Rayco C120R 2019 Parts Manual Download

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Read and understand all instructions before attempting to operate this machine. This manual

should be readily available for reference at all times.

Additional copies of this manual may be purchased. Contact your Authorized Rayco Dealer or

Rayco Manufacturing Inc.

RAYCO

Manufacturing,

Inc.

4255 E Lincoln Way

Wooster, OHIO 44606 U.S.A.

800.392.2686

raycomfg.com

Think Smart, Think Safe………

We care about your safety. When operating your RAYCO® machinery always wear an ap-

proved helmet complete with ear muffs, face shield and the proper eye wear. Never operate

under the influence of alcohol or drugs. Know your RAYCO, read and understand your owner’s

manual cover to cover.

RAYCO Manufacturing Inc. retains the right to make changes in design and specifications;

engineering; add or remove features; add improvements; or discontinue manufacturing at any

time without notice or obligation.

Thank you for buying and using RAYCO Equipment.

Summary of Contents for C120R 2019

Page 2: ...andunderstandallinstructionsbefore attempting to operate this machine This manual should be readily available for reference at all times Additional copies of this manual may be purchased from Rayco This Rayco machine was designed and manufactured by RaycoManufacturing Inc Wooster Ohio Duetocontinuous improvements Rayco reserves the right to make changes in engineering design and specifications or ...

Page 3: ...se of finding parts Please consult your local Rayco Dealer or local Engine Manufacturer Dealer for obtaining engine parts and service Operation The operation section is a reference for the new operator and a refresher for the experienced operator This section includesadiscussionofgauges switches machinecontrols attachment controls transportation and towing information Photographs and illustrations...

Page 4: ...jobs where larger mulchers just don t work The C120R rides on rubber tracks with 2 speed travel The rubber track design promotes longer track life and smooth operation by reducing debris packing in the track chain and keeps the drive components out of the hi impact areas Powerfulfinaldrivesprovidetorqueforclimbinghillsandallow the C120R to maneuver easily in difficult terrain Becauseit spurpose bu...

Page 5: ...R 4 Fuel Type DIESEL Ground Pressure With Mulcher 5 65PSI 38 9KPA Travel Speed Fast Track Travel Work 7 4 7 2 6MPH 11 2 7 5 4 1KPH Mulcher Head Standard FM120 6R Overall Width 83 IN 210 8 CM Cutting Width 71 5 IN 181 6 CM Rotor Diameter 16 75 IN 42 5 CM Teeth 36 36 Hydraulic System LO FLOW OPEN LOOP 20GPM 3 770PSI 75 7LPM 25 993KPA HI FLOW OPEN LOOP 40GPM 3 770PSI 151 4LPM 25 993KPA SUPER FLOW 52G...

Page 6: ...own of the serial number For Example C120R 001 01 19 C120R Type of Rayco equipment you have 001 Three digit for the number of produced 02 Two digit month 01 Jan 02 Feb etc 19 Two digit year 19 2019 20 2020 etc It is attached to the machine at the location shown For ready reference record it in the boxes provided on the next page of this manual For reference on communication regarding the engine re...

Page 7: ...UAL 800 392 2686 7 Serial Number Location Information Identification Numbers Model Number Serial Number Machine Engine Implement Implement Dealer Information Name Address Dealer Contact Phone Number Hours Sales Parts ...

Page 8: ...2 12 DETAIL G SCALE 2 15 59 48 47 68 44 66 CONTROL VALVE INCLUDED WITH 805860 ENGINE 21 HARNESS GROUNDING POINT DETAIL F SCALE 2 15 72 48 47 30 33 18 HARNESS GROUNDING POINT A A B B D C 23 33 27 17 65 53 E E 9 10 16 26 DETAIL D SCALE 2 15 58 28 33 27 DETAIL C SCALE 2 15 54 25 ...

Page 9: ... 5 3 41 33 1 41 33 1 31 11 29 24 9 17 33 46 DETAIL H SCALE 2 15 42 33 67 49 HARNESS GROUNDING POINT 60 61 54 DETAIL P SCALE 1 4 43 50 49 HARNESS GROUNDING POINT Main Frame Assembly 39113 Rev A J SECTION E E 22 21 25 29 11 9 26 15 24 38 DETAIL J SCALE 1 6 72 48 47 30 ...

Page 10: ...3 M N SECTION K K 32 24 63 40 1 56 33 7 62 63 6 DETAIL M SCALE 2 15 64 70 71 55 33 51 61 DETAIL N SCALE 2 15 59 48 47 68 8 NOTE CENTER VALVE PROVIDED WITH 805893 REVERSING FAN Main Frame Assembly 39113 Rev A L L K K 11 23 9 52 52 NOTE 39036 WINCH HIDDEN FOR CLARITY ...

Page 11: ...EAR ACCESS 36 1 40008 CAB LATCH ASM C120 37 1 40026 DEF FLUID SUPPLY MODULE ASM 38 1 40044 RIGHT SIDE HYD CPLR ASM C120 39 1 40130 FILTER RETURN ASM C120 40 2 722110 BOLT WHIZ 1 4 20 X 3 4 41 9 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 42 2 722201 BOLT HEX 5 16 18 X 2 GR8 43 1 722203 BOLT HEX 5 16 18X 3 4 GR8 44 3 722207 BOLT HEX 5 16 18 X 2 1 2 GR8 45 1 722503 BOLT HEX 1 2 13 x 1 1 4 46 1 724503 NUT...

Page 12: ... ITEMQTY PART DESCRIPTION 1 1 803264 FILTER ASM PRESS 3 PORT W METRIPAK SWITCH 1 NOTE 1 WIRE CONNECTOR AS FOLLOWS WHITE WIRE POSITION B RED WIRE POSITION A BLACK WIRE POSITION C OIL FILTER 762462 Filter Assembly 11543 Rev A ...

Page 13: ...C120R PARTS MANUAL 800 392 2686 13 ...

Page 14: ...HITE WIRE PIN B BLACK WIRE PIN C GREEN WIRE PIN D RED WIRE 2 ITEM QTY PART DESCRIPTION 1 1 801697 POWER UNIT HYD 12V ELEC MOTOR 2 1 801697 2 REMOTE POWER UNIT 2 BUTTON 3 1 804138 CONNECTOR WP FLAT 4 WAY FEMALE 4 1 800928 TERMINAL WEATHER PACK SOCKET 5 6 761653 TERM WTHPACK SEAL 18 20 6 2 761424 TERM WTHPACK M 14 16 7 4 761654 TERM WTHPACK F 14 16 ...

Page 15: ...1 39759 DOOR TOP WINCH C120 12 1 40206 PIN REMOVABLE WINCH PIN WELD 13 1 40208 PIN WINCH PIVOT W HOLE 14 8 722005 BOLT HEX M12 X 1 75 X 50 15 1 722119 BOLT ELEVATOR NORWAY 3 8 16 X 1 1 4 16 4 722303 BOLT HEX 3 8 16 X 1 17 1 722505 BOLT HEX 1 2 13 x 1 3 4 18 1 722508 BOLT HEX 1 2 13 x 2 5 19 2 724503 NUT HNML 1 2 13 PREV TORQ GR8 20 4 726302 WASHER LOCK 3 8 21 1 726503 WASHER FLAT 7 16 PLT USS 22 1...

Page 16: ...R PARTS MANUAL 16 Winch Stop Block Assembly 28324 1 2 3 4 ITEM QTY PART DESCRIPTION 1 1 28323 BLOCK STOP WINCH 2 4 726702 WASHER LOCK 5 8 GR8 3 4 724701 NUT HEX 5 8 11 GR8 4 4 763486 BOLT HEX 5 8 11 X 4 LG ...

Page 17: ...7 1 39123 PLATE FUEL SENDER ACCESS 8 2 722110 BOLT WHIZ 1 4 20 X 3 4 9 2 722508 BOLT HEX 1 2 13 x 2 5 10 4 724503 NUT HNML 1 2 13 PREV TORQ GR8 11 4 726301 WASHER FLAT 3 8 USS 12 2 726502 WASHER LOCK 1 2 13 1 738983 GAUGE SIGHT TEMPERATURE 14 3 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 15 8 750765 BOLT WHIZ 1 4 20 X 1 2 16 4 750917 BOLT HEX 3 8 16 X 2 1 2 17 1 761051 MAGNET HYD RES 18 1 800874...

Page 18: ...ERY W TIE DOWNS ASM 3 1 39609 BATTERY TRAY WELD 4 4 726300 WASHER FLAT 3 8 SAE 5 4 750399 BOLT WHIZ 3 8 16 X 1 GR8 2 ZP 6 3 760261 NUT HNNL 3 8 16 INS 7 1 800307 CLAMP VINYL COVERED 1 1 2 8 1 803428 CLAMP 2 VINYL 9 2 726101 WASHER FLAT 1 4 USS 10 1 724508 NUT LOCK 1 4 20 NYLOCK 11 1 722104 BOLT HEX 1 4 20 X 1 GR8 12 1 722303 BOLT HEX 3 8 16 X 1 ...

Page 19: ... 4 HOOK 2 1 35705 J HOOK 1 4 BATT TIE DOWN 10 25 3 2 724204 NUT WNNL 1 4 20 4 1 726101 WASHER FLAT 1 4 USS 5 1 801476 BATTERY C31S XHD 6 2 804607 NUT 3 8 16 STUD NUT SS 5 6 6 3 4 1 2 1 2 NOTE ONLY HAND TIGHTEN J HOOKS TO 4 LB FT USE BATTERY CORROSION PREVENATIVE ON TERMINALS NOTE BATTERY ORIENTATION DO NOT CLAMP ACROSS VENT CAP ...

Page 20: ...C120R PARTS MANUAL 20 Track Assembly 39574 ...

Page 21: ...VE W MOTOR ASM C120 3 2 39576 SPROCKET ASM C120 4 4 750762 BOLT WHIZ 5 16 18 X 3 4 5 24 763843 WASHER LOCK M20 PLAIN 6 2 803148 IDLER FRONT WHEEL ASM RUBBER 7 1 803149 IDLER SPRING PISTON ASM RH C100R 8 2 803150 ROLLER BOTTOM RUBBER 2FL 9 24 803173 BOLT MHHCS 20 X 2 5 X 40 GR10 9 BLACK 10 1 803183 IDLER SPRING PISTON ASM LH C100R 11 10 803514 ROLLER BOTTOM RUBBER 3FL 12 2 804437 TRACK RUBBER 450 X...

Page 22: ...RE INCLUDED WITH FINAL DRIVE TORQUE TO 200FT LBS WITH RED LOCTITE TORQUE TO 175FT LBS WITH RED LOCTITE ITEM QTY PART DESCRIPTION 1 18 750980 WASHER METRIC LOCK M16 2 1 805894 MOTOR PROPEL 60CC C120 3 1 806001 DRIVE FINAL 35 1 706 H1B INPUT 4 18 806178 BOLT MHHCS 16 X 2 0 X 55 ...

Page 23: ...ket Assembly 39576 ITEM QTY PART DESCRIPTION 1 2 39028 SPROCKET SEGMENT LH 20T C120 2 2 39029 SPROCKET SEGMENT RH 20T C120 3 2 39577 PLATE SPROCKET STRAP 3 BOLT 4 2 39578 PLATE SPROCKET STRAP 2 BOLT 5 18 750979 BOLT MHHCS 16 X 2 0 X 50 GR10 9 6 18 750980 WASHER METRIC LOCK M16 ...

Page 24: ...ANY AIR TO BLEED UPWARD BACK INTO THE TANK INSTALL THIS END SUPPLY FOR THE LOAD SENSE PUMP WITH THE OUTLET TUBE TOWARDS THE BOTTOM FRONT OF MACHINE THIS WAY ITEM QTY PART DESCRIPTION 1 2 39169 SUCTION END CAP WELDMENT C120 2 1 39171 TUBE SUCTION MANIFOLD C120 3 2 39579 FOOT SUCTION TUBE C120 4 4 722331 BOLT CAR 3 8 16 X 1 5 4 726300 WASHER FLAT 3 8 SAE 6 12 750050 NUT LOCK 5 16 18 NYLON 7 1 750819...

Page 25: ...C120R PARTS MANUAL 800 392 2686 25 ...

Page 26: ...nk Assembly 39581 Rev A 18 16 4 10 3 17 9 12 15 1 5 7 11 RETURN FUEL LINE 763813 HOSE FUEL LINE 3 8 J30R14T2 86 DRAW FUEL LINE 806294 HOSE FUEL LINE 1 2 J30R14T2 76 8 NOTE ITEMS NOT SHOWN 13 5 OF 763813 HOSE FUEL LINE 3 8 J30R14T2 ...

Page 27: ...T 10 4 722110 BOLT WHIZ 1 4 20 X 3 4 11 5 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 12 6 722508 BOLT HEX 1 2 13 x 2 5 13 4 724503 NUT HNML 1 2 13 PREV TORQ GR8 14 4 726501 WASHER FLAT 1 2 15 2 726502 WASHER LOCK 1 2 16 1 802952 STRAINER FUEL 6 17 5 803871 SCREW 10 24 X 1 1 2 HHCS SLOT THREAD CUTTING 18 1 804467 CAP FUEL 4 LOW PRESS VENTED 19 1 806373 ADAPTER 08MJIC X MM16X1 5 20 1 806374 ADAPTER 08MJ...

Page 28: ...C120R PARTS MANUAL 28 Electrical Panel Assembly 39582 6 8 6 5 INCLUDED WITH 805860 ENGINE INCLUDED WITH 805860 ENGINE REUSE MOUNTS AND HARDWARE FROM ENGINE ...

Page 29: ... WASHER FLAT 5 16 10 6 726202 WASHER LOCK 5 16 PLATED 11 5 726950 WASHER METRIC LOCK 6MM 12 1 736131 CIRCUIT BREAKER 30AMP MANUAL 13 2 750456 SCREW 10 24 X1 2 HH MACH 14 1 750569 SWITCH TOGGLE SPST ON OFF 15 2 750765 BOLT WHIZ 1 4 20 X 1 2 16 5 760458 NUT METRIC 6MM 1 0 PLATED 17 1 761432 CIRCUIT BREAKER 50AMP MANUAL 18 4 761707 BUFFER PCB 1 4 20 19 2 801842 BOOT CIRCUIT BREAKER 20 1 802386 DECAL ...

Page 30: ...C120R PARTS MANUAL 30 ITEM QTY PART DESCRIPTION 1 1 39597 DEBRIS CHAIN WELD C120 2 5 722700 BOLT HEX 3 4 10 X 1 1 2 GR8 3 5 726802 WASHER LOCK 3 4 2 1 3 Debris Chain Assembly 39596 ...

Page 31: ...QTY PART DESCRIPTION 1 4 722205 BOLT HEX 5 16 18 X 1 GR8 2 6 750050 NUT LOCK 5 16 18 NYLON 3 2 762962 BOLT HEX 5 16 18 X 3 1 2 GR8 4 10 763757 WASHER FLAT 5 16 HARDENED 5 1 805771 VALVE CHECK 40 PSI 6 1 FF6400 6 6 FITTING MALE CONNECTOR 6 6 7 2 39603 RETURN MANIFOLD BRACKET 8 1 39601 MANIFOLD RETURN C120 ...

Page 32: ...9604 1 2 6 4 6 5 3 ITEM QTY PART DESCRIPTION 1 4 726953 WASHER METRIC LOCK M12 2 4 760802 BOLT HEX M12 X 1 75 X 25 3 1 805892 VALVE PVG32 100 C120 4 2 750050 NUT LOCK 5 16 18 NYLON 5 2 722205 BOLT HEX 5 16 18 X 1 GR8 6 4 726201 WASHER FLAT 5 16 ...

Page 33: ... HOSE HYD 3R2T 4FSX 4FSX 38 15 1 806130 HOSE HYD 3R2T 4FSX 4FSX 50 16 1 806131 HOSE HYD 3R2T 4FSX 4FSX 46 17 1 806275 FIT TEE 4 MORFS 6 MORB 4 MORFS 18 1 806816 VALVE SHUTTLE 06 ORB STEEL Transducer Assembly 39619 Rev A 6 6 3 3 3 3 8 8 8 8 13 14 15 16 11 13 8 10 TRACK DRIVE PRESSURE 5600 PSI CUTTER PRESSURE 5100 PSI CUTTER CHARGE 350 PSI LOAD SENSE PRESSURE 3900 PSI TRACK DRIVE CHARGE PRESSURE 350...

Page 34: ... 8 16 X 3 4 GR8 2 ZP 9 2 724300 NUT HNML 3 8 16 GR8 ZP 10 12 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 11 4 750413 BOLT WHIZ 1 2 13 X 3 4 12 1 750762 BOLT WHIZ 5 16 18 X 3 4 13 1 750764 NUT WHIZ 5 16 18 SERR FLANGE L N GR8 ZN 14 2 750917 BOLT HEX 3 8 16 X 2 1 2 15 1 761146 FIT 8MJ 6MOR 16 1 761270 COUPLER QD 3 8 SAE F 17 1 761693 NIPPLE QD 1 2 SAE M 18 1 761694 COUPLER QD 1 2 SAE F 19 2 762561...

Page 35: ...2686 35 Limb Riser Assembly 39636 12 11 9 3 G DETAIL G SCALE 1 5 INSTALL MOTOR AS SHOWN WITH CASE DRAIN ON THIS SIDE A 4 STAGE 1 5 7 7 33 34 5 9 26 DETAIL A SCALE 1 4 5 27 28 HARDWARE THAT HOLDS ON LIGHTS BACKUP CAMERA AND ALARM ...

Page 36: ...C120R PARTS MANUAL 36 Limb Riser Assembly 39636 6 9 STAGE 2 29 15 NUT AND BOLT THAT HOLD FAN BOTTOM VIEW 19 35 STAGE 1 CONTINUED ...

Page 37: ...92 2686 37 Limb Riser Assembly 39636 D F DETAIL D SCALE 1 2 24 3 3 13 22 20 DETAIL F SCALE 1 2 3 2 24 STAGE 2 ADD STRAPS SCREENS AND HARDWARE 8 WIRING HARNESS C STAGE 3 31 9 ADD COOLER AND HARDWARE DETAIL C SCALE 1 2 23 16 31 ...

Page 38: ...C120R PARTS MANUAL 38 E 19 19 23 23 4 9 DETAIL E SCALE 1 4 1 21 25 10 32 4404 12 12 21 17 Limb Riser Assembly 39636 12 11 9 3 G DETAIL G SCALE 1 5 INSTALL MOTOR AS SHOWN WITH CASE DRAIN ON THIS SIDE ...

Page 39: ... 722705 BOLT HEX 5 8 11 X 2 GR8 18 2 722600 BOLT HEX 5 8 11X2 1 2GR8 19 6 724300 NUT HNML 3 8 16 GR8 ZP 20 8 724508 NUT LOCK 1 4 20 NYLOCK 21 4 724703 NUT METAL LOCK 5 8 11 22 16 726101 WASHER FLAT 1 4 USS 23 8 726301 WASHER FLAT 3 8 USS 24 4 730038 STRAP TARP W S HOOK 10 25 2 750057 NUT WHIZ 1 2 13 SERR FLANGE L N GR8 ZN 26 1 750502 ALARM BACK UP 102 dB A 27 4 750762 BOLT WHIZ 5 16 18 X 3 4 28 4 ...

Page 40: ...TITE WHEN INSTALLING SET SCREWS 1 8 GAP BETWEEN FAN HUB AND MOTOR FACE ITEM QTY PART DESCRIPTION 1 1 18849 HUB FAN LIMB RISER 2 5 722104 BOLT HEX 1 4 20 X 1 GR8 3 5 724508 NUT LOCK 1 4 20 NYLOCK 4 2 730008 SCREW SET 1 4 X 3 8 5 1 762877 FAN 24 30DEG PUSHER 6 1 764614 MOTOR HYD FAN ...

Page 41: ...IN B GROUND BLACK WIRE WIRE LEADS FROM LIGHT ARE APPROX 17 LONG TRIM TO 6 LENGTH WHILE STILL MAINTAINING WARRANTY TAG DISCARD M6 1 0 FASTENERS SUPPLIED WITH LAMP AND REPLACE WITH 5 16 18 FASTENERS AS SHOWN ITEM QTY PART DESCRIPTION 1 1 722207 BOLT HEX 5 16 18 X 2 1 2 GR8 2 1 750050 NUT LOCK 5 16 18 NYLON 3 2 762345 TERMINAL DEUTSCH PIN 4 1 802165 WEDGELOCK DEUTSCH 2 PIN W2P 5 1 802166 SOCKET DEUTS...

Page 42: ...Assembly 36717 2 3 5 4 1 6 ITEM QTY PART DESCRIPTION 1 2 36718 BAR SPACER 2 2 36719 BAR LONG SPACER 3 4 722110 BOLT WHIZ 1 4 20 X 3 4 4 8 726102 WASHER LOCK 1 4 5 8 750651 BOLT HEX 1 4 20 X 1 5GR8 6 1 803270 CONDENSER A C 19 5 X 18 95 X 1 ...

Page 43: ... Strobe 39530 1 PIN WIRE COLOR 3 2 4 PROGRAME TO FLASH PATTERN 6 ITEM QTY PART DESCRIPTION 1 1 806092 LIGHT LED ROUND MINI STROBE 2 1 803445 CONNECTOR 4 DEUTSCH MINI 3 1 803446 WEDGELOCK DEUTSCH 4 PIN MINI 4 4 802673 TERMINAL DEUTSCH SIZE 20 PIN ...

Page 44: ... Pump Assembly 39656 ITEM QTY PART DESCRIPTION 1 1 39655 MOUNT WELD HAND PUMP C120 2 1 806015 PUMP HAND TRANSFER 25 GPM 3 4 750061 NUT WHIZ 3 8 16 SERR FLANGE GR8 ZN 4 4 750399 BOLT WHIZ 3 8 16 X 1 GR8 2 ZP 5 1 761694 COUPLER QD 1 2 SAE F ...

Page 45: ...20 5 1 39665 COVER WELD MULTICOUPLER C120 6 1 39666 STEP TRACTION EMBOSS C120 7 6 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 8 4 722725 BOLT BHCS 3 8 16 X 3 4 ZP 9 4 726301 WASHER FLAT 3 8 USS 10 4 726302 WASHER LOCK 3 8 11 2 750156 BOLT WHIZ 5 16 18 X 1 12 2 750764 NUT WHIZ 5 16 18 SERR FLANGE L N GR8 ZN 13 6 750765 BOLT WHIZ 1 4 20 X 1 2 14 1 764725 FILTER ASSY HI PRESS C100 15 4 802394 BOLT HEX 3 8...

Page 46: ...C120R PARTS MANUAL 46 Multi coupler Assembly 36250 1 2 ITEM QTY PART DESCRIPTION 1 1 804931 COUPLER MALE MULTI 16 2 1 804932 COUPLER FEMALE MULTI 16 ...

Page 47: ...OR WELD C120 3 4 39692 WASHER BUMPER SHIM C120 4 12 722110 BOLT WHIZ 1 4 20 X 3 4 5 1 750050 NUT LOCK 5 16 18 NYLON 6 12 750768 NUT WHIZ 1 4 20 SERR FLANGE L N GR8 ZN 7 1 761543 BUFFER CONE SOA R80 8 1 761665 SPRING COMP 197X 975X1 5 9 1 760794 TRIM BULB STR 1 8 EDGE 3 4 SEAL 7 3 5 2 1 SHIM AS NEEDED TO OBTAIN A TIGHT SEAL WHEN WINCH IS CLOSED 8 4 6 ...

Page 48: ...CE FF6802 8 8 REFERENCE FF6802 8 8 REFERENCE FF6801 6 8 REFERENCE FF6802 8 8 REFERENCE FF6400 6 8 FF6500 6 6 REFERENCE FF6400 6 8 FF6500 6 6 REFERENCE FF6802 8 8 4 ITEM QTY PART DESCRIPTION 1 1 39694 MOUNTING PLATE 2 4 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 3 4 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 4 4 750762 BOLT WHIZ 5 16 18 X 3 4 5 1 806052 MANIFOLD LIFT ROLL SEQUENCE C120 ...

Page 49: ...392 2686 49 Battery Disconnect Assembly 39741 ITEM QTY PART DESCRIPTION 1 1 39626 MOUNT MAIN DISCONNECT 2 2 722110 BOLT WHIZ 1 4 20 X 3 4 3 2 750768 NUT WHIZ 1 4 20 SERR FLANGE L N GR8 ZN 4 1 801242 SWITCH MASTER BATTERY DISC ...

Page 50: ...ER DEF PANEL MOUNT 3 8 4900 47 WASHER 14 GA x 531x 765 4 1 722103 BOLT HEX 1 4 20 X 3 4 GR8 5 2 722104 BOLT HEX 1 4 20 X 1 GR8 6 4 722203 BOLT HEX 5 16 18X 3 4 GR8 7 1 722303 BOLT HEX 3 8 16 X 1 8 3 722305 BOLT HHCS 3 8 16X1 5 GR8 ZP 9 3 726101 WASHER FLAT 1 4 USS 10 4 726201 WASHER FLAT 5 16 11 4 760937 ISOLATOR GROMMET 484 ID ...

Page 51: ... WELD C120 2 1 40000 SLEEVE CYL GUIDE C120 3 2 805887 RING INT 1 3 4 4 1 40003 STOP WELD CAB LOCK CYL C120 5 1 40005 PIN CAB LATCH LONG C120 6 1 40006 PIN CAB LATCH SHORT C120 7 2 760870 SWITCH LEVER ACTION 8 3 750050 NUT LOCK 5 16 18 NYLON 9 3 722207 BOLT HEX 5 16 18 X 2 1 2 GR8 10 4 761598 WASHER FLAT 6 11 4 761599 NUT HNNL 6 32 12 4 800343 SCREW 6 32 X 1 1 2 HH ...

Page 52: ...2 Engine Assembly 39114 Rev A 16 NOTE 1 806141 NOT SHOWN IN DRAWING 19 20 21 B 5 15 6 2 13 11 3 7 11 9 13 11 4 7 15 11 9 DEF INJECTOR CLAMP TIGHTENING TORQUE 11 5 1 2 Nm 101 8 10 62 IN LB DETAIL B SCALE 1 4 8 12 16 1 1 16 ...

Page 53: ...TALLING PUMP STACK 17 18 Engine Assembly 39114 Rev A 6 6 13 11 3 7 11 9 13 11 4 7 15 11 9 2 15 UPSTREAM NOX SENSOR 5801624707 SUPPLIED WITH ENGINE THREAD TORQUE 50 10 Nm 36 8 7 4 FT LB INSTALL 806141 INSULATION BLANKET BETWEEN THE ENGINE DOC AND SCR NOTE ALL STAINLESS STEEL CLAMPS TO BE TIGHTEN BY HAND NO POWER TOOLS ...

Page 54: ...45 DURO YELLOW 8 2 722841 BOLT MSHCS 10 X1 5 X 35 9 4 724703 NUT METAL LOCK 5 8 11 10 8 726302 WASHER LOCK 3 8 11 8 726701 WASHER FLAT 5 8 12 2 726954 WASHER METRIC LOCK M10 13 4 763486 BOLT HEX 5 8 11 X 4 LG 14 1 765383 COUPLING FLYWHEEL 10 14T 15 1 805860 ENGINE 121 HP CAT C3 4B SKID OPU 16 1 806071 PUMP GEAR 10CC CW 9T 17 8 806146 BOLT SHCS 3 8 24 X 1 GR 8 18 1 806477 INDICATOR SERVICE 19 1 764...

Page 55: ...RT 28CC 4 1 803195 PUMP TD REAR 28CC 5 1 18284 TUBE ASSY SUCTION 6 1 806111 ELBOW 90DEG 32 SB X 32 BEADED 7 1 39610 TAIL SUPPORT ASM C120 8 10 12352 WASHER TABBED 1 2 9 1 805709 PLATE PUMP MTG SAE 3 C MOUNT 10 2 39948 TUBE TD CHARGE FILTER C120 11 12 762668 WASHER NORDLOCK 1 2 1 00 OD 12 10 722504 BOLT HEX 1 2 13 x 1 1 2 13 2 722505 BOLT HEX 1 2 13 x 1 3 4 14 12 726954 WASHER METRIC LOCK M10 15 12...

Page 56: ...AIL SUPPORT MOUNT WELD 3 1 39623 PLATE RH PUMP MNT TAIL SUPP 4 1 39624 PLATE LH PUMP MNT TAIL SUPP 5 1 712706 MOUNT ISO KIT 45 DURO YELLOW 6 4 722503 BOLT HEX 1 2 13 x 1 1 4 7 4 724503 NUT HNML 1 2 13 PREV TORQ GR8 8 1 724703 NUT METAL LOCK 5 8 11 9 2 726701 WASHER FLAT 5 8 10 1 763486 BOLT HEX 5 8 11 X 4 LG 11 4 763437 WASHER FLAT 1 2 SAE ZINC ...

Page 57: ...C SCR C120 2 1 38776 PIPE EXHAUST TAIL C120 3 1 39672 SCR MOD MOUNT WELDMENT 4 4 722209 BOLT HEX 5 16 18 X 1 1 4 5 16 724105 NUT HEX LOCK 10 24 6 4 724300 NUT HNML 3 8 16 GR8 ZP 7 4 726202 WASHER LOCK 5 16 PLATED 8 4 726300 WASHER FLAT 3 8 SAE 9 1 736101 CLAMP MUFFLER 2 1 2 HD SADDLE 10 4 751027 BOLT WHIZ 3 8 16 X 1 1 4 11 16 800812 BOLT BHCS 10 24 X 5 8 12 4 805951 ISOLATOR SILICON CUPMOUNT 40LB ...

Page 58: ...IT AROUND SENSOR PORT AMBIENT AIR TEMP SENSOR SUPPLIED WITH ENGINE RUBBER CONNECTOR SUPPLIED WITH ENGINE 4 2 1 2 ITEM QTY PART DESCRIPTION 1 1 38775 TUBE AIR TILT TO TURBO C120 2 2 763593 CLAMP CONST TORQUE 1 3 4 TO 2 5 8 SLHD 3 1 800524 INSULATION ULTRA FLEXIBLE 4 1 802202 CLAMP CONST TORQUE 3 1 4 TO 4 1 8 SLHD 5 1 AMBIENT AIR TEMP SENSOR AMBIENT AIR TEMP SENSOR ...

Page 59: ...C120R PARTS MANUAL 800 392 2686 59 ...

Page 60: ...HAND ESCAPE WINDOW USING 127 OF 12000127 APPLIED TO CAB SEAL WINDOW 38687 ONTO CAB USE 3M 760 ADHESIVE SEALANT BLACK PASTE 55 SHORE A 260PSI TENSILE STRENGTH LAY THE BEAD ABOUT 3 8 FROM INNER EDGE 15 MINUTE SKIM TIME SEAL BOTH WINDOWS 805903 ONTO CAB USE SUPPLIED RUBBER SEAL RETAINER AND SEAL ALL FOUR CORNERS USING 3M 760 ADHESIVE SEALANT BLACK PASTE 55 SHORE A 260PSI TENSILE STRENGTH LAY THE BEAD...

Page 61: ...C120R PARTS MANUAL 800 392 2686 61 Cab Assembly 39115 C120 20030119 And Below D D E E 17 SECTION D D 24 2 45 SECTION E E 47 9 22 32 34 37 31 35 C C 20 21 13 36 36 14 SECTION C C 15 16 32 33 ...

Page 62: ... UNDERSIDE LARGE 22 1 39542 FOAM CAB INTERIOR REAR 23 1 39543 FOAM CAB INTERIOR LH 24 1 39544 FOAM CAB ROOF INSULATION 25 1 39706 REAR WINDOW ASM 26 1 39707 ELECTRIC PANEL CAB BOTTOM ASM 27 1 39708 ESCAPE WINDOW ASM 28 1 39755 FRONT WINDOW ASM CAB C120 29 2 39768 SMALL SIDE WINDOW ASM C120 30 1 39769 HVAC SUB ASSEMBLY C120 31 1 39839 TOOLBOX DOOR ASM C120 32 1 39840 RADIO GROUP C120 33 1 39846 DEF...

Page 63: ...ONTO CAB USE 3M 760 ADHESIVE SEALANT BLACK PASTE 55 SHORE A 260PSI TENSILE STRENGTH LAY THE BEAD ABOUT 3 8 FROM INNER EDGE 15 MINUTE SKIM TIME SEAL BOTH WINDOWS 805903 ONTO CAB USE SUPPLIED RUBBER SEAL RETAINER AND SEAL ALL FOUR CORNERS USING 3M 760 ADHESIVE SEALANT BLACK PASTE 55 SHORE A 260PSI TENSILE STRENGTH LAY THE BEAD ABOUT 3 8 FROM INNER EDGE 15 MINUTE SKIM TIME 11 25 APPLY 49 OF 12000127 ...

Page 64: ...C120R PARTS MANUAL 64 Cab Assembly 39115 Rev A C120 20040119 And Above D D E E 17 SECTION D D 24 2 45 SECTION E E 47 9 22 32 34 37 31 35 C C 20 21 13 36 36 14 SECTION C C 15 16 32 33 ...

Page 65: ...39755 FRONT WINDOW ASM CAB C120 29 2 39768 SMALL SIDE WINDOW ASM C120 30 1 39769 HVAC SUB ASSEMBLY C120 31 1 39839 TOOLBOX DOOR ASM C120 32 1 39840 RADIO GROUP C120 33 1 39846 DEFROST ASM C120 34 10 722118 BOLT WHIZ 1 4 20 X 1 35 2 730022 CLAMP HOSE 9 16 1 1 16 36 10 750762 BOLT WHIZ 5 16 18 X 3 4 37 4 750768 NUT WHIZ 1 4 20 SERR FLANGE L N GR8 ZN 38 54 760794 TRIM BULB STR 1 8 EDGE 3 4 SEAL 39 8 ...

Page 66: ...TS MANUAL 66 Cab Tilt Pin Assembly 31809 1 2 4 750 5 313 ITEM QTY PART DESCRIPTION 1 1 31807 CAB TILT PIN WELD SHORT 2 1 761617 BOLT WHIZ 1 2 13 X 1 1 4 GR8 2 ZP 3 1 750057 NUT WHIZ 1 2 13 SERR FLANGE L N GR8 ZN ...

Page 67: ...PARTS MANUAL 800 392 2686 67 Cab Door Assembly 39331 Rev B 28 APPLY WEATHERSTRIP ON BOTTOM EDGE AND VERTICAL SECTIONS OF LOWER DOOR 39333 CAB DOOR IS INCLUDED WITH THE 39237 CAB WELDMENT 25 19 10 32 33 33 21 ...

Page 68: ...TO FRAME USE 3M 760 ADHESIVE SEALANT BLACK PASTE 55 SHORE A 260PSI TENSILE STRENGTH LAY THE BEAD ABOUT 3 8 FROM INNER EDGE 15 MINUTE SKIN TIME PRE LUBE DOOR HINGES WITH GREASE BEFORE INSTALLATION 16 31 10 26 22 30 1 21 11 14 6 18 13 14 7 23 18 24 15 5 19 19 17 16 17 ...

Page 69: ...8 NUT LOCK 1 4 20 NYLOCK 16 2 750050 NUT LOCK 5 16 18 NYLON 17 2 726101 WASHER FLAT 1 4 USS 18 5 750456 SCREW 10 24 X1 2 HH MACH 19 5 750765 BOLT WHIZ 1 4 20 X 1 2 20 1 760101 HANDLE RUBBER COATED GRAB 21 27 760261 NUT HNNL 3 8 16 INS 22 1 760704 GASKET HANDLE DOOR 23 2 760738 BRACKET MTG DOOR HANDLE 24 1 760739 LATCH ROTARY DOOR HANDLE 25 21 763598 PLUG HOLE 1 PLASTIC 26 1 763796 HANDLE PADDLE DO...

Page 70: ...0 Left Hand Mirror Assembly 39397 ITEM QTY PART DESCRIPTION 1 1 39399 MOUNT DOOR MIRROR 2 1 722104 BOLT HEX 1 4 20 X 1 GR8 3 1 726101 WASHER FLAT 1 4 USS 4 1 761596 MIRROR 5 ROUND 1 3 2 4 USE FASTENERS INCLUDED WITH MIRROR ...

Page 71: ...C120R PARTS MANUAL 800 392 2686 71 Cab Console Assembly 39474 A 11 11 11 11 11 11 11 11 2 1 22 DETAIL A SCALE 1 2 21 12 ...

Page 72: ...2 764465 SCREW 10 24 X 1 2 LOW SHCS 14 10 800009 NUT CAGE 1 4 20 15 1 800957 LAMP RED PILOT 16 1 801272 SWITCH KEYPAD CAN BUS 17 1 801842 BOOT CIRCUIT BREAKER 18 1 802759 ALARM SHUTDOWN 19 1 803760 RELAY STARTER T185 T275 20 1 803940 RADIO USB AUX REMOTE INPUT 21 2 804622 BOLT HEX 1 4 20 X 2 1 2 22 1 804962 SOCKET ACCESSORY 12V WATERPROOF 23 1 805114 OUTLET USB WATERPROOF 24 1 805231 SWITCH PUSH B...

Page 73: ...4 2 3 1 8 2 6 6 6 6 1 2 4 8 7 ITEM QTY PART DESCRIPTION 1 2 801197 FUSE MINI 5 AMP 2 3 801199 FUSE MINI 15 AMP 3 1 801200 FUSE MINI 30 AMP 4 2 802150 FUSE MINI 20 AMP 5 1 804145 MODULE POWER DISTRIBUTION RELAY 6 4 804514 RELAY MICRO 35 AMP W DIODE 7 1 805113 FUSE MINI 2 AMP 8 2 805237 FUSE MINI 7 5 AMP ...

Page 74: ...7 W 40175 REWORK REF ONLY 806375 JOYSTICK REF ONLY INSTALL SEAT HEATER SWITCH 2 REMOVE GAS SPRING ON THIS SIDE REPLACE WITH LOCK BAR 18 8 21 22 20 14 22 21 14 20 17 15 13 11 15 17 13 11 1 17 USE REAR SEAT PAN BOLTS TO SECURE SEAT SAFETY STRAPS ALIGN SEAT ADJUSTMENT RAILS WITH FRONT OF SEAT PAN WHEN INSTALLING ...

Page 75: ...2306 BOLT HEX 3 8 16X1 3 4GR8 13 6 726201 WASHER FLAT 5 16 14 8 726950 WASHER METRIC LOCK 6MM 15 6 750050 NUT LOCK 5 16 18 NYLON 16 1 750400 BOLT WHIZ 5 16 18 X 1 2 17 7 750414 BOLT WHIZ 1 2 13 X 1 GR8 2 ZP 18 2 750762 BOLT WHIZ 5 16 18 X 3 4 19 1 750764 NUT WHIZ 5 16 18 SERR FLANGE L N GR8 ZN 20 8 760458 NUT METRIC 6MM 1 0 PLATED 21 8 801183 BOLT BHCS 1 4 20 X 5 8 ZP 22 8 802310 BOLT MBHCS 6 X 1 ...

Page 76: ...AY SHROUD CONNECTOR ON OPERATOR PERSENT SWITCH 2 BLACK WIRES COMING FROM BACK OF SEAT ORIENTATION NOT CRITICAL NOTE REMOVE AND DISCARD POWER CONNECTOR ON SEAT HEATER HARNESS SUPPLIED WITH SEAT REPLACE WITH DEUTSCH DT06 2S PLUG AS FOLLOWS RED TO TERMINAL 1 BLACK TO TERMINAL 2 ITEM QTY PART DESCRIPTION 1 4 736002 TERM WTHPACK SEAL 16 14 2 2 761424 TERM WTHPACK M 14 16 3 2 761654 TERM WTHPACK F 14 16...

Page 77: ... AIR 4 2 722105 BOLT HEX 1 4 20 X 1 1 4 5 2 726101 WASHER FLAT 1 4 USS 6 2 750118 CLAMP HOSE 2 5 16 3 1 4 7 2 750400 BOLT WHIZ 5 16 18 X 1 2 8 4 750681 CLAMP HOSE 1 5 16 2 1 4 9 1 762694 AIR CLEANER AC OPT C85 10 1 762696 MOUNT AIR CLEANER C85 11 1 762739 COUPLING RUBBER 50MM 2 ID 12 4 763156 SCREW 10 X 3 8 SHEET 13 3 763157 SCREW 10 X 3 4 TF WOOD 14 1 801594 BLOWER FRESH AIR 1 SP 15 1 806406 HOSE...

Page 78: ...HANDLE DOOR WELD 3 1 27453 WASHER UHMW FRICTION 4 1 630004 KNOB PLASTIC ROUND 5 16 5 1 724104 SCREW 10 24 X 3 4 HH 6 2 724105 NUT HEX LOCK 10 24 7 5 750456 SCREW 10 24 X1 2 HH MACH 8 1 760261 NUT HNNL 3 8 16 INS 9 1 760704 GASKET HANDLE DOOR 10 2 760738 BRACKET MTG DOOR HANDLE 11 1 760739 LATCH ROTARY DOOR HANDLE 12 1 763796 HANDLE PADDLE DOOR 13 1 801980 TURNBUCKLE CAST S S 14 4 802097 SCREW 1 4 ...

Page 79: ...54 LAMP ROUND LED REWORK W DEUTSCH 3 1 39510 GUARD FRONT LED LIGHT WELD 4 2 39530 STROBE REWORK MINI 5 1 39572 HARNESS WIRING FRT LGT STROBE 6 1 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 7 2 722330 BOLT CAR 3 8 16 X 3 4 8 3 722725 BOLT BHCS 3 8 16 X 3 4 ZP 9 3 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 10 2 750399 BOLT WHIZ 3 8 16 X 1 GR8 2 ZP 11 1 802990 HORN 12V AIR ...

Page 80: ...UAL 80 Cab Left Hand Header Panel 39532 ITEM QTY PART DESCRIPTION 1 1 803298 TILTMETER 50 DEGREE 2 6 750765 BOLT WHIZ 1 4 20 X 1 2 3 1 39531 4 1 32642 DECAL TILTMETER 35 DEG 5 1 730100 GROMMET RUBBER 9 16 ID 2 3 1 4 5 ...

Page 81: ...b Right Hand Header Panel 39533 1 2 4 5 3 ITEM QTY PART DESCRIPTION 1 1 805901 DISPLAY CAMERA 9 LCD 2 1 804482 MOUNT DISPLAY 3 1 2 1 BALL ASM 3 6 750765 BOLT WHIZ 1 4 20 X 1 2 4 1 730100 GROMMET RUBBER 9 16 ID 5 1 39534 PANEL RH CAB HEADER ...

Page 82: ...ess Assembly 39535 ITEM QTY PART DESCRIPTION 1 1 39536 PANEL CAB SIDE ACCESS 2 1 39537 FOAM CAB SIDE ACCESS 3 4 750762 BOLT WHIZ 5 16 18 X 3 4 1 1 4 1 7 32 2 1 3 1 1 4 1 1 4 1 7 32 CENTER ACOUSTICAL BARRIER ON INSIDE FACE OF PANEL 2 ...

Page 83: ... 2686 83 Rear Window Assembly 39706 4 3 2 1 5 ITEM QTY PART DESCRIPTION 1 14 765279 WASHER SEALING 3 8 2 14 760261 NUT HNNL 3 8 16 INS 3 14 722337 BOLT CAR 3 8 16 X 1 1 2 4 1 39518 RETAINER REAR WINDOW 5 1 38685 WINDOW CAB REAR ...

Page 84: ...TE HVAC CAB BULKHEAD LOCK 3 4 722118 BOLT WHIZ 1 4 20 X 1 4 4 730022 CLAMP HOSE 9 16 1 1 16 5 1 801591 SEAL KWIK CABLE GLAND 5 3 REFERENCE CONNECTOR SUPPLIED WITH HARNESS 1 4 REFERENCE 2705 8 8 4 4 4 2 REFERENCE 4501 10 8 NOTE SOME ITEMS HAVE BEEN HIDDEN IN THIS VIEW FOR VISIBILITY NOTE ITEMS NOT SHOWN 1 39568 HARNESS WIRING CAB ...

Page 85: ...2 2686 85 Escape Window Assembly 39708 3 4 4 3 5 1 1 1 1 2 ITEM QTY PART DESCRIPTION 1 4 39521 ESC KNOB ASSEMBLY 2 1 39520 RETAINER ESC WINDOW 3 2 39499 ESC HANDLE LH ASM 4 2 39498 ESC HANDLE RH ASM 5 1 38688 WINDOW CAB RH ESC ...

Page 86: ...AR 3 8 16 X 1 1 2 7 4 726101 WASHER FLAT 1 4 USS 8 4 726102 WASHER LOCK 1 4 9 25 765279 WASHER SEALING 3 8 10 25 760261 NUT HNNL 3 8 16 INS 11 1 765080 CHECK VALVE C87 12 1 802609 BOTTLE WASHER ASM 13 1 802610 FITTING BULKHEAD ASM 90 14 1 805935 MOTOR WIPER ASM 15 1 805936 WIPER ARM 26 DUAL WET 16 1 805937 WIPER BLADE WINDSHIELD C120 A 2 3 1 10 15 13 16 9 6 6 6 6 5 6 5 6 5 6 5 5 6 6 6 5 6 5 6 5 6 ...

Page 87: ...0R PARTS MANUAL 800 392 2686 87 Small Side Window 39768 3 2 1 ITEM QTY PART DESCRIPTION 1 1 39484 REAR SIDE SLIDER WINDOW ASM 2 1 39952 CAB REAR SIDE SCREEN WELD 3 8 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP ...

Page 88: ...NUAL 88 HVAC Sub Assembly 39769 ITEM QTY PART DESCRIPTION 1 1 39485 HVAC REWORK 2 1 39545 DISPLAY W MOUNT ASM 3 2 730022 CLAMP HOSE 9 16 1 1 16 4 1 762807 FIT EL90 10MOR 10HE 5 1 762812 FIT EL90 MOR 10HE 1 2 3 3 4 5 ...

Page 89: ...Wall Mount 38126 2 1 5 3 4 ITEM QTY PART DESCRIPTION 1 1 805702 HVAC UNIT WALL MOUNT 2 1 38122 BRACKET ELECTRONIC WATER VALVE 3 6 750768 NUT WHIZ 1 4 20 SERR FLANGE L N GR8 ZN 4 4 722103 BOLT HEX 1 4 20 X 3 4 GR8 5 1 38104 HARNESS HVAC JUMPER ...

Page 90: ... RECT LOUVER 3 16 802167 HOSE DEFROST 2 X 9 4 4 764232 RIVET 1 8 X 337 5 2 750681 CLAMP HOSE 1 5 16 2 1 4 6 2 726202 WASHER LOCK 5 16 PLATED 7 2 726201 WASHER FLAT 5 16 8 2 764101 BOLT HEX 5 16 18 X 3 GR8 9 1 39852 DEFROST TUBE WELD C120 4 9 8 6 7 8 6 7 5 3 1 CUT MATERIAL WHEN STRETCHED TIGHT AND USE 20 OF 802167 FROM HVAC TO VENT ...

Page 91: ...C120R PARTS MANUAL 800 392 2686 91 ...

Page 92: ...9704 REMOTE ITEM QTY PART DESCRIPTION 1 1 39140 RH ENCL DOOR ASM C120 2 1 39141 LH ENCL DOOR ASM C120 3 1 39142 RH FRT ENCL CVR PANEL ASM C120 4 1 39143 LH ENCL DOOR ASM C120 5 1 39145 COVER SDR DOUBLE WALL 6 1 39146 COVER EXHAUST OUTLET WELD 7 14 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 8 3 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN ...

Page 93: ...embly 39545 6 2 4 1 5 2 5 3 ITEM QTY PART DESCRIPTION 1 1 27122 MOUNT DP600 DISPLAY 2 8 724104 SCREW 10 24 X 3 4 HH 3 8 724105 NUT HEX LOCK 10 24 4 4 801831 BOLT MHHCS 4 X 7 X 10 5 1 802710 MOUNT DISPLAY 5 1 5 BALL 6 1 803654 08 PANEL DISPLAY PROGRAMED C120 ...

Page 94: ... 6 2 728035 PIN HAIR COTTER 1 8 X 1 7 1 722205 BOLT HEX 5 16 18 X 1 GR8 8 3 726101 WASHER FLAT 1 4 USS 9 1 750050 NUT LOCK 5 16 18 NYLON 10 1 726503 WASHER FLAT 7 16 PLT USS 11 1 761373 WASHER LOCK 7 16 12 1 761634 NUT HN 7 16 14 GR8 ZY 13 4 802310 BOLT MBHCS 6 X 1 0 X 20 ZP 14 1 39147 RH ENCL DOOR WELDMENT C120 15 2 39150 HINGE DOOR WELD 16 2 29330 HINGE ADJ WELD 17 1 26466 SEAL FIRE EXT PORT 18 ...

Page 95: ... 2 6 2 728035 PIN HAIR COTTER 1 8 X 1 7 1 722205 BOLT HEX 5 16 18 X 1 GR8 8 3 726101 WASHER FLAT 1 4 USS 9 1 750050 NUT LOCK 5 16 18 NYLON 10 1 726503 WASHER FLAT 7 16 PLT USS 11 1 761373 WASHER LOCK 7 16 12 1 761634 NUT HN 7 16 14 GR8 ZY 13 4 802310 BOLT MBHCS 6 X 1 0 X 20 ZP 14 1 39147 RH ENCL DOOR WELDMENT C120 15 2 39150 HINGE DOOR WELD 16 2 29330 HINGE ADJ WELD 17 1 26466 SEAL FIRE EXT PORT 1...

Page 96: ...254 LAMP ROUND LED REWORK W DEUTSCH 3 1 39160 FRT ENCL CVR PANEL WELDMENT 4 1 39530 STROBE REWORK MINI 5 5 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 6 6 724508 NUT LOCK 1 4 20 NYLOCK 7 6 726101 WASHER FLAT 1 4 USS 8 5 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 9 6 765067 BOLT BHCS 1 4 20 X 1 10 1 801009 SENSOR ENG COMP TEMP 11 1 39509 LEXAN 5 X5 LIGHT COVER ...

Page 97: ... 39509 LEXAN 5 X5 LIGHT COVER 6 1 39530 STROBE REWORK MINI 7 2 722303 BOLT HEX 3 8 16 X 1 8 2 722725 BOLT BHCS 3 8 16 X 3 4 ZP 9 4 724508 NUT LOCK 1 4 20 NYLOCK 10 4 726101 WASHER FLAT 1 4 USS 11 4 726300 WASHER FLAT 3 8 SAE 12 2 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 13 2 760261 NUT HNNL 3 8 16 INS 14 4 765067 BOLT BHCS 1 4 20 X 1 13 11 11 7 11 8 12 7 2 3 4 14 5 10 9 1 Left Hand Enclosure ...

Page 98: ...17 Rev A 2 2 6 5 4 5 4 5 4 3 ITEM QTY PART DESCRIPTION 1 1 40081 2 2 39552 PLATE REAR DRIVE CVR C120 3 1 40084 4 18 722114 BOLT WHIZ 3 8 16 X 3 4 GR8 2 ZP 5 25 750061 NUT WHIZ 3 8 16 SERR FLANGE L N GR8 ZN 6 7 750399 BOLT WHIZ 3 8 16 X 1 GR8 2 ZP ...

Page 99: ... 3 15 16 TO 4 1 4 SLTB 8 2 801915 CLAMP CONST TORQUE 3 3 4 TO 4 5 8 SLHD 9 1 801979 HANGER EXH UNIVERSAL RUBBER 10 1 801988 CLAMP CONST TORQUE 4 1 4 TO 4 9 16 SLTB 11 4 802373 WIRE TIE 34 1 2 WIDE 12 1 806164 INSULATION FLEXIBLE FOAM 4 1 8 ID 13 1 806204 HOSE HUMP 3 75 ID X 6 L 14 1 806570 SCREEN ASSY PRECLNR C120 15 1 970127 ELBOW RUBBER 90D 4 8 13 8 2 9 7 7 15 6 4 3 3 5 12 USE 28 OF 806164 INSUL...

Page 100: ...C120R PARTS MANUAL 100 Decal Kit 39722 Rev D 12 13 3 19 14 1 5 16 6 9 18 1 10 4 35 40 36 38 39 17 37 15 8 20 22 28 12 27 26 24 23 23 25 11 31 32 7 2 30 33 21 29 41 34 ...

Page 101: ...AY PANEL 19 2 39704 DECAL FIRE SUPPRESSION 20 1 39748 DECAL LEAD AND DIESEL WARNING 21 1 39932 DECAL WINDSHIELD WASHER 22 1 39942 DECAL PWR SHUT OFF WAIT WARNING 23 1 40117 DECAL C120 MAINTENANCE CHART 24 1 40133 DECAL C120 LOGO FUEL TNK SIDE 25 1 40134 DECAL TANK STRIPE C120 26 1 40135 DECAL C120 LOGO FUEL TNK SIDE 27 1 40136 DECAL CAB LATCH INDICATOR C120 28 1 40187 DECAL RH TANK STRIPE C120 29 ...

Page 102: ...C120R PARTS MANUAL 102 Loader Arm Assembly 39887 C120 20030119 And Below 8 9 11 7 2 6 3 14 12 10 13 5 15 A DETAIL A SCALE 1 6 4 MULTIPLE COMPONENTS HIDDEN 1 14 ...

Page 103: ...1 39094 ASM ATTACHMENT PLATE C120 7 2 39111 PIN BUTT LIFT CYL 8 2 39112 PIN LDR ARM PIVOT 9 1 39889 LOADER ARM WELDMENT C120 10 2 39891 PIN BUTT ROLL CYL 11 4 722312 BOLT HEX 3 8 16 X 3 1 2 12 2 724300 NUT HNML 3 8 16 GR8 ZP 13 4 730080 GREASE ZERK 1 8 PTF STR 14 16 750400 BOLT WHIZ 5 16 18 X 1 2 15 2 760261 NUT HNNL 3 8 16 INS Loader Arm Assembly 39887 C120 20030119 And Below 4 5 4 1 14 7 12 11 5...

Page 104: ...C120R PARTS MANUAL 104 Loader Arm Assembly 39887 Rev B C120 20040119 And Above 8 9 11 7 2 6 3 14 12 10 13 5 15 A DETAIL A SCALE 1 6 4 MULTIPLE COMPONENTS HIDDEN 1 14 ...

Page 105: ... ATTACHMENT PLATE C120 7 2 39111 PIN BUTT LIFT CYL 8 2 40196 PIN LDR ARM PIVOT 9 1 39889 LOADER ARM WELDMENT C120 10 2 39891 PIN BUTT ROLL CYL 11 4 722312 BOLT HEX 3 8 16 X 3 1 2 12 2 724300 NUT HNML 3 8 16 GR8 ZP 13 4 730080 GREASE ZERK 1 8 PTF STR 14 16 750400 BOLT WHIZ 5 16 18 X 1 2 15 2 760261 NUT HNNL 3 8 16 INS 16 1 40628 TREAD 6 X 24 Loader Arm Assembly 39887 Rev B C120 20040119 And Above 4...

Page 106: ...ROLL CYL 9 2 39097 PIN ATTACH PLATE PIVOT 10 2 4900 35 WASHER 14 GA 375 X 1 25 11 4 722106 BOLT HEX 3 4 10 X 3 GR8 12 2 722311 BOLT HEX 3 8 16 X 3 GR8 13 2 722312 BOLT HEX 3 8 16 X 3 1 2 14 2 724300 NUT HNML 3 8 16 GR8 ZP 15 2 726301 WASHER FLAT 3 8 USS 16 4 726801 WASHER FLAT 3 4 USS 17 4 726802 WASHER LOCK 3 4 18 2 729999 ZERK GREASE 1 8 NPT 90DEG 19 4 730080 GREASE ZERK 1 8 PTF STR 20 2 750835 ...

Page 107: ...C120R PARTS MANUAL 800 392 2686 107 ...

Page 108: ...C120R PARTS MANUAL 108 Hydraulic Hose Schematic 806134 ...

Page 109: ...C120R PARTS MANUAL 800 392 2686 109 Hydraulic Hose Schematic 806134 ...

Page 110: ...LBOW 45 6 MORFS 10 MORB 38 1 FF6804 4 4 4 RUN TEE 4 MORFS 4 MORB 4 MORFS 39 1 6400 4 6 CONNECTOR 4 MJIC 6 MORB 40 2 FF6804 4 6 4 RUN TEE 4 MORFS 6 MORB 4 MORFS 41 1 FF6500 4 4 ELBOW 90 4 MORFS 4 FORFS SWIVEL 42 1 FF6801 8 8 ELBOW 90 8 MORFS 8 MORB 43 1 FF2408 8 PLUG 8 MORFS 44 3 FF6801 10 10 ELBOW 90 10 MORFS 10 MORB 45 1 FF6400 8 10 CONNECTOR 8 MORFS 10 MORB 46 1 FF6802 8 8 ELBOW 45 8 MORFS 8 MOR...

Page 111: ... 12FSX 12FSX 54 30 1 HOSE T5012D 12FSX 12FSX 50 31 1 HOSE T3004D 4FSX 4FSX45 37 32 1 HOSE T3010D 10FSX 10FSX90 77 33 1 HOSE T3010D 10FSX 10FSX90 54 34 1 HOSE SR20 BLANK BLANK 110 35 1 HOSE SR20 BLANK BLANK 72 36 1 HOSE SR20 BLANK BLANK 54 37 2 HOSE T3006D 6FSX 6FSX90 55 38 2 HOSE T3006 6FSX 6FSX90 43 39 1 HOSE T3004D 4FSX 4FSX 12 40 1 HOSE T3004D 4FSX 4FSX90 12 41 1 HOSE T3004D 4FSX 4FSX 14 42 1 H...

Page 112: ... SUSP PWR WHT HIGH HEAT RED BLK SWITCHOVER BLK WIPER GRD BLK WIPER GRD WHT WASH WHT ORG RH JS PWR W RH ORG WHT LH JS PWR PUR SW PWR PNK HEAT LOW SEAT PNK BLK ACC FUSE BLK ACC GRD PNK USB FUSE FLEXXAIRE FAN PURGE SWITCH SEAT SWITCH SEATBELT SWITCH SEAT AIR COMPRESSOR SEAT LOW HEAT SEAT HIGH HEAT SEAT HEATER SWITCH THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF RAYCO MFG INC ANY R...

Page 113: ...T ORG RH JS PWR WHT ORG RH JS PWR ORG WHT LH JS PWR ORG WHT LH JS PWR PUR SW PWR PNK HEAT LOW BLK RELAY GRD BLK RELAY GRD RED ACC PWR RED ACC PWR RED ACC PWR PUR SEAT COMP PUR SEAT C O M P PUR WHT DOOR SW PWR PUR WHT DOOR SW PWR PNK BLK HVAC PWR PNK BLK HVAC PWR SENSITIVITY SWITCH FLOW DIRECTION SWITCH YLW RED WORK LGTS FUSE YLW RED WORK LGTS FUSE 50A KEY SIGNAL DIODE G RY HORN RLY GRY HORN RLY OR...

Page 114: ...T SP2 07 2 MICRO PWR 18 RED WHT SP1 07 6 SAFETY OUT 18 ORG 17 9 07 7 IGN START 18 PNK 10 50 07 10 DOOR OPEN 18 YLW WHT 67 4 07 11 E STOP SIG 18 PUR WHT 13 4 07 12 KEY SIG 18 WHT 69 k 08 1 FLOW FWD 18 TAN 48 08 3 FLOW REV 18 GRY 46 08 4 LOW SENSITIVITY 18 BLU 50 08 5 HIGH SENSITIVITY 18 GRN 52 08 9 LGTS ON 18 YLW BLK 65 A3 08 10 HORN 18 GRY 65 A6 08 12 DOME LGT 18 YEL BLK 67 6 09 1 SW PWR 16 PUR SP...

Page 115: ...8 BLK SP9 23 1 MICRO GRD 18 BLK WHT SP2 23 2 RH JS PWR 18 WHT ORG 65 D7 23 3 CAN 18 YLW 24 A 23 4 CAN 18 GRN 24 B 23 5 CAN SLD 18 GRY 24 C 25 ACC PWR 16 RED SP5 27 SEAT COMP 14 PUR 65 A12 28 DOOR SW PWR 16 PUR WHT 67 2 29 HVAC PWR 14 PNK BLK 65 E6 30 SW PWR 16 PUR SP4 31 WORK LGTS FUSE 14 YLW RED 65 E2 32 HORN RLY 14 GRY BLK 65 A4 33 FF 1 12 ORG SP13 34 FF 2 12 PUR SP14 35 ACC FUSE 16 PNK BLK 65 D...

Page 116: ...4 BLK SP7 65 B9 HEAT LOW 16 PNK SP10 65 B10 RELAY GRD 14 BLK SP7 65 B12 SEAT FUSE FEED 14 RED BLK SP12 65 C9 MICRO PWR 18 RED WHT SP1 65 C10 FF 2 12 PUR SP14 65 C12 ACC PWR 16 RED SP5 65 D8 FF 2 12 PUR SP14 65 D10 ACC PWR 16 RED SP5 65 D11 KEY PWR 14 RED SP11 65 D12 FF 1 12 ORG SP13 65 E3 WIPER PWR 14 RED WHT SP16 65 E4 FF 1 12 ORG SP13 65 E5 HVAC FUSE 14 PNK BLK SP15 65 E8 FF 2 12 PUR SP14 65 E10...

Page 117: ...RED 25 65 C12 65 D10 SP6 ACC GRD 16 BLK 36 37 54 SP7 RELAY GRD 14 BLK 57 62 65 B1 65 B4 65 B7 65 B8 65 B10 SP8 HVAC GRD 14 BLK 05 4 16 2 59 SP9 CAB GRD 14 16 18 BLK 03 2 17 5 17 8 17 10 22 4 49 53 55 67 8 68 2 SP10 HEAT LOW 16 PNK 22 1 65 A9 65 B9 SP11 KEY PWR 12 14 RED 01 4 65 A10 65 D11 67 1 68 1 SP12 SEAT FUSE FEED 14 RED BLK 65 B12 65 E10 65 E12 SP13 FF 1 12 ORG 33 65 D12 65 E4 SP14 FF 2 12 PU...

Page 118: ...ROP FWD ORG FLEXXAIRE VLV ORG FLEXXAIRE VLV ORG BLK LH 2SPD ORG WHT RH 2SPD WHT FAN PITCH WHT FAN PITCH TAN HYD OIL TEMP GRY RT TRK SPD PUR LT TRK SPD GRY RT TRK SPD PUR LT TRK SPD PUR ENG ECU PWR PUR ENG ECU PWR YLW RED LGTS ON YLW RED LGTS ON GRN FUEL LVL GRN FUEL LVL ORG PROP CRG PSI ORG PROP CRG PSI PNK TRACK PSI PNK TRACK PSI WHT CUTTER GRG PSI WHT CUTTER GRG PSI BRN WORK FUNC PSI BRN WORK FU...

Page 119: ...NABLE ORG FLAP U D BLK YLW 5V GRD PUR BACKUP ALM GRN RETURN FTR PNK LIFT U D GRY LIFT ENABLE BLU ROLL ENABLE PUR ROLL U D RN H OUT GRN LT PROP FWD BRN LT PROP REV WHT RT PROP REV GRY RT PROP FWD WHT RED CUTTER FWD TAN HYD OIL TEMP TAN HYD OIL TEMP ORG ENG COMP TEMP GRN FUEL LVL PNK TRACK PSI RED KEY PWR RED KEY PWR YLW LGT PWR YLW LGT PWR BLK LGT GRD BLK LGT GRD GRN PINS CLSD GRN PINS CLSD ORG HIG...

Page 120: ... 16 ORG SP14 07 1 SUPER FLOW 18 PUR 34 28 07 3 VALVE GRD 14 BLK SP1 07 4 HI FLOW ENABLE 18 GRY 31 34 08 1 LIFT U D 18 PNK 34 29 08 3 VALVE GRD 14 BLK SP1 08 4 LIFT ENABLE 18 GRY 34 43 09 1 ROLL U D 18 PUR 34 27 09 3 VALVE GRD 14 BLK SP1 09 4 ROLL ENABLE 18 BLU 34 45 10 1 FLAP U D 18 ORG 34 33 10 3 VALVE GRD 14 BLK SP1 10 4 FLAP ENABLE 18 GRN 34 44 11 1 WINCH IN 18 WHT 31 30 11 2 VALVE GRD 14 BLK S...

Page 121: ...18 YLW RED 31 3 19 C6 LGT CB 14 YLW BLK 29 21 MICRO GRD 14 BLK WHT SP2 22 RLY GRD 14 BLK SP9 23 LGT GRD 14 BLK SP8 24 B LGT GRD 14 BLK SP8 24 A WORK LGT 14 YLW 25 26 LGT BATT PWR 14 YLW RED 60 30 A KEY PWR 18 RED SP6 30 B FUEL LVL 18 GRN 31 29 30 C MICRO GRD 18 BLK WHT SP2 31 2 BRAKE SOL 18 GRY 45 A 31 5 START RLY 18 PNK 57 3 31 7 PROP CRG PSI 18 ORG 48 4 31 9 CUTTER CRG PSI 18 WHT 49 4 31 10 WORK...

Page 122: ... 1 SHD 18 BLK 36 C 34 34 LT PROP FWD 18 GRN 80 4 34 35 LT PROP REV 18 BRN 80 1 34 36 RT PROP FWD 18 GRY 81 4 34 37 RT PROP REV 18 WHT 81 1 34 38 CUTTER FWD 18 WHT RED 76 4 34 39 FLEXXAIRE VLV 18 ORG 46 1 34 47 LH 2SPD 18 ORG BLK 42 1 34 48 RH 2SPD 18 ORG WHT 56 1 37 BATT 8 RED SP10 38 RLY GRD 14 BLK SP9 40 1 5V PWR 18 RED YLW SP4 40 4 5V GRD 18 BLK YLW SP5 41 2 FRAME GRD 14 BLK SP11 42 2 PUMP GRD ...

Page 123: ...SP13 58 A KEY PWR 18 RED SP6 58 C FRAME GRD 18 BLK SP11 59 2 PINS CLSD 18 GRN SP12 61 BATT 8 RED SP10 62 1 KEY PWR 18 RED SP6 62 4 LGT GRD 18 BLK SP8 63 1 LGT PWR 14 YLW SP7 63 2 LGT GRD 14 BLK SP8 64 B KEY PWR 18 RED SP6 65 B KEY PWR 18 RED SP6 66 B KEY PWR 18 RED SP6 67 A FRAME GRD 18 BLK SP11 67 B KEY PWR 18 RED SP6 69 PINS CLSD 18 GRN SP12 71 PINS NC NC 16 BLK WHT 74 72 PINS NO COM 16 BLK YLW ...

Page 124: ... 25 65 C12 65 D10 SP6 ACC GRD 16 BLK 36 37 54 SP7 RELAY GRD 14 BLK 57 62 65 B1 65 B4 65 B7 65 B8 65 B10 SP8 HVAC GRD 14 BLK 05 4 16 2 59 SP9 CAB GRD 14 16 18 BLK 03 2 17 5 17 8 17 10 22 4 49 53 55 67 8 68 2 SP10 HEAT LOW 16 PNK 22 1 65 A9 65 B9 SP11 KEY PWR 12 14 RED 01 4 65 A10 65 D11 67 1 68 1 SP12 SEAT FUSE FEED 14 RED BLK 65 B12 65 E10 65 E12 SP13 FF 1 12 ORG 33 65 D12 65 E4 SP14 FF 2 12 PUR 3...

Page 125: ...C120R PARTS MANUAL 800 392 2686 125 A C Schematic 39965 Rev A ...

Page 126: ...t Idler 803148 2 Idler Spring and Piston RH 803149 1 Idler Spring and Piston LH 803183 1 Bottom Roller 803150 2 Bottom Roller 803514 10 Track 804437 2 Sprocket 39576 2 MANUALS Parts PMC120R 19 Operator Service Maintenance OSMC120R 19 Operator Booklet OBC120R 19 FILTER SERVICE KIT 40161 KIT INCLUDES FILTERS IN THE FILTER SERVICE SECTION LESS HYDRAULIC VENT FILTER COMMON WEAR AND REPLACEMENT PARTS D...

Page 127: ... product to and from the place at which warranty work is performed 3 Any product that has been altered or modified in ways not approved by Rayco 4 Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow operating instructions misuse lack of proper protection during storage or accident D Unapproved Service or Modification Rayco is relieved of its obl...

Page 128: ...hink Smart Think Safe We care about your safety When operating your RAYCO machinery always wear an ap proved helmet complete with ear muffs face shield and the proper eye wear Never operate under the influence of alcohol or drugs Know your RAYCO read and understand your owner s manual cover to cover RAYCO Manufacturing Inc retains the right to make changes in design and specifications engineering ...

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