Tug - 660e

MODEL 660E ELECTRIC
MOBILE BELT CONVEYOR
OPERATION, MAINTENANCE
& PARTS MANUAL
ORIGINALLY ISSUED AUGUST 1995
Introduction 660E Mobile Electric Conveyor
NOTE: The information contained in this publication is intended

Note exclusively for the use of TUG and its customers. Disclosure to non-TUG
customers may result in legal action by TUG.
NOTE: The information contained in this document is intended to be

accurate and up to date at the time of original issue. TUG reserves the
Note right to update the information in this document, without warning, as
deemed prudent or necessary by TUG.
INTRO-ii CD315
Rev 4
660E Mobile Electric Conveyor Introduction
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. TUG assumes
no liability for personal injury or equipment failure due to any operation performed without heed to manual
revisions.
Date of original publication: August 1995
Revision Number Date Brief Description
1 April 1996 N/A
2 January 2002 N/A
3 July 2003 Format change / New info added
September 2007 Format change / IPL Changes

4
CD315 INTRO-iii
Rev 4
LIST OF EFFECTIVE PAGES
Chapter-Section Page Revision Chapter-Section Page Revision

INTRO- 1 Rev 4 SAFETY- 6 Rev 3
INTRO- 2 Rev 4
INTRO- 3 Rev 4 1-TOC- 1 Rev 4
INTRO- 4 Rev 4 1-TOC- 2 Rev 4
INTRO- 5 Rev 4
INTRO- 6 Rev 4 1-1- 1 Rev 4
INTRO- 10 Rev 4 1-1- 5 Rev 4
INTRO- 11 Rev 4 1-1- 6 Rev 4
INTRO- 12 Rev 4
INTRO- 13 Rev 4 1-2- 1 Rev 4
INTRO- 14 Rev 4 1-2- 2 Rev 4
INTRO- 15 Rev 4 1-2- 3 Rev 4
INTRO- 16 Rev 4 1-2- 4 Rev 4
INTRO- 17 Rev 4 1-2- 5 Rev 4
INTRO- 18 Rev 4 1-2- 6 Rev 4
INTRO- 19 Rev 4 1-2- 7 Rev 4
INTRO- 20 Rev 4 1-2- 8 Rev 4
INTRO- 21 Rev 4 1-2- 9 Rev 4
INTRO- 22 Rev 4 1-2- 10 Rev 4
INTRO- 23 Rev 4 1-2- 11 Rev 4
INTRO- 24 Rev 4 1-2- 12 Rev 4
INTRO- 25 Rev 4
INTRO- 26 Rev 4 1-3- 1 Rev 4
INTRO- 27 Rev 4 1-3- 2 Rev 4
INTRO- 28 Rev 4 1-3- 3 Rev 4
INTRO- 29 Rev 4 1-3- 4 Rev 4
INTRO- 30 Rev 4 1-3- 5 Rev 4
1-3- 6 Rev 4
SAFETY- 1 Rev 4
SAFETY- 2 Rev 3 1-4- 1 Rev 4
INTRO-iv CD315
Rev 4
1-5- 1 Rev 4 2-2- 8 Rev 4

1-5- 2 Rev 4 2-2- 9 Rev 4
1-5- 3 Rev 4 2-2- 10 Rev 4
1-5- 4 Rev 4 2-2- 11 Rev 3
2-2- 12 Rev 3
1-6- 1 Rev 4 2-2- 13 Rev 3
1-6- 2 Rev 4 2-2- 14 Rev 3
1-6- 3 Rev 4 2-2- 15 Rev 3
1-6- 4 Rev 4 2-2- 16 Rev 3
1-6- 5 Rev 4 2-2- 17 Rev 3
1-6- 6 Rev 4 2-2- 18 Rev 3
2-2- 19 Rev 3
2-TOC- 1 Rev 4 2-2- 20 Rev 3
2-TOC- 2 Rev 4 2-2- 21 Rev 3
2-TOC- 3 Rev 4 2-2- 22 Rev 3
2-TOC- 4 Rev 4 2-2- 23 Rev 3
2-2- 24 Rev 3
2-1- 1 Rev 4 2-2- 25 Rev 3
2-1- 2 Rev 4 2-2- 26 Rev 3
2-1- 3 Rev 4 2-2- 27 Rev 3
2-1- 4 Rev 4 2-2- 28 Rev 3
2-1- 5 Rev 4 2-2- 29 Rev 3
2-1- 6 Rev 4 2-2- 30 Rev 4
2-1- 7 Rev 4 2-2- 31 Rev 4
2-1- 8 Rev 4 2-2- 32 Rev 4
2-1- 9 Rev 4 2-2- 33 Rev 4
2-1- 10 Rev 4 2-2- 34 Rev 4
2-1- 11 Rev 4 2-2- 35 Rev 4
2-1- 12 Rev 4 2-2- 36 Rev 4
2-2- 37 Rev 4
2-2- 1 Rev 4 2-2- 38 Rev 4
2-2- 2 Rev 4 2-2- 39 Rev 4
2-2- 3 Rev 4 2-2- 40 Rev 4
2-2- 4 Rev 4 2-2- 41 Rev 4
2-2- 5 Rev 4 2-2- 42 Rev 4
2-2- 6 Rev 4 2-2- 43 Rev 4
2-2- 7 Rev 4 2-2- 44 Rev 4
CD315 INTRO-v
Rev 4
2-2- 45 Rev 4
2-2- 46 Rev 4 3-2- 1 Rev 3
2-2- 47 Rev 4 3-2- 2 Rev 3
2-2- 48 Rev 4
2-2- 49 Rev 4 3-3- 1 Rev 3
2-2- 50 Rev 4 3-3- 2 Rev 3
3-3- 3 Rev 3
2-3- 1 Rev 3 3-3- 4 Rev 3
2-3- 2 Rev 3 3-3- 5 Rev 3
2-3- 3 Rev 3 3-3- 6 Rev 3
2-3- 4 Rev 4 3-3- 7 Rev 3
2-3- 5 Rev 4 3-3- 8 Rev 3
2-3- 6 Rev 4 3-3- 9 Rev 3
2-3- 7 Rev 4 3-3- 10 Rev 3
2-3- 8 Rev 4 3-3- 11 Rev 3
2-3- 9 Rev 4 3-3- 12 Rev 3
2-3- 10 Rev 4 3-3- 13 Rev 3
2-3- 11 Rev 4 3-3- 14 Rev 3
2-3- 12 Rev 4 3-3- 15 Rev 3
3-3- 16 Rev 3
2-4- 1 Rev 3 3-3- 17 Rev 3
2-4- 2 Rev 3 3-3- 18 Rev 3
2-4- 3 Rev 3
2-4- 4 Rev 3 3-4- 1 Rev 3
2-4- 5 Rev 3 3-4- 2 Rev 3
2-4- 6 Rev 3 3-4- 3 Rev 3
3-4- 4 Rev 3
2-5- 1 Rev 3 3-4- 5 Rev 3
2-5- 2 Rev 3 3-4- 6 Rev 3
3-4- 7 Rev 3
3-TOC- 1 Rev 4 3-4- 8 Rev 3
3-TOC- 2 Rev 4 3-4- 9 Rev 3
3-TOC- 3 Rev 4 3-4- 10 Rev 3
3-TOC- 4 Rev 4
3-5- 1 Rev 3
3-1- 1 Rev 3 3-5- 2 Rev 3
3-1- 2 Rev 3 3-5- 3 Rev 3
INTRO-vi CD315
Rev 4
3-5- 4 Rev 3 4-2- 5 Rev 4

3-5- 5 Rev 3 4-2- 6 Rev 3
3-5- 6 Rev 3 4-2- 7 Rev 3
3-5- 7 Rev 3 4-2- 8 Rev 4
3-5- 8 Rev 3 4-2- 9 Rev 4
3-5- 9 Rev 3 4-2- 10 Rev 3
3-5- 10 Rev 3 4-2- 11 Rev 4
3-5- 11 Rev 3 4-2- 12 Rev 4
3-5- 12 Rev 3 4-2- 13 Rev 4
4-2- 14 Rev 4
3-6- 1 Rev 3 4-2- 15 Rev 4
3-6- 2 Rev 3 4-2- 16 Rev 4
3-6- 3 Rev 3 4-2- 17 Rev 4
3-6- 4 Rev 3 4-2- 18 Rev 3
3-6- 5 Rev 3 4-2- 19 Rev 4
3-6- 6 Rev 3 4-2- 20 Rev 3
3-6- 7 Rev 3 4-2- 21 Rev 4
3-6- 8 Rev 3 4-2- 22 Rev 3
4-2- 23 Rev 4
4-TOC- 1 Rev 4 4-2- 24 Rev 4
4-TOC- 2 Rev 4 4-2- 25 Rev 4
4-TOC- 3 Rev 4 4-2- 26 Rev 4
4-TOC- 4 Rev 4 4-2- 27 Rev 4
4-2- 28 Rev 4
4-1- 1 Rev 4 4-2- 29 Rev 4
4-1- 2 Rev 4 4-2- 30 Rev 4
4-1- 3 Rev 4 4-2- 31 Rev 4
4-1- 4 Rev 4 4-2- 32 Rev 3
4-1- 5 Rev 4 4-2- 33 Rev 3
4-1- 6 Rev 4 4-2- 34 Rev 3
4-1- 7 Rev 4 4-2- 35 Rev 4
4-1- 8 Rev 4 4-2- 36 Rev 4
4-2- 37 Rev 4
4-2- 1 Rev 4 4-2- 38 Rev 3
4-2- 2 Rev 4 4-2- 39 Rev 3
4-2- 3 Rev 4 4-2- 40 Rev 3
4-2- 4 Rev 4 4-2- 41 Rev 4
CD315 INTRO-vii
Rev 4
4-2- 42 Rev 3 4-2- 79 Rev 4

4-2- 43 Rev 3 4-2- 80 Rev 3
4-2- 44 Rev 3 4-2- 81 Rev 3
4-2- 45 Rev 3 4-2- 82 Rev 3
4-2- 46 Rev 3 4-2- 83 Rev 4
4-2- 47 Rev 4 4-2- 84 Rev 3
4-2- 48 Rev 4 4-2- 85 Rev 4
4-2- 49 Rev 4 4-2- 86 Rev 4
4-2- 50 Rev 3 4-2- 87 Rev 4
4-2- 51 Rev 3 4-2- 88 Rev 3
4-2- 52 Rev 3 4-2- 89 Rev 4
4-2- 53 Rev 3 4-2- 90 Rev 3
4-2- 54 Rev 4 4-2- 91 Rev 4
4-2- 55 Rev 4 4-2- 92 Rev 4
4-2- 56 Rev 3 4-2- 93 Rev 4
4-2- 57 Rev 3 4-2- 94 Rev 3
4-2- 58 Rev 3 4-2- 95 Rev 3
4-2- 59 Rev 3 4-2- 96 Rev 3
4-2- 60 Rev 3 4-2- 97 Rev 4
4-2- 61 Rev 4 4-2- 98 Rev 4
4-2- 62 Rev 3 4-2- 99 Rev 4
4-2- 63 Rev 4 4-2- 100 Rev 3
4-2- 64 Rev 4 4-2- 101 Rev 3
4-2- 65 Rev 4 4-2- 102 Rev 4
4-2- 66 Rev 4 4-2- 103 Rev 4
4-2- 67 Rev 4 4-2- 104 Rev 3
4-2- 68 Rev 3 4-2- 105 Rev 4
4-2- 69 Rev 4 4-2- 106 Rev 3
4-2- 70 Rev 4 4-2- 107 Rev 4
4-2- 71 Rev 4 4-2- 108 Rev 4
4-2- 72 Rev 3 4-2- 109 Rev 4
4-2- 73 Rev 3 4-2- 110 Rev 3
4-2- 74 Rev 3 4-2- 111 Rev 4
4-2- 75 Rev 3 4-2- 112 Rev 3
4-2- 76 Rev 3 4-2- 113 Rev 3
4-2- 77 Rev 3 4-2- 114 Rev 3
4-2- 78 Rev 3 4-2- 115 Rev 4
INTRO-viii CD315
Rev 4
4-2- 116 Rev 4 4-2- 153 Rev 4

4-2- 117 Rev 4 4-2- 154 Rev 4
4-2- 118 Rev 3 4-2- 155 Rev 4
4-2- 119 Rev 4 4-2- 156 Rev 3
4-2- 120 Rev 3 4-2- 157 Rev 3
4-2- 121 Rev 3 4-2- 158 Rev 3
4-2- 122 Rev 3 4-2- 159 Rev 4
4-2- 123 Rev 3 4-2- 160 Rev 3
4-2- 124 Rev 3 4-2- 161 Rev 4
4-2- 125 Rev 3 4-2- 162 Rev 3
4-2- 126 Rev 3 4-2- 163 Rev 4
4-2- 127 Rev 3 4-2- 164 Rev 4
4-2- 128 Rev 3 4-2- 165 Rev 4
4-2- 129 Rev 3 4-2- 166 Rev 3
4-2- 130 Rev 3 4-2- 167 Rev 4
4-2- 131 Rev 3 4-2- 168 Rev 4
4-2- 132 Rev 3 4-2- 169 Rev 4
4-2- 133 Rev 3 4-2- 170 Rev 3
4-2- 134 Rev 3 4-2- 171 Rev 4
4-2- 135 Rev 4 4-2- 172 Rev 4
4-2- 136 Rev 3 4-2- 173 Rev 4
4-2- 137 Rev 4 4-2- 174 Rev 4
4-2- 138 Rev 4 4-2- 175 Rev 4
4-2- 139 Rev 4 4-2- 176 Rev 4
4-2- 140 Rev 3 4-2- 177 Rev 4
4-2- 141 Rev 4 4-2- 178 Rev 4
4-2- 142 Rev 4 4-2- 179 Rev 4
4-2- 143 Rev 4 4-2- 180 Rev 4
4-2- 144 Rev 3 4-2- 181 Rev 4
4-2- 145 Rev 4 4-2- 182 Rev 3
4-2- 146 Rev 4 4-2- 183 Rev 3
4-2- 147 Rev 4 4-2- 184 Rev 3
4-2- 148 Rev 4 4-2- 185 Rev 3
4-2- 149 Rev 4 4-2- 186 Rev 3
4-2- 150 Rev 4 4-2- 187 Rev 3
4-2- 151 Rev 4 4-2- 188 Rev 4
4-2- 152 Rev 3 4-2- 189 Rev 4
CD315 INTRO-ix
Rev 4
4-2- 190 Rev 4 4-3- 1 Rev 4

4-2- 191 Rev 4 4-3- 2 Rev 4
4-2- 192 Rev 3 4-3- 3 Rev 4
4-2- 193 Rev 3 4-3- 4 Rev 4
4-2- 194 Rev 3 4-3- 5 Rev 4
4-2- 195 Rev 3 4-3- 6 Rev 4
4-2- 196 Rev 3 4-3- 7 Rev 4
4-2- 197 Rev 4 4-3- 8 Rev 4
4-2- 198 Rev 4 4-3- 9 Rev 4
4-2- 199 Rev 4 4-3- 10 Rev 4
4-2- 200 Rev 3 4-3- 11 Rev 4
4-2- 201 Rev 4 4-3- 12 Rev 4
4-2- 202 Rev 3 4-3- 13 Rev 4
4-2- 203 Rev 4 4-3- 14 Rev 4
4-2- 204 Rev 3 4-3- 15 Rev 4
4-2- 205 Rev 4 4-3- 16 Rev 4
4-2- 206 Rev 3 4-3- 17 Rev 4
4-2- 207 Rev 3 4-3- 18 Rev 4
4-2- 208 Rev 3 4-3- 19 Rev 4
4-2- 209 Rev 4 4-3- 20 Rev 4
4-2- 210 Rev 4 4-3- 21 Rev 4
4-2- 211 Rev 4 4-3- 22 Rev 4
4-2- 212 Rev 3 4-3- 23 Rev 4
4-2- 213 Rev 4 4-3- 24 Rev 4
4-2- 214 Rev 4 4-3- 25 Rev 4
4-2- 215 Rev 4 4-3- 26 Rev 4
4-2- 216 Rev 4 4-3- 27 Rev 4
4-2- 217 Rev 4 4-3- 28 Rev 4
4-2- 218 Rev 4 4-3- 29 Rev 4
4-2- 219 Rev 4 4-3- 30 Rev 4
4-2- 220 Rev 4 4-3- 31 Rev 4
4-2- 221 Rev 4 4-3- 32 Rev 4
4-2- 222 Rev 3 4-3- 33 Rev 4
4-2- 223 Rev 3 4-3- 34 Rev 4
4-2- 224 Rev 3 4-3- 35 Rev 4
4-3- 36 Rev 4
4-3- 37 Rev 4
INTRO-x CD315
Rev 4
4-3- 38 Rev 4 4-4- 24 Rev 4

4-3- 39 Rev 4 4-4- 25 Rev 4
4-3- 40 Rev 4 4-4- 26 Rev 4
4-3- 41 Rev 4 4-4- 27 Rev 4
4-3- 42 Rev 4 4-4- 28 Rev 4
4-3- 43 Rev 4 4-4- 29 Rev 4
4-3- 44 Rev 4 4-4- 30 Rev 4
4-3- 45 Rev 4 4-4- 31 Rev 4
4-3- 46 Rev 4 4-4- 32 Rev 4
4-3- 47 Rev 4 4-4- 33 Rev 4
4-3- 48 Rev 4 4-4- 34 Rev 4
4-3- 49 Rev 4 4-4- 35 Rev 4
4-3- 50 Rev 4 4-4- 36 Rev 4
4-4- 37 Rev 4
4-4- 1 Rev 4 4-4- 38 Rev 4
4-4- 2 Rev 4 4-4- 39 Rev 4
4-4- 3 Rev 4 4-4- 40 Rev 4
4-4- 4 Rev 4 4-4- 41 Rev 4
4-4- 5 Rev 4 4-4- 42 Rev 4
4-4- 6 Rev 4 4-4- 43 Rev 4
4-4- 7 Rev 4 4-4- 44 Rev 4
4-4- 8 Rev 4 4-4- 45 Rev 4
4-4- 9 Rev 4 4-4- 46 Rev 4
4-4- 10 Rev 4 4-4- 47 Rev 4
4-4- 11 Rev 4 4-4- 48 Rev 4
4-4- 12 Rev 4 4-4- 49 Rev 4
4-4- 13 Rev 4 4-4- 50 Rev 4
4-4- 14 Rev 4
4-4- 15 Rev 4 5-TOC- 1 Rev 4
4-4- 16 Rev 4 5-TOC- 2 Rev 4
4-4- 17 Rev 4
4-4- 18 Rev 4 5-1- 1 Rev 4
4-4- 19 Rev 4 5-1- 2 Rev 4
4-4- 20 Rev 4
4-4- 21 Rev 4 5-2- 1 Rev 4
4-4- 22 Rev 4 5-2- 2 Rev 4
4-4- 23 Rev 4
CD315 INTRO-xi
Rev 4
MANUAL TABLE OF CONTENTS
Front Matter
RECORD OF REVISIONS ................................................................................................... INTRO-III
LIST OF EFFECTIVE PAGES ............................................................................................ INTRO-IV
MANUAL TABLE OF CONTENTS .................................................................................... INTRO-XII
COPYRIGHT NOTICE .................................................................................................... INTRO-XXIII
INTRODUCTION ........................................................................................................... INTRO-XXIV
UNIT IDENTIFICATION .................................................................................................. INTRO-XXV
MODEL NUMBER CODING OF MOBILE BELT LOADERS ...................................... INTRO-XXVI
TECHNICAL ASSISTANCE .......................................................................................... INTRO-XXVII
WARRANTY POLICY STATEMENT ........................................................................... INTRO-XXVIII
HOW TO USE THIS MANUAL ....................................................................................... INTRO-XXX
SAFETY ............................................................................................................................... SAFETY-I

A. Discussion ..................................................................................................... SAFETY-i
B. Safety Features ............................................................................................. SAFETY-i
C. Operator Responsibilities ............................................................................. SAFETY-iii
D. Mechanic Responsibilities ........................................................................... SAFETY-iv
E. Available Safety Items as Extra Cost Options ............................................. SAFETY-vi
Chapter 1: General Information and Operating Instructions

SECTION 1: GENERAL DESCRIPTION .................................................................................. 1-1-1
A. Application ............................................................................................................ 1-1-1
B. Drive Train / Power Package ................................................................................ 1-1-1
1. Drive Train ................................................................................................. 1-1-1
2. Sevcon MCM or PowerpaK Electric Controller ......................................... 1-1-2
3. Battery ...................................................................................................... 1-1-2
C. Chassis ................................................................................................................ 1-1-3
D. Body Panels ......................................................................................................... 1-1-3
E. Electric Conveyor Mechanism (Up to S/N 510) .................................................... 1-1-4
F. Hydraulic System .................................................................................................. 1-1-5
G. Electrical System .................................................................................................. 1-1-6
INTRO-xii CD315
Rev 4
SECTION 2: OPERATION ......................................................................................................... 1-2-1

A. Instrument Panel Operation (Up to S/N 254) ........................................................ 1-2-1
B. Instrument Panel Operation (S/N 254 and Up) ..................................................... 1-2-3
C. Maneuvering Controls ........................................................................................... 1-2-6
1. Steering Wheel ......................................................................................... 1-2-6
2. Service Brake Pedal ................................................................................. 1-2-6
3. Foot Throttle .............................................................................................. 1-2-6
4. Turn Signal ................................................................................................ 1-2-7
5. Hand Throttle (Up to S/N 254) ................................................................... 1-2-7
6. Drive Direction Selector ............................................................................ 1-2-7
7. Park Brake ................................................................................................ 1-2-8
D. Conveyor Controls ................................................................................................ 1-2-8
E. 12V Electrical Supply Panel .................................................................................. 1-2-8
F. Preliminary Checks .............................................................................................. 1-2-9
1. Battery ...................................................................................................... 1-2-9
2. Tire Inflation ............................................................................................... 1-2-9
3. Hydraulic Oil Level .................................................................................... 1-2-9
4. Brakes ...................................................................................................... 1-2-9
5. Vehicle Drive ............................................................................................. 1-2-9
6. Front Lift Cylinder ...................................................................................... 1-2-9
7. Rear Lift Cylinder ...................................................................................... 1-2-9
8. Conveyor Belt Drive ................................................................................ 1-2-10
G. Operation Procedures ........................................................................................ 1-2-10
H. Conveyor Safety Props ....................................................................................... 1-2-11
SECTION 3: SPECIFICATIONS ................................................................................................ 1-3-1

A. Dimensions .......................................................................................................... 1-3-1
B. Performance ......................................................................................................... 1-3-1
C. Electrical Controls ................................................................................................ 1-3-1
D. Heights and Angles ............................................................................................... 1-3-2
E. Safety Features .................................................................................................... 1-3-4
1. Shifter/Hand Throttle Interlock (MCM Electric Controller Only) ................. 1-3-4
2. Main Power Ignition Switch ....................................................................... 1-3-4
3. Electric Belt Brake (Up to S/N 510) ........................................................... 1-3-4
4. Side/Hand Rails ........................................................................................ 1-3-4
5. Finger Guard ............................................................................................. 1-3-4
6. Shifter Guard ............................................................................................. 1-3-4
7. Safety Props ............................................................................................. 1-3-4
CD315 INTRO-xiii
Rev 4
8. Parking Brake ........................................................................................... 1-3-5

9. Parking Brake Power Diverter Switch ....................................................... 1-3-5
10. Pilot Operated Hydraulic Holding Valves ................................................... 1-3-5
11. Grit Paper .................................................................................................. 1-3-5
SECTION 4: SHIPPING .............................................................................................................. 1-4-1

A. Introduction ........................................................................................................... 1-4-1
B. Preparation for Shipment ...................................................................................... 1-4-1
C. Receiving .............................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................. 1-5-1

A. Introduction ........................................................................................................... 1-5-1
B. Short Term Storage ............................................................................................... 1-5-1
C. Extended Storage ................................................................................................. 1-5-1
SECTION 6: BATTERY CHARGING CYCLES ......................................................................... 1-6-1

A. Discussion ............................................................................................................ 1-6-1
B. Equalize Charging Procedures ............................................................................. 1-6-4
Chapter 2: Maintenance
SECTION 1: SERVICING .......................................................................................................... 2-1-1
A. Preparation for Use ............................................................................................... 2-1-1
1. Battery ...................................................................................................... 2-1-1
2. Tire Inflation ............................................................................................... 2-1-1
4. Brakes ...................................................................................................... 2-1-1
5. Vehicle Drive ............................................................................................. 2-1-1
8. Conveyor Belt Drive .................................................................................. 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily .......................................................................................................... 2-1-2
2. Weekly or at 50 Hours .............................................................................. 2-1-3
3. Monthly or 200 Hours ................................................................................ 2-1-3
4. Every Two (2) Months or 400 Hours ......................................................... 2-1-4
5. Every Six (6) Months or 1200 Hours ......................................................... 2-1-4
6. Yearly or 2400 Hours ................................................................................. 2-1-4
INTRO-xiv CD315
Rev 4
C. Lubrication ............................................................................................................ 2-1-5

D. Belt Drive Reduction Gear Box Lubrication and Maintenance .............................. 2-1-9
E. Instructions for Jacking and Positioning Vehicle ................................................. 2-1-10
F. Accelerator Cable Adjustment ............................................................................ 2-1-11
1. Accelerator .............................................................................................. 2-1-11
G. Park Brake Adjustment ....................................................................................... 2-1-11
1. Discussion .............................................................................................. 2-1-11
2. Procedure ............................................................................................... 2-1-11
SECTION 2: TROUBLESHOOTING ......................................................................................... 2-2-1

A. 72/80 Volt Systems ............................................................................................... 2-2-2
B. Hydraulic Systems ................................................................................................ 2-2-4
C. Service Brakes ..................................................................................................... 2-2-5
D. Parking Brake ....................................................................................................... 2-2-7
E. Conveyor Lifts ....................................................................................................... 2-2-8
F. Conveyor Belt ....................................................................................................... 2-2-9
G. Electrical Schematics and Wiring Diagrams ...................................................... 2-2-11
Figure 2-1. Wiring Diagram, 660E (Up to S/N 254) ........................................... 2-2-11
Figure 2-3. Wiring Diagram, 660E (S/N 254 thru 389) (Sheet 1 of 2) ................ 2-2-13
Figure 2-4. Wiring Diagram, 660E (S/N 390 and Up) (Sheet 1 of 2) .................. 2-2-15
Figure 2-10. 660E Conveyor Switch Harness - Right Front ............................... 2-2-27
Figure 2-11. 660E Conveyor Switch Harness - Left Front ................................. 2-2-28
Figure 2-12. 660E Hydraulic Schematic ............................................................ 2-2-29
Figure 2-13. Wiring Diagram, 660E (S/N 510 and Up) (Sheet 1 of 4) ................ 2-2-30
CD315 INTRO-xv
Rev 4
Figure 2-17. UAL-Wiring Diagram, 660E (S/N 874 and Up) (Sheet 1 of 4) ........ 2-2-46
SECTION 3: REMOVAL/INSTALLATION ................................................................................... 2-3-1

A. Rear Axle Removal ............................................................................................... 2-3-1
B. Rear Axle Installation ............................................................................................. 2-3-2
C. Front Axle Removal ............................................................................................... 2-3-2
D. Front Axle Installation ............................................................................................ 2-3-2
E. Conveyor Removal / Installation ........................................................................... 2-3-3
F. Conveyor Belt Drive Motor Removal ..................................................................... 2-3-3
G. Conveyor Belt Drive Motor Installation .................................................................. 2-3-4
H. Holding Valve Removal ......................................................................................... 2-3-4
I. Holding Valve Installation ....................................................................................... 2-3-5
J. Lift Cylinders Control Valve Removal .................................................................... 2-3-5
K. Lift Cylinders Control Valve Installation ................................................................. 2-3-6
L. Front Lift Cylinder Removal .................................................................................. 2-3-6
M. Lift Cylinder Installation ......................................................................................... 2-3-7
N. Rear Lift Cylinder Removal ................................................................................... 2-3-7
O. Rear Lift Cylinder Installation ................................................................................ 2-3-8
P. Hydraulic Pump Removal ..................................................................................... 2-3-8
Q. Hydraulic Pump Installation................................................................................... 2-3-9
INTRO-xvi CD315
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R. Hydraulic Pump Motor Removal / Installation ....................................................... 2-3-9

S. Hydraulic Pump Motor Brushes Inspection / Replacement .................................. 2-3-9
T. Drive Motor Brush Inspection / Replacement ..................................................... 2-3-10
U. Drive Motor Removal .......................................................................................... 2-3-10
V. Drive Motor Installation ........................................................................................ 2-3-11
W. Drive Reduction Gear Box Removal ................................................................... 2-3-11
X. Drive Reduction Gear Box Installation ................................................................ 2-3-11
SECTION 4: BELT TRACKING INSTRUCTIONS .................................................................... 2-4-1

A. Discussion ............................................................................................................ 2-4-1
B. Procedure ............................................................................................................. 2-4-2
SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS .......................................... 2-5-1
Chapter 3: Overhaul
SECTION 1: RECOMMENDED OVERHAUL PERIODS ......................................................... 3-1-1
A. General ................................................................................................................. 3-1-1
B. Hydraulic Cylinders ............................................................................................... 3-1-1
C. Hydraulic Pump .................................................................................................... 3-1-1
D. Other Components ............................................................................................... 3-1-1
SECTION 2: STEER AXLE ........................................................................................................ 3-2-1

A. Discussion ............................................................................................................ 3-2-1
B. Inspection and Overhaul ....................................................................................... 3-2-1
1. Bearings and Seals................................................................................... 3-2-1
2. Ball Joints .................................................................................................. 3-2-2
3. Connecting Rod Ends ............................................................................... 3-2-2
SECTION 3: REAR AXLE .......................................................................................................... 3-3-1

A. Description ........................................................................................................... 3-3-1
B. Removal and Installation ....................................................................................... 3-3-1
1. Rear Axle Shaft Removal and Disassembly ............................................. 3-3-1
2. Rear Axle Shaft Assembly and Installation ................................................ 3-3-3
C. Disassembly and Assembly ................................................................................. 3-3-3
1. Disassembly ............................................................................................. 3-3-3
2. Differential Case ....................................................................................... 3-3-7
CD315 INTRO-xvii
Rev 4
3. Pinion Bearing Cups ............................................................................... 3-3-11

4. Depth Gauge Check ............................................................................... 3-3-12
5. Pinion Bearing Preload ........................................................................... 3-3-13
6. Assembly of Differential into Housing ..................................................... 3-3-15
D. Specifications ..................................................................................................... 3-3-18
1. Dana Axle Adjustments ........................................................................... 3-3-18
2. Dana Axle Torque Limits ......................................................................... 3-3-18
SECTION 4: REAR WHEEL DRUM BRAKES .......................................................................... 3-4-1

A. Adjustments .......................................................................................................... 3-4-1
1. Brake Shoe Adjustment ............................................................................ 3-4-1
2. Manual Adjustment .................................................................................... 3-4-2
1. Rear Brake Drum ..................................................................................... 3-4-4
2. Brake Wheel Cylinder ............................................................................... 3-4-5
3. Rear Brake Backing Plate ......................................................................... 3-4-6
2. Master Cylinder ......................................................................................... 3-4-8
1. Wheel Torque Limits ............................................................................... 3-4-10
2. Special Tools ........................................................................................... 3-4-10
SECTION 5: FRONT WHEEL DISC BRAKES ......................................................................... 3-5-1

A. Brake Pad Replacement ...................................................................................... 3-5-1
1. Preparation ............................................................................................... 3-5-1
2. Caliper Removal ....................................................................................... 3-5-1
3. Brake Pad Removal .................................................................................. 3-5-2
4. Cleaning and Inspection ............................................................................ 3-5-2
5. Brake Pad Installation ............................................................................... 3-5-3
6. Caliper Installation ..................................................................................... 3-5-4
7. Check-Out ................................................................................................ 3-5-5
B. Caliper Overhaul ................................................................................................... 3-5-6
1. General Layout .......................................................................................... 3-5-6
2. Removal ................................................................................................... 3-5-6
3. Disassembly ............................................................................................. 3-5-6
5. Reassembly .............................................................................................. 3-5-8
INTRO-xviii CD315
Rev 4
6. Installation ................................................................................................. 3-5-9

7. Check-Out ................................................................................................ 3-5-9
C. Rotor ..................................................................................................................... 3-5-9
1. Rotor Removal .......................................................................................... 3-5-9
2. Cleaning .................................................................................................. 3-5-10
3. Inspection ................................................................................................ 3-5-10
4. Installation ............................................................................................... 3-5-10
5. Check Out ............................................................................................... 3-5-10
D. Bleeding the Disc Brake System ........................................................................ 3-5-11
1. General ................................................................................................... 3-5-11
2. Manual Bleeding ...................................................................................... 3-5-11
3. Pressure Bleeding .................................................................................. 3-5-12
4. Check-Out .............................................................................................. 3-5-12
SECTION 6: INSTRUCTIONS FOR AIR GAP CHECKING AND ADJUSTMENT

FREQUENCY (UP TO S/N 510) ........................................................................................... 3-6-1
A. Preparation: Safety Procedures ........................................................................... 3-6-2
B. Opening the Conveyor Drive Guard ...................................................................... 3-6-2
C. Checking Instruction ............................................................................................. 3-6-3
D. Adjustment Instructions ........................................................................................ 3-6-5
E. Reassembly ......................................................................................................... 3-6-7
Chapter 4: Illustrated Parts List

SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1
A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number .......................................................................... 4-1-2
2. Part Numbers and Vendor Codes ............................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-4
4. Effectivity................................................................................................... 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
D. Vendor Code Reference List ................................................................................. 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

Figure 2-1. Frame Weldment - Front View .......................................................... 4-2-2
Figure 2-2. Frame Weldment - Rear View ........................................................... 4-2-4
Figure 2-3. Frame - Body (Left Side) (Up to S/N 254) ......................................... 4-2-6
CD315 INTRO-xix
Rev 4
Figure 2-4. Frame - Body (Left Side) (S/N 254 and Up)....................................... 4-2-8
Figure 2-5. Frame - Body (Right Side) ............................................................... 4-2-10
Figure 2-6. Mirrors ............................................................................................. 4-2-12
Figure 2-7. Front Steps Option .......................................................................... 4-2-14
Figure 2-9. Seat Assembly................................................................................. 4-2-18
Figure 2-10. Battery Assembly ........................................................................... 4-2-20
Figure 2-11. Battery Assembly with Welded Battery Box ................................... 4-2-24
Figure 2-12. Battery Connectors ....................................................................... 4-2-28
Figure 2-13. Battery Connector (Eurodin Adapter Option) ................................ 4-2-30
Figure 2-14. Instrument Panel (Up to S/N 254) .................................................. 4-2-32
Figure 2-15. Instrument Panel (S/N 254 thru 389) ............................................. 4-2-34
Figure 2-16. Instrument Panel (S/N 390 and Up) ............................................... 4-2-36
Figure 2-17. Shifter Assembly (Up to S/N 254) .................................................. 4-2-38
Figure 2-18. Shifter Assembly (S/N 254 and Up) ............................................... 4-2-40
Figure 2-19. Accelerator and Shifter Linkage at Controller Enclosure ............... 4-2-42
Figure 2-20. Accelerator Pedal Assembly (Up to S/N 254) ................................ 4-2-44
Figure 2-21. Accelerator Pedal Assembly (S/N 254 thru 389) ............................ 4-2-46
Figure 2-22. Accelerator Pedal Assembly (S/N 390 and Up) ............................. 4-2-48
Figure 2-23. Circuit Breaker Installation ............................................................. 4-2-50
Figure 2-24. Park Brake Assembly (Up to S/N 254) ........................................... 4-2-52
Figure 2-25. Park Brake Assembly (S/N 254 and Up) ........................................ 4-2-54
Figure 2-26. Park Brake Cable Linkage ............................................................. 4-2-56
Figure 2-27. Brake Pedal Assembly................................................................... 4-2-58
Figure 2-28. Brake Line Diagram ....................................................................... 4-2-60
Figure 2-29. Hydro Boost and Proportion Valve ................................................. 4-2-62
Figure 2-30. Brake Lines, Front (Up to S/N 866) ................................................ 4-2-64
Figure 2-31. Brake Lines, Front (S/N 866 and Up) ............................................. 4-2-66
Figure 2-32. Brake Lines, Rear (Up to S/N 866) ................................................ 4-2-68
Figure 2-33. Brake Lines, Rear (S/N 866 and Up) ............................................. 4-2-70
Figure 2-34. Brake Caliper Assembly, Front Disc .............................................. 4-2-72
Figure 2-35. Brake Assembly, Rear ................................................................... 4-2-74
Figure 2-36. Steer Column Assembly ................................................................ 4-2-76
Figure 2-37. Steer Cylinder Assembly ................................................................ 4-2-78
Figure 2-38. Main Hydraulic System (Up to S/N 254) ........................................ 4-2-80
Figure 2-39. Hydraulic System (Right Side) ...................................................... 4-2-82
Figure 2-40. Hydraulic Assembly (UAL Specific) ................................................ 4-2-86
Figure 2-41. Manifold Assembly (Up to S/N 390) ............................................... 4-2-88
Figure 2-42. Manifold Assembly (S/N 390 thru 498) ........................................... 4-2-90
INTRO-xx CD315
Rev 4
Figure 2-43. Manifold Assembly (S/N 499 and Up) ............................................ 4-2-92
Figure 2-44. Emergency Pump Assembly ......................................................... 4-2-94
Figure 2-45. Hydraulic Control Valve (Up to S/N 499) ........................................ 4-2-96
Figure 2-46. Hydraulic Control Valve (S/N 499 and Up) ..................................... 4-2-98
Figure 2-47. Conveyor Hydraulic Lines ............................................................ 4-2-102
Figure 2-48. Lift Valve Components ................................................................. 4-2-104
Figure 2-49. Lift Cylinder - Front (Up to S/N 499) ............................................. 4-2-106
Figure 2-50. Lift Cylinder - Front (S/N 499 and Up) .......................................... 4-2-108
Figure 2-51. Lift Cylinder - Rear ....................................................................... 4-2-110
Figure 2-52. Steer Front Axle and Hub Assembly ............................................. 4-2-112
Figure 2-53. Drive Motor Assembly (Up to S/N 569) ........................................ 4-2-114
Figure 2-54. Drive Motor Assembly (S/N 569 and Up) ..................................... 4-2-116
Figure 2-55. Drive Motor Reduction Gear Assembly ........................................ 4-2-118
Figure 2-56. Drive (Rear) Axle Attachment ...................................................... 4-2-120
Figure 2-57. Drive (Rear) Axle Hub Assembly.................................................. 4-2-122
Figure 2-58. Drive (Rear) Axle Assembly ......................................................... 4-2-124
Figure 2-59. Controller Assembly - Sevcon MCM with Regen ......................... 4-2-128
Figure 2-60. Mechanical Adaptations to Sevcon MCM Controller .................... 4-2-130
Figure 2-61: SCR-Converter-Accelerator Assy (Sevcon MCM Controller) ....... 4-2-132
Figure 2-62: Controller Assembly Call-outs (Sevcon MCM Controller) ............. 4-2-133
Figure 2-63. Control Box Assembly (S/N 254 thru 498) ................................... 4-2-134
Figure 2-64. Control Box Assembly (S/N 499 and Up) ..................................... 4-2-138
Figure 2-65. Controller Assembly (S/N 254 thru 499) ...................................... 4-2-140
Figure 2-66. Controller Assembly (S/N 500 and Up) ........................................ 4-2-142
Figure 2-67. Horn Assembly ............................................................................ 4-2-144
Figure 2-68. Light Assemblies ......................................................................... 4-2-146
Figure 2-69. Spot Light Installation ................................................................... 4-2-148
Figure 2-70. Work Light Assembly ................................................................... 4-2-150
Figure 2-71. Wheels and Tires ........................................................................ 4-2-152
Figure 2-72. Conveyor Lift Arms - Front and Rear ........................................... 4-2-154
Figure 2-73. Conveyor Safety Props................................................................ 4-2-156
Figure 2-74. Cam Assembly ............................................................................ 4-2-158
Figure 2-75. Conveyor Weldment - Standard (BLE-4-2617) ............................ 4-2-160
Figure 2-76. Conveyor Weldment - Narrow (BLE-4-2618) (Up to S/N 409) ..... 4-2-162
Figure 2-77. Conveyor Weldment - Narrow (BLE-4-2618) (S/N 409 and Up) .. 4-2-164
Figure 2-78. Conveyor Guards ........................................................................ 4-2-166
Figure 2-79. Conveyor Front End - Standard ................................................... 4-2-168
Figure 2-80. Conveyor Front End - Narrow (Up to S/N 409) ............................ 4-2-170
Figure 2-81. Conveyor Front End - Narrow (S/N 409 and Up) ......................... 4-2-172
CD315 INTRO-xxi
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Figure 2-82. Conveyor Bottom Covers - Front (Option)................................... 4-2-174

Figure 2-83. Conveyor Rear End - Standard ................................................... 4-2-176
Figure 2-84. Conveyor Rear End - Narrow ...................................................... 4-2-178
Figure 2-85. Conveyor Attachments (Rear End) - Narrow ............................... 4-2-180
Figure 2-86. Switch Assembly ......................................................................... 4-2-182
Figure 2-87. Electric Belt Control Installation ................................................... 4-2-184
Figure 2-88. Conveyor Control Assembly (S/N 254 thru 389) .......................... 4-2-186
Figure 2-89. Conveyor Control Assembly (S/N 390 and Up) ............................ 4-2-188
Figure 2-90. Emergency Stop Button Installation ............................................. 4-2-190
Figure 2-91. Conveyor Drive Motor - Standard Conveyor (Up to S/N 185) ....... 4-2-192
Figure 2-92. Conveyor Drive Motor - Standard Conveyor (S/N 185 and Up) .... 4-2-194
Figure 2-93. Conveyor Drive Motor - Narrow Conveyor (Up to S/N 510) ......... 4-2-196
Figure 2-94. Conveyor Drive Motor - Narrow Conveyor (S/N 510 and Up) ...... 4-2-198
Figure 2-95. Conveyor Belt and Rollers - Standard ......................................... 4-2-200
Figure 2-96. Conveyor Belt Rollers - Narrow ................................................... 4-2-202
Figure 2-97. Side Rail Assembly ...................................................................... 4-2-204
Figure 2-98. Hand Rail Assembly (Up to S/N 185) ........................................... 4-2-206
Figure 2-99. Hand Rail Assembly (S/N 185 and Up) ........................................ 4-2-208
Figure 2-100. Hand Rail Assy - Locking w/Telescoping Handrail Extender ...... 4-2-210
Figure 2-101. Rapid Charge Assembly (Optional) ........................................... 4-2-212
Figure 2-102. Quick Charge Assembly - Top Installation (Optional) ................. 4-2-214
Figure 2-103. Rear Charge Port (Option) ........................................................ 4-2-216
Figure 2-104. Remote Charger Port Assembly (Optional) ............................... 4-2-218
Figure 2-105. Back Up Alarm ........................................................................... 4-2-220
Figure 2-106. Conveyor Switch Harness (Left Front) ...................................... 4-2-223
Figure 2-107. Conveyor Switch Harness (Right Front) .................................... 4-2-224
SECTION 3: NUMERICAL INDEX ............................................................................................. 4-3-1
SECTION 4: ALPHABETICAL INDEX ........................................................................................ 4-4-1
Chapter 5: Appendices
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1
A. Daily and Weekly and Monthly Checks ................................................................. 5-1-1
B. Bi-Monthly, 6 Months and Yearly Checks .............................................................. 5-1-2
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1

A. Description ........................................................................................................... 5-2-1
INTRO-xxii CD315
Rev 4
COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG.
Any attempt by any person other than an authorized agent of TUG. to alter the contents of this manual in any
way shall be construed as copyright infringement, punishable by all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors, protected
by the same laws governing this operation and maintenance manual.
© Copyright 2007 by TUG. All rights reserved.
CD315 INTRO-xxiii
Rev 4
INTRODUCTION
The TUG Model 660E Electric Mobile Belt Conveyor features systems that are entirely compatible with the
Model 660 loader. The drive and steer axles, the brake system and most accessories are the same as those
utilized on gasoline and diesel powered models. This feature makes the 660E easily and economically
integrated into existing 660 fleets by standardizing and streamlining spare parts support and maintenance.
Vehicle operation of the 660E is identical to that of the standard 660, making transition from one vehicle to
another smooth and safe for operators where electric and internal combustion models are used side-by-side.
Safety and convenience improve operator performance and reduce cost.
For purposes of streamlining the information contained herein, the following documentation will refer to the
TUG Model 660E Electric Mobile Belt Conveyor as the “660E.” The original TUG Model 660 Mobile Belt
Conveyor shall be referred to as the “660.”
INTRO-xxiv CD315
Rev 4
UNIT IDENTIFICATION
MODEL:
SERIAL NO:
CONVEYOR CAP.: LBS.
MANUFACTURE DATE
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
The serial number identification of each unit will appear on the nameplate along with the date of manufacture.
The mailing address of TUG is also located on the data plate below the TUG logo. This necessary information
will ensure the customer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit serial number
here:
If applicable, enter your company identification number
here:
CD315 INTRO-xxv
Rev 4
MODEL NUMBER CODING OF MOBILE BELT LOADERS
660 E - 4 - 207
Conveyor Electric Serial Number

Variations:
660 = 24' Long

661 = 28' Long
663 = 31.5" Wide
Engine: Controls:
(Blank) = Electric Drive 1 = Manual Sliding Lever
2 = Manual Rotating, 2 Places
4 = Electric Push Button, 3 Places
The model number is

stamped on the top edge
of the front bumper and on
the label plate on the right
side of the driver's com-
partment, as is the
date of manufacture.
INTRO-xxvi CD315
Rev 4
TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the 660E Mobile Electric Conveyor to:
TUG Technologies Corporation

815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
All information in this manual is based on the latest production information available at the time of publication.
Direct any questions concerning the contents or format of this manual to:
TUG Technologies Corporation

Attn: TUG Shop
815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
Fax: (770) 422-8730
Email: TugShop@tugtech..com
CD315 INTRO-xxvii
Rev 4
AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp. with respect to ground power units, air start units, tow tractors,
cargo tractors and other equipment sold for use in the commercial aviation industry (“Aircraft Ground Support Equipment”).
STATEMENT OF WARRANTY AGAINST DEFECTS
Subject to the limitations and exclusions set forth below, TUG Technologies Corp. will repair or replace any defective or malfunctioning part of the Aircraft
Ground Support equipment for a period of twenty-four (24) months from the date first placed in service, or twenty-eight (28) months from date of shipment, or
the first 2,000 hours of operation, whichever expires first. Each piece of Aircraft Ground Support Equipment shall be presumed to have been placed in service on
the date of the TUG Technologies Corp. start-up report or, if there is no such report, on the date of shipment by TUG Technologies Corp. to the first retail
purchaser (“Buyer”).
WARRANTY AGAINST PATENT INFRINGEMENT
TUG Technologies Corp. warrants that none of the Aircraft Ground Support Equipment, the use thereof within the United States, or the applications, processes
or designs employed in the manufacture thereof infringes on the valid claim of any U.S. letter patent, patent application, copyright, trade secret or any other
property right of any third party. In the event of a breach or alleged breach of this warranty TUG Technologies Corp. shall, at its own expense, defend any suit
or proceeding brought against Buyer and shall fully protect and indemnify Buyer against any liability, cost, recovery or other expense in or resulting from such
suit or claim of infringement. Buyer shall give prompt notice in writing of any notice of claim of such suit and Buyer agrees to cooperate with TUG Technologies
Corp. to enable it to make such defense. If in any such proceeding, the Aircraft Ground Support Equipment or any part thereof is held to constitute an infringement
and the full or partial use of the Aircraft Ground Support Equipment is enjoined, TUG Technologies Corp. shall, at no cost to Buyer, (i) obtain for Buyer a license
to use the Aircraft Ground Support Equipment or (ii) modify the Aircraft Ground Support Equipment so as to avoid the infringement without degradation in
performance. If TUG Technologies Corp. cannot obtain such a license, or the Aircraft Ground Support Equipment cannot be so modified, or if as a result of any
suit or infringement or alleged infringement, TUG Technologies Corp. may elect not to deliver, or may be prevented from delivering, the Aircraft Ground Support
Equipment or any part or component thereof, TUG Technologies Corp. shall, as Buyer’s exclusive remedy, promptly refund to Buyer all money paid by Buyer
for the Aircraft Ground Support Equipment.
EXCLUSIONS OF LIABILITY
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TUG TECHNOLOGIES CORP.’S LIABILITY UNDER THE FOREGOING
WARRANTY SHALL BE LIMITED TO THE COSTS OF REPAIR OR REPLACEMENT BY TUG TECHNOLOGIES CORP. OF ANY DEFECTIVE PART
OR WORKMANSHIP. TUG TECHNOLOGIES CORP. SHALL NOT HAVE ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,
INCLUDING LOSS OF USE AND LOST PROFITS, IN CONNECTION WITH THE PURCHASE, SALES, SHIPMENT, SERVICE, REPAIR OR
OPERATION ARISING FROM THE FAILURE OF ANY AIRCRAFT GROUND SUPPORT EQUIPMENT OR A COMPONENT THEREOF, OR A
BREACH OF ANY WARRANTY. IN NO EVENT SHALL TUG TECHNOLOGIES CORP.’S LIABILITY TO ANY PERSON EXCEED THE PURCHASE
PRICE OF THE TUG TECHNOLOGIES CORP. AIRCRAFT GROUND SUPPORT EQUIPMENT.
TUG Technologies Corp. will, at its sole option, repair or replace any component, part or parts, if found on examination by TUG Technologies Corp. to be
defective and if the necessary return charges are prepaid by the Buyer. This applies to TUG Technologies Corp. manufactured components. Purchased components
will be handled based on their individual warranties.
Certain Aircraft Ground Support Equipment are installed on trucks or trailers supplied by TUG Technologies Corp. but manufactured by others. In addition, most
Aircraft Ground Support Equipment includes tires that are covered by the warranty issued by the original manufacturer. The warranty of TUG Technologies Corp.
does not cover any failure of the chassis, drive train, cab or other part of the truck or trailer on which Aircraft Ground Support Equipment is installed other than
tow tractors or cargo tractors manufactured by TUG Technologies Corp.. Tires are specifically excluded from any warranty by TUG Technologies Corp. and are
covered only by the warranty, if any, extended by the original manufacturer.
TUG Technologies Corp. has not authorized any person to assume or create any different warranty, written or oral, express or implied, or any other liability on
behalf of TUG Technologies Corp. with respect to the Aircraft Ground Support Equipment.
TUG Technologies Corp. reserves the right to make changes in design and changes or improvements upon its products without any obligation upon itself to
install the same upon its products theretofore manufactured.
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some states do not permit the limitation of incidental or consequential
damages or limitation of remedies under warranties. The above limitations apply only to the extent permitted by applicable law.
BUYER’S RESPONSIBILITY
TUG Technologies Corp. provides Buyer with a copy of the relevant operator manuals containing vital information relating to the proper use and maintenance
of the Aircraft Ground Support Equipment. Additional copies of operator manuals are available from TUG Technologies Corp. at a small charge. Any repairs
arising from failure to maintain the Aircraft Ground Support Equipment in accordance with the operator manuals, from operation of the Aircraft Ground Support
Equipment in a manner not recommended by the operator manual, or from the use of fuels, lubricants or coolants not meeting the specifications set forth in the
operator manuals, are for the account of Buyer.
Many factors affect the performance and reliability of the Aircraft Ground Support Equipment. Specific output ratings and operating parameters have been
established by TUG Technologies Corp.. Operation outside of the recommended parameters can adversely affect the service life of the Aircraft Ground Support
Equipment.
Buyer shall be responsible for all repairs arising from operation of Aircraft Ground Support Equipment above its output ratings, outside its recommended operating
parameters or misuse, accident, foreign object damage or damage caused by a third party.
The Aircraft Ground Support Equipment will require repairs and adjustments over time. The repairs should be performed only by TUG Technologies Corp.
authorized mechanics and with equipment and parts meeting the TUG Technologies Corp. specifications set forth in the operating manuals. Moreover, certain
items installed on the Aircraft Ground Support Equipment, such as belts and filters, wear out over a period of time and must be periodically replaced. Buyer shall
be responsible for any filters, belts, hoses or other normal maintenance items. Buyer shall be responsible for any repairs arising from alterations to the Aircraft
Ground Support Equipment, repairs performed by a person other than authorized representatives of TUG Technologies Corp. or the use of maintenance items or
parts not meeting the TUG Technologies Corp. specifications set forth in the operator manuals. The cost of routine or required maintenance and service is the
responsibility of the Buyer. The Buyer is required to keep documented evidence of when and by whom maintenance and service are performed.
INTRO-xxviii CD315
Rev 4
IN THE EVENT OF A FAILURE

1. Unless there is a threat to life or property, Buyer shall immediately cease using any Aircraft Ground Support Equipment that exhibits any fuel or oil leak,
vibration, unusual noise, high temperature, low oil pressure, black or white smoke, excessive fuel or oil consumption, or any other abnormal condition.
2. Do not disassemble or otherwise attempt to repair the Aircraft Ground Support Equipment. Contact TUG Technologies Corp. for the name and address of
the nearest facility authorized to repair Aircraft Ground Support Equipment. Have available all serial numbers, model numbers, date of purchase and other
information that will assist TUG Technologies Corp. to identify the equipment.
3. TUG Technologies Corp.’s Warranty Department will troubleshoot the problem and direct the Buyer to the nearest authorized repair facility, or dispatch a
field service representative to the location of the Aircraft Ground Support Equipment or provide buyer with replacement parts to be installed by Buyer. Buyer
will be asked for a purchase order or other commitment to pay any expenses that are not covered by the applicable warranty.
4. TUG Technologies Corp. will repair warranted failures during normal business hours using new or remanufactured parts at the option of TUG Technologies
Corp. Warranty Department. Buyer must pay for any repairs or charges not covered by the applicable warranty at the time services are rendered unless other
arrangements are made in advance.
5. TUG Technologies Corp. will invoice Buyer for all warranty replacement parts that are shipped for Buyer installation. Buyer shall be entitled to full credit
against the cost of such part, other than transportation charges, upon the return of the failed parts and determination by TUG Technologies Corp.’s Warranty
Department that such failure was covered by warranty. Such invoice shall be payable in full unless the failed part is returned within ten (10) days after invoice
date.
IF YOU HAVE A QUESTION
If you have any questions regarding the applicable warranty on your Aircraft Ground Support Equipment, contact:
TUG Technologies Corp.

815 Allgood Road
Marietta, GA 30062
Domestic: 1-800-989-8499
Fax: (770) 422-8730
E-mail: TugShop@tugtech.com
CD315 INTRO-xxix
Rev 4
HOW TO USE THIS MANUAL
Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook
before attempting to operate the vehicle.
This handbook is divided into five chapters. Refer to the Table of Contents at the front of each chapter for
details of chapter content.
Page numbering system uses a three-part page number. The first number represents the chapter in which the
page appears, the second number indicates the section within that chapter, while the third number is the page
number within that section.
Warnings, Cautions, and Notes are used throughout this handbook. Look for the following symbols, which
point out items of importance to the safety of the individual and protection of equipment.
WARNING: SAFETY NOTES THAT MUST BE FOLLOWED TO

AVOID SERIOUS INJURY TO PERSONNEL OR EVEN DEATH.
CAUTION: SAFETY NOTES THAT NEED TO BE FOLLOWED TO

PREVENT DAMAGE TO EQUIPMENT.
Note NOTE: Relevent information for the reader, that is not hazard-related.
INTRO-xxx CD315
Rev 4
660E Mobile Electric Conveyor Safety
SAFETY
Operator and mechanic safety is so important at TUG that the initial design and build of every product
undergoes a thorough review of all the components to produce the safest equipment available today. To
reinforce this action, a separate chapter of the operator’s manual has been devoted to safety and must be read
by every operator and mechanic involved with this equipment.
The Safety chapter covers the following:
A. Discussion
B. Standard Safety Features List
C. Operator Responsibilities
D. Mechanic Responsibilities
E. Available Safety Items as Extra Cost Options
It is strongly recommended that this chapter be reproduced and bound to your operator’s book along with your
station safety rules.
A. DISCUSSION
The TUG Model 660E Mobile Belt Conveyor has been designed and built with operator and mechanic
safety in mind from the beginning. These design features and precautions combined with common
sense, make the TUG 660 Series Mobile Belt Conveyors the safest belt conveyors available today.
B. SAFETY FEATURES
The following safety features are standard equipment at no additional cost.
1. Recessed headlights.
2. Combination tail and stop lights.
3. Back-up lights.
4. Turn signals with hazard warning.
5. Dual independent brake systems.
6. Power boosted front disc brakes and rear drum brakes.
7. Adjustable over center park brake hand lever.
8. Nonslip “Morton cast” surface on brake and accelerator pedal.
CD315 SAFETY-i
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Safety 660E Mobile Electric Conveyor
9. Shifter lever guard.
10. Low center of gravity.
11. Angled right front corner.
12. Ease of maneuverability.
13. Center of steering wheel operated horn.
14. Labeled controls.
15. Left front driver position for excellent visibility.
16. Conveyor lifting emergency pump.
17. Conveyor up safety prop.
18. Hydrostatic steering.
19. Pilot pressure operated cylinder holding valves.
20. Electric belt holding brake (up to S/N 510).
21. "Soft start" belt drive.
22. Hydraulic system pressure designed at 1500 psi max.
23. Lagged belt driving roller.
24. Left side guide rail.
25. Right side combination guide rail and 32" hand rail.
26. Nonslip fender surfaces.
27. Foot cutouts in rear bumper for safe access to belt as walkway.
28. Seat belt.
29. Cable operated shoe and drum park brake rear axle.
30. Nonslip covering on floor board.
SAFETY-ii CD315
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C. OPERATOR RESPONSIBILITIES
1. Follow Station Safety Rules. If you do not have a written list of the safety rules, ask for one
prior to operating this belt loader.
2. Check belt loader lights, brakes, park brake, steering, horn, and tires before operating.
3. Do not drive a belt loader with defective brakes, steering, tires, horn, parking brake, alligator
lacing or lights. Refer to maintenance section.
4. Check conveyor belt alligator lacing for damaged or raised hooks.
5. Keep hands and feet away from rotating parts and tires. Wear secured clothing.
6. Bring belt loader to a complete halt and set park brake before dismounting.
7. Use the seat belt.
8. Do not shift direction selector with accelerator engaged.
9. Bring the belt loader to a complete stop before shifting from reverse to drive or from drive to
reverse.
10. Check that path is clear prior to backing.
a) Check local station rules and blow horn before backing up if permitted.
b) If not permitted, follow applicable station rules for alerting other personnel prior to
backing.
11. Use particular caution when in congested areas and around blind corners and row of carts. Be
alert for other equipment and personnel.
12. Never operate at speeds inconsistent with operating conditions. Limit speed to ensure
adequate time for braking in an emergency.
13. Do not use the belt loader to push other equipment. Use the proper towing equipment.
14. Do not allow the belt loader to be pushed by other equipment. Use the proper towing
equipment.
15. Do not use the belt loader as a man lift for other personnel. Use the proper equipment.
16. Do not walk on the fenders when wet or icy.
CD315 SAFETY-iii
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17. Do not walk on any part of the conveyor other than the belt as the frame may be extremely
slippery.
18. Do not ride on the belt, conveyor, or fenders.
19. Do not ride the belt if it is moving.
20. Use the right side hand rail when walking on the conveyor belt.
21. Keep hands, feet and clothing away from the underside of the conveyor.
22. Do not put your hands underneath the conveyor.
23. Do not wear rings on fingers while using the belt conveyor.
24. Check that the rear guard and filler plate at the rear roller is tight and adjusted as close to the
roller as possible.
25. Know and understand the conveyor belt control stations operation.
26. Do not put the conveyor into the aircraft.
27. Do not approach the aircraft when personnel are present in the doorway.
28. Operate at a creep speed when approaching aircraft or within 20 feet of aircraft.
29. Always approach aircraft with the conveyor in the lowered position. Stop 5 feet from the
aircraft, raise the conveyor as required and creep into position.
30. Come to a complete stop before dismounting.
31. Carry no passengers unless a seat with seat belts has been provided.
32. Do not attempt to field service this vehicle. Electrical components carry voltages that can be
lethal.
D. MECHANIC RESPONSIBILITIES
1. Keep hands and clothing away from rotating parts.
2. Wear secured clothing.
3. Use the conveyor safety prop whenever you are working under the conveyor.
SAFETY-iv CD315
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4. When tracking the conveyor belt, be sure to stop the belt when making adjustments on the left
front corner (standard conveyor) or the right front corner (narrow conveyor), as the drive
chain is in that area. The other three corners can be adjusted with the belt running, but keep
hands out from under conveyor.
5. Discharge capacitors before physically touching any electrical connections or components.
6. Disconnect the battery connector when working on or under the conveyor.
7. Disconnect the battery connector before working in the electric control box.
8. Do not substitute throttle return springs with lighter or other springs.
9. Check brakes and fill master cylinder with DOT 3 brake fluid.
10. Check all lights.
11. Check for hydraulic leaks.
12. Check horn operation.
13. Check tire and wheel condition along with proper inflation pressures.
14. Torque all lug nuts at 125 ft-lb.
15. Use proper lifting equipment safely when removing or replacing heavy components.
16. When working underneath, be sure the belt loader is supported properly on secure jack stands.
Do not rely on hydraulic jacks to support the belt loader.
17. If the belt loader is on a hydraulic or air operated lift, be sure safety support or lock is in
position prior to working under the belt loader.
18. Jack the drive wheels off the floor when troubleshooting the drive system.
19. Use caution when installing or removing battery. Electrolyte is acidic and may cause severe
burns or damage equipment or materials.
20. Take nothing for granted when the safety of the tractor or the operator is at stake. Remember,
the operator is depending on you to provide him with a safe belt loader.
21. Keep good maintenance records.
CD315 SAFETY-v
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E. AVAILABLE SAFETY ITEMS AS EXTRA COST OPTIONS
1. Backup alarm.
2. Amber flashing light.
3. Amber strobe light.
4. Mud and snow tires.
5. Work lights.
6. Reflective striping.
7. Belt motion kill, “on-off” buttons on conveyor.
8. Gap filler strip between conveyor belt and front rubber bumper.
10. Rubber bumper roll across the rear of the conveyor frame.
11. Steel channel across the rear of the conveyor frame.
SAFETY-vi CD315
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Chapter 1
660E Mobile Electric Conveyor Contents
CHAPTER 1: GENERAL INFORMATION AND

OPERATING INSTRUCTIONS
TABLE OF CONTENTS
SECTION 1: GENERAL DESCRIPTION .................................................................................. 1-1-1

A. Application ............................................................................................................ 1-1-1
B. Drive Train / Power Package ................................................................................ 1-1-1
1. Drive Train ................................................................................................. 1-1-1
2. Sevcon MCM or PowerpaK Electric Controller ......................................... 1-1-2
3. Battery ...................................................................................................... 1-1-2
C. Chassis ................................................................................................................ 1-1-3
D. Body Panels ......................................................................................................... 1-1-3
E. Electric Conveyor Mechanism (Up to S/N 510) .................................................... 1-1-4
F. Hydraulic System .................................................................................................. 1-1-5
G. Electrical System .................................................................................................. 1-1-6
SECTION 2: OPERATION ......................................................................................................... 1-2-1

A. Instrument Panel Operation (Up to S/N 254) ........................................................ 1-2-1
B. Instrument Panel Operation (S/N 254 and Up) ..................................................... 1-2-3
C. Maneuvering Controls ........................................................................................... 1-2-6
1. Steering Wheel ......................................................................................... 1-2-6
2. Service Brake Pedal ................................................................................. 1-2-6
3. Foot Throttle .............................................................................................. 1-2-6
4. Turn Signal ................................................................................................ 1-2-7
5. Hand Throttle (Up to S/N 254) ................................................................... 1-2-7
6. Drive Direction Selector ............................................................................ 1-2-7
7. Park Brake ................................................................................................ 1-2-8
D. Conveyor Controls ................................................................................................ 1-2-8
E. 12V Electrical Supply Panel .................................................................................. 1-2-8
F. Preliminary Checks .............................................................................................. 1-2-9
1. Battery ...................................................................................................... 1-2-9
2. Tire Inflation ............................................................................................... 1-2-9
4. Brakes ...................................................................................................... 1-2-9
5. Vehicle Drive ............................................................................................. 1-2-9
CD315 1-TOC-i
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Chapter 1
Contents 660E Mobile Electric Conveyor

8. Conveyor Belt Drive ................................................................................ 1-2-10
G. Operation Procedures ........................................................................................ 1-2-10
H. Conveyor Safety Props ....................................................................................... 1-2-11
SECTION 3: SPECIFICATIONS ................................................................................................ 1-3-1

A. Dimensions .......................................................................................................... 1-3-1
B. Performance ......................................................................................................... 1-3-1
C. Electrical Controls ................................................................................................ 1-3-1
D. Heights and Angles ............................................................................................... 1-3-2
E. Safety Features .................................................................................................... 1-3-4
1. Shifter/Hand Throttle Interlock (MCM Electric Controller Only) ................. 1-3-4
2. Main Power Ignition Switch ....................................................................... 1-3-4
3. Electric Belt Brake (Up to S/N 510) ........................................................... 1-3-4
4. Side/Hand Rails ........................................................................................ 1-3-4
5. Finger Guard ............................................................................................. 1-3-4
6. Shifter Guard ............................................................................................. 1-3-4
7. Safety Props ............................................................................................. 1-3-4
8. Parking Brake ........................................................................................... 1-3-5
9. Parking Brake Power Diverter Switch ....................................................... 1-3-5
10. Pilot Operated Hydraulic Holding Valves ................................................... 1-3-5
11. Grit Paper .................................................................................................. 1-3-5
SECTION 4: SHIPPING .............................................................................................................. 1-4-1

A. Introduction ........................................................................................................... 1-4-1
B. Preparation for Shipment ...................................................................................... 1-4-1
C. Receiving .............................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................. 1-5-1

A. Introduction ........................................................................................................... 1-5-1
B. Short Term Storage ............................................................................................... 1-5-1
C. Extended Storage ................................................................................................. 1-5-1
SECTION 6: BATTERY CHARGING CYCLES ......................................................................... 1-6-1

A. Discussion ............................................................................................................ 1-6-1
B. Equalize Charging Procedures ............................................................................. 1-6-4
1-TOC-ii CD315
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Chapter 1
660E Mobile Electric Conveyor Section 1
SECTION 1: GENERAL DESCRIPTION
A. APPLICATION
The TUG Model 660E is a self-propelled vehicle designed to load and unload baggage, light freight
and mail into and out of the lower hold of aircraft. The conveyor may also be used to transfer freight
from trucks or between any two points at the same or differing elevations.
B. DRIVE TRAIN / POWER PACKAGE
The drive train / power package consists of a battery and controller, electric drive motor, reduction
gear box, drive axle and related equipment.
1. Drive Train
The 660E drive train consists of a heavy-duty electric vehicle motor, a reduction gear box, a
drive shaft, and the differential contained in the rear axle (see Figure 1-1).
The drive motor is a 72/80 VDC electric motor with high torque capability and series-wound
coils. Large brushes and commutator protect against heavy overload conditions. A splash
proof enclosure is available as an option.
An additional optional feature will monitor brush wear in the traction motor, and provides a
signal when brush replacement is required to avoid armature damage.
Item 1: Electric Drive Motor

Item 2: Reduction Drive Gearbox
Figure 1-1. Drive Train
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Chapter 1
Section 1 660E Mobile Electric Conveyor
2. Sevcon MCM or PowerpaK Electric Controller

The term “controller” refers to a series of electrical and electronic components that distribute
and control the electricity used in the various systems throughout the 660E. The controller is
located in an enclosed compartment in the center of the unit, just in front of the electric drive
motor. Units built prior to S/N 254 include the Sevcon MCM model; and units with S/N 254
and up feature the Sevcon PowerpaK controller. Both Sevcon controllers offer the following
features:
(a) Thermal protection and compensation circuit, which provides over-temperature

cutback, constant current limit over the operating range, and linear rollback in over-
temperature.
(b) Adjustable acceleration rate, current limit in forward and reverse, and regenerative
braking current limit. Adjustments are accessed through a hand-held calibration unit.
(c) Special circuitry reduces the sensitivity of the throttle at the beginning of its throw,
providing very accurate control at slow speeds.
3. Battery
The 660E is designed for a 36/40-cell, 72/80 volt lead/acid battery. The battery is mounted in
the left hand side of the vehicle for convenient access (see Figure 1-2). A lockout on the
Battery Display Indicator prevents belt operation in a low battery condition.
Figure 1-2. Battery (Item 1)
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Chapter 1
C. CHASSIS
1. The vehicle is built on a heavy duty chassis which includes the power package and running
gear. The chassis has a 110" wheel base, formed steel channel frame, and is supported by the
front and rear axles.
2. The vehicle is equipped with 8.0 x 16.5 6-ply tubeless tires and 16.5 x 6.0 or 6.5 rims.
3. Hydraulic service brakes are provided on all four wheels. The master cylinder is mounted in
front of the instrument panel. Pressure is distributed to all four brake assemblies by
depressing the brake pedal.
4. The rear wheel cable-engaged parking brake is actuated by the brake lever mounted to the
right side of the seat in the operator's compartment.
D. BODY PANELS
1. The 3/16" formed steel body panels are fabricated in six sections, three on each of the right
and left sides of the vehicle. The panels are bolted to the chassis with standard mounting
hardware.
2. The front and rear sections (representing the front and rear fenders) are mounted separately
from the center section and, if necessary, may be replaced independently.
3. A body panel support structure is integrated with the vehicle chassis, which incorporates the
pivot and attaching points for the front and rear lift frames and the lift cylinders.
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Chapter 1
E. ELECTRIC CONVEYOR MECHANISM (UP TO S/N 510)
The 660E electric conveyor mechanism is the industry standard 660 conveyor, modified to accept a
72/80 VDC electric drive motor (Figure 1-3).
Figure 1-3. Electric Conveyor Drive Motor (Item 1)
1. The conveyor is fabricated from standard structural shapes and formed steel, and is attached
to the chassis through front and rear lifting frames.
2. The front cylinder, supporting the front lifting frame, raises the conveyor to 170".
3. The conveyor belt is 24" wide, supported by 2" diameter rollers, and is electric motor driven
through a roller chain reduction. The front roller is mounted in a flange block with screw
adjustable tensioner that allows 6" of adjustment. Crowder rollers under the support rollers
direct the return side of the belt into areas where required clearances around fixed
components are maintained. An inverted angle iron track on the lower forward section of the
conveyor maintains lateral stability through V-shaped rollers mounted to the front lift frame.
4. The motor is equipped with a worm gear and double reduction sprocket drive, and an electric
brake to hold the load when not moving.
5. Operator stations for controlling the conveyor belt are located at each end of the conveyor.
Remote actuation of the conveyor functions is available as an option.
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Chapter 1
F. HYDRAULIC SYSTEM
The hydraulic system provides hydraulic pressure to drive the steering and braking systems and the
conveyor lift system. On units with S/N 510 and up hydraulic power is also used to drive the
conveyor belt. The hydraulic system is driven by a single 72 or 80 VDC electric pump, and is
designed to work simultaneously with other systems (Figure 1-4).
Item 1: Hydraulic Fluid Tank

Item 2: Electric Hydraulic Pump
Item 3: Emergency Manual Lift Pump
Figure 1-4. Hydraulic System
The hydraulic schematic (Chapter 2, Section 2) represents an open center system that supplies power
to raise and lower the conveyor.
1. Hydraulic oil from the 10 gal reservoir (located in the center section body panel) is delivered
to the electrically driven hydraulic pump. This pump delivers 6 gal/min, and is capable of
producing 1500 psi.
2. The hydraulic fluid delivered by the pump passes through the two-spool, manually controlled
valve (with built-in relief and power beyond feature) that controls the front and rear lift
cylinders.
3. Oil flow is then directed to the brake booster, through the steering valve, and back to the tank
through the return line filter.
4. Both front and rear lift cylinders are locked in any position by holding valves.
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Chapter 1
G. ELECTRICAL SYSTEM
1. The 660E employs a 70/80 VDC electrical system designed to provide the optimum power
requirements for the traction motor, belt motor and hydraulics. Switching contactors transfer
power from the traction motor to the belt drive motor, and prevent unintended operation of
either system.
2. The 72/80 VDC system is managed by a state-of-the-art silicon controlled rectifier (SCR).
Advanced microprocessor technology offers improved accuracy and arcless contactor
operation. Speed control is stepless, producing smooth control through the entire speed
range. S/N 510 and Up are controlled by a mosfet controller
3. Peripheral, automotive type systems, such as the lights, horn, and many of the controls,
operate on an independently grounded 12V system. Power is provided by a 300 watt DC to
DC controller from the high voltage system and is converted to 12V.
4. The operator's compartment contains all the required accessories to drive the vehicle, and to
control the lifting and lowering of the conveyor.
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Chapter 1
SECTION 2: OPERATION
A. INSTRUMENT PANEL OPERATION (UP TO S/N 254)
The instrument panel in the operator’s compartment contains the following gauges and
electromechanical devices:
1. Battery Discharge Indicator and Hour Meter
Figure 2-1. Instrument Panel (Effective for units prior to S/N 254)
This battery discharge indicator gauge is the means by which the operator can monitor the
state of charge of the battery, and the cumulative number of hours the unit has been in
operation. The battery discharge indicator is color coded for easy legibility. Green indicates
a full charge. Yellow means that the battery has a marginal charge, and red means low. Do
not continue to use the unit once the red light has illuminated. Proceed as quickly as
possible to a recharging station. If the state of charge falls below 20% of capacity, the red
light begins to flash. At this point, the unit can initially still be driven to a charging station,
but the belt drive is automatically locked out to prevent damage to the battery.
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Chapter 1
Figure 2-2. Hour Meter (Effective for units prior to S/N 254)
2. System Indicator Light
System indicator light illuminates when the power switch is in the on position and power is
reaching the controller.
3. Power-On ("Ignition") Switch
The ignition switch is the main power switch for all systems. When the switch is on, power is
made available for the throttle, belt drive, hydraulics and all related systems. When the
switch is off, power is not available for any systems, including lights and horn.
4. Headlight Switch
The headlight switch is a standard on-off toggle providing power to the headlights. Note: The
headlights will not work if the Power-on switch is in the "off" position.
5. Spotlight Switch (Optional)
The spotlight switch is a standard on-off toggle providing power to the spotlight. Once
illuminated, the spotlight can then be maneuvered to illuminate a workspace or other target.
1-2-2 CD315
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Chapter 1
B. INSTRUMENT PANEL OPERATION (S/N 254 AND UP)
The instrument panel in the operator’s compartment contains the following components
(see Figures 2-3 and 2-4):
1. Shifter, direction control.
2. Sevcon Battery Discharge Indicator and Hour Meter
The unit consists of a 2 x 16 alphanumeric LCD display that incorporates a 10 segment BDI
(Battery Discharge Indicator), a 6-digit hours counter and a 10 character area for diagnostic
and status messages. (See Figure 2-5)
2
4
5 7
6
Figure 2-3. Instrument Panel (Effective for units with S/N 254–389)
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Chapter 1
2
4
8
5 7
6
Figure 2-4. Instrument Panel (Effective for units with S/N 390 and Up)
1-2-4 CD315
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Chapter 1
Figure 2-5. Hour Meter (Effective for units with S/N 254 and Up)
The state of battery charge is indicated by 10 segments on the display. When the battery is
deemed fully charged, all 10 segments will be lit. When the battery is deemed fully
discharged, all segments will be extinguished, with each 10% drop in capacity extinguishing
one segment. When the battery charge drops below 30%, the remaining lit segments will flash
to warn the driver of this. Do not continue to use the unit once the low charge warning has
occurred. Proceed as quickly as possible to a recharging station. If the state of charge
falls below 20% of capacity, all 10 segments will begin to flash. At this point, the unit can
initially still be driven to a charging station, but the belt drive is automatically locked out to
prevent damage to the battery.
3. Spotlight Switch (Optional)
The spotlight switch is a standard on-off toggle providing power to the spotlight. Once
illuminated, the spotlight can be maneuvered to illuminate a workspace or other target.
4. Brake Warning Light
Illuminates when a brake problem or failure occurs.
5. System Indicator Light
System indicator light illuminates when the power switch is in the on position and power is
reaching the controller.
CD315 1-2-5
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Chapter 1
6. Power-On ("Ignition") Switch
The ignition switch is the main power switch for all systems. When the switch is on, power is
made available for the throttle, belt drive, hydraulics and all related systems. When the
switch is off, power is not available for any systems, including lights and horn.
7. Headlight Switch
The headlight switch is a standard on-off toggle providing power to the headlights.
NOTE: The headlights will not work if the power-on switch is in the "off"
Note position.
C. MANEUVERING CONTROLS
Maneuvering controls on the 660E include the following:
1. Steering Wheel
The steering system is a hydraulic type powered from the hydraulic pump.
(a) To turn left, rotate the steering wheel counterclockwise.
(b) To turn right, rotate the steering wheel clockwise.
2. Service Brake Pedal

The service brake pedal operates the hydraulic brakes on the front and rear wheels.
(a) To decrease speed or stop the vehicle, depress the service brake pedal.
(b) To move the vehicle, release the service brake pedal.
3. Foot Throttle
The foot throttle is a specialized electromechanical accelerator that sends power increase/
decrease signals to the controller.
(a) To increase speed, depress foot throttle.
(b) To decrease speed, release foot throttle.
1-2-6 CD315
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Chapter 1
4. Turn Signal
The turn signal control is a lever mounted on the steering column used to indicate upcoming
turns.
5. Hand Throttle (Up to S/N 254)

The hand throttle lever is used to set the electric belt motor speed. Move the hand throttle
lever down (toward the driver’s seat) to increase belt speed. The drive direction selector will
not move into forward or reverse with the hand throttle advanced. (MCM Electric Controller
Only)
6. Drive Direction Selector

A Morse control drive direction lever connected to a flexible push/pull cable operates limit
switches that transfer current flow through the drive motor. The Morse control incorporates
the hand throttle and the drive direction selector in two levers. The lever to the left (when
seated in the driver’s compartment) is the hand throttle and the lever to the right is the drive
direction selector. (MCM Electric Controller Only)
To select a vehicle drive direction:
(a) Move direction selector lever up (toward instrument panel) to select reverse drive
direction.
(b) Move direction selector lever down (toward driver’s seat) to select forward drive
direction.
(c) Neutral is located midway between forward and reverse and is indicated by a positive
stop notch into which the spring loaded lever will fall when shifting.
(d) The hand throttle lever is used to set the electric belt motor speed. Move the hand
throttle lever down (toward the driver’s seat) to increase belt speed. (MCM Electric
Controller Only)
(e) Drive direction selector will not move into forward or reverse with the hand throttle
advanced. (MCM Electric Controller Only)
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Chapter 1
7. Park Brake
The parking brake is a cable actuated type, manually engaging the rear brake shoes into the
brake drums. The parking brake mechanism also includes an electric switch that, when
engaged, diverts power from the drive motor to the belt motor. The brake actuating device is
located to the right of the driver’s seat in the driver’s compartment.
(a) To apply parking brake, lift actuating lever up.
(b) To release parking brake, push actuating lever down.
D. CONVEYOR CONTROLS
1. Conveyor height controls in the operator’s compartment (located below driver’s seat) are
limited to:
(a) Front cylinder extension/retraction
(b) Rear cylinder extension/retraction
2. Electric belt drive controls are located on the left side of the conveyor at the front and on both
sides of the conveyor at the rear. The belt drive control buttons are labeled for FORWARD,
STOP, and REVERSE belt motion.
(a) Press FORWARD or REVERSE button to start belt motion.
(b) Press FORWARD or REVERSE button again to increase belt speed (maximum three
(3) times).
(c) Press STOP button to stop belt motion.
E. 12V ELECTRICAL SUPPLY PANEL
The main 12V electrical circuit breaker panel is located below the instrument panel. See electrical
wiring diagrams located in Chapter 2, Section 2 for description of electrical components.
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Chapter 1
F. PRELIMINARY CHECKS
1. Battery
Assuming a minimum 80% charge, the duration of usable charge of the belt loader battery
will vary from several hours to perhaps a day or more, depending on many factors. Variables
that affect length of usable charge include the percentage of initial day’s charge, intensity of
use, size and condition of battery, weight of loads and environmental factors, such as ambient
temperature. The battery should be fully charged before the unit is put into service on a daily
basis. For a complete discussion on battery charging cycles and electrolyte maintenance, see
Chapter 1, Section 6.
(a) Check the battery fluid level. Top off with distilled or approved drinking water, as
necessary.
(b) If disconnected, connect the battery cables.
2. Tire Inflation
Check air pressure in tires (45 psi) and add air, if needed.
3. Hydraulic Oil Level

Check hydraulic oil level. If low, check hydraulic system for leaks.
4. Brakes
(a) Check the level of the brake fluid in the master cylinder. If low, check for leaks in
brake lines.
(b) Check service brake to ensure it is working properly.
(c) Check park brake operation to ensure it is working properly.
5. Vehicle Drive
Check that the loader drives properly in both forward and reverse directions.
6. Front Lift Cylinder

Fully extend and retract the front cylinder to ensure that it is working properly.
7. Rear Lift Cylinder

Fully extend and retract the rear lift cylinder to ensure that it is working properly.
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Chapter 1
8. Conveyor Belt Drive

Check that the conveyor belt moves properly in both forward and reverse directions.
G. OPERATION PROCEDURES
Procedures for maneuvering the vehicle to an aircraft are outlined below:
WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED IN

THE SAFETY SECTION OF THIS MANUAL
1. Switch main power switch ("ignition") to ON.
2. Select drive direction (FWD/REV).
3. Release parking brake.
4. Depress foot throttle.
5. Maneuver vehicle with steering wheel.
6. Use service brake to decrease speed and/or stop the vehicle as needed.
7. Bring the belt loader to a complete stop before shifting from reverse to drive or from drive to
reverse.
8. Bring belt loader to a complete stop and set park brake before dismounting.
1-2-10 CD315
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Chapter 1
H. CONVEYOR SAFETY PROPS
1. The safety props are provided to support the front and rear of the conveyor for maintenance.
WARNING: ALWAYS USE THE PROPS WHEN WORKING UNDER THE

CONVEYOR.
2. To install the prop, raise the front of the conveyor to a height permitting the prop to be rotated
to the “UP” position.
3. Raise the prop to the “UP” position.
4. Slowly let the conveyor down until prop aligns with sockets on bottom of the lift arm. Be sure
the prop is fully engaged inside sockets before working under the conveyor.
NOTE: Power conveyor gently down onto prop. Structural failure may result
Note if conveyor is lowered heavily.
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Chapter 1
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1-2-12 CD315
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Chapter 1
SECTION 3: SPECIFICATIONS
A. DIMENSIONS
1. Length ................................................................................................................................ 300 in

2. Width (excluding side bumpers) .......................................................................................... 78 in
3. Height .................................................................................................................................. 59 in
4. Wheel Base ........................................................................................................................ 110 in
5. Conveyor Length (less front bumper) ............................................................................... 294 in
6. Conveyor Width - Standard Converyor (less side rails) ...................................................... 34 in
7. Conveyor Width - Narrow Conveyor (less side rails) ...................................................... 31.5 in
8. Belt Width ............................................................................................................................ 24 in
9. Battery Compartment .................................................................................. 72.5 x 14.25 x 24 in
B. PERFORMANCE
1. Top Speed ........................................................................................................................ 15 mph

2. Conveyor Capacity to 15 degree angle ............................................................................ 2000 lb
3. Conveyor Capacity to full elevation ................................................................................ 1000 lb
4. Belt Control ................................................................................................ Electric push-button
5. Electric Belt Speed .................................................................................................. 15-90 ft/min
6. Aircraft Capability ........................ Will service aircraft with door sill heights from 40" to 170"
C. ELECTRICAL CONTROLS
1. SCR Control - Sevcon MCM/PowerpaK .......................................................................... 650 A

2. Peak Traction Motor Amps ................................................................................................ 425 A
3. Peak Hydraulic Pump Motor Amps ..................................................................................... 65 A
4. Peak Belt Motor Amps ........................................................................................................ 30 A
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Chapter 1
D. HEIGHTS AND ANGLES
Figure 3-1. Full Down Rear, Full Up Front
Figure 3-2. Full Up Rear, Full Up Front
Conveyor Attitude Front Rear Angle

Front Up, Rear Down 170" 13" 35°
Front Up, Rear Up 168" 37" 27°
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Chapter 1
Figure 3-3. Full Down Rear, Full Down Front
Figure 3-4. Full Up Rear, Full Down Front
Conveyor Attitude Front Rear Angle

Front Down, Rear Down 40" 36" 1°
Front Down, Rear Up 31" 61" -6°
Nominal 747 Operation 158" 30" 26°
* The front of the conveyor is set 30" above the 128" floor
height of the 747. The rear of the conveyor is set 30" above
the ground.
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E. SAFETY FEATURES
1. Shifter/Hand Throttle Interlock (MCM Electric Controller Only)

This prevents the loader from being shifted into gear while the hand throttle is engaged by
utilizing a single track for both shifter and hand throttle. Only one lever can occupy the track
at a time. A wider neutral position allows one lever to move sideways to provide clearance for
the other.
2. Main Power Ignition Switch

The keyswitch that would normally be used to start a gasoline engine now serves as a main
power switch. When the switch is in the OFF position, power to all systems is shut off, thus
eliminating the possibility of accidental power loss from headlights or other systems
accidentally left on.
3. Electric Belt Brake (Up to S/N 510)

The electric belt brake is an electric device that, when powered, releases the conveyor belt for
normal operation. When power is cut, or if power fails during a loading operation, the belt
brake automatically engages, thus preventing the belt from freewheeling.
4. Side/Hand Rails
Mounted on the side of the conveyor, these rails prevent the load from falling off the
conveyor, as well as preventing the operator from falling should he have to climb the
conveyor to rearrange the load. When not needed, these rails hinge down to conveyor level.
5. Finger Guard
Finger guards are located on the front, rear and bottom of the conveyor. When used correctly,
the adjustable guards help to prevent the operator from getting his fingers caught between the
conveyor belt and the conveyor frame. The guards are designed to be adjusted open as the
belt stretches.
6. Shifter Guard
Integral with the R/H side of dash, this guard prevents the load from slipping off and
knocking the loader in gear, if the throttle interlock has not been positioned to lock the shift
lever in neutral position.
7. Safety Props
Painted yellow and located at the front and rear of the vehicle, these manually engaged safety
devices prevent the conveyor from drifting down during maintenance work. These devices
should be engaged any time the conveyor is in the raised position for maintenance work.
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8. Parking Brake
Cable operated and manually controlled, the parking brake manually locks the rear brakes to
prevent the loader from rolling when parked or when using the conveyor.
9. Parking Brake Power Diverter Switch

When engaged, the parking brake also diverts power from the traction drive to the conveyor
motor. This feature assures that the parking brake is locked when the conveyor is in use, and
helps to prevent the drive motor from being accidentally engaged.
10. Pilot Operated Hydraulic Holding Valves

Located on both lift cylinders, these valves hold the cylinders and the conveyor belt at the set
position. The conveyor belt valve prevents free wheeling of the belt if the load is stopped with
the conveyor at an incline.
11. Grit Paper

Grit paper is positioned on the pontoons for better traction and safer operation. Grit Paper on
pontoons should be inspected monthly and replaced as required when found to be torn or
worn off.
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1-3-6 CD315
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Chapter 1
SECTION 4: SHIPPING
A. INTRODUCTION
This section contains instructions for the preparation of shipping the belt loader from one location to
another. Normally, the shipping of the unit does not involve storage time. If the unit is to be stored
before or after shipment, refer to section 5 of this chapter for details of preparation.
B. PREPARATION FOR SHIPMENT
1. Ensure park brake is engaged. To apply parking brake, lift actuating lever up.
2. Disconnect battery.
3. Secure unit in place using the D-ring locations in the front and rear of the unit.
C. RECEIVING
Before placing the unit into operation, follow the pre-operational guidelines included in Chapter 2,
Section 1, Part A. Preparation for use.
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1-4-2 CD315
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SECTION 5: STORAGE
A. INTRODUCTION
Short term storage procedures apply to storage periods between 30 to 90 days, and extended storage
procedures for periods greater than 90 days. In either case, store the vehicle in a clean, dry place with
protection from temperature extremes and/or high humidity.
B. SHORT TERM STORAGE
1. Wash interior and exterior surfaces of vehicle with a mild detergent, and thoroughly rinse and
dry. Perform the following procedures:
(a) Place vehicle on jack stands in accordance with procedures in Chapter 2, Section 1,
paragraph E.
(b) Reduce tire pressure to 15 psi.
(c) Disconnect battery cables.
(d) Lubricate vehicle in accordance with instructions in Chapter 2, Section 1,

paragraph C.
(e) Repack front wheel bearings.
C. EXTENDED STORAGE
1. Clean interior and exterior surfaces of vehicle with a mild detergent, and thoroughly rinse and
dry. Perform the following procedures:
(a) Place vehicle on jack stands in accordance with procedures in Chapter 2, Section 1,
paragraph E.
(b) Reduce tire pressure to 15 psi and spray with a rubber preservative.
(c) Disconnect battery cables and service in accordance with step (g) below.
(d) Lubricate vehicle in accordance with instructions in Chapter 2, Section 1,

paragraph C.
(e) Repack front wheel bearings.
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(f) Drain oil from drive axle and reduction gear box. Attach a tag on steering wheel
stating, "CAUTION: Oil has been removed from axle and reduction gear box."
(g) Remove battery and store separately in a cool, dry place that is free of direct sunlight.
Recommended storeroom temperature of 32 °F to 90 °F (0 °C to 32 °C) should be
maintained. If battery is stored in the open, it must be covered for protection against
dirt and moisture. A slow charge must be applied to the battery every one or two
months.
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Chapter 1
SECTION 6: BATTERY CHARGING CYCLES
A. DISCUSSION
If you are new to the use and maintenance of an electric vehicle, there are some practical aspects of
battery charging cycles with which you should become familiar.
The act of recharging your battery is in many ways analogous to refilling the fuel tank on a gasoline
or diesel vehicle. If you fill the “tank” halfway, you will only go half as far before having to fill up
again. A battery, however, diverges from this comparison in that a partial refill of a fuel tank will not
affect the tank’s future capacity. A battery, on the other hand, will be negatively affected by frequent
partial recharges.
As the chart below indicates, (Figure 6-1) the range of a “fast charge” is typically between the 20%
and 80% capacity range. Depending on the intensity of usage, it may occasionally become necessary
to recharge a battery during the course of the day. At such times, a short charge will likely fail to
extend the charged state of the battery beyond the 80% charge.
Figure 6-1. Fast Charge Range
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Beyond the 80% point, standard charging procedures require significantly more time to push the
charge further into this upper 20% range. (Figure 6-2)
Figure 6-2. Charge Potential
If your 660E vehicle is available for use on a 24-hour day basis, it may be difficult to find the time to
restore the battery charge to its highest potential in that upper 20% range. It should be noted,
however, that perpetual use of “fast” charging cycles, without the occasional use of a full charging
cycle, may shorten the life of the battery. Batteries that are not subjected to regular equalize charging
will effectively lose that upper unused 20% charging range. At that point, the former 80% charge
increment becomes the new 100% mark. (Figure 6-3)
Subsequent fast charges only charge to 80% of the battery’s reduced potential. As this destructive
cycle proceeds, the battery again loses the upper 20% of its remaining potential until the battery is
destroyed and must be replaced.
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Figure 6-3. Battery Capacity
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Guidelines for your 660E charging regimen:
1. During quick charges, always charge battery to a minimum of 80% of capacity.
2. Never allow battery to become discharged below 20% of capacity.
3. Charge to 100% of capacity whenever possible. Put the battery on an extended or "equalize"
charge weekly.
4. Check electrolyte level and strength after the weekly equalizing charge.
WARNING: WHEN CHARGING YOUR 660E, USE ONLY A FACTORY-

AUTHORIZED CHARGING SYSTEM DESIGNED FOR A 72/80 VDC
BATTERY. NEVER ATTEMPT TO USE A STANDARD AUTOMOTIVE
TYPE 12 VOLT CHARGER.
WARNING: THE PROCESS OF CHARGING LEAD/ACID BATTERIES

CAUSES THE RELEASE OF FLAMMABLE HYDROGEN GAS!
CHARGE BATTERIES ONLY IN WELL-VENTILATED AREAS.
ISOLATE CHARGING FROM ALL SOURCES OF SPARKS OR FLAME.
DO NOT SMOKE NEAR CHARGING BATTERIES.
B. EQUALIZE CHARGING PROCEDURES
"Equalize charging," if done regularly and properly, is the one procedure that more than any other can
ensure that the battery will last through the period of the manufacturer's designed life. Equalize
charging is a procedure by which the battery is given a full charge, then trickle charged to ensure that
all the cells balance out in their degree of charge. Equalize charging should be performed on the
battery at least once per week.
Read all safety precautions before proceeding.
1. Turn the main switch to the "off" position.
2. Engage hand brake.
3. Check electrolyte levels. Fill ONLY VERY LOW OR DRY CELLS with distilled water,
and ONLY TO LOW LEVEL MARK.
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WARNING: THE CHARGING PROCESS GENERATES HEAT,

CAUSING ELECTROLYTE TO EXPAND. CELLS FILLED BEYOND
THE LOW LEVEL BEFORE CHARGING CAN SPILL OVER DURING
THE CHARGING PROCESS, CAUSING ACID DAMAGE TO
SURROUNDING AREAS AND/OR AN ENVIRONMENTAL HAZARD.
4. Make sure the charger is off. Attach charger connector to mating battery connector on the
660E.
5. Select the equalize charging cycle and charge the battery.
6. Allow the charger to complete the full cycle.
7. Make sure charger is turned off; disconnect charger.
8. Test the electrolyte in each cell using a hydrometer to ensure that all cells have acquired the
same degree of charge. Top off electrolyte to bottom of fill tube as needed.
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1-6-6 CD315
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Chapter 2
CHAPTER 2: MAINTENANCE
TABLE OF CONTENTS
SECTION 1: SERVICING .......................................................................................................... 2-1-1

A. Preparation for Use ............................................................................................... 2-1-1
1. Battery ...................................................................................................... 2-1-1
2. Tire Inflation ............................................................................................... 2-1-1
4. Brakes ...................................................................................................... 2-1-1
5. Vehicle Drive ............................................................................................. 2-1-1
8. Conveyor Belt Drive .................................................................................. 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily .......................................................................................................... 2-1-2
2. Weekly or at 50 Hours .............................................................................. 2-1-3
3. Monthly or 200 Hours ................................................................................ 2-1-3
4. Every Two (2) Months or 400 Hours ......................................................... 2-1-4
5. Every Six (6) Months or 1200 Hours ......................................................... 2-1-4
6. Yearly or 2400 Hours ................................................................................. 2-1-4
C. Lubrication ............................................................................................................ 2-1-5
D. Belt Drive Reduction Gear Box Lubrication and Maintenance .............................. 2-1-9
E. Instructions for Jacking and Positioning Vehicle ................................................. 2-1-10
F. Accelerator Cable Adjustment ............................................................................ 2-1-11
1. Accelerator .............................................................................................. 2-1-11
G. Park Brake Adjustment ....................................................................................... 2-1-11
1. Discussion .............................................................................................. 2-1-11
2. Procedure ............................................................................................... 2-1-11
SECTION 2: TROUBLESHOOTING ......................................................................................... 2-2-1

A. 72/80 Volt Systems ............................................................................................... 2-2-2
B. Hydraulic Systems ................................................................................................ 2-2-4
C. Service Brakes ..................................................................................................... 2-2-5
D. Parking Brake ....................................................................................................... 2-2-7
E. Conveyor Lifts ....................................................................................................... 2-2-8
F. Conveyor Belt ....................................................................................................... 2-2-9
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G. Electrical Schematics and Wiring Diagrams ...................................................... 2-2-11

Figure 2-10. 660E Conveyor Switch Harness - Right Front ............................... 2-2-27
Figure 2-11. 660E Conveyor Switch Harness - Left Front ................................. 2-2-28
Figure 2-12. 660E Hydraulic Schematic ............................................................ 2-2-29
2-TOC-ii CD315
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Chapter 2
SECTION 3: REMOVAL/INSTALLATION ................................................................................... 2-3-1

A. Rear Axle Removal ............................................................................................... 2-3-1
B. Rear Axle Installation ............................................................................................. 2-3-2
C. Front Axle Removal ............................................................................................... 2-3-2
D. Front Axle Installation ............................................................................................ 2-3-2
E. Conveyor Removal / Installation ........................................................................... 2-3-3
F. Conveyor Belt Drive Motor Removal ..................................................................... 2-3-3
G. Conveyor Belt Drive Motor Installation .................................................................. 2-3-4
H. Holding Valve Removal ......................................................................................... 2-3-4
I. Holding Valve Installation ....................................................................................... 2-3-5
J. Lift Cylinders Control Valve Removal .................................................................... 2-3-5
K. Lift Cylinders Control Valve Installation ................................................................. 2-3-6
L. Front Lift Cylinder Removal .................................................................................. 2-3-6
M. Lift Cylinder Installation ......................................................................................... 2-3-7
N. Rear Lift Cylinder Removal ................................................................................... 2-3-7
O. Rear Lift Cylinder Installation ................................................................................ 2-3-8
P. Hydraulic Pump Removal ..................................................................................... 2-3-8
Q. Hydraulic Pump Installation................................................................................... 2-3-9
R. Hydraulic Pump Motor Removal / Installation ....................................................... 2-3-9
S. Hydraulic Pump Motor Brushes Inspection / Replacement .................................. 2-3-9
T. Drive Motor Brush Inspection / Replacement ..................................................... 2-3-10
U. Drive Motor Removal .......................................................................................... 2-3-10
V. Drive Motor Installation ........................................................................................ 2-3-11
W. Drive Reduction Gear Box Removal ................................................................... 2-3-11
X. Drive Reduction Gear Box Installation ................................................................ 2-3-11
SECTION 4: BELT TRACKING INSTRUCTIONS .................................................................... 2-4-1

A. Discussion ............................................................................................................ 2-4-1
B. Procedure ............................................................................................................. 2-4-2
SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS .......................................... 2-5-1
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2-TOC-iv CD315
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Chapter 2
SECTION 1: SERVICING
A. PREPARATION FOR USE
1. Battery
Assuming a minimum 80% charge, the duration of usable charge of the belt loader battery will
vary from several hours to perhaps a day or more, depending on many factors. Variables that
affect length of usable charge include the percentage of initial day’s charge, intensity of use,
size and condition of battery, weight of loads and environmental factors, such as ambient
temperature. The battery should be fully charged before the unit is put into service on a daily
basis. For a complete discussion on battery charging cycles and electrolyte maintenance, see
Chapter 1, Section 6.
(a) Check the battery fluid level. Top off with distilled or approved drinking water, as
necessary.
(b) If disconnected, connect the battery cables.
2. Tire Inflation
Check air pressure in tires (45 psi) and add air, if needed.
3. Hydraulic Oil Level

Check hydraulic oil level. If low, check hydraulic system for leaks.
4. Brakes
(a) Check the level of the brake fluid in the master cylinder. If low, check for leaks in
brake lines.
(b) Check service brake to ensure it is working properly.
(c) Check park brake operation to ensure it is working properly.
5. Vehicle Drive
Check that the loader drives properly in both forward and reverse directions.
6. Front Lift Cylinder

Fully extend and retract the front cylinder to ensure that it is working properly.
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Chapter 2
7. Rear Lift Cylinder

Fully extend and retract the rear lift cylinder to ensure that it is working properly.
8. Conveyor Belt Drive

Check that the conveyor belt moves properly in both forward and reverse directions.
B. PERIODIC MAINTENANCE SCHEDULE
The tractor should be maintained in accordance with the following schedules:
1. Daily
(a) Check that all controls, including belt controls, are in good working order. Report a
faulty unit and do not use until repaired.
(b) Check battery charge and electrolyte level. The battery should be fully charged
before the unit is put into service on a daily basis. For a complete discussion on
battery charging cycles and electrolyte maintenance, see Chapter 1, Section 6.
(c) Check hydraulic oil level. If low, check for leaks.
CAUTION: THE RECOMMENDED TIRE PRESSURE LISTED IS FOR

THE TIRES THAT ARE STANDARD ON THE 660 UNIT. OTHER
OPTIONAL TIRES SHOULD BE INFLATED ACCORDING TO THE
TIRE MANUFACTURER SPECIFICATIONS.
(d) Check that the pressure of the standard pneumatic tires is 45 psi.
WARNING: DO NOT CHANGE A PNEUMATIC TIRE FOR A

CUSHION TIRE OR VICE VERSA WITHOUT FIRST CONSULTING
TUG.
(e) Check tire treads for damage. Remove any stones, etc.
(f) Check operation of the headlights and if aimed correctly.
(g) Check operation of backup, tail, stop and turn signal lights.
(h) Check operation of the cab marker lights, the heater, the wiper and the cab light, if
equipped.
(i) Sound horn.
2-1-2 CD315
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Chapter 2
2. Weekly or at 50 Hours
(a) Check conveyor belt for proper tension and alignment.
(b) Check belt drive chain adjustment.
(c) Lubricate belt drive chain.
(d) Check rear finger guard adjustment.
WARNING: LUG NUTS MUST BE RETIGHTENED TO 125 FT-LB

(135.6 N-M) AFTER ANY TIME THE LUG NUTS HAVE BEEN
LOOSENED FOR ANY REASON, AND AT THE INTERVALS
SPECIFIED IN THIS PERIODIC MAINTENANCE SECTION.
(e) Check that the wheel lug nuts are tightened to 125 ft-lb (135.6 N-m).
(f) Check the level of the brake fluid in the master cylinder. If low, top off as necessary.
(See lubrication specifications later in this section.)
(g) Check underneath for oil leaks and damage.
(h) Check ball joints for looseness.
3. Monthly or 200 Hours
(a) Check the service brake pedal for proper operation. Adjust if required.
(b) Check the parking brake. With the parking brake handle in ‘lock’ position, the unit
should not move on a 8% or less grade. If the tractor does not move, no adjustment is
necessary, but if the tractor rolls, then adjustment is advised. Follow the
recommended adjustment instructions in this section.
(c) Check brake pads and shoes; replace if pads are less than 1/8".
(d) Lubricate service brake pedal linkage pivots.
(e) Lubricate parking brake lever pivots.
(f) Lubricate throttle linkage.
(g) Lubricate conveyor belt roller bearings.
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Chapter 2
(h) Lubricate conveyor side and handrail pivots.
(i) Lubricate access cover hinges.
(j) Lubricate seat slide.
(k) Lubricate drive shaft joints.
(l) Lubricate steering axle links.
(m) Lubricate all grease fittings.
4. Every Two (2) Months or 400 Hours
(a) Change hydraulic oil filter.
(b) Check idle rpm and mixture, adjust if necessary.
(c) Inspect front wheel bearings; clean and repack.
(d) Check tie rod ends looseness.
(e) Check traction and belt motor brushes.
(f) Check belt brake adjustment.
5. Every Six (6) Months or 1200 Hours
(a) Check intake manifold bolts and tighten, if necessary.
(b) Check drive axle mounting bolts and tighten if required.
(c) Check drive axle oil level.
(d) Check reduction gear box lube (Conveyor).
(e) Check reduction gear box lube (Drive train).
6. Yearly or 2400 Hours
(a) Change drive axle oil. (See lubrication specifications later in this section.)
2-1-4 CD315
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Chapter 2
(b) Drain, flush and refill and bleed the brake system.
(c) Drain, flush and refill the hydraulic system.
C. LUBRICATION
1. Periodic lubrication should be performed. (Check service plate at passenger-side Hydraulic

Tank door for service intervals and types of lubricant).
2. Use grease at pressure zerks in the following locations as equipped:
(a) Ball joints, upper & lower (4)
(b) Tie rod ends (2)
(c) Hydraulic lift cylinders (4)
(d) Steering cylinder tie rod ends (2)
(e) Conveyor roller bearings (8)
3. Oil the following items:
(a) Parking brake lever pivot points
(b) Conveyor side and handrail pivot points
(c) Belt drive chain
(d) Motor access cover hinges
(e) Seat slide
4. Use appropriate high quality gear oil:
(a) Drive reduction gear box
(b) Belt reduction gear box
CD315 2-1-5
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Chapter 2
Figure 1-1. Chassis Lubrication Diagram
2-1-6 CD315
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Chapter 2
Figure 1-2. Body Lubrication Diagrams
CD315 2-1-7
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Chapter 2
Table 1-1. Lubrication Instructions
Hydraulic Oil (Check Level Daily)
Ambient Temperature Hydraulic Fluid

- 60 °F to + 50 °F Mobil DTE II
- 15 °F to + 140 °F Mobil DTE 13
Chassis Components
Component Interval Lubricant

Brake Cylinder Check Level Weekly DOT 3 Heavy Duty Brake Fluid
Conveyor Drive Chain Lube Weekly Same as Engine Oil
Rear Axle Check at 6 Months 85W-90 Limited Slip
Zerk Fittings Lube at 6 Months Chassis Grease
Wheel Bearings Repack at 24 Months Wheel Bearing Grease
2-1-8 CD315
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Chapter 2
D. BELT DRIVE REDUCTION GEAR BOX LUBRICATION AND MAINTENANCE
Figure 1-3. Gear Reducer Assembly

Item Description Item Description Item Description
1 Housing 16a Seal, Oil, High-Speed 31 Screw, Hex Socket Head
2 Bearing Carrier, Live End 17 Seal, Oil, Low-Speed 32 Screw, Hex Head
3 Bearing Carrier, Dead End 18 Retaining Ring, Internal High-Speed 37* Fan
4 Shim, Bearing Carrier 19 Retaining Righ, External High-Speed 38* Screw, Hex Head
5 Shaft, High-Speed 20 Fitting, Vent 39* Nut, Full Hex
(Specify Motor Frame Size) 21 Plug, Pipe 40* Lockwasher, Helical Spring
6 Shaft, Single Ext. Low-Speed 22 Lube Plug 41* Housing Fan
7 Shaft, Double Ext. Low-Speed 23 Cap, Thread Protective 42* Screw, Hex Socket Head
8 Space, Low-Speed 24 Screw, Hex Head 43* Washer
9 Shield, Grease 25 Plate, Indentification 44 Spacer (S/N 300 thru 600)
10 Worm Gear 26 Base, Horizontal 45 Key, High Speed
11 Key, Low-Speed 27 Screw, Hex Head 48 Splash Guard
12 Bearing, Ball, High-Speed 28 Base, Vertical, Low 49 Fitting, Lube
13 Cup, Bearing, Low-Speed 29 Base, Vertical, High 51 Gasket, Flip Compound
14 Cone, Bearing, Low-Speed 30 Housing, Motor Bell (3 oz Tube)
15 Plug, Bore 30a Housing, Motor Bell * For fan cooled units
16 Seal, Oil, High-Speed S/N 300 thru 700 only.
CD315 2-1-9
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Chapter 2
Precision gearing and bearings in Ohio Gear Speed Reducers, together with closer tolerances require that high
grade lubricants be used for optimum performance, maximum efficiency and long life.
The Ohio Gear Uniline Unit has been factory filled with lubricant *(A.G.M.A. #7 Compounded) in sufficient
quantity to operate at any factory recommended mounting. Reducers are shipped with pipe plugs installed in all
fitting openings. In addition a vent/fill fitting is enclosed with unit. After unit is placed in its proper mounting
position, determine location of vent/fill fitting and install. At installation it is recommended that level plug be
removed to check proper level and to drain excess lubricant if necessary.
*A.G.M.A. #7 Compounded Lubricant provides satisfactory lubrication for ambient temperatures from 20 °F
to 100 °F. For operation in ambient ranges other than above, consult factory.
Level plugs assure proper amount of lubricant for reducer to operate at an input speed of 1750 rpm. It may be
necessary to vary lubrication levels for operation at speeds other than 1750 rpm input.
A level too high may cause overheating at high speeds, or a level too low may cause premature wear or failure
at low speeds. For optimum operation at input speeds other than 1750 rpm, consult factory. For all mounting
positions where the output shaft is vertical, the plug in the upper bearing carrier should be removed and
replaced with a grease fitting furnished with unit. At each oil change, or more frequently depending upon
severity of service, introduce approximately 2 oz. of good quality NLGI #1 or #2 cup grease to upper bearing.
After 100 hours or two weeks of operation, lubricant should be drained and unit flushed. Unit should then be
refilled to proper level with filtered original fill or fresh lubricant. At intervals of 2500 operational hours or six
months (whichever occurs sooner) lubricant should be drained and replaced (under normal conditions). More
frequent intervals of lubricant change are suggested for unusual operational or environmental conditions.
Consult factory for recommendation.
E. INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE
WARNING: IMPROPER JACKING CAN RESULT IN PERSONAL

INJURY, DEATH, AND/OR POSSIBLE DAMAGE TO THE LOADER.
1. Engage the parking brake and chock the wheels.
2. Position jack under front or rear bumper and raise the loader.
3. Position jack stands under the bumper and lower the loader onto the jack stands.
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Chapter 2
F. ACCELERATOR CABLE ADJUSTMENT
1. Accelerator
(a) Ensure that the throttle pull springs and throttle pull rod are properly installed and the
accelerator cable is attached to the accelerator pedal and the throttle.
(b) Loosen the fastener(s) on the accelerator linkage clamp.
(c) Position the accelerator cable such that the accelerator pedal is all the way up and the
throttle pull springs are relaxed. Tighten the fastener(s) on the accelerator linkage
clamp.
G. PARK BRAKE ADJUSTMENT
1. Discussion
When properly adjusted, the parking brake will prevent the loader from rolling when parked on
a 8% grade. Since the parking brake is on the drive shaft and brakes through the reduction in
the differential, engaging a properly adjusted parking brake should not require an excessive
amount of force; however, some slight resistance will be present when engaging.
2. Procedure
(a) If parking brake hand lever is equipped with a locking set screw, loosen the set screw.
(b) To tighten parking brake, turn knurled knob at the end of the hand lever clockwise.
(c) To loosen parking brake, turn knurled knob at the end of the hand lever
counterclockwise.
(d) If parking brake hand lever is equipped with a locking set screw, tighten the set
screwscrew.
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Chapter 2
2-1-12 CD315
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Chapter 2
SECTION 2: TROUBLESHOOTING
The 660E is an electric vehicle and depends on sound electrical connections for all its power. Subsequently, a
higher emphasis should be placed on checking for and maintaining clean, corrosion-free electrical connections.
Many of the troubleshooting procedures listed in the following pages indicate possible connection or contact
problems that might prevent the proper flow of electricity from one point to the next.
IN ANY TROUBLESHOOTING PROCEDURE, ALWAYS LOOK FOR

Note APPROPRIATE ELECTRICAL CONNECTIONS BEFORE
ATTEMPTING TO REMOVE, REPLACE OR TROUBLESHOOT
COMPONENTS.
WARNING: WHEN TESTING AN ELECTRIC VEHICLE, JACK THE

DRIVE WHEELS OFF THE GROUND AND SECURE IN THIS
POSITION WITH JACK STANDS OF ADEQUATE CAPACITY.
WARNING: DANGER! AVOID DEATH! WHEN TESTING THE

CONTROLLER, DO NOT TOUCH HIGH VOLTAGE CONNECTIONS
EXCEPT WITH PROPER TEST EQUIPMENT. WHEN WORKING
INSIDE THE CONTROL PANEL, USE THE FOLLOWING PROCEDURE
TO DISCHARGE THE CAPACITORS INSIDE THE CONTROLLER:
1. TURN THE IGNITION KEY ON.
2. DISCONNECT THE BATTERY.
3. WAIT 10 SECONDS, THEN TURN THE KEY OFF.
CD315 2-2-1
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Chapter 2
A. 72/80 VOLT SYSTEMS
PROBLEM CAUSE CORRECTION
1. No power; unit will not drive; (a) Battery charge insufficient. (a) Charge battery.
indicator light ON.
(b) Possible controller failure. (b) Check if system reset
corrects problem: make sure
that the brake is off, shifter is
in neutral, key switch is on
and accelerator is in up
position. Turn key off and
back on again. Controller may
be failing; continue to monitor
situation.
(c) System component failure. (c) Plug handset into card &
check for fault codes. Use
fault codes to isolate problem.
(d) Broken wire or bad (d) Troubleshoot wiring.

connection.
2. No power; unit will not drive; (a) Low battery. (a) Charge battery.
indicator light OFF.
(b) Emergency stop button on (b) Pull emergency stop buttons
conveyor is engaged. out.
(c) Main contactor not pulling in (c) Determine if problem is bad

when switch is on. coil or wiring. Replace bad
contactor part.
(d) No 12V at circuit breakers (d) Replace fuse and/or

due to 80-12 converter failure converter.
or internal fuse failure.
(e) Broken wire or bad (e) Troubleshoot wiring.

connection.
2-2-2 CD315
Rev 4
Chapter 2
3. Unit drives in forward but not (a) Wire came off shifter micro (a) Reinstall wire on switch and
reverse, or unit works in switch. tie wire to harness to help
reverse but not forward. retain wire on switch.
(b) No continuity across limit (b) Adjust or replace switch.

switch(s) when engaged.
(c) Fwd/rev contactor not closing (c) Troubleshoot contactor.

in one or both directions. Repair or replace as needed.
(d) Electronic component failure. (d) Plug in handset, check

trouble codes.
4. Partial or complete loss of (a) Main Switch in "Off" position. (a) Turn main power switch on.
12V power (automotive
systems). (b) Emergency stop(s) engaged. (b) Pull emergency stops out.
(c) No power to supply side of (c) Go to Complaint 5 (below).

circuit breakers.
(d) Bad 12V ground. (d) Clean and/or tighten ground.
(e) Circuit breakers tripped. (e) Replace bad breakers.
(f) 12V wiring problem. (f) Troubleshoot 12V wiring.
5. No 12V at circuit breaker. (a) No 72/80V power going into (a) Check main fuse &
converter. troubleshoot contactor,
replacing components as
necessary.
(b) Converter or converter fuse (b) Replace converter or fuse.

bad.
CD315 2-2-3
Rev 4
Chapter 2
B. HYDRAULIC SYSTEMS
1. Hydraulic System Failure (a) Hydraulic pump fuse failure. (a) Replace fuse.
(b) Wiring and/or connections (b) Tighten 72/80 volt ground.

failure. Clean and tighten
connections at contactors.
(c) Pump contactor failure. (c) Troubleshoot contactor;

replace components as
needed.
(d) Hydraulic pump failure. (d) Troubleshoot hydraulic pump;

replace as needed.
(e) Fluid device (i.e. valves, etc.) (e) Refer to hydraulic schematic,
failure. page 2-2-29.
2-2-4 CD315
Rev 4
Chapter 2
C. SERVICE BRAKES
1. Excessive pedal travel or (a) Low fluid level. (a) Add fluid, bleed system, and
pedal goes to floor check for leaks.
consistently.
(b) Hydraulic system. (b) Refer to master cylinder.
(c) Drum brakes out of (c) Repair or replace as required.

adjustment, worn.
(d) Loose or improper (d) Repair or replace as required.

attachment of pedal, pedal
support booster & master
cylinder.
(e) Misaligned anchor plate. (e) Refer misaligned disc brake

anchor plate diagnosis.
2. Brake pedal feels spongy (a) Low fluid level. (a) Add fluid, bleed system, and
when fully applied. check for leaks.
(b) Brakes out of adjustment. (b) Adjust brakes.
(c) Front wheel bearing out of (c) Adjust front wheel bearings.
adjustment.
(d) Disc brake caliper attachment (d) Replace or tighten as

loose. required.
(e) Worn or damaged self- (e) Remove drum & check lining
adjusters. for proper adjustment.
3. Noise at wheels when brakes (a) Worn or scored brake drums (a) Inspect, repair or replace as
are applied-squeaks or and linings or rotors & pads. required.
chatter.
(b) On disc brakes- missing or (b) Replace disc brake pads.
damaged brake pad
insulators.
(c) Burrs or rust on caliper that (c) Clean or deburr caliper.

would obstruct seating of
shoe to caliper.
(d) Dirty, greased or glazed (d) Clean or replace.

linings.
CD315 2-2-5
Rev 4
Chapter 2
4. Brakes pull to one side. (a) Unequal air pressure in tires. (a) Inflate tires to correct
pressure.
(b) Grease or fluid on lining. (b) Clean, sand &/ or replace

linings.
(c) Loose or missing disc brake (c) Replace missing bolts.

caliper attaching bolts. Tighten to proper torque.
(d) Restricted brake lines or (d) Repair or replace as required.

hoses.
5. Brake warning light on. (a) Low fluid level. (a) Add fluid, bleed system &
check for leaks.
(b) Worn or damaged brake (b) Replace switch.

warning switch.
(c) Worn or damaged master (c) Perform master cylinder

cylinder. diagnostic test. Repair or
replace as required.
2-2-6 CD315
Rev 4
Chapter 2
D. PARKING BRAKE
1. Parking brake will not hold. (a) Parking brake cable out of (a) Adjust parking brake cable.
adjustment.
(b) Rear brakes out of (b) Adjust rear brakes.

adjustment.
(c) Parking brake linkage, (c) Repair or replace linkage as

release lever, clevis & rachet required.
binding.
2. Parking brake will not release (a) Manual release brake control (a) Repair or replace manual
or fully return. components binding or parking brake control.
damaged.
(b) Parking brake linkage & cable (b) Repair or replace as required.
binding.
(c) Worn or damaged rear brake (c) Check rear brake shoe
components. retracting springs & parking
brake levers. Repair as
required.
3. Parking brake lever hard to (a) Brake handle out of (a) Adjust or repair.
pull up. adjustment.
(b) Frozen or damaged brake (b) Light taps with a mallet may
cable. free cable & brakes;
otherwise apply warm air
from a ground equipment
heater.
CD315 2-2-7
Rev 4
Chapter 2
E. CONVEYOR LIFTS
1. The front & rear lift arms will (a) Low oil level due to leak in (a) Service hydraulic tank locate
not raise conveyor. system. & repair leak. Recheck
system.
(b) Defective hydraulic pump. (b) Repair or replace.
(c) Relief valve set too low. (c) Adjust or repair.
(d) Lift control valve defective. (d) Replace or repair.
2. Conveyor raises too slowly. (a) Internal valve leak. (a) Repair or replace.
(b) Internal cylinder leak. (b) Repair or replace.
(c) Low oil level in tank. (c) Add oil.
(d) Worn hydraulic pump. (d) Repair or replace.
(e) System relief valve too low. (e) Adjust.
(f) Relief valve leaking internally. (f) Repair or replace.
3. Conveyor creeps down with (a) Internal leak in cylinder or (a) Repair or replace.
control valve in the “OFF” valve.
position.
2-2-8 CD315
Rev 4
Chapter 2
F. CONVEYOR BELT
1. Conveyor belt will not work. (a) Low charge on battery; low (a) Recharge battery.
battery-power hour meter
lockout.
(b) Park brake is off. (b) Engage hand brake.
(c) Controller is not receiving (c) Check for fault codes with
proper direction and handset.
acceleration signals.
(d) Wiring or connection problem. (d) Troubleshoot wiring.
2. Belt lurches or stop/starts. (a) Battery charge low. (a) Recharge battery.
(b) Belt out of adjustment on belt (b) Tighten belt tensioners. (See
tensioners. specific section.)
(c) Worn belt motor brushes. (c) Replace belt motor brushes.
(d) Belt brake engaging (d) Troubleshoot belt brake

improperly. device, wiring and circuit
components.
3. Belt works in one direction (a) Shift lever is not in neutral. (a) Shift lever to neutral position.
only.
(b) Belt forward relay failing. (b) Replace forward relay.
(c) Belt reverse relay failing. (c) Replace reverse relay.
(d) Reversing contactor failure. (d) Troubleshoot contactor,

replace components as
needed.
4. Conveyor belt will not run in (a) Belt drive chain broken or too (a) Repair or replace.
either direction, when belt loose.
motor is running.
(b) Belt drive shaft key missing. (b) Replace.
CD315 2-2-9
Rev 4
Chapter 2
5. Forward belt speed too low (a) Loose conveyor belt. (a) Adjust rear take-up.
(b) Too much load on conveyor (b) Basic capacity is 2000 lb. At
&/or conveyor angle too conveyor angles exceeding
steep. 15°, the capacity must be
reduced below 2000 lb.
(c) Binding in belt drive or rollers. (c) Adjust, lubricate, repair or

replace.
6. Drive chain is noisy. (a) Chain is out of adjustment. (a) Adjust & lubricate.
7. Belt does not track properly. (a) Rollers are out of adjustment. (a) Adjust.
8. Conveyor belt will not run in (a) Open wiring or stop button (a) Inspect circuit & repair.
either direction when controls stuck in open circuit.
are actuated.
9. Belt will not stop when "stop" (a) Short circuit across ineffective (a) Repair or replace.
button is pushed. "STOP" button.
2-2-10 CD315
Rev 4
Chapter 2
G. ELECTRICAL SCHEMATICS AND WIRING DIAGRAMS
NOTE DIRECTION OF DIODE
NOTE DIRECTION
OF DIODE
NOTE:
SWAP NO. 26 AND NO. 27 WIRE FOR MERCURY SERVICES REVERSE SHIFTER Power Wire Locations - Sevcon MCM
Controller (Up to S/N 254)
Figure 2-1. Wiring Diagram, 660E (Up to S/N 254)
CD315 2-2-11
Rev 3
Chapter 2
72/80V Wiring Diagram with 12V

System - Sevcon MCM Controller
(Up to S/N 254)
Figure 2-2. Wiring Diagram, 660E (Up to S/N 254)
2-2-12 CD315
Rev 3
Chapter 2
Standard Beltloader Control Circuits -

Sevcon PowerpaK Controller
(S/N 254 thru 389)
Figure 2-3. Wiring Diagram, 660E (S/N 254 thru 389) (Sheet 1 of 2)
CD315 2-2-13
Rev 3
Chapter 2

(S/N 254 thru 389)
Figure 2-3. Wiring Diagram, 660E (S/N 254 Thru 389) (Sheet 2 of 2)
2-2-14 CD315
Rev 3
Chapter 2

(S/N 390 and Up)
Figure 2-4. Wiring Diagram, 660E (S/N 390 and Up) (Sheet 1 of 2)
CD315 2-2-15
Rev 3
Chapter 2

(S/N 390 and Up)
2-2-16 CD315
Rev 3
Chapter 2

Sevcon PowerpaK Controller -
Option with Charger Port
(S/N 254 thru 389)
CD315 2-2-17
Rev 3
Chapter 2

Figure 2-5. Wiring Diagram, 660E (S/N 254 thru 389) (Sheet 2 of 2) (S/N 254 thru 389)
2-2-18 CD315
Rev 3
Chapter 2

(S/N 390 and Up)
CD315 2-2-19
Rev 3
Chapter 2

(S/N 390 and Up)
2-2-20 CD315
Rev 3
Chapter 2

Option with Quick Charge /
Contactor Controller
(S/N 254 thru 389)
CD315 2-2-21
Rev 3
Chapter 2

Option with Quick Charge /
Contactor Controller
Figure 2-7. Wiring Diagram, 660E (S/N 254 Thru 389) (Sheet 2 of 2) (S/N 254 thru 389)
2-2-22 CD315
Rev 3
Chapter 2

Option with Quick Charge
(S/N 254 thru 389)
CD315 2-2-23
Rev 3
Chapter 2

(S/N 254 thru 389)
2-2-24 CD315
Rev 3
Chapter 2

(S/N 390 and Up)
CD315 2-2-25
Rev 3
Chapter 2

Sevcon PowerpaK Controller - Option
with Quick Charge
(S/N 390 and Up)
2-2-26 CD315
Rev 3
Chapter 2
Figure 2-10. 660E Conveyor Switch Harness - Right Front
CD315 2-2-27
Rev 3
Chapter 2
Figure 2-11. 660E Conveyor Switch Harness - Left Front
2-2-28 CD315
Rev 3
Chapter 2
Figure 2-12. 660E Hydraulic Schematic
CD315 2-2-29
Rev 3
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:
PROPRIETARY AND CONFIDENTIAL. USE OF THIS DRAWING WITHOUT WRITTEN

DRAWN BY: PERMISSION IS PROHIBITED.
NO. OF SHEET (s) DRAWING NO: REV.
2-2-30 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-31
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-32 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-33
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-34 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-35
Rev 4
Chapter 2
DATE:
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DWG SIZE:

2-2-36 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-37
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-38 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-39
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-40 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-41
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-42 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-43
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-44 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-45
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

Figure 2-17. UAL-Wiring Diagram, 660E (S/N 874 and Up) (Sheet 1 of 4)
2-2-46 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-47
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

2-2-48 CD315
Rev 4
Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:

CD315 2-2-49
Rev 4
Chapter 2
This page intentionally left blank.
2-2-50 CD315
Rev 4
Chapter 2
SECTION 3: REMOVAL/INSTALLATION
The following procedures for removal and installation of vehicle components outline the steps and
precautions to take when removing items for replacement or repair.
WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO

PERFORMING WORK ON THIS EQUIPMENT.
A. REAR AXLE REMOVAL
1. Jack up the rear frame of the mobile conveyor and place jack stands under the frame forward
of the rear axle.
2. Disconnect drive shaft at rear axle universal.
3. Disconnect hydraulic brake line mounted on rear axle.
CAUTION: WIPE CONNECTION CLEAN BEFORE OPENING BRAKE

SYSTEM.
CAUTION: CAP OR PLUG ALL OPEN PORTS OR LINES.
Note NOTE: Use backup wrenches on all mating parts.
4. Use a transmission jack to support the axle.
WARNING: DO NOT LIFT VEHICLE OFF JACK STANDS.
5. Remove U-bolts attaching axle to frame.
6. Lower transmission jack and roll axle to the rear.
CD315 2-3-1
Rev 4
Chapter 2
B. REAR AXLE INSTALLATION
Installation of the rear axle is performed by reversing the order of steps A1 through A6, preceding.
WARNING: BLEED AIR FROM BRAKE SYSTEM UPON

COMPLETION OF INSTALLATION.
C. FRONT AXLE REMOVAL
1. Jack up the front frame of the mobile conveyor and place jack stands under the frame
rearward of the front axle.
2. Disconnect hydraulic brake lines from front disc brake assemblies.
CAUTION: WIPE CONNECTION CLEAN BEFORE OPENING BRAKE

SYSTEM.
Note NOTE: Use backup wrenches on all mating parts.
3. Use a transmission jack to support the axle.
WARNING: DO NOT LIFT VEHICLE FRAME OFF JACK STANDS.
4. Remove U-bolts attaching axle to frame.
5. Lower transmission jack and roll axle out to the rear.
D. FRONT AXLE INSTALLATION
Installation of the front axle is performed by reversing the order of steps C1 through C5, preceding.
WARNING: BLEED AIR FROM BRAKE SYSTEM UPON

COMPLETION OF INSTALLATION.
2-3-2 CD315
Rev 4
Chapter 2
E. CONVEYOR REMOVAL / INSTALLATION
There is currently no published procedure available for the removal and installation of the conveyor
assembly. It is the opinion of TUG Technologies Corp. that this procedure should, in all probability,
never be needed. In fact, all the major components in the chassis, as well as the conveyor, are
accessible for removal and installation without the requirement of conveyor removal.
You should note, however, that should such a procedure become necessary due to severe damage of
the conveyor weldment or other cause, the electrical wiring between major chassis components and
conveyor components has been wired directly. There are no wiring disconnect points between the
conveyor and chassis. Any procedure used for the removal of the conveyor assembly would involve
the removal of the conveyor wiring harness all the way to its connection points in the chassis. An
alternate to this procedure would be the installation of terminal strips and wire connectors within the
back lower portion of the conveyor.
Should this procedure become necessary, contact your TUG Technologies Corp. representative. He
or she will make the necessary arrangements to provide you with the appropriate parts kit and/or list
of procedures.
F. CONVEYOR BELT DRIVE MOTOR REMOVAL
WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER

CONVEYOR.
WARNING: KEEP HANDS AND CLOTHING AWAY FROM

CONVEYOR BELT AND BELT DRIVE WHILE BELT IS IN MOTION.
1. Drive belt slowly, until drive chain master link is visible in the area just behind the drive
pulley.
NOTE: Do not remove master link unless other procedures (following)

Note prove unsuccessful.
WARNING: LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES.

KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM
BATTERIES. DO NOT SMOKE IN THE VICINITY OF THE BATTERY.
DO NOT SHORT BATTERY TERMINALS. BEFORE REMOVING OR
INSTALLING BATTERY, REMOVE METAL BRACKETS, WRIST
WATCH BANDS, RINGS, ETC. POSITIVE MUST BE DISCONNECTED
FIRST TO PREVENT SPARKS FROM ACCIDENTAL GROUNDING.
ALWAYS WEAR EYE PROTECTION AROUND BATTERIES. WASH
HANDS OR CLOTHING IMMEDIATELY IF YOU ACCIDENTALLY
COME IN CONTACT WITH ELECTROLYTE.
CD315 2-3-3
Rev 4
Chapter 2
2. Stop belt and disconnect battery.
3. Slacken chain.
(a) Remove all motor and brake wiring.
(b) Loosen reducer take-up bolts.
(c) Loosen reducer mounting bolts.
(d) Slide drive assembly forward.
(e) Remove chain.
4. Remove motor mounting bolts: Remove motor.
G. CONVEYOR BELT DRIVE MOTOR INSTALLATION
Installation of the drive motor is performed by reversing the order of steps Fl through F4, preceding.
H. HOLDING VALVE REMOVAL
WARNING: DISCONNECTING HYDRAULIC LINES FROM A

CONVEYOR CYLINDER-HOLDING VALVE WILL RESULT IN
LOWERING OF THE CONVEYOR NOT OTHERWISE SUPPORTED.
1. Elevate conveyor and ensure that safety prop is in place.
2. Tag and disconnect hydraulic hoses and tube fittings at the valve.
CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING

SYSTEM.
Note NOTE: Use backup wrenches on all mating fittings.
2-3-4 CD315
Rev 4
Chapter 2
WARNING: USE SAFETY PROP WHENEVER WORKING UNDER

CONVEYOR.
3. If removing the front lift cylinder holding valve, raise the front of the conveyor and support
with the safety prop.
4. If removing the rear lift cylinder holding valve, raise and block up the rear of the conveyor.
5. Remove attaching hardware and valve.
I. HOLDING VALVE INSTALLATION
Installation of the holding valve is performed by reversing the order of steps H1 through H5,
preceding.
J. LIFT CYLINDERS CONTROL VALVE REMOVAL
1. Remove seat and seat plate.
2. Remove cotter pins from hand lever to valve linkage and remove hand levers.
3. Tag and disconnect hydraulic tube fittings.

SYSTEM.
4. Remove attaching hardware and valve.
CD315 2-3-5
Rev 4
Chapter 2
K. LIFT CYLINDERS CONTROL VALVE INSTALLATION
Installation of the control valve is performed by reversing the order of steps J1 through J4, preceding.
WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR IS BLED

FROM SYSTEM.
CAUTION: DO NOT OVER TORQUE ATTACHMENT HARDWARE.

OVER TORQUING MAY DISTORT VALVE BODY AND CAUSE
BINDING OF VALVE SPOOLS. PERFORM OPERATIONAL CHECK OF
HYDRAULIC SYSTEM.
L. FRONT LIFT CYLINDER REMOVAL
1. Elevate front of belt conveyor either hydraulically or with a hoist and sling (while holding lift
cylinder control valve open).
2. Position conveyor support prop under conveyor lift arms (cylinder attaching point).
3. Disconnect hydraulic hoses from holding valve (mounted on cylinder).

SYSTEM.
WARNING: DISCONNECTING HYDRAULIC LINES FROM A

CONVEYOR LIFT CYLINDER HOLDING VALVE WILL RESULT IN
LOWERING OF THE CONVEYOR IF NOT OTHERWISE SUPPORTED.
4. Disconnect hydraulic tube fittings at each end of cylinder and remove holding valve.
5. Remove nut and pivot bolt from cylinder rod end.
6. Remove nut and pivot bolt from cylinder base end.
2-3-6 CD315
Rev 4
Chapter 2
7. Remove cylinder with portable hoist or its equivolent.
WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITH

HOIST OR CYLINDER AXLE WHILE REMOVING FRONT LIFT
CYLINDER.
M. LIFT CYLINDER INSTALLATION
1. Using a portable hoist or its equivolent, position cylinder with cylinder base mount aligned
with frame mounting bracket.
WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITH

HOIST OR CYLINDER WHILE INSTALLING FRONT LIFT
CYLINDER.
2. Install bolt and nut in cylinder base mounting hole.
3. Replace holding valve and connect hydraulic line to base of cylinder.
4. Start engine and hydraulically extend cylinder rod to lift frame attaching point.
5. Install bolt and nut.
6. Connect hydraulic line to rod end of cylinder.
WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEEN

BLED FROM SYSTEM.
7. Start engine, raise conveyor and stow conveyor support prop.
N. REAR LIFT CYLINDER REMOVAL
1. Raise rear of conveyor and block up lift frame to prevent it from lowering.
2. Tag and disconnect hydraulic hoses to holding valve.

SYSTEM.
CD315 2-3-7
Rev 4
Chapter 2
3. Disconnect hydraulic lines at each end of cylinder and remove holding valve.
4. Remove nut and bolt from rod end of cylinder.
5. Remove nut and bolt from base of cylinder.
6. Remove cylinder.
O. REAR LIFT CYLINDER INSTALLATION
Installation of the rear lift cylinder is performed by reversing the order of steps Nl through N6,
preceding.
WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEEN

BLED FROM SYSTEM.
P. HYDRAULIC PUMP REMOVAL
1. Lower conveyor down to resting position on inner frame.
2. Raise hydraulic access panel (located on top of right-center body panel).
3. Disconnect hydraulic lines from pump.

SYSTEM.
Note NOTE: Tie off loose hoses to prevent spillage.
4. Loosen and remove (2) mounting bolts from the base of pump.
5. Slide pump off pump motor shaft.
2-3-8 CD315
Rev 4
Chapter 2
Q. HYDRAULIC PUMP INSTALLATION
Installation of the hydraulic pump is performed by reversing the order of steps P1 through P5,
preceding.
R. HYDRAULIC PUMP MOTOR REMOVAL / INSTALLATION
1. Elevate front of conveyor, put safety prop in place, and allow weight of conveyor to rest on
prop.
3. Follow procedures P2 through P5 to remove hydraulic pump.
4. Disconnect (2) cables from pump motor.
Note NOTE: Positive cable attachment is to rearward end of motor.
5. Remove (4) mounting bolts.
Note NOTE: Motor must be supported before removing mounting bolts.
6. Follow these steps in reverse order to install pump motor.
S. HYDRAULIC PUMP MOTOR BRUSHES INSPECTION / REPLACEMENT
Note NOTE: Motor need not be removed for brush inspection or replacement.
2. Access pump motor.
3. Note wrap-around band with clip at rearward end of motor. Lift clip handle to release. Slide
band off motor.
4. Use flat blade screwdriver to remove brush lead screw on one brush.
CAUTION: DO NOT DROP SCREW INTO MOTOR.
5. Pull spring clip away from brush and slide brush out of guide.
CD315 2-3-9
Rev 4
Chapter 2
6. Repeat procedures 4 and 5 for other brush.
7. Reinstall or replace brushes in reverse order.
8. Reconnect battery.
T. DRIVE MOTOR BRUSH INSPECTION / REPLACEMENT
Follow procedures similar to S1 through S8. Exceptions: Drive motor is located in center of vehicle
beneath drive train cover and has (8) brushes rather than (2). Elevate front of conveyor, position
safety prop, allow conveyor to rest on safety prop.
U. DRIVE MOTOR REMOVAL
1. Elevate front of conveyor, position safety prop, allow conveyor to rest on safety prop.
WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER

CONVEYOR.
2. Jack up rear of vehicle, place on jack stands.
4. Open motor access lid.
5. Remove (4) leads from motor.
Note NOTE: All leads and terminals on motor are marked A1, A2, S1, & S2.
6. There is a cylindrical cover on the junction between the drive motor and the reduction gear
box. Remove cover by removing (4) screws.
Note NOTE: Be careful to keep track of gaskets between cover halves.
7. Manually rotate drive shaft until master link of chain is at top center.
8. Use a screwdriver to remove master link clip.
9. Use a small hammer to tap master link out of chain. Remove chain.
10. Remove (4) mounting bolts at base of drive motor. Remove drive motor.
2-3-10 CD315
Rev 4
Chapter 2
V. DRIVE MOTOR INSTALLATION
Installation of the drive motor is performed by reversing the order of steps U1 through U10,
preceding.
W. DRIVE REDUCTION GEAR BOX REMOVAL
1. Follow procedures U1 through U9 to detach drive reduction gear box from drive motor
output shaft.
2. Loosen the (2) set screws located at the reduction gear output shaft connection to the drive
shaft.
3. Loosen and remove (2) U-bolts at forward section of drive shaft.
4. Use wood block and hammer or mallet to tap forward drive shaft section toward gear box.
Tap forward only far enough to release and clear drive shaft u-joint.
5. Remove mounting bolts at base of gear box.
6. Remove gear box.
X. DRIVE REDUCTION GEAR BOX INSTALLATION
Reverse procedures in REMOVAL section to install reduction gear box. Alignment with drive shaft
and drive motor sprocket should be established before tightening gear box mounting bolts.
CD315 2-3-11
Rev 4
Chapter 2
2-3-12 CD315
Rev 4
Chapter 2
SECTION 4: BELT TRACKING INSTRUCTIONS
The following procedure is offered as a guide for aligning the cargo belt to the center of the rollers in a
minimum length of time.
WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS

WHILE CONVEYOR IS RUNNING.
Figure 1-1. Conveyor Belt Adjustment
A. DISCUSSION
Basic fundamentals of belt alignment are as follows:
1. Moving the rear idler roller to the rear on one side with the jack screw tightens that side of
the belt, causing the belt to move to the other side.
Moving the rear idler roller to the front on one side with the jack screw loosens that side of
the belt, causing the belt to move to that side.
2. Moving a crowder roller end toward the large end roller will tighten that side of the belt and
force the belt to the other side of the end roller.
Moving a crowder roller end toward the center of the conveyor will loosen that side of the
belt and allow the belt to move to that side of the end roller.
These fundamentals hold true on both ends of the conveyor.
Adjust the front crowder roller only when the belt is running in the reverse direction. Adjust
the rear crowder roller only when the belt is running forward.
CD315 2-4-1
Rev 3
Chapter 2
3. It is necessary to work from end to end when tracking a belt as adjustment at one end will
affect the other end. When tracking, make small adjustments and allow the belt to run and
settle in between adjustments. Normal time for an experienced mechanic to track a belt is 45
minutes to one hour.
B. PROCEDURE
NOTE: Refer to safety chapter prior to performing any maintenance task

Note
on this equipment and observe all applicable precautions.
1. Check the roller end bearings for failure.
2. Check the front driver and rear idler roller bearings and collar set screws. There are two set
screws in a collar that positions each roller in the frame. Insure that the rollers are centered
and that the set screws are tight. If either roller is not centered, loosen the set screws, pry the
roller into position and secure the set screws. See Figure 2 for locations.
Figure 1-2. Roller / Set Screw Locations
3. Raise the front of the conveyor; ensure that the front crowder roller is centered and that the
bearing collar set screws are tight. Make any necessary adjustments as in step 2 above.
4. Raise the rear of the conveyor and insure that the rear crowder roller is centered and that the
bearing collar set screws are tight. Make any necessary adjustments as in step 2 above.
5. Raise the front of the conveyor to approximately 4 feet high and the rear to about 3'6" high.
6. Position the front crowder in its adjusting slots as shown in Figure 3.
2-4-2 CD315
Rev 3
Chapter 2
Figure 1-3. Front Crowder Roller Adjustment Figure 1-4. Rear Crowder Roller Adjustment
7. Position the rear crowder roller in its adjusting slots as shown in Figure 4.
8. Adjust the rear idler roller at the jack screw nuts to tension the belt. Adjust the rear idler
roller so that it is equidistant from the rear end of the conveyor on both sides. Correct tension
is achieved when 4" to 6" of the belt can be rolled up at the center of the conveyor (see
Figure 5).
WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS

WHILE CONVEYOR IS RUNNING.
Figure 5: Rear Idler Adjustment
CD315 2-4-3
Rev 3
Chapter 2
9. With the belt running in the reverse direction, observe the position of the belt at the front of the
conveyor and correct as follows:
(a) To adjust belt in direction shown in Figure 6, move left side (as viewed from rear) of
the front crowder roller toward the front driver roller, both bolts, until the belt tracks
on center. Move 1/8" at a time.
Figure 6: Front Conveyor Belt Centering
WARNING: STOP CONVEYOR ANY TIME THE LEFT SIDE FRONT

CROWDER ROLLER IS ADJUSTED!
(b) To adjust belt in opposite direction, move right side (as viewed from rear) of the front
crowder roller toward the front driver roller, both bolts, until the belt tracks on center.
Move 1/8" at a time.
(c) To adjust belt in direction shown in Figure 7, move right side (as viewed from rear)
of the front crowder roller toward the front driver roller, until the belt tracks on
center. Move 1/8" at a time.
(d) To adjust belt in opposite direction, move left side (as viewed from rear) of the front
crowder roller toward the front driver roller, until the belt tracks on center. Move 1/8"
at a time.
10. Continue to make adjustments until the belt runs at the center of the front roller.
2-4-4 CD315
Rev 3
Chapter 2
Figure 7: Rear Conveyor Belt Centering
11. Continue to run the conveyor in reverse while adjusting the rear jack screw nuts to center the
belt on the rear idler roller.
12. Repeat steps 9 through 11 until both ends of the belt are centered and running true, then shift
belt into forward direction.
13. Adjust the rear crowder roller to center the belt on the rear idler roller.
14. When belt is running on center, reverse belt direction and observe alignment. If belt
alignment is still satisfactory in reverse, shift belt direction back to forward. The belt should
stay within 1/2" in both directions at both ends. If it does not, go back to step 9 and repeat
steps as often as necessary to track belt.
15. Once belt is tracked, shut off motor and securely tighten all adjusting bolts.
CD315 2-4-5
Rev 3
Chapter 2
2-4-6 CD315
Rev 3
Chapter 2
SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS
A. Adjust the following valves in the order in which they are listed. All pressure checks and settings are
to be made when the hydraulic pump is operating.
WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO

PERFORMING WORK ON THIS EQUIPMENT.
B. If not already installed, install a 0-3000 psi hydraulic gauge in the tee fitting, which is located behind
the left front wheel and approximately 6" in front of the axle.
1. Main two-lever control valve.
(a) Pressure relief valve setting is 1500 psi.
(b) The main system pressure valve is located in the left side of the two-lever valve
under the seat.
While observing the pressure gauge, move the rear cylinder lever down and hold in
the down position, dead-heading the pump. Pressure should read 1500 ± 50 psi. To
adjust, turn the valve screw clockwise to raise pressure or counterclockwise to reduce
pressure. Access is provided by hole in the plate beside the valve levers. Loosening
or tightening the lockout may require removing the seat and plate.
2. Pressure Relief Valve, Front Cylinder Down
(a) Pressure relief valve setting is 900 ± 50 psi.
(b) The blue Racine relief valve is approximately 3" x 3" x 1.5" in size and is located
under the seat. Access can be gained through the opening in the left frame rail beside
the seat.
While observing the pressure gauge, lower the front of the conveyor from the fully
raised position. Pressure should read 900 ± 50 psi.
To adjust, turn the knob on the valve clockwise to raise pressure or counterclockwise
to reduce pressure.
3. Pressure Relief Valve, Steering
(a) Pressure relief valve setting is 1000 ± 50 psi.
CD315 2-5-1
Rev 3
Chapter 2
(b) The blue Racine relief valve is approximately 3" x 3" x l.5" in size and is located
behind the left front wheel against the left frame rail.
While observing the pressure gauge, turn the steering wheel to full left and hold.
Pressure should read 1000 ± 50 psi.
To adjust, turn the knob on the valve clockwise to raise pressure or counterclockwise
to reduce pressure.
2-5-2 CD315
Rev 3
Chapter 3
CHAPTER 3: OVERHAUL
TABLE OF CONTENTS
SECTION 1: RECOMMENDED OVERHAUL PERIODS ......................................................... 3-1-1

A. General ................................................................................................................. 3-1-1
B. Hydraulic Cylinders ............................................................................................... 3-1-1
C. Hydraulic Pump .................................................................................................... 3-1-1
D. Other Components ............................................................................................... 3-1-1
SECTION 2: STEER AXLE ........................................................................................................ 3-2-1

A. Discussion ............................................................................................................ 3-2-1
B. Inspection and Overhaul ....................................................................................... 3-2-1
1. Bearings and Seals................................................................................... 3-2-1
2. Ball Joints .................................................................................................. 3-2-2
3. Connecting Rod Ends ............................................................................... 3-2-2
SECTION 3: REAR AXLE .......................................................................................................... 3-3-1

A. Description ........................................................................................................... 3-3-1
1. Rear Axle Shaft Removal and Disassembly ............................................. 3-3-1
2. Rear Axle Shaft Assembly and Installation ................................................ 3-3-3
1. Disassembly ............................................................................................. 3-3-3
2. Differential Case ....................................................................................... 3-3-7
3. Pinion Bearing Cups ............................................................................... 3-3-11
4. Depth Gauge Check ............................................................................... 3-3-12
5. Pinion Bearing Preload ........................................................................... 3-3-13
6. Assembly of Differential into Housing ..................................................... 3-3-15
1. Dana Axle Adjustments ........................................................................... 3-3-18
2. Dana Axle Torque Limits ......................................................................... 3-3-18
SECTION 4: REAR WHEEL DRUM BRAKES .......................................................................... 3-4-1

A. Adjustments .......................................................................................................... 3-4-1
1. Brake Shoe Adjustment ............................................................................ 3-4-1
2. Manual Adjustment .................................................................................... 3-4-2
CD315 3-TOC-i
Rev 4
Chapter 3

1. Rear Brake Drum ..................................................................................... 3-4-4
3. Rear Brake Backing Plate ......................................................................... 3-4-6
2. Master Cylinder ......................................................................................... 3-4-8
1. Wheel Torque Limits ............................................................................... 3-4-10
2. Special Tools ........................................................................................... 3-4-10
SECTION 5: FRONT WHEEL DISC BRAKES ......................................................................... 3-5-1

A. Brake Pad Replacement ...................................................................................... 3-5-1
1. Preparation ............................................................................................... 3-5-1
2. Caliper Removal ....................................................................................... 3-5-1
3. Brake Pad Removal .................................................................................. 3-5-2
5. Brake Pad Installation ............................................................................... 3-5-3
6. Caliper Installation ..................................................................................... 3-5-4
7. Check-Out ................................................................................................ 3-5-5
B. Caliper Overhaul ................................................................................................... 3-5-6
1. General Layout .......................................................................................... 3-5-6
2. Removal ................................................................................................... 3-5-6
3. Disassembly ............................................................................................. 3-5-6
5. Reassembly .............................................................................................. 3-5-8
6. Installation ................................................................................................. 3-5-9
7. Check-Out ................................................................................................ 3-5-9
C. Rotor ..................................................................................................................... 3-5-9
1. Rotor Removal .......................................................................................... 3-5-9
2. Cleaning .................................................................................................. 3-5-10
3. Inspection ................................................................................................ 3-5-10
4. Installation ............................................................................................... 3-5-10
5. Check Out ............................................................................................... 3-5-10
D. Bleeding the Disc Brake System ........................................................................ 3-5-11
1. General ................................................................................................... 3-5-11
2. Manual Bleeding ...................................................................................... 3-5-11
3. Pressure Bleeding .................................................................................. 3-5-12
4. Check-Out .............................................................................................. 3-5-12
3-TOC-ii CD315
Rev 4
Chapter 3
SECTION 6: INSTRUCTIONS FOR AIR GAP CHECKING AND ADJUSTMENT

FREQUENCY (UP TO S/N 510) ........................................................................................... 3-6-1
A. Preparation: Safety Procedures ........................................................................... 3-6-2
B. Opening the Conveyor Drive Guard ...................................................................... 3-6-2
C. Checking Instruction ............................................................................................. 3-6-3
D. Adjustment Instructions ........................................................................................ 3-6-5
E. Reassembly ......................................................................................................... 3-6-7
CD315 3-TOC-iii
Rev 4
Chapter 3
3-TOC-iv CD315
Rev 4
Chapter 3
SECTION 1: RECOMMENDED OVERHAUL PERIODS
A. GENERAL
The following overhaul periods are approximate and can vary greatly due to different operating
conditions. Units operating in extreme conditions, such as high or low temperatures, long periods of
sustained operation, continued operation in sand or dust, or continued exposure to sea air or moisture
require careful, regular inspections. Overhaul periods may be adjusted with time and experience in
operating this belt loader. If an overhaul of a component or system is anticipated or required, the
procedures that cover that component or system should be read and fully understood prior to
attempting any part of the overhaul.
B. HYDRAULIC CYLINDERS
Overhaul when external or internal leakage is evident, after 5,000 hours of operation under extreme
conditions, or 10,000 hours of operation under normal conditions.
C. HYDRAULIC PUMP
Overhaul when internal or external leakage is evident, or after 5,000 hours.
D. OTHER COMPONENTS
Other components, such as steering valve, drive reduction gears, differential and belt drive reduction
gears, have no specific overhaul time mark. Service regularly, troubleshoot problems as needed, and
overhaul only after the use of lesser courses of action have been eliminated as probable solutions.
CD315 3-1-1
Rev 3
Chapter 3
3-1-2 CD315
Rev 3
Chapter 3
SECTION 2: STEER AXLE
A. DISCUSSION
If vehicle has been properly lubricated and maintained and has not experienced damage to the
steering system, the steering components will provide many hours of service without any overhaul.
Should overhaul be required, follow the procedure below:
WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED IN

THE SAFETY SECTION OF THIS MANUAL!
B. INSPECTION AND OVERHAUL
Jack up the front end of the vehicle using normal jacking procedures (i.e., chock rear tires, apply hand
brake, and place blocks under vehicle front bumper). Inspect the steering linkage rod for damage.
Also check for wear of the linkage rod ball joints by grasping the rod and shaking it. If the linkage
rod ball joints are loose, replace the rod.
1. Bearings and Seals
Grasp the top and bottom of each tire and shake it in and out while observing the hub and
spindle area to detect any wobble or looseness. If any wobble or looseness is noted in the hub
and the spindle is rigid, the wheel bearings and seals should be adjusted by tightening the hub
retainer nut. If excessive noise is experienced after adjustment, the bearings and seals should
be replaced as follows:
(a) Remove the front wheels by removing the lug nuts on each wheel.
(b) Remove the hub dust cap, the outer hub retainer nut, the nut lock and the inner hub
retainer nut.
(c) Grasp the hub and slide it off the axle shaft.
(d) Remove the inner and outer seals and bearings from the hub and wipe the hub
interior clean.
(e) Inspect hub interior surfaces (bearing races) for scoring. If the races are scored or
worn, replace with new races.
(f) Install new bearings and seals into the hub, pack the bearings with lithium-based
grease, and replace the hub onto the axle shaft.
CD315 3-2-1
Rev 3
Chapter 3
(g) Secure the hub with the retainer nuts and nut lock, and replace the hub dust cap.
(h) Install the wheel.
2. Ball Joints
Grasp the top and bottom of the wheel and check for ball joint wear by observing the hub and
spindle area while shaking the wheel in and out. If the hub is rigid, but the spindle has play in
it at the axle connection, the ball joints should be replaced for each wheel as follows:
(a) Remove the front wheels.
(b) Remove the cotter pin form the castellated nut on the end of the ball joint.
(c) Remove snap ring on the opposite end of the ball joint.
(d) Press out ball joint by pressing away from the spindle.
(e) Reinstall ball joint by reversing steps 1 through 4 above, taking care not to warp the
ball joint housing during reinstallation.
3. Connecting Rod Ends

Grasp the sides of the wheel and shake it from side to side while observing the rod ends. If
excessive movement is observed in the rod connection ends, replace the connecting rod ends
as follows:
(a) Disconnect the rod ends from the spindle arms, removing the cotter pins and retainer
nuts.
(b) Remove the connecting rod and remove the rod end retainer clamps.
(c) Screw the new rod ends approximately 1/4" into each end of the rod.
(d) Install the connecting rod to the spindle arms, securing the connecting rod ends to the
spindle arms with the two (2) retainer nuts and cotter pins.
(e) With the wheels pointing straight forward, adjust the “toe-in” by turning the
connecting rod until the centerline-to-centerline distance across the back of the tires
is 0 to 1/8" longer than the centerline-to-centerline distance across the front of the
tires.
(f) After the toe-in adjustment has been accomplished, install the rod end clamps,
securing the connecting rod adjustment.
3-2-2 CD315
Rev 3
Chapter 3
SECTION 3: REAR AXLE

A. DESCRIPTION
The pinion gear and shaft is supported by two opposed roller bearings, which are assembled in the
forward side of the carrier housing. Pinion locating shims, installed between the rear bearing cup and
the cup seat, control the drive pinion depth adjustment. The pinion bearing preload is controlled by
shims located between the pinion front bearing and the shoulder on the drive pinion shaft.
The differential case assembly is supported by two opposed tapered roller (side) bearings and cups, which
are retained in the housing by removable caps. Shims, installed between each differential side bearing and
the shoulder on the case, perform three functions: they take up the differential case side clearance; they
adjust the backlash between ring gear and pinion; and they establish differential side bearing preload.
A cover on the rear of the carrier housing provides access for inspection, removal and installation of
the differential assembly and drive pinion. A metal tag, stamped with the gear ratio, part numbers and
limited slip (if applicable), is secured to the housing by two of the cover bolts.
Model 60, (Figure 1) has full-floating axle shafts. This means that loads are borne by the axle
housing and the shafts can be removed without disturbing the wheel bearings, which are tapered
roller bearings.
B. REMOVAL AND INSTALLATION
1. Rear Axle Shaft Removal and Disassembly
(a) Lift vehicle and install safety stands.
(b) Remove wheel from brake drum.
(c) Remove axle shaft bolts and pull out axle shafts. If gasket is present between the axle
shaft flange and hub, discard and replace it at time of reassembly.
(d) Remove wheel bearing outer locknut, lock washer and inner wheel bearing adjusting nut.
(e) Remove the hub and drum assembly. The outer wheel bearing cone will slide out as
the hub is removed.
(f) Place the hub on a bench and remove the grease seal. Discard the grease seal and
replace it at time of assembly.
(g) Remove the inner and outer bearing cups from the hub.
CD315 3-3-1
Rev 3
Chapter 3
Figure 1-1. Rear Axle Assembly

1. Nut, Stud 15. Shaft, Differential 30. Carrier Cover Assembly
2. Adaptor, Stud Nut 16. Bearing and Cup 31. Plug, Cover
3. Stud, Drive Axle Hub 17. Cap, Differential Bearing 32. Drive Gear and Pinion
4. Axle Shaft, R/H 18. Gear, Differential 33. Plate, Differential
Axle Shaft, L/H 19. Spacer, Differential Gear 34. Bearing, Inner Pinion
5. Nut, Rear Axle Spindle 20. Disc, Differential 35. Shim, Drive Pinion Adjustment
6. Washer, Lock 21. Bolt, Bearing Cap 36. Baffle, Pinion Bearing
7. Bearing and Race Kit - Outer 22. Shim, Differential Bearing 37. Shim, Pinion Bearing Adjustment
8. Drum and Hub Assembly 23. Bolt, Drive Gear 38. Bearing, Pinion
9. Bearing and Race Kit - Inner 24. Case, Differential 39. Slinger, Pinion
10. Seal, Rear Hub 25. Plate, Differential 40. Seal, Rear Axle
11. Nut, Brake Mounting 26. Clip, Differential Clutch 41. Flange Yoke End Assembly
12. Stud, Wheel 27. Lock, Differential Shaft 42. Washer
13. Washer, Thrust - Differential Pinion 28. Gasket Cover and RTV Sealant 43. Nut, Pinion
14. Pinion, Differential 29. Bolt, Carrier Cover 44. Differential Case Assembly
3-3-2 CD315
Rev 3
Chapter 3
2. Rear Axle Shaft Assembly and Installation
(a) Assemble the new outer bearing cup.
(b) Assemble the new inner bearing cup.
(c) Pack with grease and assemble the new bearing cone.
(d) Assemble the new grease seal. Apply a small amount of the specified grease around
the lip of the seal.
(e) Install the hub assembly onto the spindle. Pack with grease and assemble the new
outer bearing cone.
(f) Install the inner wheel bearing adjusting nut, lockwasher and outer wheel bearing
locknut.
(g) Place new gasket on axle tube.
(h) Install axle shaft in tube.
(i) Install new bolts and lockwashers and tighten to 54.2-63.7 Nm (40-50 ft-lb).
(j) Install wheel on drum.
(k) Lower vehicle.
C. DISASSEMBLY AND ASSEMBLY
1. Disassembly
(a) Remove the rear axle from the vehicle as outlined in Removal and Installation.
(b) Remove cover plate and drain lubricant from axle. The lubricant will drain out as the
cover plate is removed.
(c) Remove cover plate screws, cover plate and cover plate gasket. Discard old gasket.
Tip carrier to allow lubricant to drain completely. Also during this time clean the
cover face of the carrier, being sure it is free from any nicks and any particles left by
the old gasket.
(d) Remove bearing caps.
CD315 3-3-3
Rev 3
Chapter 3
NOTE: Mating letters are stamped on caps and carrier (Figure 4). It is
Note important that they are assembled exactly as removed. Letters or numbers
are in vertical and horizontal position.
CAUTION: BEFORE REMOVING DIFFERENTIAL CASE AND RING

GEAR, BE SURE THE AXLE SHAFTS ARE PULLED OUT FAR
ENOUGH TO PROVIDE ADEQUATE CLEARANCE FOR
DIFFERENTIAL REMOVAL.
(e) Place Differential housing spreader tool 4000-E on the case. Install dial indicator,
tool 4201-C on the case. Do not spread case more than 0.015" (0.38 mm).
NOTE: Whenever removing the ring gear bolts, always replace with new
Note bolts upon assembly.
Bearing Caps: Note Mating Numbers
Figure 1-2. Removing Bearing Caps
(f) Pry differential case from carrier with two pry bars. After differential case has been
removed, remove spreader. Use caution to avoid damage to ring and pinion. Mark or
tag bearing cups, indicating from which side they were removed.
(g) Remove differential bearings with special tool P79L-4621-A, pinion bearing cone
remover. Wire shims, bearing cup and bearing cone together. Identify from which
side they were removed (ring gear side or opposite side). If shims are damaged,
replace with new ones at time of assembly. Shims are available in thicknesses of
0.003" (0.08 mm), 0.005" (0.13 mm), 0.010" (0.25 mm), and 0.030" (0.76 mm).
Reposition case in puller and remove other bearing cone as described above. Replace
bearings whenever they are removed from the carrier.
3-3-4 CD315
Rev 3
Chapter 3
(h) Place a few shop towels over the vise to prevent the ring gear teeth from being
nicked after it is free from the case. Place case in vise. Remove ring gear bolts. Tap
ring gear with a rawhide hammer to free it from the case. Remove case and ring gear
from vise.
(i) Replace case in vise and drive out the lock pin which secures the pinion mate shaft.
Use a small drift as shown in Figure 3.
Figure 1-3. Removing Lock Pin
(j) Remove pinion mate shaft with drift as shown in Figure 4.
Side Gear Pinion Mate Shaft
Pinion Mate
Gear
Figure 1-4. Removing Pinion Mate Shaft
CD315 3-3-5
Rev 3
Chapter 3
(k) To remove side gears and pinion mate gears, rotate the side gears. This will allow the
pinion mate gears to turn to the opening of the case. Remove pinion mate gears and
the spherical washers behind the gears. Lift out side gears and thrust washers. Inspect
all parts, including the machined surfaces of the case itself. If excessive wear is
visible on all parts, it is suggested that the complete differential assembly be
replaced. If any one of the gears are to be replaced, THEY MUST BE REPLACED
AS A SET.
NOTE: Axle shafts that require endplay adjustment have a spacer block in
the differential case. The spacer block controls the end thrust of the axle
Note shaft. If the ends of the spacer block are worn, it is to be replaced during
assembly. Spacer block must not be used with ball or unitized wheel
bearings.
(l) Turn nose of carrier to a horizontal position and remove pinion nut. Hold end yoke or
flange with tool T57T-485LB companion flange holding tool, and remove pinion nut
and washer.
(m) Remove end yoke of flange. If end yoke or flange shows wear in the area of the seal
contact, it should be replaced.
CAUTION: DO NOT DROP PINION AS THIS IS LIKELY TO RESULT

IN DAMAGE.
(n) Remove pinion by tapping with a rawhide hammer.
NOTE: There are bearing preload shims on the spline end of the pinion.
These shims may stick to the pinion or bearing or fall out. These shims are
to be collected and kept together since they will be used later in assembly.
Note
Avoid damaging shims. If shims are damaged, replace with new ones. Shims
are available in thicknesses of 0.003" (0.08 mm), 0.005" (0.13 mm), 0.010"
(0.25 mm), and 0.030" (0.76 mm).
(o) Pull out pinion seal with puller D78P-1225-B, bearing cup puller. Discard seal.
REPLACE WITH NEW ONE AT TIME OF ASSEMBLY. Remove bearing cone and
outer oil slinger.
(p) Turn nose of carrier down. Remove outer pinion bearing cup with tool D78P-1225-B,
bearing cup puller. Locate driver on back edge of cup and drive cup out of carrier.
CAUTION: DO NOT NICK CARRIER BORE.
3-3-6 CD315
Rev 3
Chapter 3
NOTE: The front and rear carrier section may vary in pinion bore depth
due to the possibility of the need for either a baffle or slinger or both. The
baffle serves as a dam to assure that the pinion bearings are kept lubricated.
Note The slinger serves the purpose of assisting the lubricant to flow up through
the oil channels to lubricate the pinion bearings. If used, they are part of the
pinion setting adjustment. The four different options are shown in Figure 5.
Oil Slinger Oil Baffles
Figure 1-5. Pinion Attachments
(q) Remove the inner bearing cup with tool D78P-1225-B, bearing cup puller.
NOTE: Shims are located between the bearing cup and carrier bore and
may also include an oil baffle. If shims and baffles are bent or nicked, they
Note should be replaced at time of assembly. Wire, stack together and measure
each. If stack has to be replaced, replace with same thickness.
(r) Remove bearing from pinion with an appropriate puller.
NOTE: Both baffle and slinger are part of the pinion adjustment shims and
Note are to be kept intact for assembly.
2. Differential Case
(a) Assembly
(1) Place differential case in vise. Apply grease to new side gear thrust washers
and to hubs and thrust face of the new side gears. Assemble both side gears.
Apply grease to the new spherical washers, and the new pinion mate gears.
Assemble new pinion mate gears and washers.
CD315 3-3-7
Rev 3
Chapter 3
NOTE: For ease of assembly, all parts of side gears and pinion mate
Note
gears should be lubricated before assembly.
(2) Assemble both side gears and thrust washers, hold them in place with hand,
then assemble the pinion mate gears and washers to hold the side gears in
place.
(3) Rotate the side gears until the holes of the washers and pinion gears line up
with the holes of the case. If the gears cannot be rotated by hand, install one
of the axle shafts into the side gear spline and use a pipe wrench to turn the
shaft.
(4) Use a drift to line up the holes with those of the differential case.
(5) Assemble pinion mate shaft and drive on shaft to remove drift. Be sure lock
pin hole of the shaft is lined up with the lock pin hole in case.
(6) Assemble lock pin. Peen metal of case over pin to lock in place.
(7) Be sure flange face of the case is free of nicks and burrs. Assemble ring gear
to case. Line up holes of the ring gear with those of the case. Use new ring
gear screws. Draw up screws alternately and evenly. Torque ring gear screws
to 136-163 Nm (100-120 ft-lb).
(8) Install differential bearings onto case. Remove all nicks, burrs, dirt, etc.,
from hubs to allow bearings to rotate freely.
(9) Assemble differential case into carrier (less pinion). Mount dial indicator
with a magnetic base as shown in Figure 6. Locate tip of indicator on flat
surface of one of the ring gear screw spot faces. Mark location with chalk.
Force differential assembly as far as possible in the direction toward the
indicator. With force still applied, set indicator at zero (0).
Note NOTE: Dial indicator should have a minimum travel of 0.200" (5.08 mm).
(10) Force the differential assembly as far as it will go in the opposite direction.
Repeat these steps until they produce the same reading. Record the reading
of the indicator. This will be the total amount of shim required (less preload)
and will be calculated later during assembly. After being sure the readings
are correct, remove indicator and differential assembly from housing. DO
NOT REMOVE MASTER BEARINGS FROM DIFFERENTIAL CASE AT
THIS TIME.
3-3-8 CD315
Rev 3
Chapter 3
Figure 1-6. Assembling the Differential Case
(11) Ring gears and pinions are supplied in matched sets only. Matching numbers
on both the pinion and ring gear are etched for verification. If a new gear set
is being used, verify the number of each pinion and ring gear before
proceeding with assembly (Figure 7).
The distance from the center line of the ring gear to the bottom end of the
pinion for the model 60 (front and rear axle) is 3.125" (79.37 mm).
On the button end of each pinion, there is etched a plus number, a minus
number, or a zero which indicates the best running position for each
particular gear set. This dimension is controlled by the shimming behind the
inner pinion bearing cup.
For example, if a pinion is etched with, "plus +3 (m+8)," this pinion would
require 0.003" (0.08 mm) less shim than a pinion etched “0”. By removing
shims, the mounting distance of the pinion is increased to 3.128"
(98.45 mm).
If the old ring and pinion set is to be reused, measure the old shim pack and
build a new shim pack to this same dimension. If a baffle is used in the axle
assembly, it is considered as part of the shim pack. To change the pinion
adjustment, shims are available in thicknesses of 0.003" (0.08 mm), 0.005"
(0.13 mm), 0.010" (0.25 mm), and 0.030" (0.76 mm).
Note NOTE: If baffle or slinger is bent or damaged, it should be replaced.
CD315 3-3-9
Rev 3
Chapter 3
Table 1-1. Shim Selection Chart - Inches
Old Pinion New Pinion Marking

Marking -4 -3 -2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
Table 1-2. Shim Selection Chart - Metric
Old Pinion New Pinion Marking

Marking -10 -8 -5 -3 0 +3 +5 +8 +10
+10 +.20 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0
+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03
+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05
+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08
0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10
-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13
-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15
-8 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18
-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -.20
3-3-10 CD315
Rev 3
Chapter 3
Figure 1-7. Pinion & Ring
Measure each shim separately with a micrometer and add together to get the
total shim pack thickness from the original buildup.
If a new gear set is being used, note the (+) or (-) etching on both the old and
new pinion and adjust the thickness of the new shim pack to compensate for
the difference of these two figures. Refer to shim tables (opposite page) for
correct shim selection.
3. Pinion Bearing Cups
(a) Drive the inner pinion bearing cup into the inside of the carrier housing with the
appropriate driver tool.
(b) Turn the housing over and install the outer pinion bearing cups into the carrier with
the appropriate tool.
CD315 3-3-11
Rev 3
Chapter 3
4. Depth Gauge Check
(a) Refer to Table 3 for the correct tools for the particular axles.
NOTE: If any of the gauge surfaces become nicked, the high spots must be
Note removed with a medium India oilstone to ensure no erroneous readings are
obtained.
(b) Put a new rear pinion bearing over the proper aligning adaptor and insert into the
pinion bearing retainer assembly. Put the front pinion bearing (new or used if in good
condition) into the bearing cup, assemble the handle onto the screw and hand tighten.
Use the 3/8" square drive in the handle to obtain the proper pinion bearing preload.
(c) Center the proper gauge tube into the differential bearing bore. Install the bearing
caps and torque to proper specifications.
(d) Using a feeler gauge tool, select the thickest feeler shim that will enter between the
gauge tube and the gauge block. Insert the feeler gauge directly along the gauge
block to insure a correct reading. The feeler gauge fit between the gauge tube and the
gauge block should be a slight drag-type feeling.
(e) After the correct feeler gauge feel is obtained, check the reading. This is the
thickness oil shim(s) required, providing that there are no markings on the service
pinion gear.
NOTE: If the service pinion gear is marked with a plus (+) reading, this
amount must be subtracted from the thickness dimension obtained in step
Note (d). If the service pinion gear is marked with a minus (-) reading, this
amount must be added to the thickness dimension obtained in step (d). In
the addition, the same new rear pinion bearing that was used in the previous
steps must be used.
(f) Place the selected shim(s) and oil slinger (if used) on the pinion and press on the
bearing.
NOTE: If a baffle or slinger is used, replace with a new one upon assembly
Note (see Figure 5) and measure as part of the shim stack.
(g) After following these procedures, continue to build the remaining components with
proper pinion and differential bearing preload torques and ring gear backlash.
3-3-12 CD315
Rev 3
Chapter 3
5. Pinion Bearing Preload
(a) Assemble preload shims and slinger (if used) onto pinion. Assemble bearing cone.
(b) Pack ESA-M1C75-B lubricant or equivalent on the lips of the pinion seal and
assemble into carrier.
(c) Assemble end yoke, washer and new pinion nut. Torque nut to 325-406 Nm
(240-300 ft-lb).
(d) Using a torque wrench, rotate pinion (Figure 9). Torque to rotate pinion should read
between 2.26-4.53 Nm. To increase preload, remove shims from pinion. To decrease
preload, add shims to pinion.
The illustration in Figure 8 shows the arrow in the pinion pointing in two directions.
The arrow pointing toward the end yoke indicates that by removing pinion position
shims, the distance from the center line of the axle to pinion button is increased,
giving a plus reading. The pinion bearing preload shim pack does not affect the
pinion depth setting. Arrows on the ring gear illustrate the method to increase or
decrease backlash and differential bearing preload.
Figure 1-8. Differential Assembly
CD315 3-3-13
Rev 3
Chapter 3
Figure 1-9. Measuring Pinion Preload
Table 1-3. Pinion Depth Tool Selection
Tool Tool Axle Model

Number 60 & 61-1
Aligning T76P-4020-A3 X
Adaptor D8OT-4020-F48
Gauge Disc T78P-4020 X
D8OT-4020-F44
D8OT-4020-F45
Gauge Block T8OT-4020-F42 X
Screw T80T-4020-F42 X
Handle T76P-4020-A11 X
Gauge Tube D8OT-4020-F47
DSOT-4020-F48 X
3-3-14 CD315
Rev 3
Chapter 3
6. Assembly of Differential into Housing
(a) Ring Gear and Pinion Backlash
(1) Place differential assembly (with pinion installed) into housing. Differential
master bearings should still be assembled to case.
(2) Set up dial indicator as shown in Figure 6. Be sure to locate dial indicator on
same location as marked in step 9. Force ring gear into mesh with the
pinion. Rock ring to allow the teeth of the gears to mesh. With force still
applied to the differential case, set indicator at zero “0”
(3) Force the differential case (ring gear) away from the pinion gear to obtain an
indicator reading. Repeat until the same reading is obtained each time. This
reading will be necessary to determine the amount of shim required between
the differential case and differential bearings on the ring gear side. Remove
indicator and differential case from the carrier. Remove bearings from
differential case.
(4) Assemble the required amount of shim onto hub (ring gear side) as
determined in the above step. Place bearing cone on hub of case. Use an
appropriate installer to seat bearing cone.
(5) Assemble the remainder of the total shim pack, which was determined in
Step 9 of Differential Case Assembly on the opposite side of the differential
case. Add an additional 0.015" (0.38 mm) of shim on this side to compensate
for differential bearing preload.
For example, assume that in Step 9 of Differential Case Assembly (less

pinion), a total of 0.107" indicator reading was recorded.
In Step 3 above (with pinion) a total of 0.055" indicator reading was recorded.
This leaves a balance 0.052" of shims for the opposite side and adds up to the
0.107" which was first recorded. Add an additional 0.015" shims on the
opposite side for bearing preload and backlash.
Ring Gear Side 0.055" (1.40 mm). Opposite Side 0.052" (1.32 mm). Opposite
Side Preload 0.015" (0.38 mm).
(6) Install spreader and indicator to carrier. Do not spread carrier over 0.020"
(0.51 mm). Remove indicator.
(7) Assemble differential bearing cups to differential bearing cones.
CD315 3-3-15
Rev 3
Chapter 3
(8) Install bearing caps. Make sure the letters stamped on the caps correspond
with those on the carriers. Torque bearing cap screws to 108-122 Nm
(80-90 ft-lb).
(9) Check ring gear and pinion backlash in three equally spaced points with dial
indicator. Backlash tolerance is 0.004" (0.10 mm) to 0.009" (0.23 mm) and
cannot vary more than .002" (0.05 mm) between points checked.
High backlash is corrected by moving the ring gear closer to the pinion.
These corrections are made by switching shims from one side of the
differential case to the other.
(10) Install new cover gasket and install cover plate. Torque screws to 41-54 Nm
(30-40 ft-lb).
NOTE: There are two different design cover plates. One cover has a flat
Note mounting surface, and the other design has ribs between the screw holes.
Rib
Figure 1-10. Differential Cover Plates
Figure 10 shows the flat mounting surface cover plate side-by-side with the
ribbed surface cover plate used on Dana design axles. The flat cover plate
requires the use of a silicone rubber sealer material rather than a gasket.
The cover face of the carrier and the flat surface of the cover plate must be
free of any oil film or foreign material.
Sealant material must meet specifications of ASTN3, GE303, A19, B37, E16,
E36, 21, 22, and 23 sealant or equivalent.
3-3-16 CD315
Rev 3
Chapter 3
Figure 1-11. Application of Sealant on Non-Ribbed Cover Plate
Apply ESB-M4C92A-RTV gasket sealer or equivalent to cover plate surface.

Ensure that the sealer bead is laid on the inside of the cover screw holes. The
bead is not to pass through the holes or outside the holes.
The bead is to be 1/8" to 1/4" (3.18- 6.35 mm) high and 1/8" to 1/4"
(3.18- 6.35 mm) wide.
Assemble two cover screws into cover at the 8 o’clock and 2 o’clock
positions. Use these two screws to guide cover plate into position on the
carrier.
Install remaining screws. Tighten alternately and evenly. Torque screws to

41-54 Nm (30-40 ft-lb). Allow one hour cure time before filling carrier with
the proper amount of specified lubricant and before vehicle operation.
On the cover plate with rib design (see Figure 10), a gasket must be used. Do
not use silicone sealer. Torque screws to 41-54 Nm (30-40 ft-lb).
CD315 3-3-17
Rev 3
Chapter 3
D. SPECIFICATIONS
1. Dana Axle Adjustments
Description Specification
Backlash Between Ring Gear 0.10-0.23 mm

on Pinion (0.004-0.009")
Backlash Maximum Variation 0.05 mm

between Teeth
Pinion Bearing Preload 2.26-4.53 Nm

(20-40 ft-lb)
2. Dana Axle Torque Limits
Axle Model
Description 60.61
ft-lb Nm
Pinion Shaft Nut 250-270 339-366
Differential Bearing Cap Bolts 80-90 109-147
Rear Gear Attaching Bolts 110-125 150-169
Oil Filter Plug 20-30 28-40
U-Joint Bolts 15-20 21-27
Cover to Housing Bolts 30-40 41-54
Approx. Capacities
Axle Model Ford

Specification U.S. Pints Imp. Pints Liters
60-30 ESW-M2C105-A 5.0 4.16 2.37
3-3-18 CD315
Rev 3
Chapter 3
SECTION 4: REAR WHEEL DRUM BRAKES
A. ADJUSTMENTS
1. Brake Shoe Adjustment
The brake shoes are automatically adjusted when the vehicle is driven in reverse and the
brakes applied several times sharply. Manual brake adjustment is required only after the
brake shoes have been relined or replaced. Perform the manual adjustment with the drums
removed, using the tool and the procedure described below.
(a) Clean away all rust and dirt from the points where the shoes touch the backing plate.
(b) Apply a small amount of multi-purpose lubricant, Ford Specification ESA-M1C75-B

or equivalent to the points where the shoes touch the backing plate. Take care not to
get the lubricant on the linings.
(c) Use NAPA Brake Resetting Gauge (P/N 3377) (Figure 1), and adjust to the inside
diameter of the drum braking surface.
(d) Reverse the tool as shown in (Figure 2) and adjust the brake shoes until they touch
the gauge. The gauge contact points on the shoes (Figure 2) must be parallel to the
vehicle with the center line through the center of the axle. Hold the automatic
adjusting lever out of engagement while rotating the adjusting screw, to prevent
burring the screw slots. Be sure the adjusting screw rotates freely. If necessary,
lubricate the adjusting screw threads with a thin, uniform coating of multi-purpose
lubricant, Ford Specification ESA-NlC75-B or equivalent.
Figure 1-1. Diameter of Brake Drum Figure 1-2. Diameter of Brake Shoes
CD315 3-4-1
Rev 3
Chapter 3
(e) Install the drums. Install the retaining nuts and tighten securely.
(f) Install the wheels on the drums and tighten the mounting nuts to specification, as listed
at the end of this section.
(g) Complete the adjustment by applying the brakes several times while driving the
vehicle in reverse.
(h) After adjusting the brake shoes, check brake operation by making several stops while
driving forward.
2. Manual Adjustment
Adjust the single anchor brake by turning an adjusting screw located between the lower ends
of the shoes (Figs. 3 and 4).
(a) Raise the vehicle until the tires clear the floor.
(b) Remove the cover from the adjusting hole at the bottom of the brake backing plate,
and turn the adjusting screw inside the hole to expand the brakes shoes until they
drag against the brake drum and lock the drum (Figure 3).
Figure 1-3. Brake Shoe Adjustment
3-4-2 CD315
Rev 3
Chapter 3
(c) When the shoes are against the drum, loosen the adjusting screw an additional 10 to
12 notches so that the drum rotates freely without drag (Figure 4). If the drum does
not rotate freely, remove the wheel and drum, and blow out any dust and dirt from the
linings. Using sand paper, remove any rust from the points where the shoes touch the
backing plate. Apply a light coating of multi-purpose lubricant, Ford Specification
ESA-M1C75-B or equivalent. Do not get the lubricant on the linings. Install the
wheel and drum and adjust the shoes.
Figure 1-4. Brake Shoe Adjustment (cont'd)
(d) Install the adjusting hole cover on the brake backing plate.
(e) Check and adjust the other three brake assemblies.
(f) Apply the brakes. If the pedal travels more than halfway to the floor, there is too
much clearance between the brake shoes and the drums. Repeat Steps (a) and (b)
above.
(g) When all brake shoes have been properly adjusted, lower the vehicle and road test to
check brake operation. Perform the road test only when the brakes will apply and the
vehicle can be safely stopped.
CD315 3-4-3
Rev 3
Chapter 3
B. REMOVAL AND INSTALLATION
1. Rear Brake Drum
WARNING: UNDER NO CIRCUMSTANCES SHOULD COMPRESSED

AIR BLOW OFF BE USED TO CLEAN BRAKES, BRAKE DRUMS,
CLUTCHES, AND ASSOCIATED COMPONENTS.
(a) Removal
(1) Raise the vehicle and install safety stands under the rear axle.
(2) Remove the wheel and tire as an assembly. Loosen the rear brake shoe
adjustment screw.
(3) Remove the rear axle retaining bolts and lockwashers, axle shaft and gasket.
(4) Remove the wheel bearing locknut, lockwasher, and adjusting nut.
(5) Remove the hub and drum from the axle.
(6) Check the drum for damage or wear, repair or replace as necessary. If a new
drum will be installed, remove the wheel studs and the brake drum from the
hub.
(b) Installation
(1) Clean the ledge pads on the backing plate. Sand lightly to bare metal.
(2) Apply multi-purpose lubricant, Ford Specification ESA-M1C75-B or

equivalent, to the retracting and hold-down spring contacts on the brake
shoes and backing plate.
(3) Apply multi-purpose lubricant, Ford Specification ESA-M1C75-B or

equivalent, to the threads and socket end of the adjusting screw.
(4) Install the upper retracting spring on the primary and secondary shoes as
shown in Figure 6 and position the shoe assembly on the backing plate with
the wheel cylinder push rods in the shoe slots.
(5) Install the brake shoe hold-down springs.
3-4-4 CD315
Rev 3
Chapter 3
(6) Install the brake shoe adjustment screw assembly (with the slot in the head of
the adjusting screw toward the primary shoe), lower retracting spring,
adjusting lever spring and adjusting lever assembly. Connect the adjusting
cable to the adjusting lever. Position the cable in the cable guide and install
the cable anchor fitting on the anchor pin. Install the adjusting screw
assemblies in the same locations from which they were removed.
Interchanging the brake shoe adjusting screw assemblies from one side of the
vehicle to the other will cause the brake shoes to retract rather than expand
each time the automatic adjusting mechanism is operated. To prevent
incorrect installation, the socket end of each adjusting screw is stamped with
an R or L to indicate proper installation on the right or left side of the
vehicle. The adjusting pivot nuts can be distinguished by the number of lines
machined around the body of the nut. Two lines indicate a right hand nut;
one line indicates a left hand nut.
(7) Install the parking brake assembly in the anchor pin and secure with the
retaining nut behind the backing plate.
(8) Adjust the brakes before installing the drums, using NAPA Brake Resetting
Gauge (P/N 3377) or equivalent, as described in this section.
2. Brake Wheel Cylinder
(a) Removal
(1) Remove the wheel, drum and brake shoes. Remove the cylinder-to-shoe
connecting links.
(2) Disconnect the brake line from the brake cylinder.
(3) Remove the brake cylinder retaining bolts and lock washers, then remove the
cylinder from the backing plate.
(b) Installation
(1) Place the brake cylinder on the backing plate and install the retaining bolts
and lock washers.
(2) Install a new gasket on the brake line fitting (if equipped) and connect the
brake line to the brake cylinder.
(3) Install the brake shoes and the connecting links between the shoes and
cylinder. Install the drum and the wheel.
CD315 3-4-5
Rev 3
Chapter 3
(4) Adjust the brakes and bleed the system. Check pedal operation before
moving the vehicle.
3. Rear Brake Backing Plate
(a) Removal
(1) Remove the wheel, hub and drum assembly. Disconnect the brake line from
the brake cylinder and submerge the end of the brake line in a can containing
a small amount of brake fluid to prevent air from entering the system.
Remove the brake shoes and brake cylinder.
(2) Remove the nuts. Pull the axle shaft assembly out of the housing, using tool
4235-C and a slide hammer tool T50T-100-A. Lift off the backing plate.
(3) On units equipped with Dana integral carrier rear axles, refer to Axle Shaft-
Removal. Remove the backing plate after the axle shafts have been removed.
(b) Installation
(1) Position the rear backing plate on the retaining bolts in the axle housing
flange. Insert the axle shaft assembly into the housing so the splines engage
the differential side gear, with the bearing retainer sliding onto the retaining
bolts and against the backing plate. Install the retaining nuts through the
access hole in the axle shaft flange. Install axle shafts after referring to Axle
Shaft installation in the Rear Axle Section.
Figure 1-5. Rear Brake Assembly
3-4-6 CD315
Rev 3
Chapter 3
2) Install the brake cylinder and brake shoes.
(3) Connect the brake line to the brake cylinder and install the brake drum and
wheel. Adjust the brake shoes and bleed air from the system.
C. DISASSEMBLY AND ASSEMBLY
1. Brake Wheel Cylinder
(a) Disassembly
(1) With the wheel cylinder removed, remove the rubber boots from the ends of
the brake cylinder. Remove the pistons, cups, piston return spring and piston
expander assembly from the cylinder.
(2) Remove the bleeder screw from the cylinder.
Figure 1-6. Brake Wheel Cylinder
(b) Assembly
(1) Coat all brake cylinder parts with clean extra heavy duty brake fluid ESA-
M6C25-B or equivalent.
(2) Install the bleeder screw (Figure 6) in the brake cylinder.
(3) Place the piston return spring and piston expander assembly, cups and
pistons in the cylinder bore, and install a boot and link over each end of the
cylinder. Clamp the brake cylinder pistons against the ends of the cylinder.
When using a brake cylinder repair kit, follow the instructions in the kit and
use all of the parts provided.
CD315 3-4-7
Rev 3
Chapter 3
2. Master Cylinder
Remove the master cylinder from the vehicle. (Refer to Figure 7).
When it is necessary to repair the master cylinder during the warranty period, replace the
cylinder as a unit instead of overhauling the cylinder with a service repair kit.
(a) Disassembly
Figure 1-7. Master Cylinder Assembly
(1) Clean the outside of the master cylinder and remove the reservoir cover and
reservoir diaphragm. Drain any fluid left in the cylinder. Be careful with
brake fluid as it damages painted surfaces.
(2) Remove the push rod boot (if equipped), from the groove at the rear of the
master cylinder, and slide the boot away from the rear of the master cylinder.
(3) Remove the snap ring holding the pistons in the cylinder body.
(4) Remove the push rod (if equipped), and primary piston assembly from the
master cylinder. Discard the piston assembly, including the boot (if
equipped).
3-4-8 CD315
Rev 3
Chapter 3
WARNING: USE LOW AIR PRESSURE TO REMOVE THE PISTON.

HIGH PRESSURE COULD RESULT IN DAMAGE OR PERSONAL
INJURY.
(5) Using an air hose in the rear brake outlet port of the cylinder body, carefully
blow the secondary piston out of the cylinder body. Remove the return
spring, spring retainer, cup protector and cups from the secondary piston.
Discard the cup protector and cups.
(b) Inspection and Repair
(1) Clean all parts in clean isopropyl alcohol or Rotunda Brake Parts Washer
(model 650016) or equivalent, and inspect the parts for chipping, excessive
wear or damage. Replace them, if necessary. When using a master cylinder
repair kit, use all parts provided.
(2) Check all recesses, openings and internal passages to be sure they are open
and free of foreign matter.
(3) Inspect the hydraulic master cylinder bore for etching, pitting or rust.
Replace the master cylinder if any of these conditions exist.
(c) Assembly
(1) Remove the master cylinder from the vise. Check the outlet ports for brass
burrs and remove, if present.
(2) Dip all parts except the cylinder body in clean ESA-M6C25-B extra heavy
duty brake fluid or equivalent and lubricate the bore walls with brake fluid.
(3) Assemble the secondary cup and 0-ring back-to-back in the grooves near the
end of the secondary piston. Assemble the cup protector, primary cup, spring
retainer and secondary piston return spring on the other end of the secondary
piston.
(4) Install the secondary piston assembly in the master cylinder. Wet the seals
with the brake fluid and use caution when inserting the piston assemblies
into the bore to prevent damage to the seals.
(5) Install the primary piston assembly in the master cylinder. Push the primary
piston inward and tighten the secondary piston stop bolt to hold the
secondary piston in the bore.
CD315 3-4-9
Rev 3
Chapter 3
(6) Position the stop plate and snap ring on the primary piston. Depress the
primary piston and install the snap ring in the cylinder body.
(7) Bleed the master cylinder.
(d) Bleeding the Master Cylinder
Before installing the master cylinder on the vehicle, bleed the unit as follows:
(1) Support the master cylinder body in a soft-jawed vise and fill both fluid
reservoirs with ESA-M6C25-A extra heavy duty brake fluid or equivalent.
(2) Install plugs in the front and rear brake outlet ports. Bleed the rear brake
system first.
(3) Loosen the plug in the rear brake outlet port. Depress the primary piston
slowly to force the air out of the master cylinder. Tighten plug while piston is
depressed to prevent air from entering the master cylinder.
(4) Repeat this procedure until air ceases to exit at the outlet port.
(5) Repeat steps (3) and (4) for the front brake outlet port with the rear brake
outlet plugged.
(6) Tighten the plugs and attempt to depress the piston. The piston will resist
depression after all air is expelled.
(7) Install the cover and diaphragm assembly, being sure the cover retainer is
tightened securely. Remove the plugs.
D. SPECIFICATIONS
1. Wheel Torque Limits

Nut Size (ft-lb) Nm
1/2-20 100 136
2. Special Tools
Number Description
110002 Safe-Set Gauge
2035 N or W Brake Spring Installation / Removal Tool
4235-C Axle shaft adaptor for removal of axle shaft. To be used with T50T-100-C.
T50T-100-A Slide Hammer
J-22742 Metering Valve Bleeder
65001-G Brake Parts Washer
3-4-10 CD315
Rev 3
Chapter 3
SECTION 5: FRONT WHEEL DISC BRAKES
A. BRAKE PAD REPLACEMENT
Inspect the brake linings any time that the wheels are removed. Check both ends of the outboard pad
by looking in each end of the caliper. These are the points at which the highest rate of wear normally
occurs. However, at the same time, check the lining thickness of the inboard pad to make sure that it
has not worn prematurely. Look through the inspection hole in the caliper to view the inboard pad.
Whenever the thickness of any lining is worn to the approximate thickness of the metal backing, all
pads on the axle should be replaced.
1. Preparation
For front service, chock rear wheels and raise front of vehicle. For rear service, chock front
tires and raise rear.
2. Caliper Removal
(a) Remove 2/3 of brake fluid from master cylinder reservoir.
(b) Push the piston back into its bore. This can be accomplished by using a C-clamp.
(c) Using 3/8" Allen wrench, loosen and remove (2) mounting (retainer) bolts. (See
Figure 1.) Lift the caliper off the rotor and position on drive axle so that the brake
hose will not support the weight of the caliper.
Figure 1-1. Brake Pad Mounting Bolts
CD315 3-5-1
Rev 3
Chapter 3
Note NOTE: If only brake pads and linings are being replaced, omit step (d).
(d) Disconnect brake line from caliper and plug openings in caliper and line to prevent
fluid loss and to keep out contamination (see Figure 2).
Figure 1-2. Brake Line Disconnection

(e) Inspect mounting bolts for corrosion. If corrosion is found, use new bolts when
installing caliper.
3. Brake Pad Removal
(a) Remove the inboard pad and spring from piston. Dislodge the outboard pad and
remove from caliper.
(b) Remove sleeves from mounting bolt holes and discard. Remove the four rubber
bushings from the grooves in each of the caliper ears and discard (see Figure 3).
4. Cleaning and Inspection
(a) Examine the piston area for fluid leaks by looking for excessive moisture around
boot area. Check dust boot for cracks, cuts or other damage that would affect its
ability to seal piston bore. If leaks are present or boot shows damage, the caliper
should be overhauled (see Section B. Caliper Overhaul)
(b) If no defects are found, wipe clean the inside of the caliper, including the four ears
where bushings are to be installed. Wipe the outside surface of the dust boot so that
when the piston is pressed to the bottom of the bore, the boot will fold back without
coming out of groove.
3-5-2 CD315
Rev 3
Chapter 3
Figure 1-3. Brake Pad Assembly
5. Brake Pad Installation
(a) Using Delco Silicone Lube No. 179-651, lubricate new sleeves, new rubber bushings,
and bushing grooves. Install rubber bushings in all four caliper ears.
NOTE:It is essential that the new sleeves and rubber bushings included in
Note each Delco pad kit be used, and that lubrication instructions be followed to
ensure proper functioning of the sliding caliper design.
(b) Use Delco tool, J-22835, to install the sleeve. Position the sleeves so that the end
toward the pad is flush with the machined surface of the ear.
(c) Attach pad retainer clip to inboard pad lining so that spring vee is on inner arc of pad.
CD315 3-5-3
Rev 3
Chapter 3
(d) Install inboard pad and lining as shown (see Figure 4). Position outer arc of pad
against inner arc of caliper. Depress spring vee to collapse it and enable it to slip
inside of piston cup. Snap pad into place.
Figure 1-4. Brake Pad Installation
(e) Clip outer pad into place opposite inner pad. Make sure that the tab at the bottom of
the pad is engaged in the caliper cutout.
6. Caliper Installation
(a) Position caliper over rotor and line up holes in caliper ears with holes in the
mounting bracket. Make sure the brake hose is not twisted or kinked.
(b) Lubricate both ends of the mounting bolts with Delco Silicone Lube No. 179-651.
Start the bolts through the sleeves in the inboard caliper ears and mounting bracket,
making sure that the ends of the bolts pass under the retaining ears of the inboard
pad. Push the bolts through to engage the bushings in the outboard caliper ears,
while threading the bolts into the mounting bracket. Tighten bolts (see Figure 5).
(c) Torque bolts to 40.7-61.0 Nm (30-45 ft-lb).
(d) Remove temporary plugs from brake pipe and fittings, connect brake pipe to caliper.
Torque to 20 Nm (15 ft-lb).
(e) If brass bolt and block were removed with brake pipe, unplug fittings and install bolt
and block using (2) new copper washers. Torque to 40 Nm (30 ft-lb).
(f) Fill master cylinder and bleed hydraulic system.
(g) After installing caliper, set caliper by applying heavy force to brake pedal.
3-5-4 CD315
Rev 3
Chapter 3
Figure 1-5. Brake Caliper Installation
7. Check-Out
(a) Check brake pedal for sponginess or hard pedal.
(b) Drive vehicle slowly and make several slow speed stops.
(c) Check all brake fluid line fittings and caliper areas for fluid leakage.
(d) Correct any discrepancies before returning vehicle to service.
CD315 3-5-5
Rev 3
Chapter 3
B. CALIPER OVERHAUL
1. General Layout
Figure 1-6. Brake Caliper Assembly
2. Removal
See Paragraph A. Brake Pad Replacment in this section. Removal of the caliper for overhaul
is the same as for pad replacement, except that it will be necessary to disconnect the brake
hose.
3. Disassembly
(a) Move the caliper to a work bench for overhaul.
3-5-6 CD315
Rev 3
Chapter 3
(b) Drain fluid from caliper.
(c) Remove pad and spring clip from end of piston.
(d) Before beginning caliper disassembly, thoroughly clean exterior using denatured
alcohol.
(e) Support caliper in a vise and pad caliper interior with shop cloths. Use a piece of
1 x 6 soft pine to prevent piston from coming out completely (see Figure 7).
(f) Use just enough compressed air in caliper brake line port to force piston out.
Excessive air may cause piston to be blown out of bore and become damaged.
WARNING: USE OF COMPRESSED AIR WITHOUT WOOD BLOCK

MAY RESULT IN DAMAGE TO THE PISTON AND/OR PERSONAL
INJURY.
Figure 1-7. Brake Piston Removal
(g) Remove wood block. Gently work piston the rest of the way out of bore.
(h) Use a screwdriver to pry boot out of caliper as shown. Use care to avoid scratching
the caliper bore (See Figure 8).
(i) Remove piston seal from caliper bore. Use a piece of wood or plastic (a wooden
toothpick is ideal) so as not to damage caliper bore.
(j) Remove bleed valve.
CD315 3-5-7
Rev 3
Chapter 3
Figure 1-8. Brake Piston Boot Removal
4. Cleaning and Inspection
(a) Thoroughly clean all parts not in repair kit with denatured alcohol. Inspect caliper
bore for scoring, nicks, corrosion or wear. Use crocus cloth to polish out any light
corrosion. Replace caliper housing if bore will not clean up using crocus cloth.
(b) Carefully examine the piston exterior for scoring, nicks, corrosion and worn or
damaged surfaces. If any surface defects are detected, replace the piston.
CAUTION: THE PISTON OUTER SURFACE IS THE PRIMARY

SEALING SURFACE IN THE CALIPER ASSEMBLY. IT IS
MANUFACTURED AND PLATED TO CLOSE TOLERANCES.
REFINISHING BY ANY MEANS, OR THE USE OF ANY ABRASIVE IN
THE FIELD, IS NOT ACCEPTABLE.
5. Reassembly
(a) Lubricate piston assembly with clean brake fluid.
(b) Position the seal in the caliper bore groove.
(c) Assemble a new boot into the piston groove so that the fold faces the open end of the
piston.
(d) Press piston assembly into caliper bore using C-clamp (see Figure 9). Be careful not
to unseat the seal.
3-5-8 CD315
Rev 3
Chapter 3
Figure 1-9. Brake Piston Reassembly
(e) Position outside diameter of boot in caliper counterbore and seat with Delco tool
No. J-22904.
6. Installation
Install caliper following instructions given in Paragraph A.6. Caliper Installation in this section.
Bleed system.
7. Check-Out
(d) Correct any discrepancies before returning vehicle to service.
C. ROTOR
1. Rotor Removal
(a) Chock the rear tires. Jack the front wheels off the ground.
(b) Inspect the lug nuts, which secure the wheel to the drive axle hub, and remove.
(c) Remove the hub cap, remove the nut and washer.
(d) Remove caliper assemblies. See Paragraph A.2. Caliper Removal in this section.
CD315 3-5-9
Rev 3
Chapter 3
(e) Slide the wheel hub and rotor off the axle.
2. Cleaning
WARNING: NO SMOKING, FIRE OR OPEN FLAME IS PERMITTED

IN AREAS WHERE ALCOHOL IS BEING USED. AVOID INHALATION
OF FUMES.
(a) Clean rotor with alcohol.
(b) Use lint-free cloth to dry.
3. Inspection
(a) Inspect rubbing surfaces for evidence of corrosion, pitted or scratches. Replace if
scratched, corroded or pitted.
(b) Check the thickness and out of plane limits of the rotor. The minimum limit should
be 0.885".
4. Installation
(a) Slide the wheel hub and rotor onto the axle.
(b) Replace axle nuts, washer and hubcap. Seal with silicone sealer.
(c) Attach caliper assemblies. See Paragraph A.6. Caliper Installation in this section.
(d) Replace wheel and secure with lug nuts.
(e) Lower front wheels to the ground and unchock rear wheels.
5. Check Out
(b) Drive belt loader slowly and make several slow speed stops.
(d) Correct any discrepancies before returning vehicle to normal service.
3-5-10 CD315
Rev 3
Chapter 3
D. BLEEDING THE DISC BRAKE SYSTEM
1. General
(a) If the caliper was removed for overhaul, or if the brake hose or steel line was
disconnected for any other reason, it will be necessary to bleed all air from the
calipers and connecting lines.
(b) Prior to bleeding the system, it is important to check the master cylinder reservoir.
Use hydraulic fluid, DOT 3 Extra Heavy Duty Brake Fluid, to bring the level up to
within 1/8" of the top.
(c) Brakes can be bled either manually or with pressure bleeding equipment.
CAUTION: FLUID THAT IS DRAINED, FLUSHED OR BLED FROM A

VEHICLE’S BRAKE SYSTEM SHOULD BE DISCARDED. IT IS NOT
SAFE TO REUSE FOR ANY PURPOSE.
2. Manual Bleeding
(a) Manual bleeding requires two people, one to pump the brake pedal and another to
operate the bleeder valves. Make sure that the master cylinder is full. After the
bleeder valve is opened, depress the brake pedal one full stroke, close bleeder valve,
then allow the pedal to return slowly to the released position. Allowing the pedal to
return too quickly may draw air into the system. Continue operating the pedal in this
manner until caliper is bled. Refill the master cylinder and go on to next caliper.
CAUTION IN ORDER TO ENSURE THAT NO AIR CAN BE SUCKED

BACK INTO THE SYSTEM, THE BLEEDER VALVE MUST BE CLOSED
AT THE END OF EACH STROKE, BEFORE THE BRAKE PEDAL IS
RELEASED.
(b) Check the fluid level in the reservoir frequently during the bleeding procedure.
CD315 3-5-11
Rev 3
Chapter 3
3. Pressure Bleeding
(a) If the equipment is available, pressure bleeding is faster, since the master cylinder
does not have to be refilled several times. Pressure bleeding equipment must be of
the diaphragm type. That is, it must have a rubber diaphragm between the air supply
and the brake fluid to prevent air, moisture, oil and other contaminants from entering
the hydraulic system. Install the special bleeding adapter to the master cylinder.
Make sure that the pressure tank is at least 1/3 full of fluid.
Position the tank so that its hose will easily reach the adapter on the master cylinder
of the vehicle being serviced, then make the air pressure connection to the tank (20 to
25 psi). Open the tank valve to bleed all air out of the hose before connecting it to
the adapter. After making this connection, open the valve when ready to begin
bleeding.
CAUTION: DO NOT LIFT, MOVE OR SHAKE THE TANK AFTER AIR

PRESSURE IS APPLIED. THIS MAY CAUSE AIR TO BECOME
TRAPPED IN THE FLUID.
(b) Bleed front calipers.
NOTE: Pressure bleeding process may be completed more quickly by

Note lightly tapping the brake pedal when the bleeder valve is opened. This
creates pulsations that tend to purge air from the system.
4. Check-Out
(d) Correct any discrepancies before returning vehicle to normal service.
3-5-12 CD315
Rev 3
Chapter 3
SECTION 6: INSTRUCTIONS FOR AIR GAP CHECKING AND

ADJUSTMENT FREQUENCY (UP TO S/N 510)
Due to the variable nature of the wearing of the disc brakes (it is dependent on both frequency of use and
loading during use), it is difficult to predict exactly when the air gap will need adjustment. It is recommended
that the air gap be checked after the first 30 days of use to determine the wear rate for your application.
If the air gap shows less than 1/16" variation from the set point, no adjustments are required. Continue routine
checks every 60 days thereafter.
If the air gap shows more than a 1/16" variation from the set point, you will need to follow the included
instructions to adjust the gap back to the set point. After the initial adjustment, continue checking the air gap
every 30 hours, or less if significant adjustment (3/16" or more) is required.
It is important that the air gap does not vary more than ¼" from the start point. If the air gap is
approaching the ¼" reset point, adjust the air gap immediately.
Scope of Work:
A. Preparation: Safety Procedures

B. Opening the Conveyor Drive Guard
C. Checking Instruction
D. Adjustment Instruction
E. Reassembly
Table 1-1. Parts List

PART NUMBER DESCRIPTION QTY
BLE-1-2527 Brake, Electric Belt Drive 1

BLE-4-1005 Conveyor Drive Guard 1
or
663-4-2666 Plate Conveyor Bottom Front Cover (for Narrow Conveyor) 1
¼"- 20 x 1" Hex Head Bolt ¼" D, 1" Long 2
¼" Flat Washer ¼" ID 2
¼" x ¼" Spacer, ¼" ID, ¼" Long 2
¼" - 20 Lock Nut, ¼" ID 2
WARNING: READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE

BEGINNING PROCEDURE!
CD315 3-6-1
Rev 3
Chapter 3
A. PREPARATION: SAFETY PROCEDURES
1. Observe all safety requirements for tool usage and OSHA facility guidelines.
2. Park the belt loader on level ground. Engage emergency brake and/or chock tires.
3. Raise conveyor high enough for comfortable work on belt drive motor, which situates at the
bottom of front of conveyor.
4. Discharge capacitors.
(a) Turn the ignition key on.
(b) Disconnect the battery.
(c) Wait 10 seconds, and then turn the key off.
B. OPENING THE CONVEYOR DRIVE GUARD
1. To open conveyor drive guard, remove two ¼-20 x 1" hex head bolts, two ¼" flat washers,
two spacers (between conveyor drive guard and conveyor weldment) and two ¼"-20 lock
nuts on rear end of conveyor drive guard (see Figure 1).
Figure 1-1. Conveyor Drive Guard
3-6-2 CD315
Rev 3
Chapter 3
C. CHECKING INSTRUCTION
1. To check the air gap on the brake, remove manual release plate (see Figure 2). Use 3/16"
screwdriver to remove 6 screws, which hold manual release plate. When removing the plate,
take care not to damage the gasket. With the manual release plate off, the plunger/solenoid
assembly can be viewed.
Figure 1-2. Manual Release Plate Location
CD315 3-6-3
Rev 3
Chapter 3
2. The air gap between the plunger and solenoid should be .450" ± .030", when it is adjusted to
the SET point (see Figure 3). The SET and RESET points can be seen on the air gap label
that is affixed to the left side of the solenoid. (This label can be difficult to see unless the
whole housing is removed.)
Figure 1-3. Brake Air Gap Inspection
3-6-4 CD315
Rev 3
Chapter 3
D. ADJUSTMENT INSTRUCTIONS
1. If the air gap needs adjustment, remove the cover plate on the opposite side of the motor
brake (see Figure 4). Use 3/16" screwdriver to remove 6 screws, which hold the cover plate.
When removing the plate take care not to damage the gasket. The manual release plate was
already removed.
Figure 1-4. Cover Plate Location
CD315 3-6-5
Rev 3
Chapter 3
2. The adjustment screws are located behind the tension springs (see Figure 5). Use a 3/16" hex
wrench to adjust the adjustment screws.
(a) Turn the adjustment screws counterclockwise to increase the air gap.
(b) Turn the adjustment screws clockwise to decrease the air gap.
Adjust the gap as required to reset it back to within ± .030" of the SET point.
Figure 1-5. Brake Air Gap Adjustment
3-6-6 CD315
Rev 3
Chapter 3
E. REASSEMBLY
1. After adjustment, replace the cover plate and manual release plate. Take care to properly
install the gaskets between plates and the brake housing. Use screwdriver to install 6 screws
for cover plate installation and 6 screws for manual release plate installation.
2. Mount conveyor drive guard. Use screwdriver and ¼" wrench to install two ¼-20 x 1" hex
head bolts, two ¼" flat washers, two spacers (between conveyor drive guard and conveyor
weldment and two ¼-20 lock nuts to attach conveyor drive guard back to conveyor weldment.
3. Reconnect battery. Test belt load before returning to service.
CD315 3-6-7
Rev 3
Chapter 3
3-6-8 CD315
Rev 3
Chapter 4
CHAPTER 4: ILLUSTRATED PARTS LIST

TABLE OF CONTENTS
SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1

A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number .......................................................................... 4-1-2
2. Part Numbers and Vendor Codes ............................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-4
4. Effectivity................................................................................................... 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
D. Vendor Code Reference List ................................................................................. 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

Figure 2-1. Frame Weldment - Front View .......................................................... 4-2-2
Figure 2-2. Frame Weldment - Rear View ........................................................... 4-2-4
Figure 2-3. Frame - Body (Left Side) (Up to S/N 254) ......................................... 4-2-6
Figure 2-4. Frame - Body (Left Side) (S/N 254 and Up)....................................... 4-2-8
Figure 2-5. Frame - Body (Right Side) ............................................................... 4-2-10
Figure 2-6. Mirrors ............................................................................................. 4-2-12
Figure 2-9. Seat Assembly................................................................................. 4-2-18
Figure 2-10. Battery Assembly ........................................................................... 4-2-20
Figure 2-11. Battery Assembly with Welded Battery Box ................................... 4-2-24
Figure 2-12. Battery Connectors ....................................................................... 4-2-28
Figure 2-13. Battery Connector (Eurodin Adapter Option) ................................ 4-2-30
Figure 2-14. Instrument Panel (Up to S/N 254) .................................................. 4-2-32
Figure 2-15. Instrument Panel (S/N 254 thru 389) ............................................. 4-2-34
Figure 2-16. Instrument Panel (S/N 390 and Up) ............................................... 4-2-36
Figure 2-17. Shifter Assembly (Up to S/N 254) .................................................. 4-2-38
Figure 2-18. Shifter Assembly (S/N 254 and Up) ............................................... 4-2-40
Figure 2-19. Accelerator and Shifter Linkage at Controller Enclosure ............... 4-2-42
Figure 2-20. Accelerator Pedal Assembly (Up to S/N 254) ................................ 4-2-44
Figure 2-21. Accelerator Pedal Assembly (S/N 254 thru 389) ............................ 4-2-46
Figure 2-22. Accelerator Pedal Assembly (S/N 390 and Up) ............................. 4-2-48
Figure 2-23. Circuit Breaker Installation ............................................................. 4-2-50
Figure 2-24. Park Brake Assembly (Up to S/N 254) ........................................... 4-2-52
CD315 4-TOC-i
Rev 4
Chapter 4
Figure 2-25. Park Brake Assembly (S/N 254 and Up) ........................................ 4-2-54
Figure 2-26. Park Brake Cable Linkage ............................................................. 4-2-56
Figure 2-27. Brake Pedal Assembly................................................................... 4-2-58
Figure 2-28. Brake Line Diagram ....................................................................... 4-2-60
Figure 2-29. Hydro Boost and Proportion Valve ................................................. 4-2-62
Figure 2-30. Brake Lines, Front (Up to S/N 866) ................................................ 4-2-64
Figure 2-31. Brake Lines, Front (S/N 866 and Up) ............................................. 4-2-66
Figure 2-32. Brake Lines, Rear (Up to S/N 866) ................................................ 4-2-68
Figure 2-33. Brake Lines, Rear (S/N 866 and Up) ............................................. 4-2-70
Figure 2-34. Brake Caliper Assembly, Front Disc .............................................. 4-2-72
Figure 2-35. Brake Assembly, Rear ................................................................... 4-2-74
Figure 2-36. Steer Column Assembly ................................................................ 4-2-76
Figure 2-37. Steer Cylinder Assembly ................................................................ 4-2-78
Figure 2-38. Main Hydraulic System (Up to S/N 254) ........................................ 4-2-80
Figure 2-39. Hydraulic System (Right Side) ...................................................... 4-2-82
Figure 2-40. Hydraulic Assembly (UAL Specific) ................................................ 4-2-86
Figure 2-41. Manifold Assembly (Up to S/N 390) ............................................... 4-2-88
Figure 2-42. Manifold Assembly (S/N 390 thru 498) ........................................... 4-2-90
Figure 2-43. Manifold Assembly (S/N 499 and Up) ............................................ 4-2-92
Figure 2-44. Emergency Pump Assembly ......................................................... 4-2-94
Figure 2-45. Hydraulic Control Valve (Up to S/N 499) ........................................ 4-2-96
Figure 2-46. Hydraulic Control Valve (S/N 499 and Up) ..................................... 4-2-98
Figure 2-47. Conveyor Hydraulic Lines ............................................................ 4-2-102
Figure 2-48. Lift Valve Components ................................................................. 4-2-104
Figure 2-49. Lift Cylinder - Front (Up to S/N 499) ............................................. 4-2-106
Figure 2-50. Lift Cylinder - Front (S/N 499 and Up) .......................................... 4-2-108
Figure 2-51. Lift Cylinder - Rear ....................................................................... 4-2-110
Figure 2-52. Steer Front Axle and Hub Assembly ............................................. 4-2-112
Figure 2-53. Drive Motor Assembly (Up to S/N 569) ........................................ 4-2-114
Figure 2-54. Drive Motor Assembly (S/N 569 and Up) ..................................... 4-2-116
Figure 2-55. Drive Motor Reduction Gear Assembly ........................................ 4-2-118
Figure 2-56. Drive (Rear) Axle Attachment ...................................................... 4-2-120
Figure 2-57. Drive (Rear) Axle Hub Assembly.................................................. 4-2-122
Figure 2-58. Drive (Rear) Axle Assembly ......................................................... 4-2-124
Figure 2-59. Controller Assembly - Sevcon MCM with Regen ......................... 4-2-128
Figure 2-60. Mechanical Adaptations to Sevcon MCM Controller .................... 4-2-130
Figure 2-61: SCR-Converter-Accelerator Assy (Sevcon MCM Controller) ....... 4-2-132
Figure 2-62: Controller Assembly Call-outs (Sevcon MCM Controller) ............. 4-2-133
Figure 2-63. Control Box Assembly (S/N 254 thru 498) ................................... 4-2-134
4-TOC-ii CD315
Rev 4
Chapter 4
Figure 2-64. Control Box Assembly (S/N 499 and Up) ..................................... 4-2-138
Figure 2-65. Controller Assembly (S/N 254 thru 499) ...................................... 4-2-140
Figure 2-66. Controller Assembly (S/N 500 and Up) ........................................ 4-2-142
Figure 2-67. Horn Assembly ............................................................................ 4-2-144
Figure 2-68. Light Assemblies ......................................................................... 4-2-146
Figure 2-69. Spot Light Installation ................................................................... 4-2-148
Figure 2-70. Work Light Assembly ................................................................... 4-2-150
Figure 2-71. Wheels and Tires ........................................................................ 4-2-152
Figure 2-72. Conveyor Lift Arms - Front and Rear ........................................... 4-2-154
Figure 2-73. Conveyor Safety Props................................................................ 4-2-156
Figure 2-74. Cam Assembly ............................................................................ 4-2-158
Figure 2-75. Conveyor Weldment - Standard (BLE-4-2617) ............................ 4-2-160
Figure 2-76. Conveyor Weldment - Narrow (BLE-4-2618) (Up to S/N 409) ..... 4-2-162
Figure 2-77. Conveyor Weldment - Narrow (BLE-4-2618) (S/N 409 and Up) .. 4-2-164
Figure 2-78. Conveyor Guards ........................................................................ 4-2-166
Figure 2-79. Conveyor Front End - Standard ................................................... 4-2-168
Figure 2-80. Conveyor Front End - Narrow (Up to S/N 409) ............................ 4-2-170
Figure 2-81. Conveyor Front End - Narrow (S/N 409 and Up) ......................... 4-2-172
Figure 2-82. Conveyor Bottom Covers - Front (Option)................................... 4-2-174
Figure 2-83. Conveyor Rear End - Standard ................................................... 4-2-176
Figure 2-84. Conveyor Rear End - Narrow ...................................................... 4-2-178
Figure 2-85. Conveyor Attachments (Rear End) - Narrow ............................... 4-2-180
Figure 2-86. Switch Assembly ......................................................................... 4-2-182
Figure 2-87. Electric Belt Control Installation ................................................... 4-2-184
Figure 2-88. Conveyor Control Assembly (S/N 254 thru 389) .......................... 4-2-186
Figure 2-89. Conveyor Control Assembly (S/N 390 and Up) ............................ 4-2-188
Figure 2-90. Emergency Stop Button Installation ............................................. 4-2-190
Figure 2-91. Conveyor Drive Motor - Standard Conveyor (Up to S/N 185) ....... 4-2-192
Figure 2-92. Conveyor Drive Motor - Standard Conveyor (S/N 185 and Up) .... 4-2-194
Figure 2-93. Conveyor Drive Motor - Narrow Conveyor (Up to S/N 510) ......... 4-2-196
Figure 2-94. Conveyor Drive Motor - Narrow Conveyor (S/N 510 and Up) ...... 4-2-198
Figure 2-95. Conveyor Belt and Rollers - Standard ......................................... 4-2-200
Figure 2-96. Conveyor Belt Rollers - Narrow ................................................... 4-2-202
Figure 2-97. Side Rail Assembly ...................................................................... 4-2-204
Figure 2-98. Hand Rail Assembly (Up to S/N 185) ........................................... 4-2-206
Figure 2-99. Hand Rail Assembly (S/N 185 and Up) ........................................ 4-2-208
Figure 2-100. Hand Rail Assy - Locking w/Telescoping Handrail Extender ...... 4-2-210
Figure 2-101. Rapid Charge Assembly (Optional) ........................................... 4-2-212
Figure 2-102. Quick Charge Assembly - Top Installation (Optional) ................. 4-2-214
CD315 4-TOC-iii
Rev 4
Chapter 4
Figure 2-103. Rear Charge Port (Option) ........................................................ 4-2-216

Figure 2-104. Remote Charger Port Assembly (Optional) ............................... 4-2-218
Figure 2-105. Back Up Alarm ........................................................................... 4-2-220
Figure 2-106. Conveyor Switch Harness (Left Front) ...................................... 4-2-223
Figure 2-107. Conveyor Switch Harness (Right Front) .................................... 4-2-224
SECTION 3: NUMERICAL INDEX ............................................................................................. 4-3-1
SECTION 4: ALPHABETICAL INDEX ........................................................................................ 4-4-1
4-TOC-iv CD315
Rev 4
Chapter 4
SECTION 1: DESCRIPTION
A. INTRODUCTION
The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement parts
information as well as general part and assembly information necessary for maintenance of the TUG
Technologies Corporation Model 660E Mobile Electric Conveyor.
CD315 4-1-1
Rev 4
Chapter 4
B. USING THE ILLUSTRATED PARTS LIST
The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which
comprise the 660E Mobile Electric Conveyor. Each IPL consists of a figure illustrating a group of
related parts and a corresponding list identifying the parts by part number(s) and description. The
quantity given in the list is for the particular assembly shown in the illustration and is not necessarily
the quantity for the entire unit.
1. Figure and Index Number

The figure and index number refers to the figure on which the part is depicted. The index
number refers to the individual part shown on the illustration. See the following example for
further explanation of the Figure and Index Number.
Refers to the figure number, and the Fig & Vendor Part Tug Part
Code Descriptio
item's number on that figure. Ind Number Number
89-1 372750 ------ TM1-4-8168 Spindle, R
No Index Number: This item is 89- 372750 ------ TM1-4-8166 Spindle, L/
related to the components or
89-2 ------ ------ TM1-1-8264 Pin, King,
system in the illustration, but is
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
not actually shown. In certain
89-4 372750 ------ TM1-2-8198 Cover, Du
cases, such items are shown in
89-5 403166 ------ MI-ND-813 Bearing, T
other figures in section 4-2.
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
Figure and index number blank: This 89-8 373090 24720 T6-3001-60024 Race, Inne
item is one of possibly many items 89-9 ------ ------ TM1-ND-5287 Hub, Front
designated by a single Figure and 372750 ------ TM1-4-8196 Rotor, Cas
Index Number. The first item in 89-10 450238 ------ T6-8015-103 Stud, Whe
such a group is assigned a number; 89-11 ------ ------ TM1-ND-5287 Hub, Front
the rest of these items are listed 89 12 373317 T6 3003 105 N t L ½
directly below. These items are
generally similar in function, but
have different applicabilities or
effectivities.
NOTE: Sample tables in this section are intended to illustrate table

Note structure and format, and should not be used for reference of actual data.
Refer to applicable figure for specific required part information.
4-1-2 CD315
Rev 4
Chapter 4
2. Part Numbers and Vendor Codes

Parts are identified by part numbers assigned by TUG Technologies Corporation or, in the
case of fasteners and related materials, by industry standard specification. When applicable,
vendors’ part numbers are also included and the individual vendor for each item identified. In
a few instances, TUG part numbers are not available and only the vendor numbers are
indicated. These parts can be ordered directly from TUG Technologies Corporation using the
vendor part number in lieu of a TUG part number.
Vendor codes are provided for quick, easy reference to an individual vendor. The vendor can
be identified by referring to the Vendor Code Reference List in this section. Vendor codes
are not in any way related to the part number. They should not be used when ordering
replacement parts. They are for use as a reference only when using this manual. See the
following illustration for further explanation of Part Numbers and Vendor Codes.
Part number assigned by

TUG.
No vendor code or vendor
part number indicates that
the part is designed,
Fig & Vendor Part Tug Part
manufactured or modified Code Descriptio
Ind Number Number
by TUG.
89-1 372750 ------ TM1-4-8168 Spindle, R
89- 372750 ------ TM1-4-8166 Spindle, L/
89-2 ------ ------ TM1-1-8264 Pin, King,
89-3 373090 CB2430-16 TM1-1-8084 Bushing, S
89-4 372750 ------ TM1-2-8198 Cover, Du
89-5 403166 ------ MI-ND-813 Bearing, T
89-6 403166 CR21208K T6-3001-60022 Seal, Grea
89-7 372739 ------ MI-ND-817 Bearing, H
89-8 373090 24720 T6-3001-60024 Race, Inne
89-9 ------ ------ TM1-ND-5287 Hub, Front
372750 ------ TM1-4-8196 Rotor, Cas
89-10 450238 ------ T6-8015-103 Stud, Whe
89-11 ------ ------ TM1-ND-5287 Hub, Front
89-12 373317 ------ T6-3003-105 Nut, Lug ½
89-13 403166 15245 T6-3001-60026 Race, Out
89-14 403166 15123 T6-3001-60027 Bearing, O
89-15 261788 613108 T6-3001-60028 Washer, S
89-16 261788 ------ T6-3001-60030 Pin, Cotter
89-17 373059 ------ T6-3001-60029 Nut, Spind
89-18 261788 06-12016 T6-3001-60031 Cap, Grea
89-19 372739 EW244002 ------
TM1-1-3508 Washer, T
No TUG part number indicates that TUG has not assigned a part
number to the part, and that the part is inventoried and supplied
under the vendor part number.
CD315 4-1-3
Rev 4
Chapter 4
3. Description and Quantity

A description and quantity is provided for each part listed in the IPL. The quantity given for
subassemblies and subparts is the number of subassemblies/parts contained in the component
or system depicted by the associated illustration, not necessarily the entire vehicle.
4. Effectivity
The 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 be
found in the description column, the figure title or in notes located at the bottom of the IPL
page. 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 major
components be procured directly from TUG Technologies Corporation. Use of parts not
manufactured or supplied by TUG may void the warranty on the vehicle. When replacing structural
fasteners, use Grade 8 or higher material.
Spare parts can be ordered directly from TUG Technologies Corporaton by telephoning TUG SHOP
at 1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask for
TUG SHOP when calling. FAX messages can be sent to 770-422-8730 (U.S.).
When ordering parts, please be prepared with TUG part numbers (vendor part number and code if no
TUG part number is available), part description, figure and index number and the revision of the IPL
page (located in the footer of each page, directly under each page number).
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 after
hours will be returned during the next regular business day.
D. VENDOR CODE REFERENCE LIST
Vendor Code Vendor Name Address City, State, Zip

205659 Barloworld Handling - Decatur 5191 Snapfinger Woods Drive Decatur, GA 30035
239446 Eaton Corp/Aeroquip Inc 14615 Lone Oak Road Eden Prairie, MN 55344
239618 Preco Inc. 415 N. Maple Grove Road Boise, ID 83704
241762 Sittler Corporation 1817 South 55th Avenue, Unit 8 Cicero, IL 60804
241766 Fastenal 1000 Cobb International Blvd. Marietta, GA 30152
241894 Maxima Technologies 1811 Rohrerstown Road Lancaster, PA 17601
244001 CMC of Georgia, Inc. 25 South Beulah Street Winder, GA 30680
244126 Bay City Machine & Supply 3113 Nichols Road Bay City, TX 77414
4-1-4 CD315
Rev 4
Chapter 4

247378 Sunwest Screen Graphics Ltd. 277 Cree Crescent Winnipeg MB R3J3X4
249341 Brammer Supply, Inc. 3314 East Highway 82 Gainsville, TX 76240
249777 Peterson Manufacturing Co. 4200 East 135th Street Grandview, MO 64030
250187 EnerSys, Inc. 2366 Bernville Road Reading, PA 19605
250697 Diamond Rubber Products Corp. 4000 50th Street SW Birmingham, AL 35221
250698 Diamond Rubber Products Corp. P.O. Box 531164 Birmingham, AL 35235
250728 Teleflex Morse 640 North Lewis Road Limerick, PA 19468
254934 McMaster Carr Supply Co. 6100 Fulton Indust. Blvd. Atlanta, GA 30336
260131 Truck Lite Company Inc. 310 East Elmwood Avenue Falconer, NY 14733
262531 Impulse Manufacturing Inc 55 Impulse Indust. Drive Dawsonville, GA 30534
263516 O'Neal Steel Inc. 4075 Blue Ridge Parkway Norcross, GA 30071
263540 Peerless Electronics 9600 W. Sample Rd., Ste. 506 Coral Springs, FL 33065
263586 Quadrastat Corporation 260 West Santa Fe Street Pomona, CA 91767
265338 Buyer's Products Co. 7700 Tyler Blvd. Mentor, OH 44060
266523 Aerofast 360 Gunderson Drive Carol Stream, IL 60188
267009 Goodyear Co - Atlanta P.O. Box 277808 Atlanta, GA 30384
267599 Compression Specialties Inc. P.O. Box 4098 Casper, WY 82604
268375 Joseph T. Ryerson and Son, Inc. 600 SW 10th Street Renton, WA 98055
268697 Wise Company 5535 Pleasant View Road Bartlett, TN 38134
277028 JW Speaker Corp. W185 N11315 Whitney Dr. Germantown, WI 53022
277796 Carlton Bates Co. 1520 West Mineral Road Tempe, AZ 85283
278709 Flender Corporation 950 Tollgate Road Elgin, IL 60123
278878 Century Spring Corp. 231274 Momentum Place Chicago, IL 60689
279184 Marc C. Pope & Associates, Inc. 4910 Martin Court SE Smyrna, GA 30082
281660 EWH Spectrum, Inc. 221 West Chillicothe Avenue Bellefontaine, OH 43311
289558 TUG Technologies Corporation 815 Allgood Road Marietta, GA 30062
293912 McMaster Carr Supply Co. 6100 Fulton Indust. Blvd. Atlanta, GA 30336
294093 Carlton Bates Co. 10605 Stebbins Circle Houston, TX 77043
294594 Donaldson Co., Inc. 1400 West 94th Street Minneapolis, MN 55431
295524 Dana Corporation 1293 Glenway Drive Statesville, NC 28625
302511 Truck Lite Company Inc. 310 East Elmwood Avenue Falconer, NY 14733
329499 Cross Fluid Power P.O. Box 65486 Charlotte, NC 28265
332121 Trinity Hydraulics Inc. 5025 Wallace Drive Cumming, GA 30041
347738 MPC 15 Ridgeway Road NW Marietta, GA 30064
349137 Royal Brass & Hose 1002 Williams Drive NE Marietta, GA 30066
349146 Drive Shaft Services, Inc. 1395 Cobb Parkway North, #L Marietta, GA 30062
349373 Tech Craft Inc. 462 Roswell Street NE Marietta, GA 30060
CD315 4-1-5
Rev 4
Chapter 4

350000 Powers Machine & Tool Co. 1808 Lelia Street Austell, GA 30106
355032 Midwest Control Products Corp. 590 East Main Street Bushnell, IL 61422
357447 Atlantic Southern Products Inc. 5952 Peachtree Indust. Blvd. Norcross, GA 30071
358417 Major Machining Inc. 3240 Heritage Drive Kennesaw, GA 30144
368977 Lavanture Products Company Inc. P.O. Box 2088 Elkhart, IN 46515
369032 Bosch Braking Systems 3737 Red Arrow Highway St. Joseph, MI 49085
369142 Harlan Corp. 27 Stanley Rd. Kansas City, KS 66115
369150 Orscheln / Felsted 1177 North Moberly Street Moberly, MO 65270
369176 Georgia Steel Supply Co. 903 Huff Street NW Atlanta, GA 30318
369183 Napa Auto Parts 2590 Keene Street Kennesaw, GA 30144
369400 Atlanta Powertrain 4491 Moreland Avenue Conley, GA 30288
369403 Peterson Spring P.O. Box 5859 Athens, GA 30613
370088 Kennesaw Hardware 2775 South Main Street Kennesaw, GA 30144
371685 WASP, Inc. 20631 State Highway 55 Glenwood, MN 56334
371691 CF Gomma USA, Inc. 643 West Ellsworth Street Columbia City, IN 46725
372170 Diamond Rubber Products Corp. P.O. Box 531164 Birmingham, AL 35235
372204 Dana Corporation 1293 Glenway Drive Statesville, NC 28625
372209 Graphic Applications, Inc. P.O. Box 1115 Kennesaw, GA 30144
372245 OTR Wheel Engineering 6 Riverside Indus. Pkwy Rome, GA 30161
372291 Safety South Supplies Inc. 3411 Turkey Mountain Road NE Rome, GA 30161
372294 Jessup Manufacturing Co. 2815 West State Route 120 McHenry, IL 60050
372364 Crossville Dist 900 Indust. Blvd. Crossville, TN 38555
372578 AeroVironment, Inc. 825 South Myrtle Avenue Monrovia, CA 91016
372736 BSA Machine Shop 2771 Winston Indust. Pkwy Winston, GA 30187
372739 Motion Industries 8145 Troon Circle Austell, GA 30001
372745 Ryerson Tull Company, Inc. 4400 Peachtree Indust. Blvd. Norcross, GA 30071
372750 Tech Craft Inc. 462 Roswell Street NE Marietta, GA 30060
372857 Auto Parts Company Inc. 203 North Tennessee Street Cartersville, GA 30120
373059 Sevcon 40 North Avenue Burlington, MA 01803
373082 Austin & Thomas Hardware 1520 Broadmoor Blvd. Buford, GA 30518
373085 Roytec Industries, Inc. 306-A Bell Park Drive Woodstock, GA 30188
373087 Marc C. Pope & Associates, Inc. 4910 Martin Court SE Smyrna, GA 30082
373089 Laserform & Machine Inc. 10010 Farrow Road Columbia, SC 29203
373090 Bearings & Drives, Inc. 515 Commerce Park Drive SE Marietta, GA 30060
373094 Grainger, Inc. 2255 Northwest Parkway SE Marietta, GA 30067
373102 Georgia Control Center 3645 Zip Indust. Blvd. Atlanta, GA 30354
373117 Advanced DC Motors 6402 Deere Road #3 Syracuse, NY 13206
4-1-6 CD315
Rev 4
Chapter 4

373317 Fastenal 1000 Cobb International Blvd. Marietta, GA 30152
373338 Chantland Company Highway 3 East Humboldt, IA 50548
373345 Vescor Corporation 50 North River Street South Elgin, IL 60177
373368 Curtis Instruments, Inc. 200 Kisco Avenue Mt. Kisco, NY 10549
373386 Certified Power Inc. 390 Koopman Lane Elkhorn, WI 53121
373393 Peach State Ford 2700 Moreland Avenue Atlanta, GA 30315
373423 Rema Tip Top North America 119 Rockland Avenue Northvale, NJ 07647
373488 Threads for the South, Inc. 1076 King Indust. Drive NE Marietta, GA 30062
375297 Wes-Garde Components Group Inc. 3815 Industry Blvd. Lakeland, FL 33811
376499 Teleflex Morse 640 North Lewis Road Limerick, PA 19468
376658 Contactor Manufacturing 135 South LaSalle, Dept. 5153 Chicago, IL 60603
376710 MB Marketing Inc. P.O. Box 2296 Asheville, NC 28802
380486 Capital Rubber & Gasket Co., Inc. 2672 Lithonia Indust. Blvd. Lithonia, GA 30058
382204 Johnson Battery Co., Inc. 2186 Sylvan Road East Point, GA 30344
383678 Ford Power Products 28333 Telegraph Road, Ste. 300 Southfield, MI 48034
385455 Delta Systems, Inc. 1734 Frost Road Streetsboro, OH 44241
385900 Southern Belting & Transmission Co. 218 Ottley Drive NE Atlanta, GA 30324
389231 Hi Tech Fab Inc. 4305 Lilburn Indust. Way Lilburn, GA 30047
395898 Textile Indust. Welding 109 Lillian Drive Dalton, GA 30720
402020 Tom Jumper Chevrolet Inc. 7200 Roswell Road NE Atlanta, GA 30328
402378 Dana Corporation 5278 US Rt 24 East Antwerp, OH 45813
402530 Napa Auto Parts 2590 Keene Street Kennesaw, GA 30144
402641 Newark Electronics 22 Technology Parkway South Norcross, GA 30092
402645 Carlton Bates Company 125 Royal Woods Ct, Ste. 150 Tucker, GA 30084
402646 Carquest Auto Parts 180 North Fairground St. NE Marietta, GA 30060
402708 Ohio Gear & Transmission Inc. 33050 Lakeland Blvd. Eastlake, OH 44095
402832 Federal Mogul 6300-C Boat Rock Blvd. Atlanta, GA 30336
402975 Graybar Electric Co. Inc. 1230 Kennestone Circle NE Marietta, GA 30066
403133 McNaughton McKay Elec. 6685 Best Friend Road Norcross, GA 30071
403166 Motion Industries 8145 Troon Circle Austell, GA 30001
405491 Georgia Steel Supply Co. 903 Huff Street NW Atlanta, GA 30318
407341 TUG Technologies Corporation 815 Allgood Road Marietta, GA 30062
410026 Eaton Corp. Fluid Power 14615 Lone Oak Road Eden Prairie, MN 55344
424776 Electronic Trans.Engineering Corp. 401 South 2nd Avenue Phoenix, AZ 85003
426508 Allen & Associates 7800 North Southland Blvd. Orlando, FL
426744 Royal Brass & Hose 1002 Williams Drive NE Marietta, GA 30066
440230 AMS, Incorporated 824 Bill Rutlege Road Winder, GA 30680
452448 Engine Distributors, Inc. 400 University Court Blackwood, NJ 08012
CD315 4-1-7
Rev 4
Chapter 4

606035 O'Neal Steel Inc. 4075 Blue Ridge Parkway Norcross, GA 30071
1136099 Averest Inc. P.O. Box 45151 Atlanta, GA 30320
1172802 Volunteer Bearing and Supply 1055 Mt. View Industrial Dr. Morrison, TN 37357
1177411 Industrial Service Corp. 1731 N. Roosevelt Ave., Ste 1 Burlington, IA 52601
1178478 Maquilados Hyplasa S A DE C V Las Torres No 509 Satillo Coahuila, MX
1178565 Industrial Supply Solutions 4485 Commerce Drive Ste 102 Buford, GA 30518
4-1-8 CD315
Rev 4
Chapter 4
SECTION 2: ILLUSTRATED PARTS LIST
CD315 4-2-1
Rev 4
Chapter 4
27
18
19
15
20
14
13
27
12
17
11
28
16 10
9 29
5
21
30
8
4
7 6
22
23 3
24 2
25
1
26
Figure 2-1. Frame Weldment - Front View
4-2-2 CD315
Rev 4
Chapter 4
Table 2-1. Frame Weldment - Front View

Code Description Qty Effective
Ind Number Number
1- ------ ------ BLE-E Frame Weldment - 660E 1 101 & Up

1-1 440230 ------ 660-1-1528 Angle, Safety Prop Crossmember 2 "
1-2 440230 ------ 660-1-1087 Gusset, Left Front Bumper 1 "
1-3 440230 ------ 660-4-1007 Bumper, Steel Front 1 "
1-4 440230 ------ 660-1-1070 Gusset, Beneath Left Front Fender 1 "
1-5 440230 ------ 660-3-1028 Compartment, Driver R/H 1 "
1-6 440230 ------ 660-1-1068 Gusset, Left Front Frame 1 "
1-7 440230 ------ 660-2-1021 Bracket, Left Suspension Front 1 "
1-8 440230 ------ 660-4-1016 Crossmember, Front Safety Prop 1 "
1-9 440230 ------ BLE-4-2643 Box Weldment, Battery 1 "
1-10 369176 ------ BLE-3-1058 Crossmember, Control Box 2 "
1-11 440230 ------ 660-4-1005 Rail, Frame, L/H 1 "
1-12 440230 ------ 660-4-1015 Crossmember, Chassis Lift Arm 1 "
440230 ------ 663-4-1015 Crossmember, Narrow 1 As Req'd
Chassis Lift Arm
1-13 440230 ------ 660-4-1975 Crossmember, Rear 1 101 & Up
1-14 440230 ------ 660-1-1529 Gusset 3 "
1-15 440230 ------ 660-1-1069 Gusset, Right Front Frame 3 "
1-16 440230 ------ 660-3-1262 Mount, Rear Axle 2 "
1-17 265338 ------ MJ-ND-4006 Ring, Lashing 5/8" x 4" x 4" - 2 "
Forged w/ Bracket
1-18 440230 ------ 660-2-0839 Spacer, Rear 2 "
1-19 440230 ------ BLE-4-2635 Bumper, Rear 1 "
1-20 440230 ------ 660-1-0066 Bracket, Rear Cylinder 2 "
1-21 440230 ------ 660-4-1006 Rail, Frame, R/H 1 "
1-22 440230 ------ 660-1-1020 End, Wheel Well 2 "
1-23 440230 ------ 660-2-1019 Well, Wheel 1 "
1-24 440230 ------ 660-2-1024 Bracket, Right Suspension Front 1 "
1-25 440230 ------ 660-4-2835 Gusset, Right Fender 1 "
1-26 440230 ------ 660-1-1088 Gusset, Right Front Fender Well 1 "
1-27 357447 ------ 660-6-0582-26 Bumper, Rubber - Lift Arm (Note 1) 4 "
1-28 373089 ------ 660-2-2208 Spacer, 2" - Conveyor Bumper 2 "
(Note 1)
1-29 277028 0909482/ T6-1300-259 Light, Spot w/ Grill - Opt. 1 As Req'd
G5523-1-12V
1-30 358417 ------ 660-2-1640 Bracket, Front Work Light Mtg - Opt. 1 "
NOTE 1: These parts are not part of the frame weldment.
CD315 4-2-3
Rev 4
Chapter 4
4 3
5
6
2
7
9
10
1
11
12
21
13
19
20
14
15
16
17
18
Figure 2-2. Frame Weldment - Rear View
4-2-4 CD315
Rev 4
Chapter 4
Table 2-2. Frame Weldment - Rear View

Ind Number Number
2- ------ ------ BLE-E Frame Weldment - 660E 1 101 & Up

2-1 440230 ------ 660-3-1262 Mount, Rear Axle 2 "
2-2 440230 ------ 660-1-1018 Gusset, Front Bumper 1 "
2-3 440230 ------ 660-1-0074 Bracket, Front Cylinder 2 "
2-4 358417 ------ BLE-4-2623 Plate, Accelerator Mounting 1 "
2-5 440230 ------ 660-1-1131 Mount, Brake Pedal 2 "
2-6 440230 ------ 660-2-2848 Support, Instrument Panel 2 "
2-7 440230 ------ 660-1-1027 Compartment, Driver L/H 1 "
2-8 440230 ------ 660-2-1961 Stop, Brake Pedal 1 "
2-9 440230 64-660-1-1106 660-1-1106 Anchor, Brake Bell Crank 2 "
2-10 440230 ------ 660-1-1070 Gusset, Beneath Left Front Fender 1 "
2-11 440230 ------ 660-2-1021 Bracket, Left Suspension Front 1 "
2-12 369176 ------ BLE-1-1080 Guide, Inner Battery 2 "
2-13 369176 ------ BLE-1-1019 Gusset, Battery Cradle 2 "
2-14 358417 ------ BLE-2-2636 Cover, Rear Bumper (Note 1) 1 465 & Up
2-15 373089 ------ 660-1-0178 Flange, Rear Hoop Bumper - UAL 2 As Req'd
2-16 244001 ------ 660-2-2350 Frame, L/H Rear Step - UAL 1 "
2-17 369176 ------ 660-2-2314 Step, L/H Boom Guard 1 "
Gripstrut - UAL
2-18 426744 ------ 660-1-0179 Bumper, Rear Hoop - UAL 1 "
2-19 358417 ------ 660-1-0177 Gusset, Rear Hoop Bumper - UAL 2 "
2-20 358417 ------ 660-2-2332 Frame, R/H Rear Step - UAL 1 "
2-21 369176 ------ 660-2-2386 Step, R/H Boom Guard 1 "
Gripstrut - UAL
NOTE 1: This part not used in units with rapid charge option.
CD315 4-2-5
Rev 4
Chapter 4
Figure 2-3. Frame - Body (Left Side) (Up to S/N 254)
4-2-6 CD315
Rev 3
Chapter 4
Table 2-3. Frame - Body (Left Side) (Up to S/N 254)

Ind Number Number
3-1 293912 15665A262 BLE-1-1056 Hinge, Piano 2" x 96" (See Note 1) 1 Up to 254
3-2 389231 ------ BLE-4-1040 Door, Battery 1 "
3-3 369176 ------ 660-4-1035 Fender, Left Rear 1 "
3-4 250698 ------ 660-2-1230 Rail, Rub - Plastic, 16" 2 "
3-5 369176 ------ BLE-4-1061 Fender, Left Body 1 "
3-6 250697 ------ 660-1-1543 Liner, Fender Well 2 "
3-7 250698 ------ 660-2-1230 Rail, Rub - Plastic, 70" 1 "
3-8 358417 ------ BLE-2-1043 Fender Tie Bar 3 "
3-9 372170 ------ 660-2-1229 Rail, Rub - Left Front 1 "
3-10 373089 ------ 660-3-1167 Closeout, Headlight 1 "
3-11 263516 ------ 660-4-1037 Fender, Left Front 1 "
3-12 358417 ------ 660-2-1103 Cover, Valve Cavity & Seat Mount 1 "
Note 1: Though listed separately, the hinge and battery door are typically supplied as a single
welded assembly.
CD315 4-2-7
Rev 3
Chapter 4
36 37
38
15 21
18
34
20 32
28 17 31
16
27 22
35 10
23
24 12
33 19
13
15 29
26 14
25 30
11 12
7 10
8 6 9
5
4
2 3 8
1
Figure 2-4. Frame - Body (Left Side) (S/N 254 and Up)
4-2-8 CD315
Rev 4
Chapter 4
Table 2-4. Frame - Body (Left Side) (S/N 254 and Up)

Ind Number Number
4-1 373089 ------ 660-3-1167 Closeout, Headlight 1 Up to 569

244001 ------ 660-4-2985 Closeout, L/F Headlight 1 569 & Up
4-2 373089 ------ BLE-4-2557 Panel, Left Front Body Weldment 1 254 & Up
4-3 ------ ------ ------ Liner, Fender Well - Front Left 18.5" x 12" 1 "
4-4 373317 ------ ¼ x 1½ Fend, ¼" ID; 1½" OD 18 "
4-5 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 18 "
4-6 373089 ------ 660-1-1280 Plaque, Conveyor Control 1 Up to 440
373089 ------ BLE-1-2633 Plaque, Conveyor Control 1 440 & Up
4-7 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 4 254 & Up
4-8 373317 15005 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 18 "
4-9 ------ ------ ------ Liner, Fender Well - Middle Left 20" x 30" 1 "
4-10 373317 15109 3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 6 "
4-11 358417 ------ BLE-2-1043 Fender Tie Bar 3 "
4-12 373317 33859 3/8 Washer, Flat 3/8" ID 12 "
4-13 263516 ------ BLE-4-1076 Fender, Left Midsection Weldment 1 "
4-15 373317 33859 3/8 Washer, Flat 3/8" ID 24 "
4-16 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 12 "
4-17 244126 ------ 660-1-1039 Plate, Bolting 2 "
4-18 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 12 "
4-19 ------ ------ ------ Liner, Fender Well - Rear 20" x 24" 1 "
4-20 369176 ------ 660-4-1035 Fender, Left Rear 1 "
4-21 369176 ------ 660-2-2558 Box, Chock 16 x 16 x 5 - Opt. 1 As Req'd
373089 ------ 660-2-1032 Box, Chock 12½ x 9 x 5 - Opt. 1 "
4-22 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 4 254 & Up
4-23 263516 ------ BLE-4-2556 Bracket, Battery Term Disconnect 1 "
4-24 358417 ------ 660-2-1103 Cavity, Valve Cover / Seat Mount 1 "
4-25 373317 33859 3/8 Washer, Flat 3/8" ID 2 "
4-26 373317 ------ 3/8-16 x 1¼ Screw, 3/8" x 1¼" Long 2 "
4-27 372294 3200-22 T6-200-106 Safety Walk 22" Wide, 14' Long 1 "
4-28 389231 ------ BLE-4-1040 Door, Battery 1 "
372750 ------ BLE-4-1041 Door, Battery - 3" Extended - Opt. 1 As Req'd
4-29 250698 ------ 660-2-1230 Rail, Rub - Center 70" 1 254 & Up
4-31 373317 37341 3/8-16 Nut, Flange - LK REG 3/8-16 9 "
4-32 372170 ------ 660-2-1229 Rail, Rub - Quarter Panel 16" 2 "
4-33 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 11 "
4-34 373317 15007 ¼-20 x 1¼ Bolt, Hex Head Ø ¼-20 x 1¼" Long 11 "
4-35 372750 ------ 660-1-1464 Guard, Front Valve - Opt. 1 As Req'd
4-36 372170 10 x 4 x 4 T6-2004-154 Chock, Wheel - Opt. 2 "
372170 ------ 660-3-2593 Chock, Orange 11 x 8 x 7.75 - Opt. 1 "
4-37 293912 2175T25 T6-2004-155 Link Kit, Wheel Chocks - Opt. 1 "
4-38 293912 1585A56 T6-2004-156 Cable, ¼" Vinyl Coated Spiral - Opt. 1 "
CD315 4-2-9
Rev 4
Chapter 4
18 22 24
23
17
16 19
21
15
14
20
13
11
10
3 7 9 12
4
8
5
2 6
1
Figure 2-5. Frame - Body (Right Side)
4-2-10 CD315
Rev 3
Chapter 4
Table 2-5. Frame - Body (Right Side)

Ind Number Number
5-1 263516 ------ 660-4-1036 Fender, Right Rear 1 101 & Up

606035 ------ 660-4-2806 Fender, Right Rear - Ext. Battery Opt. 1 As Req'd
5-2 373317 15109 3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 9 101 & Up
5-3 372170 ------ 660-2-1229 Rail, Rub - Quarter Panel 16" 2 "
5-4 ------ ------ ------ Liner, Fender Well - Rear 20" x 24" 1 "
5-5 373317 ------ ¼ x 1½ Fend, ¼" ID, 1½" OD 9 "
5-7 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 9 "
5-9 373317 33859 3/8 Washer, Flat 3/8" ID 6 "
5-10 358417 ------ 660-1-1041 Strut, Right Middle Fender 3 "
5-11 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
5-12 250698 ------ 660-2-1230 Rub Rail, Plastic, 70" 1 "
5-14 373317 33859 3/8 Washer, Flat 3/8" ID 8 "
5-15 244126 ------ 660-1-1039 Plate, Bolting 2 "
5-16 389231 ------ BLE-1-1042 Door, Hydraulic 1 "
5-18 372294 3200 12" T6-200-105 Safety Walk 12" Wide, 19"Long 1 "
5-19 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 7 "
5-20 369176 ------ BLE-4-1062 Fender, Right Body 1 "
5-21 ------ ------ ------ Liner, Fender Well - Front 12" x 24" 1 "
5-22 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 8 "
5-23 263516 ------ 660-4-1038 Fender, Right Front 1 Up to 380
263516 ------ 660-4-2834 Fender, Right Front 1 380 & Up
5-24 373317 37341 3/8-16 Nut, Flange - LK REG 3/8-16 - Opt. 9 "
CD315 4-2-11
Rev 4
Chapter 4
2
1
Figure 2-6. Mirrors
4-2-12 CD315
Rev 4
Chapter 4
Table 2-6. Mirrors

Ind Number Number
6-1 440230 ----- 660-4-1007 Bumper, Steel Front 1 As Req'd

6-2 402530 97653 T6-9011-375 Mirror, 5 x 7 2 "
6-3 402530 97720 T6-9011-383 Bracket, Mirror 1 "
6-4 263516 ----- 660-2-2807 Bracket, Mirror (Passenger Side) 1 "
CD315 4-2-13
Rev 4
Chapter 4
5 3
4
1
6
7
Figure 2-7. Front Steps Option
4-2-14 CD315
Rev 4
Chapter 4
Table 2-7. Front Steps Option

Ind Number Number
7-1 440230 ----- 660-4-1007 Bumper, Steel Front 1 As Req'd

7-2 369176 ----- 660-1-0184 Step, Front Bumper 1 "
7-3 369176 ----- 660-1-2339 Step, Front Lower 2 "
7-4 372750 ----- 660-4-3004 Step, Front (Wldmt) 1 "
7-5 350000 ----- 660-4-3078 Rail, Hand - Single 1 "
7-6 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
7-7 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 4 "
CD315 4-2-15
Rev 4
Chapter 4
2
3
1
4
Figure 2-8. Front Steps Option
4-2-16 CD315
Rev 4
Chapter 4
Table 2-8. Front Steps Option

Ind Number Number
8-1 440230 ------ 660-4-1007 Bumper, Steel Front 1 As Req'd

8-2 440230 ------ 660-4-0182 Step, Front Upper - UAL Spec (Wldmt) 1 "
8-3 369176 ------ 660-1-0184 Step, Front Bumper 1 "
8-4 369176 ------ 660-1-2339 Step, Front Lower 2 "
8-5 440230 ------ 660-4-2338 Step, Front Lower - UAL Spec (Wldmt) 1 "
CD315 4-2-17
Rev 4
Chapter 4
8
7
6
1
5
2 3 4
Figure 2-9. Seat Assembly
4-2-18 CD315
Rev 3
Chapter 4
Table 2-9. Seat Assembly

Ind Number Number
9-1 358417 ------ 660-2-1103 Cavity, Valve Cover / Seat Mount 1 101 & Up
9-2 373317 37339 5/16-18 Nut, Flange Lock Hex 5/16-18 4 "
9-3 368977 E2834101-01 660-6-0581-25 Belt, Safety (Non-Retract), COM 1 "
9-4 373317 37268 ½-13 Nut, Top Lock Hex ½-13 2 "
9-5 373317 15207 ½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 2 "
9-6 268697 ------ M3-1-1053 Switch, Seat, Wise 1 Up to 141
385455 ------ M3-1-5175 Switch, Seat - Sears 1 141-428
268697 ------ M3-1-1053 Switch, Seat, Wise 1 429 & Up
9-7 373317 33859 3/8 Washer, Flat 3/8" ID 8 101 & Up
9-8 371691 ------ 4-100-101A Seat, Vinyl Bucket 1 "
CD315 4-2-19
Rev 4
Chapter 4
Figure 2-10. Battery Assembly
4-2-20 CD315
Rev 3
Chapter 4
Table 2-10. Battery Assembly

Ind Number Number
10-1 350000 ------ BLE-1-1081 Guide, Outer Battery 1 Up to 499

10-2 369176 ------ BLE-3-1017 End, Battery Cradle 2 "
10-3 369176 ------ BLE-1-1019 Gusset, Battery Cradle 2 101 & Up
10-4 369176 ------ BLE-4-1018 Cradle, Battery 1 Up to 499
10-5 263516 ------ BLE-4-1076 Fender, Left Midsection Weldment 1 101 & Up
10-7 382204 24-D85-15 BLE-1-1200-1 Battery, Deka 48V 595 AH 1 As Req'd
382204 36-D85-9 BLE-1-1201-1 Battery, Deka 72V 340 AH 1 "
382204 ------ BLE-1-1206-1 Battery, Deka 80V 340 AH 1 "
1136099 DEKA-40D85-9 BLE-1-2631 Battery, Deka 80V Johnson 1 "
w/BMID, 40 Cell
1136099 ----- BLE-1-2667 Battery Assembly, Deka 80V/ 1 "
BID/Flo-Right/EuroDin/340 AH
BMID/Flo-Right/EuroDin/340 AH
205659 36-E110-11 BLE-1-1205-2 Battery, Exide 72V 550 AH 1 "
250187 40-E75-9 BLE-1-2539 Battery, Exide 80V 300 AH 1 "
w/BWM & INJ-S40
205659 40-E110W-9 BLE-1-1208-2 Battery, Exide 80V 440 AH 1 "
250187 40-E110W-9 BLE-1-2537 Battery, Exide 80V 440 AH 1 "
w/ BIS & BWM
205659 36-85C-09 BLE-1-1201-3 Battery, GNB 72V 340 AH 1 "
------ ------ BLE-1-1202-1 Battery, Hawker 80V 320AH 1 "
10- 205659 D3E-36-550B BLE-1-1254-2 Charger, Exide 72V 550 AH 60 Hz 1 "
10- 250187 TCG40-450 BLE-1-2538 Charger, Exide 80V 450 AH 1 "
10- 205659 SCRFLX36475 BLE-1-1251-3 Charger, GNB 72V 475 AH 1 "
10- 205659 SCRFLX40475 M3-1-1260-3 Charger, GNB 80V 475 AH 1 "
10- 382204 600C3-24/450C BLE-1-1250-1 Charger, Hobart 48V 600 AH 60 Hz 1 "
10- 382204 380C3-36/450C BLE-1-1251-1 Charger, Hobart 72V 380 AH 1 "
10- 382204 ------ M3-1-1260-1 Charger, Hobart 80V 600 AH 1 "
CD315 4-2-21
Rev 4
Chapter 4
Figure 2-10. Battery Assembly (Cont'd)
4-2-22 CD315
Rev 3
Chapter 4
Table 2-10. Battery Assembly (Cont'd)

Ind Number Number
10- 281660 ------ BLE-1-2605 Cable, Battery, Positive - Hawker 1 As Req'd
10- 281660 ------ BLE-1-2606 Cable, Battery, Negative - Hawker 1 "
10- 382204 RK-1MO-210-520 MX4-10149 Watering System, Flo-Right 1 "
10- 1136099 ----- BLE-1-2660 Watering System, 1 "
Flo-Right Single Point
10- 426508 BFS-40 MX4-10263 Watering System, BFS 1 "
(For Exide/Deka 80V Batteries)
10- 426508 ------ 440E-12043 Fill Kit, Direct - 1 "
BFS Watering System
10- 372578 ------ 440E-12044 Fill Kit, Direct - 1 "
Flo-Right Watering System
10-8 424776 ------ BLE-0006 Sensor, Temperature - Opt. 1 "
10-9 389231 ------ BLE-4-1040 Door, Battery 1 254 & Up
10-10 372750 ------ BLE-1-2603 Rail, Rub - Battery Box 2 "
10-13 373317 29570 ¼-20 x 1 Screw, Phillips Ø ¼-20 x 1" Long 6 "
10-14 373317 29574 ¼-20 x 1¼ Screw, Phillips Ø ¼-20 x 1¼" Long 4 "
10-15 373089 ------ BLE-1-1084 Cradle Extension, 3" - Battery (Opt.) 4 "
CD315 4-2-23
Rev 4
Chapter 4
14
16
17
10
13 15
12
9
11 8
5
7
4
6 7
5
1
2
Figure 2-11. Battery Assembly with Welded Battery Box
4-2-24 CD315
Rev 4
Chapter 4
Table 2-11. Battery Assembly with Welded Battery Box

Ind Number Number
11-1 440230 ----- BLE-4-2643 Box, Battery (Wldmt) 1 499 & Up

440230 ----- BLE-4-2644 Box, Battery (Wldmt) - Ext. Opt. 1 As Req'd
11-2 373317 29570 ¼-20 x 1 Screw, Phillips Ø ¼-20 x 1" Long 4 101 & Up
11-3 369176 ------ BLE-1-1019 Gusset, Battery Cradle 2 "
11-5 372750 ------ BLE-1-2603 Rail, Rub - Battery Box 4 As Req'd
11-7 250697 ----- BLE-4-2634 Mat, Battery Compartment Floor 1 440 & Up
11-8 263516 ------ BLE-4-1076 Fender, Left Midsection Weldment 1 101 & Up
11-10 382204 24-D85-15 BLE-1-1200-1 Battery, Deka 48V 595 AH 1 As Req'd
382204 36-D85-9 BLE-1-1201-1 Battery, Deka 72V 340 AH 1 "
382204 ------ BLE-1-1206-1 Battery, Deka 80V 340 AH 1 "
1136099 40F75-9IST9079 BLE-2-2678 Battery, Deka 80V 500 AH, Vented 1 "
1136099 DEKA-40D85-9 BLE-1-2631 Battery, Deka 80V Johnson 1 "
w/BMID, 40 Cell
BID/Flo-Right/EuroDin/340 AH
BMID/Flo-Right/EuroDin/340 AH
250187 ------ 660-1-3268 Battery, Deserthog 80V 340AH 1 "
250187 40-E75-9 BLE-1-2539 Battery, Exide 80V 300 AH 1 "
w/BWM & INJ-S40
205659 40-E110W-9 BLE-1-1208-2 Battery, Exide 80V 440 AH 1 "
250187 40-E110W-9 BLE-1-2537 Battery, Exide 80V 440 AH 1 "
w/ BIS & BWM
205659 ------ BLE-1-1206-3 Battery, GNB 80V 340 AH 1 "
------ ------ BLE-1-1202-1 Battery, Hawker 80V 320AH 1 "
11- 250187 TCG40-450 BLE-1-2538 Charger, Exide 80V 450 AH 1 "
11- 250187 ------ BLE-2-2679 Charger, Exide, 3-Phase, 50Hz, 1 "
400VAC
11- 205659 SCRFLX36475 BLE-1-1251-3 Charger, GNB 72V 475 AH 1 "
11- 205659 SCRFLX40475 M3-1-1260-3 Charger, GNB 80V 475 AH 1 "
11- 382204 600C3-24/450C BLE-1-1250-1 Charger, Hobart 48V 600 AH 60 Hz 1 "
11- 382204 380C3-36/450C BLE-1-1251-1 Charger, Hobart 72V 380 AH 1 "
11- 382204 ------ M3-1-1260-1 Charger, Hobart 80V 600 AH 1 "
CD315 4-2-25
Rev 4
Chapter 4
14
16
17
10
13 15
12
9
11 8
5
7
4
6 7
5
1
2
Figure 2-11. Battery Assembly with Welded Battery Box (Cont'd)
4-2-26 CD315
Rev 4
Chapter 4
Table 2-11. Battery Assembly with Welded Battery Box (Cont'd)

Ind Number Number
10- 281660 ------ BLE-1-2605 Cable, Battery, Positive - Hawker 1 As Req'd
10- 281660 ------ BLE-1-2606 Cable, Battery, Negative - Hawker 1 "
10- 382204 RK-1MO-210-520 MX4-10149 Watering System, Flo-Right 1 "
10- 1136099 ----- BLE-1-2660 Watering System, 1 "
Flo-Right Single Point
10- 426508 BFS-40 MX4-10263 Watering System, BFS 1 "
(For Exide/Deka 80V Batteries)
10- 426508 ------ 440E-12043 Fill Kit, Direct - 1 "
BFS Watering System
10- 372578 ------ 440E-12044 Fill Kit, Direct - 1 "
Flo-Right Watering System
10-8 424776 ------ BLE-0006 Sensor, Temperature - Opt. 1 "
10-9 389231 ------ BLE-4-1040 Door, Battery 1 254 & Up
10-13 373317 29570 ¼-20 x 1 Screw, Phillips Ø ¼-20 x 1" Long 6 "
10-15 373089 ------ BLE-1-1084 Cradle Extension, 3" - Battery (Opt.) 4 "
CD315 4-2-27
Rev 4
Chapter 4
Figure 2-12. Battery Connectors
4-2-28 CD315
Rev 4
Chapter 4
Table 2-12. Battery Connectors

Ind Number Number
12-1 382204 ------ 42-100-700 Connector, SB350 Green 1 101 & Up

382204 ------ 42-100-701 Connector, SB350 Red 1 As Req'd
382204 ------ BLE-1-2645 Connector, SB350 Blue 1 "
382204 ------ MI-1-735 Connector, SB350 Gray 1 "
1136099 ------ BLE-1-2682 Connector, SBX350 Black 2 "
12-2 382204 ------ 42-100-702 Bracket, Mounting, SB350 Red 1 101 & Up
1136099 ------ BLE-1-2683 Bracket, Mounting, SBX350 - Opt. 1 As Req'd
12-3 382204 ------ 42-100-703 Release, Manual, SB350 Red 1 101 & Up
382204 ------ 42-100-704 Release, Manual for Truck SBX350 1 As Req'd
12-4 402645 2532 660-ND-1920 Strain Relief - ½ x ¾ NPT (CGB294) 2 101 & Up
12- 372750 ------ BLE-1-2666 Cover, Battery Connector - Opt. 1 As Req'd
12- 350000 ------ BLE-2-2672 Cover, Battery Connector - Opt. 1 "
CD315 4-2-29
Rev 4
Chapter 4
3
6
7
4
Figure 2-13. Battery Connector (Eurodin Adapter Option)
4-2-30 CD315
Rev 4
Chapter 4
Table 2-13. Battery Connector (Eurodin Adapter Option)

Ind Number Number
13-1 373087 A32470-009 BLE-1-2662 Connector, Male Pin 2/0 AWG 1 As Req'd
13-2 373087 994G4 BLE-1-2663 Bracket, Manual Release 1 "
13-3 281660 ------ BLE-1-2611 Cable, Battery (Negative) 1 "
13-4 281660 ------ BLE-1-2610 Cable, Battery (Positive) 1 "
13-5 357447 2570-26012 BLE-ND-1075 Grommet, Rubber 7/8" x 1¼" x ¼" 2 "
13-6 358417 ------ T6-8005-103 Bushing, Hand Brake 4 "
13-7 279184 A32570-1009 BLE-1-2677 Connector, Female, EuroDin 4 "
(Included w/ Battery)
CD315 4-2-31
Rev 4
Chapter 4
Figure 2-14. Instrument Panel (Up to S/N 254)
4-2-32 CD315
Rev 3
Chapter 4
Table 2-14. Instrument Panel (Up to S/N 254)

Ind Number Number
14-1 373368 803RB7280BCJ3010/ BLE-1-1057 Hourmeter / BDI, 72-80 1 Up to 254

18087703
14-2 ------ ------ 660-1-1957 Plug, Dash 4 "
14-3 376499 310168 660-4-0732-7 Shifter, Morse 1 "
14-4 267599 ------ T6-7022-105P Plug, Button ¾" 4 "
14-5 402645 293511138310 T6-7010-120 Light, Red Warning - Flat Head 1 "
14-6 402645 8801K22 T6-7010-113 Switch, Toggle 1 "
14-7 402645 956-3124 T6-7010-140 Switch, Ignition - CH Lever 1 "
14-8 373089 ------ 660-2-1029W Panel, Instrument (Wldmt) 1 "
14-9 347738 M13557 660-ND-107P Plug, Button 7/8" 1 "
CD315 4-2-33
Rev 3
Chapter 4
3
1
6 2
4
7
8
7a
5
9
10
11
6 7a
Figure 2-15. Instrument Panel (S/N 254 thru 389)
4-2-34 CD315
Rev 3
Chapter 4
Table 2-15. Instrument Panel (S/N 254 thru 389)

Ind Number Number
15-1 373089 ------ 660-2-2924W Panel, Instrument (Wldmt) 1 254-389

15-2 402645 2683 T6-9003-572 Plug, Button - Black ¾” 2 “
15-3 373059 604/60001 M3-1-5039 Display, Dash - Sevcon 1 “
15-4 402645 8801K22 T6-7010-113 Switch, Toggle (Head Light) 1 “
15-5 402645 2643 T6-9003-571 Plug, Button - Black ½” 1 “
15-6 402645 31-604 660-1-2559 Switch, Ignition, 2 Position 1 “
15-7 402645 2643 T6-9003-571 Plug, Button - Black ½” 1 “
15-7a 402645 8801K22 T6-7010-113 Switch, Toggle (Spot Light) - Opt. 1 "
15-8 373317 15005 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 5 “
15-9 373317 33891 ¼ Washer, Lock ¼” ID 4 “
15-10 402645 293511138340 T6-7010-122 Light, Green Warning - Flat Head 1 “
15-11 402645 293511138310 T6-7010-120 Light, Red Warning - Flat Head 1 “
CD315 4-2-35
Rev 4
Chapter 4
3 2
1
6 4
16
7 5
9
8
10
15
14
11
12
13
17
4 18
6
8
Figure 2-16. Instrument Panel (S/N 390 and Up)
4-2-36 CD315
Rev 4
Chapter 4
Table 2-16. Instrument Panel (S/N 390 and Up)

Ind Number Number
16-1 440230 ----- 660-2-2924W Panel, Instrument (Wldmt) 1 390 & Up

16-2 402645 HEYCO#2703 660-1-2552 Plug, Button - Black 7/8" 1 "
16-3 373059 604/6001 M3-1-5039 Display, Dash - Sevcon 1 "
16-4 402645 8801K22 T6-7010-113 Switch, Toggle (Headlight) 1 "
16-5 402645 8801K22 T6-7010-113 Switch, Toggle (Back-Up Light) 1 "
16-6 402645 2TL1-2 BLE-1-2624 Switch, Toggle, DPST Sealed 1 "
402645 ------ T6-7010-114 Switch, Toggle - 1 Pole, 2 Pos 1 "
16-7 440230 ----- BLE-1-2625 Plate, Ignition Switch Mount 1 "
16-8 402645 8801K22 T6-7010-113 Switch, Toggle (Spot Light) 1 "
16-10 373317 33891 ¼ Washer, Lock ¼" ID 4 "
16-11 372209 ----- T6-1010-159 Decal, "Made in USA" 1 "
16-12 402645 293511138340 T6-7010-122 Light, Green Warning - Flat Head 1 "
16-13 263540 ARCO-FL67WL7R T6-7010-120 Light, Red Warning - Flat Head 1 "
16-14 247378 ----- T-A2 Decal, Dash 1 "
16-15 376499 310639 BLE-1-2535 Shifter, SRE 1 "
16-16 402645 HEYCO#2683 T6-9003-572 Plug, Button - Black ¾" 3 "
16-17 402530 50-263-3 T6-7007-105 Flasher, Turn Signal 1 "
16-18 260131 9183 T6-500-137 Connector, Flasher Relay Socket 1 "
16- 281660 ------ BLE-4-2543 Harness, Dash 1 "
CD315 4-2-37
Rev 4
Chapter 4
Figure 2-17. Shifter Assembly (Up to S/N 254)
4-2-38 CD315
Rev 3
Chapter 4
Table 2-17. Shifter Assembly (Up to S/N 254)

Ind Number Number
17-1 376499 310168 660-4-0732-7 Shifter, Morse 1 Up to 254

17-2 376499 30241-003-0168 660-ND-1376 Cable, Shifter 1 “
CD315 4-2-39
Rev 3
Chapter 4
2
1
Figure 2-18. Shifter Assembly (S/N 254 and Up)
4-2-40 CD315
Rev 3
Chapter 4
Table 2-18. Shifter Assembly (S/N 254 and Up)

Ind Number Number
18-1 440230 ----- 660-2-2924W Panel, Instrument (Wldmt) 1 254 & Up

18-2 373317 15003 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 4 "
18-3 373317 33891 ¼ Washer, Lock ¼" ID 4 "
18-4 376499 310639 BLE-1-2535 Shifter, SRE 1 "
CD315 4-2-41
Rev 4
Chapter 4
Figure 2-19. Accelerator and Shifter Linkage at Controller Enclosure
4-2-42 CD315
Rev 3
Chapter 4
Table 2-19. Accelerator and Shifter Linkage at Controller Enclosure

Ind Number Number
19-1 376499 301772-000-0150 660-1-1115 Cable, Accelerator w/Boot 1 Up to 254
19-2 376499 304241-003-0168 660-ND-1376 Cable, Shifter 1 "
19-3 277796 A302408LP BLE-4-1038 Box, Electric Control 1 "
19-4 267599 86428 T6-1004-109 Yoke, Shift Linkage 1 "
19-5 369176 ------ BLE-4-1037 Plate, Base - Shifter Switches 1 "
19-6 263586 Q10272 T6-1002-155 Clamp, Cable 1 "
19-7 402645 ------ BLE-1-1055 Relief, Strain 5/8 x ¾NPT 9 "
(CGB295)
19-8 267599 87441 T6-1004-117 Pin, Clevis 1 "
19-9 372750 ------ 2-032-101 Arm, Accelerator 1 "
19-10 402645 ------ 42-100-801 Switch, Micro 2 "
19-11 376499 44719 MH-ND-956 Hanger, Cable Connector 1 "
19-12 277796 141SL BLE-1-1052 Nut, Lock - Sealing ½" 1 101-140
402645 ------ BLE-1-1502 Ring, Sealing ½" NPT 1 141-254
277796 141 660-1-2252 Nut, Conduit ½" NPT 1 "
19-13 277796 HOFF-AS075 BLE-ND-1080 Seal, Hole ¾" Dia. Conduit 2 Up to 254
19-14 250728 A031980 BLE-1-1050 Eye, Terminal for Accelerator 1 "
Cable
19-15 373317 15310 5/8-11 x 1¾ Bolt, Hex Head Ø 1 "
5/8-11 x 1¾" Long
373317 33863 5/8 Washer, Flat 5/8" 1 "
373317 37272 5/8-11 Nut, Top Lock Hex 5/8-11 1 "
19-16 402645 ------ BLE-1-1051 Nut, Lock - Sealing ¾" 11 "
294093 ------ BLE-1-1503 Ring, Sealing ¾" NPT 1 141-254
------ ------ 660-1-1921 Nut, Conduit ¾" NPT 1 "
19-17 402645 ------ 660-ND-2215 Relief Strain 3/8 x ½ NPT 1 "
(CGB116)
19-18 402645 ------ 660-ND-1920 Relief Strain ½ x ¾ NPT (CGB294) 2 "
19-19 373317 ------ M3-1-8011 Pin, Clevis 5/16 x 1¼ 1 Up to 254
19-20 ------ ------ ------ Bag, Desiccant 1 "
CD315 4-2-43
Rev 3
Chapter 4
Figure 2-20. Accelerator Pedal Assembly (Up to S/N 254)
4-2-44 CD315
Rev 3
Chapter 4
Table 2-20. Accelerator Pedal Assembly (Up to S/N 254)

Ind Number Number
20-1 263516 ------ BLE-2-1064 Pedal Assembly, Accelerator 1 Up to 254

20-2 376499 301772-000-0150 660-1-1115 Cable, Accelerator w/Boot 1 "
20-3 263586 Q10272 T6-1002-155 Clamp, Cable 1 "
20-4 369403 ------ T6-1001-123 Spring, Throttle 1 "
20-5 347738 M07855 MD-CB21-133 Clevis, Cable w/Pin and Cotter Pin 1 "
20-6 389231 ------ BLE-2-1054 Rod, Pull - Hand Throttle 1 "
CD315 4-2-45
Rev 3
Chapter 4
Figure 2-21. Accelerator Pedal Assembly (S/N 254 thru 389)
4-2-46 CD315
Rev 3
Chapter 4
Table 2-21. Accelerator Pedal Assembly (S/N 254 thru 389)

Ind Number Number
21-1 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 254-389
21-2 373317 33893 3/8 Washer, Lock 3/8" ID 1 "
21-3 373317 15115 3/8-16 x 3 Bolt, Hex Head Ø 3/8-16 x 3" Long 1 "
21-4 369403 0.098 T6-4014-119 Spring, Throttle Linkage 1 "
21-5 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
21-6 263516 ------ 2-023-101 Support, Accelerator Pedal 1 "
21-7 373317 33858 5/16 Washer, Flat 5/16" 2 "
21-9 373393 EOJZ-9735C T6-1009-103 Pedal, Accelerator 1 "
21-11 373317 33891 ¼ Washer, Lock ¼" ID 2 "
21-12 373059 656/12036 M3-1-8012 Box, Accelerator 1 "
21-13 373488 ------ BLE-1-1036 Yoke, Accelerator 1 "
21-14 373317 66046 BLE-ND-2609 Pin, Clevis 5/16" x 1" Long 1 "
21-15 373317 65035 3/32 x 7/8 Pin, Cotter Ø 3/32 x 7/8" Long 3 "
21-16 370088 SP45040 M3-1-8043 Bushing, Nylon - Accelerator Yoke 1 "
21-17 262531 ------ M3-1-8005 Arm, Accelerator Ratio 1 "
21-18 372739 SYMNSF12164 CMA-604 Bushing, Oillite 1 "
21-20 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
21-22 355032 28030577 660-1-1913 Yoke, End - Adjustable 2 "
21-23 267599 87443 T6-500-123 Pin, Park Brake 2 "
21-24 373317 36156 3/8-24 Nut, Hex 3/8-24 2 "
21-25 358417 ------ 660-1-2392 Rod, Brake 1 "
CD315 4-2-47
Rev 4
Chapter 4
10
8
7
6
5
4
12
3
2
1
Figure 2-22. Accelerator Pedal Assembly (S/N 390 and Up)
4-2-48 CD315
Rev 4
Chapter 4
Table 2-22. Accelerator Pedal Assembly (S/N 390 and Up)

Ind Number Number
22-1 376499 ------ 440E-29066 Pedal, Throttle 1 390 & Up

22-2 407341 ------ M3-1-8106 Switch, Micro for Directional 1 "
22-3 373317 ------ #4-40 Screw #4-40 2 "
22-5 373317 33857 ¼ Washer, Flat ¼" ID 4 "
22-6 350000 ------ 440E-29053 Mount, Switch (Weldment) 1 "
22-7 373317 ------ #4-40 Nut, Hex #4-40 2 "
22-8 373317 ------ #4 Washer, Lock #4 - External Tooth 2 "
22-9 373317 ------ ¼-¾ Fend Washer ¼" ID - ¾" OD 2 "
22-10 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 2 "
22-11 358417 ------ BLE-4-2623 Plate, Accelerator Mounting 1 "
22-12 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
22-13 373089 ------ BLE-3-2619 Cover, Foot Pedal 1 "
CD315 4-2-49
Rev 4
Chapter 4
Figure 2-23. Circuit Breaker Installation
4-2-50 CD315
Rev 3
Chapter 4
Table 2-23. Circuit Breaker Installation

Ind Number Number
23-1 375297 121A20-A2M 660-4-0741-5 Breaker, Circuit (20 Amp) 3 Up to 254

23-2 244126 ------ 660-1-1048 Plate, Circuit Breaker 1 "
23-3 373317 ------ #8-32 x 5/8 Screw, Round Head #8-32 x 5/8" Long 6 "
23-4 373317 ------ #8 Washer, Flat #8 12 "
23-5 373317 ------ #8 Nut, Lock - Fiber #8 6 "
23-6 373317 ------ ¼-20 x 1 Bolt, Countersunk Ø ¼-20 x 1" Long 2 "
CD315 4-2-51
Rev 3
Chapter 4
Figure 2-24. Park Brake Assembly (Up to S/N 254)
4-2-52 CD315
Rev 3
Chapter 4
Table 2-24. Park Brake Assembly (Up to S/N 254)

Ind Number Number
24-1 ------ ------ BLE-2-1077 Lever, Hand Brake (Weldment) 1 Up to 254

24-2 402645 LSA1A 660-4-0532-2 Switch, Limit (Honeywell) 1 "
24-4 373089 ------ T6-8005-105 Angle, Hand Brake 2 "
24-6 369150 6222-0132 660-3-0774-2 Cable, Park Brake 1 "
24-7 402645 ------ 660-ND-2215 Relief, Strain 3/8 x ½ NPT (CGB116) 1 "
CD315 4-2-53
Rev 3
Chapter 4
9 8
7
11
6
10
5
4
14
3
15
16
2
17 1
14
Figure 2-25. Park Brake Assembly (S/N 254 and Up)
4-2-54 CD315
Rev 4
Chapter 4
Table 2-25. Park Brake Assembly (S/N 254 and Up)

Ind Number Number
25-1 369150 6222-0132 660-3-0774-2 Cable, Park Brake 1 254 & Up

25-2 440230 ------ 660-1-1245 Anchor, Front Park Brake Cable 1 "
25-3 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 4 "
25-4 373089 ------ MH-2-606 Bracket, Park Brk App. Light Sw. 1 "
25-5 373089 ------ T6-8005-105 Angle, Hand Brake 2 "
25-6 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
25-7 373317 33857 ¼ Washer, Flat ¼" ID 4 "
25-9 369150 0218-2900 T6-8005-101 Lever, Hand Brake 1 "
25-10 373317 65035 3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" Long 1 "
25-12 373317 33893 3/8 Washer, Lock 3/8" ID 2 "
25-14 402645 DTE62RN2 42-126-101 Switch, Micro, DPDT 1 "
25-15 267599 87443 T6-500-123 Pin, Park Brake 1 "
25-17 402645 LSZ55E 660-4-0532-5 Arm, Switch Actuator for Limit 1 "
CD315 4-2-55
Rev 4
Chapter 4
Figure 2-26. Park Brake Cable Linkage
4-2-56 CD315
Rev 3
Chapter 4
Table 2-26. Park Brake Cable Linkage

Ind Number Number
26-1 369150 6222-0132 660-3-0774-2 Cable, Park Brake 1 101 & Up

26-2 372750 ------ 660-3-1687 Anchor, Park Brake Cable 1 "
26-3 383678 E0TZ-2A602A 660-ND-1679 Equalizer 1 "
26-4 402020 22555667 MD-CB21-121 Clip 2 "
26-5 372750 ------ BLE-3-1070 Anchor, Park Brake Cable 1 "
26-6 295524 ------ 660-ND-1678 Cable, Brake Short - 51" 1 "
26-7 295524 ------ 660-ND-1677 Cable, Brake Long - 95" 1 "
CD315 4-2-57
Rev 3
Chapter 4
1
4
5
2
8
3
6
17
7 9
10
16
9 7
4 7
4
11 15
9
12
13 3
14
Figure 2-27. Brake Pedal Assembly
4-2-58 CD315
Rev 3
Chapter 4
Table 2-27. Brake Pedal Assembly

Ind Number Number
27-1 440230 ------ 660-2-1961 Stop, Brake Pedal 1 101 & Up

27-2 263516 ------ 660-1-1131 Mount, Brake Pedal 2 "
27-3 373317 15223 ½-13 x 5 Bolt, Hex Head Ø ½-13 x 5" Long 2 254 & Up
27-4 373317 37268 ½-13 Nut, Top Lock Hex ½-13 4 "
27-5 373317 65035 3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" 3 101 & Up
27-6 267599 87443 T6-500-123 Pin, Park Brake 3 "
27-7 355032 280380 MD-CB1-129 Yoke 3 "
27-8 358417 ------ 660-2-1278 Pedal Assembly, Brake 1 "
27-9 373317 36256 3/8-24 Nut, Hex Jam 3/8-24 3 "
27-10 372750 ------ 660-1-1104 Rod, Brake Pedal 1 "
27-11 372739 SYMN BSF16248 MD-CB1-127 Bushing 2 "
27-12 440230 64-660-1-1106 660-1-1106 Anchor, Brake Bell Crank 2 "
27-13 373089 ------ 660-1-1105 Crank, Brake Bell 1 "
27-14 369403 ------ T6-1001-123 Spring, Throttle 2 "
27-15 262531 ------ 660-1-1358 Rod, Brake 1 "
27-16 372750 ------ X3001-109 Coupling, Brake Rod 1 "
27-17 369032 204022687 660-1-1342 Hydro-Boost Assembly 1 "
CD315 4-2-59
Rev 3
Chapter 4
Figure 2-28. Brake Line Diagram
4-2-60 CD315
Rev 3
Chapter 4
Table 2-28. Brake Line Diagram

Ind Number Number
28-1 369032 204022687 660-1-1342 Hydro-Boost Assembly 1 101 & Up

28-2 426744 ------ T6-6011-141 Line, Brake 20" 2 "
28-3 402378 302X3 T6-8011-121 Connector 5 "
28-4 426744 ------ 5-100-101 Line, Brake 51" 2 "
28-5 372739 ------ T6-6011-149 Line, Brake 40" 5 "
28-6 402378 S306 T6-6011-151 Line, Brake 6" 1 "
28-7 402378 S330 T6-6011-161 Line, Brake 30" 2 "
28-8 402530 ------ T6-8013-143 Hose, Brake Front 2 Up to 206
372857 36646 9-200-111 Hose, Brake Front 2 206 & Up
28-9 452448 D4TZ-2B257A 660-1-1110 Valve, Brake Proportioning - Cast Iron 1 Up to 550
376710 PCS-PV2 660-1-3045 Valve, Brake Proportioning 1 550 & Up
28-10 426744 ½-MNOS ------ Tee, Female Pipe 1 101 & Up
28-11 402530 ------ MG-ND-531 Switch, Brake 1 "
28-12 426744 ------ T6-6011-111 Tee 1 "
CD315 4-2-61
Rev 4
Chapter 4
20
19
18 17
16
15
13
14
7
12 8
11 3
6
5 2
1
10
4
9
Figure 2-29. Hydro Boost and Proportion Valve
4-2-62 CD315
Rev 3
Chapter 4
Table 2-29. Hydro Boost and Proportion Valve

Ind Number Number
29-2 402378 ------ T6-8011-107 Adapter, Brake Warning 1 101 & Up
29-3 426744 ------ 5-100-101 Line, Brake 51" 1 "
29-4 402378 7818 T6-600-114 Adapter, Line (Brake to Master Cylinder) 1 "
29-5 372739 ------ T6-6011-149 Line, Brake 40" 1 "
29-6 373317 29061 10/32 x ¾ Screw, Phillips PPHMS10-32 x ¾" Long 5 "
29-7 402378 302X3 T6-8011-121 Connector 2 "
29-8 373317 708759 ------ Clamp, P Vinyl - COV0709Z 10 "
29-9 373317 29073 10/32 x 1 Screw, Phillips PPHMS10-32 x 1" Long 2 "
29-10 373317 33002 3/16 Washer, Flat USS 3/16" ID 14 "
29-11 373317 37015 10/32 Nut, Lock - Nylon Insert 7 "
29-12 373317 70853 -------- Clamp, P- (Vinyl - COVO59Z1) 2 "
29-13 426744 ------ T6-6011-141 Line, Brake 20" 2 "
29-14 369032 204022687 660-1-1342 Hydro-Boost Assembly 1 "
29-15 426744 ------ 660-1-1340 Hose, Booster Return 50" 1 "
29-16 426744 ------ 660-1-1339 Hose, Booster 83" 1 "
29-17 373317 62003 ------ Clamp, Hose 1 "
29-18 426744 ------ 660-1-1359 Hose, Tank Return 1 "
29-19 426744 ------ 660-ND-1397 Adapter, Brake 1 "
29-20 426744 ------ T6-600-112 Adapter 1 "
CD315 4-2-63
Rev 4
Chapter 4
12 16
13
11
14
15 10
13
9
8
7
1
5 6
4
2
Figure 2-30. Brake Lines, Front (Up to S/N 866)
4-2-64 CD315
Rev 4
Chapter 4
Table 2-30. Brake Lines, Front (Up to S/N 866)

Ind Number Number
30-1 369183 ------ 9-200-111 Hose, Brake Front 2 Up to 866

30-2 1178478 ------ 660-1-1071 Bracket, Flex, 2 "
Brake Line (Wldmt)
30-3 402020 22555667 MD-CB21-121 Clip 2 "
30-4 402378 S330 T6-6011-161 Line, Brake 30" (Prop. Valve to 1 "
Left Front Brake Hose)
30-5 402378 S330 T6-6011-161 Line, Brake 30" 1 "
(Prop. Valve to 40" Brake Line)
30-6 402378 302X3 T6-8011-121 Connector 1 "
30-7 373317 29073 10/32 x 1 Screw, Phillips 3 "
PPHMS10-32 x 1" Long
30-11 452448 D4TZ-2B257A 660-1-1110 Valve, Brake Proportioning - 1 Up to 550
Cast Iron
30-12 402378 S306 T6-6011-151 Line, Brake 6" 1 Up to 866
(Prop. Valve to Tee)
30-13 372245 ------ 660-ND-1372 Fitting, Brake Line 2 "
30-14 372739 5605-02-02-02 660-5605-02-02-02 Fitting, Female Pipe Tee 1 "
30-16 376710 PVP 660-1-3046 Pigtail, Brake Warning 1 550 & Up
CD315 4-2-65
Rev 4
Chapter 4
15
12
11
14
4
13 10
9
8
7
1
5 6
4
2
Figure 2-31. Brake Lines, Front (S/N 866 and Up)
4-2-66 CD315
Rev 4
Chapter 4
Table 2-31. Brake Lines, Front (S/N 866 and Up)

Ind Number Number
31-1 369183 ------ 9-200-111 Hose, Brake Front 2 866 & Up

31-2 1178478 ------ 660-1-1071 Bracket, Flex, 2 "
Brake Line (Wldmt)
31-3 402020 22555667 MD-CB21-121 Clip 2 "
31-4 402378 S330 T6-6011-161 Line, Brake 30" 2 "
31-5 426744 ------ T6-6011-149 Line, Brake 40" 1 "
(Tee to 30" Brake Line)
31-6 402378 302X3 T6-8011-121 Connector 1 "
31-7 373317 29073 10/32 x 1 Screw, Phillips 3 "
31-11 376710 PCS-PV2 660-1-3045 Valve, Brake Proportioning 1 550 & Up
31-12 426744 BL310 MH-ND-565 Line, Brake 10" 1 866 & Up
(Prop. Valve to Tee)
31-13 372739 5605-02-02-02 660-5605-02-02-02 Tee, Female Pipe Fitting 1 "
31-15 376710 PVP 660-1-3046 Pigtail, Brake Warning 1 550 & Up
CD315 4-2-67
Rev 4
Chapter 4
1
2
3 4
7 3
8 15
3 13
5 8
6 11
12
9
14
10
12
Figure 2-32. Brake Lines, Rear (Up to S/N 866)
4-2-68 CD315
Rev 3
Chapter 4
Table 2-32. Brake Lines, Rear (Up to S/N 866)

Ind Number Number
32-2 426744 ------ T6-600-112 Adapter 1 Up to 866
32-3 372739 ------ T6-6011-149 Line, Brake 40" 3 "
32-6 373317 29073 10/32 x 1 Screw, Phillips 11 "
32-8 402378 302X3 T6-8011-121 Connector 2 "
32-9 402378 S306 T6-6011-151 Line, Brake 6" - Ext. Battery Box Opt. 1 "
32-10 402378 302X3 T6-8011-121 Connector - Ext. Battery Box Opt. 1 "
32-11 426744 ------ 5-100-101 Line, Brake 51" 1 "
32-12 373317 29061 10/32 x ¾ Screw, Phillips 3 "
PPHMS10-32 x ¾" Long
32-13 426744 ------ T6-6011-111 Tee 1 "
32-14 402378 S330 T6-6011-161 Line, Brake 30" 1 "
32-15 263516 ------ T6-6011-113 Angle, Tee Support 1 "
CD315 4-2-69
Rev 4
Chapter 4
1
2
3 4
7 14
8 15
11 13
5 8
6 11
12
9
3
10
12
Figure 2-33. Brake Lines, Rear (S/N 866 and Up)
4-2-70 CD315
Rev 4
Chapter 4
Table 2-33. Brake Lines, Rear (S/N 866 and Up)

Ind Number Number
33-1 376710 PCS-PV2 660-1-3045 Valve, Brake Proportioning 1 550 & Up

33-2 426744 ------ T6-600-112 Adapter 1 866 & Up
33-3 402378 S330 T6-6011-161 Line, Brake 30" 2 "
33-6 373317 29073 10/32 x 1 Screw, Phillips 11 "
33-8 402378 302X3 T6-8011-121 Connector 2 "
33-9 402378 S306 T6-6011-151 Line, Brake 6" - Ext. Battery Box Opt. 1 "
33-10 402378 302X3 T6-8011-121 Connector - Ext. Battery Box Opt. 1 "
33-11 426744 ------ 5-100-101 Line, Brake 51" 2 "
33-12 373317 29061 10/32 x ¾ Screw, Phillips 3 "
PPHMS10-32 x ¾" Long
33-13 426744 ------ T6-6011-111 Tee 1 "
33-14 372739 ------ T6-6011-149 Line, Brake 40" 1 "
33-15 263516 ------ T6-6011-113 Angle, Tee Support 1 "
CD315 4-2-71
Rev 4
Chapter 4
Figure 2-34. Brake Caliper Assembly, Front Disc
4-2-72 CD315
Rev 3
Chapter 4
Table 2-34. Brake Caliper Assembly, Front Disc

Ind Number Number
34-1 402530 242-3006 T6-8013-103 Caliper, R/H Forward, L/H Rear 1 101 & Up
34-2 402020 18012880 T6-8013-157 Piston 1 "
34-3 402530 524 T6-8013-153 Dust Boot Kit 1 "
34-4 369183 ------ T6-8013-149 Pad, Brake - Non-Organic 1 "
34-5 402530 ------ T6-8013-169 Clip, Retainer 1 "
34-6 369183 ------ T6-8013-159 Bolt, Caliper 2 "
34-7 402530 82342 T6-8013-167 Sleeve 2 "
34-8 402530 22660 T6-8013-165 Screw, Bleeder, Delco 1 "
34-9 402530 ------ T6-8013-143 Hose, Brake 1 "
34-10 241766 ------ T6-8013-147 Washer, Brake Hose 2 "
34-11 372857 14000404 T6-8013-145 Bolt, Brake Hose 1 "
CD315 4-2-73
Rev 3
Chapter 4
21 20
1 19
18
3 2
4 17
16
6 6 15
7
8
8
14
9
13
12
10
11
Figure 2-35. Brake Assembly, Rear
4-2-74 CD315
Rev 3
Chapter 4
Table 2-35. Brake Assembly, Rear

Ind Number Number
35- 372364 060WD105 060WD101 Brake Assembly, Drive Axle - L/H 1 101 & Up
35- 372364 060WD106 060WD100 Brake Assembly, Drive Axle - R/H 1 "
35- 402530 80848 660-ND-1392 Brake Adjusting Kit, L/H 1 "
35- 402530 80849 660-ND-1393 Brake Adjusting Kit, R/H 1 "
35- 402530 2253 660-ND-1394 Brake Springs Kit 1 "
35-1 402530 55358 660-1-1189 Shoes, Brake Drive Axle (set of 4/box) 1 "
35-2 402530 ------ (Note 3) Spring, Upper 2 "
35-3 ------ ------ ------ Bolt, Flange 4 "
35-4 ------ ------ ------ Plate Assembly, R/H 1 "
------ ------ ------ Plate Assembly, L/H 1 "
35-5 ------ ------ ------ Lever, L/H 1 "
------ ------ ------ Lever, R/H 1 "
35-6 402530 ------ (Note 3) Retainer, Hold Down Spring 4 "
35-7 402530 ------ (Note 2) Cover 2 "
35-8 402530 ------ (Note 3) Spring, Hold Down 4 "
35-9 402530 ------ (Note 2) Cable Assembly 2 "
35-10 402530 ------ (Note 2) Spring, L/H 1 "
402530 ------ (Note 2) Spring, R/H 1 "
35-11 402530 ------ (Note 2) Pin 2 "
35-12 402530 ------ (Note 2) Lever 2 "
35-13 402530 ------ (Note 2) Brake Adjusting Socket w/ Screw - L/H 1 "
402530 ------ (Note 2) Brake Adjusting Socket w/ Screw - R/H 1 "
35-14 402530 ------ (Note 3) Spring, Lower 2 "
35-15 402530 ------ (Note 2) Guide, Cable 2 "
35-16 402530 37132 660-ND-1380 Cylinder, Wheel - L/H 1 "
369183 37133 660-ND-1379 Cylinder, Wheel - R/H 1 "
35-17 ------ ------ ------ Link, Connecting - Cylinder 4 "
35-18 ------ ------ ------ Washer, Flat 2 "
35-19 ------ ------ ------ Bolt, Anchor 2 "
35-20 ------ ------ ------ Plate, Cam L/H 1 "
------ ------ ------ Plate, Cam R/H 1 "
35-21 ------ ------ ------ Nut, Lock 2 "
Note 1 Quantities shown are for (1) axle, (2) wheels.

Note 2 These items are not sold separately. They are sold as part of the Brake Adjusting Kit (Left or Right
Hand Side - P/N 660-ND-1392 and 660-ND-1393, respectively.)
Note 3 These items are not sold separately. They are sold as part of the Brake Springs Kit (660-ND-1394).
CD315 4-2-75
Rev 3
Chapter 4
Figure 2-36. Steer Column Assembly
4-2-76 CD315
Rev 3
Chapter 4
Table 2-36. Steer Column Assembly

Ind Number Number
36-1 426744 ------ 660-1-1175 Hose, 112" OAL (to Steer Cylinder) 2 101 & Up
36-2 426744 ------ 660-1-1339 Hose, Booster 83" 1 "
36-3 426744 ------ 660-1-1175 Hose, 112" OAL (to Manifold) 1 "
36-4 426744 ------ MI-ND-359 Fitting 4 "
36-5 372192 291-1034-001 660-1-3028 Valve, Steer 1 "
36-6 241894 ------ X4014-101 Column, Steer 1 "
36-7 402530 HB-6018 660-1-2372 Button, Horn 1 "
36-8 403166 208-1013-001 X6008-101 Horn Button Kit 1 "
36-9 249777 ------ T6-7007-101 Control, Turn Signal 1 "
36-10 403166 209-1007-001 X4004-101 Wheel, Steering 1 "
36-11 372739 21084 X4015-101 Nut, Column 1 "
CD315 4-2-77
Rev 3
Chapter 4
3
4 1
7
8
7
6
8
4
3
Figure 2-37. Steer Cylinder Assembly
4-2-78 CD315
Rev 3
Chapter 4
Table 2-37. Steer Cylinder Assembly

Ind Number Number
37-1 295524 4126-1 660-4-1050 Axle, Steer 1 101 & Up

37-2 373317 65076 1/8 x 1 Pin, Cotter Ø 1/8" x 1" Long 2 "
37-3 373317 ------ 9/16-16NF Nut, Castellated 9/16-16 2 "
37-4 373317 33862 9/16 Washer, Flat 9/16" ID 2 "
37-5 372750 ------ 660-1-1170-2 Plate, Steer Cylinder Mounting 1 "
37-6 369142 32016061 660-1-1170 End, Tie Rod 2 Up to 185
402832 ------ 660-1-2228 End, Tie Rod 2 185 & Up
37-7 426744 ------ 660-1-1175 Hose, 112" OAL 2 101 & Up
37-8 403166 ------ 660-2501-06-06 Elbow, Male 2501-06-06 2 "
37-9 373087 ------ 660-2-1031 Cylinder, Power Steer 1 "
CD315 4-2-79
Rev 4
Chapter 4
Figure 2-38. Main Hydraulic System (Up to S/N 254)
4-2-80 CD315
Rev 3
Chapter 4
Table 2-38. Main Hydraulic System (Up to S/N 254)

Ind Number Number
38-1 373117 M94-4002A BLE-1-1021 Motor, Hydraulic Pump 1 Up to 254
38-2 372750 ------ BLE-3-1067 Cover, Hydraulic Motor 1 "
38-3 372192 V10-1S3S11C20L BLE-1-1020 Pump, Hydraulic 1 "
38-4 ------ ------ 12MJ-16MBUS Fitting, 45° Hydraulic Pump 1 "
(Large)
38-5 ------ ------ 8M6-5MB45 Fitting, 45° Hydraulic Pump 1 "
(Small)
38-6 ------ ------ 8MJ-12MP90 Elbow, 90° - Hydraulic Filter 1 "
38-7 373089 ------ BLE-3-1047 Mount, Filter - Hydraulic 1 "
38-8 403166 ------ 660-4-0010-10 Filter, Hydraulic with Indicator 1 "
38-9 402530 1551 660-4-0010-19 Element, Hydraulic Filter 1 "
38-10 373345 ------ 660-4-1045 Tank, Hydraulic Assembly 1 "
38-11 373345 5201 660-4-0013-11 Cap, Filler 1 "
38-12 ------ ------ ¾ NPT 90 Elbow, Pipe 90° - ¾" 1 "
38-13 ------ ------ 1-FF-S Fitting, Pipe 1 "
38-14 ------ ------ 6-6-FTX-S Connector, Male 1 "
38-15 372739 VMH2-A9 660-4-0010-12 Valve, Ball 1 "
38-16 ------ ------ 6-8-F50X-S Connector, Straight Thread 2 "
38-17 ------ ------ 8-C50X-S Elbow, Straight Thread 1 "
38-18 403166 ------ 660-4-0010-30 Manifold, Hydraulic Large 1 "
38-19 372750 ------ BLE-1-1024 Bracket, Emergency Pump 1 "
38-20 372739 PDA-2 BLE-1-1023 Pump, Emergency Hydraulic 1 "
38-21 ------ ------ 6-CTX-S Fitting, Triple Lock 1 "
38-22 ------ ------ 6MJ-4MB Adapter 1 "
38-23 ------ ------ 6FSOX-S Connector, Straight Thread 1 "
38-24 ------ ------ 8-C50X-S Elbow, Straight Thread 1 "
38-25 426744 ------ 660-1-1258 Hose, 25" OAL Pump Suction 1 "
38-26 349137 6C2AT6FJX6FJX84 MJ-1-5003 Hose, Steer Valve/Cylinder 1 "
L/H (84")
38-27 426744 ------ 660-1-1256 Hose, 108" OAL 2 "
38-28 349137 12C2AT-12FJX-EE X4011-203C Hose, Upper Trans/Cooler (75") 1 "
38-29 372745 ------ BLE-4-1002 Mount, Jackshaft 1 "
38-30 ------ ------ ------ Adapter, Straight Reducing - 1 "
Male
CD315 4-2-81
Rev 3
Chapter 4
34 33 7
32
7 22 20
13 21 19
12
31
35 11
27 10
26 13 7 6
28 5
29 14 4 3
25
15
30 9
17 16
2
23
24 18
8 1
36
Figure 2-39. Hydraulic System (Right Side)
4-2-82 CD315
Rev 3
Chapter 4
Table 2-39. Hydraulic System (Right Side)

Ind Number Number
39-1 373117 M94-4002A BLE-1-1021 Motor, Hydraulic Pump 1 101 & Up
39-2 373317 15055 5/16-18 x 1 Bolt, Hex Head Ø 4 "
5/16-18 x 1" Long
39-3 373317 33858 5/16 Washer, Flat 5/16" ID 6 "
39-4 426744 ------ X4011-203C Hose, Upper Trans/Cooler (75") 1 Up to 270
426744 ------ TM1-1-5008 Hose, Oil Cooler 41" 1 270 & Up
39-5 426744 ------ ------ Elbow, 90° 1 101 & Up
39-6 372739 6801-08-08 660-6801-08-08 Fitting, 90° ½MT-½MP 1 "
39-7 373317 33859 3/8 Washer, Flat 3/8" ID 10 "
39-8 426744 ------ 660-1-1256 Hose, 108" OAL 1 "
(Pump to Manifold)
39-9 372192 V10- BLE-1-1020 Pump, Hydraulic 1 "
1S3S11C20L
39-10 373317 33893 3/8 Washer, Lock 3/8" ID 2 "
39-11 373317 18838 3/8-24 x 1½ Bolt, Hex Head Ø 2 "
3/8-24 x 1½" Long
39-12 372192 201L322400/ 660-ND-1371 Gauge, Hydraulic Pressure 1 "
9767150
39-13 372739 2404-08-12 660-2404-08-12 Connector, Male 2404-08-12 2 "
39-16 372739 2501-08-12 660-2501-08-12 Elbow, Male 2501-08-12 1 "
39-18 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
39-19 373317 33891 ¼ Washer, Lock ¼" ID 2 "
CD315 4-2-83
Rev 4
Chapter 4
34 33 7
32
7 22 20
13 21 19
12
31
35 11
27 10
26 13 7 6
28 5
29 14 4 3
25
15
30 9
17 16
2
23
24 18
8 1
36
Figure 2-39. Hydraulic System (Right Side) (Cont'd)
4-2-84 CD315
Rev 3
Chapter 4
Table 2-39. Hydraulic System (Right Side) (Cont'd)

Ind Number Number
39-20 373317 15005 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 4 101 & Up
39-21 373345 ALG5T 660-4-0013-19 Level, Sight Gauge 1 "
39-22 373345 ------ 660-4-1045 Tank Assembly, Hydraulic 1 "
39-23 373317 33857 ¼ Washer, Flat ¼" ID 6 "
39-24 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 2 "
39-25 426744 ------ BLE-1-2627 Hose, JIC Straight #6, 68" 1 "
39-26 426744 ------ MI-ND-803 Fitting, Hydraulic - Straight 6-6FTX 1 "
39-28 372739 5404-16-16 660-5404-16-16 Nipple, Hex 5404-16-16 1 "
39-29 372739 VMH2-A9 660-4-0010-12 Valve, Ball 1 "
39-30 372739 2404-12-16 660-2404-12-16 Connector, Male 2404-12-16 1 "
39-31 332121 ------ BLE-ND-1084-037 Tube, Hydraulic Line #37 1 "
39-32 373317 37268 ½-13 Nut, Top Lock Hex ½-13 4 "
39-33 373089 ------ BLE-3-1022 Mount, Hydraulic Tank 1 "
39-34 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
39-35 373317 15209 ½-13 x 1½ Bolt, Hex Head Ø 4 "
½-13 x 1½" Long
39-36 426744 ------ 660-1-1256 Hose, 108" OAL (Manifold to Filter) 1 "
CD315 4-2-85
Rev 4
Chapter 4
38
37
33 32
36 7
34 37
7 20
22
19
21 11
31 12
10 7
35 16
27
6
28 26 13
5
29 14 3
25 4
15
30 9
17 2
23
24 18
8 1
39
Figure 2-40. Hydraulic Assembly (UAL Specific)
4-2-86 CD315
Rev 4
Chapter 4
Table 2-40. Hydraulic Assembly (UAL Specific)

Ind Number Number
40-1 373117 M94-4002A BLE-1-1021 Motor, Hydraulic Pump 1 As Req'd

40-3 373317 33858 5/16 Washer, Flat 5/16" ID 6 "
40-4 426744 ------ TM1-1-5008 Hose, Oil Cooler 41" 1 "
40-5 426744 ------ ------ Elbow, 90° 1 "
40-6 372739 6801-08-08 660-6801-08-08 Fitting, 90° ½MT-½MP 1 "
40-7 373317 33859 3/8 Washer, Flat 3/8" ID 10 "
40-8 426744 ------ 660-1-1256 Hose, 108" OAL (Pump to Manifold) 1 "
40-9 372192 V10- BLE-1-1020 Pump, Hydraulic 1 "
1S3S11C20L
40-10 373317 33893 3/8 Washer, Lock 3/8" ID 2 "
40-12 372192 201L322400/ 660-ND-1371 Gauge, Hydraulic Pressure 1 "
9767150
40-13 372739 2404-08-12 660-2404-08-12 Connector, Male 2404-08-12 1 "
40-16 372739 2501-08-12 660-2501-08-12 Elbow, Male 2501-08-12 1 "
40-18 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
40-19 373317 33891 ¼ Washer, Lock ¼" ID 2 "
40-21 373345 ALG5T 660-4-0013-19 Level, Sight Gauge 1 "
40-22 373345 66041047 660-4-1047 Tank, Hydraulic - UAL Spec 1 "
40-23 373317 33857 ¼ Washer, Flat ¼" ID 6 "
40-24 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 2 "
40-26 426744 ------ MI-ND-803 Fitting, Hydraulic - Straight 6-6FTX 1 "
40-28 372739 5404-16-16 660-5404-16-16 Nipple, Hex 5404-16-16 1 "
40-29 372739 VMH2-A9 660-4-0010-12 Valve, Ball 1 "
40-30 372739 2404-12-16 660-2404-12-16 Connector, Male 2404-12-16 1 "
40-31 426744 ------ BLE-1-2680 Tubing, Hydraulic Line #37 (SS) 1 "
40-32 373317 37268 ½-13 Nut, Top Lock Hex ½-13 4 "
40-33 373089 ------ BLE-3-1022 Mount, Hydraulic Tank 1 "
40-34 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
40-35 373317 15209 ½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 4 "
40-36 426744 12MP-8MJ90 ------ Elbow, 90° 12MP-8MJ90 1 "
40-37 239446 FD45-1002- 660-ND-0040 Fitting, AEROQUIP 2 "
16-16
40-38 294594 DC-2 660-ND-0020 Filter, Hydraulic Tank Dessicant 1 "
CD315 4-2-87
Rev 4
Chapter 4
Figure 2-41. Manifold Assembly (Up to S/N 390)
4-2-88 CD315
Rev 3
Chapter 4
Table 2-41. Manifold Assembly (Up to S/N 390)

Ind Number Number
41-1 372739 D-20216 660-4-0010-30 Manifold, Hydraulic Large 1 101 & Up
41-2 372739 6400-06-08-0 660-6400-06-08 Fitting, Straight 3/8MT-1/2M 4 "
O-Ring (SAE)
41-3 426744 ------ 660-1-1250 Hose, 26" OAL 1 "
(Manifold EP to Emerg Pump)
41-4 426744 ------ 660-1-1256 Hose, 108" OAL 1 "
(Manifold to Motor Pump)
41-5 372739 6400-08-08-0 660-6400-08-08-0 Fitting, Straight ½MT-½M 1 "
O-Ring (SAE)
41-6 372739 6801-08-08 660-6801-08-08 Fitting, 90° ½MT-½Adj. 2 "
O-Ring (SAE)
41-7 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
41-8 373317 15117 3/8-16 x 3½ Bolt, Hex Head Ø 2 "
3/8-16 x 3½" Long
41-10 426744 ------ 660-1-1256 Hose, 108" OAL 1 "
(Manifold to Filter)
41-11 426744 ------ 660-1-1175 Hose, 112" OAL 1 "
(Manifold to Steer Valve)
41-12 426744 ------ 660-1-1359 Hose, Tank Return 1 "
(Manifold to Booster)
41-14 426744 ------ 660-1-1254 Hose, 37" Pump Pressure Swivel 1 "
(Manifold to Cont. Valve)
41-15 372739 6802-08-08 660-6802-08-08 Elbow, 45° ½MT-½Adj. 1 "
O-Ring (SAE)
41-16 --------- ------ ½ Plug, ½" 1 "
41-17 372192 201L322400/ 660-ND-1371 Gauge, Hydraulic Pressure 1 Up to 390
9767150
41-18 372739 5605-04-04-04 660-5605-04-04-04 Tee ¼FP-¼FP-¼FP 1 "
41-19 372739 5406-P-04 660-5406-P-04 Plug, ¼" MP 1 "
41-20 372739 5404-04-04 660-5404-04-04 Fitting, Straight ¼MP-¼MP 1 "
41-21 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
CD315 4-2-89
Rev 4
Chapter 4
10
6
2
11
12
13
9
14
15 8
16
7
17 6
5
18
1
2
3 4
Figure 2-42. Manifold Assembly (S/N 390 thru 498)
4-2-90 CD315
Rev 3
Chapter 4
Table 2-42. Manifold Assembly (S/N 390 thru 498)

Ind Number Number
42-1 372739 D-20216 660-4-0010-30 Manifold, Hydraulic Large 1 Up to 499
42-2 372739 6400-06-08-0 660-6400-06-08 Fitting, Straight 4 "
3/8MT-1/2M O-Ring (SAE)
42-3 426744 ------ 660-1-1250 Hose, 26" OAL 1 "
(Manifold EP to Emergency Pump)
42-4 426744 ------ 660-1-1256 Hose, 108" OAL 1 "
42-5 372739 6400-08-08-0 660-6400-08-08-0 Fitting, Straight 1 "
½MT-½M O-Ring (SAE)
42-6 372739 6801-08-08 660-6801-08-08 Fitting, 90° 2 "
½MT-½Adj. O-Ring (SAE)
42-7 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
42-8 373317 15117 3/8-16 x 3½ Bolt, Hex Head Ø 2 "
3/8-16 x 3½" Long
42-11 426744 ------ 660-1-1175 Hose, 112" OAL 1 "
42-12 426744 ------ 660-1-1359 Hose, Tank Return 1 "
42-14 426744 ------ 660-1-1254 Hose, 37" Pump Press. Swivel 1 "
(Manifold to Cont. Valve)
42-15 372739 6802-08-08 660-6802-08-08 Elbow, 45° 1 "
½MT-½ADJ O-Ring (SAE)
42-16 402645 ------ ½ Plug, ½" 1 "
42-17 426744 686-208 ------ Fitting, Quick Disconnect 1 390 & Up
42-18 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 101 & Up
42- 426744 ------ 660-2-2815 Maintenance Kit, Hydraulic Gauge 1 390 & Up
CD315 4-2-91
Rev 4
Chapter 4
10
11 2
13 6
12
2 9
14
8
15
16
17 18
7
19
6
20
5
21
22
2
1 3 4
Figure 2-43. Manifold Assembly (S/N 499 and Up)
4-2-92 CD315
Rev 4
Chapter 4
Table 2-43. Manifold Assembly (S/N 499 and Up)

Ind Number Number
43-1 372739 D-20216 660-4-0010-30 Manifold, Hydraulic Large 1 499 & Up
43-2 372739 6400-06-08-0 660-6400-06-08 Fitting, Straight 3 "
3/8MT-1/2M O-Ring (SAE)
43-3 426744 ------ 660-1-1250 Hose, 26" OAL 1 "
(Manifold EP to Emerg Pump)
43-4 426744 ------ 660-1-1256 Hose, 108" OAL 1 "
43-5 372739 6400-08-08-0 660-6400-08-08-0 Fitting, Straight 1 "
½MT-½M O-Ring (SAE)
43-6 372739 6801-08-08 660-6801-08-08 Fitting, 90° 2 "
½MT-½Adj. O-Ring (SAE)
43-7 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
43-8 373317 15117 3/8-16 x 3½ Bolt, Hex Head Ø 2 "
3/8-16 x 3½" Long
43-9 426744 ------ BLE-1-2656 Hose (Bulkhead to Manifold) 1 "
43-11 426744 ------ 660-1-1175 Hose, 112" OAL 1 "
43-12 426744 ------ 660-1-1359 Hose, Tank Return 1 "
43-13 426744 ------ BLE-1-2656 Hose (Manifold to Hyd. Cntrl Valve) 1 "
43-15 426744 6MJ-6FJX-6MJ 203102-6-6S Tee, Swivel Flare - Opt. 1 "
43-16 426744 686-502 660-ND-2850 Fitting, Test Port 6FJ Conn. - Opt. 1 "
43-17 426744 ------ 660-1-1250 Hose, 26" OAL 1 "
43-18 426744 ------ 06-08-06-070428 Tee, 3/8MJ-½MB-3/8MJ 1 "
43-19 372739 6802-08-08 660-6802-08-08 Elbow, 45° 1 "
½MT-½ADJ O-Ring (SAE)
43-20 402645 ------ ½ Plug, ½" 1 "
43-21 426744 686-208 660-ND-2849 Fitting, Test Port ¼Male 1 "
NPT Conn.
43-22 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
CD315 4-2-93
Rev 4
Chapter 4
9
8
10
11
12 7
6
5
13 4
14
Figure 2-44. Emergency Pump Assembly
4-2-94 CD315
Rev 3
Chapter 4
Table 2-44. Emergency Pump Assembly

Ind Number Number
44-1 372750 ------ BLE-2-1024 Bracket, Emergency Hydraulic 1 101 & Up
Pump
44-2 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
44-4 373317 33857 ¼ Washer, Flat ¼" ID 6 "
44-5 372739 ------ BLE-1-1023 Pump, Emergency Hydraulic 1 "
44-6 372739 6400-06-06-0 660-6400-06-06-0 Fitting, Straight 3/8MT-3/8M O-Ring 1 "
44-8 426744 ------ 660-1-1250 Hose, 26" OAL 1 "
(Emergency Pump to Manifold)
44-9 372739 6500-06-06 660-6500-06-06 Elbow, 90° 1 "
3/8MT-3/8" 37° Female Swivel Nut
44-10 372739 850-6-4 ------ Fitting, Straight 3/8-¼ 1 "
44-12 373317 33859 3/8 Washer, Flat 3/8" ID 2 "

44-14 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 3 "
CD315 4-2-95
Rev 3
Chapter 4
24
25
23 21
26
13 20 19
22 18
17
16
27
15
28 14
3 11 13
29
3
1 10
12
2
7
8 9 11
3 5
30 6
4
31
Figure 2-45. Hydraulic Control Valve (Up to S/N 499)
4-2-96 CD315
Rev 3
Chapter 4
Table 2-45. Hydraulic Control Valve (Up to S/N 499)

Ind Number Number
45-1 372739 FPSMVSNR1500 BLE-1-1046 Valve, Hydraulic Control 1 Up to 499
10LH2LH2-PB
45-2 372739 6401212F1/ BLE-1-1064 Handle Assembly, Lift Valve 2 "
MV3-H2 (part of BLE-1-1046)
45-3 426744 ------ ------ Elbow, 90° JIC½-MO-Ring-3/8 4 "
45-5 426744 ------ ------ Fitting, Straight 1 "
½MJICO-Ring-3/8
45-7 372739 6801-06-06 660-6801-06-06 Elbow, 90° 3 "
3/8MT-3/8ADJ O-Ring (SAE)
45-9 372739 2701-08-08 660-2701-08-08 Elbow, 90° ½MT-½MT Bulkhead 1 "
45-10 ------ ------ ------ Tee, ½MJIC-½MJIC-½FJIC 1 "
Swivel
45-11 372739 0306-08 660-0306-08 Nut, Lock ½" - Bulkhead 2 "
45-12 372739 2704-08-08-08 660-2704-08-08-08 Tee, ½MT-½MTBulkhead-½MT 1 "
45-13 372739 0306-06 660-0306-06 Nut, Lock 3/8" - Bulkhead 4 "
(for 2701-06-06)
45-14 372739 2700-06-06 660-2700-06-06 Fitting, Straight 2 "
3/8MT-3/8MT Bulkhead
45-19 403166 ------ 660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 1 "
45-20 289558 ------ 660-4-0010-20 Valve, Relief 1 "
45-21 372739 2501-08-06 660-2501-08-06 Elbow, 90° ½MT-3/8MP 2 "
45-23 373317 33861 ½ Washer, Flat ½" ID 4 "
45-24 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 2 "
3/8-16 x 1¼" Long
45-25 426744 ------ 660-1-1338 Hose, Lift Cylinder 39" 2 "
45-26 372739 2701-06-06 660-2701-06-06 Elbow, 90°, 3/8MT-3/8MT Blkhd 2 "
45-28 402641 23F1814 BLE-ND-002 Switch, Demand- N.O. with Plug 2 "
(part of BLE-1-1046)
45-30 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
45-31 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
CD315 4-2-97
Rev 4
Chapter 4
9
38
11 18
8 19
7 33
20 34
6
35
10 21
5 11 22
23
4
24
3 17
25
36
1 28 26
16 27 37
15 29
2 30
27
13
12 32
31
14
Figure 2-46. Hydraulic Control Valve (S/N 499 and Up)
4-2-98 CD315
Rev 4
Chapter 4
Table 2-46. Hydraulic Control Valve (S/N 499 and Up)

Ind Number Number
46-1 372739 D42146 BLE-4-2654 Valve, Hydraulic Assembly 1 499 & Up
46-2 372739 ------ (Note 1) Handle, Lift Assembly 2 "
46-3 372739 ------ (Note 1) Elbow, 90° 1 "
46-4 372739 ------ (Note 1) Elbow, 90° 1 "
46-5 372739 ------ (Note 1) Elbow, 90° 1 "
46-6 426744 ------ BLE-ND-1084-0 Line, Hydraulic Control Valve 3.25" 2 "
426744 ------ BLE-ND-1085-0 Line, Hyd. Cntrl Valve 3.25" (SS) 2 As Req'd
46-7 426744 ------ 06-08-070102 Fitting, Straight 8MJ-6MP 1 499 & Up
46-8 372739 854073 660-4-0010-20 Valve, Relief 1 "
46-9 426744 ------ ------ Elbow, 45° 6MJ-6MP45 1 "
46-10 372739 ------ (Note 1) Fitting, Straight 1 "
46-11 426744 ------ 06-08-070102 Fitting, Straight 8MJ-6MP 1 "
46-12 372739 ------ (Note 1) Plug 1 "
46-14 372739 ------ (Note 1) Elbow, 90° 1 "
46-18 426744 ----- BLE-1-2656 Hose (Valve to Bulkhead) 2 "
426744 ------ BLE-ND-1085-030 Tube, Hydraulic Line #30 (SS Opt.) 1 As Req'd
46-21 426744 ------ 08-08-08-070958 Tee, 8MJBLKD-8MJ 1 499 & Up
46-22 426744 ------ 06-06-070601 Fitting, Straight 6MJ-BLHD-UN 2 "
46-23 426744 ------ 660-ND-2212-12 Line, Hydraulic #12 1 "
426744 ------ 660-ND-2213-12 Line, Hydraulic #12 (SS Opt.) 1 As Req'd
46-24 426744 ------ 660-ND-2212-13 Line, Hydraulic #13 1 499 & Up
426744 ------ 660-ND-2213-13 Line, Hydraulic #13 (SS Opt.) 1 As Req'd
NOTE 1: These parts are included with Hydraulic Valve Assembly BLE-4-2654.
CD315 4-2-99
Rev 4
Chapter 4
9
38
11 18
8 19
7 33
20 34
6
35
10 21
5 11 22
23
4
24
3 17
25
36
1 28 26
16 27 37
15 29
2 30
27
13
12 32
31
14
Figure 2-46. Hydraulic Control Valve (S/N 499 and Up) (Cont'd)
4-2-100 CD315
Rev 3
Chapter 4
Table 2-46. Hydraulic Control Valve (S/N 499 and Up) (Cont'd)

Ind Number Number
46-25 426744 ------ 660-1-1250 Hose, 26" OAL (Tee to Manifold) 1 499 & Up
46-26 426744 ----- BLE-1-2656 Hose (Valve to Bulkhead) 1 "
46-27 426744 ------ 08-08-070701 Elbow, 90° 8MJ-BLKH90° 2 "
46-29 426744 ------ BLE-ND-1084-033 Tube, Hydraulic Line #33 1 499 & Up
46-30 426744 ------ BLE-ND-1084-035 Tube, Hydraulic Line #35 1 499 & Up
46-31 426744 ----- BLE-1-2656 Hose (Valve to Bulkhead) 1 499 & Up
46-32 372739 ------ ------ Switch, Valve 2 "
46-33 426744 ------ 08-08-070601 Fitting, Straight 8MJ-BLKH-UN 2 "
46-34 440230 ------ 660-1-0431 Bracket, Bulkhead 1 "
46-35 426744 ----- BLE-1-2650 Line, Hydraulic (at Valve #1) 1 "
426744 ----- BLE-1-2650SS Line, Hydraulic (at Valve #1) (SS) 1 As Req'd
46-36 426744 ------ 08-070118 Nut, Bulkhead 83LMD Nut 2 499 & Up
426744 ----- BLE-1-2651SS Line, Hydraulic (at Valve #2) (SS) 1 As Req'd
46-38 426744 ------ BLE-1-2627 Hose, JIC Straight #6, 68" 1 499 & Up
(Relief Valve to Front Lift Arm Valve)
NOTE 1: These parts are included with Hydraulic Valve Assembly BLE-4-2654.
CD315 4-2-101
Rev 3
Chapter 4
11
10
2
1 3
2 3
4
6
4 4
5 8
2
9
Figure 2-47. Conveyor Hydraulic Lines
4-2-102 CD315
Rev 4
Chapter 4
Table 2-47. Conveyor Hydraulic Lines

Ind Number Number
47-1 426744 ----- BLE-1-2656 Hose (Valve to Bulkhead) 2 499 & Up

47-2 426744 ----- 08-08-070601 Fitting, Straight 8MJ-BLKHD-UN 6 "
47-3 440230 ----- 660-1-0431 Bracket, Bulkhead 2 "
47-4 426744 ----- 08-070118 Nut, Bulkhead 8BLKHD-NUT 4 "
426744 ----- BLE-1-2651SS Line, Hydraulic (at Valve #2) (SS) As Req'd
47-6 426744 ----- BLE-1-2650 Line, Hydraulic (at Valve #1) 1 499 & Up
426744 ----- BLE-1-2650SS Line, Hydraulic (at Valve #1) (SS) As Req'd
47-7 426744 ----- 661-1-0033 Hose, Conveyor ½" x 132" 2 499 & Up
47-8 426744 ----- 08-08-070101 Fitting, Straight 8MJ-8MJ 4 "
47-9 410026 ----- 660-1-1251 Hose, 18" OAL 2 "
47-10 426744 ----- 660-ND-2212-28 Line, Hydraulic (#28) 2 "
426744 ----- 660-ND-2213-28 Line, Hydraulic (#28) (SS Opt.) 2 As Req'd
47-11 426744 ----- 660-1-1254 Hose, 37" Pump Pressure Swivel 2 499 & Up
CD315 4-2-103
Rev 4
Chapter 4
Figure 2-48. Lift Valve Components
4-2-104 CD315
Rev 3
Chapter 4
Table 2-48. Lift Valve Components

Ind Number Number
48-1 ------ ------ 660-4-0010-13 Valve, Relief 1 101 & Up

48-2 372739 FPSMVSNR1500 BLE-1-1046 Valve, Hydraulic Control 1 "
10LH2LH2-PB
48-3 372739 6401212F1/ BLE-1-1064 Handle Assembly, Lift Valve 1 "
MV3-H2 (part of BLE-1-1046)
48-4 402641 23F1814 BLE-ND-002 Switch, Demand- N.O. with Plug 2 "
(part of BLE-1-1046)
402641 23F1814 BLE-ND-002 Switch, Demand- N.O. with Plug 2 As Req'd
(Alternate Source)
CD315 4-2-105
Rev 4
Chapter 4
4
5 3
2
6
18
7 1
17
19
16
15
10
8
13 9
11
14
12
Figure 2-49. Lift Cylinder - Front (Up to S/N 499)
4-2-106 CD315
Rev 3
Chapter 4
Table 2-49. Lift Cylinder - Front (Up to S/N 499)

Ind Number Number
49-1 403166 ------ 660-2-0062 Cylinder, Hydraulic Front 1 101 & Up

49-2 426744 ------ 1/8 Zerk Ø 1/8" Pipe 90° 2 "
49-3 241766 ------ 660-1-0099 Pin, Lift Cylinder 2 "
49-4 373317 ------ 1-8 Nut, Lock - Nylon Insert 2 "
49-5 332121 ------ 660-2501-06-08 Elbow, 90° 3/8MT-½MT 1 "
49-6 426744 ------ 660-ND-2212-04 Line, Hydraulic #4 (660) 1 "
426744 ------ 660-ND-2213-4 Line, Hydraulic #4 (SS) - 1 As Req'd
Front Lift Cyl.
49-7 373317 62025 ------ Clamp, Hose #72 1 101 & Up
49-8 372739 2404-06-08 660-2404-06-08 Fitting, Straight ½MT-3/8MP 1 "
49-9 372739 5605-04-04-04 660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 1 "
49-10 349137 04-06-070202 660-2501-06-04 Elbow, 90° 3/8MT-¼MP 1 "
49-12 372739 5404-08-06 660-5404-08-06 Fitting, Straight ½MP-3/8MP 1 "
49-13 403166 ------ 660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 1 "
49-14 329499 ------ 660-4-0010-3 Valve, Holding 1 "
49-15 426744 ------ 660-1-1338 Hose, Lift Cylinder, 39" 2 Up to 499
49-16 372739 0306-06 660-0306-06 Nut, Lock 3/8" - Bulkhead 2 101 & Up
49-17 373317 33861 ½ Washer, Flat ½" ID 2 "
49-18 372739 2701-06-06 660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 2 "
49-19 426744 ------ 3/8 Hose, 3/8" ID x 2" Long 1 "
CD315 4-2-107
Rev 4
Chapter 4
4
5 3
2
6
18 20
7 1
17
19
16
15
10
8
13 9
11
14
12
Figure 2-50. Lift Cylinder - Front (S/N 499 and Up)
4-2-108 CD315
Rev 4
Chapter 4
Table 2-50. Lift Cylinder - Front (S/N 499 and Up)

Ind Number Number
50-1 403166 ------ 660-2-0062 Cylinder, Hydraulic Front 1 101 & Up

50-2 426744 ------ 1/8 Zerk Ø 1/8" Pipe 90° 2 "
50-3 241766 ------ 660-1-0099 Pin, Lift Cylinder 2 "
50-5 332121 ------ 660-2501-06-08 Elbow, 90° 3/8MT-½MT 1 "
50-6 426744 ------ 660-ND-2212-04 Line, Hydraulic #4 (660) 1 "
Front Lift Cyl.
50-7 373317 62025 ------ Clamp, Hose #72 1 101 & Up
50-8 372739 2404-06-08 660-2404-06-08 Fitting, Straight ½MT-3/8MP 1 "
50-9 372739 5605-04-04-04 660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 1 "
50-10 349137 04-06-070202 660-2501-06-04 Elbow, 90° 3/8MT-¼MP 1 "
50-12 372739 5404-08-06 660-5404-08-06 Fitting, Straight ½MP-3/8MP 1 "
50-13 403166 ------ 660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 1 "
50-14 329499 ------ 660-4-0010-3 Valve, Holding 1 "
50-15 426744 ------ BLE-1-2627 Hose, JIC Straight #6, 68" 2 499 & Up
50-16 372739 0306-06 660-0306-06 Nut, Lock 3/8" - Bulkhead 2 101 & Up
50-17 373317 33861 ½ Washer, Flat ½" ID 2 "
50-18 372739 2701-06-06 660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 2 "
50-19 426744 ------ 3/8 Hose, 3/8" ID x 2" Long 1 "
50-20 426744 ------ 660-1-2899 Hose, ¼" ID x 68" Long 1 499 & Up
CD315 4-2-109
Rev 4
Chapter 4
3
2
4 1
12 5
6
7
11
10 8
9
13
14
15
Figure 2-51. Lift Cylinder - Rear
4-2-110 CD315
Rev 3
Chapter 4
Table 2-51. Lift Cylinder - Rear

Ind Number Number
51-1 403166 ------ 660-2-0063 Cylinder, Hydraulic Lift Rear 1 101 & Up
51-2 241766 ------ 660-1-0099 Bolt, Lift Cylinder Pivot 2 "
51-3 426744 ------ 1/8 Zerk Ø 1/8" Pipe 90° 2 "
51-5 332121 ------ 660-2501-06-08 Elbow, 90° 3/8MT-½MP 1 "
51-6 372739 2605-06-04-06 660-2605-06-04-06 Tee 1 "
51-7 426744 ------ 660-ND-2212-10 Line, Hydraulic #10 1 "
Rear Lift Cylinder (CE Opt.)
51-8 372739 5404-08-06 660-5404-08-06 Fitting, Straight ½MP-3/8MP 1 101 & Up
51-9 329499 ------ 660-4-0010-3 Valve, Holding 1 "
51-10 403166 ------ 660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 1 "
51-11 372739 6500-06-06 660-6500-06-06 Elbow, 90° 3/8MT-3/8 1 "
37° Female Swivel
51-12 426744 ------ 660-1-1250 Hose, 26" OAL 2 "
51-13 372739 0306-06 660-0306-06 Nut, Lock 3/8" - Bulkhead 2 "
51-14 373317 33861 ½ Washer, Flat ½" ID 2 "
51-15 372739 2701-06-06 660-2701-06-06 Elbow, 90° 3/8MT-3/8Bulkhead 2 "
CD315 4-2-111
Rev 4
Chapter 4
Figure 2-52. Steer Front Axle and Hub Assembly
4-2-112 CD315
Rev 3
Chapter 4
Table 2-52. Steer Front Axle and Hub Assembly

Ind Number Number
52-1 373317 37308 ½-20 Nut, Top Lock Hex ½-20 8 101 & Up
52-2 373317 33861 ½ Washer, Flat ½" ID 8 "
52-3 373386 ------ 660-1-1121 U-Bolt, Front Axle 4 "
52-4 369183 260-1342 & 1343 660-4-1050-29 Socket Kit 2 "
52-5 372364 31026-1 660-4-1050-9 Stop, Axle 2 "
52-6 ------ ------ 660-4-1050-10 Nut, Axle 2 "
52-7 372364 29518X 660-4-1050-1L Knuckle Assembly, L/H 1 "
372364 70160X 660-4-1050-1R Knuckle Assembly, R/H 1 "
52-8 295524 4126-1 660-4-1050 Axle, Steer 1 "
52-9 372364 044TR115-4X 660-4-1050-14 Tie Rod Assembly 1 "
52-10 ------ ------ 660-4-1050-15 Cap, Plug 2 "
52-11 372364 70517X 660-4-1050-16 Spindle and Plug Assembly 2 "
52-12 ------ ------ 660-4-1050-17 Nut, Lock 12 "
52-13 ------ ------ 660-4-1050-26 Seal, Oil 2 "
52-14 373090 104910-104949 660-4-1050-19 Bearing and Race Kit - Inner 2 "
52-15 402530 ------ 660-4-1050-20 Hub and Rotor 2 "
52-16 403166 LM501349/310 KIT 660-4-1050-21 Bearing and Race Kit - Outer 2 "
52-17 372364 21588X 660-4-1050-22 Nut, Wheel Bearing with Pin 2 "
52-18 372364 36569 660-4-1050-23 Washer, Lock 2 "
52-19 372364 31139 660-4-1050-24 Nut, Wheel Bearing 2 "
52-20 372364 044HK101 660-4-1050-25 Hubcap 2 "
Note: Quantities shown are for entire front axle.
CD315 4-2-113
Rev 3
Chapter 4
29
30 28
27
31 26 24
22
18
19 25
27
17 23
26 16
21
14 20
13
13
12
11 15
10 13
2 8
7
9 6
4 5
4
3
1 2
Figure 2-53. Drive Motor Assembly (Up to S/N 569)
4-2-114 CD315
Rev 3
Chapter 4
Table 2-53. Drive Motor Assembly (Up to S/N 569)

Ind Number Number
53-2 373317 33859 3/8 Washer, Flat 3/8" ID 8 "
53-5 263516 ------ BLE-3-1027 Mount, Motor 1 "
53-6 373317 15211 ½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long 4 "
53-7 373317 33861 ½ Washer, Flat ½" ID 8 "
53-8 373317 37268 ½-13 Nut, Top Lock Hex ½-13 8 "
53-9 373317 33859 3/8 Washer, Flat 3/8" ID A/R "
53-10 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
53-11 373117 FB4-4001E BLE-1-1025 Motor, Drive 1 "
373117 203-06-4001 BLE-1-2529 Motor, Traction Drive (48V Opt.) 1 As Req'd
53-12 358417 ------ BLE-1-2558 Key, Drive Shaft 1 101 & Up
53-13 372739 5016 BLE-1-1032 Cover, Chain Coupling 1 "
53-14 372739 5016 BLE-1-1031 Coupling, Chain 1 "
53-15 372739 5016 X 1 1/8 BLE-1-1029 Sprocket, Coupling - Motor Side 2 "
53-16 278709 E80A5 BLE-1-1026 Reducer, Drive Motor 1 Up to 552
278709 E88-A5-180 BLE-1-2664 Reducer, Drive Motor 1 552-568
53-17 373317 33862 9/16 Washer, Flat 9/16" ID 4 101 & Up
53-18 373317 37272 5/8-11 Nut, Top Lock Hex 5/8-11 4 "
53-19 293912 92271A216 BLE-1-1033 Key, Step - Drive Shaft Yoke 1 "
53-20 373317 33863 5/8 Washer, Flat 5/8" ID 12 "
53-21 373386 ------ BLE-1-1028 Yoke, Drive Shaft 1 "
53-22 402646 ------ 660-1-1207 U-Bolt, Drive Shaft 2 "
53-23 373386 ------ 660-1-1116 Shaft, Drive 1 "
349146 ------ 660-1-2206 Shaft, Drive (Eco Kit) - Opt. 1 As Req'd
53-24 369400 3-70-28X 660-4-1051-7-1 Strap Set for Input Flange 1 101 & Up
53-25 295524 060AF507-8 660-4-1051 Axle, Drive 1 "
53-26 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 5 "
53-27 373317 33857 ¼ Washer, Flat ¼" ID 5 "
53-28 373089 ------ BLE-4-1065 Cover, Traction Motor 1 "
53-31 373082 ------ T6-4005-109 Handle, Hood 1 "
CD315 4-2-115
Rev 4
Chapter 4
29
30 28
27
31 26 24
22
18
19 25
27
17 23
26 16
21
14 20
13
13
12
11 15 32
10 13
2 8
7
9 6
4 5
4
3
1 2
Figure 2-54. Drive Motor Assembly (S/N 569 and Up)
4-2-116 CD315
Rev 4
Chapter 4
Table 2-54. Drive Motor Assembly (S/N 569 and Up)

Ind Number Number
54-2 373317 33859 3/8 Washer, Flat 3/8" ID 8 "
54-5 263516 ------ BLE-3-1027 Mount, Motor 1 "
54-7 373317 33861 ½ Washer, Flat ½" ID 8 "
54-8 373317 37268 ½-13 Nut, Top Lock Hex ½-13 8 "
54-9 373317 33859 3/8 Washer, Flat 3/8" ID A/R "
54-10 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
54-11 373117 FB4-4001E BLE-1-1025 Motor, Drive 1 "
373117 203-06-4001 BLE-1-2529 Motor, Traction Drive (48V Opt.) 1 As Req'd
54-12 358417 ------ BLE-1-2558 Key, Drive Shaft 1 101 & Up
54-13 372739 5016 BLE-1-1032 Cover, Chain Coupling 1 "
54-14 372739 5016 BLE-1-1031 Coupling, Chain 1 "
54-15 372739 5016 X 1 1/8 BLE-1-1029 Sprocket, Coupling - Motor Side 1 569 & Up
54-16 278709 E88-A512 BLE-1-2671 Gearbox, Reduction 1 "
54-17 373317 33862 9/16 Washer, Flat 9/16" ID 4 101 & Up
54-18 373317 37272 5/8-11 Nut, Top Lock Hex 5/8-11 4 "
54-19 293912 92271A216 BLE-1-1033 Key, Step - Drive Shaft Yoke 1 "
54-20 373317 33863 5/8 Washer, Flat 5/8" ID 12 "
54-21 373386 ------ BLE-1-1028 Yoke, Drive Shaft 1 "
54-22 402646 ------ 660-1-1207 U-Bolt, Drive Shaft 2 "
54-23 373386 ------ 660-1-1116 Shaft, Drive 1 "
349146 ------ 660-1-2206 Shaft, Drive (Eco Kit) - Opt. 1 As Req'd
54-24 369400 3-70-28X 660-4-1051-7-1 Strap Set for Input Flange 1 101 & Up
54-25 295524 060AF507-8 660-4-1051 Axle, Drive 1 "
54-26 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 5 "
54-27 373317 33857 ¼ Washer, Flat ¼" ID 5 "
54-28 373089 ------ BLE-4-1065 Cover, Traction Motor 1 "
54-31 373082 ------ T6-4005-109 Handle, Hood 1 "
54-32 372739 ------ BLE-1-2670 Coupling, Sprocket, Gearbox 1 569 & Up
CD315 4-2-117
Rev 4
Chapter 4
4
1 2 3 5 6 7 8
9 10 11
13
14
D
15
16 12
17
23
18
24
19
20 21 22
25 Flow Grease Packing

387517
30
26 31
27 32
28
31
29
30
Flow Grease Packing
387517
Flow Grease Packing depending upon design:
-horizontally: fill half
-perpendicularly: fill completely
Figure 2-55. Drive Motor Reduction Gear Assembly
4-2-118 CD315
Rev 3
Chapter 4
Table 2-55. Drive Motor Reduction Gear Assembly

Ind Number Number
55- 278709 E80A5 BLE-1-1026 Reducer, Drive Motor 1 Up to 552

278709 E88-A5-180 BLE-1-2664 Reducer, Drive Motor 1 552-568
55-1 278709 680095 ------ Housing, Gear 1 Up to 569
55-2 278709 441767 ------ Plug / Breather 1 "
55-3 278709 50979 ------ Eyebolt 1 "
55-4 278709 623547 ------ Sealing Compound Ref. "
55-5 278709 518573 ------ Gasket 1 "
55-6 278709 989613 ------ Screw, Locking / Stud 4 "
55-7 278709 51237 ------ Washer, Lock 4 "
55-8 278709 170023 ------ Nut, Hex 4 "
55-9 278709 51282 ------ Ring, Snap 1 "
55-10 278709 561070 ------ Pinion 1 "
55-11 278709 51566 ------ Key, Parallel 1 "
55-12 278709 539422 ------ Wheel, Helical Gear 1 "
55-13 278709 105811 ------ Key, Parallel 1 "
55-14 278709 11745 ------ Bearing, Radial Ball 1 "
55-15 278709 717002 ------ Cover, Bearing 1 "
55-16 278709 624632 ------ O-Ring 1 "
55-17 278709 392944 ------ Seal, Shaft 1 "
55-18 278709 50688 ------ Screw, Hex Head 4 "
55-19 278709 51327 ------ Ring, Snap 1 "
55-20 278709 988239 ------ Shaft, Output 1 "
55-21 278709 716928 ------ Bushing, Sleeve 1 "
55-22 278709 51576 ------ Key, Parallel 1 "
55-23 278709 51275 ------ Ring, Snap 1 "
55-24 278709 716952 ------ Bearing, Roller 1 "
55-26 278709 51323 ------ Ring, Snap 1 "
55-27 278709 542741 ------ Seal, Shaft 1 "
55-28 278709 102767 ------ Shaft, Input 1 "
55-29 278709 342041 ------ Cover, Housing 1 "
55-31 278709 167940 ------ Seal, Shaft 1 "
55-32 278709 105807 ------ Key, Parallel 1 "
CD315 4-2-119
Rev 4
Chapter 4
Figure 2-56. Drive (Rear) Axle Attachment
4-2-120 CD315
Rev 3
Chapter 4
Table 2-56. Drive (Rear) Axle Attachment

Ind Number Number
56-1 373317 37308 ½-20 Nut, Top Lock Hex ½-20 8 101 & Up
56-2 373317 33861 ½ Washer, Flat 8 "
56-3 295524 060AF507-8 660-4-1051 Axle, Drive (Rear) 1 "
56-4 349146 ------ 660-1-1122 U-Bolt, Rear Axle 4 "
CD315 4-2-121
Rev 3
Chapter 4
Figure 2-57. Drive (Rear) Axle Hub Assembly
4-2-122 CD315
Rev 3
Chapter 4
Table 2-57. Drive (Rear) Axle Hub Assembly

Ind Number Number
57-1 403166 ------ 660-4-1051-11 Seal, Rear Hub 2 101 & Up

57-2 373090 TIM 362A/370A 660-4-1051-20 Bearing and Race Kit - Inner 2 "
57-3 289558 ------ 660-4-1051-17 Drum and Hub Assembly 2 "
57-4 373090 TIMK 359A/354A 660-4-1051-21 Bearing and Race Kit - Outer 2 "
57-5 372364 060SR117-2 660-4-1051-23 Shaft, Axle - R/H 1 "
372364 060SR117-3 660-4-1051-24 Shaft, Axle - L/H 1 "
CD315 4-2-123
Rev 3
Chapter 4
Figure 2-58. Drive (Rear) Axle Assembly
4-2-124 CD315
Rev 3
Chapter 4
Table 2-58. Drive (Rear) Axle Assembly

Ind Number Number
58-1 ------ ------ 660-4-1051-29 Nut, Stud 16 101 & Up

58-2 372364 31534 660-4-1051-28 Adapter, Stud Nut 16 "
58-3 372364 36847 660-4-1051-22 Stud, Drive Axle Hub 16 "
58-4 372364 060SR117-2 660-4-1051-23 Shaft, Axle - R/H 1 "
372364 060SR117-3 660-4-1051-24 Shaft, Axle - L/H 1 "
58-5 372364 30636 660-4-1051-26 Nut, Rear Axle Spindle 4 "
58-6 372364 30637 660-4-1051-27 Washer, Lock 2 "
58-7 373090 TIMK 359A/354A 660-4-1051-21 Bearing and Race Kit - Outer 2 "
58-8 289558 ------ 660-4-1051-17 Drum and Hub Assembly 2 "
58-9 373090 TIM 362A/370A 660-4-1051-20 Bearing and Race Kit - Inner 2 "
58-10 403166 ------ 660-4-1051-11 Seal, Rear Hub 2 "
58-11 ------ ------ 660-4-1051-19 Nut, Brake Mounting 8 "
58-12 ------ ------ 660-4-1051-30 Stud, Wheel 16 "
58-13 ------ ------ (Note 2) Washer, Thrust - 2 "
Differential Pinion
58-14 ------ ------ (Note 2) Pinion, Differential 2 "
58-15 ------ ------ (Note 2) Shaft, Differential 1 "
58-16 372364 706047X 660-4-1051-14 Bearing and Cup 1 "
58-17 372364 ------ (Note 1) Cap, Differential Bearing 1 "
58-18 ------ ------ (Note 2) Gear, Differential 2 "
58-19 ------ ------ (Note 2) Spacer, Differential Gear 2 "
58-20 ------ ------ (Note 2) Disc, Differential 8 "
58-21 372364 ------ (Note 1) Bolt, Bearing Cap 2 "
Note 1: Housing 660-4-1051 (Item 44) includes differential bearing cap (Item 17) and bearing cap bolt
660-4-1051-13 (Item 21).
Note 2: These parts are not available individually. See service kits 660-4-1051-40 through 660-4-1051-48
for parts availibility.
Note 3: Carrier cover assembly, 660-4-1051-49 (Item 30) includes carrier cover gasket and RTV sealant
(Item 28, see note 4), carrier cover plug 660-4-1051-10 (Item 31), and carrier cover bolt
660-4-1051-12 (Item 29).
Note 4: Service ribbed cover with gasket 34685; service smooth cover with RTV sealant 38615.
CD315 4-2-125
Rev 3
Chapter 4
Figure 2-58. Drive (Rear) Axle Assembly (Cont'd)
4-2-126 CD315
Rev 3
Chapter 4
Table 2-58. Drive (Rear) Axle Assembly (Cont'd)

Ind Number Number
58-22 ------ ------ (Note 2) Shim, Differential Bearing 1 101 & Up

58-23 ------ ------ ------ Bolt, Drive Gear 12 "
58-24 ------ ------ (Note 2) Case, Differential 1 "
58-25 ------ ------ (Note 2) Plate, Differential 4 "
58-26 ------ ------ (Note 2) Clip, Differential Clutch 4 "
58-27 ------ ------ 660-4-1051-16 Lock, Differential Shaft 1 "
58-28 372364 34685/38615 (Notes 3,4) Gasket Cover and RTV Sealant 1 "
58-29 372364 34822 660-4-1051-12 Bolt, Carrier Cover (Note 3) 10 "
58-30 372364 ------ 660-4-1051-49 Carrier Cover Assembly (Note 3) 1 "
58-31 372364 ------ 660-4-1051-10 Plug, Cover (Note 3) 1 "
58-32 ------ ------ (Note 2) Drive Gear and Pinion 1 "
58-33 ------ ------ (Note 2) Plate, Differential 4 "
58-34 373090 ------ 660-4-1051-3 Bearing, Inner Pinion 1 "
58-35 ------ ------ (Note 2) Shim, Drive Pinion Adjustment 1 "
58-36 372364 30982 660-4-1051-5 Baffle, Pinion Bearing 1 "
58-37 ------ ------ (Note 2) Shim, Pinion Bearing Adjustment 1 "
58-38 372364 706046X 660-4-1051-6 Bearing, Pinion 1 "
58-39 372204 42737 660-4-1051-8 Slinger, Pinion 1 "
58-40 402530 18891 660-4-1051-4 Seal, Rear Axle 1 "
58-41 369400 3-4-5711-1X 660-4-1051-7 Flange Yoke End Assembly 1 "
58-42 372364 30275 660-4-1051-2 Washer 1 "
58-43 ------ ------ 660-4-1051-9 Nut, Pinion 1 "
58-44 372364 707097X 660-4-1051-32 Differential Case Assembly 1 "
Note 1: Housing 660-4-1051 (Item 44) includes differential bearing cap (Item 17) and bearing cap bolt
660-4-1051-13 (Item 21).
Note 2: These parts are not available individually. See service kits 660-4-1051-40 through 660-4-1051-48
for parts availibility.
Note 3: Carrier cover assembly, 660-4-1051-49 (Item 30) includes carrier cover gasket and RTV sealant
(Item 28, see note 4), carrier cover plug 660-4-1051-10 (Item 31), and carrier cover bolt
660-4-1051-12 (Item 29).
Note 4: Service ribbed cover with gasket 34685; service smooth cover with RTV sealant 38615.
CD315 4-2-127
Rev 3
Chapter 4
Figure 2-59. Controller Assembly - Sevcon MCM with Regen
4-2-128 CD315
Rev 3
Chapter 4
Table 2-59. Controller Assembly - Sevcon MCM with Regen

Ind Number Number
59-1 ------ 965/64401 ------ Rectifier, Silicone Controlled "SCR (A)" 1 Up to 254
59-2 ------ 965/44252 ------ Rectifier, Silicone Controlled "SCR (B)" 1 "
59-3 ------ 965/44227 ------ Rectifier, Silicone Controlled "SCR (C)" 1 "
59-4 ------ 840/64201 ------ Diode, Long Lead 1 "
59-5 ------ 966/11027 ------ Switch, Thermal 1 "
59-6 ------ 821/57022 ------ Capacitor 1 "
CD315 4-2-129
Rev 3
Chapter 4
Figure 2-60. Mechanical Adaptations to Sevcon MCM Controller
4-2-130 CD315
Rev 3
Chapter 4
Table 2-60. Mechanical Adaptations to Sevcon MCM Controller

Ind Number Number
60-1 281660 ------ BLE-4-1500A Harness, 3pc. Wire Kit - 1 Up to 254

72/80V Control Box
60-2 402645 KRPA11DG12 660-4-0753-2 Relay, Electric Belt Control 3 "
402645 RB08 660-4-0753-3 Base, Socket - Electric/Octagon 3 "
60-3 373488 ------ BLE-1-1036 Yoke, Accelerator 1 "
60-4 ------ ------ M10 x 1.5 Nut, Jam 2 "
60- ------ ------ BLE-4-1500B Harness, 80V Wire - Chassis 1 As Req'd
60- ------ ------ BLE-4-1500B-72 Harness, 72V Wire - Chassis 1 "
60- ------ ------ BLE-4-1502 Harness, 12V Wire 1 Up to 254
CD315 4-2-131
Rev 3
Rev 3
4-2-132
Section 2
Chapter 4
660E Mobile Electric Conveyor
Figure 2-61: SCR-Converter-Accelerator Assy (Sevcon MCM Controller)
CD315
CD315
660E Mobile Electric Conveyor
Figure 2-62: Controller Assembly Call-outs (Sevcon MCM Controller)
Rev 3
4-2-133
Section 2
Chapter 4
Chapter 4
Figure 2-63. Control Box Assembly (S/N 254 thru 498)
4-2-134 CD315
Rev 3
Chapter 4
Table 2-63. Control Box Assembly (S/N 254 thru 498)

Ind Number Number
63-1 373059 ------ ------ Panel, Sevcon PowerpaK 660E 1 254-498
63-2 403133 A-302408LP BLE-1-2567 Box, Controller 1 256 & Up
402645 ------ BLE-4-1038 Box, EBL Control (Enclosure 1 As Req'd
Modification)
63-3 373317 ------ 5/32 x 1 Screw Ø 5/32 x 1" Long 16 254 & Up
373317 ------ 5/32-1 Screw Ø 5/32 x 1" Long - Opt. 18 As Req'd
63-4 373059 622/23811 M3-1-1700-5 Converter, DC/DC 1 254 & Up
63-5 ------ ------ ------ Holder, Fuse 1 "
63-6 402530 782-1108 BLE-ND-2602 Fuse, 10 AMP 6 "
63-7 373317 ------ 5/32 Nut, Lock 5/32" ID 16 "
373317 ------ 5/32 Nut, Lock 5/32" ID - Opt. 18 As Req'd
63-8 ------ ------ ------ Strip, Terminal TB-2 1 254 & Up
63-9 372291 PC792H-1C-C1 T6-9100-105-2 Relay, Power (Reverse Light) 1 "
63-10 372578 ------ BLE-4-2552 Controller, Contact - Rapid Chg Opt. 1 As Req'd
63-11 372291 PC792H-1C-C1 T6-9100-105-2 Relay, Power (Horn Relay) 1 254 & Up
63-12 402645 ------ BLE-1-2572 Spring, Hold Down for Relay 1 254-498
63-13 402645 ------ BLE-1-2570 Relay, One N/O Contact 1 254 & Up
63-14 402645 ------ BLE-1-2571 Socket, for Plug-In Relay 1 "
63-15 ------ ------ ------ Module, Burden Resistor 1 "
63-16 373059 668/10007 BLE-1-2565 Bracket, Resistor 1 "
63-17 395898 ------ BLE-2-2590 Panel, Electrical Components 1 "
63-18 373317 ------ 5/32 Washer, Lock 5/32" ID 4 "
63-19 373317 37260 ¼ Nut, Top Lock Hex ¼-20 4 "
63-20 373317 33857 ¼ Washer, Flat ¼" ID 4 "
CD315 4-2-135
Rev 4
Chapter 4
Figure 2-63. Control Box Assembly (S/N 254 thru 498) (Cont'd)
4-2-136 CD315
Rev 3
Chapter 4
Table 2-63. Control Box Assembly (S/N 254 thru 498) (Cont'd)

Ind Number Number
63-21 373317 33891 ¼ Washer, Lock ¼" ID 4 254 & Up
63-22 373317 37264 3/8-16 Nut, Top Lock Hex 3/8 -16 4 "
63-23 373317 33893 3/8 Washer, Lock 3/8" ID 8 "
63-24 373317 33859 3/8 Washer, Flat 3/8" ID 8 "
63-25 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-18 x 1¼" Long 4 "
63-28 ------ ------ ------ Connector, 31-Pin Electrical 1 "
63-29 277796 HOFF-AS075 BLE-ND-1080 Seal, Hole Ø ¾" Conduit Hole, Black 2 "
63-29a 402645 ------ BLE-1-1055 Relief, Strain 5/8" x ¾" NPT 2 As Req'd
(CGB295)
63-29b 402975 ------ 660-ND-1921 Nut, Lock - Strain Relief, ¾" 2 "
63-29c 294093 ------ BLE-1-1503 Ring, Sealing ¾" NPT 2 "
63-30 402975 ------ 660-ND-1921 Nut, Lock - Strain Relief, ¾" 7 254 & Up
63-31 294093 ------ BLE-1-1503 Ring, Sealing ¾" NPT 7 "
63-32 402645 ------ BLE-1-1055 Relief, Strain 5/8" x ¾" NPT 7 "
(CGB295)
63-33 277796 ------ BLE-1-1501 Relief, Strain 1 254-255
277796 ------ BLE-1-1501 Relief, Strain 2 256 & Up
63-34 402645 ------ 660-ND-2215 Relief, Strain 3/8 x ½ NPT (CG116) 1 254-498
63-35 402645 ------ BLE-1-1502 Ring, Sealing ½ NPT 1 "
63-36 277796 141-T&B 660-1-2252 Nut, Conduit ½ NPT 1 "
63-37 ------ ------ ------ Connector, 14-Pin Electrical 1 256 & Up
63-38 373094 3LT32 BLE-1-2534 Connector, Compression 1½" EMT 1 254-498
CD315 4-2-137
Rev 4
Chapter 4
37
36
11
12 10
35
13
14
9
8
15 7
16 6
5
4
33 17 3
18 20 34
32
24 19 2
32 21 1 24
25
34 22
26
23 25
31
26
24
31
25
26 23
30 27
28
29 23
Figure 2-64. Control Box Assembly (S/N 499 and Up)
4-2-138 CD315
Rev 4
Chapter 4
Table 2-64. Control Box Assembly (S/N 499 and Up)

Ind Number Number
64-1 373059 ------ ------ Panel, Controller w/ 24V Coils 80V 1 499 & Up
64-2 403133 A-302408LP BLE-1-2567 Box, Controller 1 "
64-3 373317 ------ 5/32 x 1 Screw Ø 5/32 x 1" Long 16 "
64-4 373059 622/23811 M3-1-1700-5 Converter, DC/DC 1 "
64-5 ------ ------ ------ Holder, Fuse 1 "
64-6 402530 782-1108 BLE-ND-2602 Fuse, 10 AMP 8 "
64-7 373317 ------ 5/32 Nut, Lock 5/32" ID 16 "
64-8 ------ ------ ------ Strip, Terminal TB-2 1 "
64-9 372291 PC792H-1C-C1 T6-9100-105-2 Relay, Power (Back-Up Light) 1 "
64-10 372291 PC792H-1C-C1 T6-9100-105-2 Relay, Power (Horn Relay) 1 "
64-11 402645 20C228 67798 Spring, Hold Down for Plug-In Relay 1 "
64-12 402645 ------ BLE-1-2570 Relay, with one N/O Contact 1 "
64-13 402645 ------ BLE-1-2571 Socket, for Plug-In Relay 1 "
64-14 ------ ------ ------ Module, Burden Resistor 1 "
64-15 373059 668/10007 BLE-1-2565 Bracket, Resistor 1 "
64-16 395898 ------ BLE-2-2590 Panel, Electrical Components 1 "
64-17 373317 ------ 5/32 Washer, Lock 5/32" ID 4 "
64-18 373317 37260 ¼ Nut, Top Lock Hex ¼-20 4 "
64-19 373317 33857 ¼ Washer, Flat ¼" ID 4 "
64-20 373317 33891 ¼ Washer, Lock ¼" ID 4 "
64-21 373317 37264 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
64-22 373317 33893 3/8 Washer, Lock 3/8" ID 8 "
64-23 373317 33859 3/8 Washer, Flat 3/8" ID 8 "
64-24 402645 ------ BLE-1-1055 Relief, Strain 9 "
5/8" x ¾" NPT (CGB295)
64-25 294093 ------ BLE-1-1503 Ring, Sealing ¾ NPT 9 "
64-26 402975 ------ 660-ND-1921 Nut, Lock - Strain Relief, ¾" 9 "
64-27 373317 15109 3/8-16 x 1½ Bolt, Hex Head Ø 4 "
3/8-16 x 1½" Long
64-28 373317 15107 3/8-16 x 1¼ Bolt, Hex Head Ø 4 "
3/8-16 x 1¼" Long
64-31 402645 AS100 BLE-1-2673 Button, Plug 1" 3 "
64-33 277796 ------ BLE-1-1501 Relief, Strain 2 "
64-34 402645 HDBB-420-1-250 BLE-1-2646 Boot, Heat Shrink - 3M 9 "
64-35 372578 ------ BLE-4-2552 Controller, Contact - Rapid Charge 1 As Req'd
64-36 402645 C7A20 660-1-2326 Relay, 12VDC 0.9W - 1 "
Infrared Conv. Shutdown Opt.
64-37 402645 S7MP 660-1-2327 Socket, Relay Base - 1 "
Infrared Conv. Shutdown Opt.
CD315 4-2-139
Rev 4
Chapter 4
Figure 2-65. Controller Assembly (S/N 254 thru 499)
4-2-140 CD315
Rev 3
Chapter 4
Table 2-65. Controller Assembly (S/N 254 thru 499)

Ind Number Number
65- 373059 632B/86302 BLE-4-2562 Controller Assembly (PowerpaK) 1 254-499
65-1 373059 ------ ------ Panel, Sevcon PowerpaK 660E 1 "
65-2 373059 ------ ------ Mount, Contactor, Small 3 "
65-3 373059 ------ ------ Contactor, Conveyor Traction #1 1 "
65-4 373059 ------ ------ Mount, Contactor, Large 1 "
65-5 373059 ------ ------ Contactor, Forward 1 "
65-7 373059 ------ ------ Controller, Sevcon PowerpaK 1 "
65-8 373059 ------ ------ Contactor, Reverse 1 "
65-9 373059 ------ ------ Contactor, Hydraulic Pump 1 "
65-10 373059 ------ ------ Fuse, Traction Motor, 425AMP 1 "
65-11 373059 ------ ------ Fuse, Belt Motor, 50 AMP 1 "
65-12 373059 ------ ------ Contactor, Line 1 "
65-13 373059 ------ ------ Contactor, Regen 1 "
65-14 373059 SW200A-373 BLE-0007 Contactor, Charge Z40AC-SW - Opt. 1 As Req'd
65-15 373059 ------ ------ Contactor, Bypass 1 254-499
65- 281660 ------ BLE-1-2612 Cable, Quick Charge Jumper (Fuse 1 As Req'd
Bass Bar to Charge Contactor) - Opt.
CD315 4-2-141
Rev 4
Chapter 4
15
14
19
13
7
18
6
16 12
8 4
5
11
17
10
9 3
2
1
Figure 2-66. Controller Assembly (S/N 500 and Up)
4-2-142 CD315
Rev 4
Chapter 4
Table 2-66. Controller Assembly (S/N 500 and Up)

Ind Number Number
66- 373059 632B86303 BLE-4-2648 Controller w/ 24V Coils, 80V 1 500 & Up
66-1 373059 ------ ------ Panel, Controller w/ 24V Coils, 80V 1 "
66-2 373059 ------ ------ Mount, Contactor, Small 3 "
66-4 373059 ------ ------ Mount, Contactor, Large 1 "
66-5 373059 ------ ------ Contactor, Forward 1 "
66-7 373059 ------ ------ Controller 1 "
66-8 373059 ------ ------ Contactor, Reverse 1 "
66-9 373059 ------ ------ Post, Power 4 "
66-10 373059 ------ ------ Fuse, Belt Motor, 50 AMP 1 "
66-11 373059 ------ ------ Fuse, Traction Motor, 425AMP 1 "
66-12 373059 ------ ------ Contactor, Line 1 "
66-13 373059 ------ ------ Contactor, Regen 1 "
66-14 373059 ------ ------ Contactor, Bypass 1 "
66-15 373059 184/21731 BLE-1-2564 Cable, Display 1 "
66-16 373059 SW200A-373 BLE-0007 Contactor, Charge Z40AC-SW - Opt. 1 As Req'd
66-17 281660 ------ BLE-1-2612 Cable, Quick Charge Jumper 1 "
(Fuse Bass Bar to Charge Contactor)
66-18 281660 08220128CB BLE-1-2601 Cable, Negative - Rapid Charge Opt. 1 "
66-19 373059 839/12140 BLE-1-1034-14 Bar, Buss - Contactor (SW200) - Opt. 1 "
66- 402645 10-8109 BLE-1-2608 Compound, Heat Sink 1 500 & Up
CD315 4-2-143
Rev 4
Chapter 4
5
1b 1c
1d
4
1a 3
2
1e
1f
1g
1h
Figure 2-67. Horn Assembly
4-2-144 CD315
Rev 3
Chapter 4
Table 2-67. Horn Assembly

Ind Number Number
67-1 277796 ------ T6-7013-207 Horn 1 101 & Up

376658 H-48VS M3-1-5089 Horn, Electric 48V - Opt. 1 As Req'd
67-1a ------ ------ ------ Horn w/ Terminal Application 1 101 & Up
67-1b ------ ------ ------ Jumper Wire w/Connections 1 "
67-1c ------ ------ ------ Bracket 1 "
67-1d ------ ------ ------ Nut, Lock - 8mm ID 2 "
67-1e ------ ------ ------ Washer, Star 1 "
67-1f ------ ------ ------ Washer, Ground Terminal 1 "
67-1g ------ ------ ------ Bracket, L 1 "
67-1h ------ ------ ------ Bolt, Hex Head Ø 8mm 1 "
67-2 373317 33857 ¼ Washer, Flat ¼" ID 1 "
67-3 373317 33891 ¼ Washer, Lock ¼" ID 1 "
67-5 373317 ------ ------ Relay, Harness to Horn 1 "
CD315 4-2-145
Rev 4
Chapter 4
1
4
Front Lights
3
2
Rear Lights
Figure 2-68. Light Assemblies
4-2-146 CD315
Rev 4
Chapter 4
Table 2-68. Light Assemblies

Ind Number Number
68-1 277028 1400342 T6-1300-247 Headlight 2 101 & Up

68-2 260131 40004 T6-7006-107A Light, Back-up - Kit 2 "
68-3 302511 ------ T6-7006-101A Light, Tail - Kit 2 "
68-4 260131 40002Y T6-7006-115 Light, Turn Signal - Optional 2 As Req'd
CD315 4-2-147
Rev 4
Chapter 4
2
1
Figure 2-69. Spot Light Installation
4-2-148 CD315
Rev 4
Chapter 4
Table 2-69. Spot Light Installation

Ind Number Number
69-1 395898 ------ 660-3-2429 Bracket Assembly, Aligner Channel 1 As Req'd

440230 ----- 663-2-2802 Crossmember Weldment - Narrow Conv. 1 "
69-2 277028 1400342 T6-1300-247 Headlight 1 "
CD315 4-2-149
Rev 4
Chapter 4
Figure 2-70. Work Light Assembly
4-2-150 CD315
Rev 4
Chapter 4
Table 2-70. Work Light Assembly

Ind Number Number
70-1 277028 1400342 T6-1300-247 Headlight 2 As Req'd

70-2 372750 ------ 660-3-1249 Mount, Light - 13" Solid Dual 1 "
70-3 357447 2558 T6-9003-171 Grommet, Windshield 3 "
CD315 4-2-151
Rev 4
Chapter 4
Figure 2-71. Wheels and Tires
4-2-152 CD315
Rev 3
Chapter 4
Table 2-71. Wheels and Tires

Ind Number Number
71-1 1177411 ------ T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 4 101 & Up
1177411 ------ T6-9003-550 Wheel, 16.5" x 6.75", White 4 As Req'd
1177411 ------ T6-9003-549 Wheel, 16" x 6", White 4 "
1177411 ------ T6-2003-101UPS Wheel, DC 16.5 x 6.75 4 "
w/Reinf. Plate
71-2 1177411 ------ T6-2400-166 Tire, Tug Tuff, 8.00 x 16.5 4 101 & Up
1177411 ------ T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5" 10PR 4 As Req'd
1177411 ------ BLE-1-2674 Tire, 10 Ply Radial, 225/75R16 4 "
1177411 ------ TM1-ND-1013 Tire, 225/75-16 LTX AT 4 "
1177411 ------ T6-1300-101 Tire, All Season, 8.75 x 16.5 4 "
1177411 ------ T6-2400-161 Tire, Goodyear 225/75-16R LT 4 "
1177411 ------ MH-1-602 Tire, Goodyear 8 x 16 LT 4 "
1177411 ------ MH-ND-650 Tire, LT215/85R/16 4 "
1177411 ------ T6-2004-103 Tire, Rib Tread 8.0 x 16.5 4 "
267009 ------ T6-2400-160 Tire, Safari SJR LT 225/75R16 4 "
1177411 ------ T6-2400-171 Tire, Supergrip 8.75 x 16.5 10PR 4 "
Mud/Snow
71- 1177411 ------ T6-2400-205 Tire/Wheel Assembly, 4 "
10 Ply 225/75R16 Radials
1177411 ------ T6-2400-187 Tire/Wheel Assembly, 4 "
Tug Tuff, 8 x 16.5
1177411 ------ TM1-1-9814 Tire/Wheel Assembly, 4 "
Tug Tuff, 8.75 x 16.5
Goodyear 225/75R16 LT
Kelly LT225/75R16
71-3 1177411 ------ ½-20 Nut, Wheel ½-20 ZP 32 101 & Up
Note 1: Each T6-2400-205 Tire/Wheel Assembly consists of (1) BLE-1-2674 Tire and
(1) T6-9003-549 Wheel.
Note 2: Each T6-2400-187 Tire/Wheel Assembly consists of (1) T6-2400-166 Tire and
(1) T6-2400-169 Wheel.
Note 3: Each TM1-1-9814 Tire/Wheel Assembly consists of (1) T6-2400-170 Tire and
(1) T6-2400-169 Wheel.
(1) T6-2400-169 Wheel.
(1) T6-9003-549 Wheel.
CD315 4-2-153
Rev 4
Chapter 4
7 4
6
5
Figure 2-72. Conveyor Lift Arms - Front and Rear
4-2-154 CD315
Rev 4
Chapter 4
Table 2-72. Conveyor Lift Arms - Front and Rear

Ind Number Number
72-1 369176 ------ 660-4-0008 Lift Arm Weldment, Front 1 101 & Up
369176 ------ 663-4-0008 Lift Arm Weldment, Front - 1 As Req'd
Narrow Conv.
72-2 373317 37278 1-8 Nut, Top Lock Hex 1-8 4 101 & Up
72-3 403166 EF162224 660-1-0092 Bearing, Pivot 8 "
72-4 373317 15471 1-8 x 4½ Bolt, Hex Head Ø 1-8 x 4½" Long 4 "
72-5 373317 ------ 1¼ Clamp, P- (1¼") 2 "
72-6 373089 ------ T6-8005-111 Strap, Lever to Park Brake 1 529 & Up
72-7 369176 ------ 660-4-0009 Lift Arm Weldment, Rear 1 101 & Up
369176 ------ 663-4-0009 Lift Arm Weldment, Rear - 1 As Req'd
Narrow Conv.
CD315 4-2-155
Rev 4
Chapter 4
Figure 2-73. Conveyor Safety Props
4-2-156 CD315
Rev 3
Chapter 4
Table 2-73. Conveyor Safety Props

Ind Number Number
73-1 244126 ------ 660-1-0243 Safety Prop Weldment 1 101 & Up

73-2 263516 ------ 660-4-1976 Prop, Rear Safety 1 "
73-3 373317 37268 ½-13 Nut, Top Lock Hex ½-13 4 "
CD315 4-2-157
Rev 3
Chapter 4
Figure 2-74. Cam Assembly
4-2-158 CD315
Rev 3
Chapter 4
Table 2-74. Cam Assembly

Ind Number Number
74-1 369176 ------ 660-4-0008 Lift Arm Weldment, Front 1 101 & Up
369176 ------ 663-4-0008 Lift Arm Weldment, Front - Narrow Conv. 1 As Req'd
74-2 373317 15474 1-8 x 5½ Bolt, Hex Head Ø 1-8 x 5½" Long 2 101 & Up
74-3 373317 33866 1 Washer, Flat 1" ID 6 "
74-4 372739 ------ 660-4-0132-4 Wheel, V-Groove with Roller Bearing 2 "
74-5 ------ ------ 660-4-0132-2 Bushing, Sleeve 2 "
74-6 373317 37278 1-8 Nut, Top Lock Hex 1-8 2 "
74-7 262531 ------ 660-1-0293 Bracket, Cam 2 "
74-8 372739 RBC CS48L 660-4-0132-9 Follower, Cam 4 "
74-9 373317 33863 5/8 Washer, Flat 5/8" ID 12 "
74-10 373317 33897 5/8 Washer, Lock 5/8" ID 4 "
74-11 373317 37312 5/8-18 Nut, Top Lock Hex 5/8-18 4 "
CD315 4-2-159
Rev 4
Chapter 4
Figure 2-75. Conveyor Weldment - Standard (BLE-4-2617)
4-2-160 CD315
Rev 3
Chapter 4
Table 2-75. Conveyor Weldment - Standard (BLE-4-2617)

Ind Number Number
75-1 268375 ------ 660-6-0801 Rail, Conveyor - R/H 1 390 & Up

75-2 395898 ------ 660-3-2431 Crossmember, Conveyor Lift Arm 1 "
75-3 395898 ------ 660-3-2429 Bracket Assembly, Aligner Channel 2 "
75-4 395898 ------ 660-3-0808 Bracket, Crowder Roller 3 "
75-5 395898 ------ 660-3-0809 Plate, Channel - Take-up Bearing 2 "
75-6 395898 ------ 660-3-2427 Plate, Slide - Conveyor Right 1 "
75-7 395898 ------ 660-1-0173 Angle, End Crossmember 2 "
75-8 395898 ------ 660-2-2800 Brace, Tie 2 "
75-9 395898 ------ 660-3-2426 Plate, Slide - Conveyor Left 1 "
75-10 268375 ------ 660-6-0800 Rail, Conveyor - L/H 1 "
75-11 358417 ------ 660-3-1270 Bracket, Roller Support 4 "
75-12 395898 ------ 660-1-0005-30 Strap, Conveyor 6 "
75-13 395898 ------ 660-3-2428 Bracket, Small Roller Assembly 4 "
75-14 440230 64-660-3-2663 660-3-2663 Conveyor Crossmember Assembly 2 "
75-15 395898 ------ 660-3-0802 Plate, Middle 1 "
75-16 395898 ------ 660-3-0807 Bracket, Drive Roller - R/H 1 "
75-17 372745 ------ BLE-4-1002 Mount, Jackshaft 2 "
75-18 395898 ------ 660-3-0812 Bracket, Motor Mount w/Tab 1 "
75-19 262531 ------ BLE-4-1016 Mount, Conveyor Drive 1 "
75-20 395898 ------ 660-1-0005-26 Angle, Conveyor (¼") 2 "
CD315 4-2-161
Rev 4
Chapter 4
16
11
17
18
19
15
20
14
21
13
12
11 4
22
10
16
1
2
3
9
4 8
5 7
6
Figure 2-76. Conveyor Weldment - Narrow (BLE-4-2618) (Up to S/N 409)
4-2-162 CD315
Rev 3
Chapter 4
Table 2-76. Conveyor Weldment - Narrow (BLE-4-2618) (Up to S/N 409)

Ind Number Number
76-1 268375 ------ 663-4-0801 Rail, Narrow Conveyor - R/H 1 Up to 409
76-3 395898 ------ 660-3-2429 Bracket, Aligner Channel Assembly 2 "
76-4 358417 ------ 663-1-0808 Bracket, Crowder Roller - Narrow Conv. 3 "
76-5 395898 ------ 663-1-0809 Bracket, Take-up Bearing - Narr. Conv. 2 "
76-8 395898 ------ 660-2-2800 Brace, Tie 2 "
76-9 395898 ------ 660-3-2426 Plate, Slide - Conveyor Left 1 "
76-10 268375 ------ 663-4-0800 Rail, Narrow Conveyor - L/H 1 "
76-12 395898 ------ 660-1-0005-30 Strap, Conveyor 6 "
76-13 395898 ------ 660-3-2428 Bracket, Small Roller Assembly 4 "
76-14 440230 64-660-3-2663 660-3-2663 Crossmember Assembly - Std Conv. 2 "
76-15 395898 ------ 660-3-0802 Plate, Middle 1 "
76-16 395898 ------ 663-1-0173 Angle, End - Narrow Conveyor 1 "
76-17 395898 ------ 663-2-0807 Bracket, Drive Roller - Narrow 2 "
Conveyor
76-18 395898 ------ 663-3-0810 Bracket, Pillow Block / Crowder Roller 1 "
76-19 395898 ------ 663-3-0812 Bracket, Motor Mount (Wldmt) - 1 "
Narrow
76-20 440230 ------ BLE-4-1074 Mount, Jackshaft - Narrow Conveyor 1 "
76-21 372745 ------ BLE-4-1073 Crossmember, Conveyor Drive - Narrow 1 "
76-22 395898 ------ 660-1-0005-26 Angle, Conveyor (¼") 2 "
CD315 4-2-163
Rev 4
Chapter 4
4
20
16
11
3
17
18
19
15
21
13
12
11 4
14
10
16
1
2
3 22
4 9
23
5 7 8
6
Figure 2-77. Conveyor Weldment - Narrow (BLE-4-2618) (S/N 409 and Up)
4-2-164 CD315
Rev 4
Chapter 4
Table 2-77. Conveyor Weldment - Narrow (BLE-4-2618) (S/N 409 and Up)

Ind Number Number
77-1 268375 ------ 663-4-0801 Rail, Narrow Conveyor - R/H 1 409 & Up
77-3 440230 ------ 663-2-2802 Crossmember Wldmt - Narrow Conv. 2 "
77-4 358417 ------ 663-1-0808 Bracket, Crowder Roller - Narrow Conv. 3 "
77-5 395898 ------ 663-1-0809 Bracket, Take-up Bearing - Narr. Conv. 2 "
77-8 395898 ------ 660-2-2800 Brace, Tie 2 "
369176 ------ 663-2-2782 Bar, Tie Brace 2 As Req'd
77-9 395898 ------ 660-3-2426 Plate, Slide - Conveyor Left 1 409 & Up
77-10 268375 ------ 663-4-0800 Rail, Narrow Conveyor - L/H 1 "
77-12 395898 ------ 660-1-0005-30 Strap, Conveyor 6 "
77-13 440230 ------ 663-2-2803 Crossmember Wldmt - Narrow Conv. 5 "
77-14 395898 ------ 660-1-0005-26 Angle, Conveyor (¼") 2 "
77-15 395898 ------ 660-3-0802 Plate, Middle 1 "
77-16 395898 ------ 663-1-0173 Angle, End - Narrow Conveyor 1 "
77-17 395898 ------ 663-2-0807 Bracket, Drive Roller - Narrow Conveyor 2 "
77-18 395898 ------ 663-3-0810 Bracket, Pillow Block / Crowder Roller 1 "
77-19 395898 ------ 663-3-0812 Bracket, Motor Mount (Wldmt) - Narrow 1 "
77-20 1172802 ------ 663-1-0338 Bearing, 1" Pillow Block 1 "
77-21 606035 ------ 663-2-2340 Reinforcement, Narrow Conveyor Front 1 "
77-22 373089 ------ 663-2-0803 Cap, End - Rear L/H 1 "
77-23 373089 ------ 663-2-0804 Cap, End - Rear R/H 1 "
CD315 4-2-165
Rev 4
Chapter 4
Figure 2-78. Conveyor Guards
4-2-166 CD315
Rev 3
Chapter 4
Table 2-78. Conveyor Guards

Ind Number Number
78-1 ------ ------ BLE-6-2599 Conveyor Weldment 1 185-389

------ ------ BLE-4-2617 Conveyor Weldment - Standard 1 390 & Up
------ ------ BLE-4-2618 Conveyor Weldment - Narrow 1 As Req'd
440230 ------ 661-4-2833K Conveyor Weldment - Extended 1 "
------ ------ 661-4-3061 Conveyor Weldment - CE Extended 1 "
78-2 373089 ------ 660-2-1360 Guard, V-Groove Caster - R/H 1 185 & Up
78-3 373089 ------ 660-2-1074 Guard, V-Groove Caster - L/H 1 "
78-4 371685 ------ 660-ND-1505 Bumper, Plastic 2 "
78-5 373089 ------ 660-1-1510 Guard, Finger L/H Front Roller 1 "
78-6 373089 ------ 660-1-1511 Guard, Finger R/H Front Roller 1 "
78-7 369176 ------ 660-3-0120-2 Channel, Bumper Roll 1 "
78-8 250698 ------ 660-3-0120-1 Bumper Roll 1 "
78-9 262531 ------ BLE-4-1016 Mount, Conveyor Drive 1 "
78-10 372750 ------ BLE-4-1005 Guard, Conveyor Drive 1 "
78-11 373089 ------ 660-3-0987 Guard, Finger - Rear Wldmt Assembly 1 "
CD315 4-2-167
Rev 4
Chapter 4
9 8 7
6
11 5
10
12 3
13 4
14 16
20
15 2
17
1
23
21
22 24
18
19
Figure 2-79. Conveyor Front End - Standard
4-2-168 CD315
Rev 4
Chapter 4
Table 2-79. Conveyor Front End - Standard

Ind Number Number

79-2 373089 ------ 660-2-1074 Guard, V-Groove Caster - L/H 1 185 & Up
79-4 373089 ------ 660-1-2470 Cover, Crowder Roller 1 As Req'd
Adjustment Access
79-5 250697 ------ 660-2-2836 Pad, Nylon - Front Left Side 1 "
79-6 373089 ------ 660-1-1510 Guard, Finger L/H Front Roller 1 185 & Up
79-7 372170 ------ 663-3-2605 Bumper, D-Style 8" L/F - Opt. 1 As Req'd
79-8 373089 ------ 660-3-0962 Guard, Spacer/Finger - 1 "
Front Bumper Roll (Opt.)
79-9 369176 ------ 660-3-0120-2 Channel, Roll Bumper 1 185 & Up
79-10 373089 ------ 660-1-1511 Guard, Finger R/H Front Roller 1 "
79-11 250698 ------ 660-3-0120-1 Bumper, Roll 1 "
79-12 372170 ------ 663-3-2668 Bumper, D-Style 8" R/F - Opt. 1 As Req'd
79-14 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
79-15 250697 ------ 660-2-2837 Pad, Nylon - Front Right Side 1 "
79-16 373317 33858 5/16 Washer, Flat 5/16" ID 12 185 & Up
79-17 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 12 185 & Up
79-18 372170 ------ 660-2-2662 Guard, Nylon - 2 As Req'd
Conv. Rail Bottom (Opt.)
350000 ------ 660-1-2363 Guard, Nylon R/H - 1 "
350000 ------ 660-1-2362 Guard, Nylon L/H - 1 "
79-19 373089 ------ 660-2-1360 Guard, V-Groove Caster - R/H 1 185 & Up
79-20 358417 ------ 663-1-2698 Plate, D-Bumper Retainer - Opt. 2 As Req'd
79-21 606035 ------ 660-2-1672 Guard, Front Belt Closeout - Opt. 1 "
79-22 372750 ------ 660-2-1671 Guard, Front Crossmember 1 "
Anchor - Opt.
79-23 402645 Q236E 660-1-3266 Emitter, Infrared Switch - Opt. 1 "
79-24 402645 Q23SN6R 660-1-3267 Receiver, Infrared Switch - Opt. 1 "
CD315 4-2-169
Rev 4
Chapter 4
9 8 7
10
6
11
12
13 3
14 5
2
4
15 1
21
16
17
18
19
20
Figure 2-80. Conveyor Front End - Narrow (Up to S/N 409)
4-2-170 CD315
Rev 3
Chapter 4
Table 2-80. Conveyor Front End - Narrow (Up to S/N 409)

Ind Number Number
80-1 ------ ------ BLE-4-2618 Conveyor Weldment - Narrow 1 Up to 409

80-2 373423 ------ 663-2-2672 Pad Assembly - L/H Side 1 "
80-4 373317 37262 5/16-18 Nut, Top Lock Hex 5/16-18 12 "
80-5 373317 33858 5/16 Washer, Flat 5/16" ID 12 "
80-6 373317 ------ ¼-20 x 1 Bolt, Counter Sink Ø ¼-20 x 1" Long 4 "
80-7 373089 ------ 663-3-2607 Guard, Front Roller, L/H, Square 1 "
80-8 358417 ------ 663-4-2264 Cap, End - Front L/H (Wldmt) 1 "
80-9 358417 ------ 663-1-2698 Plate, D-Bumper Retainer 2 "
80-10 372170 ------ 663-3-2605 Bumper, 8" L/F D-Style (Narrow Conv.) 1 "
80-11 372739 143P86410 663-1-0338 Bearing, 1" Pillow Block 1 "
80-12 373089 ------ 663-3-2608 Guard, Front Roller, R/H, Square 1 "
80-13 373089 ------ 663-4-2263 Cap, End - Front R/H (Wldmt) 1 "
80-14 372170 ------ 663-3-2668 Bumper, 8" R/F D-Style (Narrow Conv.) 1 "
80-16 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
80-17 373423 ------ 663-2-2671 Pad Assembly - R/H Side 1 "
80-18 372170 ------ 660-2-2662 Guard, Conveyor Rail Bottom 2 "
80-19 350000 ------ 663-4-2666 Plate, Conveyor Bottom Front Cover 1 "
80-20 244001 ------ 663-2-2684 Guard, V-Groove Caster Narrow R/H 1 "
80-21 244001 ------ 663-2-2683 Guard, V-Groove Caster Narrow L/H 1 "
CD315 4-2-171
Rev 4
Chapter 4
3
11
4 11
15 16
15
6
6 7
9
8
10
12
17
13
18
14
Figure 2-81. Conveyor Front End - Narrow (S/N 409 and Up)
4-2-172 CD315
Rev 4
Chapter 4
Table 2-81. Conveyor Front End - Narrow (S/N 409 and Up)

Ind Number Number
81-1 372736 ------ 660-1-1511 Guard, Finger - R/H Front Roller 1 409 & Up
372750 ------ 663-1-2335 Guard, Finger - R/H (Narrow) (UAL) - Opt. 1 As Req'd
373089 ------ 663-3-2608 Guard, Front Roller, R/H Square 1 "
(Narrow) - Opt.
81-2 372736 ------ 660-1-1510 Guard, Finger - L/H Front Roller 1 409 & Up
373089 ------ 663-1-2334 Guard, Finger - L/H (Narrow) (UAL) - Opt. 1 As Req'd
373089 ------ 663-3-2607 Guard, Front Roller, L/H Square - 1 "
Narrow - Opt.
81-3 373423 ------ 663-2-2671 Pad Assy, R/H Side - Opt. 1 "
250697 ------ 660-2-2837 Pad, Nylon - Front Right Side - Opt. 1 "
250697 ------ 660-2-2810 Pad, Nylon - Passenger Side w/slots 1 "
(Narrow) - Opt.
81-4 373089 ------ 663-4-2263 Cap, End - Front R/H, Wldmt 1 409 & Up
81-5 373089 ------ 663-4-2264 Cap, End - Front L/H, Wldmt 1 "
81-6 369176 ------ 663-3-2319 Plate, Conveyor D-Bumper 2 "
81-7 372170 ------ 660-2-2662 Guard, Nylon - Conveyor Rail Bottom 1 "
(No slot)
373089 ------ 660-1-2363 Guard, R/H Nylon - Conveyor Rail 1 As Req'd
Bottom - Opt.
81-8 372170 ------ 660-2-2662 Guard, Nylon - Conveyor Rail Bottom 1 409 & Up
(No slot)
373089 ------ 660-1-2362 Guard, L/H Nylon - Conveyor Rail 1 As Req'd
Bottom - Opt.
81-9 402645 Q236E 660-1-3266 Emitter, Infrared Switch - Opt. 1 "
81-10 402645 Q23SN6R 660-1-3267 Receiver, Infrared Switch - Opt. 1 "
81-11 372170 ------ 660-1-2244 Pad, Front Slope - Conveyor - Opt. 2 "
81-12 372736 ------ 663-2-2356 Mount, Adjustable Lower Finger Guard 1 "
- Opt.
81-13 358417 ------ 663-2-2355 Guard, Adjustable Lower Finger - Opt. 1 "
81-14 350000 ------ 663-4-2666 Plate, Conveyor Bottom Front Cover - Opt. 1 "
81-15 372170 ------ 663-3-2318 Bumper, D Style 6" - White Urethane 2 "
- Opt.
81-16 373423 ------ 663-2-2672 Pad Assy, L/H Side - Opt. 1 "
250697 ------ 660-2-2809 Pad, Nylon - Drivers Side w/slots 1 "
(Narrow) - Opt.
250697 ------ 660-2-2836 Pad, Nylon - Front Left Side 1 "
81-17 244001 ------ 663-2-2684 Guard, V-Groove Caster Narrow R/H - Opt. 1 "
81-18 244001 ------ 663-2-2683 Guard, V-Groove Caster Narrow L/H - Opt. 1 "
CD315 4-2-173
Rev 4
Chapter 4
6
3 5
2
Figure 2-82. Conveyor Bottom Covers - Front (Option)
4-2-174 CD315
Rev 4
Chapter 4
Table 2-82. Conveyor Bottom Covers - Front (Option)

Ind Number Number
82-1 ------ ------ 663-4-2831 Conveyor Weldment - Narrow 1 As Req'd

82-2 358417 ------ 663-2-2355 Guard, Adjustable, Lower Finger 1 "
82-4 372736 ------ 663-4-2342 Cover, Conveyor Front Bottom - Hinged 1 "
82-5 373089 ------ 663-2-2480 Closeout, Narrow Conveyor, L/F Bottom 1 "
82-6 373089 ------ 663-1-2477 Closeout, Narrow Conveyor, Front 1 "
R/H Bottom
CD315 4-2-175
Rev 4
Chapter 4
1 2
5
11 6
10
7
12
8
9
Figure 2-83. Conveyor Rear End - Standard
4-2-176 CD315
Rev 4
Chapter 4
Table 2-83. Conveyor Rear End - Standard

Ind Number Number

83-2 373089 ------ 660-3-0987 Guard, Finger - Rear (Wldmt) 1 As Req'd
83-3 263516 ------ 660-1-0967 Block, Pinch 2 "
83-4 373089 ------ 660-1-1669 Washer, Rubber Bumper 4 "
83-5 372170 ------ 660-2-1694 Bumper, D-Style - Rear Conveyor 2 "
83-7 373317 33891 ¼ Washer, Lock ¼" ID 4 "
83-8 250698 ------ 660-3-0120-1 Bumper, Roll 1 "
83-9 263516 ------ 660-2-0380 Guard, Conveyor Hoop 1 "
83-10 373089 ------ 660-1-1644 Cover, Chain 2 "
83-12 373089 ------ 660-2-1527 Guard, Rear Switch 2 "
CD315 4-2-177
Rev 4
Chapter 4
1 2
12 4
5
11 8 6
7
10
9
13 15
14
Figure 2-84. Conveyor Rear End - Narrow
4-2-178 CD315
Rev 4
Chapter 4
Table 2-84. Conveyor Rear End - Narrow

Ind Number Number
84-1 ------ ------ BLE-4-2618 Conveyor Weldment, Narrow 1 As Req'd

84-2 395898 ------ 660-3-0987 Guard, Finger - Rear Weld Assy 1 "
84-3 263516 ------ 660-1-0967 Block, Pinch 2 "
84-4 373089 ------ 660-1-1669 Washer, Rubber Bumper 4 "
84-5 372170 ------ 660-2-1694 Bumper, D-Style - Rear Conveyor 2 "
84-6 373317 15007 ¼-20 x 1¼ Bolt, Hex Head Ø 4 "
¼-20 x 1¼" Long
84-7 373317 33891 ¼ Washer, Lock ¼" ID 4 "
84-8 373089 ------ 660-2-1692 Plate, Cover - Lower Left Rear 1 "
84-9 372750 ------ 660-2-1693 Plate, Cover - Lower Right Rear 1 "
84-10 373089 ------ 660-1-1644 Cover, Chain 2 "
84-11 395898 ------ 663-4-2788 Crossmember, Conveyor Lift 1 "
Arm - Narrow
84-12 373089 ------ 660-2-1527 Guard, Rear Switch 2 "
84-13 606035 ------ 660-3-1638 Closeout, Rear Roller 2 - Opt. 2 "
84-14 373089 ------ 660-1-1670 Plate, Rear IDLER Cover - Opt. 2 "
84-15 606035 ------ 660-2-2723 Guard, Conveyor Hoop (Narrow) 1 "
- Opt.
------ ------ 660-2-3000-1 Guard, Conveyor Hoop 135° 1 "
(Narrow) - Opt.
CD315 4-2-179
Rev 4
Chapter 4
Figure 2-85. Conveyor Attachments (Rear End) - Narrow
4-2-180 CD315
Rev 4
Chapter 4
Table 2-85. Conveyor Attachments (Rear End) - Narrow

Ind Number Number
85-1 358417 ------ 663-2-2355 Guard, Adjustable Lower Finger 1 As Req'd

85-3 373089 ------ 660-1-1670 Plate, Rear Idler Cover 2 "
85-4 263516 ------ 660-3-1639 Closeout, Left Rear Roller - Conveyor 1 "
85-5 263516 ------ 660-3-1638 Closeout, Right Rear Roller - Conveyor 1 "
85-6 373089 ------ 660-2-1509 Guard, Stop Button (Standard Size) 2 "
358417 ------ 660-2-1517 Guard, Stop Button (Oversize) - Opt. A/R "
85-7 372750 ------ 660-2-1562 Guard, Electric Control Box 1 "
85-8 373089 ------ 660-1-1644 Cover, Chain 1 "
85-9 373089 ------ 663-4-2268 Guard, Finger - Rear Weld Assembly 1 "
85-10 ------ ------ 663-3-2331 Cover, Rear Bottom - Conveyor 1 "
373089 ------ 660-2-1607 Plate, Rear Bottom Cover (CE Opt.) 1 "
85- 373089 ------ 660-1-2470 Cover, Crowder Roller 1 "
Adjustment Access
CD315 4-2-181
Rev 4
Chapter 4
Figure 2-86. Switch Assembly
4-2-182 CD315
Rev 3
Chapter 4
Table 2-86. Switch Assembly

Ind Number Number
86-1 402645 F44G12 660-4-0753-14 Box, Wire Way - Electric 1 Up to 254

86-2 402645 ------ 660-4-0741-7 Block, Terminal 1 "
86-3 ------ ------ 660-4-0741-3 Socket Base 2 "
86-4 ------ ------ 660-4-0741-2 Relay 2 "
CD315 4-2-183
Rev 3
Chapter 4
Figure 2-87. Electric Belt Control Installation
4-2-184 CD315
Rev 3
Chapter 4
Table 2-87. Electric Belt Control Installation

Ind Number Number
87-1 373102 XAP-G39203 660-ND-1438 Box & Cover, Switch - Electric Control 1 Up to 254
87-2 373102 ZB2-BZ101 660-ND-1444 Block, Contact N.O. (FWD and RVS) 2 "
87-3 373082 ------ 660-ND-1445 Block, Contact N.C. (Stop) 1 "
87-4 373102 ZB2-BY2305 660-ND-1442 Nameplate, Forward 2 "
87-5 373102 ZB2-BY2304 660-ND-1441 Nameplate, Stop 2 "
87-6 373102 ZB2-BY2306 660-ND-1443 Nameplate, Reverse 2 "
87-7 373102 ZB2-BP3 660-ND-1439 Push Button, Green Head 2 "
87-8 373102 ZB2-BP4 660-ND-1440 Push Button, Red Head 1 "
87-9 372750 ------ 660-2-0958 Guard, Electric Control Box 1 "
87-10 372750 ------ 660-3-1605 Holster, Front Control 1 "
87-11 402645 ------ 660-ND-1920 Relief, Strain ½ x ¾ NPT (CGB294) 1 "
87-12 372750 ------ 660-1-1686 Hook, Hanger - Electric Control Box 1 "
87-13 372750 ------ 660-2-1685 Hanger, Electric Control Box 1 "
CD315 4-2-185
Rev 3
Chapter 4
Note: This figure shows only one of three locations.
Figure 2-88. Conveyor Control Assembly (S/N 254 thru 389)
4-2-186 CD315
Rev 3
Chapter 4
Table 2-88. Conveyor Control Assembly (S/N 254 thru 389)

Ind Number Number
88-1 358417 ------ 660-2-1562 Guard, Electric Control Box 3 254-389

358417 ------ 660-2-1562 Guard, Electric Control Box - Opt 2 As Req'd
88-2 373102 ZB2-BP4 660-ND-1440 Push Button - Red Head 3 254-389
88-3 373102 ZB2-BP3 660-ND-1439 Push Button - Green Head 6 "
88-4 373102 ZB2-BY2306 660-ND-1443 Nameplate, Reverse 3 "
88-5 373102 ZB2-BY2305 660-ND-1442 Nameplate, Forward 3 "
88-6 373102 ZB2-BY2304 660-ND-1441 Nameplate, Stop 3 "
88-7 373102 XAP-G39203 660-ND-1438 Box and Cover, Switch - Electric 3 "
Control, 3-Hole
88-8 373102 ZB2-BZ101 660-ND-1444 Block, Contact - N.O. (FWD & RVS) 9 "
88-9 402645 ------ 660-ND-1920 Relief, Strain ½ x ¾ NPT (CGB294) 3 "
------ ------ ------ Plug, ¾" - Opt. 2 As Req'd
CD315 4-2-187
Rev 3
Chapter 4
FRONT 8
4
9
11
10
4
1
2
5
6
7
3
REAR
Location of Second
Control Box
Figure 2-89. Conveyor Control Assembly (S/N 390 and Up)
4-2-188 CD315
Rev 4
Chapter 4
Table 2-89. Conveyor Control Assembly (S/N 390 and Up)

Ind Number Number
89-1 358417 ------ 660-2-1562 Guard, Electric Control Box 2 390 & Up
89-2 373102 ZB2-BP4 660-ND-1440 Push Button - Red Head 2 "
89-3 373102 ZB2-BP3 660-ND-1439 Push Button - Green Head 4 "
89-4 372209 ------ T-A7 Decal, "Forward-Neutral-Reverse" 2 "
89-5 373102 XAP-G39203 660-ND-1438 Box and Cover, Switch - 2 "
Electric Control, 3-Hole
89-6 373102 ZB2-BZ101 660-ND-1444 Block, Contact - NO (FWD & RVS) 4 "
89-7 ------ ------ ¾ Plug, ¾" 1 "
89-8 373085 ------ 660-2-2841 Control Assembly, Recessed - L/H 1 "
89-9 373085 ------ 660-2-2839 Control Assembly, Recessed - R/H 1 "
89-10 372209 ------ T-A6 Decal, "Reverse-Neutral-Forward" 1 "
89- 373102 ZB2-BY2306 660-ND-1443 Nameplate, Reverse 2 "
89- 373102 ZB2-BY2305 660-ND-1442 Nameplate, Forward 2 "
89- 373102 ZB2-BY2304 660-ND-1441 Nameplate, Stop 2 "
89-11 293912 ------ 663-2-2351 Guard, Conveyor Control Bracket, R/H 1 "
CD315 4-2-189
Rev 4
Chapter 4
11
10
4 1
9 FRONT
7
6
5
3
2 4
1
REAR
Figure 2-90. Emergency Stop Button Installation
4-2-190 CD315
Rev 4
Chapter 4
Table 2-90. Emergency Stop Button Installation

Ind Number Number
90-1 373102 ZB2-B554 660-ND-1676 Button, Locking - Red 4 As Req'd

373102 ZB2-BC4 660-1-2425 Switch, Momentary Stop - 4 "
Narrow Conveyor
90-2 373089 ------ 660-2-1509 Guard, Stop Button (Standard Size) 2 "
358417 ------ 660-2-1517 Guard, Stop Button (Oversize) - Opt. 2 "
90-3 358417 ------ 660-2-2855 Mount, Top E-Stop Switch 2 "
90-4 373082 ------ 660-ND-1445 Block, Contact - NC (Stop) 4 "
373102 ZB2-BZ101 660-ND-1444 Block, Contact - NO 4 "
90-5 373317 27283 6-32 x ¼ Screw, Slotted Pan Head Ø 8 "
6-32 x ¼" Long
90-6 373317 ------ 0123490 Washer, Lock - Regular #6 8 "
90-7 358417 ------ 660-2-2854 Mount, E-Stop Switch 2 "
90-8 281660 ------ 660-2-2432 Harness, Wiring, Conveyor E-Stop 1 "
90-9 ------ ------ ------ Grommet - BG901 4 "
90-10 372750 ------ 660-2-2845-2 Mount, E-Stop Switch 2 "
90-11 395898 ------ 663-1-2341 Cup, Recessed - Safety Stop Button 2 "
CD315 4-2-191
Rev 4
Chapter 4
Figure 2-91. Conveyor Drive Motor - Standard Conveyor (Up to S/N 185)
4-2-192 CD315
Rev 3
Chapter 4
Table 2-91. Conveyor Drive Motor - Standard Conveyor (Up to S/N 185)

Ind Number Number
91-1 373117 BB4-4001 BLE-1-1041 Motor, Conveyor Drive 1 101 & Up

91-2 241762 X6-62006-551-Z0DD BLE-1-1003 Brake, Electric 1 Up to 185
(72/80V)
91-3 ------ ------ BLE-1-1005 Reducer, Belt Drive Speed 1 "
91-4 372739 50BS12 BLE-1-1012 Sprocket, Small, Jackshaft 2 101 & Up
91-5 267599 87466 660-6-0004-42 Keystock, ¼" x 12" 4 Up to 185
91-6 385900 ------ 660-6-0004-19 Link, Master 2 101 & Up
91-7 372739 50BS24F x 1-1/8 BLE-1-1013 Sprocket, Large, Jackshaft 2 "
91-8 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller 2 "
91-9 373089 ------ BLE-1-1015 Jackshaft 1 "
91-10 372739 FAFN VAS 1-1/8 BLE-1-1014 Bearing, Pillow Block, Jackshaft 2 "
91-11 403166 ------ 660-6-0004-17 Link, Chain ½ - Conveyor Drive 1 "
CD315 4-2-193
Rev 3
Chapter 4
Figure 2-92. Conveyor Drive Motor - Standard Conveyor (S/N 185 and Up)
4-2-194 CD315
Rev 3
Chapter 4
Table 2-92. Conveyor Drive Motor - Standard Conveyor (S/N 185 and Up)

Ind Number Number
92-1 373117 BB4-4001 BLE-1-1041 Motor, Conveyor Drive 1 101 & Up

92-2 403166 ------ BLE-1-2527 Brake, Electric Belt Drive - 80V 1 185 & Up
372739 105-6746-05- BLE-1-2528 Brake, Electric Belt Drive - 48V (Opt.) 1 As Req'd
WF-48VDC
92-3 402708 ------ BLE-1-1003L Reducer, Belt Drive Speed, L/S 2 185 & Up
92-4 372739 50BS12 BLE-1-1012 Sprocket, Small, Jackshaft 1 101 & Up
92-5 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller - 3¼' Long 1 "
92-6 440230 ------ 660-4-0008-15 Keystock 3 185 & Up
92-7 372739 50BS24F x 1-1/8 BLE-1-1013 Sprocket, Large, Jackshaft 1 101 & Up
92-9 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
92-10 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
92-11 373089 ------ BLE-1-1015 Jackshaft 1 "
92-13 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller - 4' Long 1 "
92-14 403166 50BS24 x 1.25 660-6-0004-14 Sprocket, Drive Roller 1 185 & Up
92-15 373386 ------ 660-1-0144 Roller, Drive, with Lagging 1 101 & Up
92-16 385900 ------ 660-6-0004-19 Link, Master 2 "
92-17 403166 ------ 660-6-0004-17 Link, Chain ½ - Conveyor Drive 2 "
CD315 4-2-195
Rev 3
Chapter 4
18
17
5 13
16
17 18
8
6 A
11
12 6 A 5
4 6
13 8 3
A 4 7
6 9 2
14 10
1
15
Figure 2-93. Conveyor Drive Motor - Narrow Conveyor (Up to S/N 510)
4-2-196 CD315
Rev 3
Chapter 4
Table 2-93. Conveyor Drive Motor - Narrow Conveyor (Up to S/N 510)

Ind Number Number
93-1 373117 BB4-4001 BLE-1-1041 Motor, Conveyor Drive 1 Up to 510
93-2 403166 ------ BLE-1-2527 Brake, Electric Belt Drive - 80V 1 "
93-3 402708 ------ BLE-1-1003R Reducer, Belt Drive Speed, R/S 1 "
93-4 372739 50BS12 BLE-1-1012 Sprocket, Small, Jackshaft 1 "
93-5 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller - 3¼' Long 1 "
93-6 358417 ------ BLE-1-2558 Key, Drive Shaft 4 "
93-7 372739 50BS24F x 1-1/8 BLE-1-1013 Sprocket, Large, Jackshaft 1 "
93-9 373317 33859 3/8 Washer, Flat 3/8" ID 4 "
93-10 373317 33893 3/8 Washer, Lock 3/8" ID 4 "
93-11 373089 ------ BLE-1-1015 Jackshaft 1 "
93-12 373317 15109 3/8-16 x 1½ Bolt, Hex Head Ø 4 "
3/8-16 x 1½" Long
93-13 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller - 4' Long 1 "
93-14 403166 50BS24 x 1.25 660-6-0004-14 Sprocket, Drive Roller 1 "
93-15 373386 ------ 660-1-0144 Roller, Drive, with Lagging 1 "
93-16 440230 ------ BLE-4-1074 Mount, Jackshaft - Narrow Conv. 1 "
93-17 403166 ------ 660-6-0004-17 Chain, ½-Link - Conveyor Drive 2 "
93-18 385900 ------ 660-6-0004-19 Link, Master 2 "
CD315 4-2-197
Rev 4
Chapter 4
19 A
18
18 19
8
16
9
15
7
14 6 4
17
A 13
11 3
4 5
12
1 2
10
Figure 2-94. Conveyor Drive Motor - Narrow Conveyor (S/N 510 and Up)
4-2-198 CD315
Rev 4
Chapter 4
Table 2-94. Conveyor Drive Motor - Narrow Conveyor (S/N 510 and Up)

Ind Number Number
94-1 372739 MLHRF200R4B BLE-1-2652 Motor, Hydraulic Belt Drive 1 510 & Up
94-2 373317 37268 ½-13 Nut, Top Lock Hex ½-13 4 "
94-3 426744 ----- 08-08-070601 Fitting, Straight 8MJ-BLKHD-UN 1 "
94-4 426744 ----- 08-08-070321 Fitting, 45° 8MJ-8FJX45 2 "
94-5 426744 ----- 660-1-1254 Hose, 37" Pump Pressure Swivel 2 "
94-6 426744 ----- 08-08-070101 Fitting, Straight 8MJ-8MJ 1 "
94-7 372739 50B12 660-1-0020 Sprocket, Hydraulic Motor 1 "
94-9 263516 ----- 660-2-0935 Plate, Mounting 1 "
94-10 373338 ----- 663-1-0144 Roller, Drive 1 "
94-11 358417 ------ BLE-1-2558 Key, Drive Shaft 1 "
94-12 372739 50B27F-1-1/4 660-1-2365 Sprocket, 27-Tooth, Drive Roller 1 "
94-13 373317 33861 ½ Washer, Flat ½" 1 "
94-14 372739 ------ ------ Nut, Castellated (Incl. w/ Motor) 1 "
94-15 373317 ------ ½-13 x 1¾ Bolt, Counter-Sink Ø 1 "
½-13 x 1½" Long
94-16 373317 65080 1/8 x 2 Pin, Cotter Ø 1/8 x 2 4 "
94-17 372739 Diamond #50 660-6-0004-18 Chain, Drive Roller - 4.125' Long 1 "
94-18 403166 ------ 660-6-0004-17 Chain, ½-Link - Conveyor Drive 1 "
94-19 385900 ------ 660-6-0004-19 Link, Master 1 "
CD315 4-2-199
Rev 4
Chapter 4
Figure 2-95. Conveyor Belt and Rollers - Standard
4-2-200 CD315
Rev 3
Chapter 4
Table 2-95. Conveyor Belt and Rollers - Standard

Ind Number Number

95-2 403166 ------ 660-6-0004-16 Bearing, Flange 2 101 & Up
95-3 373386 ------ 660-1-0144 Roller, Drive w/Lagging 1 "
95-4 403166 ------ 660-1-0338 Bearing, Crowder Roller 4 "
95-5 263516 ------ 660-1-0211 Roller, Crowder 2 "
95-6 403166 197L12C-22 660-6-0004-22 Roller, 22" 57 "
95-7 403166 ------ 660-1-2409 Roller, 22" - Heavy Duty 2 "
95-8 403166 ------ 660-6-0004-15 Bearing, Take-Up 2 "
95-9 373386 ------ 660-1-0145 Roller, Idler 1 "
95-10 241766 ------ 660-6-0004-27 Pin, Roll 2 "
95-11 373317 36116 ¾-10 Nut, Hex ¾-10 8 "
95-12 373317 W1525189 ¾-10 x 9 Stud, Threaded Ø ¾-10 x 9" Long 2 "
95-13 263516 ------ 660-1-0967 Block, Pinch 2 "
95-14 373089 ------ 660-3-0987 Guard, Finger - Rear Wldmt Assembly 1 "
95-15 380486 ------ 660-6-0004-23 Belt, Conveyor - 24" x 588" 1 "
380486 ------ 660-1-2557 Belt, Conveyor - GA Duck - Opt. 1 As Req'd
95-16 385900 20-24 660-6-0004-24 Alligator Lacing Kit 1 101 & Up
CD315 4-2-201
Rev 4
Chapter 4
17
16
2 18
3 17
2 1 15
6
6
4 18
5 14
4 13
6
10
8
4 12 9
5
11
Figure 2-96. Conveyor Belt Rollers - Narrow
4-2-202 CD315
Rev 3
Chapter 4
Table 2-96. Conveyor Belt Rollers - Narrow

Ind Number Number
96-1 ------ ------ BLE-4-2618 Conveyor Weldment - Narrow 1 As Req'd

96-2 403166 ------ 660-6-0004-16 Bearing, Flange 2 "
96-3 373338 ------ 663-1-0144 Roller, Drive - Narrow Conveyor 1 "
96-4 403166 ------ 663-1-0338 Bearing, Crowder Roller 4 "
96-5 263516 ------ 660-1-0211 Roller, Crowder 2 "
96-6 403166 197L12C-22 660-6-0004-22 Roller, 22" 57 "
96-7 403166 ------ 660-1-2409 Roller, 22" Heavy Duty 2 "
96-8 403166 ------ 660-6-0004-15 Bearing, Take-Up 2 "
96-9 373386 ------ 660-1-0145 Roller, Idler 1 "
96-10 241766 ------ 660-6-0004-27 Pin, Roll 2 "
96-11 373317 36116 ¾-10 Nut, Hex ¾-10 8 "
96-12 373317 W1525189 ¾-10 x 9 Stud, Threaded - ¾-10 x 9" Long 2 "
96-13 263516 ------ 660-1-0967 Block, Pinch 2 "
96-14 373089 ------ 660-3-0987 Guard, Finger - Rear (Wldmt) 1 "
96-15 380486 ------ 660-6-0004-23 Belt, Conveyor - 24" x 588" 1 "
1178565 ------ 660-ND-1005 Belt, Conveyor, Goodyear Wedge 1 "
Grip
96-16 385900 20-24 660-6-0004-24 Alligator Lacing Kit 1 "
96-18 403166 ------ 660-6-0004-20 Roller, 24" 2 "
CD315 4-2-203
Rev 4
Chapter 4
Figure 2-97. Side Rail Assembly
4-2-204 CD315
Rev 3
Chapter 4
Table 2-97. Side Rail Assembly

Ind Number Number

97-2 395898 ------ 660-2-1305L Bracket, Pivot Assembly Left-Side Rail 4 185 & Up
97-3 395898 ------ 660-2-0814 Bracket, Handrail Upright Spring 2 "
97-4 373317 ------ ½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 4 "
97-5 262531 ------ 660-1-0263 Arm, Pivot 3 Up to 543
358417 ------ 660-1-3048 Arm, Pivot (Wldmt) 3 543 & Up
97-6 350000 ------ 660-1-0271 Pin, Pivot - Short 3 185 & Up
97-7 395898 ------ 660-4-0254 Handrail Weldment - L/H Standard 1 "
97-8 373089 ------ 660-1-0275 Arm, Spring with Tab 1 "
97-9 369403 ------ 660-4-0137-9 Spring, Extension 1 "
97-10 373317 ------ 660-1-2555 Pin, Pivot - Long Handrail 1 "
97-11 266523 D8-23R 660-4-0137-12 Pin, Detent, COM 1 "
97-12 373317 33861 ½ Washer, Flat ½" ID 4 "
97-13 373317 ------ ½-13 Nut, Jam Nylock ½-13 4 "
CD315 4-2-205
Rev 4
Chapter 4
Figure 2-98. Hand Rail Assembly (Up to S/N 185)
4-2-206 CD315
Rev 3
Chapter 4
Table 2-98. Hand Rail Assembly (Up to S/N 185)

Ind Number Number
98-1 ------ ------ 660-4-0138 Handrail Assembly - R/H 32" 1 Up to 185

------ ------ 660-4-0909 Handrail Assembly - L/H 32" 1 "
98-2 ------ ------ 660-4-0300 Handrail Weldment - R/H Standard 1 "
------ ------ 660-4-0969 Handrail Weldment - L/H Standard 1 "
98-3 372750 ------ 660-2-0265 Arm, Handrail Pivot, with Tab 3 101 & Up
98-4 373089 ------ 660-2-0266 Arm, Handrail Pivot 1 "
98-5 350000 ------ 660-1-0271 Pin, Pivot - Short 4 "
98-6 373317 ------ ¼-20 Screw, Set 8 Up to 185
98-7 373317 ------ 660-4-0137-11 Cable, Aircraft 2 "
98-8 266523 D8-23R 660-4-0137-12 Pin, Detent 2 101 & Up
98-9 369403 ------ 660-4-0137-9 Spring, Extension 3 Up to 185
98-10 350000 ------ 660-1-0271 Pin, Pivot - Short 4 101 & Up
CD315 4-2-207
Rev 3
Chapter 4
11
12
10
1
9 2
8
3
7
Figure 2-99. Hand Rail Assembly (S/N 185 and Up)
4-2-208 CD315
Rev 3
Chapter 4
Table 2-99. Hand Rail Assembly (S/N 185 and Up)

Ind Number Number

99-2 395898 ------ 660-2-1305R Bracket, Pivot Assembly R/Side Rail 4 185 & Up
99-3 395898 ------ 660-2-0814 Bracket, Handrail Upright Spring 3 "
99-4 373317 33861 ½ Washer, Flat ½" ID 4 "
99-5 373317 ------ ½-13 Nut, Jam Nylock ½-13 4 "
99-6 373317 ------ ½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 4 "
99-7 372750 ------ 660-2-0265 Arm, Handrail Pivot, with Tab 3 "
99-8 266523 D8-23R 660-4-0137-12 Pin, Detent 1 "
99-9 373317 ------ 660-1-2555 Pin, Pivot - Long Handrail 1 "
99-10 350000 ------ 660-1-0271 Pin, Pivot - Short 3 "
99-11 395898 ------ 660-4-0300 Handrail Weldment - R/H Standard 1 As Req'd
440230 ------ 660-4-3007 Handrail Weldment - R/H 1 "
99-12 373089 ------ 660-2-0266 Arm, Handrail Pivot 1 185 & Up
CD315 4-2-209
Rev 4
Chapter 4
Figure 2-100. Hand Rail Assy - Locking w/Telescoping Handrail Extender
4-2-210 CD315
Rev 4
Chapter 4
Table 2-100. Hand Rail Assy - Locking w/Telescoping Handrail Extender
Fig & Vendor Part

Code Tug Part Number Description Qty Effective
Ind Number
100-1 349373 ------ 660-4-2352 Handrail Weldment, R/H - 1 As Req'd

UAL Spec.
100-2 350000 ------ 660-1-0271 Pin, Pivot, Short 4 "
100-3 278878 81159S 660-ND-2216 Spring, 7" Extension 3 "
100-4 372750 ------ 660-2-0265 Arm, Handrail Pivot, w/ Tab 3 "
100-5 440230 ------ 660-2-0266 Arm, Handrail Pivot 1 "
100-6 358417 ------ 660-3-0462 Collar, R/H Handrail Lock - 1 "
UAL Spec.
100-7 372750 ------ 660-1-0472 Plate, Handrail Lock Collar - UAL 1 "
100-8 372750 ------ 660-2-0460 Handle Weldment, Lock - UAL 1 "
100-9 372750 ------ 660-1-2349 Latch, Handrail Safety 1 "
100-10 358417 ------ 660-2-0454 Link, Handrail - UAL Spec. 1 "
100-11 358417 ------ 660-2-2369 Housing, R/H Handrail 1 "
Positive Lock
100-12 369176 1 x 1/16 660-1-2368 Tube, Stainless Telescoping 1 "
100-13 357447 64.2 660-1-2388 Bumper, Telescoping Tube 1 "
100-14 373089 ------ 660-4-0600-5 Bumper, COM 3 "
100-15 278878 ------ 660-1-2389 Spring, Handrail Lock Handle 1 "
100-16 372750 ------ 660-1-2390 Spacer, Conveyor Rail to Clevis 1 "
100-17 373090 C100S 660-1-2387 Collar, Telescoping Tube Set 1 "
100-18 372750 ------ 660-2-2383 Arm, Handrail Rear Slider Pivot 1 "
100-19 373089 ------ 660-2-2357 Support, Handrail Rear Down 1 "
100-20 254934 ------ 663-1-2274 Bumper, Protective Handle 1 "
100-21 ------ ------ 660-1-2224 Spacer, Handrail 3 "
100-22 372736 ------ 660-1-2391 Spacer, Inner Clevis 1 "
100-23 452448 D3TZ-2857A TPG-D3TZ-2857A Clevis, Parking Brake 1 "
CD315 4-2-211
Rev 4
Chapter 4
Figure 2-101. Rapid Charge Assembly (Optional)
4-2-212 CD315
Rev 3
Chapter 4
Table 2-101. Rapid Charge Assembly (Optional)

Ind Number Number
101-1 373317 15003 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 5 As Req'd
101-2 373317 33891 ¼ Washer, Lock ¼" ID 5 "
101-3 373089 ------ BLE-1-2583 Bar, Cover Clamp 2 "
101-5 405491 ------ BLE-2-2578 Bumper, Rear - Electric Quick Charge 1 "
1178565 ------ BLE-2-1071 Bumper, Rear w/Charge Fort 1 "
101-6 373089 ------ T6-4103-236 Cover, Hole - Radiator Shroud 1 "
101-7 373317 ------ 10/32 x ½ Screw, Phillips Head 10/32 x ½" Long 2 "
101-8 373317 ------ 10/32 Washer, Flat 10/32 2 "
101-9 373317 ------ 5/16 Screw, Socket Head 5/16 x 1.25" Long 4 "
101-10 373317 ------ 10/32 Nut, Lock 10/32 2 "
101-11 373089 ------ BLE-2-2587 Mount, Receptacle & Switch - Wldmt 1 "
101-12 373089 ------ BLE-1-2585 Spacer, Receptacle Stand-off 4 "
101-13 372170 ------ BLE-1-2584 Cover, Electrical Components 1 "
101-14 402645 ------ 42-100-801 Switch, Micro 1 "
101-15 ------ ------ BLE-1-2586 Housing, Burton Receptacle (Altered) 1 "
101-16 373317 37260 ¼-20 Nut, Top Lock Hex ¼-20 4 "
101-17 373317 33857 ¼ Washer, Flat ¼" ID 4 "
101-18 249341 ------ BLE-1-2577 Receptacle, Rapid Charge 1 "
CD315 4-2-213
Rev 4
Chapter 4
4
6
7
8 3
2
10
1
9
Figure 2-102. Quick Charge Assembly - Top Installation (Optional)
4-2-214 CD315
Rev 4
Chapter 4
Table 2-102. Quick Charge Assembly - Top Installation (Optional)

Ind Number Number
102-1 395898 ------ BLE-0002-5 Angle, Enclosure Mounting 2 As Req'd

102-3 395898 ------ BLE-0003 Housing, Receptacle Mount 1 "
102-4 395898 ------ BLE-0002-3 Lid, Enclosure 1 "
102-5 395898 ------ BLE-0001 Enclosure, Receptacle - Rapid Charge 1 "
102-6 ------ ------ BLE-0005 Receptacle, Machined - Rapid Charge 1 "
102-7 373317 ------ ¼-28 x 1 Screw, Hex Head Machine Ø 4 "
¼-28 x 1" Long
102-8 373317 33891 ¼ Washer, Lock ¼" ID 1 "
102-9 281660 ------ BLE-1-2601 Cable, Negative - Rapid Charge 1 "
102-10 281660 ------ BLE-1-2600 Cable, Positive - Rapid Charge 1 "
CD315 4-2-215
Rev 4
Chapter 4
15 14 9
13 7
16
12
11 4
10
3 1
2
6 2
17
18
5
Figure 2-103. Rear Charge Port (Option)
4-2-216 CD315
Rev 4
Chapter 4
Table 2-103. Rear Charge Port (Option)

Ind Number Number
103-1 440230 ------ BLE-4-2635 Bumper, Rear 1 As Req'd

103-2 373317 37337 ¼-20 Nut, Flange ¼-20 6 "
103-3 402645 IA23S BLE-1-2675 Sensor, Fiber Optic 2 "
103-4 402645 Q45VR3F BLE-1-2676 Controller, Fiber Optic 1 "
103-5 373317 0127286 ¼ P-Clamp, ¼'ID 2 "
103-7 440230 ------ 440E-99017 Box, Rapid Charge Connector Wldmt 1 "
103-8 1136099 ------ BLE-1-2682 Connector, SBX 350 Black 1 "
103-10 369176 ------ BLE-3-1068 Bracket, Remote Charge Connection 1 "
103-11 402645 ------ 660-1-2252 Nut, Conduit ½ NPT 1 "
103-12 402645 5302 BLE-1-1502 Ring, Sealing ½ NPT 1 "
103-13 402645 2521 660-ND-2215 Relief, Strain 3/8 x ½ NPT (CGB116) 1 "
103-14 281660 ------ BLE-1-2601 Cable, Negative - Rapid Charge 1 "
103-15 402645 SEC100B MX4-10251 Relief, Strain 4/0 2 "
103-16 281660 ------ BLE-1-2600 Cable, Positive - Rapid Charge 1 "
103-17 373082 4100B3-1/8C MG-1-320 Trim-Lok, 7.5" Long 1 "
103-18 372750 ------ BLE-2-2684 Closeout, Rear Charge Port 1 "
CD315 4-2-217
Rev 4
Chapter 4
5
4
3
Figure 2-104. Remote Charger Port Assembly (Optional)
4-2-218 CD315
Rev 4
Chapter 4
Table 2-104. Remote Charger Port Assembly (Optional)

Ind Number Number
104-1 369176 ------ BLE-2-1071 Bumper, Rear with Charger Port 1 As Req'd
104-2 402645 ------ 42-100-801 Switch, Micro 1 "
104-3 402645 ------ 660-ND-2215 Relief, Strain 3/8 x ½ NPT (CGB116) 1 "
104-4 373089 ------ MH-2-606 Bracket, Park Brake App. Light Sw. 1 "
104-5 382204 ------ BLE-1-2533 Connector, Battery SB x 350 Black 1 "
1136099 ------ BLE-1-2682 Connector, SBX 350 Black 1 "
104-6 373089 ------ T6-4103-236 Cover, Hole - Radiator Shroud 1 399-402
369176 ------ BLE-1-1070 Door, Charger Port 1 403 & Up
372750 ------ BLE-2-2684 Closeout, Rear Charge Port 1 "
104-7 372209 ------ BLE-1-2665 Decal, "Charge Port" 1 552 & Up
CD315 4-2-219
Rev 4
Chapter 4
1
3
2
Figure 2-105. Back Up Alarm
4-2-220 CD315
Rev 4
Chapter 4
Table 2-105. Back Up Alarm

Ind Number Number
105-1 440230 ----- BLE-4-2635 Bumper, Rear 1 As Req'd

105-2 440230 ----- 660-1-1069 Gusset, Right Front Frame 1 "
105-3 239618 Model 230 T6-1300-181 Alarm, Back-Up - 12VDC 1 "
CD315 4-2-221
Rev 4
Chapter 4
4-2-222 CD315
Rev 3
Chapter 4
Figure 2-54. Conveyor Switch Harness (Left Front)
CD315 4-2-223
Rev 4
Chapter 4
Figure 2-55. Conveyor Switch Harness (Right Front)
4-2-224 CD315
Rev 4
Chapter 4
SECTION 3: NUMERICAL INDEX
Tug Part Number Description Fig & Ind#
------ Adapter, Straight Reducing - Male 38-30

------ Bag, Desiccant 19-20
------ Bearing, Radial Ball 55-14
------ Bearing, Roller 55-24
------ BMID, 80V, GSE (Part of MX4-10279 & 80) 11-16
------ Bolt, Anchor 35-19
------ Bolt, Drive Gear 58-23
------ Bolt, Flange 35-3
------ Bolt, Hex Head Ø 8mm 67-1h
------ Bracket 67-1c
------ Bracket, L 67-1g
------ Bushing, Sleeve 55-21
------ Cable, Battery to Connector (Negative) 11-13
------ Cable, Battery to Connector (Positive) 11-12
------ Capacitor 59-6
------ Clamp, Hose 29-17
------ Clamp, Hose #72 49-7
------ Clamp, Hose #72 50-7
------ Clamp, P Vinyl - COV0709Z 29-8
------ Connector, 14-Pin Electrical 63-37
------ Contactor, Bypass 65-15
------ Contactor, Conveyor Traction #1 65-3
------ Contactor, Forward 65-5
------ Contactor, Hydraulic Pump 65-9
CD315 4-3-1
Rev 4
Chapter 4
------ Contactor, Line 65-12

------ Contactor, Regen 65-13
------ Contactor, Reverse 65-8
------ Controller 66-7
------ Controller, Sevcon PowerpaK 65-7
------ Cover, Bearing 55-15
------ Cover, Housing 55-29
------ Diode, Long Lead 59-4
------ Elbow, 45° 6MJ-6MP45 46-9
------ Elbow, 90° 39-5
------ Elbow, 90° 40-5
------ Elbow, 90° 12MP-8MJ90 40-36
------ Elbow, 90° JIC½-MO-Ring-3/8 45-3
------ Eyebolt 55-3
------ Fitting, Quick Disconnect 42-17
------ Fitting, Straight ½ MJICO-Ring-3/8 45-5
------ Fitting, Straight 3/8-¼ 44-10
------ Fuse, Belt Motor, 50 AMP 65-11
------ Fuse, Traction Motor, 425AMP 65-10
------ Gasket 55-5
------ Grommet - BG901 90-9
------ Holder, Fuse 63-5
------ Horn w/ Terminal Application 67-1a
------ Housing, Gear 55-1
------ Installation Kit, BMID (Part of MX4-10279 & 80) 11-17
------ Jumper Wire w/Connections 67-1b
------ Key, Parallel 55-11
------ Lever, L/H 35-5
4-3-2 CD315
Rev 4
Chapter 4
------ Lever, R/H 35-5

------ Liner, Fender Well - Front 12" x 24" 5-21
------ Liner, Fender Well - Front Left 18.5" x 12" 4-3
------ Liner, Fender Well - Middle Left 20" x 30" 4-9
------ Liner, Fender Well - Rear 20" x 24" 4-19
------ Link, Connecting - Cylinder 35-17
------ Module, Burden Resistor 63-15
------ Mount, Contactor, Large 65-4
------ Mount, Contactor, Small 65-2
------ Nut, Castellated (Incl. w/ Motor) 94-14
------ Nut, Hex 55-8
------ Nut, Lock 35-21
------ Nut, Lock - 8mm ID 67-1d
------ O-Ring 55-16
------ Panel, Controller w/ 24V Coils 80V 64-1
------ Panel, Controller w/ 24V Coils, 80V 66-1
------ Panel, Sevcon PowerpaK 660E 63-1
------ Pinion 55-10
------ Plate Assembly, L/H 35-4
------ Plate Assembly, R/H 35-4
------ Plate, Cam L/H 35-20
------ Plate, Cam R/H 35-20
------ Plug / Breather 55-2
------ Plug, ¾" - Opt. 88-9
------ Post, Power 66-9
------ Rectifier, Silicone Controlled "SCR (A)" 59-1
------ Rectifier, Silicone Controlled "SCR (B)" 59-2
------ Rectifier, Silicone Controlled "SCR (C)" 59-3
------ Relay, Harness to Horn 67-5
------ Ring, Snap 55-9
------ Ring, Snap 55-19
------ Ring, Snap 55-23
CD315 4-3-3
Rev 4
Chapter 4
------ Ring, Snap 55-26

------ Screw, Hex Head 55-18
------ Screw, Locking / Stud 55-6
------ Seal, Shaft 55-17
------ Seal, Shaft 55-27
------ Seal, Shaft 55-31
------ Sealing Compound 55-4
------ Shaft, Input 55-28
------ Shaft, Output 55-20
------ Strip, Terminal TB-2 63-8
------ Switch, Thermal 59-5
------ Switch, Valve 46-32
------ Tee, ½MJIC-½MJIC-½FJIC Swivel 45-10
------ Tee, Female Pipe 28-10
------ Thermistor, 2.5" (Part of MX4-10280) 11-15
------ Washer, Flat 35-18
------ Washer, Ground Terminal 67-1f
------ Washer, Lock 55-7
------ Washer, Star 67-1e
------ Wheel, Helical Gear 55-12
-------- Clamp, P- (Vinyl - COVO59Z1) 29-12
1 Washer, Flat 1" ID 74-3
5/32 Nut, Lock 5/32" ID 63-7
5/32 Nut, Lock 5/32" ID 64-7
5/32 Nut, Lock 5/32" ID - Opt. 63-7
5/32 Washer, Lock 5/32" ID 63-18
5/32 Washer, Lock 5/32" ID 64-17
10/32 Nut, Lock - Nylon Insert 29-11
4-3-4 CD315
Rev 4
Chapter 4

10/32 Nut, Lock 10/32 101-10
10/32 Washer, Flat 10/32 101-8
1-8 Nut, Lock - Nylon Insert 49-4
1-8 Nut, Top Lock Hex 1-8 72-2
1/8 Zerk Ø 1/8" Pipe 90° 49-2
1/8 Zerk Ø 1/8" Pipe 90° 50-2
1/8 Zerk Ø 1/8" Pipe 90° 51-3
3/8 Hose, 3/8" ID x 2" Long 49-19
3/8 Hose, 3/8" ID x 2" Long 50-19
3/8 Washer, Flat 3/8" ID 4-12
CD315 4-3-5
Rev 4
Chapter 4
3/8 Washer, Lock 3/8" ID 21-2

3/16 Washer, Flat USS 3/16" ID 29-10
5/8 Washer, Flat 5/8" 19-15
5/16 Screw, Socket Head 5/16 x 1.25" Long 101-9
5/16 Washer, Flat 5/16" 21-7
5/16 Washer, Flat 5/16" ID 39-3
5/16 Washer, Flat 5/16" ID 40-3
5/16 Washer, Flat 5/16" ID 79-16
5/16 Washer, Flat 5/16" ID 80-5
9/16 Washer, Flat 9/16" ID 37-4
9/16 Washer, Flat 9/16" ID 53-17
9/16 Washer, Flat 9/16" ID 54-17
5/8-11 Nut, Top Lock Hex 5/8-11 19-15
5/8-11 Nut, Top Lock Hex 5/8-11 53-18
5/8-11 Nut, Top Lock Hex 5/8-11 54-18
3/8-16 Nut, Flange - LK REG 3/8-16 4-31
3/8-16 Nut, Flange - LK REG 3/8-16 - Opt. 5-24
3/8-16 Nut, Top Lock Hex 3/8 -16 63-22
3/8-16 Nut, Top Lock Hex 3/8-16 4-16
3/8-16 Nut, Top Lock Hex 3/8-16 4-18
3/8-16 Nut, Top Lock Hex 3/8-16 5-11
3/8-16 Nut, Top Lock Hex 3/8-16 5-22
4-3-6 CD315
Rev 4
Chapter 4
3/8-16 Nut, Top Lock Hex 3/8-16 7-6

3/8-16 Nut, Top Lock Hex 3/8-16 21-1
3/8-16 Nut, Top Lock Hex 3/8-16 21-20
3/8-16 Nut, Top Lock Hex 3/8-16 25-6
3/8-16 Nut, Top Lock Hex 3/8-16 39-34
3/8-16 Nut, Top Lock Hex 3/8-16 40-34
3/8-16 Nut, Top Lock Hex 3/8-16 40-21
3/8-16 Nut, Top Lock Hex 3/8-16 41-21
3/8-16 Nut, Top Lock Hex 3/8-16 42-18
3/8-16 Nut, Top Lock Hex 3/8-16 43-22
3/8-16 Nut, Top Lock Hex 3/8-16 44-2
3/8-16 Nut, Top Lock Hex 3/8-16 45-31
3/8-16 Nut, Top Lock Hex 3/8-16 53-10
3/8-16 Nut, Top Lock Hex 3/8-16 54-10
3/8-16 Nut, Top Lock Hex 3/8-16 64-21
5/8-18 Nut, Top Lock Hex 5/8-18 74-11
5/16-18 Nut, Flange Lock Hex 5/16-18 9-2
5/16-18 Nut, Top Lock Hex 5/16-18 21-5
5/16-18 Nut, Top Lock Hex 5/16-18 22-12
5/16-18 Nut, Top Lock Hex 5/16-18 39-18
5/16-18 Nut, Top Lock Hex 5/16-18 40-18
5/16-18 Nut, Top Lock Hex 5/16-18 79-17
5/16-18 Nut, Top Lock Hex 5/16-18 80-4
3/8-24 Nut, Hex 3/8-24 21-24
3/8-24 Nut, Hex Jam 3/8-24 27-9
67798 Spring, Hold Down for Plug-In Relay 64-11
0123490 Washer, Lock - Regular #6 90-6
½ Plug, ½" 40-16
½ Plug, ½" 41-16
½ Plug, ½" 42-16
½ Plug, ½" 43-20
#4 Washer, Lock #4 - External Tooth 22-8
#4-40 Nut, Hex #4-40 22-7
#4-40 Screw #4-40 22-3
#8 Nut, Lock - Fiber #8 23-5
#8 Washer, Flat #8 23-4
#8-32 x 5/8 Screw, Round Head #8-32 x 5/8" Long 23-3
CD315 4-3-7
Rev 4
Chapter 4
(Note 1) Bolt, Bearing Cap 58-21

(Note 1) Cap, Differential Bearing 58-17
(Note 1) Elbow, 90° 46-3
(Note 1) Elbow, 90° 46-4
(Note 1) Elbow, 90° 46-5
(Note 1) Elbow, 90° 46-14
(Note 1) Fitting, Straight 46-10
(Note 1) Handle, Lift Assembly 46-2
(Note 1) Plug 46-12
(Note 2) Brake Adjusting Socket w/ Screw - L/H 35-13
(Note 2) Brake Adjusting Socket w/ Screw - R/H 35-13
(Note 2) Cable Assembly 35-9
(Note 2) Case, Differential 58-24
(Note 2) Clip, Differential Clutch 58-26
(Note 2) Cover 35-7
(Note 2) Disc, Differential 58-20
(Note 2) Drive Gear and Pinion 58-32
(Note 2) Gear, Differential 58-18
(Note 2) Guide, Cable 35-15
(Note 2) Lever 35-12
(Note 2) Pin 35-11
(Note 2) Pinion, Differential 58-14
(Note 2) Plate, Differential 58-25
(Note 2) Shaft, Differential 58-15
(Note 2) Shim, Differential Bearing 58-22
(Note 2) Shim, Drive Pinion Adjustment 58-35
(Note 2) Shim, Pinion Bearing Adjustment 58-37
(Note 2) Spacer, Differential Gear 58-19
(Note 2) Spring, L/H 35-10
(Note 2) Spring, R/H 35-10
(Note 2) Washer, Thrust - Differential Pinion 58-13
(Note 3) Retainer, Hold Down Spring 35-6
(Note 3) Spring, Hold Down 35-8
4-3-8 CD315
Rev 4
Chapter 4
(Note 3) Spring, Lower 35-14

(Note 3) Spring, Upper 35-2
(Notes 3,4) Gasket Cover and RTV Sealant 58-28
06-06-070601 Fitting, Straight 6MJ-BLHD-UN 46-22
06-08-06-070428 Tee, 3/8MJ-½MB-3/8MJ 43-18
06-08-070102 Fitting, Straight 8MJ-6MP 46-7
060WD100 Brake Assembly, Drive Axle - R/H 35-
060WD101 Brake Assembly, Drive Axle - L/H 35-
08-070118 Nut, Bulkhead 83LMD Nut 46-36
08-070118 Nut, Bulkhead 8BLKHD-NUT 47-4
08-08-070101 Fitting, Straight 8MJ-8MJ 47-8
08-08-070321 Fitting, 45° 8MJ-8FJX45 94-4
08-08-070601 Fitting, Straight 8MJ-BLKHD-UN 47-2
08-08-070601 Fitting, Straight 8MJ-BLKH-UN 46-33
08-08-070701 Elbow, 90° 8MJ-BLKH90° 46-27
08-08-08-070958 Tee, 8MJBLKD-8MJ 46-21
¼ Nut, Top Lock Hex ¼-20 63-19
¼ P-Clamp, ¼'ID 103-5
¼ Washer, Flat ¼" ID 22-5
¼ Washer, Lock ¼" ID 16-10
CD315 4-3-9
Rev 4
Chapter 4

¼ Washer, Lock ¼” ID 15-9
¼-¾ Fend Washer ¼" ID - ¾" OD 22-9
¼ x 1½ Fend, ¼" ID, 1½" OD 5-5
¼ x 1½ Fend, ¼" ID; 1½" OD 4-4
¼-20 Nut, Flange ¼-20 103-2
¼-20 Nut, Top Lock Hex ¼-20 4-5
¼-20 Nut, Top Lock Hex ¼-20 10-12
¼-20 Nut, Top Lock Hex ¼-20 22-10
¼-20 Nut, Top Lock Hex ¼-20 39-24
¼-20 Nut, Top Lock Hex ¼-20 40-24
¼-20 Nut, Top Lock Hex ¼-20 44-14
¼-20 Nut, Top Lock Hex ¼-20 53-26
¼-20 Nut, Top Lock Hex ¼-20 54-26
¼-20 Nut, Top Lock Hex ¼-20 101-16
¼-20 Screw, Set 98-6
¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 18-2
4-3-10 CD315
Rev 4
Chapter 4

¼-20 x 1 Bolt, Counter Sink Ø ¼-20 x 1" Long 80-6
¼-20 x 1 Bolt, Countersunk Ø ¼-20 x 1" Long 23-6
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 4-8
¼-20 x 1 Screw, Phillips Ø ¼-20 x 1" Long 10-13
¼-20 x 1¼ Bolt, Hex Head Ø ¼-20 x 1¼" Long 4-34
¼-20 x 1¼ Screw, Phillips Ø ¼-20 x 1¼" Long 10-14
¼-28 x 1 Screw, Hex Head Machine Ø ¼-28 x 1" Long 102-7
½ Washer, Flat 56-2
½ Washer, Flat ½" 94-13
½ Washer, Flat ½" ID 45-23
CD315 4-3-11
Rev 4
Chapter 4

½-13 Nut, Jam Nylock ½-13 97-13
½-13 Nut, Jam Nylock ½-13 99-5
½-13 Nut, Top Lock Hex ½-13 9-4
½-13 Nut, Top Lock Hex ½-13 39-32
½-13 Nut, Top Lock Hex ½-13 40-32
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 9-5
½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 39-35
½-13 x 1¾ Bolt, Counter-Sink Ø ½-13 x 1½" Long 94-15
½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long 53-6
½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 97-4
½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 99-6
½-20 Nut, Wheel ½-20 ZP 71-3
¾ Plug, ¾" 89-7
¾ NPT 90 Elbow, Pipe 90° - ¾" 38-12
¾-10 Nut, Hex ¾-10 95-11
¾-10 Nut, Hex ¾-10 96-11
¾-10 x 9 Stud, Threaded - ¾-10 x 9" Long 96-12
¾-10 x 9 Stud, Threaded Ø ¾-10 x 9" Long 95-12
1/8 x 1 Pin, Cotter Ø 1/8" x 1" Long 37-2
1/8 x 2 Pin, Cotter Ø 1/8 x 2 94-16
10/32 x ½ Screw, Phillips Head 10/32 x ½" Long 101-7
10/32 x ¾ Screw, Phillips PPHMS10-32 x ¾" Long 29-6
4-3-12 CD315
Rev 4
Chapter 4

10/32 x 1 Screw, Phillips PPHMS10-32 x 1" Long 29-9
1¼ Clamp, P- (1¼") 72-5
12MJ-16MBUS Fitting, 45° Hydraulic Pump (Large) 38-4
1-8 x 4½ Bolt, Hex Head Ø 1-8 x 4½" Long 72-4
1-FF-S Fitting, Pipe 38-13
2-023-101 Support, Accelerator Pedal 21-6
203102-6-6S Tee, Swivel Flare - Opt. 43-15
2-032-101 Arm, Accelerator 19-9
3/32 x 7/8 Pin, Cotter Ø 3/32 x 7/8" Long 21-15
3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" 27-5
3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" Long 25-10
3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 39-27
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 4-22
3/8-16 x 1¼ Screw, 3/8" x 1¼" Long 4-26
3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 4-10
CD315 4-3-13
Rev 4
Chapter 4

4-100-101A Seat, Vinyl Bucket 9-8
42-100-700 Connector, SB350 Green 12-1
42-100-701 Connector, SB350 Red 12-1
42-100-702 Bracket, Mounting, SB350 Red 12-2
42-100-703 Release, Manual, SB350 Red 12-3
42-100-704 Release, Manual for Truck SBX350 12-3
42-100-801 Switch, Micro 19-10
42-100-801 Switch, Micro 101-14
42-100-801 Switch, Micro 104-2
42-126-101 Switch, Micro, DPDT 25-14
440E-12043 Fill Kit, Direct - BFS Watering System 10-
440E-12044 Fill Kit, Direct - Flo-Right Watering System 10-
440E-29053 Mount, Switch (Weldment) 22-6
440E-29066 Pedal, Throttle 22-1
440E-99017 Box, Rapid Charge Connector Wldmt 103-7
5/32 x 1 Screw Ø 5/32 x 1" Long 63-3
5/32 x 1 Screw Ø 5/32 x 1" Long 64-3
4-3-14 CD315
Rev 4
Chapter 4
5/32-1 Screw Ø 5/32 x 1" Long - Opt. 63-3

5/8-11 x 1¾ Bolt, Hex Head Ø 5/8-11 x 1¾" Long 19-15
5-100-101 Line, Brake 51" 28-4
5-100-101 Line, Brake 51" 29-3
5-100-101 Line, Brake 51" 32-11
5-100-101 Line, Brake 51" 33-11
6-32 x ¼ Screw, Slotted Pan Head Ø 6-32 x ¼" Long 90-5
660-0306-06 Nut, Lock 3/8" - Bulkhead 49-16
660-0306-06 Nut, Lock 3/8" - Bulkhead (for 2701-06-06) 45-13
660-0306-08 Nut, Lock ½" - Bulkhead 45-11
660-1-0005-26 Angle, Conveyor (¼") 75-20
660-1-0005-26 Angle, Conveyor (¼") 76-22
660-1-0005-26 Angle, Conveyor (¼") 77-14
660-1-0005-30 Strap, Conveyor 75-12
660-1-0005-30 Strap, Conveyor 76-12
660-1-0005-30 Strap, Conveyor 77-12
660-1-0020 Sprocket, Hydraulic Motor 94-7
660-1-0066 Bracket, Rear Cylinder 1-20
660-1-0074 Bracket, Front Cylinder 2-3
660-1-0092 Bearing, Pivot 72-3
660-1-0099 Bolt, Lift Cylinder Pivot 51-2
660-1-0099 Pin, Lift Cylinder 49-3
660-1-0144 Roller, Drive w/Lagging 95-3
660-1-0144 Roller, Drive, with Lagging 92-15
660-1-0145 Roller, Idler 95-9
660-1-0145 Roller, Idler 96-9
660-1-0173 Angle, End Crossmember 75-7
660-1-0177 Gusset, Rear Hoop Bumper - UAL 2-19
660-1-0178 Flange, Rear Hoop Bumper - UAL 2-15
CD315 4-3-15
Rev 4
Chapter 4
660-1-0179 Bumper, Rear Hoop - UAL 2-18

660-1-0184 Step, Front Bumper 7-2
660-1-0211 Roller, Crowder 95-5
660-1-0243 Safety Prop Weldment 73-1
660-1-0263 Arm, Pivot 97-5
660-1-0271 Pin, Pivot - Short 97-6
660-1-0271 Pin, Pivot - Short 98-5
660-1-0271 Pin, Pivot - Short 98-10
660-1-0271 Pin, Pivot - Short 99-10
660-1-0271 Pin, Pivot, Short 100-2
660-1-0275 Arm, Spring with Tab 97-8
660-1-0293 Bracket, Cam 74-7
660-1-0338 Bearing, Crowder Roller 95-4
660-1-0431 Bracket, Bulkhead 46-34
660-1-0472 Plate, Handrail Lock Collar - UAL 100-7
660-1-0967 Block, Pinch 83-3
660-1-0967 Block, Pinch 84-3
660-1-0967 Block, Pinch 95-13
660-1-0967 Block, Pinch 96-13
660-1-1018 Gusset, Front Bumper 2-2
660-1-1020 End, Wheel Well 1-22
660-1-1027 Compartment, Driver L/H 2-7
660-1-1039 Plate, Bolting 4-17
660-1-1041 Strut, Right Middle Fender 5-10
660-1-1048 Plate, Circuit Breaker 23-2
660-1-1068 Gusset, Left Front Frame 1-6
660-1-1069 Gusset, Right Front Frame 1-15
660-1-1070 Gusset, Beneath Left Front Fender 1-4
660-1-1071 Bracket, Flex, Brake Line (Wldmt) 30-2
660-1-1087 Gusset, Left Front Bumper 1-2
4-3-16 CD315
Rev 4
Chapter 4
660-1-1088 Gusset, Right Front Fender Well 1-26

660-1-1104 Rod, Brake Pedal 27-10
660-1-1105 Crank, Brake Bell 27-13
660-1-1106 Anchor, Brake Bell Crank 2-9
660-1-1110 Valve, Brake Proportioning - Cast Iron 28-9
660-1-1115 Cable, Accelerator w/Boot 19-1
660-1-1116 Shaft, Drive 53-23
660-1-1116 Shaft, Drive 54-23
660-1-1121 U-Bolt, Front Axle 52-3
660-1-1122 U-Bolt, Rear Axle 56-4
660-1-1131 Mount, Brake Pedal 2-5
660-1-1170 End, Tie Rod 37-6
660-1-1170-2 Plate, Steer Cylinder Mounting 37-5
660-1-1175 Hose, 112" OAL 37-7
660-1-1175 Hose, 112" OAL (Manifold to Steer Valve) 40-11
660-1-1175 Hose, 112" OAL (to Manifold) 36-3
660-1-1175 Hose, 112" OAL (to Steer Cylinder) 36-1
660-1-1189 Shoes, Brake Drive Axle (set of 4/box) 35-1
660-1-1207 U-Bolt, Drive Shaft 53-22
660-1-1245 Anchor, Front Park Brake Cable 25-2
660-1-1250 Hose, 26" OAL 43-17
660-1-1250 Hose, 26" OAL 51-12
660-1-1250 Hose, 26" OAL (Emergency Pump to Manifold) 44-8
660-1-1250 Hose, 26" OAL (Manifold EP to Emerg Pump) 41-3
660-1-1250 Hose, 26" OAL (Manifold EP to Emergency Pump) 40-3
CD315 4-3-17
Rev 4
Chapter 4
660-1-1250 Hose, 26" OAL (Tee to Manifold) 46-25

660-1-1251 Hose, 18" OAL 47-9
660-1-1254 Hose, 37" Pump Press. Swivel (Manifold to Cont. Valve) 42-14
660-1-1254 Hose, 37" Pump Pressure Swivel 47-11
660-1-1254 Hose, 37" Pump Pressure Swivel (Manifold to Cont. Valve) 40-14
660-1-1256 Hose, 108" OAL 38-27
660-1-1256 Hose, 108" OAL (Manifold to Filter) 39-36
660-1-1256 Hose, 108" OAL (Manifold to Motor Pump) 40-4
660-1-1256 Hose, 108" OAL (Pump to Manifold) 39-8
660-1-1258 Hose, 25" OAL Pump Suction 38-25
660-1-1280 Plaque, Conveyor Control 4-6
660-1-1338 Hose, Lift Cylinder 39" 45-25
660-1-1338 Hose, Lift Cylinder, 39" 49-15
660-1-1339 Hose, Booster 83" 29-16
660-1-1339 Hose, Booster 83" 36-2
660-1-1340 Hose, Booster Return 50" 29-15
660-1-1340 Hose, Booster Return 50" (Manifold to Booster) 40-13
660-1-1342 Hydro-Boost Assembly 27-17
660-1-1358 Rod, Brake 27-15
660-1-1359 Hose, Tank Return 29-18
660-1-1359 Hose, Tank Return (Manifold to Booster) 40-12
4-3-18 CD315
Rev 4
Chapter 4

660-1-1464 Guard, Front Valve - Opt. 4-35
660-1-1510 Guard, Finger - L/H Front Roller 81-2
660-1-1510 Guard, Finger L/H Front Roller 78-5
660-1-1511 Guard, Finger - R/H Front Roller 81-1
660-1-1511 Guard, Finger R/H Front Roller 78-6
660-1-1528 Angle, Safety Prop Crossmember 1-1
660-1-1529 Gusset 1-14
660-1-1543 Liner, Fender Well 3-6
660-1-1644 Cover, Chain 83-10
660-1-1644 Cover, Chain 84-10
660-1-1644 Cover, Chain 85-8
660-1-1669 Washer, Rubber Bumper 83-4
660-1-1670 Plate, Rear Idler Cover 85-3
660-1-1670 Plate, Rear IDLER Cover - Opt. 84-14
660-1-1686 Hook, Hanger - Electric Control Box 87-12
660-1-1913 Yoke, End - Adjustable 21-22
660-1-1921 Nut, Conduit ¾" NPT 19-16
660-1-1957 Plug, Dash 14-2
660-1-2206 Shaft, Drive (Eco Kit) - Opt. 53-23
660-1-2224 Spacer, Handrail 100-21
660-1-2228 End, Tie Rod 37-6
660-1-2244 Pad, Front Slope - Conveyor - Opt. 81-11
660-1-2252 Nut, Conduit ½ NPT 63-36
660-1-2252 Nut, Conduit ½ NPT 103-11
660-1-2252 Nut, Conduit ½" NPT 19-12
660-1-2326 Relay, 12VDC 0.9W - Infrared Conv. Shutdown Opt. 64-36
660-1-2327 Socket, Relay Base - Infrared Conv. Shutdown Opt. 64-37
660-1-2339 Step, Front Lower 7-3
CD315 4-3-19
Rev 4
Chapter 4

660-1-2349 Latch, Handrail Safety 100-9
660-1-2362 Guard, L/H Nylon - Conveyor Rail Bottom - Opt. 81-8
660-1-2362 Guard, Nylon L/H - Conv. Rail Bottom (Opt.) 79-18
660-1-2363 Guard, Nylon R/H - Conv. Rail Bottom (Opt.) 79-18
660-1-2363 Guard, R/H Nylon - Conveyor Rail Bottom - Opt. 81-7
660-1-2365 Sprocket, 27-Tooth, Drive Roller 94-12
660-1-2368 Tube, Stainless Telescoping 100-12
660-1-2372 Button, Horn 36-7
660-1-2387 Collar, Telescoping Tube Set 100-17
660-1-2388 Bumper, Telescoping Tube 100-13
660-1-2389 Spring, Handrail Lock Handle 100-15
660-1-2390 Spacer, Conveyor Rail to Clevis 100-16
660-1-2391 Spacer, Inner Clevis 100-22
660-1-2392 Rod, Brake 21-25
660-1-2409 Roller, 22" - Heavy Duty 95-7
660-1-2409 Roller, 22" Heavy Duty 96-7
660-1-2425 Switch, Momentary Stop - Narrow Conveyor 90-1
660-1-2470 Cover, Crowder Roller Adjustment Access 79-4
660-1-2470 Cover, Crowder Roller Adjustment Access 85-
660-1-2552 Plug, Button - Black 7/8" 16-2
660-1-2555 Pin, Pivot - Long Handrail 97-10
660-1-2557 Belt, Conveyor - GA Duck - Opt. 95-15
660-1-2559 Switch, Ignition, 2 Position 15-6
660-1-2899 Hose, ¼" ID x 68" Long 50-20
660-1-3028 Valve, Steer 36-5
660-1-3045 Valve, Brake Proportioning 28-9
660-1-3046 Pigtail, Brake Warning 30-16
660-1-3048 Arm, Pivot (Wldmt) 97-
660-1-3266 Emitter, Infrared Switch - Opt. 79-23
4-3-20 CD315
Rev 4
Chapter 4

660-1-3267 Receiver, Infrared Switch - Opt. 79-24
660-1-3268 Battery, Deserthog 80V 340AH 11-10
660-2-0062 Cylinder, Hydraulic Front 49-1
660-2-0063 Cylinder, Hydraulic Lift Rear 51-1
660-2-0265 Arm, Handrail Pivot, w/ Tab 100-4
660-2-0265 Arm, Handrail Pivot, with Tab 98-3
660-2-0266 Arm, Handrail Pivot 98-4
660-2-0380 Guard, Conveyor Hoop 83-9
660-2-0454 Link, Handrail - UAL Spec. 100-10
660-2-0460 Handle Weldment, Lock - UAL 100-8
660-2-0814 Bracket, Handrail Upright Spring 97-3
660-2-0839 Spacer, Rear 1-18
660-2-0935 Plate, Mounting 94-9
660-2-0958 Guard, Electric Control Box 87-9
660-2-1019 Well, Wheel 1-23
660-2-1021 Bracket, Left Suspension Front 1-7
660-2-1024 Bracket, Right Suspension Front 1-24
660-2-1029W Panel, Instrument (Wldmt) 14-8
660-2-1031 Cylinder, Power Steer 37-9
660-2-1032 Box, Chock 12½ x 9 x 5 - Opt. 4-21
660-2-1074 Guard, V-Groove Caster - L/H 78-3
660-2-1103 Cavity, Valve Cover / Seat Mount 4-24
660-2-1103 Cover, Valve Cavity & Seat Mount 3-12
660-2-1229 Rail, Rub - Left Front 3-9
660-2-1229 Rail, Rub - Quarter Panel 16" 4-32
660-2-1230 Rail, Rub - Center 70" 4-29
CD315 4-3-21
Rev 4
Chapter 4
660-2-1230 Rail, Rub - Plastic, 16" 3-4

660-2-1230 Rail, Rub - Plastic, 70" 3-7
660-2-1230 Rub Rail, Plastic, 70" 5-12
660-2-1278 Pedal Assembly, Brake 27-8
660-2-1305L Bracket, Pivot Assembly Left-Side Rail 97-2
660-2-1305R Bracket, Pivot Assembly R/Side Rail 99-2
660-2-1360 Guard, V-Groove Caster - R/H 78-2
660-2-1509 Guard, Stop Button (Standard Size) 85-6
660-2-1517 Guard, Stop Button (Oversize) - Opt. 85-6
660-2-1527 Guard, Rear Switch 83-12
660-2-1562 Guard, Electric Control Box - Opt 88-1
660-2-1607 Plate, Rear Bottom Cover (CE Opt.) 85-10
660-2-1640 Bracket, Front Work Light Mtg - Opt. 1-30
660-2-1671 Guard, Front Crossmember Anchor - Opt. 79-22
660-2-1672 Guard, Front Belt Closeout - Opt. 79-21
660-2-1685 Hanger, Electric Control Box 87-13
660-2-1692 Plate, Cover - Lower Left Rear 84-8
660-2-1693 Plate, Cover - Lower Right Rear 84-9
660-2-1694 Bumper, D-Style - Rear Conveyor 83-5
660-2-1961 Stop, Brake Pedal 2-8
660-2-2208 Spacer, 2" - Conveyor Bumper (Note 1) 1-28
660-2-2314 Step, L/H Boom Guard Gripstrut - UAL 2-17
660-2-2332 Frame, R/H Rear Step - UAL 2-20
660-2-2350 Frame, L/H Rear Step - UAL 2-16
660-2-2357 Support, Handrail Rear Down 100-19
660-2-2369 Housing, R/H Handrail Positive Lock 100-11
660-2-2383 Arm, Handrail Rear Slider Pivot 100-18
660-2-2386 Step, R/H Boom Guard Gripstrut - UAL 2-21
4-3-22 CD315
Rev 4
Chapter 4
660-2-2432 Harness, Wiring, Conveyor E-Stop 90-8

660-2-2558 Box, Chock 16 x 16 x 5 - Opt. 4-21
660-2-2662 Guard, Conveyor Rail Bottom 80-18
660-2-2662 Guard, Nylon - Conv. Rail Bottom (Opt.) 79-18
660-2-2662 Guard, Nylon - Conveyor Rail Bottom (No slot) 81-7
660-2-2723 Guard, Conveyor Hoop (Narrow) - Opt. 84-15
660-2-2800 Brace, Tie 75-8
660-2-2800 Brace, Tie 76-8
660-2-2800 Brace, Tie 77-8
660-2-2807 Bracket, Mirror (Passenger Side) 6-4
660-2-2809 Pad, Nylon - Drivers Side w/slots (Narrow) - Opt. 81-16
660-2-2810 Pad, Nylon - Passenger Side w/slots (Narrow) - Opt. 81-3
660-2-2815 Maintenance Kit, Hydraulic Gauge 42-
660-2-2836 Pad, Nylon - Front Left Side 79-5
660-2-2837 Pad, Nylon - Front Right Side 79-15
660-2-2837 Pad, Nylon - Front Right Side - Opt. 81-3
660-2-2839 Control Assembly, Recessed - R/H 89-9
660-2-2841 Control Assembly, Recessed - L/H 89-8
660-2-2845-2 Mount, E-Stop Switch 90-10
660-2-2848 Support, Instrument Panel 2-6
660-2-2854 Mount, E-Stop Switch 90-7
660-2-2855 Mount, Top E-Stop Switch 90-3
660-2-3000-1 Guard, Conveyor Hoop 135° (Narrow) - Opt. 84-15
660-2404-06-08 Fitting, Straight ½MT-3/8MP 49-8
660-2404-08-12 Connector, Male 2404-08-12 39-13
660-2404-08-12 Connector, Male 2404-08-12 40-13
660-2404-12-16 Connector, Male 2404-12-16 39-30
660-2404-12-16 Connector, Male 2404-12-16 40-30
660-2501-06-04 Elbow, 90° 3/8MT-¼MP 49-10
660-2501-06-04 Elbow, 90° 3/8MT-¼MP 50-10
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 45-19
CD315 4-3-23
Rev 4
Chapter 4
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 49-13

660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 50-13
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 51-10
660-2501-06-06 Elbow, Male 2501-06-06 37-8
660-2501-06-08 Elbow, 90° 3/8MT-½MP 51-5
660-2501-06-08 Elbow, 90° 3/8MT-½MT 49-5
660-2501-06-08 Elbow, 90° 3/8MT-½MT 50-5
660-2501-08-06 Elbow, 90° ½MT-3/8MP 45-21
660-2501-08-12 Elbow, Male 2501-08-12 39-16
660-2501-08-12 Elbow, Male 2501-08-12 40-16
660-2605-06-04-06 Tee 51-6
660-2700-06-06 Fitting, Straight 3/8MT-3/8MT Bulkhead 45-14
660-2701-06-06 Elbow, 90° 3/8MT-3/8Bulkhead 51-15
660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 49-18
660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 50-18
660-2701-06-06 Elbow, 90°, 3/8MT-3/8MT Blkhd 45-26
660-2701-08-08 Elbow, 90° ½MT-½MT Bulkhead 45-9
660-2704-08-08-08 Tee, ½MT-½MTBulkhead-½MT 45-12
660-3-0120-1 Bumper Roll 78-8
660-3-0120-1 Bumper, Roll 79-11
660-3-0120-1 Bumper, Roll 83-8
660-3-0120-2 Channel, Bumper Roll 78-7
660-3-0120-2 Channel, Roll Bumper 79-9
660-3-0462 Collar, R/H Handrail Lock - UAL Spec. 100-6
660-3-0774-2 Cable, Park Brake 24-6
660-3-0802 Plate, Middle 75-15
660-3-0802 Plate, Middle 76-15
660-3-0802 Plate, Middle 77-15
660-3-0807 Bracket, Drive Roller - R/H 75-16
660-3-0808 Bracket, Crowder Roller 75-4
660-3-0809 Plate, Channel - Take-up Bearing 75-5
660-3-0812 Bracket, Motor Mount w/Tab 75-18
660-3-0962 Guard, Spacer/Finger - Front Bumper Roll (Opt.) 79-8
660-3-0987 Guard, Finger - Rear (Wldmt) 83-2
4-3-24 CD315
Rev 4
Chapter 4
660-3-0987 Guard, Finger - Rear Weld Assy 84-2

660-3-0987 Guard, Finger - Rear Wldmt Assembly 78-11
660-3-1028 Compartment, Driver R/H 1-5
660-3-1167 Closeout, Headlight 3-10
660-3-1249 Mount, Light - 13" Solid Dual 70-2
660-3-1262 Mount, Rear Axle 1-16
660-3-1270 Bracket, Roller Support 75-11
660-3-1605 Holster, Front Control 87-10
660-3-1638 Closeout, Rear Roller 2 - Opt. 84-13
660-3-1638 Closeout, Right Rear Roller - Conveyor 85-5
660-3-1639 Closeout, Left Rear Roller - Conveyor 85-4
660-3-1687 Anchor, Park Brake Cable 26-2
660-3-2426 Plate, Slide - Conveyor Left 75-9
660-3-2427 Plate, Slide - Conveyor Right 75-6
660-3-2428 Bracket, Small Roller Assembly 75-13
660-3-2429 Bracket Assembly, Aligner Channel 69-1
660-3-2429 Bracket, Aligner Channel Assembly 76-3
660-3-2431 Crossmember, Conveyor Lift Arm 75-2
660-3-2593 Chock, Orange 11 x 8 x 7.75 - Opt. 4-36
660-3-2663 Conveyor Crossmember Assembly 75-14
660-3-2663 Crossmember Assembly - Std Conv. 76-14
660-4-0008 Lift Arm Weldment, Front 72-1
CD315 4-3-25
Rev 4
Chapter 4
660-4-0008-15 Keystock 92-6

660-4-0009 Lift Arm Weldment, Rear 72-7
660-4-0010-10 Filter, Hydraulic with Indicator 38-8
660-4-0010-12 Valve, Ball 38-15
660-4-0010-12 Valve, Ball 39-29
660-4-0010-12 Valve, Ball 40-29
660-4-0010-13 Valve, Relief 48-1
660-4-0010-19 Element, Hydraulic Filter 38-9
660-4-0010-20 Valve, Relief 45-20
660-4-0010-20 Valve, Relief 46-8
660-4-0010-3 Valve, Holding 49-14
660-4-0010-3 Valve, Holding 50-14
660-4-0010-3 Valve, Holding 51-9
660-4-0010-30 Manifold, Hydraulic Large 38-18
660-4-0013-11 Cap, Filler 38-11
660-4-0013-19 Level, Sight Gauge 39-21
660-4-0132-2 Bushing, Sleeve 74-5
660-4-0132-4 Wheel, V-Groove with Roller Bearing 74-4
660-4-0132-9 Follower, Cam 74-8
660-4-0137-11 Cable, Aircraft 98-7
660-4-0137-12 Pin, Detent 98-8
660-4-0137-12 Pin, Detent 99-8
660-4-0137-12 Pin, Detent, COM 97-11
660-4-0137-9 Spring, Extension 97-9
660-4-0138 Handrail Assembly - R/H 32" 98-1
660-4-0182 Step, Front Upper - UAL Spec (Wldmt) 8-2
660-4-0254 Handrail Weldment - L/H Standard 97-7
4-3-26 CD315
Rev 4
Chapter 4
660-4-0300 Handrail Weldment - R/H Standard 98-2

660-4-0532-2 Switch, Limit (Honeywell) 24-2
660-4-0532-5 Arm, Switch Actuator for Limit 25-17
660-4-0600-5 Bumper, COM 100-14
660-4-0732-7 Shifter, Morse 14-3
660-4-0732-7 Shifter, Morse 17-1
660-4-0741-2 Relay 86-4
660-4-0741-3 Socket Base 86-3
660-4-0741-5 Breaker, Circuit (20 Amp) 23-1
660-4-0741-7 Block, Terminal 86-2
660-4-0753-14 Box, Wire Way - Electric 86-1
660-4-0753-2 Relay, Electric Belt Control 60-2
660-4-0753-3 Base, Socket - Electric/Octagon 60-2
660-4-0909 Handrail Assembly - L/H 32" 98-1
660-4-1005 Rail, Frame, L/H 1-11
660-4-1006 Rail, Frame, R/H 1-21
660-4-1007 Bumper, Steel Front 1-3
660-4-1015 Crossmember, Chassis Lift Arm 1-12
660-4-1016 Crossmember, Front Safety Prop 1-8
660-4-1035 Fender, Left Rear 3-3
660-4-1036 Fender, Right Rear 5-1
660-4-1037 Fender, Left Front 3-11
660-4-1038 Fender, Right Front 5-23
660-4-1045 Tank Assembly, Hydraulic 39-22
660-4-1045 Tank, Hydraulic Assembly 38-10
660-4-1047 Tank, Hydraulic - UAL Spec 40-22
660-4-1050 Axle, Steer 37-1
660-4-1050 Axle, Steer 52-8
660-4-1050-10 Nut, Axle 52-6
660-4-1050-14 Tie Rod Assembly 52-9
660-4-1050-15 Cap, Plug 52-10
CD315 4-3-27
Rev 4
Chapter 4
660-4-1050-16 Spindle and Plug Assembly 52-11

660-4-1050-17 Nut, Lock 52-12
660-4-1050-19 Bearing and Race Kit - Inner 52-14
660-4-1050-1L Knuckle Assembly, L/H 52-7
660-4-1050-1R Knuckle Assembly, R/H 52-7
660-4-1050-20 Hub and Rotor 52-15
660-4-1050-21 Bearing and Race Kit - Outer 52-16
660-4-1050-22 Nut, Wheel Bearing with Pin 52-17
660-4-1050-23 Washer, Lock 52-18
660-4-1050-24 Nut, Wheel Bearing 52-19
660-4-1050-25 Hubcap 52-20
660-4-1050-26 Seal, Oil 52-13
660-4-1050-29 Socket Kit 52-4
660-4-1050-9 Stop, Axle 52-5
660-4-1051 Axle, Drive 53-25
660-4-1051 Axle, Drive 54-25
660-4-1051 Axle, Drive (Rear) 56-3
660-4-1051-10 Plug, Cover (Note 3) 58-31
660-4-1051-11 Seal, Rear Hub 57-1
660-4-1051-11 Seal, Rear Hub 58-10
660-4-1051-12 Bolt, Carrier Cover (Note 3) 58-29
660-4-1051-14 Bearing and Cup 58-16
660-4-1051-16 Lock, Differential Shaft 58-27
660-4-1051-17 Drum and Hub Assembly 57-3
660-4-1051-19 Nut, Brake Mounting 58-11
660-4-1051-2 Washer 58-42
660-4-1051-22 Stud, Drive Axle Hub 58-3
660-4-1051-23 Shaft, Axle - R/H 57-5
660-4-1051-23 Shaft, Axle - R/H 58-4
660-4-1051-24 Shaft, Axle - L/H 57-5
660-4-1051-24 Shaft, Axle - L/H 58-4
660-4-1051-26 Nut, Rear Axle Spindle 58-5
4-3-28 CD315
Rev 4
Chapter 4
660-4-1051-27 Washer, Lock 58-6

660-4-1051-28 Adapter, Stud Nut 58-2
660-4-1051-29 Nut, Stud 58-1
660-4-1051-3 Bearing, Inner Pinion 58-34
660-4-1051-30 Stud, Wheel 58-12
660-4-1051-32 Differential Case Assembly 58-44
660-4-1051-4 Seal, Rear Axle 58-40
660-4-1051-49 Carrier Cover Assembly (Note 3) 58-30
660-4-1051-5 Baffle, Pinion Bearing 58-36
660-4-1051-6 Bearing, Pinion 58-38
660-4-1051-7 Flange Yoke End Assembly 58-41
660-4-1051-7-1 Strap Set for Input Flange 53-24
660-4-1051-8 Slinger, Pinion 58-39
660-4-1051-9 Nut, Pinion 58-43
660-4-1975 Crossmember, Rear 1-13
660-4-1976 Prop, Rear Safety 73-2
660-4-2338 Step, Front Lower - UAL Spec (Wldmt) 8-5
660-4-2352 Handrail Weldment, R/H - UAL Spec. 100-1
660-4-2806 Fender, Right Rear - Ext. Battery Opt. 5-1
660-4-2835 Gusset, Right Fender 1-25
660-4-2985 Closeout, L/F Headlight 4-1
660-4-3004 Step, Front (Wldmt) 7-4
660-4-3007 Handrail Weldment - R/H 99-11
660-4-3078 Rail, Hand - Single 7-5
660-5404-04-04 Fitting, Straight ¼MP-¼MP 40-20
660-5404-08-06 Fitting, Straight ½MP-3/8MP 49-12
660-5404-16-16 Nipple, Hex 5404-16-16 39-28
660-5404-16-16 Nipple, Hex 5404-16-16 40-28
660-5406-P-04 Plug, ¼" MP 40-19
660-5406-P-04 Plug, ¼" MP 41-19
CD315 4-3-29
Rev 4
Chapter 4
660-5605-02-02-02 Fitting, Female Pipe Tee 30-14

660-5605-02-02-02 Tee, Female Pipe Fitting 31-13
660-5605-04-04-04 Tee ¼FP-¼FP-¼FP 40-18
660-5605-04-04-04 Tee ¼FP-¼FP-¼FP 41-18
660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 49-9
660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 50-9
660-6-0004-14 Sprocket, Drive Roller 92-14
660-6-0004-15 Bearing, Take-Up 95-8
660-6-0004-15 Bearing, Take-Up 96-8
660-6-0004-16 Bearing, Flange 95-2
660-6-0004-16 Bearing, Flange 96-2
660-6-0004-17 Chain, ½-Link - Conveyor Drive 93-17
660-6-0004-17 Link, Chain ½ - Conveyor Drive 91-11
660-6-0004-18 Chain, Drive Roller 91-8
660-6-0004-18 Chain, Drive Roller - 3¼' Long 92-5
660-6-0004-18 Chain, Drive Roller - 4' Long 92-13
660-6-0004-18 Chain, Drive Roller - 4.125' Long 94-17
660-6-0004-19 Link, Master 91-6
660-6-0004-19 Link, Master 92-16
660-6-0004-19 Link, Master 93-18
660-6-0004-19 Link, Master 94-19
660-6-0004-20 Roller, 24" 96-18
660-6-0004-22 Roller, 22" 95-6
660-6-0004-22 Roller, 22" 96-6
660-6-0004-23 Belt, Conveyor - 24" x 588" 95-15
660-6-0004-23 Belt, Conveyor - 24" x 588" 96-15
660-6-0004-24 Alligator Lacing Kit 95-16
660-6-0004-27 Pin, Roll 95-10
660-6-0004-27 Pin, Roll 96-10
660-6-0004-42 Keystock, ¼" x 12" 91-5
660-6-0581-25 Belt, Safety (Non-Retract), COM 9-3
4-3-30 CD315
Rev 4
Chapter 4
660-6-0582-26 Bumper, Rubber - Lift Arm (Note 1) 1-27

660-6-0800 Rail, Conveyor - L/H 75-10
660-6-0801 Rail, Conveyor - R/H 75-1
660-6400-06-06-0 Fitting, Straight 3/8MT-3/8M O-Ring 44-6
660-6400-06-08 Fitting, Straight 3/8MT-1/2M O-Ring (SAE) 40-2
660-6400-08-08-0 Fitting, Straight ½MT-½M O-Ring (SAE) 40-5
660-6500-06-06 Elbow, 90° 3/8MT-3/8 37° Female Swivel 51-11
660-6500-06-06 Elbow, 90° 3/8MT-3/8" 37° Female Swivel Nut 44-9
660-6801-06-06 Elbow, 90° 3/8MT-3/8ADJ O-Ring (SAE) 45-7
660-6801-08-08 Fitting, 90° ½MT-½Adj. O-Ring (SAE) 40-6
660-6801-08-08 Fitting, 90° ½MT-½MP 39-6
660-6801-08-08 Fitting, 90° ½MT-½MP 40-6
660-6802-08-08 Elbow, 45° ½MT-½ADJ O-Ring (SAE) 42-15
660-6802-08-08 Elbow, 45° ½MT-½Adj. O-Ring (SAE) 40-15
660-ND-0020 Filter, Hydraulic Tank Dessicant 40-38
660-ND-0040 Fitting, AEROQUIP 40-37
660-ND-1005 Belt, Conveyor, Goodyear Wedge Grip 96-15
660-ND-107P Plug, Button 7/8" 14-9
660-ND-1371 Gauge, Hydraulic Pressure 39-12
660-ND-1372 Fitting, Brake Line 30-13
660-ND-1376 Cable, Shifter 17-2
660-ND-1379 Cylinder, Wheel - R/H 35-16
CD315 4-3-31
Rev 4
Chapter 4
660-ND-1380 Cylinder, Wheel - L/H 35-16

660-ND-1392 Brake Adjusting Kit, L/H 35-
660-ND-1393 Brake Adjusting Kit, R/H 35-
660-ND-1394 Brake Springs Kit 35-
660-ND-1397 Adapter, Brake 29-19
660-ND-1438 Box & Cover, Switch - Electric Control 87-1
660-ND-1438 Box and Cover, Switch - Electric Control, 3-Hole 88-7
660-ND-1439 Push Button - Green Head 88-3
660-ND-1439 Push Button, Green Head 87-7
660-ND-1440 Push Button - Red Head 88-2
660-ND-1440 Push Button, Red Head 87-8
660-ND-1441 Nameplate, Stop 87-5
660-ND-1441 Nameplate, Stop 89-
660-ND-1442 Nameplate, Forward 87-4
660-ND-1442 Nameplate, Forward 89-
660-ND-1443 Nameplate, Reverse 87-6
660-ND-1443 Nameplate, Reverse 89-
660-ND-1444 Block, Contact - N.O. (FWD & RVS) 88-8
660-ND-1444 Block, Contact - NO 90-4
660-ND-1444 Block, Contact - NO (FWD & RVS) 89-6
660-ND-1444 Block, Contact N.O. (FWD and RVS) 87-2
660-ND-1445 Block, Contact - NC (Stop) 90-4
660-ND-1445 Block, Contact N.C. (Stop) 87-3
660-ND-1505 Bumper, Plastic 78-4
660-ND-1676 Button, Locking - Red 90-1
660-ND-1677 Cable, Brake Long - 95" 26-7
660-ND-1678 Cable, Brake Short - 51" 26-6
660-ND-1679 Equalizer 26-3
660-ND-1920 Relief Strain ½ x ¾ NPT (CGB294) 19-18
660-ND-1920 Relief, Strain ½ x ¾ NPT (CGB294) 87-11
4-3-32 CD315
Rev 4
Chapter 4
660-ND-1920 Strain Relief - ½ x ¾ NPT (CGB294) 12-4

660-ND-1921 Nut, Lock - Strain Relief, ¾" 63-29b
660-ND-1921 Nut, Lock - Strain Relief, ¾" 63-30
660-ND-2212-04 Line, Hydraulic #4 (660) 49-6
660-ND-2212-10 Line, Hydraulic #10 51-7
660-ND-2212-28 Line, Hydraulic (#28) 47-10
660-ND-2213-10 Line, Hydraulic #10 (SS) - Rear Lift Cylinder (CE Opt.) 51-7
660-ND-2213-12 Line, Hydraulic #12 (SS Opt.) 46-23
660-ND-2213-28 Line, Hydraulic (#28) (SS Opt.) 47-10
660-ND-2213-4 Line, Hydraulic #4 (SS) - Front Lift Cyl. 49-6
660-ND-2215 Relief Strain 3/8 x ½ NPT (CGB116) 19-17
660-ND-2215 Relief, Strain 3/8 x ½ NPT (CG116) 63-34
660-ND-2215 Relief, Strain 3/8 x ½ NPT (CGB116) 24-7
660-ND-2216 Spring, 7" Extension 100-3
660-ND-2849 Fitting, Test Port ¼Male NPT Conn. 43-21
660-ND-2850 Fitting, Test Port 6FJ Conn. - Opt. 43-16
661-1-0033 Hose, Conveyor ½" x 132" 47-7
661-4-2833K Conveyor Weldment - Extended 78-1
661-4-3061 Conveyor Weldment - CE Extended 78-1
663-1-0144 Roller, Drive 94-10
663-1-0144 Roller, Drive - Narrow Conveyor 96-3
663-1-0173 Angle, End - Narrow Conveyor 76-16
663-1-0338 Bearing, 1" Pillow Block 77-20
663-1-0808 Bracket, Crowder Roller - Narrow Conv. 76-4
663-1-0809 Bracket, Take-up Bearing - Narr. Conv. 76-5
CD315 4-3-33
Rev 4
Chapter 4

663-1-2274 Bumper, Protective Handle 100-20
663-1-2334 Guard, Finger - L/H (Narrow) (UAL) - Opt. 81-2
663-1-2335 Guard, Finger - R/H (Narrow) (UAL) - Opt. 81-1
663-1-2341 Cup, Recessed - Safety Stop Button 90-11
663-1-2477 Closeout, Narrow Conveyor, Front R/H Bottom 82-6
663-1-2698 Plate, D-Bumper Retainer 80-9
663-1-2698 Plate, D-Bumper Retainer - Opt. 79-20
663-2-0803 Cap, End - Rear L/H 77-22
663-2-0804 Cap, End - Rear R/H 77-23
663-2-0807 Bracket, Drive Roller - Narrow Conveyor 76-17
663-2-2340 Reinforcement, Narrow Conveyor Front 77-21
663-2-2351 Guard, Conveyor Control Bracket, R/H 89-11
663-2-2355 Guard, Adjustable Lower Finger 85-1
663-2-2355 Guard, Adjustable Lower Finger - Opt. 81-13
663-2-2355 Guard, Adjustable, Lower Finger 82-2
663-2-2356 Mount, Adjustable Lower Finger Guard 82-3
663-2-2356 Mount, Adjustable Lower Finger Guard - Opt. 81-12
663-2-2480 Closeout, Narrow Conveyor, L/F Bottom 82-5
663-2-2671 Pad Assembly - R/H Side 80-17
663-2-2671 Pad Assy, R/H Side - Opt. 81-3
663-2-2672 Pad Assembly - L/H Side 80-2
663-2-2672 Pad Assy, L/H Side - Opt. 81-16
663-2-2683 Guard, V-Groove Caster Narrow L/H 80-21
663-2-2683 Guard, V-Groove Caster Narrow L/H - Opt. 81-18
663-2-2684 Guard, V-Groove Caster Narrow R/H 80-20
663-2-2684 Guard, V-Groove Caster Narrow R/H - Opt. 81-17
663-2-2782 Bar, Tie Brace 77-8
663-2-2802 Crossmember Weldment - Narrow Conv. 69-1
663-2-2802 Crossmember Wldmt - Narrow Conv. 77-3
663-3-0810 Bracket, Pillow Block / Crowder Roller 76-18
663-3-0812 Bracket, Motor Mount (Wldmt) - Narrow 76-19
4-3-34 CD315
Rev 4
Chapter 4
663-3-2318 Bumper, D Style 6" - White Urethane - Opt. 81-15

663-3-2319 Plate, Conveyor D-Bumper 81-6
663-3-2331 Cover, Rear Bottom - Conveyor 85-10
663-3-2605 Bumper, 8" L/F D-Style (Narrow Conv.) 80-10
663-3-2605 Bumper, D-Style 8" L/F - Opt. 79-7
663-3-2607 Guard, Front Roller, L/H Square - Narrow - Opt. 81-2
663-3-2607 Guard, Front Roller, L/H, Square 80-7
663-3-2608 Guard, Front Roller, R/H Square (Narrow) - Opt. 81-1
663-3-2608 Guard, Front Roller, R/H, Square 80-12
663-3-2668 Bumper, 8" R/F D-Style (Narrow Conv.) 80-14
663-3-2668 Bumper, D-Style 8" R/F - Opt. 79-12
663-4-0008 Lift Arm Weldment, Front - Narrow Conv. 72-1
663-4-0009 Lift Arm Weldment, Rear - Narrow Conv. 72-7
663-4-0800 Rail, Narrow Conveyor - L/H 76-10
663-4-0801 Rail, Narrow Conveyor - R/H 76-1
663-4-1015 Crossmember, Narrow Chassis Lift Arm 1-12
663-4-2263 Cap, End - Front R/H (Wldmt) 80-13
663-4-2263 Cap, End - Front R/H, Wldmt 81-4
663-4-2264 Cap, End - Front L/H (Wldmt) 80-8
663-4-2264 Cap, End - Front L/H, Wldmt 81-5
663-4-2268 Guard, Finger - Rear Weld Assembly 85-9
663-4-2342 Cover, Conveyor Front Bottom - Hinged 82-4
663-4-2666 Plate, Conveyor Bottom Front Cover 80-19
663-4-2666 Plate, Conveyor Bottom Front Cover - Opt. 81-14
663-4-2788 Crossmember, Conveyor Lift Arm - Narrow 84-11
663-4-2831 Conveyor Weldment - Narrow 82-1
6-6-FTX-S Connector, Male 38-14
6-8-F50X-S Connector, Straight Thread 38-16
6-CTX-S Fitting, Triple Lock 38-21
6FSOX-S Connector, Straight Thread 38-23
6MJ-4MB Adapter 38-22
8-C50X-S Elbow, Straight Thread 38-17
CD315 4-3-35
Rev 4
Chapter 4

8M6-5MB45 Fitting, 45° Hydraulic Pump (Small) 38-5
8MJ-12MP90 Elbow, 90° - Hydraulic Filter 38-6
9/16-16NF Nut, Castellated 9/16-16 37-3
9-200-111 Hose, Brake Front 28-8
BLE-0001 Enclosure, Receptacle - Rapid Charge 102-5
BLE-0002-3 Lid, Enclosure 102-4
BLE-0002-5 Angle, Enclosure Mounting 102-1
BLE-0003 Housing, Receptacle Mount 102-3
BLE-0005 Receptacle, Machined - Rapid Charge 102-6
BLE-0006 Sensor, Temperature - Opt. 10-8
BLE-0007 Contactor, Charge Z40AC-SW - Opt. 65-14
BLE-1-1003 Brake, Electric 91-2
BLE-1-1003L Reducer, Belt Drive Speed, L/S 92-3
BLE-1-1003R Reducer, Belt Drive Speed, R/S 93-3
BLE-1-1005 Reducer, Belt Drive Speed 91-3
BLE-1-1012 Sprocket, Small, Jackshaft 91-4
BLE-1-1013 Sprocket, Large, Jackshaft 91-7
BLE-1-1014 Bearing, Pillow Block, Jackshaft 91-10
BLE-1-1015 Jackshaft 91-9
BLE-1-1019 Gusset, Battery Cradle 2-13
BLE-1-1020 Pump, Hydraulic 38-3
4-3-36 CD315
Rev 4
Chapter 4
BLE-1-1021 Motor, Hydraulic Pump 38-1

BLE-1-1023 Pump, Emergency Hydraulic 38-20
BLE-1-1024 Bracket, Emergency Pump 38-19
BLE-1-1025 Motor, Drive 53-11
BLE-1-1026 Reducer, Drive Motor 53-16
BLE-1-1026 Reducer, Drive Motor 55-
BLE-1-1028 Yoke, Drive Shaft 53-21
BLE-1-1029 Sprocket, Coupling - Motor Side 53-15
BLE-1-1031 Coupling, Chain 53-14
BLE-1-1032 Cover, Chain Coupling 53-13
BLE-1-1033 Key, Step - Drive Shaft Yoke 53-19
BLE-1-1034-14 Bar, Buss - Contactor (SW200) - Opt. 66-19
BLE-1-1036 Yoke, Accelerator 21-13
BLE-1-1041 Motor, Conveyor Drive 91-1
BLE-1-1042 Door, Hydraulic 5-16
BLE-1-1046 Valve, Hydraulic Control 45-1
BLE-1-1050 Eye, Terminal for Accelerator Cable 19-14
BLE-1-1051 Nut, Lock - Sealing ¾" 19-16
BLE-1-1052 Nut, Lock - Sealing ½" 19-12
BLE-1-1055 Relief, Strain 5/8 x ¾NPT (CGB295) 19-7
BLE-1-1055 Relief, Strain 5/8" x ¾" NPT (CGB295) 63-29a
BLE-1-1055 Relief, Strain 5/8" x ¾" NPT (CGB295) 63-32
BLE-1-1056 Hinge, Piano 2" x 96" (See Note 1) 3-1
CD315 4-3-37
Rev 4
Chapter 4
BLE-1-1057 Hourmeter / BDI, 72-80 14-1

BLE-1-1064 Handle Assembly, Lift Valve (part of BLE-1-1046) 45-2
BLE-1-1070 Door, Charger Port 104-6
BLE-1-1080 Guide, Inner Battery 2-12
BLE-1-1081 Guide, Outer Battery 10-1
BLE-1-1084 Cradle Extension, 3" - Battery (Opt.) 10-15
BLE-1-1200-1 Battery, Deka 48V 595 AH 10-7
BLE-1-1201-3 Battery, GNB 72V 340 AH 10-7
BLE-1-1202-1 Battery, Hawker 80V 320AH 10-7
BLE-1-1205-2 Battery, Exide 72V 550 AH 10-7
BLE-1-1250-1 Charger, Hobart 48V 600 AH 60 Hz 10-
BLE-1-1251-1 Charger, Hobart 72V 380 AH 10-
BLE-1-1251-3 Charger, GNB 72V 475 AH 10-
BLE-1-1254-2 Charger, Exide 72V 550 AH 60 Hz 10-
4-3-38 CD315
Rev 4
Chapter 4

BLE-1-1501 Relief, Strain 63-33
BLE-1-1502 Ring, Sealing ½ NPT 63-35
BLE-1-1502 Ring, Sealing ½" NPT 19-12
BLE-1-1503 Ring, Sealing ¾ NPT 64-25
BLE-1-1503 Ring, Sealing ¾" NPT 19-16
BLE-1-1503 Ring, Sealing ¾" NPT 63-29c
BLE-1-2527 Brake, Electric Belt Drive - 80V 92-2
BLE-1-2528 Brake, Electric Belt Drive - 48V (Opt.) 92-2
BLE-1-2529 Motor, Traction Drive (48V Opt.) 53-11
BLE-1-2533 Connector, Battery SB x 350 Black 104-5
BLE-1-2534 Connector, Compression 1½" EMT 63-38
BLE-1-2535 Shifter, SRE 16-15
BLE-1-2537 Battery, Exide 80V 440 AH w/ BIS & BWM 10-7
BLE-1-2538 Charger, Exide 80V 450 AH 10-
BLE-1-2539 Battery, Exide 80V 300 AH w/BWM & INJ-S40 10-7
BLE-1-2558 Key, Drive Shaft 53-12
BLE-1-2564 Cable, Display 66-15
BLE-1-2565 Bracket, Resistor 63-16
BLE-1-2567 Box, Controller 63-2
BLE-1-2570 Relay, One N/O Contact 63-13
BLE-1-2570 Relay, with one N/O Contact 64-12
CD315 4-3-39
Rev 4
Chapter 4
BLE-1-2571 Socket, for Plug-In Relay 63-14

BLE-1-2572 Spring, Hold Down for Relay 63-12
BLE-1-2577 Receptacle, Rapid Charge 101-18
BLE-1-2583 Bar, Cover Clamp 101-3
BLE-1-2584 Cover, Electrical Components 101-13
BLE-1-2585 Spacer, Receptacle Stand-off 101-12
BLE-1-2586 Housing, Burton Receptacle (Altered) 101-15
BLE-1-2600 Cable, Positive - Rapid Charge 102-10
BLE-1-2601 Cable, Negative - Rapid Charge 102-9
BLE-1-2601 Cable, Negative - Rapid Charge Opt. 66-18
BLE-1-2603 Rail, Rub - Battery Box 10-10
BLE-1-2605 Cable, Battery, Positive - Hawker 10-
BLE-1-2605 Cable, Battery, Positive - Hawker 11-12
BLE-1-2606 Cable, Battery, Negative - Hawker 10-
BLE-1-2606 Cable, Battery, Negative - Hawker 11-13
BLE-1-2608 Compound, Heat Sink 66-
BLE-1-2610 Cable, Battery (Positive) 13-4
BLE-1-2611 Cable, Battery (Negative) 13-3
BLE-1-2612 Cable, Quick Charge Jumper (Fuse Bass Bar to Charge Contactor) 66-17
BLE-1-2612 Cable, Quick Charge Jumper (Fuse Bass Bar to Charge Contactor) - Opt. 65-
BLE-1-2624 Switch, Toggle, DPST Sealed 16-6
BLE-1-2625 Plate, Ignition Switch Mount 16-7
BLE-1-2627 Hose, JIC Straight #6, 68" 39-25
BLE-1-2627 Hose, JIC Straight #6, 68" (Relief Valve to Front Lift Arm Valve) 46-38
BLE-1-2631 Battery, Deka 80V Johnson w/BMID, 40 Cell 10-7
BLE-1-2632 Watering System, BFS (For Exide/Deka 72V Batteries) 11-11
BLE-1-2633 Plaque, Conveyor Control 4-6
4-3-40 CD315
Rev 4
Chapter 4
BLE-1-2645 Connector, SB350 Blue 12-1

BLE-1-2646 Boot, Heat Shrink - 3M 64-34
BLE-1-2650 Line, Hydraulic (at Valve #1) 46-35
BLE-1-2650SS Line, Hydraulic (at Valve #1) (SS) 46-35
BLE-1-2652 Motor, Hydraulic Belt Drive 94-1
BLE-1-2656 Hose (Bulkhead to Manifold) 43-9
BLE-1-2656 Hose (Manifold to Hyd. Cntrl Valve) 43-13
BLE-1-2656 Hose (Valve to Bulkhead) 46-18
BLE-1-2660 Watering System, Flo-Right Single Point 10-
BLE-1-2660 Watering System, Flo-Right Single Point 11-11
BLE-1-2662 Connector, Male Pin 2/0 AWG 13-1
BLE-1-2663 Bracket, Manual Release 13-2
BLE-1-2665 Decal, "Charge Port" 104-7
BLE-1-2666 Cover, Battery Connector - Opt. 12-
BLE-1-2667 Battery Assembly, Deka 80V/BID/Flo-Right/EuroDin/340 AH 10-7
BLE-1-2668 Battery Assembly, Deka 80V/BMID/Flo-Right/EuroDin/340 AH 10-7
BLE-1-2670 Coupling, Sprocket, Gearbox 54-32
BLE-1-2671 Gearbox, Reduction 54-16
BLE-1-2673 Button, Plug 1" 64-31
BLE-1-2674 Tire, 10 Ply Radial, 225/75R16 71-2
BLE-1-2675 Sensor, Fiber Optic 103-3
BLE-1-2676 Controller, Fiber Optic 103-4
BLE-1-2677 Connector, Female, EuroDin (Included w/ Battery) 13-7
BLE-1-2680 Tubing, Hydraulic Line #37 (SS) 40-31
CD315 4-3-41
Rev 4
Chapter 4
BLE-1-2682 Connector, SBX 350 Black 103-8

BLE-1-2682 Connector, SBX350 Black 12-1
BLE-1-2683 Bracket, Mounting, SBX350 - Opt. 12-2
BLE-2-1024 Bracket, Emergency Hydraulic Pump 44-1
BLE-2-1043 Fender Tie Bar 3-8
BLE-2-1054 Rod, Pull - Hand Throttle 20-6
BLE-2-1064 Pedal Assembly, Accelerator 20-1
BLE-2-1071 Bumper, Rear w/Charge Fort 101-5
BLE-2-1071 Bumper, Rear with Charger Port 104-1
BLE-2-1077 Lever, Hand Brake (Weldment) 24-1
BLE-2-2578 Bumper, Rear - Electric Quick Charge 101-5
BLE-2-2587 Mount, Receptacle & Switch - Wldmt 101-11
BLE-2-2590 Panel, Electrical Components 63-17
BLE-2-2636 Cover, Rear Bumper (Note 1) 2-14
BLE-2-2678 Battery, Deka 80V 500 AH, Vented 11-10
BLE-2-2679 Charger, Exide, 3-Phase, 50Hz, 400VAC 11-
BLE-2-2684 Closeout, Rear Charge Port 103-18
BLE-3-1017 End, Battery Cradle 10-2
BLE-3-1022 Mount, Hydraulic Tank 39-33
BLE-3-1027 Mount, Motor 53-5
BLE-3-1047 Mount, Filter - Hydraulic 38-7
BLE-3-1058 Crossmember, Control Box 1-10
BLE-3-1067 Cover, Hydraulic Motor 38-2
BLE-3-1068 Bracket, Remote Charge Connection 103-10
BLE-3-1070 Anchor, Park Brake Cable 26-5
BLE-3-2619 Cover, Foot Pedal 22-13
BLE-4-1002 Mount, Jackshaft 38-29
4-3-42 CD315
Rev 4
Chapter 4
BLE-4-1005 Guard, Conveyor Drive 78-10

BLE-4-1016 Mount, Conveyor Drive 75-19
BLE-4-1018 Cradle, Battery 10-4
BLE-4-1037 Plate, Base - Shifter Switches 19-5
BLE-4-1038 Box, EBL Control (Enclosure Modification) 63-2
BLE-4-1038 Box, Electric Control 19-3
BLE-4-1040 Door, Battery 3-2
BLE-4-1041 Door, Battery - 3" Extended - Opt. 4-28
BLE-4-1061 Fender, Left Body 3-5
BLE-4-1062 Fender, Right Body 5-20
BLE-4-1065 Cover, Traction Motor 53-28
BLE-4-1073 Crossmember, Conveyor Drive - Narrow 76-21
BLE-4-1074 Mount, Jackshaft - Narrow Conv. 93-16
BLE-4-1074 Mount, Jackshaft - Narrow Conveyor 76-20
BLE-4-1076 Fender, Left Midsection Weldment 4-13
BLE-4-1500A Harness, 3pc. Wire Kit - 72/80V Control Box 60-1
BLE-4-1500B Harness, 80V Wire - Chassis 60-
BLE-4-1500B-72 Harness, 72V Wire - Chassis 60-
BLE-4-1502 Harness, 12V Wire 60-
BLE-4-2543 Harness, Dash 16-
BLE-4-2552 Controller, Contact - Rapid Charge 64-35
BLE-4-2552 Controller, Contact - Rapid Chg Opt. 63-10
BLE-4-2556 Bracket, Battery Term Disconnect 4-23
BLE-4-2557 Panel, Left Front Body Weldment 4-2
BLE-4-2562 Controller Assembly (PowerpaK) 65-
BLE-4-2617 Conveyor Weldment - Standard 78-1
CD315 4-3-43
Rev 4
Chapter 4

BLE-4-2617 Conveyor Weldment - Standard 97-
BLE-4-2618 Conveyor Weldment - Narrow 78-1
BLE-4-2618 Conveyor Weldment - Narrow 97-
BLE-4-2618 Conveyor Weldment, Narrow 84-1
BLE-4-2623 Plate, Accelerator Mounting 2-4
BLE-4-2634 Mat, Battery Compartment Floor 11-7
BLE-4-2635 Bumper, Rear 1-19
BLE-4-2643 Box Weldment, Battery 1-9
BLE-4-2643 Box, Battery (Wldmt) 11-1
BLE-4-2644 Box, Battery (Wldmt) - Ext. Opt. 11-1
BLE-4-2648 Controller w/ 24V Coils, 80V 66-
BLE-4-2654 Valve, Hydraulic Assembly 46-1
BLE-6-2599 Conveyor Weldment 78-1
BLE-E Frame Weldment - 660E 1-
BLE-ND-002 Switch, Demand- N.O. with Plug (Alternate Source) 48-4
BLE-ND-002 Switch, Demand- N.O. with Plug (part of BLE-1-1046) 45-28
BLE-ND-1075 Grommet, Rubber 7/8" x 1¼" x ¼" 13-5
BLE-ND-1080 Seal, Hole ¾" Dia. Conduit 19-13
BLE-ND-1080 Seal, Hole Ø ¾" Conduit Hole, Black 63-29
BLE-ND-1084-0 Line, Hydraulic Control Valve 3.25" 46-6
BLE-ND-1084-029 Tube, Hydraulic Line #29 45-17
4-3-44 CD315
Rev 4
Chapter 4

BLE-ND-1085-0 Line, Hyd. Cntrl Valve 3.25" (SS) 46-6
BLE-ND-1085-030 Tube, Hydraulic Line #30 (SS Opt.) 46-20
BLE-ND-2602 Fuse, 10 AMP 63-6
BLE-ND-2609 Pin, Clevis 5/16" x 1" Long 21-14
CMA-604 Bushing, Oillite 21-18
M10 x 1.5 Nut, Jam 60-4
M3-1-1053 Switch, Seat, Wise 9-6
M3-1-1260-1 Charger, Hobart 80V 600 AH 10-
M3-1-1260-3 Charger, GNB 80V 475 AH 10-
M3-1-1260-3 Charger, GNB 80V 475 AH 11-
M3-1-1700-5 Converter, DC/DC 63-4
M3-1-5039 Display, Dash - Sevcon 15-3
CD315 4-3-45
Rev 4
Chapter 4
M3-1-5089 Horn, Electric 48V - Opt. 67-1

M3-1-5175 Switch, Seat - Sears 9-6
M3-1-8005 Arm, Accelerator Ratio 21-17
M3-1-8011 Pin, Clevis 5/16 x 1¼ 19-19
M3-1-8012 Box, Accelerator 21-12
M3-1-8043 Bushing, Nylon - Accelerator Yoke 21-16
M3-1-8106 Switch, Micro for Directional 22-2
MD-CB1-127 Bushing 27-11
MD-CB1-129 Yoke 27-7
MD-CB21-121 Clip 26-4
MD-CB21-121 Clip 30-3
MD-CB21-121 Clip 31-3
MD-CB21-133 Clevis, Cable w/Pin and Cotter Pin 20-5
MG-1-320 Trim-Lok, 7.5" Long 103-17
MG-ND-531 Switch, Brake 28-11
MH-1-602 Tire, Goodyear 8 x 16 LT 71-2
MH-2-606 Bracket, Park Brake App. Light Sw. 104-4
MH-2-606 Bracket, Park Brk App. Light Sw. 25-4
MH-ND-565 Line, Brake 10" (Prop. Valve to Tee) 31-12
MH-ND-650 Tire, LT215/85R/16 71-2
MH-ND-956 Hanger, Cable Connector 19-11
MI-1-735 Connector, SB350 Gray 12-1
MI-ND-359 Fitting 36-4
MI-ND-803 Fitting, Hydraulic - Straight 6-6FTX 39-26
MJ-1-5003 Hose, Steer Valve/Cylinder L/H (84") 38-26
MJ-ND-4006 Ring, Lashing 5/8" x 4" x 4" - Forged w/ Bracket 1-17
MX4-10149 Watering System, Flo-Right 10-
MX4-10149 Watering System, Flo-Right 11-11
MX4-10251 Relief, Strain 4/0 103-15
MX4-10263 Watering System, BFS (For Exide/Deka 80V Batteries) 10-
MX4-10263 Watering System, BFS (For Exide/Deka 80V Batteries) 11-11
MX4-10279 BMID Assembly, Exide 80V Battery 11-
MX4-10280 BMID Assembly, Deka 80V Battery 11-
T6-1001-123 Spring, Throttle 20-4
4-3-46 CD315
Rev 4
Chapter 4

T6-1002-155 Clamp, Cable 19-6
T6-1002-155 Clamp, Cable 20-3
T6-1004-109 Yoke, Shift Linkage 19-4
T6-1004-117 Pin, Clevis 19-8
T6-1009-103 Pedal, Accelerator 21-9
T6-1010-159 Decal, "Made in USA" 16-11
T6-1300-101 Tire, All Season, 8.75 x 16.5 71-2
T6-1300-181 Alarm, Back-Up - 12VDC 105-3
T6-1300-247 Headlight 68-1
T6-1300-247 Headlight 69-2
T6-1300-247 Headlight 70-1
T6-1300-259 Light, Spot w/ Grill - Opt. 1-29
T6-200-105 Safety Walk 12" Wide, 19"Long 5-18
T6-200-106 Safety Walk 22" Wide, 14' Long 4-27
T6-2003-101UPS Wheel, DC 16.5 x 6.75 w/Reinf. Plate 71-1
T6-2004-103 Tire, Rib Tread 8.0 x 16.5 71-2
T6-2004-154 Chock, Wheel - Opt. 4-36
T6-2004-155 Link Kit, Wheel Chocks - Opt. 4-37
T6-2004-156 Cable, ¼" Vinyl Coated Spiral - Opt. 4-38
T6-2400-160 Tire, Safari SJR LT 225/75R16 71-2
T6-2400-161 Tire, Goodyear 225/75-16R LT 71-2
T6-2400-166 Tire, Tug Tuff, 8.00 x 16.5 71-2
T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 71-1
T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5" 10PR 71-2
T6-2400-171 Tire, Supergrip 8.75 x 16.5 10PR Mud/Snow 71-2
T6-2400-185 Tire/Wheel Assembly, Goodyear 225/75R16 LT 71-
T6-2400-187 Tire/Wheel Assembly, Tug Tuff, 8 x 16.5 71-
T6-2400-205 Tire/Wheel Assembly, 10 Ply 225/75R16 Radials 71-
T6-2400-206 Tire/Wheel Assembly, Kelly LT225/75R16 71-
T6-4005-109 Handle, Hood 53-31
T6-4005-109 Handle, Hood 54-31
T6-4014-119 Spring, Throttle Linkage 21-4
T6-4103-236 Cover, Hole - Radiator Shroud 101-6
T6-500-123 Pin, Park Brake 21-23
CD315 4-3-47
Rev 4
Chapter 4

T6-500-137 Connector, Flasher Relay Socket 16-18
T6-600-112 Adapter 29-20
T6-600-112 Adapter 32-2
T6-600-112 Adapter 33-2
T6-600-114 Adapter, Line (Brake to Master Cylinder) 29-4
T6-6011-111 Tee 28-12
T6-6011-111 Tee 32-13
T6-6011-111 Tee 33-13
T6-6011-113 Angle, Tee Support 32-15
T6-6011-141 Line, Brake 20" 28-2
T6-6011-141 Line, Brake 20" 29-13
T6-6011-149 Line, Brake 40" 28-5
T6-6011-149 Line, Brake 40" 29-5
T6-6011-149 Line, Brake 40" 32-3
T6-6011-149 Line, Brake 40" 33-14
T6-6011-149 Line, Brake 40" (Tee to 30" Brake Line) 31-5
T6-6011-151 Line, Brake 6" 28-6
T6-6011-151 Line, Brake 6" - Ext. Battery Box Opt. 32-9
T6-6011-151 Line, Brake 6" (Prop. Valve to Tee) 30-12
T6-6011-161 Line, Brake 30" 28-7
T6-6011-161 Line, Brake 30" 31-4
T6-6011-161 Line, Brake 30" 32-14
T6-6011-161 Line, Brake 30" 33-3
T6-6011-161 Line, Brake 30" (Prop. Valve to 40" Brake Line) 30-5
T6-6011-161 Line, Brake 30" (Prop. Valve to Left Front Brake Hose) 30-4
T6-7006-101A Light, Tail - Kit 68-3
T6-7006-107A Light, Back-up - Kit 68-2
T6-7006-115 Light, Turn Signal - Optional 68-4
T6-7007-101 Control, Turn Signal 36-9
T6-7007-105 Flasher, Turn Signal 16-17
T6-7010-113 Switch, Toggle 14-6
T6-7010-113 Switch, Toggle (Back-Up Light) 16-5
T6-7010-113 Switch, Toggle (Head Light) 15-4
T6-7010-113 Switch, Toggle (Headlight) 16-4
4-3-48 CD315
Rev 4
Chapter 4
T6-7010-113 Switch, Toggle (Spot Light) 16-8

T6-7010-113 Switch, Toggle (Spot Light) - Opt. 15-7a
T6-7010-114 Switch, Toggle - 1 Pole, 2 Pos 16-6
T6-7010-120 Light, Red Warning - Flat Head 14-5
T6-7010-122 Light, Green Warning - Flat Head 15-10
T6-7010-140 Switch, Ignition - CH Lever 14-7
T6-7013-207 Horn 67-1
T6-7022-105P Plug, Button ¾" 14-4
T6-8005-101 Lever, Hand Brake 25-9
T6-8005-103 Bushing, Hand Brake 13-6
T6-8005-105 Angle, Hand Brake 24-4
T6-8005-111 Strap, Lever to Park Brake 72-6
T6-8011-107 Adapter, Brake Warning 29-2
T6-8011-121 Connector 28-3
T6-8011-121 Connector 29-7
T6-8011-121 Connector 30-6
T6-8011-121 Connector 31-6
T6-8011-121 Connector 32-8
T6-8011-121 Connector 33-8
T6-8011-121 Connector - Ext. Battery Box Opt. 32-10
T6-8013-103 Caliper, R/H Forward, L/H Rear 34-1
T6-8013-143 Hose, Brake 34-9
T6-8013-143 Hose, Brake Front 28-8
T6-8013-145 Bolt, Brake Hose 34-11
T6-8013-147 Washer, Brake Hose 34-10
T6-8013-149 Pad, Brake - Non-Organic 34-4
T6-8013-153 Dust Boot Kit 34-3
T6-8013-157 Piston 34-2
T6-8013-159 Bolt, Caliper 34-6
CD315 4-3-49
Rev 4
Chapter 4
T6-8013-165 Screw, Bleeder, Delco 34-8

T6-8013-167 Sleeve 34-7
T6-8013-169 Clip, Retainer 34-5
T6-9003-171 Grommet, Windshield 70-3
T6-9003-549 Wheel, 16" x 6", White 71-1
T6-9003-550 Wheel, 16.5" x 6.75", White 71-1
T6-9003-571 Plug, Button - Black ½” 15-5
T6-9003-572 Plug, Button - Black ¾" 16-16
T6-9003-572 Plug, Button - Black ¾” 15-2
T6-9011-375 Mirror, 5 x 7 6-2
T6-9011-383 Bracket, Mirror 6-3
T6-9100-105-2 Relay, Power (Back-Up Light) 64-9
T6-9100-105-2 Relay, Power (Horn Relay) 63-11
T6-9100-105-2 Relay, Power (Reverse Light) 63-9
T-A2 Decal, Dash 16-14
T-A6 Decal, "Reverse-Neutral-Forward" 89-10
T-A7 Decal, "Forward-Neutral-Reverse" 89-4
TM1-1-5008 Hose, Oil Cooler 41" 39-4
TM1-1-9814 Tire/Wheel Assembly, Tug Tuff, 8.75 x 16.5 71-
TM1-ND-1013 Tire, 225/75-16 LTX AT 71-2
TPG-D3TZ-2857A Clevis, Parking Brake 100-23
X3001-109 Coupling, Brake Rod 27-16
X4004-101 Wheel, Steering 36-10
X4011-203C Hose, Upper Trans/Cooler (75") 38-28
X4014-101 Column, Steer 36-6
X4015-101 Nut, Column 36-11
X6008-101 Horn Button Kit 36-8
4-3-50 CD315
Rev 4
Chapter 4
SECTION 4: ALPHABETICAL INDEX
T6-600-112 Adapter 29-20

T6-600-112 Adapter 32-2
T6-600-112 Adapter 33-2
6MJ-4MB Adapter 38-22
660-ND-1397 Adapter, Brake 29-19
T6-8011-107 Adapter, Brake Warning 29-2
T6-600-114 Adapter, Line (Brake to Master Cylinder) 29-4
------ Adapter, Straight Reducing - Male 38-30
660-4-1051-28 Adapter, Stud Nut 58-2
T6-1300-181 Alarm, Back-Up - 12VDC 105-3
660-1-1245 Anchor, Front Park Brake Cable 25-2
660-3-1687 Anchor, Park Brake Cable 26-2
BLE-3-1070 Anchor, Park Brake Cable 26-5
660-1-0005-26 Angle, Conveyor (¼") 75-20
660-1-0005-26 Angle, Conveyor (¼") 76-22
660-1-0005-26 Angle, Conveyor (¼") 77-14
BLE-0002-5 Angle, Enclosure Mounting 102-1
660-1-1528 Angle, Safety Prop Crossmember 1-1
2-032-101 Arm, Accelerator 19-9
M3-1-8005 Arm, Accelerator Ratio 21-17
CD315 4-4-1
Rev 4
Chapter 4

660-2-0265 Arm, Handrail Pivot, w/ Tab 100-4
660-2-2383 Arm, Handrail Rear Slider Pivot 100-18
660-1-0263 Arm, Pivot 97-5
660-1-3048 Arm, Pivot (Wldmt) 97-
660-1-0275 Arm, Spring with Tab 97-8
660-4-0532-5 Arm, Switch Actuator for Limit 25-17
660-4-1051 Axle, Drive 53-25
660-4-1051 Axle, Drive 54-25
660-4-1051 Axle, Drive (Rear) 56-3
660-4-1050 Axle, Steer 37-1
660-4-1050 Axle, Steer 52-8
660-4-1051-5 Baffle, Pinion Bearing 58-36
------ Bag, Desiccant 19-20
BLE-1-1034-14 Bar, Buss - Contactor (SW200) - Opt. 66-19
BLE-1-2583 Bar, Cover Clamp 101-3
663-2-2782 Bar, Tie Brace 77-8
660-4-0753-3 Base, Socket - Electric/Octagon 60-2
BLE-2-2678 Battery, Deka 80V 500 AH, Vented 11-10
660-1-3268 Battery, Deserthog 80V 340AH 11-10
4-3-2 CD315
Rev 4
Chapter 4

660-4-1051-14 Bearing and Cup 58-16
660-6-0004-16 Bearing, Flange 95-2
660-6-0004-16 Bearing, Flange 96-2
660-4-1051-3 Bearing, Inner Pinion 58-34
660-4-1051-6 Bearing, Pinion 58-38
660-1-0092 Bearing, Pivot 72-3
CD315 4-3-3
Rev 4
Chapter 4
------ Bearing, Roller 55-24

660-6-0004-15 Bearing, Take-Up 95-8
660-6-0004-15 Bearing, Take-Up 96-8
660-6-0004-23 Belt, Conveyor - 24" x 588" 95-15
660-6-0004-23 Belt, Conveyor - 24" x 588" 96-15
660-1-2557 Belt, Conveyor - GA Duck - Opt. 95-15
660-ND-1005 Belt, Conveyor, Goodyear Wedge Grip 96-15
660-6-0581-25 Belt, Safety (Non-Retract), COM 9-3
660-ND-1444 Block, Contact - N.O. (FWD & RVS) 88-8
660-ND-1445 Block, Contact - NC (Stop) 90-4
660-ND-1444 Block, Contact - NO 90-4
660-ND-1444 Block, Contact - NO (FWD & RVS) 89-6
660-ND-1445 Block, Contact N.C. (Stop) 87-3
660-ND-1444 Block, Contact N.O. (FWD and RVS) 87-2
660-1-0967 Block, Pinch 83-3
660-1-0967 Block, Pinch 84-3
660-1-0967 Block, Pinch 95-13
660-1-0967 Block, Pinch 96-13
660-4-0741-7 Block, Terminal 86-2
MX4-10280 BMID Assembly, Deka 80V Battery 11-
MX4-10279 BMID Assembly, Exide 80V Battery 11-
------ BMID, 80V, GSE (Part of MX4-10279 & 80) 11-16
½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 97-4
½-13 x 2¾ Bolt Ø ½-13 x 2¾" Long 99-6
------ Bolt, Anchor 35-19
(Note 1) Bolt, Bearing Cap 58-21
T6-8013-145 Bolt, Brake Hose 34-11
T6-8013-159 Bolt, Caliper 34-6
660-4-1051-12 Bolt, Carrier Cover (Note 3) 58-29
¼-20 x 1 Bolt, Counter Sink Ø ¼-20 x 1" Long 80-6
½-13 x 1¾ Bolt, Counter-Sink Ø ½-13 x 1½" Long 94-15
¼-20 x 1 Bolt, Countersunk Ø ¼-20 x 1" Long 23-6
------ Bolt, Drive Gear 58-23
------ Bolt, Flange 35-3
4-3-4 CD315
Rev 4
Chapter 4

½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 9-5
CD315 4-3-5
Rev 4
Chapter 4

5/8-11 x 1¾ Bolt, Hex Head Ø 5/8-11 x 1¾" Long 19-15
4-3-6 CD315
Rev 4
Chapter 4

------ Bolt, Hex Head Ø 8mm 67-1h
660-1-0099 Bolt, Lift Cylinder Pivot 51-2
BLE-1-2646 Boot, Heat Shrink - 3M 64-34
660-ND-1438 Box & Cover, Switch - Electric Control 87-1
BLE-4-2643 Box Weldment, Battery 1-9
M3-1-8012 Box, Accelerator 21-12
BLE-4-2643 Box, Battery (Wldmt) 11-1
BLE-4-2644 Box, Battery (Wldmt) - Ext. Opt. 11-1
660-2-1032 Box, Chock 12½ x 9 x 5 - Opt. 4-21
660-2-2558 Box, Chock 16 x 16 x 5 - Opt. 4-21
BLE-4-1038 Box, EBL Control (Enclosure Modification) 63-2
BLE-4-1038 Box, Electric Control 19-3
440E-99017 Box, Rapid Charge Connector Wldmt 103-7
660-4-0753-14 Box, Wire Way - Electric 86-1
660-2-2800 Brace, Tie 75-8
660-2-2800 Brace, Tie 76-8
660-2-2800 Brace, Tie 77-8
------ Bracket 67-1c
660-3-2429 Bracket, Aligner Channel Assembly 76-3
BLE-4-2556 Bracket, Battery Term Disconnect 4-23
660-1-0293 Bracket, Cam 74-7
660-3-0808 Bracket, Crowder Roller 75-4
660-3-0807 Bracket, Drive Roller - R/H 75-16
CD315 4-3-7
Rev 4
Chapter 4
BLE-2-1024 Bracket, Emergency Hydraulic Pump 44-1

BLE-1-1024 Bracket, Emergency Pump 38-19
660-1-0074 Bracket, Front Cylinder 2-3
660-2-1640 Bracket, Front Work Light Mtg - Opt. 1-30
------ Bracket, L 67-1g
BLE-1-2663 Bracket, Manual Release 13-2
T6-9011-383 Bracket, Mirror 6-3
660-2-2807 Bracket, Mirror (Passenger Side) 6-4
660-3-0812 Bracket, Motor Mount w/Tab 75-18
42-100-702 Bracket, Mounting, SB350 Red 12-2
BLE-1-2683 Bracket, Mounting, SBX350 - Opt. 12-2
MH-2-606 Bracket, Park Brake App. Light Sw. 104-4
MH-2-606 Bracket, Park Brk App. Light Sw. 25-4
660-2-1305L Bracket, Pivot Assembly Left-Side Rail 97-2
660-2-1305R Bracket, Pivot Assembly R/Side Rail 99-2
660-1-0066 Bracket, Rear Cylinder 1-20
BLE-3-1068 Bracket, Remote Charge Connection 103-10
660-2-1024 Bracket, Right Suspension Front 1-24
4-3-8 CD315
Rev 4
Chapter 4

660-ND-1392 Brake Adjusting Kit, L/H 35-
660-ND-1393 Brake Adjusting Kit, R/H 35-
(Note 2) Brake Adjusting Socket w/ Screw - L/H 35-13
(Note 2) Brake Adjusting Socket w/ Screw - R/H 35-13
060WD101 Brake Assembly, Drive Axle - L/H 35-
060WD100 Brake Assembly, Drive Axle - R/H 35-
660-ND-1394 Brake Springs Kit 35-
BLE-1-1003 Brake, Electric 91-2
BLE-1-2528 Brake, Electric Belt Drive - 48V (Opt.) 92-2
660-4-0741-5 Breaker, Circuit (20 Amp) 23-1
660-3-0120-1 Bumper Roll 78-8
663-3-2605 Bumper, 8" L/F D-Style (Narrow Conv.) 80-10
663-3-2668 Bumper, 8" R/F D-Style (Narrow Conv.) 80-14
660-4-0600-5 Bumper, COM 100-14
663-3-2318 Bumper, D Style 6" - White Urethane - Opt. 81-15
663-3-2605 Bumper, D-Style 8" L/F - Opt. 79-7
663-3-2668 Bumper, D-Style 8" R/F - Opt. 79-12
660-ND-1505 Bumper, Plastic 78-4
663-1-2274 Bumper, Protective Handle 100-20
BLE-2-2578 Bumper, Rear - Electric Quick Charge 101-5
660-1-0179 Bumper, Rear Hoop - UAL 2-18
BLE-2-1071 Bumper, Rear w/Charge Fort 101-5
BLE-2-1071 Bumper, Rear with Charger Port 104-1
660-3-0120-1 Bumper, Roll 79-11
660-3-0120-1 Bumper, Roll 83-8
660-6-0582-26 Bumper, Rubber - Lift Arm (Note 1) 1-27
CD315 4-3-9
Rev 4
Chapter 4

660-1-2388 Bumper, Telescoping Tube 100-13
MD-CB1-127 Bushing 27-11
M3-1-8043 Bushing, Nylon - Accelerator Yoke 21-16
CMA-604 Bushing, Oillite 21-18
------ Bushing, Sleeve 55-21
660-4-0132-2 Bushing, Sleeve 74-5
660-1-2372 Button, Horn 36-7
660-ND-1676 Button, Locking - Red 90-1
BLE-1-2673 Button, Plug 1" 64-31
(Note 2) Cable Assembly 35-9
T6-2004-156 Cable, ¼" Vinyl Coated Spiral - Opt. 4-38
660-4-0137-11 Cable, Aircraft 98-7
BLE-1-2611 Cable, Battery (Negative) 13-3
BLE-1-2610 Cable, Battery (Positive) 13-4
------ Cable, Battery to Connector (Negative) 11-13
------ Cable, Battery to Connector (Positive) 11-12
BLE-1-2606 Cable, Battery, Negative - Hawker 10-
BLE-1-2606 Cable, Battery, Negative - Hawker 11-13
BLE-1-2605 Cable, Battery, Positive - Hawker 10-
BLE-1-2605 Cable, Battery, Positive - Hawker 11-12
660-ND-1677 Cable, Brake Long - 95" 26-7
660-ND-1678 Cable, Brake Short - 51" 26-6
BLE-1-2564 Cable, Display 66-15
BLE-1-2601 Cable, Negative - Rapid Charge Opt. 66-18
4-3-10 CD315
Rev 4
Chapter 4

BLE-1-2612 Cable, Quick Charge Jumper (Fuse Bass Bar to Charge Contactor) 66-17
BLE-1-2612 Cable, Quick Charge Jumper (Fuse Bass Bar to Charge Contactor) - Opt. 65-
T6-8013-103 Caliper, R/H Forward, L/H Rear 34-1
(Note 1) Cap, Differential Bearing 58-17
663-4-2264 Cap, End - Front L/H (Wldmt) 80-8
663-4-2264 Cap, End - Front L/H, Wldmt 81-5
663-4-2263 Cap, End - Front R/H (Wldmt) 80-13
663-4-2263 Cap, End - Front R/H, Wldmt 81-4
663-2-0803 Cap, End - Rear L/H 77-22
663-2-0804 Cap, End - Rear R/H 77-23
660-4-0013-11 Cap, Filler 38-11
660-4-1050-15 Cap, Plug 52-10
------ Capacitor 59-6
660-4-1051-49 Carrier Cover Assembly (Note 3) 58-30
(Note 2) Case, Differential 58-24
660-6-0004-18 Chain, Drive Roller 91-8
660-6-0004-18 Chain, Drive Roller - 4.125' Long 94-17
660-3-0120-2 Channel, Bumper Roll 78-7
660-3-0120-2 Channel, Roll Bumper 79-9
CD315 4-3-11
Rev 4
Chapter 4
BLE-2-2679 Charger, Exide, 3-Phase, 50Hz, 400VAC 11-

M3-1-1260-3 Charger, GNB 80V 475 AH 10-
M3-1-1260-3 Charger, GNB 80V 475 AH 11-
660-3-2593 Chock, Orange 11 x 8 x 7.75 - Opt. 4-36
T6-2004-154 Chock, Wheel - Opt. 4-36
T6-1002-155 Clamp, Cable 19-6
T6-1002-155 Clamp, Cable 20-3
------ Clamp, Hose 29-17
------ Clamp, Hose #72 49-7
------ Clamp, Hose #72 50-7
1¼ Clamp, P- (1¼") 72-5
------ Clamp, P Vinyl - COV0709Z 29-8
MD-CB21-133 Clevis, Cable w/Pin and Cotter Pin 20-5
TPG-D3TZ-2857A Clevis, Parking Brake 100-23
MD-CB21-121 Clip 26-4
MD-CB21-121 Clip 30-3
MD-CB21-121 Clip 31-3
(Note 2) Clip, Differential Clutch 58-26
T6-8013-169 Clip, Retainer 34-5
660-4-2985 Closeout, L/F Headlight 4-1
660-3-1639 Closeout, Left Rear Roller - Conveyor 85-4
663-1-2477 Closeout, Narrow Conveyor, Front R/H Bottom 82-6
4-3-12 CD315
Rev 4
Chapter 4
663-2-2480 Closeout, Narrow Conveyor, L/F Bottom 82-5

660-3-1638 Closeout, Rear Roller 2 - Opt. 84-13
660-3-1638 Closeout, Right Rear Roller - Conveyor 85-5
660-3-0462 Collar, R/H Handrail Lock - UAL Spec. 100-6
660-1-2387 Collar, Telescoping Tube Set 100-17
X4014-101 Column, Steer 36-6
660-1-1027 Compartment, Driver L/H 2-7
660-3-1028 Compartment, Driver R/H 1-5
BLE-1-2608 Compound, Heat Sink 66-
T6-8011-121 Connector 28-3
T6-8011-121 Connector 29-7
T6-8011-121 Connector 30-6
T6-8011-121 Connector 31-6
T6-8011-121 Connector 32-8
T6-8011-121 Connector 33-8
BLE-1-2533 Connector, Battery SB x 350 Black 104-5
BLE-1-2534 Connector, Compression 1½" EMT 63-38
BLE-1-2677 Connector, Female, EuroDin (Included w/ Battery) 13-7
T6-500-137 Connector, Flasher Relay Socket 16-18
6-6-FTX-S Connector, Male 38-14
660-2404-08-12 Connector, Male 2404-08-12 39-13
660-2404-08-12 Connector, Male 2404-08-12 40-13
660-2404-12-16 Connector, Male 2404-12-16 39-30
660-2404-12-16 Connector, Male 2404-12-16 40-30
BLE-1-2662 Connector, Male Pin 2/0 AWG 13-1
BLE-1-2645 Connector, SB350 Blue 12-1
MI-1-735 Connector, SB350 Gray 12-1
42-100-700 Connector, SB350 Green 12-1
42-100-701 Connector, SB350 Red 12-1
CD315 4-3-13
Rev 4
Chapter 4

BLE-1-2682 Connector, SBX350 Black 12-1
6-8-F50X-S Connector, Straight Thread 38-16
6FSOX-S Connector, Straight Thread 38-23
------ Contactor, Hydraulic Pump 65-9
660-2-2841 Control Assembly, Recessed - L/H 89-8
660-2-2839 Control Assembly, Recessed - R/H 89-9
T6-7007-101 Control, Turn Signal 36-9
------ Controller 66-7
BLE-4-2562 Controller Assembly (PowerpaK) 65-
BLE-4-2648 Controller w/ 24V Coils, 80V 66-
BLE-4-2552 Controller, Contact - Rapid Charge 64-35
BLE-4-2552 Controller, Contact - Rapid Chg Opt. 63-10
BLE-1-2676 Controller, Fiber Optic 103-4
------ Controller, Sevcon PowerpaK 65-7
660-3-2663 Conveyor Crossmember Assembly 75-14
4-3-14 CD315
Rev 4
Chapter 4

661-4-3061 Conveyor Weldment - CE Extended 78-1
661-4-2833K Conveyor Weldment - Extended 78-1
663-4-2831 Conveyor Weldment - Narrow 82-1
BLE-4-2618 Conveyor Weldment - Narrow 97-
BLE-4-2617 Conveyor Weldment - Standard 97-
BLE-4-2618 Conveyor Weldment, Narrow 84-1
X3001-109 Coupling, Brake Rod 27-16
BLE-1-2670 Coupling, Sprocket, Gearbox 54-32
(Note 2) Cover 35-7
------ Cover, Bearing 55-15
660-1-1644 Cover, Chain 83-10
660-1-1644 Cover, Chain 84-10
660-1-1644 Cover, Chain 85-8
663-4-2342 Cover, Conveyor Front Bottom - Hinged 82-4
660-1-2470 Cover, Crowder Roller Adjustment Access 79-4
660-1-2470 Cover, Crowder Roller Adjustment Access 85-
BLE-1-2584 Cover, Electrical Components 101-13
BLE-3-2619 Cover, Foot Pedal 22-13
CD315 4-3-15
Rev 4
Chapter 4

------ Cover, Housing 55-29
663-3-2331 Cover, Rear Bottom - Conveyor 85-10
BLE-2-2636 Cover, Rear Bumper (Note 1) 2-14
660-2-1103 Cover, Valve Cavity & Seat Mount 3-12
BLE-1-1084 Cradle Extension, 3" - Battery (Opt.) 10-15
BLE-4-1018 Cradle, Battery 10-4
660-1-1105 Crank, Brake Bell 27-13
660-3-2663 Crossmember Assembly - Std Conv. 76-14
663-2-2802 Crossmember Weldment - Narrow Conv. 69-1
660-4-1015 Crossmember, Chassis Lift Arm 1-12
BLE-3-1058 Crossmember, Control Box 1-10
BLE-4-1073 Crossmember, Conveyor Drive - Narrow 76-21
663-4-2788 Crossmember, Conveyor Lift Arm - Narrow 84-11
660-4-1016 Crossmember, Front Safety Prop 1-8
663-4-1015 Crossmember, Narrow Chassis Lift Arm 1-12
660-4-1975 Crossmember, Rear 1-13
663-1-2341 Cup, Recessed - Safety Stop Button 90-11
660-2-0063 Cylinder, Hydraulic Lift Rear 51-1
660-2-1031 Cylinder, Power Steer 37-9
660-ND-1380 Cylinder, Wheel - L/H 35-16
660-ND-1379 Cylinder, Wheel - R/H 35-16
BLE-1-2665 Decal, "Charge Port" 104-7
4-3-16 CD315
Rev 4
Chapter 4
T-A7 Decal, "Forward-Neutral-Reverse" 89-4

T6-1010-159 Decal, "Made in USA" 16-11
T-A6 Decal, "Reverse-Neutral-Forward" 89-10
T-A2 Decal, Dash 16-14
660-4-1051-32 Differential Case Assembly 58-44
------ Diode, Long Lead 59-4
(Note 2) Disc, Differential 58-20
BLE-1-1070 Door, Charger Port 104-6
BLE-1-1042 Door, Hydraulic 5-16
(Note 2) Drive Gear and Pinion 58-32
T6-8013-153 Dust Boot Kit 34-3
------ Elbow, 45° 6MJ-6MP45 46-9
------ Elbow, 90° 39-5
------ Elbow, 90° 40-5
(Note 1) Elbow, 90° 46-3
(Note 1) Elbow, 90° 46-4
(Note 1) Elbow, 90° 46-5
(Note 1) Elbow, 90° 46-14
8MJ-12MP90 Elbow, 90° - Hydraulic Filter 38-6
660-2701-08-08 Elbow, 90° ½MT-½MT Bulkhead 45-9
660-2501-08-06 Elbow, 90° ½MT-3/8MP 45-21
------ Elbow, 90° 12MP-8MJ90 40-36
CD315 4-3-17
Rev 4
Chapter 4
660-2501-06-04 Elbow, 90° 3/8MT-¼MP 49-10

660-2501-06-04 Elbow, 90° 3/8MT-¼MP 50-10
660-2501-06-08 Elbow, 90° 3/8MT-½MP 51-5
660-2501-06-08 Elbow, 90° 3/8MT-½MT 49-5
660-2501-06-08 Elbow, 90° 3/8MT-½MT 50-5
660-6500-06-06 Elbow, 90° 3/8MT-3/8 37° Female Swivel 51-11
660-6500-06-06 Elbow, 90° 3/8MT-3/8" 37° Female Swivel Nut 44-9
660-6801-06-06 Elbow, 90° 3/8MT-3/8ADJ O-Ring (SAE) 45-7
660-2701-06-06 Elbow, 90° 3/8MT-3/8Bulkhead 51-15
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 45-19
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 49-13
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 50-13
660-2501-06-06 Elbow, 90° 3/8MT-3/8MP 51-10
660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 49-18
660-2701-06-06 Elbow, 90° 3/8MT-3/8MT Blkhd 50-18
08-08-070701 Elbow, 90° 8MJ-BLKH90° 46-27
------ Elbow, 90° JIC½-MO-Ring-3/8 45-3
660-2701-06-06 Elbow, 90°, 3/8MT-3/8MT Blkhd 45-26
660-2501-06-06 Elbow, Male 2501-06-06 37-8
660-2501-08-12 Elbow, Male 2501-08-12 39-16
660-2501-08-12 Elbow, Male 2501-08-12 40-16
¾ NPT 90 Elbow, Pipe 90° - ¾" 38-12
BLE-0001 Enclosure, Receptacle - Rapid Charge 102-5
BLE-3-1017 End, Battery Cradle 10-2
660-1-1170 End, Tie Rod 37-6
660-1-2228 End, Tie Rod 37-6
660-1-1020 End, Wheel Well 1-22
660-ND-1679 Equalizer 26-3
BLE-1-1050 Eye, Terminal for Accelerator Cable 19-14
------ Eyebolt 55-3
4-3-18 CD315
Rev 4
Chapter 4
¼-¾ Fend Washer ¼" ID - ¾" OD 22-9

¼ x 1½ Fend, ¼" ID, 1½" OD 5-5
¼ x 1½ Fend, ¼" ID; 1½" OD 4-4
BLE-4-1061 Fender, Left Body 3-5
660-4-1037 Fender, Left Front 3-11
BLE-4-1062 Fender, Right Body 5-20
660-4-1036 Fender, Right Rear 5-1
660-4-2806 Fender, Right Rear - Ext. Battery Opt. 5-1
660-ND-0020 Filter, Hydraulic Tank Dessicant 40-38
MI-ND-359 Fitting 36-4
08-08-070321 Fitting, 45° 8MJ-8FJX45 94-4
12MJ-16MBUS Fitting, 45° Hydraulic Pump (Large) 38-4
8M6-5MB45 Fitting, 45° Hydraulic Pump (Small) 38-5
660-6801-08-08 Fitting, 90° ½MT-½MP 39-6
660-6801-08-08 Fitting, 90° ½MT-½MP 40-6
660-ND-0040 Fitting, AEROQUIP 40-37
660-ND-1372 Fitting, Brake Line 30-13
CD315 4-3-19
Rev 4
Chapter 4
660-5605-02-02-02 Fitting, Female Pipe Tee 30-14

1-FF-S Fitting, Pipe 38-13
------ Fitting, Quick Disconnect 42-17
------ Fitting, Straight ½ MJICO-Ring-3/8 45-5
------ Fitting, Straight 3/8-¼ 44-10
660-6400-06-06-0 Fitting, Straight 3/8MT-3/8M O-Ring 44-6
660-2700-06-06 Fitting, Straight 3/8MT-3/8MT Bulkhead 45-14
06-06-070601 Fitting, Straight 6MJ-BLHD-UN 46-22
4-3-20 CD315
Rev 4
Chapter 4
08-08-070601 Fitting, Straight 8MJ-BLKH-UN 46-33

660-ND-2849 Fitting, Test Port ¼Male NPT Conn. 43-21
660-ND-2850 Fitting, Test Port 6FJ Conn. - Opt. 43-16
6-CTX-S Fitting, Triple Lock 38-21
660-4-1051-7 Flange Yoke End Assembly 58-41
660-1-0178 Flange, Rear Hoop Bumper - UAL 2-15
T6-7007-105 Flasher, Turn Signal 16-17
660-4-0132-9 Follower, Cam 74-8
660-2-2350 Frame, L/H Rear Step - UAL 2-16
660-2-2332 Frame, R/H Rear Step - UAL 2-20
------ Gasket 55-5
(Notes 3,4) Gasket Cover and RTV Sealant 58-28
(Note 2) Gear, Differential 58-18
BLE-1-2671 Gearbox, Reduction 54-16
------ Grommet - BG901 90-9
BLE-ND-1075 Grommet, Rubber 7/8" x 1¼" x ¼" 13-5
T6-9003-171 Grommet, Windshield 70-3
663-2-2355 Guard, Adjustable Lower Finger 85-1
663-2-2355 Guard, Adjustable Lower Finger - Opt. 81-13
663-2-2355 Guard, Adjustable, Lower Finger 82-2
663-2-2351 Guard, Conveyor Control Bracket, R/H 89-11
BLE-4-1005 Guard, Conveyor Drive 78-10
660-2-0380 Guard, Conveyor Hoop 83-9
660-2-2723 Guard, Conveyor Hoop (Narrow) - Opt. 84-15
660-2-3000-1 Guard, Conveyor Hoop 135° (Narrow) - Opt. 84-15
CD315 4-3-21
Rev 4
Chapter 4
660-2-2662 Guard, Conveyor Rail Bottom 80-18

660-2-1562 Guard, Electric Control Box - Opt 88-1
663-1-2334 Guard, Finger - L/H (Narrow) (UAL) - Opt. 81-2
660-1-1510 Guard, Finger - L/H Front Roller 81-2
663-1-2335 Guard, Finger - R/H (Narrow) (UAL) - Opt. 81-1
660-1-1511 Guard, Finger - R/H Front Roller 81-1
663-4-2268 Guard, Finger - Rear Weld Assembly 85-9
660-3-0987 Guard, Finger - Rear Weld Assy 84-2
660-2-1672 Guard, Front Belt Closeout - Opt. 79-21
660-2-1671 Guard, Front Crossmember Anchor - Opt. 79-22
663-3-2607 Guard, Front Roller, L/H Square - Narrow - Opt. 81-2
663-3-2607 Guard, Front Roller, L/H, Square 80-7
663-3-2608 Guard, Front Roller, R/H Square (Narrow) - Opt. 81-1
663-3-2608 Guard, Front Roller, R/H, Square 80-12
660-1-1464 Guard, Front Valve - Opt. 4-35
660-1-2362 Guard, L/H Nylon - Conveyor Rail Bottom - Opt. 81-8
660-2-2662 Guard, Nylon - Conv. Rail Bottom (Opt.) 79-18
660-1-2362 Guard, Nylon L/H - Conv. Rail Bottom (Opt.) 79-18
660-1-2363 Guard, Nylon R/H - Conv. Rail Bottom (Opt.) 79-18
660-1-2363 Guard, R/H Nylon - Conveyor Rail Bottom - Opt. 81-7
660-3-0962 Guard, Spacer/Finger - Front Bumper Roll (Opt.) 79-8
4-3-22 CD315
Rev 4
Chapter 4

663-2-2683 Guard, V-Groove Caster Narrow L/H 80-21
663-2-2683 Guard, V-Groove Caster Narrow L/H - Opt. 81-18
663-2-2684 Guard, V-Groove Caster Narrow R/H 80-20
663-2-2684 Guard, V-Groove Caster Narrow R/H - Opt. 81-17
(Note 2) Guide, Cable 35-15
BLE-1-1081 Guide, Outer Battery 10-1
660-1-1529 Gusset 1-14
660-1-1018 Gusset, Front Bumper 2-2
660-1-1087 Gusset, Left Front Bumper 1-2
660-1-1068 Gusset, Left Front Frame 1-6
660-1-0177 Gusset, Rear Hoop Bumper - UAL 2-19
660-4-2835 Gusset, Right Fender 1-25
660-1-1088 Gusset, Right Front Fender Well 1-26
660-2-0460 Handle Weldment, Lock - UAL 100-8
T6-4005-109 Handle, Hood 53-31
T6-4005-109 Handle, Hood 54-31
(Note 1) Handle, Lift Assembly 46-2
CD315 4-3-23
Rev 4
Chapter 4
660-4-0909 Handrail Assembly - L/H 32" 98-1

660-4-0138 Handrail Assembly - R/H 32" 98-1
660-4-3007 Handrail Weldment - R/H 99-11
660-4-2352 Handrail Weldment, R/H - UAL Spec. 100-1
MH-ND-956 Hanger, Cable Connector 19-11
660-2-1685 Hanger, Electric Control Box 87-13
BLE-4-1502 Harness, 12V Wire 60-
BLE-4-1500A Harness, 3pc. Wire Kit - 72/80V Control Box 60-1
BLE-4-1500B-72 Harness, 72V Wire - Chassis 60-
BLE-4-1500B Harness, 80V Wire - Chassis 60-
BLE-4-2543 Harness, Dash 16-
660-2-2432 Harness, Wiring, Conveyor E-Stop 90-8
T6-1300-247 Headlight 68-1
T6-1300-247 Headlight 69-2
T6-1300-247 Headlight 70-1
BLE-1-1056 Hinge, Piano 2" x 96" (See Note 1) 3-1
660-3-1605 Holster, Front Control 87-10
660-1-1686 Hook, Hanger - Electric Control Box 87-12
T6-7013-207 Horn 67-1
X6008-101 Horn Button Kit 36-8
------ Horn w/ Terminal Application 67-1a
M3-1-5089 Horn, Electric 48V - Opt. 67-1
BLE-1-2656 Hose (Bulkhead to Manifold) 43-9
BLE-1-2656 Hose (Manifold to Hyd. Cntrl Valve) 43-13
660-1-2899 Hose, ¼" ID x 68" Long 50-20
660-1-1256 Hose, 108" OAL 38-27
4-3-24 CD315
Rev 4
Chapter 4

660-1-1175 Hose, 112" OAL 37-7
660-1-1175 Hose, 112" OAL (to Manifold) 36-3
660-1-1175 Hose, 112" OAL (to Steer Cylinder) 36-1
660-1-1251 Hose, 18" OAL 47-9
660-1-1258 Hose, 25" OAL Pump Suction 38-25
660-1-1250 Hose, 26" OAL 43-17
660-1-1250 Hose, 26" OAL 51-12
660-1-1250 Hose, 26" OAL (Emergency Pump to Manifold) 44-8
660-1-1250 Hose, 26" OAL (Manifold EP to Emerg Pump) 41-3
660-1-1250 Hose, 26" OAL (Tee to Manifold) 46-25
3/8 Hose, 3/8" ID x 2" Long 49-19
3/8 Hose, 3/8" ID x 2" Long 50-19
660-1-1254 Hose, 37" Pump Press. Swivel (Manifold to Cont. Valve) 42-14
660-1-1339 Hose, Booster 83" 29-16
660-1-1339 Hose, Booster 83" 36-2
CD315 4-3-25
Rev 4
Chapter 4
660-1-1340 Hose, Booster Return 50" 29-15

T6-8013-143 Hose, Brake 34-9
T6-8013-143 Hose, Brake Front 28-8
661-1-0033 Hose, Conveyor ½" x 132" 47-7
BLE-1-2627 Hose, JIC Straight #6, 68" (Relief Valve to Front Lift Arm Valve) 46-38
660-1-1338 Hose, Lift Cylinder 39" 45-25
660-1-1338 Hose, Lift Cylinder, 39" 49-15
MJ-1-5003 Hose, Steer Valve/Cylinder L/H (84") 38-26
660-1-1359 Hose, Tank Return 29-18
BLE-1-1057 Hourmeter / BDI, 72-80 14-1
BLE-1-2586 Housing, Burton Receptacle (Altered) 101-15
------ Housing, Gear 55-1
660-2-2369 Housing, R/H Handrail Positive Lock 100-11
BLE-0003 Housing, Receptacle Mount 102-3
660-4-1050-20 Hub and Rotor 52-15
660-4-1050-25 Hubcap 52-20
4-3-26 CD315
Rev 4
Chapter 4

------ Installation Kit, BMID (Part of MX4-10279 & 80) 11-17
------ Jumper Wire w/Connections 67-1b
660-4-0008-15 Keystock 92-6
660-6-0004-42 Keystock, ¼" x 12" 91-5
660-4-1050-1L Knuckle Assembly, L/H 52-7
660-4-1050-1R Knuckle Assembly, R/H 52-7
660-1-2349 Latch, Handrail Safety 100-9
(Note 2) Lever 35-12
T6-8005-101 Lever, Hand Brake 25-9
BLE-2-1077 Lever, Hand Brake (Weldment) 24-1
------ Lever, L/H 35-5
------ Lever, R/H 35-5
BLE-0002-3 Lid, Enclosure 102-4
660-4-0009 Lift Arm Weldment, Rear 72-7
663-4-0009 Lift Arm Weldment, Rear - Narrow Conv. 72-7
T6-7006-107A Light, Back-up - Kit 68-2
CD315 4-3-27
Rev 4
Chapter 4

T6-1300-259 Light, Spot w/ Grill - Opt. 1-29
T6-7006-101A Light, Tail - Kit 68-3
T6-7006-115 Light, Turn Signal - Optional 68-4
MH-ND-565 Line, Brake 10" (Prop. Valve to Tee) 31-12
T6-6011-141 Line, Brake 20" 28-2
T6-6011-141 Line, Brake 20" 29-13
T6-6011-161 Line, Brake 30" 28-7
T6-6011-161 Line, Brake 30" 31-4
T6-6011-161 Line, Brake 30" 32-14
T6-6011-161 Line, Brake 30" 33-3
T6-6011-161 Line, Brake 30" (Prop. Valve to 40" Brake Line) 30-5
T6-6011-161 Line, Brake 30" (Prop. Valve to Left Front Brake Hose) 30-4
T6-6011-149 Line, Brake 40" 28-5
T6-6011-149 Line, Brake 40" 29-5
T6-6011-149 Line, Brake 40" 32-3
T6-6011-149 Line, Brake 40" 33-14
T6-6011-149 Line, Brake 40" (Tee to 30" Brake Line) 31-5
5-100-101 Line, Brake 51" 28-4
5-100-101 Line, Brake 51" 29-3
5-100-101 Line, Brake 51" 32-11
5-100-101 Line, Brake 51" 33-11
T6-6011-151 Line, Brake 6" 28-6
T6-6011-151 Line, Brake 6" (Prop. Valve to Tee) 30-12
BLE-ND-1085-0 Line, Hyd. Cntrl Valve 3.25" (SS) 46-6
660-ND-2213-10 Line, Hydraulic #10 (SS) - Rear Lift Cylinder (CE Opt.) 51-7
4-3-28 CD315
Rev 4
Chapter 4

660-ND-2212-28 Line, Hydraulic (#28) 47-10
660-ND-2213-28 Line, Hydraulic (#28) (SS Opt.) 47-10
BLE-ND-1084-0 Line, Hydraulic Control Valve 3.25" 46-6
660-1-1543 Liner, Fender Well 3-6
------ Liner, Fender Well - Front 12" x 24" 5-21
------ Liner, Fender Well - Front Left 18.5" x 12" 4-3
------ Liner, Fender Well - Middle Left 20" x 30" 4-9
T6-2004-155 Link Kit, Wheel Chocks - Opt. 4-37
------ Link, Connecting - Cylinder 35-17
660-2-0454 Link, Handrail - UAL Spec. 100-10
660-6-0004-19 Link, Master 91-6
660-6-0004-19 Link, Master 92-16
660-6-0004-19 Link, Master 93-18
660-6-0004-19 Link, Master 94-19
660-4-1051-16 Lock, Differential Shaft 58-27
660-2-2815 Maintenance Kit, Hydraulic Gauge 42-
CD315 4-3-29
Rev 4
Chapter 4
BLE-4-2634 Mat, Battery Compartment Floor 11-7

T6-9011-375 Mirror, 5 x 7 6-2
BLE-1-2652 Motor, Hydraulic Belt Drive 94-1
663-2-2356 Mount, Adjustable Lower Finger Guard - Opt. 81-12
660-2-2854 Mount, E-Stop Switch 90-7
660-2-2845-2 Mount, E-Stop Switch 90-10
BLE-3-1047 Mount, Filter - Hydraulic 38-7
BLE-4-1074 Mount, Jackshaft - Narrow Conv. 93-16
BLE-4-1074 Mount, Jackshaft - Narrow Conveyor 76-20
660-3-1249 Mount, Light - 13" Solid Dual 70-2
4-3-30 CD315
Rev 4
Chapter 4

BLE-2-2587 Mount, Receptacle & Switch - Wldmt 101-11
440E-29053 Mount, Switch (Weldment) 22-6
660-2-2855 Mount, Top E-Stop Switch 90-3
660-ND-1442 Nameplate, Forward 89-
660-ND-1443 Nameplate, Reverse 89-
660-ND-1441 Nameplate, Stop 89-
660-5404-16-16 Nipple, Hex 5404-16-16 39-28
660-5404-16-16 Nipple, Hex 5404-16-16 40-28
660-4-1050-10 Nut, Axle 52-6
660-4-1051-19 Nut, Brake Mounting 58-11
08-070118 Nut, Bulkhead 83LMD Nut 46-36
08-070118 Nut, Bulkhead 8BLKHD-NUT 47-4
------ Nut, Castellated (Incl. w/ Motor) 94-14
9/16-16NF Nut, Castellated 9/16-16 37-3
X4015-101 Nut, Column 36-11
660-1-2252 Nut, Conduit ½ NPT 63-36
660-1-2252 Nut, Conduit ½ NPT 103-11
660-1-2252 Nut, Conduit ½" NPT 19-12
660-1-1921 Nut, Conduit ¾" NPT 19-16
3/8-16 Nut, Flange - LK REG 3/8-16 4-31
3/8-16 Nut, Flange - LK REG 3/8-16 - Opt. 5-24
¼-20 Nut, Flange ¼-20 103-2
5/16-18 Nut, Flange Lock Hex 5/16-18 9-2
------ Nut, Hex 55-8
#4-40 Nut, Hex #4-40 22-7
¾-10 Nut, Hex ¾-10 95-11
¾-10 Nut, Hex ¾-10 96-11
3/8-24 Nut, Hex 3/8-24 21-24
CD315 4-3-31
Rev 4
Chapter 4
3/8-24 Nut, Hex Jam 3/8-24 27-9

M10 x 1.5 Nut, Jam 60-4
½-13 Nut, Jam Nylock ½-13 97-13
½-13 Nut, Jam Nylock ½-13 99-5
------ Nut, Lock 35-21
660-4-1050-17 Nut, Lock 52-12
------ Nut, Lock - 8mm ID 67-1d
#8 Nut, Lock - Fiber #8 23-5
BLE-1-1052 Nut, Lock - Sealing ½" 19-12
BLE-1-1051 Nut, Lock - Sealing ¾" 19-16
660-ND-1921 Nut, Lock - Strain Relief, ¾" 63-29b
660-0306-08 Nut, Lock ½" - Bulkhead 45-11
10/32 Nut, Lock 10/32 101-10
660-0306-06 Nut, Lock 3/8" - Bulkhead (for 2701-06-06) 45-13
5/32 Nut, Lock 5/32" ID 63-7
5/32 Nut, Lock 5/32" ID 64-7
5/32 Nut, Lock 5/32" ID - Opt. 63-7
660-4-1051-9 Nut, Pinion 58-43
660-4-1051-26 Nut, Rear Axle Spindle 58-5
660-4-1051-29 Nut, Stud 58-1
4-3-32 CD315
Rev 4
Chapter 4

¼-20 Nut, Top Lock Hex ¼-20 10-12
¼-20 Nut, Top Lock Hex ¼-20 22-10
¼-20 Nut, Top Lock Hex ¼-20 39-24
¼-20 Nut, Top Lock Hex ¼-20 40-24
¼-20 Nut, Top Lock Hex ¼-20 44-14
¼-20 Nut, Top Lock Hex ¼-20 53-26
¼-20 Nut, Top Lock Hex ¼-20 54-26
¼-20 Nut, Top Lock Hex ¼-20 101-16
½-13 Nut, Top Lock Hex ½-13 39-32
½-13 Nut, Top Lock Hex ½-13 40-32
3/8-16 Nut, Top Lock Hex 3/8 -16 63-22
3/8-16 Nut, Top Lock Hex 3/8-16 4-16
3/8-16 Nut, Top Lock Hex 3/8-16 4-18
3/8-16 Nut, Top Lock Hex 3/8-16 5-11
3/8-16 Nut, Top Lock Hex 3/8-16 5-22
3/8-16 Nut, Top Lock Hex 3/8-16 7-6
3/8-16 Nut, Top Lock Hex 3/8-16 21-1
3/8-16 Nut, Top Lock Hex 3/8-16 21-20
3/8-16 Nut, Top Lock Hex 3/8-16 25-6
3/8-16 Nut, Top Lock Hex 3/8-16 39-34
3/8-16 Nut, Top Lock Hex 3/8-16 40-34
3/8-16 Nut, Top Lock Hex 3/8-16 40-21
CD315 4-3-33
Rev 4
Chapter 4
3/8-16 Nut, Top Lock Hex 3/8-16 41-21

3/8-16 Nut, Top Lock Hex 3/8-16 42-18
3/8-16 Nut, Top Lock Hex 3/8-16 43-22
3/8-16 Nut, Top Lock Hex 3/8-16 44-2
3/8-16 Nut, Top Lock Hex 3/8-16 45-31
3/8-16 Nut, Top Lock Hex 3/8-16 53-10
3/8-16 Nut, Top Lock Hex 3/8-16 54-10
3/8-16 Nut, Top Lock Hex 3/8-16 64-21
5/16-18 Nut, Top Lock Hex 5/16-18 21-5
5/16-18 Nut, Top Lock Hex 5/16-18 22-12
5/16-18 Nut, Top Lock Hex 5/16-18 39-18
5/16-18 Nut, Top Lock Hex 5/16-18 40-18
5/16-18 Nut, Top Lock Hex 5/16-18 79-17
5/16-18 Nut, Top Lock Hex 5/16-18 80-4
5/8-11 Nut, Top Lock Hex 5/8-11 19-15
5/8-11 Nut, Top Lock Hex 5/8-11 53-18
5/8-11 Nut, Top Lock Hex 5/8-11 54-18
5/8-18 Nut, Top Lock Hex 5/8-18 74-11
½-20 Nut, Wheel ½-20 ZP 71-3
660-4-1050-24 Nut, Wheel Bearing 52-19
660-4-1050-22 Nut, Wheel Bearing with Pin 52-17
------ O-Ring 55-16
663-2-2672 Pad Assembly - L/H Side 80-2
663-2-2671 Pad Assembly - R/H Side 80-17
663-2-2672 Pad Assy, L/H Side - Opt. 81-16
663-2-2671 Pad Assy, R/H Side - Opt. 81-3
T6-8013-149 Pad, Brake - Non-Organic 34-4
660-1-2244 Pad, Front Slope - Conveyor - Opt. 81-11
660-2-2809 Pad, Nylon - Drivers Side w/slots (Narrow) - Opt. 81-16
660-2-2837 Pad, Nylon - Front Right Side 79-15
660-2-2837 Pad, Nylon - Front Right Side - Opt. 81-3
660-2-2810 Pad, Nylon - Passenger Side w/slots (Narrow) - Opt. 81-3
------ Panel, Controller w/ 24V Coils 80V 64-1
------ Panel, Controller w/ 24V Coils, 80V 66-1
4-3-34 CD315
Rev 4
Chapter 4

BLE-4-2557 Panel, Left Front Body Weldment 4-2
¼ P-Clamp, ¼'ID 103-5
BLE-2-1064 Pedal Assembly, Accelerator 20-1
660-2-1278 Pedal Assembly, Brake 27-8
T6-1009-103 Pedal, Accelerator 21-9
440E-29066 Pedal, Throttle 22-1
(Note 2) Pin 35-11
T6-1004-117 Pin, Clevis 19-8
M3-1-8011 Pin, Clevis 5/16 x 1¼ 19-19
BLE-ND-2609 Pin, Clevis 5/16" x 1" Long 21-14
1/8 x 2 Pin, Cotter Ø 1/8 x 2 94-16
1/8 x 1 Pin, Cotter Ø 1/8" x 1" Long 37-2
3/32 x 7/8 Pin, Cotter Ø 3/32 x 7/8" Long 21-15
3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" 27-5
3/32 x 7/8 Pin, Cotter Ø 3/32" x 7/8" Long 25-10
660-4-0137-12 Pin, Detent 98-8
660-4-0137-12 Pin, Detent 99-8
660-4-0137-12 Pin, Detent, COM 97-11
660-1-0271 Pin, Pivot - Short 97-6
660-1-0271 Pin, Pivot - Short 98-5
660-1-0271 Pin, Pivot - Short 98-10
CD315 4-3-35
Rev 4
Chapter 4
660-1-0271 Pin, Pivot - Short 99-10

660-1-0271 Pin, Pivot, Short 100-2
660-6-0004-27 Pin, Roll 95-10
660-6-0004-27 Pin, Roll 96-10
------ Pinion 55-10
(Note 2) Pinion, Differential 58-14
T6-8013-157 Piston 34-2
660-1-1280 Plaque, Conveyor Control 4-6
BLE-1-2633 Plaque, Conveyor Control 4-6
------ Plate Assembly, L/H 35-4
------ Plate Assembly, R/H 35-4
BLE-4-1037 Plate, Base - Shifter Switches 19-5
------ Plate, Cam L/H 35-20
------ Plate, Cam R/H 35-20
660-3-0809 Plate, Channel - Take-up Bearing 75-5
660-1-1048 Plate, Circuit Breaker 23-2
663-4-2666 Plate, Conveyor Bottom Front Cover 80-19
663-4-2666 Plate, Conveyor Bottom Front Cover - Opt. 81-14
663-3-2319 Plate, Conveyor D-Bumper 81-6
660-2-1692 Plate, Cover - Lower Left Rear 84-8
660-2-1693 Plate, Cover - Lower Right Rear 84-9
663-1-2698 Plate, D-Bumper Retainer 80-9
663-1-2698 Plate, D-Bumper Retainer - Opt. 79-20
660-1-0472 Plate, Handrail Lock Collar - UAL 100-7
BLE-1-2625 Plate, Ignition Switch Mount 16-7
660-3-0802 Plate, Middle 75-15
660-3-0802 Plate, Middle 76-15
660-3-0802 Plate, Middle 77-15
660-2-0935 Plate, Mounting 94-9
660-2-1607 Plate, Rear Bottom Cover (CE Opt.) 85-10
660-1-1670 Plate, Rear Idler Cover 85-3
4-3-36 CD315
Rev 4
Chapter 4
660-1-1670 Plate, Rear IDLER Cover - Opt. 84-14

660-1-1170-2 Plate, Steer Cylinder Mounting 37-5
(Note 1) Plug 46-12
------ Plug / Breather 55-2
660-5406-P-04 Plug, ¼" MP 40-19
660-5406-P-04 Plug, ¼" MP 41-19
½ Plug, ½" 40-16
½ Plug, ½" 41-16
½ Plug, ½" 42-16
½ Plug, ½" 43-20
¾ Plug, ¾" 89-7
------ Plug, ¾" - Opt. 88-9
T6-9003-572 Plug, Button - Black ¾" 16-16
T6-9003-572 Plug, Button - Black ¾” 15-2
660-1-2552 Plug, Button - Black 7/8" 16-2
T6-7022-105P Plug, Button ¾" 14-4
660-ND-107P Plug, Button 7/8" 14-9
660-4-1051-10 Plug, Cover (Note 3) 58-31
660-1-1957 Plug, Dash 14-2
------ Post, Power 66-9
660-4-1976 Prop, Rear Safety 73-2
CD315 4-3-37
Rev 4
Chapter 4

660-ND-1439 Push Button, Green Head 87-7
660-ND-1440 Push Button, Red Head 87-8
660-6-0800 Rail, Conveyor - L/H 75-10
660-6-0801 Rail, Conveyor - R/H 75-1
660-4-1005 Rail, Frame, L/H 1-11
660-4-1006 Rail, Frame, R/H 1-21
660-4-3078 Rail, Hand - Single 7-5
660-2-1230 Rail, Rub - Center 70" 4-29
660-2-1229 Rail, Rub - Left Front 3-9
660-2-1230 Rail, Rub - Plastic, 16" 3-4
660-2-1230 Rail, Rub - Plastic, 70" 3-7
BLE-0005 Receptacle, Machined - Rapid Charge 102-6
BLE-1-2577 Receptacle, Rapid Charge 101-18
------ Rectifier, Silicone Controlled "SCR (A)" 59-1
------ Rectifier, Silicone Controlled "SCR (B)" 59-2
------ Rectifier, Silicone Controlled "SCR (C)" 59-3
BLE-1-1005 Reducer, Belt Drive Speed 91-3
BLE-1-1003L Reducer, Belt Drive Speed, L/S 92-3
BLE-1-1003R Reducer, Belt Drive Speed, R/S 93-3
663-2-2340 Reinforcement, Narrow Conveyor Front 77-21
660-4-0741-2 Relay 86-4
4-3-38 CD315
Rev 4
Chapter 4
660-1-2326 Relay, 12VDC 0.9W - Infrared Conv. Shutdown Opt. 64-36

660-4-0753-2 Relay, Electric Belt Control 60-2
------ Relay, Harness to Horn 67-5
BLE-1-2570 Relay, One N/O Contact 63-13
T6-9100-105-2 Relay, Power (Back-Up Light) 64-9
T6-9100-105-2 Relay, Power (Reverse Light) 63-9
BLE-1-2570 Relay, with one N/O Contact 64-12
42-100-704 Release, Manual for Truck SBX350 12-3
42-100-703 Release, Manual, SB350 Red 12-3
660-ND-1920 Relief Strain ½ x ¾ NPT (CGB294) 19-18
660-ND-2215 Relief Strain 3/8 x ½ NPT (CGB116) 19-17
660-ND-2215 Relief, Strain 3/8 x ½ NPT (CG116) 63-34
MX4-10251 Relief, Strain 4/0 103-15
BLE-1-1055 Relief, Strain 5/8 x ¾NPT (CGB295) 19-7
BLE-1-1055 Relief, Strain 5/8" x ¾" NPT (CGB295) 63-29a
(Note 3) Retainer, Hold Down Spring 35-6
MJ-ND-4006 Ring, Lashing 5/8" x 4" x 4" - Forged w/ Bracket 1-17
BLE-1-1502 Ring, Sealing ½" NPT 19-12
BLE-1-1503 Ring, Sealing ¾ NPT 64-25
BLE-1-1503 Ring, Sealing ¾" NPT 63-29c
------ Ring, Snap 55-9
CD315 4-3-39
Rev 4
Chapter 4
------ Ring, Snap 55-19

------ Ring, Snap 55-23
------ Ring, Snap 55-26
660-1-2392 Rod, Brake 21-25
660-1-1358 Rod, Brake 27-15
660-1-1104 Rod, Brake Pedal 27-10
BLE-2-1054 Rod, Pull - Hand Throttle 20-6
660-6-0004-22 Roller, 22" 95-6
660-6-0004-22 Roller, 22" 96-6
660-1-2409 Roller, 22" - Heavy Duty 95-7
660-1-2409 Roller, 22" Heavy Duty 96-7
660-6-0004-20 Roller, 24" 96-18
663-1-0144 Roller, Drive 94-10
663-1-0144 Roller, Drive - Narrow Conveyor 96-3
660-1-0144 Roller, Drive w/Lagging 95-3
660-1-0145 Roller, Idler 95-9
660-1-0145 Roller, Idler 96-9
660-2-1230 Rub Rail, Plastic, 70" 5-12
660-1-0243 Safety Prop Weldment 73-1
T6-200-105 Safety Walk 12" Wide, 19"Long 5-18
T6-200-106 Safety Walk 22" Wide, 14' Long 4-27
#4-40 Screw #4-40 22-3
5/32 x 1 Screw Ø 5/32 x 1" Long 63-3
5/32 x 1 Screw Ø 5/32 x 1" Long 64-3
5/32-1 Screw Ø 5/32 x 1" Long - Opt. 63-3
3/8-16 x 1¼ Screw, 3/8" x 1¼" Long 4-26
T6-8013-165 Screw, Bleeder, Delco 34-8
------ Screw, Hex Head 55-18
¼-28 x 1 Screw, Hex Head Machine Ø ¼-28 x 1" Long 102-7
------ Screw, Locking / Stud 55-6
10/32 x ½ Screw, Phillips Head 10/32 x ½" Long 101-7
4-3-40 CD315
Rev 4
Chapter 4

#8-32 x 5/8 Screw, Round Head #8-32 x 5/8" Long 23-3
¼-20 Screw, Set 98-6
6-32 x ¼ Screw, Slotted Pan Head Ø 6-32 x ¼" Long 90-5
5/16 Screw, Socket Head 5/16 x 1.25" Long 101-9
BLE-ND-1080 Seal, Hole ¾" Dia. Conduit 19-13
BLE-ND-1080 Seal, Hole Ø ¾" Conduit Hole, Black 63-29
660-4-1050-26 Seal, Oil 52-13
660-4-1051-4 Seal, Rear Axle 58-40
660-4-1051-11 Seal, Rear Hub 57-1
660-4-1051-11 Seal, Rear Hub 58-10
------ Seal, Shaft 55-17
------ Seal, Shaft 55-27
------ Seal, Shaft 55-31
------ Sealing Compound 55-4
4-100-101A Seat, Vinyl Bucket 9-8
BLE-1-2675 Sensor, Fiber Optic 103-3
BLE-0006 Sensor, Temperature - Opt. 10-8
660-4-1051-24 Shaft, Axle - L/H 57-5
660-4-1051-24 Shaft, Axle - L/H 58-4
660-4-1051-23 Shaft, Axle - R/H 57-5
660-4-1051-23 Shaft, Axle - R/H 58-4
(Note 2) Shaft, Differential 58-15
660-1-1116 Shaft, Drive 53-23
660-1-1116 Shaft, Drive 54-23
------ Shaft, Input 55-28
CD315 4-3-41
Rev 4
Chapter 4
------ Shaft, Output 55-20

660-4-0732-7 Shifter, Morse 14-3
660-4-0732-7 Shifter, Morse 17-1
(Note 2) Shim, Differential Bearing 58-22
(Note 2) Shim, Drive Pinion Adjustment 58-35
(Note 2) Shim, Pinion Bearing Adjustment 58-37
660-1-1189 Shoes, Brake Drive Axle (set of 4/box) 35-1
T6-8013-167 Sleeve 34-7
660-4-1051-8 Slinger, Pinion 58-39
660-4-0741-3 Socket Base 86-3
660-4-1050-29 Socket Kit 52-4
660-1-2327 Socket, Relay Base - Infrared Conv. Shutdown Opt. 64-37
660-2-2208 Spacer, 2" - Conveyor Bumper (Note 1) 1-28
660-1-2390 Spacer, Conveyor Rail to Clevis 100-16
(Note 2) Spacer, Differential Gear 58-19
660-1-2224 Spacer, Handrail 100-21
660-1-2391 Spacer, Inner Clevis 100-22
660-2-0839 Spacer, Rear 1-18
BLE-1-2585 Spacer, Receptacle Stand-off 101-12
660-4-1050-16 Spindle and Plug Assembly 52-11
660-ND-2216 Spring, 7" Extension 100-3
660-1-2389 Spring, Handrail Lock Handle 100-15
(Note 3) Spring, Hold Down 35-8
67798 Spring, Hold Down for Plug-In Relay 64-11
BLE-1-2572 Spring, Hold Down for Relay 63-12
(Note 2) Spring, L/H 35-10
(Note 3) Spring, Lower 35-14
(Note 2) Spring, R/H 35-10
T6-4014-119 Spring, Throttle Linkage 21-4
4-3-42 CD315
Rev 4
Chapter 4
(Note 3) Spring, Upper 35-2

660-1-2365 Sprocket, 27-Tooth, Drive Roller 94-12
660-1-0020 Sprocket, Hydraulic Motor 94-7
660-4-3004 Step, Front (Wldmt) 7-4
660-4-2338 Step, Front Lower - UAL Spec (Wldmt) 8-5
660-4-0182 Step, Front Upper - UAL Spec (Wldmt) 8-2
660-2-2314 Step, L/H Boom Guard Gripstrut - UAL 2-17
660-2-2386 Step, R/H Boom Guard Gripstrut - UAL 2-21
660-4-1050-9 Stop, Axle 52-5
660-ND-1920 Strain Relief - ½ x ¾ NPT (CGB294) 12-4
660-1-0005-30 Strap, Conveyor 75-12
660-1-0005-30 Strap, Conveyor 76-12
660-1-0005-30 Strap, Conveyor 77-12
T6-8005-111 Strap, Lever to Park Brake 72-6
660-1-1041 Strut, Right Middle Fender 5-10
660-4-1051-22 Stud, Drive Axle Hub 58-3
¾-10 x 9 Stud, Threaded - ¾-10 x 9" Long 96-12
CD315 4-3-43
Rev 4
Chapter 4
¾-10 x 9 Stud, Threaded Ø ¾-10 x 9" Long 95-12

660-4-1051-30 Stud, Wheel 58-12
2-023-101 Support, Accelerator Pedal 21-6
660-2-2357 Support, Handrail Rear Down 100-19
660-2-2848 Support, Instrument Panel 2-6
BLE-ND-002 Switch, Demand- N.O. with Plug (Alternate Source) 48-4
T6-7010-140 Switch, Ignition - CH Lever 14-7
660-1-2559 Switch, Ignition, 2 Position 15-6
660-4-0532-2 Switch, Limit (Honeywell) 24-2
42-100-801 Switch, Micro 19-10
42-100-801 Switch, Micro 101-14
42-100-801 Switch, Micro 104-2
M3-1-8106 Switch, Micro for Directional 22-2
42-126-101 Switch, Micro, DPDT 25-14
660-1-2425 Switch, Momentary Stop - Narrow Conveyor 90-1
M3-1-5175 Switch, Seat - Sears 9-6
------ Switch, Thermal 59-5
T6-7010-113 Switch, Toggle 14-6
T6-7010-114 Switch, Toggle - 1 Pole, 2 Pos 16-6
T6-7010-113 Switch, Toggle (Back-Up Light) 16-5
T6-7010-113 Switch, Toggle (Head Light) 15-4
T6-7010-113 Switch, Toggle (Headlight) 16-4
T6-7010-113 Switch, Toggle (Spot Light) 16-8
T6-7010-113 Switch, Toggle (Spot Light) - Opt. 15-7a
BLE-1-2624 Switch, Toggle, DPST Sealed 16-6
------ Switch, Valve 46-32
660-4-1045 Tank Assembly, Hydraulic 39-22
660-4-1047 Tank, Hydraulic - UAL Spec 40-22
660-4-1045 Tank, Hydraulic Assembly 38-10
T6-6011-111 Tee 28-12
4-3-44 CD315
Rev 4
Chapter 4
T6-6011-111 Tee 32-13

T6-6011-111 Tee 33-13
660-2605-06-04-06 Tee 51-6
660-5605-04-04-04 Tee ¼FP-¼FP-¼FP 40-18
660-5605-04-04-04 Tee ¼FP-¼FP-¼FP 41-18
660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 49-9
660-5605-04-04-04 Tee, ¼FP-¼FP-¼FP 50-9
------ Tee, ½MJIC-½MJIC-½FJIC Swivel 45-10
660-2704-08-08-08 Tee, ½MT-½MTBulkhead-½MT 45-12
06-08-06-070428 Tee, 3/8MJ-½MB-3/8MJ 43-18
08-08-08-070958 Tee, 8MJBLKD-8MJ 46-21
------ Tee, Female Pipe 28-10
660-5605-02-02-02 Tee, Female Pipe Fitting 31-13
203102-6-6S Tee, Swivel Flare - Opt. 43-15
660-4-1050-14 Tie Rod Assembly 52-9
BLE-1-2674 Tire, 10 Ply Radial, 225/75R16 71-2
TM1-ND-1013 Tire, 225/75-16 LTX AT 71-2
T6-1300-101 Tire, All Season, 8.75 x 16.5 71-2
T6-2400-161 Tire, Goodyear 225/75-16R LT 71-2
MH-1-602 Tire, Goodyear 8 x 16 LT 71-2
MH-ND-650 Tire, LT215/85R/16 71-2
T6-2004-103 Tire, Rib Tread 8.0 x 16.5 71-2
T6-2400-160 Tire, Safari SJR LT 225/75R16 71-2
T6-2400-171 Tire, Supergrip 8.75 x 16.5 10PR Mud/Snow 71-2
T6-2400-166 Tire, Tug Tuff, 8.00 x 16.5 71-2
T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5" 10PR 71-2
T6-2400-205 Tire/Wheel Assembly, 10 Ply 225/75R16 Radials 71-
T6-2400-185 Tire/Wheel Assembly, Goodyear 225/75R16 LT 71-
T6-2400-206 Tire/Wheel Assembly, Kelly LT225/75R16 71-
T6-2400-187 Tire/Wheel Assembly, Tug Tuff, 8 x 16.5 71-
TM1-1-9814 Tire/Wheel Assembly, Tug Tuff, 8.75 x 16.5 71-
MG-1-320 Trim-Lok, 7.5" Long 103-17
CD315 4-3-45
Rev 4
Chapter 4

660-1-2368 Tube, Stainless Telescoping 100-12
BLE-1-2680 Tubing, Hydraulic Line #37 (SS) 40-31
660-1-1121 U-Bolt, Front Axle 52-3
660-1-1122 U-Bolt, Rear Axle 56-4
660-4-0010-12 Valve, Ball 38-15
660-4-0010-12 Valve, Ball 39-29
660-4-0010-12 Valve, Ball 40-29
4-3-46 CD315
Rev 4
Chapter 4

660-4-0010-3 Valve, Holding 49-14
660-4-0010-3 Valve, Holding 50-14
660-4-0010-3 Valve, Holding 51-9
BLE-4-2654 Valve, Hydraulic Assembly 46-1
660-4-0010-20 Valve, Relief 45-20
660-4-0010-20 Valve, Relief 46-8
660-4-0010-13 Valve, Relief 48-1
660-1-3028 Valve, Steer 36-5
660-4-1051-2 Washer 58-42
T6-8013-147 Washer, Brake Hose 34-10
------ Washer, Flat 35-18
½ Washer, Flat 56-2
#8 Washer, Flat #8 23-4
½ Washer, Flat ½" 94-13
CD315 4-3-47
Rev 4
Chapter 4
1 Washer, Flat 1" ID 74-3

10/32 Washer, Flat 10/32 101-8
5/16 Washer, Flat 5/16" 21-7
5/16 Washer, Flat 5/16" ID 39-3
5/16 Washer, Flat 5/16" ID 40-3
5/16 Washer, Flat 5/16" ID 79-16
5/16 Washer, Flat 5/16" ID 80-5
5/8 Washer, Flat 5/8" 19-15
9/16 Washer, Flat 9/16" ID 37-4
9/16 Washer, Flat 9/16" ID 53-17
4-3-48 CD315
Rev 4
Chapter 4
9/16 Washer, Flat 9/16" ID 54-17

------ Washer, Ground Terminal 67-1f
660-4-1050-23 Washer, Lock 52-18
------ Washer, Lock 55-7
660-4-1051-27 Washer, Lock 58-6
0123490 Washer, Lock - Regular #6 90-6
#4 Washer, Lock #4 - External Tooth 22-8
¼ Washer, Lock ¼” ID 15-9
5/32 Washer, Lock 5/32" ID 63-18
5/32 Washer, Lock 5/32" ID 64-17
CD315 4-3-49
Rev 4
Chapter 4

------ Washer, Star 67-1e
(Note 2) Washer, Thrust - Differential Pinion 58-13
BLE-1-2632 Watering System, BFS (For Exide/Deka 72V Batteries) 11-11
MX4-10263 Watering System, BFS (For Exide/Deka 80V Batteries) 10-
MX4-10263 Watering System, BFS (For Exide/Deka 80V Batteries) 11-11
MX4-10149 Watering System, Flo-Right 10-
MX4-10149 Watering System, Flo-Right 11-11
BLE-1-2660 Watering System, Flo-Right Single Point 10-
BLE-1-2660 Watering System, Flo-Right Single Point 11-11
660-2-1019 Well, Wheel 1-23
T6-9003-549 Wheel, 16" x 6", White 71-1
T6-9003-550 Wheel, 16.5" x 6.75", White 71-1
T6-2003-101UPS Wheel, DC 16.5 x 6.75 w/Reinf. Plate 71-1
------ Wheel, Helical Gear 55-12
X4004-101 Wheel, Steering 36-10
T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 71-1
660-4-0132-4 Wheel, V-Groove with Roller Bearing 74-4
MD-CB1-129 Yoke 27-7
T6-1004-109 Yoke, Shift Linkage 19-4
1/8 Zerk Ø 1/8" Pipe 90° 49-2
1/8 Zerk Ø 1/8" Pipe 90° 50-2
1/8 Zerk Ø 1/8" Pipe 90° 51-3
4-3-50 CD315
Rev 4
Chapter 5
CHAPTER 5: APPENDICES
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1

A. Daily and Weekly and Monthly Checks ................................................................. 5-1-1
B. Bi-Monthly, 6 Months and Yearly Checks .............................................................. 5-1-2
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1

A. Description ........................................................................................................... 5-2-1
CD315 5-TOC-i
Rev 4
Chapter 5
5-TOC-ii CD315
Rev 4
Chapter 5
SECTION 1: PERIODIC MAINTENANCE CHECKLIST
A. DAILY AND WEEKLY AND MONTHLY CHECKS
TUG Model 660E Electric Conveyor

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 50 200 400 1200 2400

Check controls are in good working order.
Check battery charge and electrolyte level.
Check hydraulic oil level.
Check tire pressure and treads for damage.
Check headlight operation.
Check backup, tail, stop and turn signal lights.
Check operation of cab marker lights, heater, wiper
and cab lights if equipped.
Sound horn.
Check conveyor belt for proper tension and alignment.
Check drive belt chain adjustment.
Lubricate belt drive chain.
Check rear finger guard adjustment.
Check that the wheel lug nuts are tightened.
Check brake fluid level.
Check for oil leaks and damage.
Check ball joints for looseness.
Check the service brake pedal for proper operation.
Check the parking brake.
Check brake pads and shoes.
Lubricate service brake pedal linkage pivots.
Lubricate parking brake lever pivots.
Lubricate throttle linkage.
Lubricate conveyor belt roller bearings.
Lubricate conveyor side and handrail pivots.
Lubricate access cover hinges.
Lubricate seat slide.
Lubricate drive shaft joints.
Lubricate steering axle links.
Lubricate all grease fittings.
CD315 5-1-1
Rev 4
Chapter 5
B. BI-MONTHLY, 6 MONTHS AND YEARLY CHECKS
TUG Model 660E Electric Conveyor

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 50 200 400 1200 2400

Change hydraulic oil filter
Check idle rpm and mixture.
Inspect front wheel bearings, clean and repack.
Check tie rod ends looseness.
Check traction and belt motor brushes.
Check belt brake adjustment.
Check intake manifold bolts and tighten.
Check drive axle mounting bolts and tighten.
Check drive axle oil level.
Check reduction gear box lube (conveyor).
Check reduction gear box lube (drive train).
Change drive axle oil.
Drain, flush and refill and bleed brake system.
Drain, Flush and refill the hydraulic system.
5-1-2 CD315
Rev 4
Chapter 5
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS
A. DESCRIPTION
The following pages/booklets contain additional information relevant to the operation and
service of the 660E Mobile Electric Conveyor.
CD315 5-2-1
Rev 4
Chapter 5
5-2-2 CD315
Rev 4
660E
Electric Belt Loader
PowerpaK Series –
Traction/Belt Controller
815 Allgood Road ■ Marietta, GA 30062-3305 USA ■ Tel: (770) 422-7230 ■ Fax: (770) 428-7315
174/32061
TUG 660E Belt Loader
Powerpak - Traction/Belt Controller
DOCUMENT: TUG 660E Electric Belt Loader.

Powerpak Panel Number 632B86302
Prepared By: Joseph Mini
Copies: TUG
Steve Lorenz
Kevin O’Keeffe
Steve Parent
Rev: 1 A B C D
5/25/01 6/04/01 7/30/01 2/04/02 4/11/02
Document Change Page:
Rev 1: 5/25/01 – Original, Pre-Production Release.
Rev A: 6/04/01 – Production Release.
Rev B: 7/30/01 – Wiring Diagram Updated.
Rev C: 2/04/02 – BDI cuts belt feature added.
Rev D: 4/11/02 – Wiring Diagram updated to rev. C.
TUG 660E Belt Loader 2 of 20 Rev:D
174/32061
Table Of Contents
Table Of Contents ......................................... 3

Document Purpose .......................................... 4
1.0 Definition ............................................ 4
1.1 Displays .............................................. 5
2.0 Scope ................................................. 5
3.0 Inputs and Outputs .................................... 5
3.1 Power Cable Wiring .................................. 5
3.2 Control Inputs ...................................... 6
3.2.1 Power Supply Inputs ............................... 6
3.2.2 Signal Inputs ..................................... 6
3.3 Control Outputs (Contactor drivers) ................ 7
4.0 Modes of Operation ................................... 7
4.1 Traction Drive Mode ................................ 7
4.2 BELT Mode .......................................... 7
4.3 PUMP MODE .......................................... 8
5.0 Features ............................................. 8
5.1 Features in BELT MODE .............................. 8
5.1.1 Selectable control of BELT motor speed ........... 8
5.1.2 Belt Brake ....................................... 9
5.1.2.1 Belt change over contactor diagnostics........ 9
5.1.3 Belt Conveyor Lift Or Lower ..................... 10
5.1.4 Soft start ...................................... 10
5.1.5 Soft stop ....................................... 10
5.1.6 Low Voltage BDI Cutout .......................... 10
5.1.7 Programmable Low Voltage Cutout ................. 11
5.1.8 Current Limit Timeout ........................... 11
5.1.9 BELT HOURS Counter .............................. 11
5.1.10 High Speed Bypass/Field Weakening .............. 11
5.2 Features in TRACTION mode ......................... 12
5.2.1 Speed control ................................... 12
5.2.2 Wire off detect ................................. 12
5.2.3 Soft start ...................................... 12
5.2.4 Soft stop ....................................... 13
5.2.5 Low Voltage BDI Cutout .......................... 13
5.2.6 Programmable Low Voltage Cutback
(low voltage start) ............................. 13
5.2.7 Programmable High Voltage Initialize and Cutout . 13
5.2.8 TRACTION HOURS Counter .......................... 13
5.2.9 Regenerative Braking ............................ 14
5.2.10 Belt Height Speed Cutback ...................... 14
5.3 Adjustable Parameters ............................. 14
5.4 Fault Status Code Legend (Top Level Of Display) ... 16
5.5 General Features .................................. 17
5.5.1 Diagnostics ..................................... 17
5.5.2 Environmental requirements ...................... 18
5.5.3 Accelerator input ............................... 19
Figure 1. Wiring Diagram .............................. 20
174/32061
Document Purpose
The purpose of this document is to describe the operational

controller functionality of the vehicle.
1.0 Definition
The S&S Tug 660E Belt Loader Controller provides Traction

Drive and Belt functionality for an Aircraft Luggage Belt
Loader vehicle.
A single 72/80 V., 600Amp Series Powerpak Controller with a

high I/O logic will provide for this control. The Traction
Drive is powered by a Series wound D.C. Motor. Belt Load
functionality is powered by a separate Series Wound Motor.
Non-proportional Control will be provided for a separate
Pump Motor for the Hydraulic Vehicle Functions.
The Traction functionality will be bi-directional and speed

will be proportional to the foot accelerator demand. High
Speed Bypass will be provided. The Belt functionality will
be bi-directional and have (3) selectable speeds that are
programmable via the Sevcon Hand Held Calibrator. The
separate pump motor used for Hydraulic functions, power
steer, brakes and Lift/Lower of Belt Conveyor, operates at
full speed via the Pump /Power Steer contactor.
Basic Functions are:

1. TRACTION MODE
2. BELT MODE will operate mutually exclusive of
TRACTION MODE.
3. PUMP/POWER STEER will operate simultaneously with
TRACTION MODE but will not operate in BELT.
174/32061
1.1 Displays
The Powerpak controller supports (2) types of displays:
CAN Hand Held Calibrator Display (662/14030)

CAN Dashboard Display (Optional) (604/60001)
• The Calibrator Display allows for personality

adjustments, display’s of vehicle status and vehicle
inputs (Test Display).
• The standard Dashboard Display option features a 10

segment BDI. Key on, traction or belt hours count can be
displayed. A 10 character area for displaying Vehicle
status and diagnostic messages.
• Certain vehicle status messages, such as ‘Handbrake ON’

can be enabled via the setup menu.
2.0 Scope
This specification outlines the modes of operation, inputs

and outputs, and essential features proposed for the Belt
Loader controller.
3.0 Inputs and Outputs
The following sections define the required I/O for the Belt
Loader controller.
3.1 Power Cable Wiring
The following power connections shall be provided:
Battery Positive
Battery Negative
(4) Connections for the Traction Motor.
(4) Connections for the Belt Motor.
174/32061
(2) Connections for the Pump/Power steer Motor.
The proposed layout of the power circuit is shown in figure

1.
3.2 Control Inputs
The following control inputs shall be provided (see figure

1):
3.2.1 Power Supply Inputs
- E-Stop - Interrupts battery voltage to controller,

Contactors and Key Switch Line.
- Key SW - Applies a battery positive voltage (low
current feed) to controller to power up
logic.
3.2.2 Signal Inputs
- Forward SW - Selects FORWARD Traction function.

- Reverse SW - Selects REVERSE Traction function.
- FS1 SW - Foot Switch associated with the accelerator
to enable DRIVE.
- Footbrake SW – (Optional) Applies signal to controller to
start Pump/Power steer contactor . Can
be used to increase regen braking level.
Is also used to start pump/power steer
contactor for belt raise and lower.
- Belt FWD. SW - Selects momentary FORWARD Belt function.
- Belt REV. SW - Selects momentary REVERSE Belt function.
- Belt Stop SW - Stops Belt.
- Handbrake SW - Selects Traction or Belt Functionality.Hand
Brake Sw closed sets controller in belt
mode, Sw open sets controller in drive
mode. Sw closed while in drive stops PWM.
- Seat SW - Disables traction drive if open.
- Belt height
limit SW – Invokes speed cut back when belt is raised.
- Belt Change
Over Detect - Monitors position of belt change over
contactors and detects fault if contactors
do not switch to belt position when belt
function is selected.
174/32061
- Accelerator - Active accelerator: 3.5v - 0.0v
for minimum to maximum demand respectively.
3.3 Control Outputs (Contactor drivers)
The following outputs will be provided:
NOTE: Each driver output has a maximum synching current of 2

Amps (total driver current = 16 Amps).
- FORWARD direction contactor driver.

- REVERSE direction contactor driver.
- REGEN contactor driver
- Belt Brake contactor driver.
- Drive/Belt motor changeover contactors (2) driver.
- Pump / Power Steer Contactor driver.
- High-Speed Bypass Contactor driver.
4.0 Modes of Operation
All modes of operation will be dependent on:
Emergency Stop Switches (E-Stop)

Position of Hand Brake determining drive or belt mode
TRACTION or Belt Switches
4.1 Traction Drive Mode
DRIVE in either FORWARD or REVERSE will start only if the

following conditions are satisfied:
- Proper state of MODE input.

- No procedure or diagnostic faults present.
- Seat switch closed FWD or REV TRACTION Switch selected
as appropriate, F.S.1 Switch Closed.
- Handbrake Off.
4.2 BELT Mode
Belt mode will start only if the following conditions are

satisfied:
- Proper MODE select sequence.

174/32061
- No procedure or diagnostic faults present.
- Traction direction switch in neutral and seat switch
open.
- Handbrake on.
- FWD or REV Belt Switch selected as appropriate.
4.3 PUMP MODE
4.3.1. PUMP motor will start whenever TRACTION MODE is

active, depression of the accelerator and closing F.S.1 will
start the pump motor.
4.3.2. When the pump motor is activated, the pump/power

steer contactor will close and full battery voltage will be
applied to the PUMP motor.
4.3.3. The pump/power steer contactor will also close,
energizing the pump motor when the conveyer up/down switch
is activated.
5.0 Features
The following sections define the features incorporated into
the traction/belt loader controller which are in addition
to, or different from, standard PowerpaK traction controller
features.
5.1 Features in BELT MODE
5.1.1 Selectable control of BELT motor speed
Up to (3) programmable speeds are available via three Belt

Speed adjustable Personalities. To configure the Belt Speeds
to three adjustable speeds adjust each Speed Personality to
different speeds. If (2) Belt Speeds are desirable then set
the second and third Speed Personalities equal. If only a
single Belt Speed is desirable then set all (3) Speed
Personalities equal.
174/32061
The desired BELT speed is selected according to the sequence
of pushes of the Momentary Forward and Reverse push buttons.
BELT MODE will commence once a BELT DIRECTION switch is

momentarily pressed and released. The BELT will move at a
programmed speed. If the same BELT DIRECTION switch is
momentarily pressed a second time, BELT speed will advance
to the second programmed speed. If the same BELT DIRECTION
switch is momentarily pressed a third time, the BELT speed
will increase to a third programmed speed.
If the same BELT DIRECTION switch is momentarily pressed

again, the BELT speed will decrease to the second
programmable speed. If the same BELT DIRECTION switch is
momentarily pressed once again, the BELT speed will decrease
to the first programmed speed. This completes a full cycle
of BELT speed options. Further presses of the same BELT
DIRECTION switch will repeat the above scenario of
increasing then decreasing BELT speed.
If the BELT STOP switch is momentarily pressed, BELT
movement will slow to a stop dependent on the Deceleration
Delay Personality.
If the BELT is moving in a particular direction and the

opposite BELT DIRECTION switch is pressed, the BELT will
first come to a stop, dependent on the Deceleration Delay
Personality, and then proceed to the first programmed speed
in the new direction.
5.1.2 Belt Brake
The BELT BRAKE will be applied whenever the BELT STOP

function is selected and after SOFT STOP (dependent on the
Deceleration Delay Personality) has occurred and the belt
brake delay has run out.
5.1.2.1 Belt change over contactor diagnostics

Diagnostics to shut down belt mode operation if change over
contactors do not switch over to connect the belt motor. The
change over contactors are monitored via aux. Interlock
switches installed on change over contactors.
174/32061
5.1.3 Belt Conveyor Lift Or Lower
The BELT CONVEYOR is RAISED or LOWERED by the hydraulics

system. Control switches that are visible to the SEVCON
controller enable the hydraulic PUMP motor. A pump/power
steer contactor will apply full battery to the PUMP motor
during these types of CONVEYOR operations.
5.1.4 Soft start
The BELT motor speed control shall incorporate a "soft

start" facility by applying acceleration delay to the
selected programmed speed step changes in the applied
percentage on of the switching element. The duration of the
acceleration delay shall be variable between 0.1 seconds and
5.0 seconds via the SEVCON Calibrator. Separate acceleration
delay personalities exist for TRACTION and BELT MODES.
5.1.5 Soft stop
The BELT motor speed control shall incorporate a "soft stop"

facility by applying deceleration delay to changes in the
programmed speed steps applied percentage on of the
switching element. The duration of the deceleration delay
shall be variable between 0.1 seconds and 5.0 seconds via
the SEVCON Calibrator. Separate deceleration delay
personalities exist for TRACTION and BELT modes.
No dynamic braking will be applied to the Belt Motor. The

motor voltage will ramp down to zero, dependent on the
Deceleration Delay, before allowing the direction change.
5.1.6 Low Voltage BDI Cutout
If BDI cuts Belt personality is enabled and the battery

voltage drops below the BDI programmable CUTOUT LEVEL, the
controller shall shut down BELT Mode. The SEVCON Calibrator
will display ‘BDI Cutout’ and the LED will flash a 7-flash
code. If the optional dashboard display is installed, the
BDI segment display will continuously display the state of
charge left and flash once the batteries are discharged
below a programmable WARNING LEVEL.
174/32061
5.1.7 Programmable Low Voltage Cutout
If the battery falls below the programmable LOW VOLTAGE

CUTBACK, current limit will be linearly invoked. The SEVCON
Calibrator will display Low Battery Voltage and the LED will
flash a 7-flash code.
5.1.8 Current Limit Timeout
Belt motor current will be limited to the Belt Current Limit

Personality setting. If the motor is at this level for the
adjustable Current Limit Timeout Personality, then a 5-flash
fault will be issued and the Belt Motor voltage will be
reduced to zero. The Belt Direction and Belt Brake
Contactors will be opened. This condition can only be
cleared by power recycle.
5.1.9 BELT HOURS Counter
The accrued BELT MODE time will be monitored and stored and
displayed as total BELT HOURS.
5.1.10 High Speed Bypass/Field Weakening
Both of these options will be disable in Belt Mode.
174/32061
5.2 Features in TRACTION mode
5.2.1 Speed control
The TRACTION motor speed, when in TRACTION mode, shall be

controlled by varying the percentage on of the switching
element in relation to the accelerator input. The
accelerator input shall be of the type as defined in 3.2 for
minimum to maximum speed.
When TRACTION MODE is activated a fixed creep shall be

applied to the TRACTION motor at zero demand. Displacement
of the accelerator input shall result in a linear increase
in percentage on from the creep to 100% ON (as determined by
the Traction Maximum Speed Personality) over the full range
of accelerator input.
5.2.2 Wire off detect
In the event of the accelerator input becoming detached,

pulsing in this mode will occur at the accelerator creep
speed. A 6-flash fault diagnostic will occur.
5.2.3 Soft start
The TRACTION MOTOR speed control shall incorporate a "soft

start" facility by applying acceleration delay to changes in
the applied percentage on of the switching element. The
duration of the acceleration delay shall be variable between
0.1 seconds and 5.0 seconds via the SEVCON Calibrator.
Separate acceleration delay personalities exist for TRACTION
and BELT MODES.
174/32061
5.2.4 Soft stop
The TRACTION motor speed control shall incorporate a "soft

stop" facility by applying deceleration delay to changes in
the applied percentage on of the switching element. The
duration of the deceleration delay shall be variable between
0.1 seconds and 5.0 seconds via the SEVCON Calibrator.
Separate deceleration delay personalities exist for TRACTION
and BELT MODES.
If BDI is enabled, BDI cutout will reduce the traction speed

to the level set in the speed cutback 2 personality.
5.2.6 Programmable Low Voltage Cutback (low voltage start)

START personality, current limit will be linearly invoked.
The SEVCON Calibrator will display Battery Low. The LED will
flash a 7-flash code.
5.2.7 Programmable High Voltage Initialize and Cutout
The HIGH VOLTAGE INITIALIZE personality has an affect on the

level of regen braking, during regen braking the battery
voltage rises, if it rises to the level set in the HIGH
BATTERY START personality the regen braking level is reduced
in attempt to keep the battery voltage from further rise. If
the battery is above the programmable HIGH BATTERY CUTOUT
personality, TRACTION will cease and all contactor drives
will be de-energized to prevent coil damage. Vehicle free-
wheeling will occur and mechanical braking will be required.
The SEVCON Calibrator will display Battery High. The LED
will flash a 7-flash code.
5.2.8 TRACTION HOURS Counter
The accrued DRIVE MODE time will be monitored and stored and
displayed as total TRACTION HOURS.
174/32061
5.2.9 Regenerative Braking
Regenerative braking will be utilized in traction mode.

Braking levels are selectable (see Powerpak Series Manual).
5.2.10 Belt Height Speed Cutback
A normally closed switch that opens when the belt is raised

invokes speed cut back.
5.3 Adjustable Parameters
See Personality List 171T86304
TEST Menu
Cal Ref. Input Displayed Min Max Step

Displayed Displayed Size
1.3.1 Accelerator % 0 % 100 % 1 %

(Item 61) Range
1.3.2 Accelerator 0.0 V 5.0 V 0.02
(Item 62) Voltage V
1.3.2a Belt Demand % 0 % 100 % 1 %
(Item 175)
1.3.3 Footbrake % Range 0 % 100 % 1 %
(Item 63)
1.3.4 Footbrake Voltage 0.0 V 5.0 V 0.02
(Item 64) V
1.3.5 Economy % Range 0 % 100 % 1 %
(Item 65)
1.3.6 Economy Voltage 0.0 V 5.0 V 0.02
(Item 66) V
1.3.7 O.Temp Pot % Range 0 % 100 % 1 %
(Item 143)
1.3.8 O.Temp Voltage 0.0 V 5.0 V 0.02
(Item 144) V
1.3.9 Forward Open Closed
(Item 67) Switch
1.3.10 Reverse Open Closed
(Item 68) Switch
1.3.11 FS1 Open Closed
(Item 69)
174/32061
Cal Ref. Input Displayed Min Max Step
Displayed Displayed Size
1.3.12 Belly Open Closed

(Item 70)
1.3.14 Tiller Open Closed
(Item 72)
1.3.15 Speed Cutback 1 Open Closed
(Item 73)
(Item 74)
(Item 75)
1.3.18 Inch Forward Open Closed
(Item 76)
1.3.19 Inch Reverse Open Closed
(Item 77)
1.3.20 Handbrake Open Closed
(Item 78)
1.3.21 Footbrake Open Closed
(Item 79)
1.3.22 Power Steer Open Closed
(Item 80) Trigger Input
1.3.23 Pump Contactor Open Closed
(Item 81) Trigger
1.3.24 Speed Limit Switch Open Closed
(Item 153)
1.3.25 Side Load Switch Open Closed
(Item 154)
1.3.26 Speed Encoder xxxx
(Item 145) Count
1.3.27 Brushes Worn Open Closed
(Item 156)
1.3.28 Belt Forward Open Closed
(Item 171)
1.3.29 Belt Reverse Open Closed
(Item 172)
1.3.30 Belt Stop Open Closed
(Item 173)
1.3.31 Belt Brake Sense Open(> Closed(<
(Item 174) Voltage Input 4.0v) 0.5v)
1.3.32 SOFTWARE VERSION VX.XXXX

(Item 82)
1.3.33 Serial Number XXXXXXXX
174/32061
5.4 Fault Status Code Legend (Top Level Of Display)
Dashboard Display Calibrator Description

Display
Rotating Disp “OK” No fault
“RUN “Testing” Only visible when power-
TESTS” up diagnostics are
running
Check connections if not
clearing
“BDI “BDI Cutout” Battery voltage has
CUT” fallen below the cutout
level.
“TRAC “Thermal Controller in thermal
HOT” Cutback” cutback
“ACCEL “Accel. Fault” Accelerator fault sensed
FAULT” Faulty Accelerator
(accelerator voltage
0.5v above programmable
ZERO VOLTAGE;
accelerator voltage 0.5v
below programmable ZERO
VOLTAGE at power-up.
Faulty Accelerator or
Faulty Logic Board
“CONT “Contactor o/c” Contactor failed to
FAULT” close Faulty Contactor,
Motor O/C, Faulty Logic
Board
“CONT “Contactor s/c” Contactor welded closed.
FAULT” Faulty Contactor or
wiring.
“SEQ “Sequence Multiple Direction
FAULT” Fault” switches active or
active during power-up.
“2 DIR “2 Dir. Fault” Both Direction switches
FAULT” active
“SRO “SRO Fault” If enabled, DIR switch
FAULT” selected >2 seconds
after FS1.
“BAT. “Battery Low” Battery fell below low
LOW” personality level
“BAT. “Battery High” Battery rose above high
HIGH” personality level
“PERS “Pers Error” Personalities out of
ERROR” range at power up.
174/32061
Dashboard Display Calibrator Description
Display
“CRC “CRC Error” During power-up a
ERROR” personality CRC error
occurred.
Check all personalities
then Power Recycle – If
not cleared replace
logic board.
“CAP. “Cap Fault” Filter capacitors have
FAULT” failed to charge.
“COIL “Coil s/c” A contactor coil s/c or
S/C” wired incorrectly.
“MOSFET “Mosfet s/c” An MOSFET short has been
S/C” detected
“HAND “Handbrake ON” Handbrake ON Message
BRAKE”
“TRAC “Trac Ilim Traction Current Limit
ILIM” Fault” has timed out.
“BELT “Belt Ilim Belt Current Limit has
ILIM” Fault” timed out.
“FAIL” “FAIL” Power Up Diagnostics
Failure
5.5 General Features
NOTE: Reference “SEVCON Powerpak SERIES

Manual”
5.5.1 Diagnostics
A subset of standard POWERPAK controller diagnostics shall

apply.
LED on - controller operational.
LED off - Internal fault.
1 flash - Personality/CRC fault.

This fault is usually an internal failure of the non-
volatile memory. To clear this fault, check all adjustable
personality settings and power-recycle. If fault persists or
this failure is re-current, replace logic card.
174/32061
2 flash - Procedure fault.
This includes DIRECTION, BELT, OR SRO fault if enabled.
Recycle through NEUTRAL to clear.
3 flash – Motor permanently Low.

Bypass contactor s/c or MOSFET s/c.
This fault shuts down all modes. Recycle through NEUTRAL to
clear.
4 flash - Motor permanently high.

This includes DIRECTION contactor welded or open. BELT BRAKE
fault is included in this fault. The CONTACTOR fault shuts
down all modes. The BRAKE fault disables BELT MODE, sets
demand to zero and opens the Belt Direction pair contactors.
Key switch recycle to clear.
5 flash - Motor Current Limit Timeout

Either TRACTION or BELT motor has been in current limit for
the specific time out delay. This fault will reduce motor
voltage to zero for the specific mode that has been in
current limit. sets demand to zero and opens the Direction
pair contactors. Key switch recycle to clear.
6 flash - Faulty accelerator or Speed Probe.

This includes the accelerator greater than 15% at power on,
and wire off. If wire-off occurs during active function,
motor speed will default to accelerator fault creep
7 flash - Battery voltage fault.

This includes battery voltage excessively HIGH or LOW (set
by special adjustable personalities) or BDI has reached
cutout level. NEUTRAL RECYCLE to clear.
8 flash - Thermal cutback.
This includes MOSFET temperature above 75 degrees
centigrade. Self-clearing.
9 flash - Contactor coil is shorted or miss-wired.

POWER RECYCLE to clear.
5.5.2 Environmental requirements
As per standard Powerpak.
174/32061
5.5.3 Accelerator input
The accelerator input shall be provided protection from

electromagnetic interference, where required, by external
screening.
174/32061
Figure 1. Wiring Diagram
174/32061
660E
Hydraulic Belt Loader
PowerpaK Series –
Traction/Belt Controller
815 Allgood Road ■ Marietta, GA 30062-3305 USA ■ Tel: (770) 422-7230 ■ Fax: (770) 428-7315
174/32069
TUG660E – Hydraulic Belt Loader
PowerpaK Series - Traction/Belt Controller
DOCUMENT: TUG – Hydraulic Belt Loader
Prepared By: Kevin O’Keeffe
Copies: Tom Schmitzer – SS TUG

Steve Lorenz
Steve Parent
Rev: A
Date: 12/31/04
Document Change Page:
Rev A: 12/31/04 – Production Issue.

Page 2 of 19 Rev: A
174/32069
Software Change Page:
Version 3.06D: Controller : 632T86312

Logic : 662T86312
Personality : 171T86312_A

Page 3 of 19 Rev: A
174/32069
Table of Contents
Table of Contents.............................................................................................................. 4
Document Purpose ........................................................................................................... 5
1.0 Definition ..................................................................................................................... 5
1.1 Displays................................................................................................................... 6
2.0 Scope .......................................................................................................................... 6
3.0 Inputs and Outputs...................................................................................................... 7
3.1 Power Inputs and Outputs....................................................................................... 7
3.2 Control Inputs.......................................................................................................... 7
3.2.1 Power Inputs .................................................................................................... 7
3.2.2 Signal Inputs .................................................................................................... 7
3.3 Control Outputs ....................................................................................................... 8
4.0 Modes of Operation..................................................................................................... 8
4.1 Belt Mode ................................................................................................................ 8
4.2 Traction Drive Mode................................................................................................ 9
4.3 Hours Counters ....................................................................................................... 9
5.0 Features ...................................................................................................................... 9
5.1 Features in Belt Mode ............................................................................................. 9
5.1.1 Selectable control of BELT motor speed ................................................... 9
5.1.2 Belt Conveyor Lift or Lower ..................................................................... 10
5.1.3 Soft start .................................................................................................. 10
5.1.4 Soft stop .................................................................................................. 10
5.1.5 Low Voltage BDI Warning and Cutout..................................................... 11
5.1.6 Programmable Low Voltage Cutout......................................................... 11
5.1.7 Current Limit Timeout .............................................................................. 11
5.1.8 Thermal Limit Protection.......................................................................... 11
5.2 Features in Traction Mode .................................................................................... 11
5.2.1 Speed control .......................................................................................... 11
5.2.2 Wire off detect ......................................................................................... 12
5.2.3 Soft start .................................................................................................. 12
5.2.4 Soft stop .................................................................................................. 12
5.2.5 Low Voltage BDI Cutout .......................................................................... 12
5.2.6 Programmable Low Voltage Cutout......................................................... 12
5.2.7 Programmable High Voltage Initialize and Cutout................................... 12
5.2.8 Current Limit Timeout .............................................................................. 13
5.2.9 Thermal Limit Protection.......................................................................... 13
5.2.10 Traction Hours Counter ................................................................................ 13
5.2.11 Conveyor Raised Speed Cutback ................................................................ 13
5.2.12 Reverse Speed Cutback .............................................................................. 13
5.3 Adjustable parameters .......................................................................................... 14
5.4 Fault Status Code Legend (Top Level of Display) ................................................ 15
5.5 General features ................................................................................................... 16
5.5.1 Diagnostics..................................................................................................... 16
5.5.2 Environmental requirements .......................................................................... 17
5.5.3 Accelerator input ............................................................................................ 17
GRAPH 1 – Thermal limit cutback .................................................................................. 18
Figure 1 Wiring Diagram ................................................................................................. 19

Page 4 of 19 Rev: A
174/32069
Document Purpose
The purpose of this document is to describe the operational controller

functionality of the vehicle.
1.0 Definition
The TUG Hydraulic Belt Loader Controller provides Traction Drive and Belt
functionality for an Aircraft Luggage Belt Loader vehicle.
A single 80v, 600Amp Sevcon PowerpaK Controller with a high input / output
module will provide for this control. The Traction Drive is powered by a Series 15
hp Traction Electric Motor. Belt Load functionality is powered by a separate 5 hp
Compound Wound Motor.
The Traction functionality will be bi-directional and speed will be proportional to

the foot accelerator demand. High Speed Bypass will be provided. The Belt
functionality will be bi-directional and have (3) selectable speeds that are
programmable via the Sevcon Hand Held Calibrator. The Hydraulic functions,
Power Steer, Lift/Lower of Belt Conveyor, operate at full speed.
Basic Functions are:

1. TRACTION MODE
2. BELT MODE will operate mutually exclusive of TRACTION MODE.
3. HYDRAULIC PUMP will operate simultaneously with TRACTION
MODE at a constant voltage output. During BELT MODE it will
operate as a variable voltage output based on the speed selected.

Page 5 of 19 Rev: A
174/32069
1.1 Displays
The PowerpaK controller supports (3) types of displays:
CAN Hand Held Calibrator Display (662/14030)

CAN Dashboard Display (Optional) (604/60001)
CAN Full Dashboard Display (Optional) (604/60004)
• The Calibrator Display allows for personality adjustments, display’s of vehicle

status and vehicle inputs (Test Display).
• The Dashboard Display option features a status display (ref. “Fault Status
Code Legend”) of Battery BDI, Traction, Key On and BELT MODE elapsed
time, Battery Voltage, Traction Motor Current, Traction Motor Voltage and
Accelerator % ON (selectable via the Hand Held Calibrator) vehicle status.
• Certain vehicle status messages, such as ‘Handbrake ON’ can be enabled

via the setup menu.
• The Full Dashboard Display option consists of a custom graphic LCD display
housed in a SEVCON designed rectangular plastic case. The display
incorporates a 10 segment BDI (Battery Discharge Indicator), a 6-digit hours
counter and a 14-character area for diagnostic and status messages. The
display has 11 warning symbols which can be lit by the controller (via the
CANbus) or by 8 active low switch inputs. When there are no diagnostic
messages the top line of the message area can be used to indicate one of a
number of status. In addition there are two multipurpose indicators, that can
be reprogrammed using the calibrator to show one of a selection of system
status readings.
2.0 Scope
This specification outlines the modes of operation, inputs and outputs, and
essential features proposed for the Belt Loader controller.

Page 6 of 19 Rev: A
174/32069
3.0 Inputs and Outputs
The following sections define the required I/O for the Belt Loader controller.
3.1 Power Inputs and Outputs
The following power connections shall be provided:
Battery Positive
Battery Negative
(4) Connections for the Traction Motor
(2) Connections for the Belt Motor
The proposed layout of the power circuit is shown in figure 1.
3.2 Control Inputs
The following control inputs shall be provided (see figure 1):
3.2.1 Power Inputs
- E-Stop - Interrupts battery voltage to controller, motors and Key

Switch.
- Key SW - applies battery voltage to controller.
3.2.2 Signal Inputs
- Forward SW - Selects FORWARD Traction function.

- Reverse SW - Selects REVERSE Traction function with
speed cutback.
- FS1 SW - Foot Switch associated with the accelerator
to enable DRIVE.
- Conveyor Raised SW - Sets speed cutback 1.
- Belt Forward SW - Selects momentary FORWARD Belt
functions (speeds).
- Belt Reverse SW - Selects momentary REVERSE Belt
functions (speeds).
- Belt Stop SW - Stops Belt.
- Handbrake SW - Selects Traction / Belt Mode functionality.
- Hydraulic Pump SW - Selects conveyor functions.

Page 7 of 19 Rev: A
174/32069
- Analog Active Linear Accelerator Traction Speed demand.
Or
- Active accelerator: 3.5v - 0.0v for no demand to maximum demand

respectively.
Both the no demand setting and the maximum demand settings are
adjustable via the SEVCON Calibrator.
3.3 Control Outputs
The following outputs will be provided:
NOTE: Each output handles a maximum current of 2 Amps.
- Forward Traction contactor driver.

- Reverse Traction contactor driver.
- Traction / Belt Mode contactor driver.
- High-Speed Traction Bypass Contactor driver.
- Hydraulic Pump Contactor driver.
- Belt Forward Valve driver.
- Belt Reverse Valve driver.
- Hydraulic Pump Unload / Conveyor Valve driver.
4.0 Modes of Operation
All modes of operation will be dependent on:
Emergency Stop Switches (E-Stop)

Traction or Belt Switches
4.1 Belt Mode
Belt mode will start only if the following conditions are satisfied:
No procedure or diagnostic faults present.

Forward or Reverse Belt Switch selected as appropriate.
Handbrake Engaged.

Page 8 of 19 Rev: A
174/32069
4.2 Traction Drive Mode
DRIVE in either Forward or Reverse will start only if the following

conditions are satisfied:
No procedure or diagnostic faults present.

Forward or Reverse Traction Switch selected as appropriate.
Handbrake released.
4.3 Hours Counters
There are three hours count displays available, Key hours, Traction only
hours, and Pump / All Power hours. The default display will be the All
Power hour’s counter.
5.0 Features
The following sections define the features incorporated into the controller,
which are in addition to or different from, standard PowerpaK traction
controller features.
5.1 Features in Belt Mode
5.1.1 Selectable control of BELT motor speed
Up to (3) programmable speeds are available via three Belt Speed

adjustable Personalities. To configure the Belt Speeds to three
adjustable speeds adjust each Speed Personality to different
speeds. If (2) Belt Speeds are desirable then set the second and
third Speed Personalities equal. If only a single Belt Speed is
desirable then set all (3) Speed Personalities equal.
The desired BELT speed is selected according to the sequence of
pushes of the Momentary forward and reverses push buttons.
At all times when the Belt is being driven, the appropriate belt
direction valve will be activated as well as the unload valve.
BELT MODE will commence once a BELT DIRECTION switch is

momentarily pressed. The BELT will move at a programmed
speed. If the same BELT DIRECTION switch is momentarily
pressed a second time, BELT speed will advance to the second
programmed speed. If the same BELT DIRECTION switch is
momentarily pressed a third time, the BELT speed will increase to a
third programmed speed.
If the same BELT DIRECTION switch is momentarily pressed

again, the BELT speed will decrease to the second programmable
Page 9 of 19 Rev: A
174/32069
speed. If the same BELT DIRECTION switch is momentarily
pressed once again, the BELT speed will decrease to the first
programmed speed. This completes a full cycle of BELT speed
options. Further presses of the same BELT DIRECTION switch will
repeat the above scenario of increasing then decreasing BELT
speed.
If the BELT STOP switch is momentarily pressed, BELT movement

will slow to a stop dependent on the Deceleration Delay
Personality.
If the BELT is moving in a particular direction and the opposite

BELT DIRECTION switch is pressed, the BELT will first come to a
stop, dependent on the Deceleration Delay Personality, and then
proceed to the first programmed speed in the new direction.
5.1.2 Belt Conveyor Lift or Lower
The BELT CONVEYOR is raised or lowered by the hydraulics

system. The conveyor only operates at full power when the belt is
not engaged. When the when the belt is in motion, the conveyor
will operate at a slower speed dictated by the speed of the belt.
Control switches that feed both the controller with a “low” signal and
the Conveyor Raise or Lower valves with a “high” signal are used to
activate this feature. When the low signal is sent to the controller,
the valve connected to the (high) closed switch will activate. Also,
the unload valve will activate at this time.
5.1.3 Soft start
The BELT motor speed control shall incorporate a "soft start" facility
by applying acceleration delay to the selected programmed speed
step changes in the applied percentage on of the switching
element. The duration of the acceleration delay shall be variable
between 0.1 seconds and 5.0 seconds via the SEVCON Calibrator.
Separate acceleration delay personalities exist for TRACTION and
BELT MODES.
5.1.4 Soft stop
The BELT motor speed control shall incorporate a "soft stop" facility
by applying deceleration delay to changes in the programmed
speed steps applied percentage on of the switching element. The
duration of the deceleration delay shall be variable between 0.1
seconds and 5.0 seconds via the SEVCON Calibrator. Separate
deceleration delay personalities exist for TRACTION and BELT
modes.
No dynamic braking will be applied to the Belt Motor. The motor
voltage will ramp down to zero, dependent on the Deceleration
Delay, before allowing the direction change or contactor drop-out.

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174/32069
5.1.5 Low Voltage BDI Warning and Cutout
If the optional dashboard display is installed, the BDI segment

display will continuously display the state of charge left and flash
once the batteries are discharged below a programmable
WARNING LEVEL.
Also, if “BDI” and “BDI cuts Belt” setup personalities are enabled
and the battery voltage drops below the BDI programmable cutout
levels, the controller shall shut down BELT Mode. The SEVCON
Calibrator will display ‘BDI Cutout’ and the LED will flash a 7-flash
code.

CUTBACK, current limit will be linearly invoked. The SEVCON
Calibrator will display Low Battery Voltage and the LED will flash a
7-flash code.
Belt motor current will be limited to the Belt Current Limit

Personality setting. If the motor is at this level for the adjustable
Current Limit Timeout Personality, then a 5-flash fault will be issued
and the Belt Motor voltage will be reduced to zero. The Belt
Direction and Belt Unload Valves will be opened. This condition
can only be cleared by power recycle. A setting of zero disables
this feature.
5.1.8 Thermal Limit Protection
The PowerpaK controller monitors the temperature of its

powerframe. If the temperature increases above 75°c, it will begin
to cutback the maximum current limit allowed. If the current limit
personality is set lower than the maximum current allowed by the
controller (i.e. 650A controller set to 500A), current limit will begin at
progressively higher temperatures. If the controller reaches 95°c,
the current limit is reduced to 0A. (See graph 1) When thermal limit
occurs, the LED will flash 8 times and the optional dashboard
display will show “thermal cutback”.
5.2 Features in Traction Mode
5.2.1 Speed control
The TRACTION motor speed, when in TRACTION mode, shall be

controlled by varying the percentage on of the switching element in
relation to the accelerator input. The accelerator input shall be of
the type as defined in 3.2 for minimum to maximum speed.

174/32069
When TRACTION MODE is activated a fixed creep shall be applied
to the TRACTION motor at zero demand. Displacement of the
accelerator input shall result in a linear increase in percentage on
from the creep to 100% ON (as determined by the Traction
Maximum Speed Personality) over the full range of accelerator
input.
Refer to figure 2 for clarification.
5.2.2 Wire off detect
In the event of the accelerator input becoming detached, pulsing in

this mode will occur at the accelerator creep speed. A 6-flash fault
diagnostic will occur.
5.2.3 Soft start
The TRACTION MOTOR speed control shall incorporate a "soft

start" facility by applying acceleration delay to changes in the
applied percentage on of the switching element. The duration of
the acceleration delay shall be variable between 0.1 seconds and
5.0 seconds via the SEVCON Calibrator. Separate acceleration
delay personalities exist for TRACTION and BELT MODES.
5.2.4 Soft stop
The TRACTION motor speed control shall incorporate a "soft stop"

facility by applying deceleration delay to changes in the applied
percentage on of the switching element. The duration of the
deceleration delay shall be variable between 0.1 seconds and 5.0
seconds via the SEVCON Calibrator. Separate deceleration delay
personalities exist for TRACTION and BELT MODES.
If BDI is enabled, BDI cutout will set the maximum allowable

traction speed to the Speed Cutback 2 setting.

CUTBACK personality, current limit will be linearly invoked. The
SEVCON Calibrator will display Battery Low. The LED will flash a
7-flash code.
5.2.7 Programmable High Voltage Initialize and Cutout
If the battery is above the HIGH VOLTAGE INITIALIZE personality,

the controller will change from REGEN to PLUG braking. If the
battery is above the programmable HIGH VOLTAGE CUTBACK

174/32069
personality, TRACTION will cease and all contactor drives will be
de-energized to prevent coil damage. Vehicle freewheeling will
occur and mechanical braking will be required. The SEVCON
Calibrator will display Battery High. The LED will flash a 7-flash
code.
Traction Motor current will be limited to the Traction Current Limit

Personality. If the Traction Motor is at this level for the adjustable
Current Limit Timeout Personality, then a 5-flash fault will be issued
and the Traction Motor voltage will be reduced to zero. The
direction contactors will be opened. This condition can only be
cleared by power recycle.
5.2.9 Thermal Limit Protection
The PowerpaK controller monitors the temperature of its

powerframe. If the temperature increases above 75°c, it will begin
to cutback the maximum current limit allowed. If the current limit
personality is set lower than the maximum current allowed by the
controller (i.e. 650A controller set to 500A), current limit will begin at
progressively higher temperatures. If the controller reaches 95°c,
the current limit is reduced to 0A. (See graph 1) When thermal limit
occurs, the LED will flash 8 times and the optional dashboard
display will show “thermal cutback”.
5.2.10 Traction Hours Counter
The accrued DRIVE MODE time will be monitored and displayed as

Traction Hours.
5.2.11 Conveyor Raised Speed Cutback
This input will limit the maximum speed of the vehicle when the
switch is opened (conveyor is raised) to the Speed Cutback 1
personality.
5.2.12 Reverse Speed Cutback
When driving in reverse the maximum speed will be set to Speed

Cutback 2.

174/32069
5.3 Adjustable parameters
The following features shall be customer adjustable personalities

via the SEVCON Calibrator.
NOTE: Reference “Sevcon PowerpaK SERIES Manual” and

Personality set-up sheet 171T86312
Traction Status Menu
Calibrator Min Max

Visible Description Step Value
Ref. Value Value
1.2.1 9 Battery Voltage 0V 127 V 0.1 V +
1.2.2 9 Traction Motor Voltage 0V 127 V 0.5 V
1.2.3 9 Traction Motor Current 0A 1200 A 6A +
1.2.4 9 Traction Controller Temp. -30 °C +225 °C 1 °C + -
1.2.5 9 Traction MOSFET Voltage 0V 127 V 0.5 V
1.2.6 9 Capacitor Voltage 0V 127 V 0.5 V
1.2.7 Speed Sensor Indication 0 KPH 60 KPH 1.0 KPH
1.2.8 9 Key Switch Hours Count 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.9 9 Traction Pulsing Hours Count 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.10 9 Pump Pulsing Hours Count 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.11 9 Belt Pulsing Hours Count 0 Hrs 65279.9 Hrs 0.1 Hrs
- 9 Service Log Reset press + followed by - to reset service log
Note 1: Log Info shows where the + and - keys can be used to access the service max and min data.
Note 2: 1.1.10 Pump Hour meter not used when belt loader vehicle is selected.
Traction Test Menu
Calibrator Min Max

Visible Description Variation Value
Ref. Value Value
1.3.1 9 Accelerator % Range 0% 100 % -
1.3.2 9 Accelerator Voltage Range 0.0 V 5.0 V -
1.3.2a 9 Belt Demand % Range 0% 100 % -
1.3.3 Footbrake Pot. % Range 0% 100 % -
1.3.4 Footbrake Pot. Voltage Range 0.0 V 5.0 V -
1.3.5 Economy Pot. % Range 0% 100 % -
1.3.6 Economy Pot. Voltage Range 0.0 V 5.0 V -
1.3.7 9 O. Temp Pot. % Range 0% 100 % -
1.3.8 9 O. Temp Pot. Voltage Range 0.0 V 5.0 V -
1.3.9 9 Forward Switch Open Closed -
1.3.10 9 Reverse Switch Open Closed -
1.3.11 9 FS1 Switch Open Closed -
1.3.12 Belly Switch Open Closed -
1.3.13 9 Seat Switch Open Closed -
1.3.14 Tiller Switch Open Closed -
1.3.15 9 Speed Cutback 1 Switch Open Closed -

174/32069
1.3.16 Speed Cutback 2 Switch Open Closed -
1.3.17 Speed Cutback 3 Switch Open Closed -
1.3.18 Inch Forward Switch Open Closed -
1.3.19 Inch Reverse Switch Open Closed -
1.3.20 9 Handbrake Switch Open Closed -
1.3.21 Footbrake Switch Open Closed -
1.3.22 Power Steer Trigger Input Switch Open Closed -
1.3.23 9 Pump Contactor Trigger Switch Open Closed -
1.3.24 Speed Limit Switch Open Closed -
1.3.25 Sideload Switch Open Closed -
1.3.26 Speed Encoder Switch Open Closed -
1.3.27 Brushes Worn Switch Open Closed -
1.3.28 9 Belt Forward Switch Open Closed -
1.3.29 9 Belt Reverse Switch Open Closed -
1.3.30 9 Belt Stop Switch Open Closed -
1.3.31 Belt Brake input Range 0.0 V 5.0 V -
1.3.32 9 Software Version/Revision 000.00 999.99 -
1.3.33 9 Controller Serial Number 00000000 99999999 -
Note: As with the personalities, only relevant switch tests will be shown determined by configuration.
5.4 Fault Status Code Legend (Top Level of Display)
Dashboard Display Calibrator Display Description

Rotating Disp “OK” No fault
“RUN “Testing” Only visible when power-up diagnostics are running
TESTS” Check connections if not clearing
“BDI “BDI Cutout” Battery voltage has fallen below the cutout level.
CUT”
“TRAC “Thermal Cutback” Controller in thermal cutback
HOT”
“ACCEL “Accel. Fault” Accelerator fault sensed
FAULT” Faulty Accelerator(accelerator voltage 0.5v above
programmable ZERO VOLTAGE; accelerator
voltage 0.5v below programmable ZERO VOLTAGE
at power-up.
Faulty Accelerator or Faulty Logic Board
“CONT “Contactor o/c” Contactor failed to close
FAULT” Faulty Contactor, Motor O/C, Faulty Logic Board
“CONT “Contactor s/c” Contactor welded closed.
FAULT” Faulty Contactor or wiring.
“SEQ “Sequence Fault” Multiple Direction switches active or active during
FAULT” power-up.
“2 DIR “2 Dir. Fault” Both Direction switches active
FAULT”
“SRO “SRO Fault” If enabled, DIR switch selected >2 seconds after
FAULT” FS1.

174/32069
“INCH “Inch Fault” Inch switch in neutral at power up, both inch sws
FAULT” selected, inch selected with seat sw closed.
“BAT. “Battery Low” Battery fell below low personality level
LOW”
“BAT. “Battery High” Battery rose above high personality level
HIGH”
“PERS “Pers Error” Personalities out of range at power up.
ERROR”
“CRC “CRC Error” During power-up a personality CRC error occurred.
ERROR” Check all personalities then Power Recycle – If not
cleared replace logic board.
“CAP. “Cap Fault” Filter capacitors have failed to charge.
FAULT”
“COIL “Coil s/c” A contactor coil is s/c or miswired.
S/C”
“MOSFET “Mosfet s/c” An MOSFET short has been detected
S/C”
“BELLY “Belly Fault” Belly Fault has occurred.
FAULT”
“Canbus Fault” Can connection between controllers has been
disconnected.
“HAND “Handbrake ON” Handbrake ON Message
BRAKE”
“TRAC “Trac Ilim Fault” Traction Current Limit has timed out.
ILIM”
“BELT “Belt Ilim Fault” Belt Current Limit has timed out.
ILIM”
“FAIL” “FAIL” Power Up Diagnostics Failure
5.5 General features
5.5.1 Diagnostics
A subset of standard PowerpaK controller diagnostics shall apply.

LED on - controller operational.
LED off - Internal fault.
1 flash - Personality/CRC fault.

This fault is usually an internal failure of the non-volatile
memory. To clear this fault, check all adjustable personality
settings and power-recycle. If fault persists or this failure is
re-current, replace logic card.
2 flash - Procedure fault.

This includes DIRECTION, BELT, OR SRO fault if enabled.
Recycle through NEUTRAL to clear.

174/32069
3 flash - Motor permanently Low.
Bypass contactor s/c or MOSFET s/c.
This fault shuts down all modes. Recycle through
NEUTRAL to clear.
4 flash - Motor permanently high.

These include DIRECTION contactors welded or open.
The CONTACTOR fault shuts down all modes. A Key
switch recycle needed to clear.
5 flash - Motor Current Limit Timeout.

Either TRACTION or BELT motor has been in current limit
for the specific time out delay. This fault will reduce motor
voltage to zero for the specific mode that has been in
current limit. Demand is set to zero and the Direction pair
contactors open. A Key switch recycle needed to clear.
6 flash - Faulty accelerator or Speed Probe.
This includes the accelerator greater than 15% at power on,
and wire off. If wire-off occurs during active function, motor
speed will default to accelerator fault creep
7 flash - Battery voltage fault.

This includes battery voltage excessively HIGH or LOW (set
by special adjustable personalities) or BDI has reached
cutout level. NEUTRAL RECYCLE to clear.
8 flash - Thermal cutback.

This includes MOSFET heatsink temperature above 75
degrees centigrade. Self-clearing.
9 flash - Contactor coil is shorted or miss-wired.

A Key switch recycle needed to clear.
5.5.2 Environmental requirements
As per standard PowerpaK.
5.5.3 Accelerator input
The accelerator input shall be provided protection from

electromagnetic interference, where required, by external screening.

174/32069
GRAPH 1 – Thermal limit cutback
Thermal Cutback Characteristic
100
% of Maximum Current
80
60
40
20
0
75 80 85 90 95
Controller Internal Temperature
( Deg C )

174/32069
Figure 1 Wiring Diagram

174/32069

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MODEL 660E ELECTRIC

MOBILE BELT CONVEYOR

NOTE: The information contained in this publication is intended

NOTE: The information contained in this document is intended to be

City: State: Zip Code:

Date of original publication: August 1995

Revision Number Date Brief Description

1 April 1996 N/A

2 January 2002 N/A

3 July 2003 Format change / New info added

September 2007 Format change / IPL Changes

LIST OF EFFECTIVE PAGES

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

1-5- 1 Rev 4 2-2- 8 Rev 4

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

3-5- 4 Rev 3 4-2- 5 Rev 4

Chapter-Section Page Revision Chapter-Section Page Revision

4-2- 42 Rev 3 4-2- 79 Rev 4

Chapter-Section Page Revision Chapter-Section Page Revision

4-2- 116 Rev 4 4-2- 153 Rev 4

Chapter-Section Page Revision Chapter-Section Page Revision

4-2- 190 Rev 4 4-3- 1 Rev 4

Chapter-Section Page Revision Chapter-Section Page Revision

4-3- 38 Rev 4 4-4- 24 Rev 4

MANUAL TABLE OF CONTENTS

SAFETY ............................................................................................................................... SAFETY-I

Chapter 1: General Information and Operating Instructions

SECTION 2: OPERATION ......................................................................................................... 1-2-1

SECTION 3: SPECIFICATIONS ................................................................................................ 1-3-1

8. Parking Brake ........................................................................................... 1-3-5

SECTION 4: SHIPPING .............................................................................................................. 1-4-1

SECTION 5: STORAGE ............................................................................................................. 1-5-1

SECTION 6: BATTERY CHARGING CYCLES ......................................................................... 1-6-1

C. Lubrication ............................................................................................................ 2-1-5

SECTION 2: TROUBLESHOOTING ......................................................................................... 2-2-1

SECTION 3: REMOVAL/INSTALLATION ................................................................................... 2-3-1

R. Hydraulic Pump Motor Removal / Installation ....................................................... 2-3-9

SECTION 4: BELT TRACKING INSTRUCTIONS .................................................................... 2-4-1

SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS .......................................... 2-5-1

SECTION 2: STEER AXLE ........................................................................................................ 3-2-1

SECTION 3: REAR AXLE .......................................................................................................... 3-3-1

3. Pinion Bearing Cups ............................................................................... 3-3-11

SECTION 4: REAR WHEEL DRUM BRAKES .......................................................................... 3-4-1

SECTION 5: FRONT WHEEL DISC BRAKES ......................................................................... 3-5-1

6. Installation ................................................................................................. 3-5-9

SECTION 6: INSTRUCTIONS FOR AIR GAP CHECKING AND ADJUSTMENT

Chapter 4: Illustrated Parts List

SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

Figure 2-82. Conveyor Bottom Covers - Front (Option)................................... 4-2-174

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

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

SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1

This manual contains the confidential and proprietary information of TUG.

© Copyright 2007 by TUG. All rights reserved.

If applicable, enter your company identification number

MODEL NUMBER CODING OF MOBILE BELT LOADERS

Conveyor Electric Serial Number

660 = 24' Long

The model number is

TUG Technologies Corporation

TUG Technologies Corporation