970851 Decal, Warning, Do Not Shift 1 1115 & Up21-42 G1-30148-8 Clamp, Engine Diagnostic 1 "21-43 12970961 Decal, Caution Aircraft Towing 1 "21-44 G35-30060 Cover, Wiring Close Out 1 "21-45 T6-9011-485 Decal, Thank you 1 "21-46 12951195 Cover, Dash - L/H Side, GT35 1 "21-47 1028 Warning: Avoid Injury 1 "21-48 12960884 Cover Plate, Cab Wire & Hoses 1 "21-49 T6-9011-702-1 Switch, Ignition, Lever, Waterproof 1 "

T6-9011-701-1 Switch, Ignition, Keyed, Waterproof - Opt 1 As Req'd21-50 ML-26 Decal, Caution: Tractor Complete Stop 1 1115 & Up21-51 G35-30050 Bracket, Diagnostic Port Relocation - Opt. 1 As Req'd21-52 G35-30051 Plate, Cover, Dash LTS, Lexan - Opt. 1 "21-53 '------ Foam, 3/8" Thick, 3.5" Long - Opt. 1 "21-54 ENGR-20101 Lebel, Export Only - Opt 1 "21-55 G35-30110 Support, Cover Plate, ZF LCD - Opt 1 "21-56 G35-30109 Cover, Plate, ZF LCD, Lexan - Opt 1 "21-57 ELE-10042 Switch, Toggle, 2 Positions (Momentary)-Code Switch 1 1115 & Up21-58 T6-6011-113 Angle, Tee Support 1 "

* P/N G35-30097 Dash Panel Assembly includes items 7-13, 17-21, 27, and 30.Prop

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4-2-46Orig

CD400


Figure 2-22. Upper Instrument Panel Assembly

3

56

12

4

7

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4-2-47Orig

CD400


Table 2-22. Upper Instrument Panel Assembly

Fig & Ind


22-1 C35-3014 Panel, Switch, Upper Cab 1 1115 & Up22-2 12970868 Decal, Wiper Front Windshield 1 "22-3 G35-30031 Diode, Silicone, 6 AMP, 1000V 12 "22-4 12970867 Decal, Wiper, Rear Windshield 1 "22-5 MR-1252 Switch, Wiper 1 "22-6 G35-30062 Switch, Dual Wiper/Washer 1 "22-7 HRN-35D3-CAB Harness, Cab 1 "

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4-2-48Orig

CD400


Figure 2-23. Accelerator Pedal Installation

Table 2-23. Accelerator Pedal Installation

1

2

Fig & Ind


23-1 G1-30101-6 Pedal, Accelerator 1 1115 & Up23-2 ¼-20x¾ Screw, ¼"-20 x ¾ Long 4 "

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4-2-49Orig

CD400


Figure 2-24. Brake Assembly

3

4

7 19

16

16

17

1918

17

18

2

56

8

910

2

11

12

13

14

15

20

20

Table 2-24. Brake Assembly

Fig & Ind


24-1 G35-30085 Valve, Tandem Brake 1 1115 & Up24-2 76948 Elbow, 90°, ¼" Tube 4 "24-3 G35-30121-24 Hose, Hydraulic (Brake Valve to Pressure Switch) 1 "24-4 G35-30121-22 Hose, Hydraulic (Brake Valve to Front Axle) 1 "24-5 G35-30121-8 Hose Assembly (Brake Valve to Manifold) 1 "24-6 G35-30121-8 Hose Assembly (Brake Valve to Manifold) 1 "24-7 12990669 Plate, Access, Brake Pedal 1 "24-8 76916 Adapter, Connector, ¼" Tube 2 "24-9 12872931 Tee, Adapter, AEROQUIP 1 "24-10 12951374 Tube Assembly, Crossover Brake Valve 1 "24-11 G35-30121-27 Hose Assembly (Brake Valve to Manifold) 1 "24-12 203002-4-4S Tee, Adapter, 37° Flare (with Nut) 1 "24-13 2242-4-4S Adapter, ¼" JIC to ¼" Pipe 1 "24-14 011714 Switch, Pressure 1 "24-15 G35-30121-23 Hose, Hydraulic (Pressure Switch to Rear Axle) 1 "24-16 G35-30121-25 Hose, Hydraulic (Brake Supply on Axles) 2 "24-17 221501-6-4S Adapter, Connector, Swivel, 6FJ-4MJ 2 "24-18 06-06-070221 Elbow, 6MJx6FJ-90 Degr. Fitting 2 "24-19 203102-6-6S Tee, Adapter, Swivel Flare 2 "24-20 GG108-NP06-14 Fitting, Aeroquip, 14mm-6MJ 4 "

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4-2-50Orig

CD400


Figure 2-25. Steering Column Assembly

4

5

1

3

791014

8

6

1113

12

2

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4-2-51Orig

CD400


Table 2-25. Steering Column Assembly

Fig & Ind


25-1 TM1-1-9675 Button, Horn, 2 W ire 1 1115 & Up25-2 X4015-101 Nut, Column 1 "25-3 M3-1-8020 Wheel, Steering, 14" Diameter, VIP, with Boot 1 "25-4 97887 Control, Turn Signal - 7 W ire (EASwitch) 1 "25-5 204-1043 Column, Steering, 8" 1 "

X4014-101 Column, Steering - Cab Opt 1 As Req'd25-6 3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 4 1115 & Up25-7 3/8 Washer, Lock 3/8" ID 4 "25-8 212-1006 Valve, Steering, 14.1 Cir 1 "25-9 06-08-070120 Adapter, Connector, 6MJ-8MB 2 "25-10 G35-30121-5 Hose (Steer Valve to Manifold, Return) 1 "25-11 G35-30121-21 Hose (Steer Valve to L/S Front Axle) 1 "

G35-10085 Hose, Tee To Steer Valve - Emerg. Steer.Opt 1 As Req'd25-12 TM1-ND-8003 Elbow, 90° - Pump Outlet 2 1115 & Up25-13 G35-30121-26 Hose (Steer Valve to R/S Front Axle) 1 "25-14 G35-30121-1 Hose, Supply (Manifold to Steering Valve) 1 "

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4-2-52Orig

CD400


Figure 2-26. Engine Installation

1

2

4

5

3

6

7

8

9

10

11

12

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4-2-53Orig

CD400


Table 2-26. Engine Installation

Fig & Ind


26-1 ENG-G35-D4I Engine, Deutz, TCD3.6L, Tier 4I 1 1115 & UpENG-G35-3.6EXP Engine, 3.6L W/Cooler, T3 EXP - Opt 1 As Req'd

26-2 ¾-16 x 3¾ Bolt, Hex Head Ø ¾-16 x 3¾" Long 2 1115 & Up26-3 ¾ Washer, Flat ¾" ID 4 "26-4 ½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾" Long 4 "26-5 ½ Washer, Lock ½" ID 4 "26-6 MT-4-2220 Isolator, Front 2 "26-7 TM1-1-5005 Washer, Stop Engine Mount 2 "26-8 ¾-16 Nut, Top Lock Hex ¾-16 2 "26-9 G35-30093-22 Mount, Motor, Front, Weldment 2 "26-10 G35-30114 Bracket, Rear Engine Lifting 1 "26-11 ENG-G35-D4I-2 Bracket, Engine Mounting, LH 1 "26-12 ENG-G35-D4I-1 Bracket, Engine Mounting, RH 1 "

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Figure 2-27. Engine Assembly

7

10

13

6

2

31

8

9

1516

11

12

141718

19

25

341235

3637

40

24

38

45

5

20 21

2223

27 28

2924

26

32

30

3133

28

39

42

43

41

44

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Table 2-27. Engine Assembly

Fig & Ind

Tug Part Number Description

QtyEffective

27- ENG-G35-D4I Engine, Deutz, TCD3.6L T4I 1 1115 & UpENG-G35-3.6EXP Engine, 3.6L W/Cooler, T3 EXP - Opt 1 As Req'd

27-1 ENG-G35-D4I-22 Fan, Deutz, TD2012 L04M, Tier 3 1 1115 & Up27-2 ------- Hose, Colling, 5/16" ID 1 "27-3 ENG-G35-D4I-7 Belt, Alternator/Water Pump, Deutz 3.6L 1 "27-4 ENG-GT110-DIII24-4 Relay, Glow Plug, Deutz 1 "27-5 HRN-35D4I-111 Harness, Main GT35-D4I 1 "27-6 ENG-GT110-DIII24-350 Transmitter, Cooling Temperature 1 "27-7 T-10408 Cap, Oil Filling 1 "27-8 ENG-G35-D4I-23 Harness, Engine Tier 4I 1 "27-9 ENG-G35-D4I-24 Converter, Catalic, Diesel, Oxidation 1 "

ENG-G35-3.6EXP-1 Muffler, Engine 3.6L Tier 3 - Opt 1 As Req'd27-10 ENG-G35-D4I-34 Clamp, Converter 2 1115 & Up27-11 G35-30133 Compressor, Air, Kit - Opt 1 As Req'd27-12 G35-30135-9 Cable, From Alternator To Starter 1 1115 & Up27-13 ENG-G35-D4I-25 Dipstick 1 "27-14 G35-30126 Bracket, Dipstick Mount 1 "27-15 117-4421 Filter, Oil - Deutz 1 "27-16 ENG-G35-D4I-5 Alternator, Deutz 3.6L, 24V, 55 A 1 "27-17 ENG-GT110-DIII24-265 Sensor, Pressure ( Lubric.Oil Pressure) 1 "27-18 ENG-G35-D4I-26 Transmitter, Speed, Via Camshaft 1 "27-19 ENG-G35-D4I-8 Belt, Fan Drive, Deutz 3.6L - Opt 1 As Req'd27-20 ENG-G35-D4I-26 Transmitter, Speed Via Crankshaft 1 1115 & Up27-21* ENG-G35-D4I-32 Control Unit, Engine, Unprogramed 1 "27-22 ENG-G35-D4I-31 Harness, Connecting Engine, Deutz 3.6L, Tier 4I 1 "27-23 G35-30149 Hose, Deutz, Heater to Valve - Opt 1 As Req'd

* ECU required special programming for each engine serial number.

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Figure 2-27. Engine Assembly (Con'd)

7

10

13

6

2

31

8

9

1516

11

12

141718

19

25

341235

3637

40

24

38

45

5

20 21

2223

27 28

2924

26

32

30

3133

28

39

42

43

41

44

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Table 2-27. Engine Assembly (Cont'd)

Fig & Ind


27-24 HDW-10085 Fitting, Straight, 22MM - 8MJ - Opt 2 As Req'd27-25 ENG-G35-D4I-30 Injector, Fuel 4 1115 & Up27-26 ENG-GT110-DIII24-349 Transmitter, Air Pressure Charge 1 "27-27 ENG-GT110-DIII24-271 Sensor, Rail Pressure (Repair Kit) 1 "27-28 12892907 Hose, Coolant Heater, 5/8"ID - Opt 15' As Req'd27-29 4797-10B Fitting, SAE AERO - Opt 1 "27-30 HDW-10019 Reducer, 5 Female x 5/8 Male - Opt 1 "27-31 78899 Adapter, Connector, Male, 5/8"Tube OD JICx ½"Male 1 "27-32 TM1-ND-5253 Valve, Ball Deutz Heater - Opt 1 "27-33 2071-10-10S Adapter, Elbow 90 Degree - Opt 1 "27-34 TM1-1-8308 Barb, 5/8" Hose -Opt 1 "27-35 G35-30135-7 Cable, From Starter To E1 24V Stud 1 1115 & Up27-36 ENG-G35-D4I-29 Plug, Central (For Engine Control) 1 "27-37 ENG-G35-D4I-6 Starter, Deutz 3.6L, 24V, 4.0 kW 1 "27-38 TP-10457 Plug, Oil Drain 1 "27-39 ---------- Outlet, Exhaust 1 "27-40 ENG-G35-D4I-27 Glow Plug 4 "27-41 G35-30121-16 Hose, Fuel, Filter To Engine 1 As Req'd27-42 G35-30135-1 Cable, From Engine To Chassis Ground Stud 1 1115 & Up27-43 G35-30121-15 Hose, Fuel, Return To Tank 1 "27-44 6000103 Diode, Alternator 1 "

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Figure 2-28. AC Compressor Installation

Table 2-28. AC Compressor Installation

1

2 3

5

7

4

6

Fig & Ind


28-1 ------- Pulley, AC (Comes with AC Compressor Kit) - Opt 1 As Req-d28-2 G35-30133 Compressor, AC, Kit - Opt 1 "28-3 G35-30143-3 Hose, AC Discharge - Opt 1 "28-4 G35-30143-2 Hose, AC Suction - Opt 1 "28-5 ENG-G35-D4I-8 Belt, Fan Drive, Deutz 3.6L - Opt 1 "28-6 G1-30228 Relay, 24V, 50A, SPST - Opt 1 "28-7 MT-1-1275 Circuit Breaker, 40 AMP - O pt 1 "

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Table 2-29. Heater Assembly

Figure 2-29. Heater Assembly

1

32

4

5

67

89

10

11

1312

14

4

15

Fig & Ind


29-1 ENG-G35-D4I Engine, Deutz, TCD3.6L T4I 1 1115 & Up29-2 HDW-10085 Adapter, Heater, Deutz M26 - 1.5 2 As Req'd29-3 G35-30149 Hose, Deutz, Heater to Valve - Opt 1 "29-4 12892907 Hose, Coolant Heater, 5/8"ID - Opt 20' "29-5 4797-10B Fitting, SAE AERO - Opt 1 "29-6 HDW-10019 Reducer, 5 Female x 5/8 Male - Opt 1 "29-7 78899 Adapter, Connector, Male, 5/8"Tube OD JIC X

½"Male Pipe, 10MJ-8MP - Opt1 "

29-8 TM1-ND-5253 Valve, Ball Deutz Heater - Opt 1 "29-9 2071-10-10S Adapter, Elbow 90 Degree - Opt 1 "29-10 TM1-1-8308 Barb, 5/8" Hose -Opt 1 "29-11 C35-3025 Heater, High Output -Opt 1 "29-12 12892901 Clamp, Hose, With Liner 4 "29-13 ------ Hose, Ø 2½", 8" Long 2 "29-14 C35-3036 Defroster, Duct, High Output 1 "29-15 G35-30138 Cover, Fresh Air Heater Opening 1 1115 & Up

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CD400


Figure 2-30. Block Heater and Heater Assembly

Table 2-30. Block Heater and Heater Assembly

2

5

8

10

11

16

13

7

9

15

12

3

1

4

11

6

14

7

7

7

Fig & Ind


30-1 G35-30149 Hose, Deutz, Heater to Valve - Opt 1 As Req'd30-2 HDW-10085 Adapter, Heater, Deutz M26 - 1.5 2 "30-3 78899 Adapter, Connector, Male, 5/8"Tube OD JIC X ½ Male Pipe,

10MJ-8MP - Opt1 "

30-4 TM1-ND-5253 Valve, Ball Deutz Heater - Opt 1 "30-5 TM1-1-8308 Barb, 5/8" Hose -Opt 1 "30-6 12892904 Clamp, Hose, With Liner, 1" 12 "30-7 12892907 Hose, Coolant Heater, 5/8"ID - Opt 30' "30-8 2071-10-10S Adapter, Elbow 90 Degree - Opt 1 "30-9 HDW-10019 Reducer, 5 Female x 5/8 Male - Opt 1 "30-10 4797-10B Fitting, SAE AERO - Opt 1 "30-11 MD-ZO1-105 Pipe, Y, Heater 2 "30-12 THA201-T10 Heater, Coolant, 120 VAC, 2000 - Opt 1 "

THA202-T10 Heater, Coolant, 240 VAC, 2000 - Opt 1 "30-13 C35-3025 Heater, High Output -Opt 1 "30-14 ------ Hose, Ø 2½", 8" Long 2 "30-15 12892901 Clamp, Hose, With Liner 4 "30-16 C35-3036 Defroster, Duct, High Output 1 "

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1

1112

1314

1516

17

2

3

5

9

6

8

7

4

10

Figure 2-31. AirIntake Assembly Table 2-31. AirIntake Assembly

Fig & Ind


31-1 ENG-G35-D4I Engine, Deutz TCD 3.6L T4I 1 1115 & Up31-2 114-8606 Clip, Hose 1 "31-3 G35-30112 Pipe, Intake, Air Cleaner/ Turbo 1 "31-4 ------ Clamp, Hose, IDEAL 5064 2 "31-5 RL490 Elbow, 90 Deg 1 "31-6 M8 Washer, Flat, 8mmID 4 "31-7 M8 Washer, Lock, 8mm ID 4 "31-8 M8-1.25 x 20 Bolt, Hex Head Ø M8-1.25 x 20mm Long 4 "31-9 G35-30127 Bracket, Air Filter, Deutz 3.6 1 "31-10 G35-30027 Filter, Air 1 "31-11 G35-30027-6 Clip, U- 4 "31-12 G35-30027-3 Latch 2 "31-13 G35-30027-1 Filter, Primary 1 "31-14 G35-30027-4 Valve, Vacuator 1 "31-15 G35-30027-2 Filter, Safety 1 "31-16 G35-30027-5 Cover 1 "31-17 39135-001 Indicator, Service 1 "

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CD400


Table 2-32. AirIntake Assembly, Tier 4i

1

23

4

6

5

Figure 2-32. Exhaust Assembly, Tier 4i

Fig & Ind


32-1 ENG-G35-D4I Engine, Deutz, TCD 3.6L, T4I 1 1115 & UpENG-G35-3.6EXP Engine, 3.6L W/Cooler, T3 EXP - Opt 1 As Req'dENG-G35-3.6EXP-1 Muffler, 3.6L Engine Tier 3 1 "

32-2 ENG-G35-D4I-33 Clamp, Exhaust Outlet 1 1115 & Up32-3 ENG-G35-D4I-28 Gasket, Exhaust Outlet 1 "32-4 G35-30111 Pipe, Exhaust DOC Outlet 1 "32-5 G35-30107 Panel, Rear Heat Shield 1 "32-6 6000630 Cap, Rain, 3" 1 "

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CD400


Figure 2-32a. Exhaust Assembly, Tier 3

Table 2-32a. Exhaust Assembly, Tier 3

6

910

9

9

5

8

2

13

1214

1

7

4

Fig & Ind


32a-1 ENG-G35III-DEUTZ-11 Clamp, Heavy Duty, Exhaust 2.5 1 As Req-d32a-2 10mm x 25 Bolt. Hex Head, Flange, M10x25 4 "32a-3 ENG-G35III-DEUTZ-10 Foil Heat Cable Wrap, 1" Dia.(Not Shown) 1 "32a-4 ENG-G35III-DEUTZ-12 Muffler, 6.62 1 "32a-5 ENG-G35III-DEUTZ-14 Ring, Mounting 2 "32a-6 ENG-G35III-DEUTZ-13 Bracket, Muffler 1 "32a-7 ENG-G35III-DEUTZ-15 Tube, Flange, Muffler 1 "32a-8 3/8-16 Nut, Hex Head, 3/8-16, Centerlock, ZP 4 "32a-9 ENG-G35III-DEUTZ-8 Washer, 3/8" HHCS, Narrow 10 "32a-10 3/8-16x1-1/8 Bolt, 3/8-16x1 1/8, HHCS 4 "32a-11 ENG-G35III-DEUTZ-9 Cap, Poly 2½"ID (Not Shown) 1 "32a-12 ENG-GT110-DIII24-68 Bracket 2 "32a-13 ENG-G35III-DEUTZ-16 Clip 1 "32a-14 ENG-G35III-DEUTZ-1 Nut 1 "

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CD400


Figure 2-33. Exhaust (Rear Option) Assembly

1

23

4

5

7

6

Table 2-33. Exhaust (Rear Option) Assembly

Fig & Ind


33-1 ENG-G35-D4I Engine, Deutz, TCD 3.6L, T4I 1 1115 & UpENG-G35-3.6EXP Engine, 3.6L W/Cooler, T3 EXP - Opt 1 As Req'dENG-G35-3.6EXP-1 Muffler, 3.6L Engine Tier 3 1 "

33-2 ENG-G35-D4I-33 Clamp, Exhaust Outlet 1 1115 & Up33-3 ENG-G35-D4I-28 Gasket, Exhaust Outlet 1 "33-4 G35-30137 Exhaust Pipe, Rear Exiting - Opt 1 As Req'd33-5 12931611 Clamp - Opt 3 "33-6 G35-30140 Pipe, Under Axle - Opt 1 "33-7 G35-30136 Pipe, Tail - Opt 1 "

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CD400


Figure 2-34. Cooling System Table 2-34. Cooling System

1

4

2

5

3

6

89

1011

12

1315

16

17

18

1920

22

14

21

26

24

17

3

37

23

25

Fig & Ind


34-1 G35-30108 Cooler, Transmission, ZF 1 1115 & Up34-2 G35-30119 Mount, Transmission Cooler, LH 1 "34-3 ENG-G35-D4i-13 Hose, Connector, Rubber 3 "34-4 G35-30121-14 Hose, Transmission To Cooler, Bottom 1 "34-5 G35-30121-13 Hose, Transmission To Cooler, Top 1 "34-6 ENG-G35-D4i-18 Hose, Radiator 5/16"ID, To Overflow Bottle 1 "34-7 ENG-G35-D4i-21 Cap, Radiator 1 "34-8 ENG-G35-D4i-15 Pipe, Top Right 1 "34-9 G35-30120 Mount, Transmission Cooler,RH 1 "34-10 ENG-G35-D4i-18 Hose, Radiator, 5/16"ID, To Engine 1 "34-11 ENG-G35-D4i-18 Hose, Radiator 5/16"ID 1 "34-12 ENG-G35-D4i-20 Sensor, Coolant Lever 1 "34-13 G35-30121-11 Hose, Hydraulic Pump To Cooler 1 "34-14 HRN-35D4I-111 Harness, Main GT35-D4I 1 "34-15 ENG-G35-D4i-16 Pipe, Bottom, Right 1 "34-16 G35-30121-12 Hose, Hydraulic, Cooler To Tank 1 "34-17 76958 Adapter, Elbow 90 Degr . 8MJ-12MB90 2 "34-18 ENG-G35-D4i-17 Elbow, Hose 1 "34-19 ENG-G35-D4i-19 Clamp, Hose, Radiator 8 "34-20 ENG-G35-D4i-14 Pipe, Top, Left 1 "34-21 ENG-G35-D4i-11 Pipe, Bottom, Left 1 "34-22 ENG-G35-D4i-12 Radiator Assembly 1 "34-23 ------- Clamp, Hose, IDEAL, Size 32 4 "34-24 G35-30134 Mount, Radiator Package 1 "34-25 660-1-2412 Damper, Vibration - Oil Cooler 4 "34-26 T6-4055-109 Bottle, Radiator Overflow W/Bracket 1 "

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CD400


Figure 2-35. Fuel System

5

9

7

13

8

25

27

26

1

32

4

6

10

1112

14

15

16

1718

21

3

19

20

22

23

24

28

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CD400


Table 2-35. Fuel System

Fig & Ind


35-1 G35-10051 Tank, Fuel 1 1115 & Up35-2 ENG-660-44-1 Prefilter, Fuel, Deutz 3.6L 1 "35-3 G35-10067 Fitting, Fuel Filter, 16MM-8MJ 4 "35-4 G35-30121-17 Hose, Fuel, Tank To Water Separator 1 "35-5 HRN-35D4I-111 Harness, Main GT35-D4I 1 "35-6 G35-30121-19 Hose, Filter, Drain 1 "35-7 80220 Coupling, Pipe, Full, 2" NPT 1 "35-8 G35-30121-20 Hose, Fuel, Water Separator To Fuel Pump 1 "35-9 G35-30121-15 Hose, Fuel, Retun To Tank 1 "35-10 79481 Nipple, Pipe, 2" x 3" Tube, S/40 1 "35-11 T6-6004-101S O-Ring 1 "35-12 T6-6004-101GREEN Cap Assembly, Fuel - Diesel (Green) 1 "35-13 87046 Valve, Check, In-Line, 3/8" NPT 1 "35-14 2083-12-6S Fitting, Aeroquip, Pipe to Pipe 1 "35-15 12951375 Tube, Return - Fuel Tank 1 "35-16 202x6 Adapter, Connector, Male, Ø 3/8" Tube 1 "35-17 G35-10049 Tube, Fuel Pickup 1 "35-18 ENG-G35-D4i-3 Pump, Fuel, Deutz 3.6L 1 "35-19 G35-30121-15 Hose, Fuel, Pump To Main Filter 1 "35-20 ENG-G35-D4I-10 Harness, Fuel Pressure Switch 1 "35-21 ENG-GT110-DIII24-265 Sensor, Fuel Pressure 1 "35-22 ENG-G35-D4i-4 Filter, Fuel Element Secondary (1.1L), Deutz 3.6L 1 "35-23 G35-30121-16 Hose, Fuel Filter To Engine 1 "35-24 21275 Belt, Cotton, Webbed, White, 1/8" 2 "35-25 12951344 Strap, Fuel Tank 2 "35-26 5/16-18 Nut, Flange Lock Hex 5/16-18 8 "35-27 12970431-50 Bracket, Fuel Tank Strap (part of frame) 1 "35-28 810131 Sender, Fuel 1 "

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CD400


Figure 2-36. Fuel Assembly (With Heater Option)

3

9

7

13

8

25

27

26

1

3

2

4

10

1112

14

15

16

17

18

21

3

19

20

28

22

23

24

29

31

5

6

33

34

35

32

36

28

30

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CD400


Table 2-36. Fuel Assembly (With Heater Option)

Fig & Ind


36-1 G35-10051 Tank, Fuel 1 1115 & Up36-2 ENG-660-44-1 Prefilter, Fuel, Deutz 3.6L 1 "36-3 G35-10067 Fitting, Fuel Filter, 16MM-8MJ 4 "36-4 G35-30150 Hose, Fuel, Tank To Fuel Heater - Opt 1 As Req'd36-5 HRN-35D4I-111 Harness, Main GT35-D4I 1 1115 & Up36-6 G35-30121-19 Hose, Filter, Drain 1 "36-7 80220 Coupling, Pipe, Full, 2" NPT 1 "36-8 G35-30121-20 Hose, Fuel, Water Separator To Fuel Pump 1 "36-9 G35-30121-15 Hose, Fuel, Retun To Tank 1 "36-10 79481 Nipple, Pipe, 2" x 3" Tube, S/40 1 "36-11 T6-6004-101S O-Ring 1 "36-12 T6-6004-101GREEN Cap Assembly, Fuel - Diesel (Green) 1 "36-13 87046 Valve, Check, In-Line, 3/8" NPT 1 "36-14 2083-12-6S Fitting, Aeroquip, Pipe to Pipe 1 "36-15 12951375 Tube, Return - Fuel Tank 1 "36-16 202x6 Adapter, Connector, Male, Ø 3/8" Tube 1 "36-17 G35-10049 Tube, Fuel Pickup 1 "36-18 ENG-G35-D4i-3 Pump, Fuel, Deutz 3.6L 1 "36-19 G35-30121-15 Hose, Fuel, Pump To Main Filter 1 "36-20 ENG-G35-D4I-10 Harness, Fuel Pressure Switch 1 "36-21 ENG-GT110-DIII24-265 Sensor, Fuel Pressure 1 "36-22 ENG-G35-D4i-4 Filter, Fuel Element Secondary (1.1L), Deutz 3.6L 1 "36-23 G35-30121-16 Hose, Fuel Filter To Engine 1 "36-24 21275 Belt, Cotton, Webbed, White, 1/8" 2 "36-25 12951344 Strap, Fuel Tank 2 "36-26 5/16-18 Nut, Flange Lock Hex 5/16-18 8 "36-27 12970431-50 Bracket, Fuel Tank Strap (part of frame) 1 "36-28 76958 Elbow, Adapter, 90 Degr., 8MJ-12MB90 - Opt 2 As Req'd36-29 G1-30198 Heater, Fuel, 24V - Opt 1 "36-30 G35-30151 Hose, Fuel Heater To Prefilter - Opt 1 "36-31 AS-10180 Boot, Cover Plug - Opt 1 "36-32 2615 Receptacle, Twistlock, Male, 30 A - 120V - Opt 1 "

AS-10178 Connector, Male, Flange, 240V - Opt 1 "36-33 G1-10092 Bracket, Mounting, 240 Plug - Opt 1 "36-34 WP2 Cover, Receptacle, Waterproof - Opt 1 "36-35 AS-10179 Connector, Cord, Female (Service Item) - Opt 1 "36-36 ------- Box, Heater Assembly - Opt 1 "

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CD400


Figure 2-37. Heater Box Assembly

1

1

2

3

4

5

6

7

8

9

10

11

16

1718

19

121315

121415

20

Coolant Heater

Battery Heater

Battery Heater

Steering PumpHeater

10

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4-2-71Orig

CD400


Table 2-37. Heater Box Assembly

Fig & Ind


37-1 A-865JFG Enclosure, Fiberglass 1 As Req'd37-2 ¼-20 x 1 Bolt, Hex Head, Ø ¼"-20 x 1" Long 4 "37-3 A-6P6 Panel, Back - Hoffman Box 1 "37-4 660-1-2252 Nut, Conduit Lock 141 6 "37-5 619934-15 Socket, 3 PDT Relay 1 "37-6 619934-05 Relay, 3 PDT, 7.5 Amp,120 VAC 1 "

RH3B-U-AC240V Relay, 3PDT, 10 Amp, 240 VAC 1 "37-7 619934-19 Spring, Relay Hold Down For 3 Pole 1 "37-8 RB6SN-L Ring, 16-14 AWG #6 15 "37-9 67487 Board, Terminal, 20 Amp, 6 Point 1 "37-10 2922NM Connector, STRT.1/2" Strain Relief 5 "37-11 15300027 Connector 1 "37-12 12015323 Seal, W eather, Green, 14-16GA 4 "37-13 12048159 Terminal 2 "37-14 12077411 Terminal Metri-Pack 2 "37-15 15300014 Lock, Secondary, Connector 2 "37-16 A10767X5 Connector, 2521 T-B 1 "37-17 AS-10180 Boot , Waterproof 1 "37-18 2615 Receptacle, Twistlock, Male, 30A, 1 "

AS-10178 Connector, Male, Flanged, 240 VAC 1 "37-19 G1-10092 Bracket, 240 Plug MTG 1 "37-20 WP2 Cover, Receptacle, Water Proof 1 "

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CD400


Figure 2-38. Transmission Installation

3

45

6

7

1 2

15

1617

18

18

17

1918

20

19

9

8

10 11

12 13

14

3123

25

2627

28

30

21

22

24

24

24

3332

34

35

36

38

37

29

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4-2-73Orig

CD400


Table 2-38. Transmission Installation

Fig & Ind


38-1 G35-30035 Transmission, 4WG190, ZF 1 1115 & Up38-2 0750131027 Breather 1 "38-3 G35-30013 Pump, Eaton Hydraulic 1 "38-4 G35-30015-7 Transmitter, Inductive, for Engine Speed 1 "38-5 G35-30015-9 Filter, Oil 1 "38-6 G35-30015-6 Switch, Difference Pressure (Tappet Switch) 1 "38-7 G35-30015-15 Transmitter, Speed 1 "38-8 G35-30015-7 Transmitter, Inductive (Intermediate Gear Train Speed) 1 "38-9 G35-30015-7 Transmitter, Inductive, for Turbine Speed 1 "38-10 G35-30033 Mount, Park Brake, FSG88 1 "38-11 G35-30121-6 Hose, Hydraulic (Manifold to Park Brake Caliper) 1 "38-12 G35-30015-3 Caliper, Park Brake 1 "38-13 G35-30015-5 Pad Kit, Parking Brake 1 "38-14 G35-30035-3 Screw, Yoke Retaining 2 "38-15 G35-30015-4 Disk, Brake 1 "38-16 ¾-16 Nut, Top Lock Hex ¾-16 2 "38-17 ¾ Washer, Flat ¾" ID 4 "38-18 SSB33-1000-4 Mount, 2-Piece, 1125 Lbs @ .03in. 2 "38-19 G35-30093-9 Mount, Transmission (Part of Frame) 2 "38-20 ¾-16 x 3 Bolt, Hex Head Ø ¾-16 x 3" Long 2 "38-21 G35-30003 Mount, Transmission, ZF 1 "38-22 G35-30121-13 Hose, Transmission, To Cooler,Top 1 "38-23 G35-30121-14 Hose, Transmission, To Cooler, Bottom 1 "38-24 G35-30102-1 Harness, Transmission 1 "38-25 76966 Elbow 90 Degree, Adapter 16MJ-16MB90 2 "38-26 G35-30015-12 Plug, Oil Drain 1 "38-27 G35-30015-13 O-Ring 1 "38-28 G35-30015-8 Sensor, Temperature 1 "38-29 G35-30132 Adapter, Torque Conv; ZF To Deutz Tier 4I 1 "38-30 G35-30131 Adapter, Flexplate Conv. ; ZF To Deutz Tier 4I 1 "38-31 G35-30015-18 Connector, Engine 1 "38-32 G35-30035-4 O-Ring, Front Output Yoke 1 "38-33 G35-30035-2 Washer, Yoke Retaining 1 "38-34 G35-30035-5 Yoke, Front Output 1 "38-35 G35-30035-6 Control Unit (for 4WG190, ZF) 1 "38-36 10/32 x 1 Screw, Countersunk Socket Head Ø 10/32 x 1" Long 4 "38-37 10/32 Nut, Lock 10/32 4 "38-38 G35-30034 Fitting, Park Brake Caliper 1 "

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Figure 2-39. Drive Shaft Installation

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Table 2-39. Drive Shaft Installation

Fig & Ind


39-1 G35-30087 Axle, Rigid, Dana 123 1 1115 & Up39-2 G35-30115 Drive Shaft, Rear, ZF/Dana 1 "39-3 ------ Washer, Lock, 3/8 Hi Alloy L/W YWZC 16 "39-4 ------ Bolt, Hex Head Ø 3/8-24 x 1¾" Long, G8 HHCS 16 "39-5 G35-30035 Transmission 4WG-190 1 "39-6 M10 Washer, Lock M10 16 "39-7 M10-1.25 x 45 Bolt, Hex Head Ø M10-1.25 x 45mm Long 16 "39-8 G35-30116 Drive Shaft, Front, ZF/Dana 1 "39-9 G35-30086 Axle, Steer, Dana 223 1 "

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Figure 2-40. Front Axle Assembly

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Table 2-40. Front Axle Assembly

Fig & Ind


40-1 G35-30086 Axle, Steer, Dana 223 1 1115 & Up40-2 G35-30121-22 Hose, Hydraulic (Brake Valve to Front Axle) 1 "40-3 GG108-NP06-14 Fitting, Aeroquip, 14mm-6MJ 2 "40-4 221501-6-4S Adapter, Connector, Swivel, 6FJ-4MJ 1 "40-5 G35-30093-13 Crossmember, Front Axle (Part of the Frame) 2 "40-6 203102-6-6S Tee, Swivel Flare 1 "40-7 12902827 Washer, Flat 1" SAE 8 "40-8 1 Washer, Lock 1" ID 4 "40-9 12902724 Nut, 1"-8NC, Lock, Hex, Grade 8, Zinc 4 "40-10 06-06-070221 Elbow, 6MJx6FJ90 Degr., Fitting 1 "40-11 G35-30121-25 Hose, Hydraulic (Brake Suplly Axles) 1 "40-12 G35-30121-21 Hose, Hydraulic (Steer Valve L to L/S Front Axle) 1 "40-13 TM1-ND-8003 Elbow, 90 Degr 1 "40-14 06-08-070120 Fitting, 6MJx8MB 1 "40-15 G35-30121-26 Hose, Hydraulic (Steer Valve R to R/S Front Axle) 1 "40-16 1-8 x 6 Bolt, Hex Head Ø 1-8 x 6" Long 4 "40-17 M22x1.5 Nut, Lug, 22 mm x 1.5 10 "

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Figure 2-41 Rear Axle Assembly

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Table 2-41. Rear Axle Assembly

Fig & Ind


41-1 G35-30087 Axle, Rigid, Dana 123 1 1115 & Up41-2 G35-30121-23 Hose, Hydraulic (Press.Switch To Rear Axle) 1 "41-3 203102-6-6S Tee, Adapter, Swivel Flare 1 "41-4 G35-30093-26 Gusset, Rear Axle, Outer 4 "41-5 G35-30002-3 Pad, Axle 2 "41-6 06-06-070221 Elbow, 6MJx6FJ-90° Fitting 1 "41-7 GG108-NP06-14 Fitting, Aeroquip, 14mm-6MJ 4 "41-8 12970431-31 Angle, Support 4 "41-9 12902724 Nut, 1"-8NC, Lock, Hex, Grade 8, Zinc 8 "41-10 G35-30121-25 Hose, Hydraulic (Brake Supply on Axle) 1 "41-11 MT-2-1026 Bolt, Cradle Pivot, 11" Long 2 8 "41-12 12970525 Pad, Axle - Rear 2 "41-13 12902827 Washer, Flat 1" ID SAE 16 "

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Figure 2-42. Hydraulic Assembly

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221917

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16

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3231

40

35

4746

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48

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24

3334

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41

42

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Table 2-42. Hydraulic Assembly

Fig & Ind


42-1 3AT30-2 Accumulator, 3000 psi, 1qt Size 2 1115 & Up42-2 3043T34 U-Bolt & Nuts, 2.5"X5/16-18 THD 2 "42-3 12970530 Bracket, Accumulator Mounting 1 "42-4 660-4-3524 Elbow, 90°, 4MJ-8MP90 2 "42-5 G35-30121-4 Hose, Hydr., Manifold To Top Accumulator 1 "42-6 G35-30121-3 Hose, Hydr., Manifold To Bottom Accumulator 1 "42-7 2083-8-8S Nipple, Pipe 2 "42-8 G35-30090 Manifold, Hydraulic, 4I 1 "42-9 76916 Adapter, Connector, 1/4" Tube, 4MJ-6MB 5 "42-10 06-08-070120 Fitting, 6MJ-8MB 2 "42-11 12872931 Tee, Adapter, Aeroquip 1 "42-12 12951213 Switch, Pressure, 800 PSIG 1 "42-13 2242-2-4S Adapter, Connector 1/8 Pipe To 7/16 JIC Female, 2FP-4FJX 1 "42-14 G35-30121-1 Hose, Hydr., Manifold To Steer Valve (P) 1 "42-15 G35-30121-8 Hose, Hydr., Manifold To Brake Valve (Front Serv. Brake) 1 "42-16 G35-30121-8 Hose, Hydr., Manifold To Brake Valve (Rear Serv. Brake) 1 "42-17 011714 Switch, Pressure, 50PSI 1 "42-18 2242-4-4S Adapter, 1/4"JIC to 1/4" Pipe 4FP-4FJX 1 "42-19 G35-30121-5 Hose, Hydr., Steer Valve (T) to Manifold Return 1 "42-20 76912 Adapter, Connector, 1/4" Tube, 4MJ-4MB 1 "42-21 G35-30121-27 Hose, Brake Valve to Manifold 1 "42-22 G35-30121-6 Hose, Hydr. Manifold/Park Brake Calipers 1 "42-23 76948 Adapter, Elbow 90 Degree, 4MJ-6MB90 1 "42-24 2071-4-4S Adapter, Elbow 90 Degree, 7/16 Tube, 4MJ-4FJX90 1 "42-25 2071-10-10S Adapter, Elbow 90 Degree, 10MJ-10FJX90 1 "

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Figure 2-42. Hydraulic Assembly (Cont'd)

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Table 2-42. Hydraulic Assembly (Cont'd)

Fig & Ind


42-26 76923 Adapter, Connector, 1/2" Tube, 8MJ-8MB 2 1115 & Up42-27 G35-30121-11 Hose, Hydr. Pump to Cooler 1 "42-28 G35-30121-10 Hose, Hydr. Manifold to Filter 1 "42-29 G35-30121-2 Hose, Hydr. Pump/Manifold, Supply 1 "42-30 08-10-070120 Fitting, Straight, 10MB-8MJ 1 "42-31 G35-30013 Pump, Eaton Hydraulic 1 "42-32 202702-24-16S Fitting, Straight, 24MB-16MJ 1 "42-33 ½ Washer, Flat ½" ID 4 "42-34 ½ Washer, Lock ½" ID 4 "42-35 76964 Elbow, 90°, 16MB-8MJ90 1 "42-36 96355 Bolt, Hex Head Ø ½-13 x 3½" Long 4 "42-37 G35-30121-7 Hose, Hydr. Tank to Pump 1 "42-38 EH-2802 Pad, Heater - 250 Watts, 120V - Opt. 1 As Req'd

EH-3202 Pad, Heater - 250 Watts, 220V - Opt. 1 "42-39 440E-98015 Decal, Dexron III 1 1115 & Up42-40 08-08-070102 Fitting, Straight, 8MP-8MJ 1 "42-41 G35-30121-12 Hose, Hydr., Cooler to Tank 1 1115 & Up42-42 G35-30121-9 Hose, Hydr., Filter to Tank 1 "42-43 HDW-10079 Fitting, Straight, 20MP-16MJ 1 "42-44 TM1-ND-6508 Elbow, Res. Outlet, 90°, 12MJ-12MP90 2 "42-45 78899 Adapter, Connector, Male 5/8"Tube OD JVCx ½" 1 "42-46 912950 Tank, Power Steering 1 "42-47 T6-4900-118 Bracket, Transmission Filter 1 "42-48 660-4-0010-10 Filter, Hydraulic, with Indicator 1 "

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Figure 2-43. Hydraulic Assembly With Emergency Pump Option

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9

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Table 2-43. Hydraulic Assembly With Emergency Pump Option

Fig & Ind


43-1 3AT30-2 Accumulator, 3000 psi, 1qt Size 2 1115 & Up43-2 3043T34 U-Bolt & Nuts, 2.5"X5/16-18 THD 2 "43-3 12970530 Bracket, Accumulator Mounting 1 "43-4 660-4-3524 Elbow, 90°, 4MJ-8MP90 2 "43-5 G35-30121-4 Hose, Hydr., Manifold To Top Accumulator 1 "43-6 G35-30121-3 Hose, Hydr., Manifold To Bottom Accumulator 1 "43-7 2083-8-8S Nipple, Pipe 2 "43-8 G35-30090 Manifold, Hydraulic, 4I 1 "43-9 76916 Adapter, Connector, 1/4" Tube, 4MJ-6MB 5 "43-10 06-08-070120 Fitting, 6MJ-8MB 2 "43-11 12872931 Tee, Adapter, Aeroquip 1 "43-12 12951213 Switch, Pressure, 800 PSIG 1 "43-13 2242-2-4S Adapter, Connector 1/8 Pipe To 7/16 JIC Female, 2FP-4FJX 1 "43-14 G35-30121-1 Hose, Hydr., Manifold To Steer Valve (P) 1 "43-15 G35-30121-8 Hose, Hydr., Manifold To Brake Valve (Front Serv. Brake) 1 "43-16 G35-30121-8 Hose, Hydr., Manifold To Brake Valve (Rear Serv. Brake) 1 "43-17 011714 Switch, Pressure, 50PSI 1 "43-18 2242-4-4S Adapter, 1/4"JIC to 1/4" Pipe 4FP-4FJX 1 "43-19 G35-30121-5 Hose, Hydr., Steer Valve (T) to Manifold Return 1 "43-20 76912 Adapter, Connector, 1/4" Tube, 4MJ-4MB 1 "43-21 G35-30121-27 Hose, Brake Valve to Manifold 1 "43-22 G35-30121-6 Hose, Hydr. Manifold/Park Brake Calipers 1 "43-23 76948 Adapter, Elbow 90 Degree, 4MJ-6MB90 1 "43-24 2071-4-4S Adapter, Elbow 90 Degree, 7/16 Tube, 4MJ-4FJX90 1 "43-25 2071-10-10S Adapter, Elbow 90 Degree, 10MJ-10FJX90 1 "

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Figure 2-43. Hydraulic Assembly With Emergency Pump Option (Cont'd)

21

2022

7

34

65

8

18

9

101112

1314

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3231

40

35

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Table 2-43. Hydraulic Assembly With Emergency Pump Option (Cont'd)

Fig & Ind


43-26 76923 Adapter, Connector, 1/2" Tube, 8MJ-8MB 2 1115 & Up43-27 G35-30121-11 Hose, Hydr. Pump to Cooler 1 "43-28 G35-30121-10 Hose, Hydr. Manifold to Filter 1 "43-29 G35-30121-2 Hose, Hydr. Pump/Manifold, Supply 1 "43-30 08-10-070120 Fitting, Straight, 10MB-8MJ 1 "43-31 G35-30013 Pump, Eaton Hydraulic 1 "43-32 202702-24-16S Fitting, Straight, 24MB-16MJ 1 "43-33 ½ Washer, Flat ½" ID 4 "43-34 ½ Washer, Lock ½" ID 4 "43-35 76964 Elbow, 90°, 16MB-8MJ90 1 "43-36 96355 Bolt, Hex Head Ø ½-13 x 3½" Long 4 "43-37 G35-30121-7 Hose, Hydr. Tank to Pump 1 "43-38 EH-2802 Pad, Heater - 250 Watts, 120V - Opt. 1 As Req'd

EH-3202 Pad, Heater - 250 Watts, 220V - Opt. 1 "43-39 440E-98015 Decal, Dexron III 1 1115 & Up43-40 08-08-070102 Fitting, Straight, 8MP-8MJ 1 "43-41 G35-10082 Hose, Steering (Tank To Emergency Pump)-Opt 1 As Req'd43-42 203102-8-8S Tee, Adapter, Swivel Flare, 8MJ-8FJX-8MJ "43-43 G35-30121-12 Hose, Hydr., Cooler to Tank 1 1115 & Up43-44 G35-30121-9 Hose, Hydr., Filter to Tank 1 "43-45 HDW-10079 Fitting, Straight, 20MP-16MJ 1 "43-46 TM1-ND-6508 Elbow, Res. Outlet, 90°, 12MJ-12MP9

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