Cat Motograder 20k-Manual

OPERATION & MAINTENANCE MANUAL
UG20K MOTOR GRADER

SERIAL # 330C04
Ground Force Worldwide

5650 E. Seltice Way
Post Falls, Idaho 83854
1 (208) 664-9291
info@gfworldwide.com | www.gfworldwide.com
©
Copyright 2009, by Ground Force Worldwide. All rights reserved. No part of this manual may be reproduced in any form or by
any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and written
consent from Ground Force Worldwide as governed by the United States and International Copyright Laws.
Printing History: First Edition – November 2011
REVISION DATE APPROVED DESCRIPTION

0 08/09/2017 CMoler Initial release
INTRODUCTION
Valued Ground Force customer:

Thank you for selecting Ground Force Worldwide as your mine equipment supplier.
Our business is based on providing our customers with innovative solutions, manufac-
tured of high quality, heavy-duty materials designed to out-perform in the most extreme
applications.
Upon purchase of your equipment, we strive to provide superior service throughout the life
of your product. Our Parts & Product Support Department is here to assist you by answer-
ing technical questions, troubleshooting your equipment when needed, and expediting your
parts ordering. We stock the most commonly used parts for your equipment and can ship
overnight, when needed. Our Parts and Product Support Representatives (PPSRs) are avail-
able 24/7.
Ground Force Worldwide proudly provides superior customer service through the life of your
equipment. Call us anytime at 1 (208) 664-9291, or e-mail service@gfworldwide.com, and
let us assist you.
Sincerely,
Ground Force Worldwide
Documentation Department
CONTACT US
Ground Force Manufacturing, LLC
6001 E. Seltice Way
Post Falls, ID 83854 USA
Phone: +1 (208) 664-9291

Fax: +1 (208) 664-9475
General E-mail: info@gfworldwide.com

Parts & Product Support E-mail: service@gfworldwide.com
Web: www.gfworldwide.com
2 SAFETY, OPERATION & MAINTENANCE MANUAL

INTRODUCTION
WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 3

INTRODUCTION
BASE MODEL SPECIFICATIONS OPERATING SPECIFICATIONS

• 120K2 Motor Grader (Tier 3) Cat C7 ACERT
® TM
Engine ENGINE
• Standard power 145hp/108kW Model Cat® C7 ACERTTM
• Standard operator controls with tilt steering wheel Base Power
• Air-actuated, multiple disc brakes 108kW 145 HP
(All Gears - Net)
• Fuel tank 80.6 gal (305 L) TOP SPEED
CUSTOM MODIFICATIONS AND OPTIONS FWD 45.7 KM/H 28.4 MPH
• Overall length approx. 331 in (8410 mm) REV 36.1 KM/H 22.4 MPH
• Wheelbase approx. 231 in (5870 mm) TURNING RADIUS, OUTSIDE FRONT TIRES
• Outside turning radius to 287 in (7290 mm)
• Custom manufactured cab (Multiple options) 7290 MM 287 IN
◦◦ Fully enclosed cab with HVAC, with or without STEERING RANGE - LEFT/RIGHT
ROPS FOPS 47.5 DEGREES
◦◦ Open cab, ROPS FOPS structure ARTICULATION ANGLE - LEFT/RIGHT
◦◦ No cab, with or without ROPS FOPS moveable 20 DEGREES
roll-bar
• Finished machine height range between 96 in – 113 POWER TRAIN
in (2,438 mm – 2,870 mm) FORWARD/REVERSE
8 FWD / 6 REV*
• Width of machine approx. 96.4 in (2,450) GEARS
• Modified operator controls to suit lower cab height DIRECT DRIVE,
TRANSMISSION
• Reduced height of moldboard lift cylinders POWERSHIFT
• Optional moldboard reduction to 10 ft (3,048 mm) * May change with order spec
• Radiator protection structure
• Front end counter weight and push block BRAKES*
• Fire suppression SERVICE AIR ACTUATED, MULTIPLE OIL-DISC
• Diesel particulate filter PARKING AIR ACTUATED, MULTIPLE OIL-DISC
• Exhaust system heat wrap
*Brakes meet the following standards: SAE J/ISO 3450 JAN 98.
• Rear view camera
• Multiple tire options FORWARD GEAR SPEEDS*
CERTIFICATIONS 1ST 3.9 KM/H 2.4 MPH 5TH 16.8 KM/H 10.4 MPH
• ROPS/FOPS - (ISO 3471 / ISO 3449) 2ND 5.3 KM/H 3.3 MPH 6TH 22.8 KM/H 14.2 MPH
• Steering: ISO 5010:1992 3RD 7.7 KM/H 4.8 MPH 7TH 31.4 KM/H 19.5 MPH
• Brakes: ISO 3450:1996 4TH 10.6 KM/H 6.6 MPH 8TH 45.7 KM/H 28.4 MPH
• CE certified where applicable
REVERSE GEAR SPEEDS*
SPECIAL FEATURES 1ST 3.1 KM/H 1.9 MPH 4TH 13.3 KM/H 8.2 MPH
• LED lighting packages 2ND 5.8 KM/H 3.6 MPH 5TH 24.8 KM/H 15.4 MPH
• Reflective striping 3RD 8.4 KM/H 5.2 MPH 6TH 36.1 KM/H 22.4 MPH
• Operation & maintenance manual * Maximum travel speeds calculated at high idle on standard
machine configuration with 14.00-24 12 PR (G-2) tires.

INTRODUCTION
OPERATING SPECIFICATIONS OPERATING SPECIFICATIONS

MOLDBOARD HYDRAULIC SYSTEM
BLADE WIDTH 3M 10 FT LOAD SENSING,
CIRCUIT TYPE
BLADE RANGE CLOSED CENTER, PPPC
CIRCLE CENTERSHIFT PUMP TYPE VARIABLE PISTON
RIGHT 356 MM 25.8 IN 210.5 55.6
PUMP OUTPUT*
L/MIN GAL/MIN
LEFT 658 MM 25.8 IN
MAXIMUM SYSTEM 25,500
MOLDBOARD SIDESHIFT 3,699 PSI
PRESSURE KPA
RIGHT 663 MM 14 IN STANDBY PRESSURE 3600 KPA 522.1 PSI
LEFT 208 MM 8.2 IN RESERVOIR TANK
24.5L 6.5 GAL
MAXIMUM BLADE CAPACITY
5 90 DEGREES
4 3 2 1
POSITION ANGLE *PUMP MEASURED AT 2,150 RPM REVISIONS
BLADE TIP RANGE SERVICE REFILL REV. ECN. DESCRIPTION DAT
FORWARD 40 DEGREES FUEL CAPACITY 305 L 80.6 GAL

BACKWARD 5 DEGREES COOLING SYSTEM 40 L 10.6 GAL
FRAME ENGINE
8 OIL 25
7 L 6.6 GAL 6
CIRCLE TRANS/DIFF/FINAL DRIVES 47 L 12.4 GAL

DIAMETER 1530 MM 60.2 IN TANDEM HOUSING (EACH) 49 L 12.9 GAL
BLADE BEAM THICKNESS 30MM 1.2 IN FRONT WHEEL SPINDLE
0.5L 0.1 GAL
DRAWBAR BEARING HOUSING
HEIGHT 127 MM 5 IN D CIRCLE DRIVE HOUSING 7L 1.9 L
WIDTH 76.2 MM 3 IN DIMENSIONS
FRONT AXLE GROSS VEHICLE WEIGHT 14,061 KG 31,000 LBS
HEIGHT TO CENTER 572 MM 22.5 IN HEIGHT 2845 MM 112 IN
WHEEL LEAN, LEFT/RIGHT 18 DEGREES LENGTH 8410 MM 331 IN
TOTAL OSCILLATION PER SIDE 32 DEGREES WIDTH 2850 MM 98 IN
112"
2844.80mm C
331"
8407.40mm
98"
2489.20mm
B
CUSTOMER APPROVAL
8 DRAWING 7 6 5 4 3 2 1
REVISIONS
BASE MACHINE: REV. ECN. DESCRIPTION DATE ORIGINATOR
- 482-7861 120K2 MOTOR GRADER (NO CAB);
- 0P9002 LANE 2 ORDER;
- 460-6436 ROADING AR;
- 320-9924 BLADE GRP - 12 FT / 144 IN (3658 MM);
- MODIFY STANDARD, VERTICAL EXHAUST STACK ON BASIC
- 368-3025 GENERAL AR WITH 145 HP C7.1 ACERT®
GRADER TO LOW PROFILE HORIZONTAL EXHAUST POSITION;
(U.S. EPA TIER 3) ENGINE; - HEAVY-DUTY FABRICATED FRONT GRILL/PUSH
D - INCLUDES LOWERING HEIGHT OF AIR BREATHER; D
- AIR OPERATED, MULTIPLE OIL-DISC BRAKES; BLOCK / COUNTERWEIGHT; PAINTED BLACK;
- PAINTED BLACK.
- 442-1756 HITCH GRP;
- 424-8612 OPTION GRP DRAWBAR & HYDRAULIC TIP;
- 434-6589 VALVE GRP BASE+2;
- 434-4115 BATTERY GRP;
- 461-2961 LIGHTING - LOW BAR;
- 482-8590 NO ROPS CAN - PANEL & PEDESTAL;
- 113-4254 SEAT, BASIC;
- 387-2851 MIRROR GRP; - MODIFIED FINAL MOLDBOARD IS REDUCED TO
- 319-4492 NO PRODUCT LINK; OVERALL LENGTH OF 10 FT / 120 IN (3048 MM):
- 461-2764 NO ACCUGRADE HYDRAULICS; - MODIFIED MOLDBOARD COMES FITTED WITH
- 340-2640 TIRE AR, 14.00-24 TR TL508 (9X24 RIM); INITIAL SET OF MODIFIED CUTTING EDGES;
- 437-0691 NO LOCK OUT, CANOPY; - MANUFACTURE LOW-PROFILE, OPEN-AIR, REMOVABLE OPERATOR STATION - MODIFICATION ALSO INCLUDES SHORTENING OF
- 465-6950 OPTION, COOLING; AND CANOPY FOR 120K2 MOTOR GRADER; BLADE EXTENSION CYLINDER, AS REQUIRED;
- 434-8087 TANK GRP (AIR); - OVERALL HEIGHT APPROX. 111 IN (2819 MM); - PAINT CAT® YELLOW MODIFIED AREAS;
- 5P2506 LITERATURE GRP SERIALIZED MEDIA; - CANOPY IS ROPS / FOPS CERTIFIED; (ISO 3471:2008 / ISO 3449:2005)
- 439-5724 BOTTOM GUARD GRP; - INCLUDES MODIFICATIONS TO OPERATOR CONTROLS/ PEDALS TO
C - 0P3380 ENGLISH LITERATURE; ACCOMMODATE LOWER PROFILE FLOOR PAN; C
- 0P6759 WEATHER GRP -40C; - HYDRAULIC VALVE BANK RELOCATED FOR IMPROVED BLADE OPERATION;
- 0P2630 CERTIFICATE OF ORIGIN; - LOW-PROFILE OPERATOR SEAT WITH 2 IN (51 mm) MECHANICAL - WHEEL CHOCK HOLDERS AND JUMBO WHEEL CHOCKS
- 0P6690 RO/RO; SUSPENSION; ADDED TO MACHINE; LOCATED LOWER LH SIDE OF ENGINE
- PAINTED CAT® YELLOW; COWLING; CHOCKS ARE ANSI / MSHA COMPLIANT;
- CUSTOM EXTERIOR MIRROR MOUNTS AND BRACKETS FOR INSTALLATION OF CAT® OEM MIRRORS;
FIRE SUPPRESSION SYSTEM WITH
MANUAL ACTUATION:
- SHORTEN MOLDBOARD LIFT CYLINDERS SO THAT OVERALL CYLINDER HEIGHT IS BELOW THE LEVEL OF
- ANSUL® LT-101-30 SINGLE TANK;
SELECTED OPERATOR'S STATION TO MITIGATE LIKELIHOOD OF DAMAGE TO CYLINDERS IN UG APPLICATION;
- (6) NOZZLE FIRE SUPPRESSION
- REPLACE AND MODIFY HYDRAULIC HOSES AS NECESSARY;
SYSTEM W/ (2) MANUAL ACTUATORS;
- PAINT MODIFIED AREAS CAT® YELLOW;
- ENGINE SHUT DOWN;
MISCELLANEOUS: - NO AUTOMATIC DETECTION;
- ALL DIMENSIONS ARE APPROXIMATE; - INSTALLED AND CERTIFIED;
- FRONT HEADLIGHTS;
B - REAR TAIL / STOP LIGHTS;
B
- FRONT & REAR TURN SIGNALS;
- PAINT CAT® YELLOW - ANY MODIFIED AREAS;
- STANDARD CATERPILLAR® & GROUND FORCE WARRANTIES;
- OPERATIONS & PARTS MANUAL PROVIDED;
- OPERATIONAL HAZARD INFORMATION INCLUDED AT DELIVERY; WILL BE ATTACHED TO STEERING WHEEL;
- FOB PORT OF HOUSTON, TX;
DIMENSIONS:
- (8) LED WORK LIGHTS; CONSISTS OF (2) REAR, (2) FRONT - WHEELBASE (FRONT AXLE TO MID-TANDEM/TRUNNION), STANDARD: 231.1 IN (5870 MM);
BOTTOM OF CAB, (4) ON SPINE FACING FRONT; - TURNING RADIUS, STANDARD: 287 IN (7290 MM) (OUTSIDE FRONT TIRES);
- OVERALL LENGTH (FRONT COUNTERWEIGHT TO REAR OF MACHINE/BUMPER TO BUMPER), STANDARD:
- CUSTOM SWING STEP FOR EASY INGRESS / EGRESS; 343 IN (8712 MM); MACHINE WIDTH (OUTSIDE FRONT TIRES), STANDARD: 96.4 IN (2449 MM);
- HEAVY-DUTY FABRICATED BUMPER / CRASH GUARD TO PROTECT UNLESS OTHERWISE SPECIFIED: NAME DATE
RADIATOR AND REAR OF MACHINE; PAINTED BLACK;
DIMENSIONS ARE IN INCHES
DRAWN WB 6/9/2017 GROUND FORCE MFG.
TOLERANCES: CHECKED JLW 6/12/2017 TITLE:
FRACTIONAL 1/16
A ANGULAR: MACH/BEND .25 ENG APPR. CM 06/12/2017 A
RELIANZ COLOMBIA
CUSTOMER APPROVAL:_______________________ TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003 UG20K GRADER
PLEASE SIGN AND RETURN TO GROUND FORCE MFG PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC TOLERANCING
DATE:______
PER: ASME Y14.5 M-1982
FAX NUMBER (209)664-9475. THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
B CA-330C04 0
"IF DRAWINGS ARE NOT SIGNED, DATED, AND RETURNED TO DRAWING IS THE SOLE PROPERTY OF MATERIAL:
GROUND FORCE (VIA FAX OR E-MAIL) WITHIN 48 HRS, GROUND GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
FORCE MFG WILL CONSIDER THIS AS AN ACCEPTANCE OF THE WITHOUT THE WRITTEN PERMISSION OF
DESIGN AND WILL PROCEED WITH THE PROJECT." GROUND FORCE MFG., LLC. IS
PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:64 WEIGHT: SHEET 1 OF 1
6 8 7 6 5 4 3 2 1
SAFETY, OPERATION & MAINTENANCE MANUAL
SAFET Y

SAFETY
WARNING 2.5 BATTERY FUMES AND EXPLOSIONS

DO NOT attempt to use this equipment until you have • Follow battery manufacturer’s instruc-
thoroughly read this manual. It includes important tions when working on or near a battery
safety precautions, detailed starting, operating and
• Stop engine before disconnecting or
maintenance instructions, and parts lists.
connecting battery cables, battery charg-
ing cables, or servicing battery
2.1 READ INSTRUCTIONS • Always wear a face shield, rubber gloves and protec-
tive clothing when working on battery
• Read and follow the Owner’s Manual • Batteries produce explosive gases during normal
carefully before installing, operating, or operation and when being charged. Keep sparks,
servicing equipment. Read safety informa- flames, cigarettes and other ignition sources away
tion at the beginning of the manual and from batteries
in each section. Heed warning labels on
equipment • Observe correct polarity (+ and -) on batteries
• Use only genuine replacement parts from • Disconnect negative cable (-) first and reconnect
manufacturer negative (-) cable last
• Perform maintenance and service according to the • DO NOT tip battery
Owner’s Manual • Replace damaged battery
• ALWAYS follow National, State, and Local codes • Do NOT charge a frozen battery
• Do NOT charge battery in a closed area or where
2.2 GENERAL SAFETY HAZARDS ventilation is restricted
• Always ensure vehicle is CLEAR of • In case of battery acid getting on face, on skin, or
personnel before starting vehicle in eyes, flush immediately with water for 5 minutes
• Always use wheel chocks when servic- and seek medical attention as soon as possible
ing or working on vehicle
2.6 FIRE HAZARD

2.3 ENGINE EXHAUST CAN KILL • Stop engine while fueling
• Operate in open, well ventilated areas • DO NOT smoke while fueling
or vent exhaust outside • DO NOT leave nozzle unattended while
fueling
• Wipe up spilled fuel and allow fumes to clear before
2.4 MOVING PARTS CAN INJURE OR starting engine
CAUSE DEATH
• DO NOT overfill tank, fuel expansion may cause
• Do not operate with doors open or overflow
guards off or removed
• Stop engine before servicing
• Keep hands, hair, loose clothing and tools away
from moving parts and machinery

SAFETY
2.7 ELECTRICAL SHOCK CAN KILL 2.9 PINCH POINT HAZARDS

• DO NOT touch electrically live parts • Never place yourself between a piece
with skin or wet clothing of heavy equipment or machinery and an
• Insulate yourself from work and use immovable object
safety ground • Never work within the swing radius of
• Always wear dry insulated gloves when working on rotating equipment
electrical equipment • Always work at a safe distance from equipment
• Always lockout/tagout equipment before perform- • Caught-In hazards exist when workers remove or dis-
ing electrical work able guards. Use extra caution when removing this
safety equipment as required for servicing
• Never place your hands or body near moving parts
2.8 FALL HAZARDS • Gloves, long sleeve shirts, hair, and loose fitting
• Equipment operators and mainte- clothing can be hazardous if caught in moving parts
nance Personnel are susceptible to falls • Never exceed maximum load limits according to the
from Equipment during repair and servic- equipment and machinery specifications
ing. Prevent falls and slips by following
• All workers should wear bright protective clothing.
these guidelines:
Signs that are highly visible should be set up in a
• ON-SITE FALL HAZARD requirements supersede all way to warn and discourage nonworkers from enter-
of the guidelines listed below. Closely follow on-site ing site
safety rules.
• Never forget one simple rule: PARKING BRAKES.
• Know and identify what slip, fall and trip hazards They are easy to operate and can save lives
are, and what preventative measures are required
• Always use wheel chocks when working on or near a
• Survey work area on and around equipment for slip vehicle
and fall hazards and remove hazards from area
• Always verify that vehicle is clear before starting
• Never jump from equipment to the ground
• Use three points of contact when climbing
equipment
• Where there is a danger of falling use a FALL
PROTECTION SYSTEM per OSHA AND MSHA
requirements.
• Always follow national, state and local codes:
https://www.osha.gov/SLTC/fallprotection/

SAFETY
2.10 COMPRESSED AIR HAZARDS 2.11 LOCK-OUT/TAG-OUT

FOLLOW ON-SITE COMPRESSED AIR HAZARDS SAFETY
REQUIREMENTS FOR PLACE OF OPERATIONS. THE
FOLLOWING ARE ONLY BASIC GUIDELINES:
LOCK-OUT
DANGER PROCEDURES
COMPRESSED AIR 1. IDENTIFY the types of energy sources
used, potential hazards, and control
• Incorrect installation or operation of this unit could devices.
result in equipment failure and personal injury. 2. NOTIFY all affected employees.
Only qualified persons should install, operate, and
3. TURN OFF all operating controls.
service this unit according to the owner’s manual,
and industry standards, always in compliance with 4. LOCATE all energy sources
National, State and Local codes 5. ISOLATE all energy sources by blocking,
bleeding and ventilating stored energy as
• DO NOT exceed the rated output or capacity of
found in springs, hydraulic systems, elec-
the compressor or any equipment in the com-
trical systems and pneumatic systems.
pressed air system Before working on the com-
pressed air system, follow the in house (on site) 6. LOCK-OUT all switches and energy con-
LOCKOUT/TAG-OUT procedure of the unit trols in the “OFF or “SAFE” POSITION.
7. TEST operating controls. Put all controls
• Turn off and follow above lockout/tag out proce-
in “ON” position. Be sure no one can get
dure; ensure that the pressure is released from the
hurt before testing.
system, and cannot accidently be applied
8. RETURN all operating controls to the
• The air compressor can start up at any time the “OFF” Position.
switch is “on.” Use caution any time the switch is on
9. PERFORM required task.
10. REMOVE lock-out devices only after
the equipment is fully assembled and
all affected employees have been
notified. Each lock-out device must be
removed by the person who put it on.

SAFETY
2.12 GUIDELINES
Equipment and vehicles must be maintained to be safe and reliable. Due to Ground Force Worldwide’s global
presence and distribution and the myriad of local, state, and federal regulations it is impractical to provide
specific details of these regulations. The following are basic guide lines, which do NOT supersede on site
requirements and regulations, which MUST be followed.
• Ensure that ALL operators have been trained on the • Equipment should have roll-over protection, and
equipment they use and operate protection from falling debris as required by law
• Check vehicles at the beginning of each shift to • Ensure that vehicles used to transport workers have
ensure the parts, equipment and accessories are seat belts, firmly secured and adequate for the
in safe operating condition. Repair or replace any number of workers to be carried or transported
defective parts or equipment prior to use • DO NOT modify the equipment’s capacity or safety
• Ensure the service, emergency and park brake sys- features without written approval from the Ground
tems are operational. Verify audible backup alarm Force Mfg. Engineering Department
system is operational and working. Headlights, tail • Prior to permitting equipment or vehicles on to an
lights, and brake lights MUST be operational. Verify access roadway or grade, verify that the roadway
the windshield is clear and the windshield wipers or grade is constructed and maintained to safely
are operational accommodate the equipment, vehicles and loads
• DO NOT operate vehicle in reverse with an involved
obstructed rear view unless it has a signal alarm • Vehicles and equipment loaded from the top must
capable of being heard above ambient noise levels have cab shields or canopies to protect the operator
or a signal observer indicates that it is safe to move while loading
vehicle. Some operational areas require a spotter at
• Verify the Pre-Shift Inspection has been completed
all times
and signed off
This safety guide is provided by Ground Force Worldwide to assist you in making a safer workplace. Specific
regulations of place of operations supersede all basic recommendations provided in preceding sections.
For more information contact your National, State, or local authority. The following links are provided to assist
you in compliance:
Occupational Safety and Health Administration

Mine Safety and Health Administration
Canadian Centre for Occupational Health and Safety
European Agency for Safety and Health at Work
Safe Work Australia

SAFETY
2.13 FIRE EXTINGUISHER USE

Sound the fire alarm and call the fire
department, if appropriate.
Identify a safe evacuation path before
approaching the fire. Do not allow the fire,
heat, or smoke to come between you and
your evacuation path.
Select the appropriate type of fire
extinguisher.
Discharge the extinguisher within its effec-
tive range using the P.A.S.S. technique
(pull, aim, squeeze, sweep).
Back away from an extinguished fire in
case it flames up again.
Evacuate immediately if the extinguisher
is empty and the fire is not out.
Evacuate immediately if the fire pro-
gresses beyond the incipient stage.
Most fire extinguishers operate using
the following P.A.S.S. technique:
• PULL - Pull the pin. This will also break
the tamper seal.
• AIM - Aim low, pointing the extinguisher
nozzle (or its horn or hose) at the base of
the fire.
• NOTE: Do not touch the plastic discharge
horn on CO2 extinguishers. It gets very
cold and may damage skin.
• SQUEEZE - Squeeze the handle to release
the extinguishing agent.
• SWEEP - Sweep from side to side at the
base of the fire until it appears to be
out. Watch the area. If the fire re-ignites,
repeat steps 2 - 4.
• WARNING: If you have the slightest
doubt about your ability to fight a fire,
EVACUATE IMMEDIATELY

SAFETY
2.14 PERSONAL PROTECTIVE EQUIPMENT

• Hard hats. All persons shall wear suitable hard hats when in an area where falling objects
may create a hazard.
• Protective footwear. All persons shall wear suitable protective footwear when in or around
an area where a hazard exists which could cause an injury to the feet.
• Eye protection. All persons shall wear safety glasses, goggles, or face shields or other suit-
able protective devices when in or around an area where a hazard exists which could cause
injury to unprotected eyes.
• Safety belts and lines. Safety belts and lines shall be worn when persons work where there
is danger of falling; a second person shall tend the lifeline when bins, tanks, or other dan-
gerous areas are entered.
• Reflective clothing. Wear reflective clothing which is highly visible (360 degrees) when the
arms are up or down or when the body is in any position and even on top of hard hat.
• Ear protection. Ear protection must be worn when the noise exposure level is above 85 dBA.
• Respirators. A respirator should be worn if there is danger of harmful dusts, fogs, smokes,
mists, gases, vapors, and sprays.
• Hand protection. Wear appropriate gloves if there is danger of skin absorption of harmful
substances, chemical or thermal burns, electrical dangers, bruises, abrasions, cuts, punc-
tures, fractures or amputations.

OPERATION

OPERATION
MOTOR GRADER COMMISSIONING PROCEDURE

To ensure that the unit is ready to be placed in ser- WHEEL LEAN LOCKING BOLT
vice, Ground Force has professionally pre-commis-
sioned your motor grader. Before operation there are The wheel lean locking bolt must be removed
two items that need to be performed prior to move- before operation. Refer to the enclosed Caterpillar
ment of the motor grader, these were installed to Operations and Maintenance Manual.
insure safe shipping of your vehicle:
WARNING
FRAME LOCK PIN
• DO NOT OPERATE THE MACHINE WITH THE WHEEL
The frame lock pin must be removed to articulate the
machine. Refer to the enclosed Caterpillar Operations LEAN BOLT IN THE LOCKED POSITION. MACHINE
and Maintenance Manual for location and instruc- DAMAGE MAY OCCUR.
tions to remove this pin. If further guidance or clarification is required, Please
contact Ground Force Parts and Product Support
Department via e-mail at service@gfworldwide.com
or by telephone at 1 (208) 664-9291
MOTOR GRADER OPERATION PROCEDURES
The modified UGF20K motor grader operates exactly HEATER AND AIR CONDITIONING UNIT
the same as an original 120K2. There are only two (OPTIONAL)
major differences from the original unit:
To accommodate the reduced dimension cab
OPERATIONS Underground Force has replaced the stock heater
and air conditioning system with a Red Dot, Model
This motor grader operates the same as the original R-9750. This unit is simple to operate with only two
OEM grader with just the previously listed differences. operator controls:
Refer to the Caterpillar Operation and Maintenance
manual in the last section of this manual for detailed
• Fan Switch. The fan switch changes fan speed from
operating instructions. Low, Medium and High speeds.
• Mode Switch. This switch selects mode of operation,
BLADE RANGE the settings are as follows. Use to select the below
desired modes:
Refer to the Operating Range section for modified
blade range specifications. All operator controls ◦◦ Heat
remain the same, and only size and movement of ◦◦ Off
blade have been modified. ◦◦ Cool

OPERATION
OPERATING RANGE
When operating a underground modified motor WARNING
grader, the operator can cause conditions which
damage the motor grader. The following pages have THE MOTOR GRADER CAN BE SEVERELY
diagrams which identify potential damage causing
conditions. Operators should familiarize themselves DAMAGED BY OPERATING WITH IMPROPER
with these conditions and refrain from operating the BLADE ANGLE. CARE SHOULD BE TAKEN
motor grader in conditions that will cause damage.
AT ALL TIMES TO BE AWARE OF THE
There are four conditions that cause damage:
1. Blade angle set to an acute angle which rubs on BLADE ANGLE AND THAT IT IS NOT IN
tires or chassis. AN OVEREXTENDED POSITION CAUSING
2. Side-shifting the blade which allows rotation of DAMAGE TO THE BODY, BRAKES, HOSES
blade into a damaging position.
3. Blade angle can be set improperly which allows
AND OR TIRES.
movement of the blade to hit and damage cab
and body components.
4. Since the grader articulates while steering, the
operator can steer hard enough to the left or
right to cause tires to rub on the chassis.
BLADE ANGLE
DAMAGE POINT

OPERATION
BLADE ANGLE
DAMAGE POINT
BLADE ANGLE
DAMAGE POINT

OPERATION
BLADE ANGLE
DAMAGE POINT
BLADE ANGLE
DAMAGE POINT

OPERATION
BLADE ANGLE
DAMAGE POINT
BLADE ANGLE
DAMAGE POINT

OPERATION
ARTICULATED TOO FAR - TIRE

HITTING UNDER SECTION OF CAB.
WITH TIRES INSTALLED BY GF THIS
WILL NOT HAPPEN. AFTERMARKET
TIRES THAT ARE OVERSIZED WILL
BLADE EITHER SWIVELED AND/OR CAUSE THIS CONDITION.
TILTED TOO FAR AND HITTING
LADDER. APPLIES TO BOTH DRIVER
AND CHASSIS SIDE AS LADDERS
ARE INSTALLED ON BOTH SIDES.

MAINTENANCE
SCHEDULES
GENERAL MAINTENANCE
There are no changes to the original Caterpillar maintenance sched-
ules. For safe and reliable operations of your new Ground Force motor
grader refer to the Caterpillar Operation & Maintenance manual for
complete maintenance procedures.
CAB AIR FILTER

Ground Force Worldwide recommends the cab air filter(s) are checked
every two weeks and replaced as necessary. See the Caterpillar
Operation & Maintenance manual for instructions.

PARTS DRAWINGS

8 7 6 5 4 3 2 1
Material Part WEIGHT REVISIONS
ITEM QTY. DESCRIPTION ERP
Number (lbs)
REV. ECN. DESCRIPTION DATE ORIGINATOR
1 1 SERIAL NUMBER PLATE SH10GAX96 1.09 330C04-SERIAL
2 1 CAB COVER SHEET SH16GAX60 46.21 90181117339 15

3 1 MOLDBOARD CUTS 0 91081916153 1 26
1 2
4 1 FUSE BOX 26.97 91081916190 1 1 6
22" 11
5 1 INSTRUMENT PANEL ASSEMBLY 120K 30.47 91081916283
1 5
MOTOR GRADER 1
1 D
D 6 1 12H ROPS/FOPS STRUCTURE 855.76 91081916788 MATCH DRILL AND MOUNT CAB
7 1 12H ROPS MOUNTING ASSEMBLY 887.59 91081916789 PAN WITH 3/8" HARDWARE.
8 1 VALVE BLOCK MOUNT ASSEMBLY 234.51 91081920656 12
9 1 120K2 SIDE SHIFT CYLINDER MODS 0 91081922018 1
18
10 1 SEAT PAN 35.2 91081922031
13 2
11 1 REAR BUMPER ASSEMBLY 406.66 91081922044 1
13
12 1 OPEN CAB MIRRORS 36 91081922051 16 "
13 1 WHEEL CHOCK HOLDER 125.4 91081923242 DETAIL A
120K CUTTING EDGE 8
14 1 MODIFICATIONS 0 91081923522 SCALE 1 : 12 1
120K2 STANDARD EXHAUST
15 1 13.36 91081926392
MODIFICATION
GRADER FABRICATED
16 1 1000.09 91081926633
COUNTERWEIGHT
17 1 120K2 LONG SPINE STUD LAYOUT 1097.9 91081926673
120K2 132-4926 CYLINDER
18 2 194.4 91081927358 22
MODIFICATION
19 1 120K2 OPEN CAB GENERAL 0 91081927374 1
ELECTRICAL
C 20 1 120K2 LONG SPINE OPEN CAB 0 91081927379
10 C
DECAL/BRANDING DRAWING 1
120K2 OPEN CAB LOWER OPEN
21 1 352.33 91081927380
CAB MOUNTING
4
22 1 120K2 OPEN CAB 479.99 91081927381
1
23 1 120K2 MG PEDALS OVERALLS 90.13 91081927406
21
24 216 VELCRO WRAP 3" 0 PS-BV-300 1
25 48 VELCRO WRAP 4" 0 PS-BV-400
23
SEAT, K-GRADER SENTINEL
26 1 41.18 UGI-K0050-SEN 1
COMPACT VINYL SUSPENSION -CENTER CAP SHEET ON ROPS. 16
SEATBELT, 3" RETRACTABLE KIT - KAB
27 1 UPPER 0 UGI-SB3-KB -USE SEAM SEAL BETWEEN SHEET, CENTER 1
ROPS TUBES, AND PERIMETER ROPS TUBES.
-CENTER STEERING ASSEMBLY OVER 2
1 22
OPENING IN TUNNEL PLATE.
1 1 3
-ASJUST LENGTH OF LINK RODS AS NEEDED.
B A 1 8"
C 11 20
MOUNT (2) WORK LIGHTS BACK OF CAB CAN BE FLUSH WITH
1 1
TO SIDE COVERS OR FORWARD OF BACK OF
B CHASSIS MOUNT PLATFORM, BUT B
CANNOT BE BEHIND!
19 1
12"
1 INSTALL 3/8" RUBBER BETWEEN
WRAP CAB PAN AND UPPER AND
CORNERS LOWER MOUNTING
ONLY 3/16
1" PLATFORMS.
C MOUNT (2) WORK LIGHTS *DO NOT INSTALL RUBBER
TO REAR BUMPER UNDER ROPS FEE.*
SECTION C-C
DETAIL B
* ____ REQUIRED SCALE 1 : 12
MOUNT (2) WORK LIGHTS MOUNT (2) WORK LIGHTS UNLESS OTHERWISE SPECIFIED: NAME DATE
TO FRONT COVERS BELOW CAB
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES. FRACTIONAL 1/16
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED. ANGULAR: MACH/BEND .25 ENG APPR. CM 06/12/2017 A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 RELIANZ COLUMBIA
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. THREE PLACE DECIMAL .003 UG20K GRADER
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC TOLERANCING
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
B 330C04 0
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF MATERIAL:
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:48 WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Material Part WEIGHT
ITEM QTY. DESCRIPTION ERP REVISIONS
Number (lbs)
1 8 3/4"-10 NC GR8 NUT, PLATED 0.144 0105.075.01.20 REV. ECN. DESCRIPTION DATE ORIGINATOR
2 4 3/4" X 7" NC GR8 BOLT PLATED 3.92 0801.075.0700.20
3 8 3/4" FLAT WASHER L-9 0.048 0945.075.0.20
4 4 MOUNTING CAT 1.96 103-4953
5 4 WASHER 22MM X 100MM X 10MM 5.16 8X-0674
D 6 2 ROPS PIN CR4140X2.25C 10.22 90181116372 D

7 2 BOLT RING PL.25X60C 1.66 90181116373
8 4 PLATE WASHER PL.25X60C 2.4 90181116374
9 2 LOWER BOLT PLATE PL.5X60C 6.34 90181116579
10 1 TAG ROPS-120K2 METAL TAG 0 TAGS-ROPS-120K2
-DRILL AND TAP FOR 3/8"-16 7

-SECURE WITH 3/8"x3/4" LONG GR-8 BOLT 2 8
-USE LOCK-TITE ON BOLT 4 2
-TORQUE TO 44 FT-LBS
4
8
C 4 C
6 4
2 4
3
8
5
4 9 1
2 8
--IMPORTANT--
6
SECTION A-A ENSURE THAT THERE IS NO SKIRT
2
7 BOARD OR RUBBER BETWEEN
2 6 ROPS FEET AND MOUNTING BASE.
7 2
2
A
B 8
8
B
4
4
-INSERT AND SECURE ROPS PINS PRIOR TO BOLTING.

-USE NEW CAT OEM ROPS RUBBER ISOLATION MOUNTS AND WASHER PLATES.
9 -REPLACE BOLTS WITH LONGER 3/4"-10 GR-8 BOLTS AS NEEDED.
2
A 9 -INSERT BOLT, FLAT WASHER, AND PLATE WASHER FROM TOP.
2 -ON BOTTOM SIDE USE FLAT WASHER, THEN DOUBLE GRADE-8 NUTS. * ____ REQUIRED
-TORQUE BOLT AND FIRST NUT TO 317 FT-LBS.
-TORQUE JAM NUT AGAINST FIRST NUT TO 350 FT-LBS.
**ENSURE THAT YOU DO NOT LOOSEN THE FIRST NUT BY HOLDING TO BOLT UNLESS OTHERWISE SPECIFIED: NAME DATE
FRONT VIEW
WHEN TIGHTENING.**
TOLERANCES: CHECKED ETR 4/15/2014 TITLE:
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED. ANGULAR: MACH/BEND .25 ENG APPR. JLW 04/15/2014 A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 12H ROPS MOUNTING
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. THREE PLACE DECIMAL .003 ASSEMBLY
SIZE DWG. NO. REV
B 916789 0
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:12 WEIGHT: 887.59 SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Number (lbs)
1 1 INCHING PEDAL ASSEMBLY 15.91 91081927419
2 1 DS FOOT REST 3.5 91081918215
3 1 CS FOOT REST 5.61 91081918216
4 1 BRAKE/ACCEL PEDAL ASSEMBLY 37.91 91081927420
5 1 DS PEDAL COVER - 120K OPEN CAB 12.16 91081925277
D 6 1 CS PEDAL COVER - 120K OPEN CAB 15.05 91081927423 D
2 MATCH DRILL CAB PAN

1 AND THRU BOLT WITH
NOTE: 1
1/4-20 BOLTS AS NEEDED 6
SEE SUB ASSEMBLIES FOR 1
1
MOUNTING INFORMATION FOR COVER MOUNTING.
NOT SHOWN HERE.
MATCH DRILL AND TAP
TS FOR 1/4-20 BOLTS
AND BOLT AS NEEDED
FOR COVER MOUNTING
5
1 2
1
C C
4
1
5
1
6 1
1 1
4 3-D VIEW
1
3
1
TOP VIEW
B B
* ____ REQUIRED
UNLESS OTHERWISE SPECIFIED: NAME DATE

4
1 DIMENSIONS ARE IN INCHES
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 120K2 MG PEDALS
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. SIDE VIEW THREE PLACE DECIMAL .003 OVERALLS
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH COVER SIDE HIDDEN FOR CLARITY
SIZE DWG. NO. REV
B 927406 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Number (lbs)
1 2 WELD STUD 3/8-16 X 2" 0.12 101010127
2 1 PEDAL MOUNT PLATE PL.188X96 1.45 90181115372
3 1 MOUNT TAB-SMALL PL.375X96 0.53 90181115373
4 1 MOUNT TAB-LARGE PL.75X96 1.59 90181115374
5 1 THROTTLE SPRING MOUNT PL.188X96 1.42 90181115377
D 6 1 DRIVE SHAFT, 1/2"OD X 7 3/4"L 92001346K18 0.43 90181115381 D

7 1 SPRING TENSION PLATE PL.5X96 0.71 90181120344
8 1 BRAKE ROD 0.22 90181125069

RE-USE ORIGINAL
9 1 ACCELERATOR LINK 0.22 90181125084 THROTTLE RETURN SPRING 5
10 1 FLATBAR 3/16 X 3 FB.188X3 0.59 90181125088 1
RE-USE ORIGINAL CLEVIS
11 1 FLATBAR 3/16 X 2 FB.188X2 0.4 90181125092 HARDWARE-TYP.
12 1 ACTUATOR MOUNT PLATE PL.188A36 2.56 90181147583
13 1 ACCELERATOR PEDAL 2.34 91081918213
14 1 FLANGED SLEEVE BEARING PTFE 0.01 92002706T26 9

15 1 FLANGED SLEEVE BEARING PTFE 0.04 92002706T43 1
4"
CAT BRAKE
VALVE #8X-2650
C THROTTLE SENSOR
C
#266-1467 CAT BRAKE
8
VALVE #8X-2650
1
7
1
15
1
RE-USE ORIGINAL BRAKE RETURN SPRING
CAT BRAKE PEDAL

#270-4924
RE-USE ORIGINAL
PEDAL STOP-TYP.
B B
12
1
6
1
11
1 * ____ REQUIRED

13 TOLERANCES: CHECKED JLW 6/12/2017 TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES. 1 FRACTIONAL 1/16
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 BRAKE/ACCEL PEDAL
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. THE INFORMATION CONTAINED IN THIS SIZE DWG. NO. REV
B 927420 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Number (lbs)
1 1 PEDAL MOUNT PLATE PL.188X96 1.45 90181115372
2 2 MOUNT TAB-SMALL PL.375X96 1.06 90181115373

1 2
DRIVE SHAFT, 1/2"OD X 5 1/4"L
3 1 STEEL 92001346K18 0.29 90181115375 1 2 9
4 1 CLUTCH SHAFT RETAINER PL.188X96 0.09 90181115376 2
6
5 1 INCHING PEDAL MOUNT PLATE SH10GAX96 2.11 90181119619
1
D 6 1 FLATBAR 3/16 X 3 FB.188X3 0.79 90181125118 CAT PEDAL #207-4922 CAT CLUTCH SENSOR; D
7 1 FLATBAR 3/16 X 2 FB.188X2 0.53 90181125119
CAT LEVER #180-7147 CAT #214-4863
8 1 CLUTCH ROD 0.24 90181125120
9 2 FLANGED SLEEVE BEARING PTFE 0.02 92002706T26
CAM POSITION TO BE
5" SET DURING ASSEMBLY
CAT CAM #180-4027

MOUNT ACTUATOR TO B 1"
PEDASTAL USING 3/8" GR-8 MICRO-SWITCH TO
HARDWARE AND NYLOC NUTS. 3
BE POSITIONED
AND MOUNTED 1
DURING ASSEMBLY. 8
-NOT SHOWN- 9
2 4 2 1
2 1 5
DETAIL B 1
SCALE 1 : 4
C A A C
1
1
CAT CLUTCH SENSOR; CAT #214-4863 8 CAT PEDAL #207-4922

1 CAT PEDAL #207-4922
CAT CLUTCH SENSOR; CAT #214-4863

8
BLACK RETURN SPRING 1
-NOT SHOWN FOR CLARITY-
SHAFT TO
1/8 KEEPER
B B
1
42"
RE-USE ORIGINAL CLEVIS HARDWARE.
3
1 DRILL AND TAP
5 SUPPORT TAB
FOR 1/4" BOLT
1 CAT PEDAL #207-4922
C DETAIL C
SCALE 1 : 4
1
1 3
6 16 "
6 * ____ REQUIRED
1
2 5
2
4 16 "
7
RE-USE ORIGINAL PEDAL DIMENSIONS ARE IN INCHES
STOP; CAT #172-4211 TOLERANCES: CHECKED JLW 6/12/2017 TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES. 1 FRACTIONAL 1/16
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 INCHING PEDAL
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH SECTION A-A
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE.
NOTE: THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
B 927419 0
8.
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING.
ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
1) UNLESS OTHERWISE NOTED, ALL GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WELDS TO BE 3/16" FILLET ALL-AROUND. WITHOUT THE WRITTEN PERMISSION OF
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Number (lbs)
1 1 MOUNT PLATE PL.188X96 0.23 90181145083
2 1 UPPER MOUNT PLATE PL.188X96 0.55 90181145084
3 1 EXHAUST PIPE 9200004EXHT 9.51 90181145092
4 1 4" EXHAUST ELBOW MODIFICATION 3.06 91081926393

CAT EXHAUST MOD - MIXING
5 1 0 91081926395
SECTION
D 6 1 CAT EXHAUST MOD - TIP SECTION 0 91081926397 D
B
6 3
25° 1 1
5
3 1
54"
2 4
10°
1 1
6" B
END OF TIP APPROX. FLUSH WITH

1
REAR OF ENGINE COWLING.
1
C C
SLOPE ENTIRE EXHAUST SYSTEM TOWARD

REAR OF MACHINE SLIGHTLY. TYP
3/16 1/8
3/16
1
C
8"
5
11 8 "
.5° A
C
RE-USE FACTORY EXHAUST CLAMP
B B
A
* ____ REQUIRED

TOLERANCES: CHECKED ETR 1/3/2017 TITLE:
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 120K2 STANDARD
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. THREE PLACE DECIMAL .003 EXHAUST
MODIFICATION
SIZE DWG. NO. REV
B 926392 0
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
D D
13"
34"
1
21"± 2 "
-REMOVE 13" FROM BODY AND ROD OF

CYLINDER FROM THIS SIDE OF THE TRUNION MOUNT.
C -CYLINDER SHOP TO DETERMINE BEST LOCATION C
FOR CUTS.
11
54 16 "
11
41 16 "
11
20 16 "
11
20 16 "
B B
NOTES:
-OVERALL LENGTH DIMENSIONS SHOWN ARE
FOR REFERENCE ONLY AND MAY VARY.
-DIMENSION FROM THE TRUNION TO THE TOP
* ____ REQUIRED OF THE CYLINDER IS THE CRITICAL DIMENSION.
132-4926 CYLINDER 132-4926 MODIFIED CYLINDER
NAME DATE
WITH 13" REMOVED FROM UNLESS OTHERWISE SPECIFIED:
BODY AND ROD DIMENSIONS ARE IN INCHES

TOLERANCES: CHECKED CJG 5/30/2017 TITLE:
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED. TWO PLACE DECIMAL .010 120K2 132-4926
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. THREE PLACE DECIMAL .003 CYLINDER
MODIFICATION
SIZE DWG. NO. REV
B 927358 0
8 7 6 5 4 3 2 1
112-5575 - ORIGINAL CYLINDER
24" OF CYLINDER SHIM

INTERNAL FOR STOP
112-5575-M - MODIFIED CYLINDER
NOTE: DO NOT SHORTEN BODY

OR ROD OF CYLINDER
*= 120K2 SIDE SHIFT CYLINDER MODS

** =
*** = +
E.5650 SELTICE WAY POST FALLS,ID 83854 208/664-9291
This design and print are the property of Ground Force

1 N/A REVISED TO SAVE RESOURCES 1/30/2014 CW JLW MFG., L.L.C. Information contained thereon may not be
used or the print reproduced without the written
Rev.No. ECN # Revision note Date Signature Checked permission of Ground Force MFG., L.L.C. 922018
1) CUT AT LOCATIONS SHOWN.
2) WELD TOGETHER AS SHOWN BELOW.
FRONT VIEW - UNCUT
4-1B01
FRONT VIEW - CUT
Item Qty. Stock Material Size GFM Part # Material Weight Lb. Reference
*= 120K CUTTING EDGE MODIFICATIONS

** =
*** = +
JLW 05.27.2015
MFG., L.L.C. Information contained thereon may not be
Rev.No. ECN # Revision note Date Signature Checked permission of Ground Force MFG., L.L.C. 923522
ELECTRICAL
SCHEMATICS

2
RECEP PLUG 1
SPDT MANUAL SPST MANUAL 11 16
SWITCH SWITCH 1< 1- 1 16
2< 2-
3< 3-
4< 4- SPARE
F1 14G YELLOW
5< 5- REAR LIGHTS MH04- 01 MH02- 01
6< 6- 14G YELLOW
R1 MH04- 03 MH02- 03
14G RED
SPARE MH04- 04 MH05- 02
14G RED
F2 MH05- 01 MH02- 04
BLACK
RECEP PLUG MH03- 02 MH01-
A< A-
BATTERY D1 SPARE
B< B-
C< C- 3 F3 RED
+ - 16 9 3 TYP FUSE BOX R2
16 8 D10 RH10
87
D2 SPARE
F4 D9 86 87a 85 B10 GROUND
RH04
A- 30
SPARE MH04 MH02 B9
B- F5
A-
B-
C-
X1 33
4
1
2
308 YELLOW 1<
2<
14G YELLOW
1-
2-
308 YELLOW
RED
14G YELLOW A-
C- A- SPARE 390 YELLOW 3< 3- 390 YELLOW RED
F6 1 14G RED B-
B- FUSE CONNECTOR 4 105 RED 4< 4- 105 RED 2 AMP
A9 C-
C- OTHER THAN
DEUTSCH FIRE SUPPRESSION
1- 1< RH10 PRESSURE SWITCH
SPARE BROWN RED
F7 RH01- 01 RH03- 01 2- 2< FUSE BOX RH11
BROWN
RH01- 02 RH10- C3
BROWN MH05 RH12
RELAY RELAY LOGIC RH01- 03 RH02- 01
BLACK
87 SPARE RH02- 02 RH03- 02
F8 YELLOW OVER BLACK RH10- C4
RED
RH05- 01
86 85
86 87a 85 330C04 PINK
RH10- D2 RH06- 01
87a RED
SHUTDOWN RH06- 03 RH07- 01
RED 15 AMP
30 30 RH06- 04 RH09- 01 L1
ENGINE F9 2 AMP 1 RH08- 01
BLACK
RH05- 02
14G RED
87 SHUTDOWN 16 BLACK
RH08- 02 RH07- 02
BLACK
R2 R LIGHTS RH08- 03 RH09- 02
RED RED
F10 7.5 AMP RH10- D1 RH10- B3 RH10- B4
RED
RH10- B1 RH09- A10
BLACK
RH10- B2 RH04-
RED
RH10- A9 RH11- B BACKUP SIGNAL BUSS
1 1 RED
16 RH10- D9 RH11- A RH01
16 RED
RH10- D10 RH12- 01 BROWN
RED 1-
RH10- B9 RH12- 02 FUSE BOX R1
BLACK 2-
RH10- B10 RH04- D2 RH10
3-
87
4-
D1 86 87a 85 B2 GROUND
RH04
WORK LIGHT 30 BACKUP LIGHT
B1 7.5 AMP CHASSIS BACKUP PLUG
GROUND BUSS BACKUP SIGNAL BUSS A10 RH02
RH08 RH01 BROWN
BUSE BOX RH10 1- 1<
DT06-4S-CE04 DT06-4S-CE04 BLACK
RH10 FUSE BOX 2- 2< RH03
5 6 5
WORK LIGHT BACKUP LIGHT DIODE D1

POWER BUSS BACKUP LIGHT RH10
RH06 RH02 B3 C3 RED CHASSIS WORK LIGHT PLUG
DT06-4S-CE04 DT06-2S-CE04 B4 C4 RED
GROUND 1<
PINK RH05
RH04 2<
10 6 5
CHASSIS WORK
PRESSURE SWITCH CHASSIS BACKUP PLUG WORK LIGHT PLUG
LIGHT PLUG
RH11 RH03 RH07
RH05
DT06-2S-CE04 DT04-2P-CE04 DT06-2S-CE04
DT04-2P-CE04
120
1-
120 8 WORK LIGHT PLUG
BREAKER WORK LIGHT 2-
3 5 RED
RH04 POWER BUSS 3- 1-
RED RH07
RH06 4- 2-
6
RH09 DT06-2S-CE04 BLACK
25 56 19 20 56 1-
BLACK WORK LIGHT PLUG
WORK LIGHT 2-
BLACK
GROUND BUSS 3- 1-
RH09
RH08 4- 2-
MOLD BOARD LIGHT

EXTENTION
DH02
DT04-3P-CE04 PINK MID DS LIGHT
6 LH07- 01 LH01- 01 LIGHT SUPPLY 1< 1-
PINK LH03
LH07- 02 LH03- 01 2< 2- RED
PINK LH01 CH01- 01 CH02- 01
LH07- 03 LH04- 01 ORANGE BRAKE LIGHT RED BRAKE LIGHT SWITCH BRAKE LIGHT CHASSIS
PINK CH01- 02 CH02- 02 1< 1-
LH07- 04 LH02- 01 WHITE VALVE PLUG ORANGE PLUG
PINK PINK CH03- 01 CH04- 01 2< 2-
INCHING PEDAL LH07- 05 LH05- 01 1- BLACK CH01 CH02
SWITCH CHASSIS CS CAB DISCONNECT PINK PINK CH03- 02 CH04- 02
LH07- 06 LH06- 01 2- WHITE
PLUG DH03 DT06-6S 14G RED BLACK LIGHT POWER BUSS PINK CH05- 01 CH06- 01
DH01- A DH02- A INCHING PEDAL LH08- 01 LH01- 02 3- BLACK
DH04 14G YELLOW PINK BLACK PINK FRONT DS LIGHT CH05- 02 CH06- 02
DH01- B DH02- B LIMIT SWITCH PH01- 01 PH03- A LH08- 02 LH03- 02 LH07 4- 1-
14G BLACK 5 BLUE ORANGE WHITE LH BRAKE PRESSURE LH BRAKE PRESSURE
DT04-3P-CE04 DH01- C DH02- C PH03 PH01 PH01- 02 PH03- B BLACK PINK LH04 CH07- 01 CH08- A LH BRAKE PRESSURE 1< 1-
6 RINGS YELLOW LH08- 03 LH04- 02 5- 2- BROWN WHITE CHASSIS PLUG
PINK PINK PH01- 03 PH03- C BLACK PINK CH07- 02 CH08- B VALVE PLUG CH03 2< 2-
DH03- 01 DH04- A A- 1< PH02 LH08- 04 LH02- 02 6- GREEN
6 BLUE GREEN BLACK CH07- 03 CH08- C CH04
LONG FRAME DH03- 02 DH04- B BLUE PH01- 04 PH02- NO LH08- 05 LH05- 02
YELLOW INCHING PEDAL INCHING PEDAL B- 2< BLUE RED
DH03- 03 DH04- C YELLOW PH01- 05 PH02- C BLACK CH07- 04 CH09- 01
SWITCH C- 3< BLUE LH08- 06 LH06- 02 BLACK
GREEN GREEN PH01- 06 PH02- NC CH07- 05 CH09- 02
DH03- 04 DH05- A PH02 4 < E974-CB91 1< RH BRAKE PRESSURE RH BRAKE PRESSURE
BLUE LIGHT SUPPLY BLACK
DH03- 05 DH05- B BLUE 2< 1- FRONT CS LIGHT RH BRAKE PRESSURE 1< 1- CHASSIS PLUG
INCHING PEDAL BLUE 5 < J765-CB92 LH02 BLACK
DH03- 06 DH05- C BLUE INCHING PEDAL LH05 VALVE PLUG CH05 2< 2-
CHASSIS PLUG 6 < C977-CB96 2- CH06
MOLD BOARD LIGHT POSITION SENSOR CS CAB DISCONNECT
DH05 EXTENTION DT06-3S-CE04 PH01 DT04-6P BLACK
9 20 LIGHT 1-
DT04-3P-CE04 DH01 DT06-3S-CE04 PH03 BLACK
6 44 6 GROUND 2- THROTTLE POSITION SWITCH
BLACK A< THROTTLE POSITION
BUSS 3-
MID DS LIGHT LH08 BLACK BRAKE LIGHT CHASSIS B< SENSOR CHASSIS PLUG
LIGHT GROUND BUSS 4- 1- MID CS LIGHT
LH03 BLACK PLUG C< CH08
LH08 5- 2- LH06 ORANGE
DT06-2S-CE04 BLACK CH02 1-
DT06-6S 6- BROWN
10 DT04-2P-CE04 CS CAB DISCONNECT 2-
GREEN
5 CH07 3-
RED BRAKE PEDAL LIMIT SWITCH BRAKE LIMIT SWITCH
4- 1< CHASSIS PLUG
INCHING PEDAL BLACK
4 5- 2<
SWITCH CHASSIS CS CAB DISCONNECT CH09
6-
PLUG DH03 DT06-6S
DH04 FRONT DS LIGHT FRONT CS LIGHT LH BRAKE PRESSURE
LIGHT SUPPLY
DT04-3P-CE04 LH04 LH05 CHASSIS PLUG
6 LH02
DT06-2S-CE04 DT06-2S-CE04 CS CAB DISCONNECT
DT06-2S-CE04 LIGHT POWER CH04
SHORT FRAME CH07
BRAKE PEDAL LIMIT 5 BUSS DT04-2P-CE04
ORANGE DT06-2S-CE04
PH06 PH04 SWITCH PH04- 01 PH06- A 5
6 BROWN LH07
PINK ORANGE PH04- 02 PH06- B 12 SHORT FRAME
DH03- 01 DH04- A A- 1< RINGS GREEN 4 DT06-6S 15
BLUE THROTTLE POSITION BROWN PH04- 03 PH06- C
DH03- 02 DH04- B B- 2< PH05 RED
INCHING PEDAL YELLOW BRAKE PEDAL SENSOR GREEN PH04- 04 PH05- C 5
DH03- 03 DH04- C LIMIT SWITCH C- 3< BLACK
CHASSIS PLUG GREEN RED PH04- 05 PH05- NO
DH03- 04 DH05- A 4<
DH05 BLUE PH05 RH BRAKE PRESSURE BRAKE LIGHT
DH03- 05 DH05- B BLACK LIGHT SUPPLY MID CS LIGHT
DT04-3P-CE04 BLUE 5< CHASSIS PLUG VALVE PLUG
6 44 DH03- 06 DH05- C LH01 LH06
6< THROTTLE POSITION CH06 CH01
DT06-2S-CE04 DT06-2S-CE04
SENSOR CS CAB DISCONNECT 15 25 27 45 78 DT04-2P-CE04 DT06-2S-CE04
DT06-3S-CE04 5 8
18 22 PH04 DT04-6P
PH06
14G RED MOLD BOARD LIGHTS MOLD BOARD LIGHT

MOLD BOARD LIGHT A- A< EXTENTION
14G YELLOW THROTTLE POSITION LH BRAKE PRESSURE
EXTENTION DH01 B- B< DH02
14G BLACK SENSOR CHASSIS PLUG VALVE PLUG
C- C<
CH08 CH03
DT04-2P-CE04 DT06-2S-CE04
5 8
MID DS LIGHT
INCHING PEDAL SWITCH INCHING PEDAL LIGHT GROUND BUSS
A< LH03 LH08
PINK SWITCH CHASSIS
1- B< DT06-2S-CE04 DT06-6S
CS CAB BLUE PLUG
2- C< 50
DISCONNECT YELLOW DH04 BRAKE LIMIT SWITCH RH BRAKE PRESSURE
3- CHASSIS PLUG
DH03 GREEN VALVE PLUG
4- CH09
BLUE INCHING PEDAL CH05
5- A< INCHING PEDAL 4 DT06-2S-CE04
BLUE DT06-2S-CE04
6- B< CHASSIS PLUG 5 45 8
C< DH05 FRONT DS LIGHT FRONT CS LIGHT
LIGHT SUPPLY
LH04 LH05
LH02
DT06-2S-CE04 LIGHT POWER
5 BUSS
LH07
4 DT06-6S 40
40 LONG FRAME
LIGHT SUPPLY MID CS LIGHT

LH01 LH06
15 20 24 24 96
330C04 ELECTRICAL
WORLDWIDE
WORLD'S FINEST MINE SUPPORT EQUIPMENT

Rev.No. ECN # Revision note Date Signature Checked permission of Ground Force MFG., L.L.C.
MOLD BOARD LIGHT
EXTENTION
DH02
DT04-3P-CE04
6
INCHING PEDAL
SWITCH CHASSIS CS CAB DISCONNECT
PLUG DH03 DT06-6S 14G RED
DH01- A DH02- A INCHING PEDAL
DH04 14G YELLOW PINK
DH01- B DH02- B LIMIT SWITCH PH01- 01 PH03- A
14G BLACK 5 BLUE
DT04-3P-CE04 DH01- C DH02- C PH03 PH01 PH01- 02 PH03- B
6 PINK RINGS YELLOW
DH03- 01 DH04- A PINK PH01- 03 PH03- C
6 BLUE A- 1< PH02 GREEN
LONG FRAME DH03- 02 DH04- B BLUE PH01- 04 PH02- NO
YELLOW INCHING PEDAL INCHING PEDAL B- 2< BLUE
DH03- 03 DH04- C YELLOW PH01- 05 PH02- C
GREEN SWITCH C- 3< BLUE
DH03- 04 DH05- A GREEN PH01- 06 PH02- NC
BLUE PH02 4 < E974-CB91
DH03- 05 DH05- B BLUE
INCHING PEDAL BLUE 5 < J765-CB92
DH03- 06 DH05- C BLUE INCHING PEDAL
CHASSIS PLUG 6 < C977-CB96 POSITION SENSOR
MOLD BOARD LIGHT CS CAB DISCONNECT
DH05 EXTENTION DT06-3S-CE04 PH01 DT04-6P
9 20
DT04-3P-CE04 DH01 DT06-3S-CE04 PH03
6 44 6
INCHING PEDAL
SWITCH CHASSIS CS CAB DISCONNECT
PLUG DH03 DT06-6S
DH04
DT04-3P-CE04
6
SHORT FRAME
BRAKE PEDAL LIMIT ORANGE
PH06 PH04 SWITCH PH04- 01 PH06- A
PINK 6 BROWN
DH03- 01 DH04- A ORANGE PH04- 02 PH06- B
A- 1< RINGS GREEN
BLUE THROTTLE POSITION BROWN PH04- 03 PH06- C
DH03- 02 DH04- B B- 2< PH05 RED
INCHING PEDAL YELLOW BRAKE PEDAL SENSOR GREEN PH04- 04 PH05- C
DH03- 03 DH04- C LIMIT SWITCH C- 3< BLACK
CHASSIS PLUG GREEN RED PH04- 05 PH05- NO
DH03- 04 DH05- A 4<
DH05 BLUE PH05
DH03- 05 DH05- B BLACK
DT04-3P-CE04 BLUE 5<
6 44 DH03- 06 DH05- C 6< THROTTLE POSITION
SENSOR CS CAB DISCONNECT
DT06-3S-CE04 PH04 DT04-6P
18 22
PH06
14G RED MOLD BOARD LIGHTS MOLD BOARD LIGHT

MOLD BOARD LIGHT A- A< EXTENTION
14G YELLOW
EXTENTION DH01 B- B< DH02
14G BLACK
C- C<
INCHING PEDAL SWITCH INCHING PEDAL

A<
PINK SWITCH CHASSIS
1- B<
CS CAB BLUE PLUG
DISCONNECT 2- C<
YELLOW DH04
3-
DH03 GREEN
4-
BLUE INCHING PEDAL
5- A< INCHING PEDAL
6- BLUE
B< CHASSIS PLUG
C< DH05
330C04 MISC HARNESSES

WORLDWIDE

PINK MID DS LIGHT
LH07- 01 LH01- 01 LIGHT SUPPLY 1< 1-
PINK LH03
LH07- 02 LH03- 01 2< 2- RED
PINK LH01 CH01- 01 CH02- 01
LH07- 03 LH04- 01 ORANGE BRAKE LIGHT RED BRAKE LIGHT SWITCH BRAKE LIGHT CHASSIS
PINK CH01- 02 CH02- 02 1< 1-
LH07- 04 LH02- 01 WHITE VALVE PLUG ORANGE PLUG
PINK PINK CH03- 01 CH04- 01 2< 2-
LH07- 05 LH05- 01 1- BLACK CH01 CH02
PINK PINK CH03- 02 CH04- 02
LH07- 06 LH06- 01 2- WHITE
BLACK LIGHT POWER BUSS PINK CH05- 01 CH06- 01
LH08- 01 LH01- 02 3- BLACK
BLACK PINK FRONT DS LIGHT CH05- 02 CH06- 02
LH08- 02 LH03- 02 LH07 4- 1- ORANGE WHITE LH BRAKE PRESSURE LH BRAKE PRESSURE
BLACK PINK LH04 CH07- 01 CH08- A LH BRAKE PRESSURE 1< 1-
LH08- 03 LH04- 02 5- 2- BROWN WHITE CHASSIS PLUG
BLACK PINK CH07- 02 CH08- B VALVE PLUG CH03 2< 2-
LH08- 04 LH02- 02 6- GREEN CH04
BLACK CH07- 03 CH08- C
LH08- 05 LH05- 02 RED
BLACK CH07- 04 CH09- 01
LH08- 06 LH06- 02 BLACK
CH07- 05 CH09- 02
LIGHT SUPPLY 1< BLACK RH BRAKE PRESSURE RH BRAKE PRESSURE
2< 1- FRONT CS LIGHT RH BRAKE PRESSURE 1< 1- CHASSIS PLUG
LH02 VALVE PLUG CH05 BLACK
2- LH05 2< 2-
CH06
BLACK
LIGHT 1-
BLACK
GROUND 2- THROTTLE POSITION SWITCH
BLACK A< THROTTLE POSITION
BUSS 3-
MID DS LIGHT LH08 BLACK BRAKE LIGHT CHASSIS B< SENSOR CHASSIS PLUG
LIGHT GROUND BUSS 4- 1- MID CS LIGHT
LH03 BLACK PLUG C< CH08
LH08 5- 2- LH06 ORANGE
DT06-2S-CE04 BLACK CH02 1-
DT06-6S 6- BROWN
10 DT04-2P-CE04 CS CAB DISCONNECT 2-
GREEN
5 CH07 3-
RED BRAKE PEDAL LIMIT SWITCH BRAKE LIMIT SWITCH
4- 1< CHASSIS PLUG
BLACK
4 5- 2<
CH09
6-
FRONT DS LIGHT FRONT CS LIGHT LH BRAKE PRESSURE
LIGHT SUPPLY
LH04 LH05 CHASSIS PLUG
LH02
DT06-2S-CE04 DT06-2S-CE04 CS CAB DISCONNECT
DT06-2S-CE04 LIGHT POWER CH04
5 DT04-2P-CE04 CH07
BUSS DT06-2S-CE04
LH07 5
12 SHORT FRAME
4 DT06-6S 15
5
LIGHT SUPPLY RH BRAKE PRESSURE BRAKE LIGHT

MID CS LIGHT
CHASSIS PLUG VALVE PLUG
LH01 LH06
DT06-2S-CE04 CH06 CH01
DT06-2S-CE04
15 25 27 45 78 DT04-2P-CE04 DT06-2S-CE04
5 8
THROTTLE POSITION LH BRAKE PRESSURE

SENSOR CHASSIS PLUG VALVE PLUG
CH08 CH03
DT04-2P-CE04 DT06-2S-CE04
5 8
MID DS LIGHT
LIGHT GROUND BUSS
LH03 LH08
DT06-2S-CE04 DT06-6S
50
BRAKE LIMIT SWITCH RH BRAKE PRESSURE
CHASSIS PLUG VALVE PLUG
CH09 CH05
4 DT06-2S-CE04 DT06-2S-CE04
5 45 8
FRONT DS LIGHT FRONT CS LIGHT
LIGHT SUPPLY
LH04 LH05
LH02
DT06-2S-CE04 LIGHT POWER
5 BUSS
LH07
4 DT06-6S 40
40 LONG FRAME
LIGHT SUPPLY MID CS LIGHT

LH01 LH06
15 20 24 24 96
330C04 LIGHT HARNESS

WORLDWIDE

14G YELLOW
MH04- 01 MH02- 01
14G YELLOW
MH04- 03 MH02- 03
14G RED
MH04- 04 MH05- 02
14G RED
MH05- 01 MH02- 04
BLACK
MH03- 02 MH01-
RED
FUSE BOX R2
D10 RH10
87
D9 86 87a 85 B10 GROUND

RH04
30
MH04 MH02 B9
14G YELLOW
308 YELLOW 1< 1- 308 YELLOW
2< 2- RED
14G YELLOW A-
390 YELLOW 3< 3- 390 YELLOW RED
14G RED B-
105 RED 4< 4- 105 RED 2 AMP
A9 C-
FIRE SUPPRESSION
1- 1< RH10 PRESSURE SWITCH
BROWN RED
RH01- 01 RH03- 01 2- 2< FUSE BOX RH11
BROWN
RH01- 02 RH10- C3
BROWN MH05 RH12
RH01- 03 RH02- 01
BLACK
RH02- 02 RH03- 02
RED
RH10- C4 RH05- 01
PINK
RH10- D2 RH06- 01
RED
RH06- 03 RH07- 01
RED 15 AMP
RH06- 04 RH09- 01 L1
BLACK 14G RED
RH08- 01 RH05- 02
BLACK
RH08- 02 RH07- 02
BLACK
RH08- 03 RH09- 02
RED RED
RH10- D1 RH10- B3 RH10- B4
RED
RH10- B1 RH09- A10
BLACK
RH10- B2 RH04-
RED
RH10- A9 RH11- B BACKUP SIGNAL BUSS
RED
RH10- D9 RH11- A RH01
RED
RH10- D10 RH12- 01 BROWN
RED 1-
RH10- B9 RH12- 02 FUSE BOX R1
BLACK 2-
RH10- B10 RH04- D2 RH10
3-
87
4-
D1 86 87a 85 B2 GROUND
RH04
WORK LIGHT 30 BACKUP LIGHT
B1 7.5 AMP CHASSIS BACKUP PLUG
GROUND BUSS BACKUP SIGNAL BUSS A10 RH02
RH08 RH01 BROWN
BUSE BOX RH10 1- 1<
DT06-4S-CE04 DT06-4S-CE04 BLACK
RH10 FUSE BOX 2- 2< RH03
5 6 5
WORK LIGHT BACKUP LIGHT DIODE D1

POWER BUSS BACKUP LIGHT RH10
RH06 RH02 B3 C3 RED CHASSIS WORK LIGHT PLUG
DT06-4S-CE04 DT06-2S-CE04 B4 C4 RED
GROUND 1<
PINK RH05
RH04 2<
10 6 5
CHASSIS WORK
PRESSURE SWITCH CHASSIS BACKUP PLUG WORK LIGHT PLUG
LIGHT PLUG
RH11 RH03 RH07
RH05
DT06-2S-CE04 DT04-2P-CE04 DT06-2S-CE04
DT04-2P-CE04
120
1-
BREAKER WORK LIGHT 2-
3 5 RED
RH04 POWER BUSS 3- 1-
RED RH07
RH06 4- 2-
6
RH09 DT06-2S-CE04 BLACK
25 56 19 20 56 1-
BLACK WORK LIGHT PLUG
WORK LIGHT 2-
BLACK
GROUND BUSS 3- 1-
RH09
RH08 4- 2-
330C04 REAR HARNESS

WORLDWIDE

RECEP PLUG
SPDT MANUAL SPST MANUAL
SWITCH SWITCH 1< 1-
2< 2-
3< 3-
4< 4-
5< 5-
6< 6-
RECEP PLUG
A< A-
BATTERY
B< B-
+ - C< C-
A-
B-
A- C-
B-
C- A-
B- FUSE CONNECTOR
C- OTHER THAN
DEUTSCH
RELAY RELAY LOGIC

87
86 85
86 87a 85
87a
30 30
87
KEY
WORLDWIDE

HOSE LIST

330C04 HOSE LIST; 120K2; LONG SPINE HOSE
FACE LENGTH
CUT LENGTH
CLOCKING
FACE-TO-
(IN.)
HOSE # FROM FITTING TO FITTING SIZE SPEC
RIGHT SIDE SPOOL C/S
000 REAR ARTICULATION PORT A #6 90° FF TEE @ FRAME FOR ARTICULATION #6 ST FF MALE #6 487/722 38 40-1/8"
001 REAR ARTICULATION PORT B #6 90° FF TEE @ FRAME FOR ARTICULATION #6 ST FF MALE #6 487/722 38 40-1/8"
002 CENTER SHIFT TOP PORT #6 ST FF BLIND END OF CYLINDER #6 90° FF #6 487/722 300 302-1/16"
003 CENTER SHIFT BOTTOM PORT #6 ST FF ROD END OF CYLINDER #6 45° FF #6 487/722 318 320-1/4"
004 WHEEL LEAN TOP PORT #6 ST FF BLIND END OF CYLINDER #6 90° FF #6 487/722 186 188-1/16"
005 WHEEL LEAN BOTTOM PORT #6 ST FF ROD END OF CYLINDER #6 45° FF #6 487/722 186 188-1/4"
006 RIGHT SIDE BLADE BOTTOM PORT #8 ST FF RIGHT SIDE LIFT CYLINDER #8 45° FF #8 487/722 121 123-1/2"
007 RIGHT SIDE BLADE TOP PORT #6 ST FF RIGHT SIDE LIFT CYLINDER #6 90° FF #6 487/722 144 146-1/16"
008 LOAD SENSE #6 ST FF LOAD SENSE PORT ON SIDE OF PUMP #6 ST FF #6 487/722 78 79-13/16"
009 RETURN #12 ST FF RETURN PORT ON PUMP #12 ST FF #12 487/722 74 76-1/2"
010 PRESSURE #12 90° FF PRESSURE PORT ON PUMP #12 ST FF #12 487/722 73 76-5/16"
LEFT SIDE SPOOL D/S
011 BLADE TILT PORT #6 90° FF TOP PORT #6 ST FF #6 487/722 276 278-1/16"
012 BLADE TILT PORT #6 45° FF BOTTOM PORT #6 ST FF #6 487/722 270 272-1/4"
013 LEFT SIDE BLADE TOP PORT #6 90° FF LEFT SIDE CYLINDER LIFT #6 ST FF #6 487/722 144 146-1/16"
014 LEFT SIDE BLADE BOTTOM PORT #8 45° FF LEFT SIDE CYLINDER LIFT #8 ST FF #8 487/722 121 123-1/2"
015 BLADE SIDE SHIFT TOP PORT #6 90° FF TOP PORT #6 ST FF #6 487/722 273 275-1/16"
016 BLADE SIDE SHIFT BOTTOM PORT #6 45° FF BOTTOM PORT #6 ST FF #6 487/722 268 270-1/4"
017 BLADE ROTATE TOP PORT #8 ST FF TOP PORT #8 90° FF #8 487/722 256 258-5/16"
018 BLADE ROTATE BOTTOM PORT #8 ST FF BOTTOM PORT #8 45° FF #8 487/722 253 255-1/2"
019 LOAD SENSE #6 ST FF LOAD SENSE PORT ON SIDE OF PUMP #6 90° FF #6 487/722 70 72-1/16"
020 RETURN #12 ST FF RETURN PORT ON PUMP #12 ST FF #12 487/722 67 69-1/2"
021 PRESSURE #12 90° FF PRESSURE PORT ON PUMP #12 ST FF #12 487/722 64 67-5/16"
STEERING HOSES
200 RIGHT SIDE STEERING #12 ST FF FRONT STEERING CYLINDER #12 ST FF #12 487/722 120" 122-1/2"
201 LEFT SIDE STEERING #12 ST FF FRONT STEERING CYLINDER #12 ST FF #12 487/722 111" 113-1/2"
BRAKE HOSES
300 BRAKE VALVE CURBSIDE #6 ST MNPT RIGHT SIDE REAR BRAKE #6 ST MNPT #6 487/722 36" 38-11/16"
301 BRAKE VALVE CURBSIDE #6 ST MNPT RIGHT SIDE AIR TANK #6 ST MNPT #6 487/722 36" 38-11/16"
302 BRAKE VALVE DRIVERSIDE #6 ST MNPT LEFT SIDE REAR BRAKE #6 ST MNPT #6 487/722 36" 38-11/16"
303 BRAKE VALVE DRIVERSIDE #6 ST MNPT LEFT SIDE AIR TANK #6 ST MNPT #6 487/722 36" 38-11/16"
304 BRAKE VALVE #4 ST MNPT SERVICE BRAKE VALVE #4 ST MNPT #4 487/722 55" 57-1/2"
330C04 HOSE LIST.xlsm

1OF1
MASTER PARTS LIST

MASTER PARTS LIST
52,000 gal. Water Body 330C04
PART NUMBER DESCRIPTION PICTURE
Body / Chassis Parts
J844X.25 HOSE 1/4"OD SYNFLEX
32100.75X3 SKIRTBOARD, 3/4" X 3" X 10' W/10GA
9200004EXHT EXHAUST PIPE 4"
92117W41630 EXHAUST ELBOW 4" M/F
Sleeve Bearing, Flanged, PTFE, for 1/2"

92002706T26
Shaft Diameter, 5/8" OD, 1/2" Length
Sleeve Bearing, Flanged, PTFE, for 1"

92002706T43
Shaft Diameter, 1" Length
SEAT, K-GRADER SENTINEL COMPACT

UGI-K0050-SEN
VINYL SUSPENSION
NO IMAGE
UGI-KAB-150436 SENSOR, SEAT
AVAILABLE
SEATBELT, 3" RETRACTABLE KIT -

UGI-SB3-KB
KAB UPPER
10-2X.75 HOSE 3/4" 300 PSI GENERAL PURPOSE
HK1713 CLAMP 1" DIA
PS-BV-300 VELCRO WRAP 3"
PS-BV-400 VELCRO WRAP 4"
KON430032 WHEEL CHOCK, YELLOW
Electrical Parts
60098075738 RELAY 24V SPDT MICRO ISO
7700EL041 SOLENOID, 24VDC NORMALLY

11600EL030 SWITCH, SNAP ACTION 20AMP
CIRCUIT BREAKER, 70A MANUAL

60000CCB070
RESET
60098046250 FUSE - 2 AMP MINI
60098046254 FUSE - 7.5 AMP MINI
MINI FUSE PANEL 3 OR 5 RELAY 10

60098046345
MINI FUSE
LIGHT 12-48V 42W LED FLOOD CRI 90

61075005622
AMP DRAW 3.2/12V 1.6/24V
WARRANT Y

LIMITED WARRANTY
LIMITED WARRANTY
A. GROUND FORCE MANUFACTURING, LLC (GFM) warrants that the specialty equipment manufactured by (GFM), including acces-
sory equipment and parts manufactured by (GFM), shall be free from:
1. Defects in material and workmanship furnished by (GFM) and used in the fabrication thereof;
2. Defects arising from the selection of materials or processes of manufacture;
3. Defects in the design thereof in view of the state of the art on the date hereof.
The foregoing warranty shall apply also to accessories, equipment, and parts manufactured to (GFM) detailed design and
specifications and supplied to (GFM) by other manufacturers.
B. (GFM) makes no warranty with regard to component parts not manufactured by (GFM), but agrees to assign to the purchaser
all of its rights under any original manufacturer’s warranty covering such component parts and agrees to assist the purchaser
in making such contacts with the manufacturer of such component parts as may be necessary to protect its right under the
warranty covering them.
C. In case of defects in materials, defects in workmanship, defects arising from the selection of material or processes of manu-
facture, or defects inherent in the design, such defects must become apparent in the machine, accessory, equipment, or part
manufactured by (GFM) within one calendar year or 5,000 hours of operations, whichever shall first expire after the equip-
ment is commissioned by the original purchaser. It is required that the original purchaser complete the Product Registration
Form within 45 days from the time the equipment is placed into service. Failure to complete the Product Registration Form will
void the warranty. The date of commissioning must be within 12 months from the original date of invoice by GFM. End user
must provide all information, which is relevant to the warranty, to GFM upon request. GFM reserves the right to determine
what information is relevant.
The extent of (GFM) liability under this warranty, as to defects in materials, defects in workmanship, defects arising from the
selection of material or processes of manufacture, or defects inherent in the design, is limited to the repair of such defects, or
to the repair or replacement (with a new or rebuilt similar item, free from the defect in question) of any accessory, equipment,
or part manufactured by (GFM), which is defective in any such respects.
D. The (GFM) Limited Warranty does not cover, and (GFM) makes no warranty with respect to:
a. Defects not reported and defective items not returned to (GFM) within the warranty period;
b. Failure and damages due to misapplication, lack of proper maintenance, abuse, improper installation, or abnormal condi-
tions of temperature, moisture, dirt or corrosive matter;
c. Failure due to operation, intentional or otherwise, in any improper manner;
d. Damage caused by components, or parts, or accessories built by others, or which were not manufactured, nor installed,
nor sold by (GFM);
e. Damage that results from continued use of equipment after a defect has become apparent;
f. Item(s) which have/has in any way been altered by anyone other than an authorized representative of (GFM);
g. Damage which occurs during shipment, or otherwise, without the fault of (GFM);
h. Taxes, consumables, environmental fees, or surcharges;
i. Freight, transportation, or shipping;
j. Rental expenses;
k. Travel expenses, including travel labor, mileage, lodging and meals;
E. (GFM) shall in no way be liable for any expenses incurred by the purchaser in any attempt to repair, replace, or rework any
originally defective item of sale. (GFM) shall in no way be liable for any losses, costs, forfeiture or damages (including loss of
profits, liabilities of the purchaser, its customers, or third persons, and all other consequential damages), whether direct or
indirect, and whether or not resulting from, or contributed to by the default, or negligence of (GFM), its agents, employees and
subcontractors, which might be claimed as a result of the defect, use, or failure of the item delivered.
Except as stated, there is no warranty, express or implied, in connection with the design, manufacture, sale, service or use of
the machinery, accessories, equipment and parts sold by (GFM). (GFM) liability on its warranty shall in no event exceed the
cost of the item of sale.
Effective October, 2016

DISTRIBUTOR WARRANTY
DISTRIBUTOR WARRANTY POLICY
GROUND FORCE MANUFACTURING, LLC (GFM) will allow warranty claims for repairs on (GFM) manufactured
equipment per the terms laid out in this warranty policy. All claims must follow the rules set forth in this
policy; no other payment schedule will be recognized by (GFM). Proper procedure, including paper work,
must be followed for warranty to be considered. The following warranty schedule will be applicable:
• Labor will be credited at 80% of the Distributor’s prevailing in-shop service charge (at the time the repair
is performed) up to, but not to exceed $80 per hour for straight time, or $100 per hour for approved
overtime.
• Normally only straight time labor rate based on a 10 hour/day schedule will be paid. Overtime labor rate
applies to labor over 10 hours worked on any day on (GFM) equipment ONLY. For example, if the tech-
nician works for a number of hours on other equipment and their hours move into overtime pay when
they are working on (GFM) equipment, only straight time labor will be paid until they have worked for 10
hours on the (GFM) equipment, irrespective of how many hours they have been working. Any exceptions
for warranty payment to be made on overtime labor claims must be preapproved by the (GFM) Product
Support Department. Otherwise all labor hours submitted for payment will be paid at straight time.
• A warranty job number must be assigned by (GFM) and referred to in any billing. The warranty job
number expires 90 days from the date it is assigned by (GFM).
• All warranty labor hours are subject to review by (GFM) Product Support Department for validity. Excess
labor hours charged due to Distributor’s technicians’ inexperience or lack of training on the servicing
of (GFM) equipment is not covered under warranty.
• All warranty work, which may entail major repair of (GFM) equipment, is subject to being performed by
(GFM) technicians dispatched from (GFM) plant rather than by Distributor’s technicians. The deci-
sion whether to have (GFM) technicians perform said repair work is solely at the discretion of (GFM).
Major repair work performed by Distributor without pre-approval from (GFM) is subject to claim denial.
• Warranty expenses incurred because of the failure of a component part used by (GFM) in the manufac-
ture of equipment (GFM) builds is subject to coverage under the warranty of the component manu-
facturer in regards to the cost of the part, mileage, and to the labor cost for replacing it. (GFM)
will submit non-GFM manufactured parts returned to (GFM) for warranty consideration to the component
manufacturer; credit will be issued for the part if deemed payable by the component manufacturer
(parts are billed for, when shipped, as per (GFM) Parts Warranty Policy).
• Warranty claims must be made in writing, utilizing the proper forms provided to the Distributor by
(GFM). A detailed labor report will be required for warranty labor consideration.
• Claims arising f ro m defects in materials, defects in workmanship, defects arising from the selection of
material or processes of manufacture, or defects inherent in the design will be c r edited within 60 days
from receipt of the warranty claim documentation at (GFM) if allowed.
• Warranty claims arising from component parts not manufactured by (GFM) will be credited per the respec-
tive manufacturer’s warranty once the respective manufacturer has settled the claim.
This warranty policy supersedes any prior policy or understanding, expressed or implied, relating to war-
ranty on (GFM) manufactured equipment.
Effective August 2016

PARTS WARRANTY
WARRANTY PARTS
GROUND FORCE MANUFACTURING, LLC (GFM) utilizes parts made by many vendors. All vendor component
parts have their respective manufacturer’s warranties. (GFM) makes no warranty with regard to component
parts not manufactured by GFM, but agrees to assign to the purchaser all of its rights under any original
manufacturer’s warranty covering such component parts, and agrees to assist the purchaser in making such
contacts with the manufacturer of such component parts as may be necessary to protect its right under the
warranty covering them.
HOW TO FILE A CLAIM
1. Locate the (GFM) serial number (six digits).

2. Prepare a PO for the replacement part and shipping
3. Call (GFM) at (208) 664-9291 with the serial number of your (GFM) equipment and the purchase order
number and request to speak with the Parts and Product Support Representative for your area.
4. (GFM) will ship the part out to you, along with a Return Materials Authorization (RMA).
5. Replace the failed part and return it, along with the RGA, to the address instructed on the RGA.
6. Upon arrival, (GFM) will route the part to the appropriate vendor for warranty consideration.
7. The vendor will report their findings to (GFM) and either deny the claim or issue a credit.
8. (GFM) will forward the vendor’s findings to you, the customer. If a credit is issued, by the vendor, (GFM)
will pass the credit on to you by issuing a credit to your account.
Effective August, 2016

PRODUCT REGISTRATION
PRODUCT REGISTRATION
(Must be completed and submitted within 45 days of commissioning to activate warranty coverage)
Please visit our Web site to submit your product registration form online.
GROUND FORCE PRODUCT REGISTRATION

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OPERATION & MAINTENANCE MANUAL

UG20K MOTOR GRADER

Ground Force Worldwide

REVISION DATE APPROVED DESCRIPTION

Valued Ground Force customer:

Phone: +1 (208) 664-9291

General E-mail: info@gfworldwide.com

2 SAFETY, OPERATION & MAINTENANCE MANUAL

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 3

BASE MODEL SPECIFICATIONS OPERATING SPECIFICATIONS

4 SAFETY, OPERATION & MAINTENANCE MANUAL

OPERATING SPECIFICATIONS OPERATING SPECIFICATIONS

FORWARD 40 DEGREES FUEL CAPACITY 305 L 80.6 GAL

CIRCLE TRANS/DIFF/FINAL DRIVES 47 L 12.4 GAL

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 7

WARNING 2.5 BATTERY FUMES AND EXPLOSIONS

2.6 FIRE HAZARD

8 SAFETY, OPERATION & MAINTENANCE MANUAL

2.7 ELECTRICAL SHOCK CAN KILL 2.9 PINCH POINT HAZARDS

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 9

2.10 COMPRESSED AIR HAZARDS 2.11 LOCK-OUT/TAG-OUT

10 SAFETY, OPERATION & MAINTENANCE MANUAL

Occupational Safety and Health Administration

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 11

2.13 FIRE EXTINGUISHER USE

12 SAFETY, OPERATION & MAINTENANCE MANUAL

2.14 PERSONAL PROTECTIVE EQUIPMENT

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 13

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 14

MOTOR GRADER COMMISSIONING PROCEDURE

MOTOR GRADER OPERATION PROCEDURES

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 15

16 SAFETY, OPERATION & MAINTENANCE MANUAL

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 17

18 SAFETY, OPERATION & MAINTENANCE MANUAL

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 19

ARTICULATED TOO FAR - TIRE

20 SAFETY, OPERATION & MAINTENANCE MANUAL

CAB AIR FILTER

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 21

WWW.GFWORLDWIDE.COM | +1 (208) 664-9291 22

2 1 CAB COVER SHEET SH16GAX60 46.21 90181117339 15

2 4 3/4" X 7" NC GR8 BOLT PLATED 3.92 0801.075.0700.20

3 8 3/4" FLAT WASHER L-9 0.048 0945.075.0.20

4 4 MOUNTING CAT 1.96 103-4953

5 4 WASHER 22MM X 100MM X 10MM 5.16 8X-0674

D 6 2 ROPS PIN CR4140X2.25C 10.22 90181116372 D

8 4 PLATE WASHER PL.25X60C 2.4 90181116374

9 2 LOWER BOLT PLATE PL.5X60C 6.34 90181116579

10 1 TAG ROPS-120K2 METAL TAG 0 TAGS-ROPS-120K2

-DRILL AND TAP FOR 3/8"-16 7

-INSERT AND SECURE ROPS PINS PRIOR TO BOLTING.

2 1 DS FOOT REST 3.5 91081918215

3 1 CS FOOT REST 5.61 91081918216

4 1 BRAKE/ACCEL PEDAL ASSEMBLY 37.91 91081927420

5 1 DS PEDAL COVER - 120K OPEN CAB 12.16 91081925277

D 6 1 CS PEDAL COVER - 120K OPEN CAB 15.05 91081927423 D

2 MATCH DRILL CAB PAN

UNLESS OTHERWISE SPECIFIED: NAME DATE

2 1 PEDAL MOUNT PLATE PL.188X96 1.45 90181115372

3 1 MOUNT TAB-SMALL PL.375X96 0.53 90181115373

4 1 MOUNT TAB-LARGE PL.75X96 1.59 90181115374

5 1 THROTTLE SPRING MOUNT PL.188X96 1.42 90181115377

D 6 1 DRIVE SHAFT, 1/2"OD X 7 3/4"L 92001346K18 0.43 90181115381 D