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MERLIN

PATHFINDER PFHT-6L

Parts Manual

Serial Number Range PTF-00001 / PTF-00002

PM-PFHT-6L ver: 01-8/12
 Hydraulic Schematics

PM-PFHT-6L ver: 01-8/12 Page 1

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 Electrical Schematics

PM-PFHT-6L ver: 01-8/12 Page 2

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 Control Panel/ Engine Wiring Loom

PM-PFHT-6L ver: 01-8/12 Page 3

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 Section 3 Illustrated Parts Manual
MACHINE LEFT SIDE VIEW
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11
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12

14 15

Item Part No. Qty Description of Part

1 M110-0590 2 Decal – Lift Point
2 M110-0568 1 Control Panel Door Assembly
3 M110-0592 1 Decal – Emergency Stop
4 M110-0572 1 Emergency Stop
5 M110-0573 1 Starter Isolator Switch
6 M110-0593 1 Decal – Tie Down Point
7 M110-0591 1 Decal – Merlin
8 M110-0569 1 Left Door Assembly
9 M110-0571 1 Left Bottom Panel
10 M110-0594 1 Decal – Outrigger Warning
11 M110-0021 1 Outrigger Spring Latch
12 M110-0264 1 Outrigger Assembly
13 M110-0035 1 Left Mudguard
14 M110-0030 1 16” x 6.0J Rim
15 M110-0031 1 225/75 16” Tyre
Not Illustrated
M110-0173 1 Gas Strut (200) with Ball Hinge

PM-PFHT-6L ver: 01-8/12 Page 4

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 MACHINE RIGHT SIDE VIEW
1

3 7

4 8

5 9

6 12

10

11

Item Part No. Qty Description of Part

1 M110-0590 2 Decal – Lift Point
2 M110-0591 1 Decal – Merlin
3 M110-0570 1 Right Door Assembly
4 M110-0594 1 Decal – Outrigger Warning
5 M110-0021 1 Outrigger Spring Latch
6 M110-0264 1 Outrigger Assembly
7 M110-0600 1 Decal – Battery Hazard
8 M110-0571 1 Right Bottom Panel
9 M110-0375 1 Right Mudguard
10 M110-0030 1 16” x 6.0J Rim
11 M110-0031 1 225/75 16” Tyre
12 M110-0593 1 Decal – Tie Down Point
Not Illustrated
M110-0172 1 Gas Strut (300) with Ball Hinge

PM-PFHT-6L ver: 01-8/12 Page 5

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 MACHINE FRONT VIEW

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6
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16 13

17 14

18 21

19

Item Part No. Qty Description of Part

1 M110-0551 1 Lightbar Assembly (See Lightbar Assembly Section)
2 M110-0408 1 Mast Rotation Lock Pin and Spring
3 M110-0068 1 Mast Rotation Screw Lock
4 M110-0033 1 Fire Extinguisher
5 M110-0574 1 Fire Extinguisher Bracket
6 M110-0575 2 Lightbar Tie-Down Eye Hook
7 M110-0595 1 Decal – Crush Zone
8 M110-0444 1 Inlet Vent
9 M110-0221 1 Front Panel
10 M110-0194 1 Front Bottom Panel
11 M110-0444 1 Inlet Vent
12 M110-0395 1 Transport Jack
13 M110-0577 1 Transport Jack Pin
14 M110-0576 1 Transport Jack Bracket Assembly
15 M110-0019 1 Drawbar Lock Pin
16 M110-0578 1 Drawbar Assembly
17 M110-0579 1 Ring Hitch
18 M110-0580 2 Safety Chain Assembly
19 M110-0581 1 Outrigger Jack Assembly
20 M110-0582 1 Mast Rotation Handle Grip
21 M110-0583 1 Trailer Lights Connector

PM-PFHT-6L ver: 01-8/12 Page 6

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 MACHINE REAR VIEW
1

2
11
3

7
9

10

Item Part No. Qty Description of Part

1 M110-0596 1 Decal – Stay Clear of Boom
2 M110-0327 1 Rear Panel
3 M110-0486 1 Exhaust Vent
4 M110-0597 1 Decal – Hot Exhaust
5 M110-0023 2 Trailer Lights
6 M110-0594 1 Decal – Outrigger Warning
7 M110-0598 2 Decal – Forklift Lifting
8 M110-0021 1 Outrigger Spring Latch
9 M110-0264 1 Outrigger Assembly
10 M110-0581 1 Outrigger Jack Assembly
11 M110-0345 1 Rear Mast Rest

PM-PFHT-6L ver: 01-8/12 Page 7

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 MAST HYDRAULIC SYSTEM

PM-PFHT-6L ver: 01-8/12 Page 8

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 MAST HYDRAULIC SYSTEM

Item Part No. Qty Description of Part

1 M110-0507 1 Hydraulic Oil Reservoir
2 M110-0510 1 Max Level Decal
3 M110-0508 3 Solenoid Valve
4 M110-0505 1 Electric Motor
5 M110-0506 1 Relieve Valve Kit
6 M110-0509 1 Solenoid Motor Run 12 Volt

PM-PFHT-6L ver: 01-8/12 Page 9

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 CONTROL PANEL

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22

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20
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19
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 CONTROL PANEL
Item Part No. Qty Description of Part
1 M110-0503 1 Panel Light
2 M110-0480 1 Hour Meter Decal
3 M110-0481 1 Fuel Gauge Decal
4 M110-0465 1 Fuel Gauge
5 M110-0466 1 Hour Meter
6 M110-0472 1 Hydraulic Cylinder Extension Decal
7 M110-0470 3 Hydraulic Control Rocker Switch
8 M110-0483 1 Panel Lock
9 M110-0478 1 Hydraulic Cylinder Retraction Decal
10 M110-0468 1 Beacon Light Toggle Switch
11 M110-0475 1 Beacon Light Decal
12 M110-0470 1 Hydraulic Enable Rocker Switch
13 M110-0474 1 Hydraulic Enable Decal
14 M110-0469 6 10A Light Switch and Breaker
15 M110-0467 1 Light Switch and Breaker Cover
16 M110-0476 1 Light Switch Decal
17 M110-0477 1 Interior Lights Off Decal
18 M110-0471 2 Interior Lights Rocker Switch
19 M110-0473 1 Interior Lights On Decal
20 M110-0461 1 Hatz Key Start Control Switch
21 M110-0479 1 Key Start Decal
22 M110-0482 1 Generator Control Panel Decal

PM-PFHT-6L ver: 01-8/12 Page 11

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 ENGINE & ALTERNATOR ASSEMBLY

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11

7
10
8
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 ENGINE & ALTERNATOR ASSEMBLY
Item Part No. Qty Description of Part
1 M110-0448 1 Engine, Hatz 1B30
2 M110-0449 1 Generator, Mecc Alte AL3
3 M110-0447 4 Engine and Generator Mountings
4 M110-0513 1 Top Battery Tray Clamp
5 M110-0238 2 Battery 12 Volt 90D23L
6 M110-0413 1 Top Battery Tray
7 M110-0437 1 Bottom Battery Tray
8 M110-0511 1 Bottom Battery Tray Clamp
9 M110-0498 1 Double Pole Battery Isolator
10 M110-0419 1 Battery Isolator Mounting Bracket
11 M110-0223 1 Oil Evacuation Pump Bracket
12 M110-0446 1 Oil Evacuation Pump

PM-PFHT-6L ver: 01-8/12 Page 13

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 MAST ASSEMBLY

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17

16
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1
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3 10

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 MAST ASSEMBLY
Item Part No. Qty Description of Part
1 M110-0042 1 Base
2 M110-0054 1 Mount - Rotation
3 M110-0084 1 Link - Lower
4 M110-0085 2 Link - Upper
5 M110-0092 1 Mast - Main
6 M110-0110 1 Mast - Extension
7 M110-0134 2 M2 Pin
8 M110-0283 4 M2 Bushing
9 M110-0135 1 CYD 2 Base Pin
10 M110-0383 2 CYD 2 Base Pin Circlip
11 M110-0133 2 M1 Pin
12 M110-0282 4 M1 Bushing
13 M110-0380 1 CYD 1 Pin
14 M110-0381 2 1” Lockpin
15 M110-0137 1 CYD 3 Base Pin
16 M110-0136 1 Lightbar Pin
17 M110-0382 2 Lightbar Pin Washer
18 M110-0383 2 Lightbar Pin Circlip
The following items are part of the mast assembly, but are not illustrated.
M110-0102 1 Roller
M110-0099 1 Roller bolt
M110-0101 2 Roller bolt washer
M110-0100 1 Roller bolt nut
M110-0584 1 Mast Wearpad Top
M110-0103 2 Mast Wearpad Side
M110-0105 6 Mast Wearpad bolt
M110-0560 6 Mast Wearpad spring washer
M110-0107 6 Mast Wearpad washer
M110-0561 2 M10x40 bolt
M110-0562 2 M10 washer
M110-0563 2 M10 spring washer
M110-0564 1 M10 Jamnut
M110-0426 1 Rubber Mast Rest
M110-0585 2 M8 x 40 bolt
M110-0586 2 M8 washer
M110-0587 2 M8 Jamnut
M110-0588 1 Cable track
M110-0611 2 Cable track M3 mounting bolt
M110-0567 2 Cable track M3 mounting washer
M110-0612 2 Cable track M3 mounting spring washer
M110-0613 4 Cable track M3 mounting nut

PM-PFHT-6L ver: 01-8/12 Page 15

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 MAST ASSEMBLY
Item Part No. Qty Description of Part
M110-0589 2 Cable track M4 mounting bolt
M110-0567 2 Cable track M4 mounting washer
M110-0612 2 Cable track M4 mounting spring washer
M110-0613 4 Cable track M4 mounting nut
M110-0067 3 1/8 BSP Grease Nipple
M110-0566 4 Cable Case Mounting Screw
M110-0567 4 Cable Case Mounting Washers
M110-0565 1 Cable Case Cover
M110-0425 1 CYD 3 Top Pin
M110-0407 2 CYD 3 Top Washer
M110-0383 2 Lightbar Pin Circlip

PM-PFHT-6L ver: 01-8/12 Page 16

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 CYLINDERS

Cylinder Part No. Qty Description

1 M110-0116 1 Lift Cylinder
2 M110-0117 1 Tele Cylinder (Not shown)
3 M110-0404 1 Tilt Cylinder

PM-PFHT-6L ver: 01-8/12 Page 17

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 LIGHT BAR ASSEMBLY

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12

13

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Item Part No. Qty Description of Part

1 M110-0406 2 Lightbar Bushing
2 M110-0552 6 300W Lamp Unit
3 M110-0554 24 Lamp Grip Bolt
4 M110-0555 24 Lamp Grip Bolt Washer
5 M110-0614 24 Lamp Rubber Washer
6 M110-0557 4 M14 Nyloc Nut
7 M110-0558 8 M14 Washer
8 M110-0556 4 M14x70 Bolt
9 M110-0366 6 Lamp Bracket
10 M110-0550 1 Junction Box Assembly
11 M110-0599 1 Decal – Electrical Hazard
12 M110-0575 2 Tie-Down Eye Bolt
13 M110-0586 2 M8 Washer
14 M110-0587 2 M8 Jamnut

PM-PFHT-6L ver: 01-8/12 Page 18

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 OTHER CHASSIS COMPONENTS

Item Part No. Qty Description of Part

Not Illustrated
M110-0028 1 Axle Assembly
M110-0615 4 Wheel Chocks

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 Recommended Parts

Part Number Description Quantity

M110-0552 LED Lamp-300W 1
M110-0496 Fuel Filter In-Line 2
M110-0517 Fuel Filter In-Line Back Up 1
M110-0487 Fuel Filter Fixed 1
M110-0518 Engine Oil Filter 1
M110-0519 Oil Filter Washer 2
M110-0446 Oil Evacuation Pump 1
M110-0494 Fuel Pump Electric 1
M110-0617 Seal Kit - Lift Cylinder 1
M110-0618 Seal Kit - Extension Cylinder 1
M110-0619 Seal Kit - Tilt Cylinder 1
M110-0147 Hose Assembly – Lift Cylinder 1
M110-0515 Hose Assembly – Extension Cylinder 1
M110-0516 Hose Assembly – Tilt Cylinder 1
M110-0488 Filler Cap - Fuel Tank 1
M110-0620 Wear Pad Assembly Top 1
M110-0621 Wear Pad Assembly Sides 2
M110-0102 Guide Roller 1

RP-PFHT-6L ver: 01-8/12 Page 20