Parts List for Mobile Lighting Tower Lower Chassis Assembly

PARTS LIST
MODEL: TL-90
MOBILE LIGHTING TOWER
Caution: Do not attempt to operate this machine until

you have read and understood completely
ALL instructions and guidelines contained.
Keep this manual available at all times for
Operators and Service Engineers.
Morris Site Machinery Ltd

Head Office: Station Road, Four Ashes, Wolverhampton, West Midlands WV10 7DB
Lincolnshire Office: Belchmire Lane, Gosberton, Lincolnshire PE11 4HG
Tel: 01775 840 020 Email: support@morrismachinery.co.uk
ISSUE DATE: February 2014

Morris Site Machinery Limited
Machine Information
Enter the machine Serial Number here for future

reference when ordering replacement parts.
……………………………………………….
Enter name and address of Authorised Distributor if

applicable.
……………………………………………….
……………………………………………….
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ALWAYS USE GENUINE PARTS
S.PM 003-6.34 i 13.02.2014

Table of Contents
Machine Information ............................................................................................................... i
Table of Contents................................................................................................................... ii
1 Lower Chassis Assembly ............................................................................................. 1
2 Overrun Assembly........................................................................................................ 3
3 Brake Drum Assembly ................................................................................................. 4
4 Upper Chassis Assembly ............................................................................................. 7
5 ‘A’ Frame Assembly ................................................................................................... 11
6 Fuel Tank Assembly................................................................................................... 13
7 Lifting Frame Assembly .............................................................................................. 14
8 Engine & Alternator Assemblies ................................................................................. 15
9 Cover Assembly ......................................................................................................... 21
10 Foam Kit ..................................................................................................................... 25
11 Control Panel Assemblies .......................................................................................... 27
12 Socket Box Assemblies .............................................................................................. 31
13 Ballast Assembly ........................................................................................................ 32
14 Power Pack Assembly ............................................................................................... 33
15 Mast ........................................................................................................................... 35
16 Lightbar Assembly...................................................................................................... 45
17 Powertilt Assembly (optional) ..................................................................................... 47
18 AutoRun Assembly (optional) ..................................................................................... 48
19 Label Explanations ..................................................................................................... 51
20 Wiring Diagrams......................................................................................................... 56
S.PM 003-6.34 ii 13.02.2014

1 Lower Chassis Assembly
1.1 Drawing
S.PM 003-6.34 1 13.02.2014

1.2 Parts
Lower Chassis Assembly TL-90 TC16663.01
Item Part Name Part Number Quantity
1 Axle (Assembly) 20K.630.000 1

2 Chassis Mid Pressing TC16252 1
3 Threaded Stop TC16251 1
4 Front Plate TC15658 1
5 Back Plate TC15657 1
6 Pressing Mast Conversion TC16250 1
7 Front Drawbar Mounting TC15643 1
8 Overrun Device (complete) 20K.629.000 1

9 40mm Cast Tow Eye 20K.643.000 1
10 50mm Ball Hitch (optional) 20K.644.000 1
11 Half Cast Clamp (complete) 20K.707.000 1
12 Half Cast Clamp 20K.707.001 1
13 Washer 20K.629.021 1
14 Lever 20K.629.020 1
15 Jockey Wheel (complete) 20K.632.000 1
16 Handbrake Loom (Assembly) WL15592 1
17 Breakaway Cable (also on Overrun Assembly) 20K.462.008 1
18 Switch Mounting Bracket TC15585 1
19 Alarm Switch 01E.247.000 1
20 Alarm Switch Tube TC15586 1
21 Front Brake Cable 20K.635.000 1

22 Rear Brake Cable 20K.695.000 2
23 M10 Locknut (Front) 20K.635.001 1
24 Balance Bar 20K.635.002 1
25 Ball Nut 20K.635.003 1
26 M10 Locknut (Rear) 20K.635.004 1
27 Wheel & Tyre (complete) 20K.614.004 2
28 Tyre 185 / 70 R13 20K.614.001 2
29 Wheel Rim (only) 20K.614.000 2
30 M20 Cable Gland 20K.645.000 1

31 M20 Locknut 20K.645.001 1
32 M5 x 20 Socket Hd. Screw 49S.109.000 2
33 M5 Flat Washer 89S.001.000 2
34 M5 Nyloc Nut 80S.016.000 2
35 M8 x 20 Setscrew 27S.143.000 4
36 M8 Flat Washer 89S.003.000 8
37 M8 Nyloc Nut 80S.018.000 4
38 M10 x 30 Setscrew 27S.171.000 4
39 M10 Flat Washer 89S.004.000 5
40 M10 Nyloc Nut 80S.019.000 5
41 M12 x 1.5 Spherical Wheel Bolt 20K.437.015 A 8
42 M12 x 35 Setscrew 06S.181.000 8
43 M12 x 40 Setscrew 06S.182.000 8
44 M12 x 50 Bolt 06S.184.000 4
45 M12 x 75 Bolt 06S.187.000 2
46 M12 x 110 Bolt 06S.196.000 2
47 M12 Flat Washer 89S.005.000 34
48 M12 Nyloc Nut 80S.020.000 26
49 M14 x 180 Bolt 06S.222.000 1
50 M14 Flat Washer 89S.006.000 2
51 M14 Nyloc Nut 80S.021.000 1
S.PM 003-6.34 2 13.02.2014

2 Overrun Assembly
2.1 Drawing
2.2 Parts
Overrun Assembly TL-90 TC16671.01
1 Overrun Device (complete) 20K.629.000 1

2 Gaiter 20K.629.003 1
3 Front Bearing Bush 20K.629.005 1
4 Profile Ring 20K.629.004 1
5 Draw Tube 20K.629.007 1
6 Rear Bearing Bush 20K.629.008 1
7 Shock Absorber 20K.629.001 1
8 Plate Rotating 20K.629.016 1
9 Bell Crank 20K.629.010 1
10 Breakaway Cable (also on Lower Chassis Assembly) 20K.462.008 1

11 Handbrake Assembly (complete) 20K.629.013 1
12 Handbrake Pivot Post 20K.629.012 1
13 Handbrake Pivot Spacer 20K.629.017 1
14 Grease Nipple (Bell Crank) 20K.629.009 1

15 Grease Nipple (Bearing Cartridge) 20K.629.011 2
16 M12 x 120 Bolt 20K.629.015 1
17 M12 Nyloc Nut 20K.629.002 2
S.PM 003-6.34 3 13.02.2014

Page intentionally left blank.
S.PM 003-6.34 4 13.02.2014

3 Brake Drum Assembly
3.1 Drawing
S.PM 003-6.34 5 13.02.2014

3.2 Parts
Brake Drum Assembly TL-90 TC16670.01
1 L-H. Back Plate 20K.613.001 1

R-H. Back Plate 20K.613.002 1
2 Brake Cable Shell 20K.437.027 1
3 Rear Brake Cable (also shown on Lower Chassis) 20K.695.000 1
4 Cable Eye 20K.437.002 1
5 Stub Axle 20K.628.003 1
6 Brake Shoe (pair) 20K.437.005 1
7 Pull-off Spring 20K.437.006 1
8 Shoe Retaining Spring 20K.437.020 2
9 Expanding Clutch 20K.437.007 1
10 Brake Drum with Bearing & Circlip 20K.613.004 1
11 Bearing (only) 20K.613.011 1
12 Reverse Lever Spring 20K.437.004 1

13 L-H. & R-H. Reverse Lever 20K.437.003A 1
14 Bearing Bolt 20K.437.018 1
15 Ø4mm x 20mm Split Pin - DIN 94 20K.437.019 1
16 Adjuster Cam 20K.613.007A 1
17 Adjuster Screw & Nut 20K.613.007B 1
18 Adjuster Wheel 20K.613.007C 1
19 Adjuster Plate 20K.613.007D 1
20 Plastic Plug 20K.437.025 2

21 Shoe Retaining Spring Retaining Clip 20K.437.026 4
22 Flange Nut 20K.613.005 1
23 Dust Cap 20K.613.006 1
24 M12 x 1.5 Spherical Wheel Bolt 20K.437.015 A 4
25 M20 x 60 Socket Hd Bolt 20K.628.001 1
Parts not shown on Illustration

L-H. & R-H. Brake Drum Assembly (complete) 20K.750.000 2
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4 Upper Chassis Assembly
4.1 Drawing
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4.2 Parts
Chassis Assembly TL-90 TC16647.01
1 Chassis Welded (Assembly) TC16254 1

2 Index Bolt Assembly (includes #3) IB01554 4
3 M16 x 1.5 Locknut (part of #2) 72S.057.000 4
4 Mudguard 20K.634.000 2
5 Amber Reflector (Rectangular) 20K.633.000 2
6 Mud Flap TR17160 2
7 Mud Flap Mounting Bracket TC17200 2
8 Ø1” BSP Bund Drain Plug 20K.611.000 1
1
9 Ø ∕2” BSP Bulkhead Adaptor 01H.315.000 1
1
10 Ø ∕2” BSP Dowty Seal 01H.434.000 1
1
11 Ø ∕2” BSP Locknut 11H.541.001 1
1
12 Ø ∕2” BSP Female Cap 01H.341.000 1
13 Prop Stand (includes #14) 20K.427.011 4

13 Wind Down Prop Stand (optional) 20K.725.000 4
13 Short Wind Down Prop Stand (optional) 20K.711.000 4
14 Plastic Cap 20K.427.011 A 4

15 Front Stabiliser Leg TC15195 2
16 L-H. Rear Stabiliser Leg TC16263 1
17 R-H. Rear Stabiliser Leg TC16264 1
18 L-H. Guide Stop TC16304 1
19 R-H. Guide Stop TC16305 1
20 Plastic End Cap 02A.025.000 4
21 L-H. Rear Pivot (complete) TC17131 1
22 R-H. Rear Pivot (complete) TC17130 1
23 Ø60mm Circlip 22K.059.000 2
24 Lock Pin PM17086 2
25 Spring SP17088 2
26 M12 Flat Washer BZP 89S.005.000 2
27 Ø3mm Split Pin 99S.518.000 2
28 Pressed Steel Clamp & Washer & Handle 20K.629.019 4
29 Pressed Steel Clamp 20K.629.018 4
30 Ø10mm x 60mm Roll Pin 99S.835.001 4
31 Clamp Washer 20K.629.021 4
32 Clamp Lever 20K.629.020 4
33 Fuel Filter (Assembly) 20K.553.000 1

34 Fuel Filter Holder 22M.001.009 1
35 In-Line Fuel Filter 20K.578.000 1
36 Ø8mm x 60mm Fuel Supply Hose 20K.681.000 1
38 Ø8mm x 280mm Fuel Supply Hose 22M.001.004 1
40 Electronic Fuel Pump 20K.646.000 1
41 Fuel Pump Mounting Bracket TC16344 1
Petro-Chemical Applications (optional) 20K.715.000
36 Ø8mm x 60mm Braided Fuel Supply Hose 20K.715.002 1

Kit includes Ø5mm x 500mm Braided Fuel Return Hose
20K.715.005 1
(on Engine & Alternator Assembly)
S.PM 003-6.34 8 13.02.2014

4.3 Drawing
S.PM 003-6.34 9 13.02.2014

4.4 Parts
Chassis Assembly TL-90 TC16647.01
Optional Extras for Chassis

42 Tow Bar TC16358 1
43 Tow Pivot Pin 01J.002.000 1
44 Pivot Pin Lynch Pin 01J.003.000 1
45 Ø11-16mm Jubilee Clip 22K.041.000 7

46 M6 x 16 Setscrew 27S.123.000 2
47 M6 x 20 Setscrew 06S.824.000 6
48 M6 Flat Washer 89S.002.000 10
49 M6 Spring Washer 92S.002.000 6
50 M6 Repair Washer 89S.019.000 6
51 M6 Nyloc Nut 80S.017.000 8
52 M8 x 20 Setscrew 27S.143.000 12
53 M8 x 25 Setscrew 27S.145.000 4
54 M8 x 30 Brass Setscrew 27S.146.001 1
55 M8 Flat Washer 89S.003.000 16
56 M8 Brass Flat Washer 27S.003.002 4
59 M8 Nyloc Nut 80S.018.000 8
60 M8 Brass Plain Nut 72S.003.004 2
61 M10 x 25 Setscrew 27S.170.000 4
62 M10 x 30 Setscrew 27S.171.000 4
63 M10 x 70 Bolt 06S.148.000 8
64 M10 Flat Washer 89S.004.000 32
65 M10 Nyloc Nut 80S.019.000 16
S.PM 003-6.34 10 13.02.2014

5 ‘A’ Frame Assembly
5.1 Drawing
S.PM 003-6.34 11 13.02.2014

5.2 Parts
‘A' Frame Assembly TL-90 TC16276.01
1 ‘A' Frame Pressing TC15256 1

2 Battery Mounting Bracket TC15601 1
3 Battery 01E.571.000 1
4 Battery Clamp Angle TC15678 1
5 Battery Rod TC15582 2
6 Battery Terminal Covers 01E.579.000 2
7 Mast Lock Plate (Outer) TM15550 1

8 Index Bolt Assembly (includes #9) IB01554 1
9 M16 x 1.5 Locknut (part of #8) 72S.057.000 1
10 M10 Shouldered Bolt TC15252 6
11 M14 Washer 89S.006.000 6
12 Wearpad (Rotator) TM15192 6
13 Locking Handle (Assembly) TC16301 1
14 M12 x 75 Cap Screw 48S.189.000 1
15 M12 Flat Washer 89S.005.000 3
16 M12 Nyloc Nut 80S.020.000 1
17 M6 Flat Washer 89S.002.000 2

18 M6 Nyloc Nut 80S.017.000 2
19 M8 x 20 Setscrew 27S.143.000 2
20 M8 x 25 Setscrew 27S.168.000 4
21 M8 Flat Washer 89S.003.000 18
22 M8 Nyloc Nut 80S.018.000 6
23 M10 x 25 Setscrew 27S.170.000 8
24 M10 Flat Washer 89S.004.000 22
25 M10 Nyloc Nut 80S.019.000 15
110 volt Socket Outlets Transformer (optional) TC16676.01
26 Transformer Mounting Bracket TC15540 1

27 110 volt CTE Transformer 11E.012.000 1
28 Battery Rod TC15582 2
29 PG21 Cable Gland 20K.441.000 1

30 PG21 Locknut 20K.441.001 1
31 M6 Flat Washer 89S.002.000 2
32 M6 Nyloc Nut 80S.017.000 2
33 M8 x 20 Setscrew 27S.168.000 4
34 M8 Flat Washer 89S.003.000 8
35 M8 Nyloc Nut 80S.018.000 4

Transformer Wiring Loom WL15807 1
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6 Fuel Tank Assembly
6.1 Drawing 6.2 Parts
Fuel Tank Assembly (Plastic Tank) TL-90 FT16278.02
Item Part Name Part Quantity

Number
Fuel Tank Assembly (includes items 2, 5, 6, 8, 9,

FT17458 1
10, 11, 12, 13)
1 Fuel Tank FT17494 1
2 Fuel Filler Cap 20K.650.001 1
2 Locking Fuel Filler Cap (includes Keys) [optional] 20K.650.003 1
Key (Locking Fuel Filler Cap) 20K.650.005 2
3 Clamp Bracket FT15919 3

4 Support Tab FT15924 1
5 Outer Cowl FT15912 1
6 Fuel Filler Strainer 20K.650.002 1
7 Gasket FT16005 1
8 Fuel Level Indicator 20K.674.000 1

9 Feed Pipe (Assembly) FT16710 1
1 1
10 Ø ∕2” - ∕4” BSP Reducer M/F 01H.280.000 1
1
11 Ø ∕4” BSP Ø6mm Bango 01H.607.000 1
1
12 Ø ∕4” BSP Ø8mm Bango 01H.606.000 1
1
13 Ø ∕4” BSP Bonded Seal 01H.432.000 4
1
14 Ø ∕4” BSP Bango Bolt 01H.606.001 2
1
15 Ø ∕2” BSP ‘O’ Ring 01H.853.000 2
16 Ø9.5-12mm Jubilee Clip 22K.040.000 1

18 M6 x 12 Setscrew 27S.121.000 4
19 M6 Flat Washer 89S.002.000 4
20 M10 x 25 Setscrew 27S.170.000 5
21 M10 Flat Washer 89S.004.000 10
22 M10 Nyloc Nut 80S.019.000 5
S.PM 003-6.34 13 13.02.2014

7 Lifting Frame Assembly
Lift Frame Assembly TL-90 TC16662.01
1 Horizontal Lift Frame TC15407 1

2 Lift Eye TC15404 1
3 Vertical Pressing TC15395 2
4 Lifting Bracket TC15263 1
5 M10 x 30 Setscrew 27S.171.000 12

6 M10 Flat Washer 89S.004.000 20
8 M10 Nyloc Nut 80S.019.000 12
9 M12 x 30 Setscrew 27S.196.000 6
11 M12 Flat Washer 89S.005.000 6
S.PM 003-6.34 14 13.02.2014

8 Engine & Alternator Assemblies
8.1 Kubota D905
8.1.1 Drawing
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8.1.2 Parts
Engine & Alternator Assembly (Kubota D905) TL-90 EM16659.01
1 Kubota D905 3-Cylinder Diesel Engine 22M.001.000 1

2 Engine Fan 20K.568.000 1
3
3 37.6" x ∕8" Fan Belt 20K.561.000 1
4 Starter (Assembly) 20K.560.000 1
5 Engine Starter Link TC10587 1
6 Engine Mounting Bracket EM15220 2
7 Anti-Vibration Mount 02A.051.000 4
8 Engine Oil Filter 20K.555.000 1

9 Engine Glow Plug 22M.001.007 3
10 Oil Filler Plug 22M.001.021 2
11 Dipstick 22M.001.010 1
12 Engine Oil Pressure Switch 20K.575.000 1
13 Engine Water Temperature Switch 20K.551.000 1
1
14 Ø ∕2” BSP x 430mm Engine Drain Hose 11H.541.000 1
1
15 Ø ∕2” BSP x M22 Adaptor 01H.216.000 1
16 Sealing Washer (15451-9667-0) 20K.573.001 1
17 Fuel Stop Solenoid 20K.565.000 1
18 Ø5mm x 650mm Fuel Return Hose 20K.746.000 1
19 Water Pump (Assembly) 20K.571.000 1
20 Water Pump Gasket 20K.572.000 1
21 Engine Thermostat 20K.577.000 1
22 Thermostat Gasket 22M.001.018 1
23 Water Pump to Thermostat Hose 22M.001.015 1
24 Head Cover Gasket 22M.001.017 1
25 Earth Lead (Engine to Chassis and Powerpack) WL15377 1
26 Aluminium Radiator 20K.651.000 1

27 Radiator Cowl TC15299 1
28 Radiator Cowl Infill TC15513 1
29 Radiator Top Hose 20K.566.000 1
30 Radiator Bottom Hose 20K.567.000 1
31 Radiator Mount Top (15111-7218-0) 20K.651.001 2
32 Radiator Mount Bottom (15111-7219-0) 20K.651.002 2
33 Radiator Bolt (15108-7238-0) 20K.651.003 2
34 Washer (Radiator Mount (15111-7220-0)) 20K.651.004 4
35 Radiator Mounting Bracket TC15225 1
36 Radiator Filler Cap 22M.001.012 1
37 Radiator Hose Clip 22M.001.020 4
38 Stay Bracket (also on Cover Assembly) TC16293 1
39 Flexible Exhaust (Assembly) EX15455 1

40 Ø50mm x 1500mm x 3mm Exhaust Bandage 04A.003.000 1
41 Exhaust Gasket 20K.549.000 1
42 Ø38mm Exhaust Clamp 20K.075.000 1
43 Exhaust Silencer EX15450 1
Petro-Chemical Applications Kit (optional) 20K.715.000
18 Ø5mm x 650mm Braided Fuel Return Hose 20K.715.005 1

Kit includes Ø8mm x 1200mm Braided Fuel Supply Hose
20K.715.003 1
(on Upper Chassis Assembly)
S.PM 003-6.34 16 13.02.2014

8.1.3 Drawing
S.PM 003-6.34 17 13.02.2014

8.1.4 Parts
Engine & Alternator Assembly (Kubota D905) TL-90 EM16659.01
44 LT3 110 4P Alternator 01E.538.000 1

45 LT3 110 4P Alternator 31.5 µFd Capacitor 01E.538.001 1
46 LT3 110 4P Alternator Diode 01E.534.002 2
47 Alternator Mounting Bracket AM15512 1
3 1
48 ∕8” UNC x 1 ∕4” Bolt (Stator) 11S.037.000 9
3
49 ∕8” Flat Washer (Stator) 87S.004.000 13
3
50 ∕8” Spring Washer (Stator) 91S.003.000 14
5 3
51 ∕16” UNC x ∕4” Setscrew (Rotor) 57S.017.000 6
5
52 ∕16” Spring Washer (Rotor) 91S.002.000 6
53 Ø9.5-12mm Jubilee Clip 22K.040.000 1

55 M6 x 12 Setscrew 27S.121.000 2
56 M6 x 16 Setscrew 27S.123.000 2
57 M6 Flat Washer 89S.002.000 6
59 M6 Nyloc Nut 80S.017.000 2
60 M8 x 20 Setscrew 27S.143.000 13
61 M8 x 25 Setscrew 27S.168.000 2
62 M8 x 30 Setscrew 27S.146.000 4
63 M8 Flat Washer 89S.003.000 26
65 M8 Nyloc Nut 80S.018.000 8
66 M10 x 30 Setscrew 27S.171.000 9
67 M10 Flat Washer 89S.004.000 9
69 M10 Nyloc Nut 80S.019.000 1
70 M12 x 35 Setscrew 27S.197.000 4
71 M12 Flat Washer 89S.005.000 9

‘R’ Clip (05515-61000) 20K.651.005 2
Rear Bearing - LT3 Alternator 62L.001.000 1
Engine Wiring Loom WL16186 1
Earth Cable WL15607 1
Battery Positive Cable WL15376 1
Battery Negative Cable WL15375 1
Emergency Stop to Power Pack Cable WL15991 1
Power Pack to Starter Cable WL15510 1
S.PM 003-6.34 18 13.02.2014

8.2 Perkins 403C.11G
8.2.1 Drawing
S.PM 003-6.34 19 13.02.2014

8.2.2 Parts
Engine & Alternator Assembly (Perkins 403C.11G) TL-90 GA15845.01
1 Perkins 403C - 11G 3-Cylinder Diesel Engine 29M.001.000 1

2 Engine Oil Filter 29M.001.002 1
3 Fuel Filter (Assembly) 29M.001.003 1
4 In-Line Fuel Filter 20K.578.000 1
3
5 Ø ∕4” BSP Engine Drain Hose 11H.533.000 1
3
6 Ø ∕4” BSP x M16 Adaptor 01H.224.016 1
7 Sealing Washer 29M.001.004 1
3
8 Ø ∕4” BSP Bulkhead Adaptor 01H.317.000 1
3
9 Ø ∕4” BSP Dowty Seal 01H.436.000 1
3
10 Ø ∕4” BSP Female Cap 01H.343.000 1
11 Relay 01E.573.001 3
12 Relay Base 01E.573.002 3
13 Relay Mounting Bracket TC15556 1
14 Engine Mounting Bracket EM15786 2
15 Anti-Vibration Mount 02A.051.000 4
16 Radiator 20K.664.000 1
17 Radiator Cowl TC16285 1
18 Radiator Top Hose 20K.664.001 1
19 Radiator Bottom Hose 20K.664.002 1
20 Radiator Anti-Vibration Mount 20K.664.003 2
21 Radiator Mounting Bracket TC15803 1
22 Radiator Hose Clip 20K.664.004 4
23 Air Filter (Assembly) 20K.663.000 1

24 Air Filter Mounting Bracket TC15822 1
25 Air Filter Element 20K.663.001 1
26 Flexible Exhaust (Assembly) EX15796 1
27 Ø38mm Exhaust Clamp 20K.075.000 1
28 Exhaust Silencer EX15798 1
29 LT3 110 4P Alternator 01E.538.000 1

30 Capacitor - LT3 Alternator 01E.538.001 1
31 Diode - LT3 Alternator 01E.534.002 1
32 Alternator Mounting Bracket AM15787 1
3 1
33 ∕8” UNC x 1 ∕4” Bolt (Stator) 11S.037.000 8
3
34 ∕8” Flat Washer (Stator) 87S.004.000 12
3
35 ∕8” Spring Washer (Stator) 91S.002.000 14
5 3
36 ∕16” UNC x ∕4” Setscrew (Rotor) 04S.030.000 6
5
37 ∕16” Spring Washer (Rotor) 91S.002.000 6
38 M8 x 20 Setscrew 27S.143.000 8
39 M8 x 30 Setscrew 27S.146.000 5
3 3
40 ∕8” UNC x ∕4” Setscrew 32S.030.000 2
41 M10 x 30 Setscrew 26S.196.000 8
42 M12 x 35 Setscrew 27S.197.000 4

Rear Bearing - LT3 Alternator 62L.001.000 1
Engine Wiring Loom WL15795 1
Engine Wiring Loom* WL16378 1
Earth Cable WL15607 1
Battery Positive Cable WL15993 1
Battery Negative Cable WL15375 1
Emergency Stop to Power Pack Cable WL15991 1
Power Pack to Starter Cable WL15510 1
S.PM 003-6.34 20 13.02.2014

9 Cover Assembly
9.1 Drawing
S.PM 003-6.34 21 13.02.2014

9.2 Parts
Cover Assembly TL-90 TC16645.01
1 Front Panel TC15297 1

2 SMC Identification Plate LA10454 1
3 Front Reflector Mounting TC15558 2
4 Front Clear Reflector 20K.633.001 2
5 R-H. Front Panel (Assembly) TC15314 1

6 L-H. Front Panel (Assembly) TC15306 1
7 Battery Access Cover TC15543 1
8 R-H. Rear Cover (Assembly) TC16291 1
9 L-H. Rear Cover (Assembly) TC16290 1
10 Control Panel Door CP16300 1
11 Emergency Stop (Assembly) 20K.675.000 1
12 Emergency Stop Mounting Dish SK15989 1
13 Sounder 20K.657.000 1
14 Sounder Mounting Bracket TC15557 1
15 Top Rear Hinged Cover Panel TC16286 1

16 Telescopic Stay TC16295 1
17 Stay Bracket (also on Engine Assembly) TC16293 2
18 Top Rear Fixed Cover Panel TC16287 1
19 Top Front Cover Panel TC15918 1
20 Fuel Level Perspex Cover (includes #21 & #22) 20K.639.000 1
21 Gasket (part of #20) 20K.639.001 1
22 Flange - Perspex Cover (part of #20) TC15304 1
23 Inner Cowl - Fuel Filler FT15917 1
24 Gasket FT15931 1
25 L-H. Rear Corner Panel TC16306 1

26 R-H. Rear Corner Panel TC16289 1
27 Rear Centre Panel TC15283 1
28 Rear Brace (Assembly) TC16292 1
29 Rear Access Door TC16299 1
30 Operation Manual Holder TC16532 1
31 Radiator Header Tank 20K.647.000 1
32 Header Tank Mounting Bracket 20K.647.001 1
33 R-H. Rear Lamp (Filament) 02E.949.000 1
34 L-H. Rear Lamp (Filament) 02E.948.000 1
35 18mm Deep Triangular Lock (Assembly) 20K.721.001 3

36 40mm Deep Triangular Lock (Assembly) 20K.722.001 1
37 Washer (Triangular Lock) TC16307 1
38 Key (Triangular Lock) 20K.496.000 2
39 Small Hinge 20K.595.000 2
40 Large Hinge 20K.774.000 4
S.PM 003-6.34 22 13.02.2014

9.3 Drawing
S.PM 003-6.34 23 13.02.2014

9.4 Parts
Cover Assembly TL-90 TC16645.01
41 M3 x 10 Pop Rivet 99S.908.000 10

42 M4 x 10 Pan Head Screw 66S.001.000 2
43 M4 x 12 Countersunk Screw 06S.823.000 4
1
44 Number 10 x /2" Self Tapping Pan Head Screw 60S.004.000 8
46 M4 Flat Washer 90S.016.000 8
48 M4 Nyloc Nut 80S.027.001 8
49 M5 x 12 Setscrew 27S.102.000 8
50 M5 x 15 Posi-Drive 66S.201.000 6
51 M5 Flat Washer 89S.001.000 8
53 M6 x 15 Torx Screw 06S.824.000 8
54 M6 x 12 Setscrew 27S.121.000 16
55 M6 x 16 Setscrew 27S.123.000 2
56 M6 Flat Washer 89S.002.000 16
59 M6 Nyloc Nut 80S.017.000 15
60 M8 x 20 Torx Screw 06S.825.000 73

Sounder Loom (Assembly) WL16189 1
Road Light Wiring Loom (Assembly) WL16974 1
Knock on Rubber (Mudguard) 05A.020.000 2.5 metres
Large Knock on Rubber (Door Seal) 05A.007.000 6.15 metres
Small Knock on Rubber (Door Seal) 05A.019.000 1
S.PM 003-6.34 24 13.02.2014

10 Foam Kit
10.1 Drawing
10.2 Parts
Foam Kit TL-90 FK16311.03
1 R-H. Rear Corner Foam FK15477 1

2 L-H. Rear Corner Foam FK15478 1
3 R-H. Side Rear Foam FK15480 1
4 L-H. Side Rear Foam FK15481 1
5 Top Front Foam FK16281 1
6 Top Hinged Door Foam FK16282 1
7 Rear Door Foam FK16308 1
8 Self-Adhesive Seal (order by metre) O5A.015.000 1.06 metres
S.PM 003-6.34 25 13.02.2014

S.PM 003-6.34 26 13.02.2014

11 Control Panel Assemblies
11.1 230 volt
11.1.1 Drawing
S.PM 003-6.34 27 13.02.2014

11.1.2 Parts
Control Panel Assembly (230 volt) TL-90 CP16184.01
1 Control Enclosure CP16117 1

2 Upper Panel CP16119 1
3 Breaker Panel CP15537 1
4 Connector Panel Ballast / Supply CP15538 1
5 Connector Panel Sockets CP15539 1
6 Rear Cover CP16146 1
7 Rear Blanking Panel CP15828 1
8 Diaphragm Grommet 15A.039.000 1
9 270mm Din Rail CP16648 1

10 MCB C10 Single Pole 13E.025.000 4
11 MCB B16 Single Pole 13E.005.000 2
12 RCCD 63A 2 Pole 13E.001.000 1
13 Neon Voltage Indicator 02E.406.000 1
14 Engine / Mast Control Module 01E.592.000 1
15 Socket & Cable Assembly (Ballast Connector) 14E.020.000 4

16 Socket & Cable Assembly (Outlet Sockets) 14E.021.000 2
17 Socket & Cable Assembly (Alternator Connector) WL16650 1
18 Socket & Cable Assembly (Spiral Cable Connector) WL16651 1
*Items 17 & 18 are supplied complete with Item 4
Items 19-23 are only installed on the Control Panel for the Kubota Engine build
19 Air Filter (complete) 20K.559.000 1
22 Air Filter Band 22M.001.002 2
23 Air Inlet Hose 22M.001.006 1
24 PG9 Cable Gland 20K.726.000 1

25 PG9 Locknut 20K.726.001 1
26 M3 x 12 Posi-Drive 06S.820.000 12
27 M3 Flat Washer 89S.017.000 12
28 M3 Nyloc Nut 80S.028.000 12
29 M4 x 10 Posi-Drive 66S.202.000 20
30 M6 x 15 Posi-Drive 66S.200.000 2
31 M6 x 25 Setscrew 27S.127.000 2
32 M6 Flat Washer 89S.002.000 4
33 M6 Plain Nut 73S.002.000 2
34 M8 x 20 Torx Screw 06S.825.000 6
35 M8 x 25 Setscrew 27S.168.000 2
36 M8 Flat Washer 89S.003.000 10
37 M8 Plain Nut 73S.003.000 2
38 M8 Nyloc Nut 80S.018.000 6
Supplied with AutoRun Module (also shown on AutoRun Assembly)
39 AutoRun Assembly (optional) CP16345 1

Positive Feed Cable Module WL15994 1
Rubber Strip Air Cleaner 22K.559.002 3
S.PM 003-6.34 28 13.02.2014

11.2 110 volt
11.2.1 Drawing
S.PM 003-6.34 29 13.02.2014

11.2.2 Parts
Control Panel Assembly (110 volt) TL-90 CP16185.01
1 Control Enclosure CP16117 1

2 Upper Panel CP16119 1
3 Breaker Panel CP15537 1
4 Connector Panel Ballast / Supply CP15538 1
5 Connector Panel Sockets CP15539 1
6 Rear Cover CP16146 1
7 Diaphragm Grommet 15A.039.000 1

9 MCB C10 Single Pole 13E.025.000 4
10 MCB B16 Single Pole 13E.005.000 2
11 RCCD 63A 2 Pole 13E.001.000 1
12 Neon Voltage Indicator 02E.406.000 1
13 Engine / Mast Control Module 01E.592.000 1
14 Socket & Cable Assembly (Ballast Connector) 14E.020.000 4

15 Socket & Cable Assembly (Outlet Sockets) WL16652 2
16 Socket & Cable Assembly (Alternator Connector) WL16650 1
17 Socket & Cable Assembly (Spiral Cable Connector) WL16651 1
18 Socket & Cable Assembly (Transformer Connector) WL16653 1
* Items 16 & 17 are supplied complete with Item 4
Items 19-23 are only installed on the Control Panel for the Kubota Engine build
19 Air Filter (complete) 20K.559.000 1
22 Air Filter Band 22M.001.002 2
23 Air Inlet Hose 22M.001.006 1

25 PG9 Locknut 20K.726.001 1
26 M3 x 12 Posi-Drive 06S.820.000 12
27 M3 Flat Washer 89S.017.000 12
28 M3 Nyloc Nut 80S.028.000 12
29 M4 x 10 Posi-Drive 66S.202.000 20
30 M6 x 15 Posi-Drive 66S.200.000 2
31 M6 x 25 Setscrew 27S.127.000 2
32 M6 Flat Washer 89S.002.000 4
33 M6 Plain Nut 73S.002.000 2
34 M8 x 20 Torx Screw 06S.825.000 6
35 M8 x 25 Setscrew 27S.168.000 2
36 M8 Flat Washer 89S.003.000 10
37 M8 Plain Nut 73S.003.000 2
38 M8 Nyloc Nut 80S.018.000 6
Supplied with AutoRun Module (also shown on AutoRun Assembly)
39 AutoRun Assembly (optional) CP16345 1

Positive Feed Cable Module WL15994 1
Rubber Strip Air Cleaner 22K.559.002 3
S.PM 003-6.34 30 13.02.2014

12 Socket Box Assemblies
12.1 Drawing
12.2 Parts
Socket Box Assembly 230 volt TL-90 CP16114.01
1 Socket Box TC15547 1

2 Cable (Assembly) WL15591 2
3 16 Amp 230 volt Socket 14E.004.000 2
4 PG13.5 Cable Gland 20K.679.000 2

5 PG13.5 Locknut 20K.679.001 2
6 M5 x 20 Setscrew 34S.106.000 8
7 M5 Star Washer 96S.001.000 8
8 M6 x 16 Torx Screw 06S.824.000 4
Socket Box Assembly 110 volt TL-90 (optional) CP16115.01
1 Socket Box TC15547 1

2 Cable (Assembly) WL15591 2
3A 16 Amp 110 volt Socket 14E.006.000 2
4 PG13.5 Cable Gland 20K.679.000 2

5 PG13.5 Locknut 20K.679.001 2
6 M5 x 20 Setscrew 34S.106.000 8
7 M5 Star Washer 96S.001.000 8
8 M6 x 16 Torx Screw 06S.824.000 4
S.PM 003-6.34 31 13.02.2014

13 Ballast Assembly
13.1 Drawing
13.2 Parts
Ballast Assembly TL-90 TC16280.01
Item Part name Part Number Quantity
1 Ballast (complete) 11E.016.000 4

2 Ballast Top - Ignitor & Capacitor (Assembly) 11E.007.007 4
3 L-H. Ballast Cable (Short) WL15373 2
4 R-H. Ballast Cable (Long) WL15511 2
5 Upper Ballast Mounting Bracket TC15388 2

7 PG16 Locknut 20K.442.001 4
8 M6 x 16 Setscrew 27S.123.000 12
9 M6 x 20 Setscrew 27S.125.000 4
10 M6 Flat Washer 89S.002.000 32
11 M6 Nyloc Nut 80S.017.000 16
12 M8 x 20 Setscrew 27S.143.000 8
13 M8 Flat Washer 89S.003.000 16
14 M8 Nyloc Nut 80S.018.000 8

60 µFd Capacitor 11E.007.001 4
Ignitor 02E.525.002 4
S.PM 003-6.34 32 13.02.2014

14 Power Pack Assembly
14.1 Drawing
S.PM 003-6.34 33 13.02.2014

14.2 Parts
Power Pack Assembly TL-90 PP16661.01
1 Power Pack (complete) 20K.710.000 1

2 Power Pack Mounting Bracket 20K.710.001 1
3 Main Valve Body Block (complete) 20K.710.002 1
4 Motor (Assembly) 20K.710.003 1
5 Pump (Assembly) 20K.710.007 1
6 Plastic Tank 20K.710.004 1
7 Filler Extension TC15608 1
8 Filler Cap PP17287 1
1 1
9 Ø ∕4” x ∕4” BSP Adaptor 01H.158.000 1
1
10 Ø ∕4” BSP Bonded Seal 01H.432.000 1
1
11 Ø ∕4” BSP Hose (Assembly) 11H.529.000 1
12 Pressure Switch 20K.649.000 1

3
13 Ø ∕8" BSP Blanking Plug 01H.327.000 1
14 ‘O’ Ring 01H.433.000 2
15 Relief Valve 20K.710.005 1
16 Spool Solenoid 20K.642.003 1

17 Spool 20K.642.004 1
18 Restrictor 20K.710.008 1
19 Motor Solenoid 20K.642.005 1
20 L-H. Connection Link (Motor) 20K.710.006 1
21 R-H. Connection Link (Solenoid) SK15983 1
22 M8 x 30 Setscrew 27S.146.000 1
23 M8 Flat Washer 89S.003.000 12
25 M8 Plain Nut 72S.003.001 7
26 M8 Nyloc Nut 80S.018.000 1
27 M10 x 20 Setscrew 27S.168.000 2
29 M12 Plain Nut 73S.005.000 1
Special Tools (not shown on Illustration)

Power Pack Resistor Tool WE17251 1
S.PM 003-6.34 34 13.02.2014

15 Mast
15.1 Section 1 Assembly
15.1.1 Drawing
S.PM 003-6.34 35 13.02.2014

15.1.2 Parts
Mast Section 1 Assembly TL-90 TM16294.01
1 Mast Assembly (complete) TM15196 1

2 Mast Section 1 TM15171 1
3 Mast Lock Plate (Inner) TM15552 1
4 Pin-Wire Retention PM15486 1
5 Upper Cable Cover TM15982 1
6 Lower Cable Cover TM15984 1
7 Hydraulic Cylinder HC10533 1

8 Bonded Seal 01H.432.000 1
9 Male Adaptor 01H.158.000 1
10 Pin-Hydraulic Cylinder Base PM15434 1
11 Wearpad (Black) TM15362 4

12 Wearpad (Rotator) TM15191 1
13 Bottom Washer TM16540 1
14 Ø16mm Circlip 22K.053.000 2

15 Ø20mm Circlip 22K.056.000 2
16 M6 x 12 Setscrew 27S.121.000 8
17 M6 x 30 Setscrew 27S.128.000 8
18 M6 Flat Washer 89S.002.000 24
20 M6 Nyloc Nut 80S.017.000 8
21 M8 x 20 Setscrew 27S.143.000 1
22 M8 x 30 Setscrew 27S.146.000 2
23 M8 Flat Washer 89S.003.000 4
25 M8 Nyloc Nut 80S.018.000 2

Mast Service Kit TM16180 1
Cable Cleat (No. 6) 15A.040.000 3
Plastic Plug 02A.062.000 2
S.PM 003-6.34 36 13.02.2014

15.2.1 Drawing 15.2.2 Parts

2 Large Pulley Assembly (includes #3) TM15490 1
3 Pin Pulley (part of #2) PM15819 1
4 Pin-Hydraulic Cylinder Rod PM15433 1
5 Pin-Wire Retention PM15486 1
6 Round Wearpad (Black) TM15364 8

7 Wearpad (White) TM15164 1
8 Wearpad (Green) TM15363 1
9 Ø6mm x 35mm Roll Pin 99S.836.000 1

10 Ø16mm Circlip 22K.053.000 2
11 Ø20mm Circlip 22K.056.000 2
12 M6 x 30 Setscrew 27S.128.000 2
13 M6 x 30 Setscrew 27S.128.000 2
13 M6 x 35 Setscrew (if Powertilt fitted) 27S.129.000 2
14 M6 Flat Washer 89S.002.000 8
15 M6 Nyloc Nut 80S.017.000 4
Extras supplied with Powertilt (also shown on Powertilt Assembly)
16 Powertilt Park Mounting Bracket TM16807 1
S.PM 003-6.34 37 13.02.2014


2 Large Pulley Assembly (includes #3) TM15490 1
4 Pin-Wire Retention (Bottom) PM15486 1
5 Pin-Wire Retention (Top) PM15218 1
6 Ø8mm x 1460mm Wire Rope WR16352 1
7 Round Wearpad (Green) TM15365 2

8 Round Wearpad (Yellow) TM00114 4
10 Wearpad (Green) TM15363 1
11 Ø6mm x 35mm Roll Pin 99S.836.000 1

12 Ø10mm Circlip 22K.052.000 2
13 Ø16mm Circlip 22K.053.000 2
14 M6 x 30 Setscrew 27S.128.000 4
15 M6 Flat Washer 89S.002.000 8
16 M6 Nyloc Nut 80S.017.000 4
S.PM 003-6.34 38 13.02.2014

15.4 Section 4 Assembly 15.4.2 Parts
15.4.1 Drawing Mast Section 4 Assembly TL-90 TM16316.01

2 Small Pulley Assembly (includes #3) TM15491 1
7 Round Wearpad (Green) TM15365 2

9 Wearpad (Yellow) TM15165 1
11 Ø6mm x 30mm Roll Pin 99S.835.000 1

12 Ø10mm Circlip 22K.052.000 2
13 Ø16mm Circlip 22K.053.000 2
14 M6 x 30 Setscrew 27S.128.000 4
15 M6 Flat Washer 89S.002.000 8
16 M6 Nyloc Nut 80S.017.000 4
S.PM 003-6.34 39 13.02.2014


6 Ø6.4mm x 1405mm Wire Rope WR16353 1
7 Round Wearpad (White) TM00115 2

11 Ø6mm x 30mm Roll Pin 99S.835.000 1

12 Ø10mm Circlip 22K.052.000 4
13 M6 x 30 Setscrew 27S.128.000 4
14 M6 Flat Washer 89S.002.000 8
15 M6 Nyloc Nut 80S.017.000 4
S.PM 003-6.34 40 13.02.2014



11 Ø6mm x 30mm Roll Pin 99S.835.000 1

12 Ø10mm Circlip 22K.052.000 4
13 M6 x 30 Setscrew 27S.128.000 4
14 M6 Flat Washer 89S.002.000 8
15 M6 Nyloc Nut 80S.017.000 4
S.PM 003-6.34 41 13.02.2014



9 Ø6mm x 30mm Roll Pin 99S.835.000 1

10 Ø10mm Circlip 22K.052.000 4
S.PM 003-6.34 42 13.02.2014

15.8.1 Drawings 15.8.2 Parts


7 Wearpad (Red) TM15277 2
8 Ø6mm x 30mm Roll Pin 99S.835.000 1

9 Ø10mm Circlip 22K.052.000 2
10 M6 x 30 Setscrew 27S.128.000 4
11 M6 Flat Washer 89S.002.000 8
12 M6 Nyloc Nut 80S.017.000 4
S.PM 003-6.34 43 13.02.2014


5 Ø10mm Circlip 22K.052.000 2

6 M10 x 30 Setscrew 27S.171.000 4
7 M10 Flat Washer on Lightbar Assembly 89S.004.000 4
8 M10 Nyloc Nut 80S.019.000 4
S.PM 003-6.34 44 13.02.2014

16 Lightbar Assembly
16.1 Drawing
S.PM 003-6.34 45 13.02.2014

16.2 Parts
Lightbar Assembly TL-90 TM16053.01
1 Lightbar TM15717 1
2 Terminal Box (Assembly) 03E.069.000 1
3 Lamp to Box Connection Cable WL15516 4
4 Spiral Cable (Assembly) WL15583 1
5 Lamp Assembly with Lens (not Bulb) 02E.528.000 4

6 Lamp Bracket TM15887 4
7 Lamp - Tommy Bar (Assembly) TM16268 8
8 Bracket - Tommy Bar (Assembly) TM15723 4
9 ‘R’ Clip 22K.080.000 8
10 Lamp Glass 02E.528.002 4
11 Lamp Cast Body (only) 02E.528.006 4
12 Lamp Connection Box 02E.528.010 4
13 Lamp Pivot Plate 02E.528.004 8
14 Clamp Washer 02E.528.005 8
15 Ø3mm x 30mm Roll Pin 99S.832.000 4

16 PG16 Cable Gland 20K.442.000 4
17 PG16 Locknut 20K.442.001 4
18 PG21 Cable Gland 20K.441.000 1
19 PG21 Locknut 20K.441.001 1
20 M20 x 1.5 Cable Gland 20K.733.000 5
21 M20 x 1.5 Locknut 20K.733.001 5
23 M5 Flat Washer 89S.001.000 4
24 M5 Nyloc Nut 80S.016.000 4
25 M10 x 25 Setscrew 27S.170.000 8
26 M10 x 30 Setscrew 27S.171.000 4
26 M10 x 35 Setscrew (if LDR Sensor or Powertilt fitted) 27S.172.000 2
27 M10 Flat Washer 89S.004.000 24
29 M10 Nyloc Nut 80S.019.000 4
30 M10 Locknut 73S.004.003 8
31 M14 Nyloc Nut 80S.021.000 4
32 M16 Serrated Washer 96S.007.000 4
Optional extras for AutoRun Module (also shown on AutoRun Assembly)
33 LDR Sensor 01E.596.000 1

Metal Halide Bulb (1000W) 02E.525.003 4
Bulb Retaining Clip 02E.528.003 4
Lamp (Body, Lens, Bulb, Clip & Cable) 02E.528.100 4
Glass Retainer Clamp 02E.528.007 8
Hinge and Retainer 02E.528.011 8
15 Amp Terminal Block (3-way) 01E.577.001 1
15 Amp Terminal Block (4-way) 01E.577.000 3
S.PM 003-6.34 46 13.02.2014

17 Powertilt Assembly (optional)
Powertilt Assembly TL-90 TM15505.01
1 Upper Bracket TM15495 1

2 Actuator Bracket TM15503 1
3 Actuator Top Bracket TM15497 1
4 Actuator 20K.690.000 1
5 Rain Cover TM17196 1
Powertilt Park Mounting Bracket
6 TM16807 1
(also on Mast Section 2 Assembly)
7 Powertilt Park Nylon Spacer WP16808 6
8 M6 x 16 Torx Screw 06S.824.000 6

9 M6 Flat Washer 89S.002.000 6
10 M6 Nyloc Nut 80S.017.000 6
11 M10 x 30 Setscrew 27S.171.000 10
12 M10 x 35 Setscrew 27S.172.000 2
13 M10 x 120 Setscrew 06S.154.000 1
14 M10 x 55 Bolt 06S.145.000 1
15 M10 Flat Washer 89S.004.000 16
16 M10 Nyloc Nut 80S.019.000 8
17 M14 Shouldered Bolt PM03116 2
18 Bush WB03115 2
19 M14 Flat Washer 89S.006.000 2
20 M14 Nyloc Nut 80S.021.000 2
S.PM 003-6.34 47 13.02.2014

S.PM 003-6.34 48 13.02.2014

18 AutoRun Assembly (optional)
18.1 Drawing
S.PM 003-6.34 49 13.02.2014

18.2 Parts
AutoRun Assembly TL-90 CP16345.01
1 Base CP16347 1
2 End Panel CP16348 1
3 Cover CP16349 1
5 Printed Circuit Board 20K.743.000 1
6 Contactor 20K.743.001 1
7 Timer 20K.743.002 1
8 Selector Switch Knob (includes #9) 20K.743.003 1
9 Selector Switch (part of #8) 20K.743.003 1
10 Plug & Internal Cable WL16672 1

11 Power Outlet Cable WL16673 1
12 Control Module Cable WL16674 1
13 Instruction Label LA16350 1

14 Flash Triangle Label LA15464 1
15 AutoRun Selector Label LA16706 1
16 PG13.5 Cable Gland 20K.679.000 1

17 PG13.5 Locknut 20K.679.001 1
19 PG7 Locknut 20K.744.001 1
21 M3 Flat Washer 89S.017.000 8
22 M3 Plain Nut 73S.020.000 4
23 M3 Nyloc Nut 80S.028.000 4
25 M6 x 12 Setscrew 27S.121.000 1
26 M6 x 20 Setscrew 27S.125.000 1
27 M6 Flat Washer 89S.002.000 6
28 M6 Plain Nut 73S.002.000 3
Optional extras for AutoRun Module (also shown on Lightbar Assembly)
29 LDR Sensor 01E.596.000 1

30 LDR Sensor Bracket CP16705 1
31 M10 x 35 Setscrew 27S.172.000 2

32 M10 Flat Washer on Lightbar Assembly 89S.004.000 4
33 M10 Nyloc Nut 80S.019.000 2
S.PM 003-6.34 50 13.02.2014

19 Label Explanations
19.1 External Labels
19.1.1 Front Elevation
19.1.2 Side Elevation
S.PM 003-6.34 51 13.02.2014

19.1.3 Rear Elevation and Radiator
19.1.4 Upper Elevation
S.PM 003-6.34 52 13.02.2014

19.2 Control Labels
19.2.1 Emergency Stop and Control Panel
LA16325
19.3 Individual Labels

19.3.1 Danger Symbols
LA15461.02
- Danger of entanglement and cutting:
- Presence of rotating parts, pulleys, belts and fan.
LA16533.01
- Danger of burns:
- Hot surfaces.
LA15459.03
- Danger of electric discharge:
- Consult the Operation Manual.
- Danger of corrosive acid leaks.
LA01945.01
- Danger of burns:
- Possibility of pressurised hot water expulsion.
LA15447.02
- The fuels are highly flammable and can be explosive.
- Fill in well-ventilated area with Engine switched off.
- Do not smoke or create sparks while filling.
- Immediately clean off any fuel leaks.
S.PM 003-6.34 53 13.02.2014

LA15464.01
- Danger of electric discharge:
- Consult the Operation Manual.
LA15992.03 (optional)
- Danger of machine starting automatically.
LA15602.03
- Danger of broken glass falling from a height.
- Do not operate lamps with broken glass.
LA15604.02 LA15584.04
- Danger of Death: - Danger of Death:
- Consult the Operation Manual. - Consult the Operation Manual.
19.3.2 Obligation Symbols
LA15603.04
- Obligation to connect equipment to earth.
LA03022.01
- Obligation to ensure Bund is drained regularly.
LA16351.02
- Obligation to deploy all Stabiliser Legs.
LA16165.01
- Obligation to ensure the machine is on level ground.
- Refer to instructions.
S.PM 003-6.34 54 13.02.2014

- Obligation to ensure the AutoRun and Emergency Stop are switched ‘OFF’.
LA17279.02
- Obligation to ensure the machine is on level ground.
- Refer to instructions.
19.3.3 Information Symbols
LA15462.01
- Indicates the position of the Lifting Hook(s) of the unit.
LA16312.01
- Indicates the position of the forklift pockets.
LA15649.01
- Indicates the sound pressure level.
LA15933.02
- Indicates where to source parts.
LA16996.01
- Indicates the location of the Operation Manual.
LA15587.01
- Indicates lamp deployment positions.
LA16666.04
- Vehicle identification plate.
S.PM 003-6.34 55 13.02.2014

20 Wiring Diagrams
20.1 Kubota Engine - Combined Module
S.PM 003-6.34 56 13.02.2014

20.2 Perkins Engine - Combined Module
S.PM 003-6.34 57 13.02.2014

20.3 230 volt Wiring Diagram
S.PM 003-6.34 58 13.02.2014

20.4 230/110 volt Wiring Diagram
S.PM 003-6.34 59 13.02.2014

Parts List for Mobile Lighting Tower Lower Chassis Assembly

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Parts List for Mobile Lighting Tower Lower Chassis Assembly

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PARTS LIST

Caution: Do not attempt to operate this machine until

Morris Site Machinery Ltd

ISSUE DATE: February 2014

Enter the machine Serial Number here for future

Enter name and address of Authorised Distributor if

ALWAYS USE GENUINE PARTS

S.PM 003-6.34 i 13.02.2014

1 Lower Chassis Assembly ............................................................................................. 1

3 Brake Drum Assembly ................................................................................................. 4

4 Upper Chassis Assembly ............................................................................................. 7

5 ‘A’ Frame Assembly ................................................................................................... 11

6 Fuel Tank Assembly................................................................................................... 13

7 Lifting Frame Assembly .............................................................................................. 14

8 Engine & Alternator Assemblies ................................................................................. 15

9 Cover Assembly ......................................................................................................... 21

10 Foam Kit ..................................................................................................................... 25

11 Control Panel Assemblies .......................................................................................... 27

12 Socket Box Assemblies .............................................................................................. 31

13 Ballast Assembly ........................................................................................................ 32

14 Power Pack Assembly ............................................................................................... 33

17 Powertilt Assembly (optional) ..................................................................................... 47

18 AutoRun Assembly (optional) ..................................................................................... 48

19 Label Explanations ..................................................................................................... 51

S.PM 003-6.34 ii 13.02.2014

S.PM 003-6.34 1 13.02.2014

Item Part Name Part Number Quantity

1 Axle (Assembly) 20K.630.000 1

8 Overrun Device (complete) 20K.629.000 1

21 Front Brake Cable 20K.635.000 1

30 M20 Cable Gland 20K.645.000 1

S.PM 003-6.34 2 13.02.2014

Item Part Name Part Number Quantity

1 Overrun Device (complete) 20K.629.000 1

10 Breakaway Cable (also on Lower Chassis Assembly) 20K.462.008 1

14 Grease Nipple (Bell Crank) 20K.629.009 1

S.PM 003-6.34 3 13.02.2014

Page intentionally left blank.

S.PM 003-6.34 4 13.02.2014

S.PM 003-6.34 5 13.02.2014

Item Part Name Part Number Quantity

1 L-H. Back Plate 20K.613.001 1

12 Reverse Lever Spring 20K.437.004 1

20 Plastic Plug 20K.437.025 2

Parts not shown on Illustration

S.PM 003-6.34 6 13.02.2014

S.PM 003-6.34 7 13.02.2014

Item Part Name Part Number Quantity

1 Chassis Welded (Assembly) TC16254 1

13 Prop Stand (includes #14) 20K.427.011 4

14 Plastic Cap 20K.427.011 A 4

33 Fuel Filter (Assembly) 20K.553.000 1

Petro-Chemical Applications (optional) 20K.715.000

36 Ø8mm x 60mm Braided Fuel Supply Hose 20K.715.002 1

S.PM 003-6.34 8 13.02.2014

S.PM 003-6.34 9 13.02.2014

Item Part Name Part Number Quantity

Optional Extras for Chassis

45 Ø11-16mm Jubilee Clip 22K.041.000 7

S.PM 003-6.34 10 13.02.2014

S.PM 003-6.34 11 13.02.2014

Item Part Name Part Number Quantity