Chapter 7 Mechanical

MECHANICAL - PARTS LIST AND SCHEMATICS - AP8600 Chapter 7
MECHANICAL PARTS
MECHANICAL OVERVIEW ....................................................................... 7 - 2

CHASSIS AND COMPONENTS ............................................................... 7 - 4
HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM ........... 7 - 6
HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM ........... 7 - 8
HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM ......... 7 - 10
DEADMAN AND SERVICE BRAKE PEDAL MECHANISMS ................ 7 - 12
DEADMAN CALIPERS AND HARDWARE ............................................ 7 - 14
SERVICE BRAKE PEDAL ASSEMBLY ................................................. 7 - 16
PARK BRAKE ASSEMBLY, CALIPER END .......................................... 7 - 18
PARK BRAKE ASSEMBLY, PEDAL ...................................................... 7 - 20
PARK BRAKE ASSEMBLY, PEDAL ...................................................... 7 - 22
STEERING ASSEMBLY .......................................................................... 7 - 24
SUSPENDED STEERING ASSEMBLY PART 1 ................................... 7 - 28
SUSPENDED STEERING ASSEMBLY PART 2 ................................... 7 - 30
TWO-SPEED WINCH ASSEMBLY ......................................................... 7 - 32
TWO-SPEED WINCH ASSEMBLY ......................................................... 7 - 34
DIFFERENTIAL DRIVE, STANDARD..................................................... 7 - 36
DIFFERENTIAL DRIVE, STANDARD..................................................... 7 - 38
DIFFERENTIAL DRIVE, LIMITED SLIP ................................................. 7 - 40
DRIVE CHAIN AND SPROCKETS ......................................................... 7 - 42
TIRES AND WHEELS .............................................................................. 7 - 44
CRADLE ASSEMBLY .............................................................................. 7 - 46
LADDER ASSEMBLY .............................................................................. 7 - 48
LEKTRO PAGE 7 - 1 03.04.11

MECHANICAL OVERVIEW
LEKTRO PAGE 7 - 2 03.04.11

MECHANICAL OVERVIEW
ITEM DESCRIPTION PAGE
1. Chassis and Components -------------------------------------------------------- 7 - 4

2. Service Brake Pedal Mechanisms --------------------------------------------- 7 - 6
3. Dead Man Calipers and Hardware --------------------------------------------- 7 - 8
4. Steering Assembly ----------------------------------------------------------------- 7 - 14
5. Two-Speed Winch Assembly ---------------------------------------------------- 7 - 22
6. Differential Drive, Standard ------------------------------------------------------ 7 - 24
7. Differential Drive, Limited Slip --------------------------------------------------- 7 - 26
8. Drive Chain and Sprockets ------------------------------------------------------ 7 - 28
9. Tires / Wheels ----------------------------------------------------------------------- 7 - 30
10. Ladder Assembly ------------------------------------------------------------------- 7 - 34
11. Cradle Assembly -------------------------------------------------------------------- 7 - 32
12. Hold Back Bar Assembly (See Adapters / Accessories)
LEKTRO PAGE 7 - 3 03.05.13

CHASSIS AND COMPONENTS

8
9
20
15
8
21 19 10
19 2 32
21
13 3
28 26
31
6
22 5 5
4
6 7
7
29
30
17
25
14
12
24
11
25
23
27 34
13
13
37
36
35
37
33
18
16 Ma860300
LEKTRO PAGE 7 - 4 00.07.30

CHASSIS AND COMPONENTS
Item # Part # Item Description QTY
1 Chassis 1
2 APM103-86C-1 Deck, Rear 1
3 APM103-86C-2 Deck, Middle 1
4 APM103-86B Deck, Front 1
5 APM111A Roller, Strap 3
6 3/8-16 UNC Hex Gripco Nut 3
7 3/8-16 UNC Hex Head Cap Screw x 5 Long 3
8 APM104 Back Rest Pad 2
9 M1802-2 Arm Rest, Right 1
10 M1802-2 Arm Rest, Left 1
11 10-24 Elastic Stop Nut 4
12 10-24 Oval Head Screw x 5/8 Long 4
13 10/24 Truss Head Screw x 1/2 Long 7
14 APM127 Handle, Passenger 1
15 1/4-20 UNF Hex Head Cap Screw 4
16 PSI468 Non Skid Floor Material 3pcs.
17 APM125 Cover, Control Handle Guide 1
18 Platform, Operator 1
19 1/4-28 UNF Bolt x 3/4 long 5
20 APM130 Accessory Box 1
21 1/4-28 UNF Nyloc Nut 5
22 APM133 Chain Guard 1
23 APM124 Cover, Brake Pedal 1
24 APM102-86A Cover, Cowl 1
25 PS2150 3/4 Velcro 1 set
26 APM411C Fairlead, Winch Strap 1
27 APM124C Cover, Access 1
28 1/4 Hex Head Cap Screw x 2-1/4 long 4
29 1/4-20 UNC Nut 4
30 1/4 Lock Washer 4
31 1/4 Flat Washer 4
32 M1802D-4A Metric Mounting Screw 2
33 1/2-13 UNC Hex Head Cap Screw x 1-1/4 long
34 1/2-13 UNC ESNA Nut 2
35 3/8-16 UNC Hex Head Cap Screw x 1-1/4 3
36 3/8-16 UNC Nyloc Nut 3
LEKTRO PAGE 7 - 5 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM
LEKTRO PAGE 7 - 6 03.10.31

1 APM116A Deadman Pedal 1

2 APM210A Service Brake Pedal 1
3 APM215 Cotter Pin 4
4 M1052-1 Bushing 4
5 APM220A Clevis Pin 4
6 APM209 Clevis 4
7 3/8 NF Nut 5
8 M1055A Connecting Rod 2
10 3/8 x 1-1/4 NF Bolt 2
11 APM211 Service Brake Tension Spring 2
12 3/8 NF Gripco Nut 2
13 3/8 x 5 NF Bolt 1
14 3/8 x 4-1/2 NF Bolt 1
15 APM232 Deadman Pivot Arm 1
16 3/8 x 2 NC All Thread Bolt 1
18 APM117-1 Deadman Redal Anchor Pin 1
19 3/8 NC Bolt 1
20 APM2401-8 Hairpin Clip 1
21 APM208A Push Rod (Deadman) 1
22 APM208B Push Rod (Service Pedal) 1
LEKTRO PAGE 7 - 7 03.10.31

LEKTRO PAGE 7 - 8 03.10.31

1 APM116C Deadman Pedal 1

3 Cotter Pin 4
4 M1052-1 Bushing 4
6 APM209 Clevis 4
7 3/8 NF Nut 5
8 M1055A Connecting Rod 2
10 3/8 x 1-1/4 NF Bolt 2
12 3/8 NC Gripco Nut 2
13 3/8 x 5 NC Bolt 1
14 3/8 x 4-1/2 NC Bolt 1
15 APM232A Deadman Pivot Arm 1
16 3/8 x 2 NC Bolt 1
18 APM117A-1 Deadman Redal Anchor Pin 1
19 APM205A Spring Guide Tube 1
20 3/8 x 3-1/2 NF Bolt 1
22 M1055A Push Rod 1
23 APM203A Deadman Compression Spring 1
24 APM215A Spring Adjustment Slug 1
25 APM204A Compression Spring Carrier 1
26 1/2 NC Bolt 1
28 10/32 x 2 Bolt 2
29 Switch 1
31 10/32 Nut 2
32 Cotter Pin 1
LEKTRO PAGE 7 - 9 03.10.31

LEKTRO PAGE 7 - 10 03.10.31

1 APM116B Deadman Pedal 1

3 Cotter Pin 4
4 M1052-1 Bushing 4
6 APM209 Clevis 4
7 3/8 NF Nut 5
8 M1055B Connecting Rod 2
10 3/8 x 1-1/4 NF Bolt 2
13 3/8 x 5 NF Bolt 1
14 3/8 x 4-1/2 NF Bolt 1
15 APM232 Deadman Pivot Arm 1
18 APM117A-1 Deadman Redal Anchor Pin 1
20 M1051 Spring 2
21 APM209A Push Rod (Deadman) 1
22 APM208B Push Rod (Service Pedal) 1
23 1/4 x 3/4 NC Bolt 2
25 Deadman Switch 1
26 APM233 Cable Anchor 1
27 APM234 Pivot Arm Pin 1
28 APM235 Clip 2
29 Screw 1
30 APM236 Pivot Arm 1
31 APM237 Cable Pivot
Pivot Anchor Tube 4
LEKTRO PAGE 7 - 11 03.10.31

DEADMAN AND SERVICE BRAKE PEDAL MECHANISMS
20
19
15 18
17
16
22
13
12
10
11 2
21
14 2
6 9
2
2
29
5 21
25 2
3
2 23
25
8 10
28
3 10
27
4
21
24
1
LEKTRO PAGE 7 - 12 96.11.03

DEADMAN AND SERVICE BRAKE PEDAL MECHANISMS
1 APM116C Pedal, Deadman Brake 1

2 3/8" NCT Hex Nyloc Nut
3 3/8" NCT Hex Head Cap Screw x 1-1/2" Long
4 3/8" NFT All Thread Cap Screw x 2" Long 1
5 Rod, Connecting 1
6 Cotter Pin 4
7 M1106D Spring Deadman Pedal 1
8 APM209 Clevis, Rod End 3
9 APM209B Clevis 1
10 M1052-1 Bushing 3
11 M1052-2 Washer 1
12 M1201D-15 Anchor, Brake Cable 1
13 3/8" NCT Hex Head Cap Screw
14 M1201D-8A Bracket, Brake Cable Receiver 1
15 Screw, 6/32 x 1 2
16 E501B Micro Switch 1
17 M1201D-10A Bracket, Micro Switch Mount 1
19 1/4" NCT Hex Head Cap Screw 2
20 Brake Cable Assembly (See M1200F) 2
21 3/8" NCT Hex Head Cap Screw 7
22 M1201D-7 Anchor, Cable 1
23 Bellcrank, Brake 1
24 APM210A Pedal, Service Brake 1
26 H650A Master Cylinder (See Hydraulic Section) 1
27 M1051 Spring 1
28 APM209A Bearing, Spherical Rod End 1
LEKTRO PAGE 7 - 13 03.10.31

DEADMAN CALIPERS AND HARDWARE
LEKTRO PAGE 7 - 14 00.07.30

DEADMAN CALIPERS AND HARDWARE
1 M1200G Caliper & Cable Assembly 1

2 M1214C Caliper Floating Mount 1
3&4 M1203D Caliper Pads (2 in Kit) 1 set
5 M1215C Caliper Anchor Plate 1
6 M8 x 1.25 x 20 mm Bolt 4
8 3/8 NF Bolt x 1-1/4 4
10 3/8 NF Nyoc Nut 4
11 Deadman Mechanism Assembly 1
LEKTRO PAGE 7 - 15 03.10.31

SERVICE BRAKE PEDAL ASSEMBLY
5
6 15
7 9
8
2
3
11
10
10
14
12
Service Brake Pedal
13
ma864800
Note: For Service Brake Master Cylinder and Caliper Assembly

see Chapter 5 Hydraulic
LEKTRO PAGE 7 - 16 01.05.05

SERVICE BRAKE PEDAL ASSEMBLY
1 H650A Master Cylinder 1

2 3/8-24 UNF Nut Nyloc 6
3 3/8 Flat Washer 2
4 M1051 Service Brake Tension Spring 1
5 APM208B Plunger, 3/8 x 4 All Tread 1
6 Cotter Pin 1/8 x 1 1
7 APM209 Clevis 3
9 3/8 - 16 UNC Hex Head Cap Screw x 1-1/2 Long 3
10 M1052-1 Bushing 2
11 Brake Bellcrank 1
13 Non Skid 1
14 3/8-24 UNF Bolt x 5 1
15 3/8-24 UNF Hex Nut
LEKTRO PAGE 7 - 17 02.03.01

PARK BRAKE ASSEMBLY, CALIPER END
9 13
14
11
9
H1 25
15 16
22
3 24
23
1 4 36
5 10 17
8
27 20
9 11
12
21
19
6 18
9 11
2 7
12 35
10
28 34
29
28
10 33
32
21
31
19 30
LEKTRO PAGE 7 - 18 01.05.05

PARK BRAKE ASSEMBLY, CALIPER END
M1225 Tol-O-Matic Brake Caliper Assembly (Includes Items 1-6)
1 M1225-2 Mount, Brake Caliper 1

2 M1225-3 Brake Pad 2
3 M1225-4 Lever, Brake Caliper 1
4 M1225-5 Washer 1
5 M1225-6 Shoulder Bolt 1
6 M1225-7 Caliper Housing 1
7 f6dj8801 Shim,Brake Pad
(Required on older vehicles with 5/32 thick brake disc) 1
8 fadj4702 Mount, Tolomatic Brake Caliper 1
9 3/8 Lock washer 4
10 3/8-24 UNF Hex ESNA Nut 5
11 3/8-16 UNC Hex Head Cap Screw x 3/4 Long 4
12 3/8-24 UNF Hex Head Cap Screw x 1-1/4 Long 2
13 H1228H 1/2-20 UNF Hex Flanged Nut 1
14 fadj4800 Bracket, Slave Cylinder Anchor 1
15 1/4-20 UNC Hex Head Cap Screw x 1-3/4 Long 1
16 1/4-20 UNC Hex ESNA Nut 1
17 H625 Hydraulic Slave Cylinder 1
18 f6dj8001 Clevis, Slave Cylinder 1
19 f6dj7101 Pin, Clevis 3/8 x 1 2
20 5/16-24 UNF Hex Nut 1
21 1/8 Cotter Pin x 1 2
22 Plug, 1/8 Pipe 1
23 F55 Elbow, 1/8 NPT to #4 Male Flare 1
24 F184 Tee, 1/8 NPT Running 1
25 H808 Bleed Valve 1
27 M1106D Spring, Deadman Pedal 1
28 M1227 Bushing, TSI-1214-8 2
29 fadj4500 Crank, Link 1
30 f6dj9700 Link, Caliper 2
31 f6dj4600 Drag Link, Spring 1
32 fadj4900 Crank, Slave Cylinder 1
33 3/8-24 UNF Hex Head Cap Screw x 3 Long 1
34 Woodruf Key, 1/4 x 3/4 1
35 M346 Snap Ring 1
36 M1227H Rod End Bearing 1
Hose # Part # From To Hose Hose From To

Type Length Fitting Fitting
H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295
LEKTRO PAGE 7 - 19 03.05.13

PARK BRAKE ASSEMBLY, PEDAL
Old Style Master Cylinder Used on Vehicle Production Run # A86103-5
1
3
15
H1
2
4
6
15
15
7 15
9 13
8
10
6
20
11 24
19
22
23
22 21
LEKTRO PAGE 7 - 20 03.04.11


Old Style Master Cylinder Used on Vehicle Production Run # A86103-5
1 H650A Master Cylinder 1

2 H650A-2,3,4,5,6 Banjo Fitting 1
3 F109 Elbow, 90 Degree #4 Male to 1/8 NPT Male 1
4 fadi2202 Mount Bracket, Park brake Master Cylinder 1
5 1/4-20 UNC Hex Head Cap Screw x 1/2 Long
6 3/8- 16 UNC Hex Head Cap Screw x 1-1/4 Long 5
7 f6dj4602 Plunger, Master Cylinder 4 1
8 APM209 Clevis 2
9 APM220A Pin, Clevis 2
10 1/8 Cotter Pin 2
11 fadj2301 Bell Crank, Park Brake 1
12 Rod, 4,Park Brake Pedal Linkage 1
13 3/8 - 24 UNF Hex Jam Nut 5
14 fadj4102 Pedal, Deadman Brake 1
15 3/8- 16 UNC Hex ESNA Nut 8
16 3/8 - 16 UNC Hex Head Cap Screw x 1 Long 1
17 1/4 Stainless Steel Lock Washer 1
18 M1051 Spring, Pedal 1
20 f6dj10001 Bracket, Park Brake Switch 1
21 Screw, 8-32 x 1 Long 2
22 Washer #8 2
24 8-32 Hex Nut 2
25 Non Skid, Pedal 1
26 Pin, Pedal Hinge 1
27 3/8-16 UNC Hex Nut 1
28 M1201D-12 3/8-24 UNF All Thread Bolt x 2-1/2 long 1
30 APM251 Spacer 1
31 3/8-24 UNF Hex Head Cap Screw x 2 long 1

LEKTRO PAGE 7 - 21 03.05.13


New Style Master Cylinder Used on Vehicle Production Run # A86203-5
LEKTRO PAGE 7 - 22 03.05.13


New Style Master Cylinder Used on Vehicle Production Run # A86203-5
1 H650D Master Cylinder 1

2 F249 1/8 Pipe Nipple 1
3 F121 1/8 Street Elbow 1
4 fadi2208 Mount Bracket, Park Brake Master Cylinder 1
5 1/4-20 UNC Hex Head Cap Screw x 1/2 Long 1
7 Plunger, Master Cylinder 1
8 APM209 Clevis 2
9 APM220A Pin, Clevis 2
10 Cotter Pin, 1/8 2
11 fadj2307 Bell Crank, Park Brake 1
12 Rod, 4,Park Brake Pedal Linkage 1
13 3/8 - 24 UNF Hex Jam Nut 5
14 fadj4102 Pedal, Deadman Brake 1
17 1/4 Stainless Steel Lock Washer 1
18 M1051A Spring, Pedal 1
20 f6dj10006 Bracket, Park Brake Switch 1
21 Screw, 8-32 x 1 Long 2
22 Washer #8 4
24 8-32 ESNA Hex Nut 2
25 Non Skid, Pedal 1
26 Pin, Pedal Hinge 1
27 F122 1/8 Male Pipe x #4 JIC 45 Degree Elbow 1
28 H650D-2 Reservoir, Brake Fluid 1
29 M1225-9 Bushing, Park Brake Bellcrank 2
30 APM209A Bearing, 3/8 Spherical Rod End 1
31 M1201D-12 3/8-24 UNF All Thread Bolt x 2-1/2 long 1
33 3/8-24 UNF Hex Head Cap Screw x 1-1/2 1
34 3/8-16 UNC Hex Nut 1
35 APM251 Spacer 1
36 3/8-16 UNC Hex Head Cap Screw x 1 long 1
37 3/8 Flat Washer, Stainless Steel 2

LEKTRO PAGE 7 - 23 03.05.13

STEERING ASSEMBLY
12
10 11
9
3 4 8 13
39 8
38 2 7
40 9
6 15 14
16
61 14 9
5 10 17
42 1
11 21
45
46
18
44
22
19
20 24 63
43 49 47,48 22
23 27
50
28
41
23 29
25
30
22
26 32
31 33
51 34
35 36
52A
52B 54
55
56 37
53
56 34
55
57 54 33
60 62 32
31
58 59
LEKTRO PAGE 7 - 24 03.02.01

STEERING ASSEMBLY
1 APM301A Steering Wheel 1

2 1/4 Trusshead Screw x 3/4 Long 2
3 M342A Steering Knob Assembly 1
4 1/4-20 UNC Hex Esna Nut 2
5 3/4-16 UNF Elastic Stop 1/2 Nut 1
6 M346 Snap Ring 1
7 APM308B Steering Shaft 1
8 APM311 Woodruff Key 2
10 APM302B Bearing, Steering Wheel Shaft 2
11 7/16-14 UNC Esna Nut 4
12 1/4-20 UNC Set Screw 2
13 UTM311 Sprocket 1
14 1/2 Flat Washer Spacers 4
16 M345 Spacer 3
17 M612A Gearbox Assembly 1
18 APM319C Pitman Arm 1
20 7/8-14 UNF Hex Nut 1
23 5/8-18 UNFHex Half Nut 2
24 APM324C Drag Link Body 1
25 M2012-1 Rod End Bearing 1
26 5/8-18 UNF Elastic Nut 2
27 5/16-18 UNC Hex Head CapScrew x 3/4 Long 1
28 APM327E-2 Retainer 1
29 APM327E Bell Crank, Splined 1
30 M721 1-12 UNF 1/2 Nut 1
31 M720 Bearing Spacer 2
32 M716A Seal 2
33 M718 Bearing Cone 2
34 M719 Bearing Cup 2
35 APM334-AL Caster Plate 1
36 1/2-13 UNC Esna Nut 4
37 1/2-13 UNC Bolt x 1-3/4 Long 4
38 3/32 x 1 Cotter Pin 1
40 APM209 Clevis 41
(Cont.)
Note: Diagram and Parts List for optional

suspended steer axle assembly will be issued
later. Call Lektro Parts Dept. for information.
LEKTRO PAGE 7 - 25 03.02.01

STEERING ASSEMBLY
41 3/8-24 UNF Hex Esna Nut 2

42 APM353 Idler Tension Shaft 1
43 3/8-16 UNC Gripco 1
44 APM352 Tensioner Arm 1
45 3/8-16 UNC Bolt x 5 Long 1
46 M771 Idler Sproket 2
47 APM313A Steering Chain #40 (40-1/2 with 1/2 Link) Long 1
48 PS361 Master Link Kit 1
49 APM354 Spring 1
50 3/8 Fender Washer 1
51 APM334J Caster Spindle / Axle, Splined 1
52A APM347A Spacer 5/8 Wide 2
52B APM347B Spacer 1/2 Wide 2
53 APM338K-1 Wheel Hub 2
54 APM338K-11 Bearing Seal 2
55 APM338K-12 Bearing Cup 2
56 APM338K-13 Bearing Cone 2
57 APM338K-2 Wheel Stud 5
58 APM347B Spacer 1
59 M524A Castle Nut 1
60 M820 1/2-20 UNF Lug Nut 10
61 3/8-24 UNF Hex Nut
LEKTRO PAGE 7 - 26 03.05.13

Intentionally left blank
LEKTRO PAGE 7 - 27 95.09.01

SUSPENDED STEERING ASSEMBLY PART 1

1
9 8
10
11
12
13A 6
13B
14
15 5
16
17
16
15
22 14
18
21 19
20
madz0701
LEKTRO PAGE 7 - 28
03.05.13

1 5/16-18 UNC Hex Head CapScrew x 3/4 Long 1
2 APM327E-2 Retainer 1
3 APM327E Bell Crank, Splined 1
4 M721 1-12 UNF 1/2 Nut 1
5 M720 Bearing Spacer 2
6 M716A Seal 2
7 M718 Bearing Cone 2
8 M719 Bearing Cup 2
9 fadz100-3 Caster Plate 1
10 1/2-13 UNC Hex Esna Nut 6
12 Suspended Stearing Assembly (See Suspended Steering
Assembly Part 2) 1
13A APM347A Spacer 5/8 Wide 2
13B APM347B Spacer 1/2 Wide 2
17 APM338K-1 Wheel Hub 2

14 APM338K-11 Bearing Seal 2
15 APM338K-13 Bearing Cone 2
16 APM338K-12 Bearing Cup 2
22 APM338K-2 Wheel Stud 5
19 M524A Castle Nut 1

20 M820 1/2-20 UNF Lug Nut 10
LEKTRO PAGE 7 - 29 03.05.13

17
3
2
12
80
6
5
8I
7
10
11
13
15
12
14
madz0700
16
LEKTRO PAGE 7 - 30
03.02.01

madz0700 Suspended Steering Assembly
1 Spindle, Verticle Flanged 1

2 1/2-20 UNF Hex Nyloc Nut 8
3 5/16-24 UNF Hex Head Cap Screw x 1 Long 2
4 5/16-24 UNF Hex Nyloc Nut 2
5 UTM700A-5 Shock Absorber 1
6 UTM700A-6 Hat Bushing, Upper 2
7 UTM700A-7 Spring, Compression 2
8I UTM700A-8 Spring, Suspended Steering, Inner 1
80 f6dz9809 Spring, Suspended Steering, Outer 1
9 UTM700A-9 Hat Bushing, Lower 2
10 fadz3500 Axle, Suspended Steering 1
11 fadz3600 Mount Bracket, Shock Absorber 1
12 1/2-20 UNF Grade 8 Hex Head Cap Screw x 2-1/4 long 8
13 3/8-24 UNF Hex Nyloc Jam Nut 1
14 UTM700A-14 10 MM Hex Head Cap Screw x 2-3/8 long 1
16 1/2-13 UNC Grade 8 Hex Head Cap Screw x 5 long 2
17 1/2-13 UNC Hex Nyloc Nut
LEKTRO PAGE 7 - 31 03.02.01

TWO-SPEED WINCH ASSEMBLY
LEKTRO PAGE 7 - 32 03.10.31

APM405C Two-Speed Winch Assembly 1
1 Winch Base
2 Shaft Bushing
3 E-Ring
4 Latch Plate
5 APM405A-20 Ratchet Lever 1
6 Compress Spring
7 Ratchet Sleeve
8 Shaft Bushing
9 Spacer Washer
10 APM405A-5 Primary Drive Shaft 1
11 Intermediate Drive Shaft
12 APM405A-19 Ratchet Pawl 1
13 APM405A-3 Spring 1
14 Winch Hub
15 Spacer (reel)
16 Locknut
17 Locknut
18 Reel Shaft
19 Ratchet Bolt
20 APM405A-6 Winch Handle
21 Nut
22 Spacer
23 Spacer
24 Bolt
25 APM405A-25 Plate
26 APM402A Cable Assembly 1
APM402B Winch Nylon Strap 1
27 APM403B Strut Strap 1
LEKTRO PAGE 7 - 33 03.10.31

LEKTRO PAGE 7 - 34 00.07.30

APM405B Two-Speed Winch Assembly 1
A Reel Assembly, 2.5 Hub (For Strap) 1

B Winch Base Assembly 1
C Gear Cover 1
D Shoulder Bolt 1
E APM405B-2 Winch Gear Shield 1
F Rope Side Spacer 1
G 1/2-20 UNF Lock Nut 1
M Short Drive Shaft Assembly 1
N 20 Tooth Gear Assembly 1
O Washer 1
P 3/8-16 UNC Gear Retaining Screw 1
Q 1 Needle Bearing 1
R 5/8 Needle Bearing 2
S Cover Screw 2
T APM405B-3 Winch Handle Assembly 1
U APM405B-9 Roll Pin 1
V APM405B-5 Ratchet Plunger 1
W APM405B-6 Ratchet Spring 1
X APM405B-11 Brake Handle 1
Y Retaining Pin 3
Z Clevis Pin 1
AA APM405B-18 Oillite Bearing 2
BB APM405B-19 Retaining Ring 2
CC Spacer Washer 2
DD APM405B-7 Intermediate Drive Shaft Assembly 1
EE APM405B-8 Primary Drive Shaft Assembly 1
FF Drive Shaft Bearing Housing 2
GG Brake Band 1
HH Brake Drum Assembly 1
JJ Roll Pin 1
KK APM405B-20 Retaining Ring 1
24 3/8-24 UNF Hex Head Bolt 4
26 APM402FB Winch Strap with Hook, 2 x 144 1
NP APM405B-10 Winch Strap Retaining Bolt Assy (Flat Head, GR 8) 1
LEKTRO PAGE 7 - 35 03.06.26

DIFFERENTIAL DRIVE, STANDARD
LEKTRO PAGE 7 - 36 99.02.22

M800DS Differential Assembly
1 M801SB Differential Housing 1

2 M806S Ring and Pinion Set (Specify Ratio) 1
3 M825S Bearing Cone, Timken Roller 1
4 M821S Bearing Cup, Timken Roller 1
5 M824S Shim 1
6 M836S Crunch Tube 1
9 M829S Pinion Seal 1
10 M816SC Pinion Yoke 1
11 M823S 3/4 Washer (Hardened) 1
12 M830S Pinion Shaft Nut 1
13 Bearing Anchor Retainer Bolt 4
14 M803S Cover 1
15 M802S Differential Gasket 1
16 M805S Gear Case Plug 1
17 5/16 x 5/8 NC Bolt 10
18 Bearing Anchor 2
19 M809S Shim
22 M810S Cage Housing 1
23 M812S 3/8 x 3/4 NF Grade 8 Bolt 8
24 M814S Spider Gear 2
25 M817S Side Gear 1
26 M815S Thrust Washer (Spider Gear) 2
27 M818S Thrust Washer (Side Gear) 2
28 M813S Spider Pin 1
29 M811S Drift Pin 2
30 M833S Modified Screw 8
32 M837SBA Inner Seal 2
33 M831PC Press Collar 2
34 M831SB Bearing (Axle) w/ Press Collar 2
35 M820 Lug Nut 10
36 M832 Bearing Flange 2
37 M819SB Drive Axle 2
38 M819-3F Wheel Stud 10
LEKTRO PAGE 7 - 37 99.02.22

LEKTRO PAGE 7 - 38 99.02.22

M800DS Differential Assembly
1 M801D Differential Housing 1

2 M806D Ring and Pinion Set (Specify Ratio) 1
3 M825D Bearing Cone, Timken Roller 1
4 M82ID Bearing Cup, Timken Roller 1
5 M824D Shim 1
7 M825D Bearing Cup, Timken Roller 1
9 M829D Pinion Seal 1
10 M816DE-2 Pinion Yoke 1
11 M823D 3/4 Washer (Hardened) 1
12 M830D Pinion Shaft Nut 1
14 M803D Cover 1
15 M802D Differential Gasket 1
16 M805D Gear Case Plug 1
17 5/16-18 UNC Bolt x 5/8 10
18 Bearing Anchor 2
19 M809D Shim
22 M810D Cage Housing 1
23 M812D 3/8-24 UNF Grade 8 Bolt x 3/4 8
24 M814D Spider Gear 2
25 M817D Side Gear 1
26 M815D Thrust Washer (Spider Gear) 2
27 M818D Thrust Washer (Side Gear) 2
28 M813D Spider Pin 1
29 M811D Drift Pin 2
30 M833D Modified Screw 8
31 3/8-24 UNF Gripco Nut 8
33 M831PC Press Collar 2
34 M831SB-1 Bearing (Axle) w/ Press Collar 2
35 M820 Lug Nut 10
37 M819SB Drive Axle 2
38 M819-3F Wheel Stud 10
39 M816DE-3 Brake Disc 1
LEKTRO PAGE 7 - 39 03.10.31

DIFFERENTIAL DRIVE, LIMITED SLIP
10 10A
13
29
LEKTRO PAGE 7 - 40 03.04.11

DIFFERENTIAL DRIVE, LIMITED SLIP

M800DP Differential Assembly - Posi 1
1 M801D Differential Housing 1

2 M806D Ring and Pinion Set (Specify Ratio) 1
4 Shim (As Req.)
5 Washer 1
6 M824D Shim 1
8 Shim 1
9 M829D Pinion Seal 1
10 M816DE-2 Disk Brake Flange 1
10A M816DE-3 Brake Disc 1
11 M823D 3/4 Washer(Hardened) 1
12 M830D Pinion Shaft Nut 1
14 M803D Cover 1
15 M802D Differential Gasket 1
16 M805D Gear Case Plug 1
17 5/16-18 UNC Bolt x 5/8 10
19 Bearing Anchor 2
22
23 M812D 3/8-24 UNF Grade 8 Bolt x 3/4 8
24 M814D Spider Gear 2
25 M815D Thrust Washer (Spider Gear) 2
26
27 M818D Thrust Washer (See Gear) 2
28 M813D Spider Pin 1
30 M833D Modified Screw 8
31 3/8-24 UNF Gripco Nut 8
33 M831DC Press Collar 2
34 M831SB-1 Bearing (Axle) 2
35
37 M819DSB Drive Axle 2
38 M819-3L Wheel Stud 10
39 M810D Cage Housing 1
40 M817D Side Gear 1
46 M820 Lug Nut 10
LEKTRO PAGE 7 - 41 03.10.31

DRIVE CHAIN AND SPROCKETS
LEKTRO PAGE 7 - 42 95.09.01

DRIVE CHAIN AND SPROCKETS
1 Drive Motor, 36 Volt (See BA, Electrical Section) 1

2 M902 Drive Sprocket 1
3 M903 3/16 x 2 Key 1
4 M904 Drive Sprocket Bushing 1
5 1/4-20 UNC Cap Screw GR 8 x 5/8 2
6 M906 Motor Adjustment Saddle (2.5 HP) 1
M906A Motor Adjustment Saddle (5.0 HP) (Optional) 1
7 M907B Drive Chain 44-3/4 #DBL35 1
8 M908C Drive Sprocket 1
9 M909 Connector Link 1
10 5/16-24 UNF Bolt x1-1/4 4
12 3/8-16 UNC Nut 1
13 3/8-16 UNC All Thread Bolt x 4 1
14 5/16 Flatwasher (5.0 HP Only) 4
15 5/16-24 UNF Nut Nyloc 4
16 3/8-24 UNF Bolt x 1-1/4 4
17 3/8 Lockwasher 4
18 M918 Tension Saddle 1
19 1/2-13 UNC Nut 1
20 M923 5/16 Flatwasher 4
21 M922 1/2-13 UNC Bolt x 3 4
NP M909A Chain Half Link (As Needed) 1
NOTE: If motor sprocket is to be replaced,

a new 3/16 x 2 Key, Item #3, should also be installed.
LEKTRO PAGE 7 - 43 03.05.13

TIRES AND WHEELS
LEKTRO PAGE 7 - 44 95.06.15

TIRES AND WHEELS
APM2251 Tire & Wheel Assembly (Drive) 4

APM2250A Tire and Wheel Assembly (Steer) 2
1 M2258D Drive Wheel 1
2 M2260 400 x 8 Tube 1
3 APM2201B 400 x 8 Tire (Traction) 1
4 M2258D-1 Steer Wheel 1
5 APM2201E 400 x 8 Tire (Highway) 1
M2258DA Poly Drive Wheel 2
3/8-24 UNF Cap Screw Grade 8 x 1 20
3/8-24 UNF Gripco Grade C 20
3/8 Harden Washer 20
Drive Rim Assembly 2
M2252B Poly Steel Wheel 2
7/16-20 UNF Caps Screw GR x 1 5
7/16-20 UNF Gripco Grade C 5
M2258D-1 Steer Rim Assembly 2
LEKTRO PAGE 7 - 45 02.03.01

CRADLE ASSEMBLY
9
11
10
13
9
11
3
10
12
7 15
14
6 5
8 1
16 m6fa0300
LEKTRO PAGE 7 - 46 00.07.30

CRADLE ASSEMBLY
APM 1000A Cradle Assembly 1

1 APM1011A Cradle 1
2 APM1002 Left Side Gate (Center of Gate Shaft to Anchor Pin 11) 1
2A APM1002A Left Side Gate (Center of Gate Shaft to Anchor Pin 14-1/2) 1
3 APM1003 Right Side Gate (Center of Gate Shaft to Anchor Pin 11) 1
3A APM1003A Right Side Gate (Center of Gate Shaft to Anchor Pin 14-1/2) 1
4 5/16-18 UNC Set Screw 1
5 1/4 -24 Grease Fitting 2
6 APM1007 Side Gate Guide Shaft 1
7 Cradle Anchor Shaft 1
8 3/8-16 UNC Brass Flathead Screw x 3/4 8
9 1/2-13 UNC Hex Nut 2
10 APM1008A-1 Side Gate Bushing 2
11 1/2-13 UNC Bolt x 1-14 2
12 APM1013 Spring 2
13 APM1014-1 Latch, Side Gate 2
14 APM1015 Roll Pin 2
15 APM1013-1 Washer 2
16 APM1005C UHMW Wear Plate 1
LEKTRO PAGE 7 - 47 03.10.31

LADDER ASSEMBLY
LEKTRO PAGE 7 - 48 95.06.15

LADDER ASSEMBLY
APM2301A Ladder Assembly
1 APM2304A Ladder 1
2 APM2303A Extendable Handle 1
3 APM2305A Locking Mechanism 1
4 APM2306A Non-Skid Material 3
5 APM2302A Vibration Dampeners 2
6 1/4-20 UNC Trus Head Screw x 1/2 2
7 1/4-28 UNF Bolt x 2 4
9 1/4 x 1-1/2 1
LEKTRO PAGE 7 - 49 02.03.01

END OF CHAPTER
LEKTRO PAGE 7 - 50 00.07.30

Chapter 7 Mechanical

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Chapter 7 Mechanical

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MECHANICAL - PARTS LIST AND SCHEMATICS - AP8600 Chapter 7

MECHANICAL OVERVIEW ....................................................................... 7 - 2

LEKTRO PAGE 7 - 1 03.04.11

LEKTRO PAGE 7 - 2 03.04.11

ITEM DESCRIPTION PAGE

1. Chassis and Components -------------------------------------------------------- 7 - 4

LEKTRO PAGE 7 - 3 03.05.13

CHASSIS AND COMPONENTS

LEKTRO PAGE 7 - 4 00.07.30

CHASSIS AND COMPONENTS

Item # Part # Item Description QTY

LEKTRO PAGE 7 - 5 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

LEKTRO PAGE 7 - 6 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

Item # Part # Item Description QTY

1 APM116A Deadman Pedal 1

LEKTRO PAGE 7 - 7 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

LEKTRO PAGE 7 - 8 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

Item # Part # Item Description QTY

1 APM116C Deadman Pedal 1

LEKTRO PAGE 7 - 9 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

LEKTRO PAGE 7 - 10 03.10.31

HYDRAULIC DEADMAN AND SERVICE BRAKE MECHANISM

Item # Part # Item Description QTY

1 APM116B Deadman Pedal 1

LEKTRO PAGE 7 - 11 03.10.31

DEADMAN AND SERVICE BRAKE PEDAL MECHANISMS

LEKTRO PAGE 7 - 12 96.11.03

DEADMAN AND SERVICE BRAKE PEDAL MECHANISMS

Item # Part # Item Description QTY

1 APM116C Pedal, Deadman Brake 1

LEKTRO PAGE 7 - 13 03.10.31

DEADMAN CALIPERS AND HARDWARE

LEKTRO PAGE 7 - 14 00.07.30

DEADMAN CALIPERS AND HARDWARE

Item # Part # Item Description QTY

1 M1200G Caliper & Cable Assembly 1

LEKTRO PAGE 7 - 15 03.10.31

SERVICE BRAKE PEDAL ASSEMBLY

Note: For Service Brake Master Cylinder and Caliper Assembly

LEKTRO PAGE 7 - 16 01.05.05

SERVICE BRAKE PEDAL ASSEMBLY

Item # Part # Item Description QTY

1 H650A Master Cylinder 1

LEKTRO PAGE 7 - 17 02.03.01

LEKTRO PAGE 7 - 18 01.05.05

PARK BRAKE ASSEMBLY, CALIPER END

Item # Part # Item Description QTY

M1225 Tol-O-Matic Brake Caliper Assembly (Includes Items 1-6)

1 M1225-2 Mount, Brake Caliper 1

Hose # Part # From To Hose Hose From To

H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295

LEKTRO PAGE 7 - 19 03.05.13

LEKTRO PAGE 7 - 20 03.04.11

PARK BRAKE ASSEMBLY, PEDAL

Item # Part # Item Description QTY

1 H650A Master Cylinder 1

Hose # Part # From To Hose Hose From To

H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295

H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295

H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295

H1 Master Cylinder Slave Cylinder 560-4 102 f295 f295

18 1/8 x 2 Cotter Pin 2

A Reel Assembly, 2.5 Hub (For Strap) 1