Gradall 544B User Manual
®
PART MANUAL
®
®
CORPORATE OFFICE
544B
9104-4337
August 25, 2006
Starting Serial No.
0155299S
GRADALL DIVISION
JLG INDUSTRIES, INC.
1 JLG DRIVE
McConnellsburg, PA
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417
JLG INDUSTRIES, INC.
406 Mill Avenue S.W.
New Philadelphia, OH
44663
USA
Telephone: (330) 339-2211
Fax: (330) 339-8458
INTRODUCTION
Table of Contents
Starting Serial No. 0155299S
Original Issue 3-90
SECTION 1 - INTRODUCTION
Revised 1-19-96
Table of Contents ...................................................................................................... 1-1 thru 1-4
Alphabetical Index................................................................................................... 1-5 thru 1-10
Service Kits ...........................................................................................................................1-11
Part Number Index ................................................................................................ 1-12 thru 1-27
*
SECTION 2 - CHASSIS & ATTACHING PARTS
Frame Shrouding & Trim ........................................................................................................ 2-1
Cab Enclosure, Wiper & Defroster ......................................................................................... 2-2
Heater & Piping ...................................................................................................................... 2-3
Front Axle Cradle & Mounting ................................................................................................ 2-4
Rear Steering Axle & Attaching Parts..................................................................................... 2-5
Outrigger & Attaching Parts.................................................................................................... 2-6
Cab Glass .............................................................................................................................. 2-7
SECTION 3 - BOOMS
First Boom Section................................................................................................................. 3-1
Second Boom Section............................................................................................................ 3-2
Third Boom Section................................................................................................................ 3-3
Fourth Boom Section.............................................................................................................. 3-4
Push Beam & Cables ............................................................................................................. 3-5
Quick Switch Assembly .......................................................................................................... 3-6
SECTION 4 - ATTACHMENTS & ACCESSORIES
Attachments ........................................................................................................................... 4-1
Slope Piler Carriage 66"......................................................................................................... 4-2
SECTION 5 - ENGINE & ATTACHING PARTS
Engine Left Side View ............................................................................................................ 5-1
Engine Right Side View................................................................................................... 5-2, 5-3
Fuel Tank & Lines................................................................................................................... 5-4
Radiator & Hoses ................................................................................................................... 5-5
Ether Starting Kit .................................................................................................................... 5-6
Air Cleaner Piping .................................................................................................................. 5-7
Air Cleaner ............................................................................................................................. 5-8
Exhaust System ..................................................................................................................... 5-9
SECTION 6 - DRIVE TRAIN
Transmission Mounting & Controls......................................................................................... 6-1
Flex Plate & Torque Converter ............................................................................................... 6-2
Case & Converter Housing.............................................................................................. 6-3, 6-4
Transmission Drive Gearing................................................................................................... 6-5
Clutch & Gear Group (Reverse, 2nd & Low) .......................................................................... 6-6
Clutch & Gear Group (Forward, Output & 3rd)....................................................................... 6-7
Clutch Assemblies.................................................................................................................. 6-8
Modulator Valve...................................................................................................................... 6-9
Control Valve........................................................................................................................ 6-10
* Added Part number index pages 1-12 thru 1-27.
1-1KG
INTRODUCTION
Table of Contents
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-16-94
SECTION 6 - DRIVE TRAIN (Continued)
Propeller Shaft ......................................................................................................................6-11
Front Axle Assembly.............................................................................................................6-12
Front Axle Housing............................................................................................................... 6-13
Front Axle Differential Carrier ............................................................................................... 6-14
Front Axle Shaft & Planetary Wheel End.............................................................................. 6-15
Wheels & Tires ..................................................................................................................... 6-16
Planetary Hub ...................................................................................................................... 6-17
Front Axle Service Brakes.................................................................................................... 6-18
Front Axle Parking Brake...................................................................................................... 6-19
SECTION 7 - CONTROLS
Forward & Reverse, Speed Selector...................................................................................... 7-1
Boom Tilt & Sway ................................................................................................................... 7-2
Accelerator Linkage................................................................................................................ 7-3
Steering Column..................................................................................................................... 7-4
SECTION 8 - BRAKES
Hydraulics & Service Brake Lines .......................................................................................... 8-1
Hydraulics & Parking Brake Lines .......................................................................................... 8-2
Brake Pedal & Inching Linkage .............................................................................................. 8-3
Accumulator, Charging Valve & Lines .................................................................................... 8-4
SECTION 9 - HYDRAULIC CIRCUITS
Oil Supply & Pressure Lines............................................................................................ 9-1, 9-2
Dump Circuit ................................................................................................................... 9-3, 9-4
Rear Drive ....................................................................................................................... 9-5, 9-6
Steering.................................................................................................................................. 9-7
Lift Cylinder ............................................................................................................................ 9-8
Crowd Cylinder.............................................................................................................. 9-9, 9-10
Tilt Cylinder ..................................................................................................................9-11, 9-12
Sway Cylinder ...................................................................................................................... 9-13
Joystick Circuit ..................................................................................................................... 9-14
Outrigger Cylinder ................................................................................................................ 9-15
Stabilizer Cylinder ................................................................................................................ 9-16
SECTION 10 - HYDRAULIC COMPONENTS
Lift Cylinder .......................................................................................................................... 10-1
Crowd Cylinder..................................................................................................................... 10-2
Crowd Extension Cylinder .................................................................................................... 10-3
Tilt Cylinder .......................................................................................................................... 10-4
Compensating Cylinder........................................................................................................ 10-5
Sway Cylinder ...................................................................................................................... 10-6
Steering Cylinder.................................................................................................................. 10-7
Stabilizer Cylinder ................................................................................................................ 10-8
KG
1-2
INTRODUCTION
Table of Contents
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-16-94
SECTION 10 - HYDRAULIC COMPONENTS (continued)
Outrigger Cylinder ................................................................................................................ 10-9
Main Control Valve ............................................................................................................. 10-10
Priority Flow Contrlol Valve .................................................................................................10-11
Forward Reverse Control Valve ......................................................................................... 10-12
Series Parallel Control Valve.............................................................................................. 10-13
Solenoid Valve (Three-Way, Two Position) ......................................................................... 10-14
Stabilizer Valve................................................................................................................... 10-15
Outrigger Control Valve ...................................................................................................... 10-16
Accumulator Charge Valve................................................................................................. 10-17
Counterbalance Vavle ........................................................................................................ 10-18
Brake Valve ........................................................................................................................ 10-19
Parking Brake Valve ........................................................................................................... 10-20
Directional Control Valve .................................................................................................... 10-21
Main Hydraulic Pump ......................................................................................................... 10-22
Pilot Pump.......................................................................................................................... 10-23
Rear Drive Motor................................................................................................................ 10-24
Oil Reservoir Filter.............................................................................................................. 10-25
Hydraulic Oil Reservoir....................................................................................................... 10-26
Solenoid Valve (Two Way, Normally Open) ........................................................................ 10-27
Solenoid Valve (Two Way, Normally Closed)...................................................................... 10-28
Hydraulic Controller (Joystick)............................................................................................ 10-29
Dual P.O. Check Valve ............................................................................................ 10-30, 10-31
SECTION 11 - ELECTRICAL
Instrument Panel & Wiring Harness ......................................................................................11-1
Batteries & Cables.................................................................................................................11-2
Boom Section Electrical ........................................................................................................11-3
Miscellaneous Electrical Components...................................................................................11-4
SECTION 12 - MISCELLANEOUS
Frame decals ....................................................................................................................... 12-1
Boom Decals........................................................................................................................ 12-2
SECTION 13 - OPTIONAL EQUIPMENT
Dual Hose Reel Assembly.................................................................................................... 13-1
Dual Hose Reel & Hydraulic System.................................................................................... 13-2
Sway, Auxiliary & Tilt Controls .............................................................................................. 13-3
100 Degree Swing Fork Assembly ....................................................................................... 13-4
100 Degree Drywall Swing Fork Assembly........................................................................... 13-5
180 Degree Swing Frame Assembly ........................................................................... 13-6, 13-7
Swing V alv e Assembly ......................................................................................................... 13-8
Single Hose Reel & Hydraulic System ................................................................................. 13-9
Winch & Hydraulic System ................................................................................................. 13-10
Single Hose Reel Assembly ................................................................................................ 13-11
KG
1-3
INTRODUCTION
Table of contents
Starting Serial No. 0155299S
Original Issue 3-90
Revised 6-1-99
SECTION 13 - OPTIONAL EQUIPMENT (continued)
Winch Assembly .......................................................................................................13-12, 13-13
Hydraulic Cylinder (Jarp).................................................................................................... 13-14
Hydraulic Cylinder (Iowa)................................................................................................... 13-15
Electrics for Auxiliary Hydraulics........................................................................................ 13-16
Chassis Auxiliary Electrics................................................................................................. 13-17
Slope Piler Carriage........................................................................................................... 13-18
Sway Cylinder.................................................................................................................... 13-19
Dual P.O. Check Valve........................................................................................................ 13-20
Six Foot Mast ..................................................................................................................... 13-21
Auxiliary Controls Assembly .............................................................................................. 13-22
Tilt on Joystick.................................................................................................................... 13-23
Cab Enclosure................................................................................................................... 13-24
Block Heater....................................................................................................................... 13-25
Rear Steering Axle Advantage Kit...................................................................................... 13-26
Steering Cylinder ............................................................................................................... 13-27
Rear Axle Rework Kit......................................................................................................... 13-28
*
JH
* Added page 13-28.
1-4
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
ACCELERATOR CABLE ........................................................................................................7-3
ACCELERATOR PEDAL.........................................................................................................7-3
ACCUMULATOR.....................................................................................................................8-4
ACCUMULATOR CHARGE VALVE .............................................................................8-4, 10-17
AIR CLEANER .................................................................................................................5-7, 5-8
AIR CLEANER ELEMENT......................................................................................................5-8
AIR CLEANER SERVICE INDICATOR...................................................................................5-7
ALTERNATOR.........................................................................................................................5-3
ALTERNATOR FAN ................................................................................................................. 5-3
AMMETER ........................................................................................................................... 11-1
ATTACHMENTS......................................................................................................................4-1
AUXILIARY CONTROLS ASSEMBLY ............................................................................... 13-22
BATTERY............................................................................................................................. 11-2
BATTERY CABLES ............................................................................................................. 11-2
BEARING PADS (Boom sections)......................................................................3-1, 3-2, 3-3, 3-4
BOOM DECALS................................................................................................................... 12-2
BOOM SECTIONS.............................................................................................3-1, 3-2, 3-3, 3-4
BOOM SECTIONS ELECTRICAL ....................................................................................... 11-3
BRAKE PEDAL .......................................................................................................................8-3
BRAKE VALVE ................................................................................................................... 10-19
BRAKE WARNING LIGHT ................................................................................................... 11-1
BREATHER (Filler cap)...................................................................................................... 10-26
CAB.........................................................................................................................................2-2
CAB DOOR.............................................................................................................................2-2
CARRIAGE & FORKS ............................................................................................................4-1
CHARGE VALVE (Accumulator)...................................................................................8-4, 10-17
CIRCUIT BREAKERS ......................................................................................................... 11-1
COMPENSATING CYLINDER ............................................................................................. 10-5
COMPENSATING CYLINDER HYDRAULIC CIRCUIT ............................................... 9-11, 9-12
CONTROL VALVES ..........................................10-10, 10-11, 10-12, 10-13, 10-16, 10-18, 10-21
COUNTERBALANCE VALVE ............................................................................................ 10-18
COUNTERWEIGHT................................................................................................................2-1
CRADLE .................................................................................................................................2-4
CRADLE MOUNTING PIN......................................................................................................2-4
CROWD CYLINDER ............................................................................................................ 10-2
CROWD CYLINDER HYUDRAULIC CIRCUIT ............................................................. 9-9, 9-10
CROWD EXTENSION CYLINDER ...................................................................................... 10-3
CROWD EXTENSION HYDRAULIC CIRCUIT .............................................................. 9-9, 9-10
DECALS ......................................................................................................................12-1, 12-2
DECK......................................................................................................................................2-1
DEFROSTER FAN..................................................................................................................2-2
DIRECTIONAL CONTROL VALVE .................................................................................... 10-21
KG
1-5
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
DOOR .....................................................................................................................................2-2
DOOR HANDLES ................................................................................................................... 2-2
DRIVE BELT ...........................................................................................................................5-3
DUAL P.O. CHECK VALVE ............................................................................10-30, 10-31, 13-20
DUMP CIRCUIT...............................................................................................................9-3, 9-4
ELECTRICAL SYSTEMS ...................................................................................11-1, 11-2, 11-4
ELECTRICAL SYSTEMS (boom sections) .......................................................................... 11-3
ENGINE LEFT SIDE VIEW .....................................................................................................5-3
ENGINE MOUNT ....................................................................................................................5-2
ENGINE RIGHT SIDE VIEW...................................................................................................5-2
ENGINE THROTTLE CONTROL ............................................................................................7-3
ETHER STARTING KIT ..........................................................................................................5-6
EXHAUST MANIFOLD ...........................................................................................................5-3
EXHAUST PIPE ......................................................................................................................5-9
EXHAUST STACK ..................................................................................................................5-9
EXHAUST SYSTEM ...............................................................................................................5-9
EXTENSION CABLE ..............................................................................................................3-5
FAN BELT ...............................................................................................................................5-3
FAN GUARD ...........................................................................................................................5-5
FAN SHROUD ........................................................................................................................5-5
FILTERS.....................................................................................................5-2, 6-5, 10-25, 10-26
FILTER ELEMENT ...................................................................................................10-25, 10-26
FIRST BOOM SECTION .........................................................................................................3-1
FIRST BOOM SECTION MOUNTING PIN..............................................................................3-1
FORWARD REVERSE CONTROL VALVE........................................................................ 10-12
FORWARD SHIFT CONTROL ROD .......................................................................................7-1
FOURTH BOOM SECTION ....................................................................................................3-4
FRAME ...................................................................................................................................2-1
FRAME SHROUDING & TRIM................................................................................................2-1
FRONT AXLE ......................................................................................................................6-12
FRONT AXLE BRAKE......................................................................................................... 6-18
FRONT AXLE CRADLE .........................................................................................................2-4
FRONT AXLE DIFFERENTIAL CARRIER .......................................................................... 6-14
FRONT AXLE HOUSING..................................................................................................... 6-13
FRONT AXLE PARKING BRAKE ........................................................................................ 6-19
FRONT AXLE SHAFT & PLANETARY WHEEL END ......................................................... 6-15
FRONT DISC WHEEL & RIM............................................................................................... 6-16
FUEL GAUGE...................................................................................................................... 11-1
FUEL LEVEL SENDER ..........................................................................................................5-4
FUEL LINES ...........................................................................................................................5-4
FUEL TANK & CAP .................................................................................................................5-4
GROUND CABLE ..........................................................................................................5-2, 11-2
KG
1-6
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
HEATER................................................................................................................................. 2-3
HEAT SHIELD ........................................................................................................................ 5-9
HEATER SWITCH.................................................................................................................. 2-3
HOOD .................................................................................................................................... 2-1
HORN....................................................................................................................................11-4
HORN BUTTON....................................................................................................................11-1
HORN RELAY .......................................................................................................................11-4
HORN WIRING ..................................................................................................................... 11-4
HOSE CARRIER..........................................................................................................9-11, 9-12
HOURMETER .......................................................................................................................11-1
HYDRAULIC CIRCUITS.......................................................................................... 9-1 thru 9-16
HYDRAULIC CONTROLLER (Joystick)............................................................................. 10-29
IGNITION SWITCH ...............................................................................................................11-1
INCHING VALVE ............................................................................................................. 8-2, 8-3
INSTRUMENT PANEL ..........................................................................................................11-1
JOYSTICK (Hydraulic Controller)....................................................................................... 10-29
JOYSTICK HYDRAULIC CIRCUIT ...................................................................................... 9-14
KITS ......................................................................................................................................1-11
LIFT CYLINDER................................................................................................................... 10-9
LIFT CYLINDER HYDRAULIC CURCUIT.............................................................................. 9-8
MAIN BOOM SECTIONS .................................................................................. 3-1, 3-2, 3-3, 3-4
MAIN HYDRAULIC PUMP .......................................................................................... 5-1, 10-22
MISCELLANEOUS ELECTRICAL COMPONENTS ..............................................................11-4
MUFFLER .............................................................................................................................. 5-9
NEGATIVE BATTERY CABLE ..............................................................................................11-2
OIL COOLER .................................................................................................................. 9-3, 9-4
OIL FILTER (Hydraulic) ........................................................................................... 10-25, 10-26
OIL PRESSURE GAUGE......................................................................................................11-1
OIL PRESSURE SENDER..................................................................................................... 5-2
OIL RESERVOIR ............................................................................................................... 10-26
OIL SUPPLY & PRESSURE LINES ................................................................................ 9-1, 9-2
OUTRIGGER ARM................................................................................................................. 2-6
OUTRIGGER CONTROL VALVE ....................................................................................... 10-16
OUTRIGGER CYLINDER .................................................................................................... 10-9
OUTRIGGER CYLINDER HYDRAULIC CIRCUIT ............................................................... 9-15
OUTRIGGER SHOE .............................................................................................................. 2-6
KG
1-7
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
PARKING BRAKE LINES....................................................................................................... 8-2
PARKING BRAKE VALVE .................................................................................................. 10-20
PILOT PUMP ..................................................................................................................... 10-23
POSITIVE BATTERY CABLE................................................................................................11-2
PRIORITY FLOW CONTROL VALVE .................................................................................10-11
PROPELLER SHAFT ............................................................................................................6-11
PUSH BEAM & CABLES........................................................................................................ 3-5
QUICK SWITCH ASSEMBLY................................................................................................. 3-6
RADIATOR & HOSES ............................................................................................................ 5-5
REAR AXLE FRAME.............................................................................................................. 2-5
REAR AXLE MOUNTING PIN................................................................................................ 2-5
REAR DRIVE MOTOR ....................................................................................................... 10-24
REAR STEERING AXLE ........................................................................................................ 2-5
REAR STEERING AXLE PLANETARY HUB ...................................................................... 6-17
RELIEF VALVE....................................................................................................................... 8-4
REPAIR KITS ........................................................................................................................1-11
RESERVOIR ...................................................................................................................... 10-26
RESERVOIR FILLER-BREATHER..................................................................................... 10-26
RESERVOIR FILTER ......................................................................................................... 10-20
RESERVOIR SUPPLY CIRCUIT..................................................................................... 9-1, 9-2
RETRACTION CABLES......................................................................................................... 3-5
REVERSE SHIFT CONTROL ROD ....................................................................................... 7-1
SAND BUCKET...................................................................................................................... 4-1
SEAT ...................................................................................................................................... 2-1
SEAT BELT ............................................................................................................................ 2-1
SECOND BOOM SECTION ................................................................................................... 3-2
SERIES PARALLEL VALVE ............................................................................................... 10-13
SERVICE BRAKE LINES....................................................................................................... 8-1
SERVICE KITS ......................................................................................................................1-11
SHUT-OFF VALVES ........................................................................................................ 2-3, 5-2
SIX FOOT MAST................................................................................................................ 13-21
SLOPE PILER CARRIAGE ................................................................................................ 13-18
SOLENOID VALVES .................................................................................... 10-14, 10-27, 10-28
SOLENOID VALVE (Three-Way, Two Position).................................................................. 10-14
SOLENOID VALVE (Two-Way, Normally Closed) .............................................................. 10-28
SOLENOID VALVE (Two-Way, Normally Open)................................................................. 10-27
SPINNER KNOB ................................................................................................................... . 7-4
KG
1-8
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
STABILIZER CYLINDER ..................................................................................................... 10-8
STABILIZER CYLINDER HYDRAULIC CIRCUIT................................................................. 9-16
STABILIZER VALVE........................................................................................................... 10-15
STARTER BUTTON ..............................................................................................................11-1
STARTER MOTOR ................................................................................................................. 5-3
STARTER SOLENOID ........................................................................................................... 5-1
STEERING COLUMN ............................................................................................................ 7-4
STEERING CYLINDER........................................................................................................ 10-7
STEERING CYLINDER HYDRAULIC CIRCUIT..................................................................... 9-7
STEERING KNUCKLES......................................................................................................... 2-5
STEERING ORBITROL.......................................................................................................... 7-4
STEERING WHEEL ............................................................................................................... 7-4
SUPPLY HYDRAULIC CIRCUIT ..................................................................................... 9-1, 9-2
SWAY CONTROL HANDLE & LINKAGE ............................................................................... 7-2
SWAY CYLINDER..................................................................................................... 10-6, 13-19
SWAY CYLINDER HYDRAULIC CIRCUIT........................................................................... 9-13
THIRD BOOM SECTION ....................................................................................................... 3-3
TIE ROD ARM........................................................................................................................ 2-5
TILT CONTROL HANDLE & LINKAGE .................................................................................. 7-2
TILT CYLINDER ................................................................................................................... 10-4
TILT CYLINDER HYDRAULIC CIRCUIT......................................................................9-11, 9-12
TILT ON JOYSTICK ........................................................................................................... 13-23
TORQUE CONVERTER ......................................................................................................... 6-2
TRANSMISSION.................................................................................................................... 6-1
TRANSMISSION CASE & CONVERTER HOUSING...................................................... 6-3, 6-4
TRANSMISSION CHARGE PUMP ........................................................................................ 6-5
TRANSMISSION CLUTCH ASSEMBLIES............................................................................. 6-8
TRANSMISSION CLUTCH & GEARING (Forward, Output & Third)...................................... 6-7
TRANSMISSION CLUTCH & GEARING (Reverse, Second & Low)...................................... 6-6
TRANSMISSION CONTROL VALVE ................................................................................... 6-10
TRANSMISSION DISCONNECT SWITCH ............................................................................ 8-3
TRANSMISSION DRIVE GEARING ...................................................................................... 6-5
TRANSMISSION FLEX PLATE & TORQUE CONVERTER................................................... 6-2
TRANSMISSION MODULATOR VALVE ................................................................................ 6-9
TRANSMISSION TEMPERATURE GAUGE .........................................................................11-1
TRAVEL ALARM ...................................................................................................................11-4
V-BELT ................................................................................................................................... 5-3
WATER SEPARATOR ............................................................................................................ 5-4
WATER TEMPERATURE GAUGE........................................................................................11-1
WATER TEMPERATURE SENDER ....................................................................................... 5-2
KG
1-9
INTRODUCTION
Alphabetical Index
Starting Serial No. 0155299S
Original Issue 3-90
Revised 12-19-94
WEATHER STRIP ...................................................................................................................2-2
WHEELS & TIRES............................................................................................................... 6-16
WINDOWS ..............................................................................................................................2-2
WINDSHIELD WIPER ARM ....................................................................................................2-2
WINDSHIELD WIPER BLADE ................................................................................................2-2
WINDSHEILD WIPER MOTOR ...............................................................................................2-2
WIRING HARNESS .............................................................................................. 5-1, 11-1, 11-3
KG
1-10
Starting Serial No. 0155299S
SECTION PAGE NO. PART NO. DESCRIPTION
2 2-5 9103-5240 KING PIN & BUSHING SET
2 2-5 9104-5152 STEERING CYLINDER PIN KIT
*
6 6-2 9103-4238 DRIVE PLATE KIT
7 7-4 9020-6567 STEERING ORBITROL SEAL KIT
INTRODUCTION
Service Kits
Original Issue 3-90
Revised 3-30-95
8 8-2 9103-4018 INCHING VALVE SEAL KIT
10 10-1 9103-4278 LIFT CYLINDER SEAL KIT
10 10-2 9104-4320 CROWD CYLINDER SEAL KIT
10 10-3 9103-4290 CROWD EXTENSION CYLINDER SEAL KIT
10 10-4 9103-4278 TILT CYLINDER SEAL KIT
10 10-5 9103-4278 COMPENSATING CYLINDER SEAL KIT
10 10-6 9103-4297 SWAY CYLINDER SEAL KIT
10 10-7 9103-4301 STEERING CYLINDER SEAL KIT
10 10-8 9104-4330 STABILIZER CYLINDER SEAL KIT
10 10-9 9103-4278 OUTRIGGER CYLINDER SEAL KIT
10 10-13 7738-4264 FOUR-WAY SOLENOID VALVE SEAL KIT
9104-4343 DIFFERENTIAL PRESSURE SENSING
VALVE SEAL KIT
9104-4345 DIFFERENTIAL PRESSURE SENSING
VALVE SEAL KIT
10 10-15 9104-4002 STABILIZER VALVE SEAL KIT
10 10-23 9104-4354 PILOT PUMP MAJOR KIT
9103-4019 PILOT PUMP SEAL KIT
KG
* Added steering cylinder pin kit.
1-11
CHASSIS & ATTACHING PARTS
Frame Shrouding & Trim
Starting Serial No. 0155299S
Original Issue 3-90
Revised 2-12-97
Item Part No. Qty. Description Of Part
1 9103-5096 1 DECK ASSY
2 8855-1010 2 LOCKWASHER, 5/16
3 8820-1021 2 HEX HD CAPSCREW, 5/16-18X1-1/4,
4 8852-1308 4 HEX LOCKNUT, 1/2-13
5 9103-1260 1 TANK COVER
6 8540-1340 4 HARDENED WASHER
7 8820-1066 4 HEX HD CAPSCREW, 1/2-13X1-1/4
8 9020-6196 AR TRIM, 11 FT. LONG
9 8826-1017 6 SOCKET BUTTON HD CAPSCREW
10 8856-1107 16 FLAT WASHER, 1/4
11 9103-1075 1 HINGE
12 8852-1304 6 HEX LOCKNUT, 1/4-20
13 8368-3311 2 PAWL LATCH
14 9103-1074 1 FRONT SERVICE DOOR
15 9103-3320 1 LEVEL GAUGE
16 8826-1009 8 SOCKET BUTTON HD CAPSCREW,
17 8856-1105 16 FLAT WASHER, #10
*
18 8852-1605 8 HEX LOCKNUT, #10-24
19 9103-3077 1 HINGE
20 9103-1067 1 SIDE SERVICE DOOR
21 9020-7458 2 DRAW LATCH
22 9002-8951 8 POP RIVET
23 9104-6032 1 FRAME WELDMENT
24 9104-1080 1 BOOM COVER
25 8820-1031 4 HEX HD CAPSCREW, 3/8-16X1/2 GR5
26 8856-1109 4 FLAT WASHER, 3/8
27 9104-0002 1 COUNTERWEIGHT
28 8820-1115 3 HEX HD CAPSCREW, 3/4-10X3 GR5
29 8856-1009 3 FLAT WASHER, 3/4
30 9020-6194 AR TRIM, 8 FT. LONG
31 9103-6079 1 REAR CAB COVER
32 7714-3004 3 LOCK SCREW
33 9060-2885 1 BRACKET
34 7714-3006 3 LOCK NUT
KG
GR5
GR5
1/4-20X7/8
#10-24X5/8
* Changed quantity on item 17, added items 63 thru 69.
Item Part No. Qty. Description Of Part
35 8820-1003 8 HEX HD CAPSCREW, 1/4-20X3/4 GR5
36 8855-1009 8 LOCKWASHER, 1/4
37 8820-1118 2 HEX HD CAPSCREW, 3/4-10X3-3/4
38 9104-5027 1 REAR HOOD ASSY (includes items 16
39 9103-6016 1 FRONT HOOD ASSY
40 9103-3485 1 SEAT (standard)
9112-4107 1 SLIDE ADJ. KIT
9104-3237 1 SEAT W/BELTS (optional)
41 8667-1164 2 SPACER
42 7714-3006 4 LOCK NUT
43 9103-3029 1 SEAT BELT
44 8820-1050 2 HEX HD CAPSCREW, 7/16-14X1 GR5
45 8850-1007 2 HEX NUT, 7/16-14
46 9020-5746 1 HEATER COVER
47 7714-3003 8 LOCK SCREW
48 7714-3006 4 LOCK NUT
49 7710-3044 4 CLIP NUT
50 9020-5730 1 VALVE COVER
51 9104-6056 1 JOYSTICK COVER
52 8820-1018 2 HEX HD CAPSCREW, 5/16-18X3/4,
53 8855-1010 2 LOCKWASHER, 5/16
54 8850-1005 2 HEX NUT, 5/16-18
55 9020-6196 AR TRIM, 4 FT. LONG
56 9103-1363 1 CAB BOTTOM COVER
57 7714-3003 1 LOCK SCREW
58 9020-6200 AR TRIM, 15.7" LONG
59 8820-4912 1 HEX HD CAPSCREW, 1/4-20X1 GR5
60 8856-1107 1 FLAT WASHER, 1/4
61 8852-1204 1 HEX LOCKNUT, 1/4-20
62 8368-3291 1 MIRROR (starting S/N 0155436. For
63 8507-1132 2 SEMI OFFSET HINGE
*
64 8507-1028 2 SPRING & BRACKET
*
65 8830-1092 8 RD HD MACH SCREW, 10-24X5/8
*
66 8855-1007 8 LOCKWASHER, #10
*
67 8850-1612 8 HEX NUT, #10-24
*
68 9103-1456 1 SERVICE DOOR
*
69 9103-1457 1 SERVICE DOOR
*
GR5
thru 20)
GR5
earlier models use service kit
9104-5150)
2-1
CHASSIS & ATTACHING PARTS
Cab Enclosure, Wiper & Defroster
Starting Serial No. 0155299S
Original Issue 3-90
Revised 2-7-97
Item Part No. Qty. Description Of Part
1 9103-1361 2 WINDOW HOLD DOWN BAR
2 9002-7319 AR SELF TAPPING SCREW (window hold
3 9020-0755 AR BULK WEATHERSTRIPPING (50 feet)
4 9040-3036 1 FRONT WINDOW
5 9103-1362 4 WINDOW HOLD BAR
6 8820-1003 1 HEX HD CPASCREW, 1/4-20X3/4,
7 9103-3464 1 WINDSHIELD WIPER ARM
8 9103-3465 1 WIPER BLADE
9 9002-7214 1 WIPER MOTOR SHAFT GROMMET
10 9002-7319 5 SELF TAPPING SCREW
11 9020-6025 1 WIPER MOTOR MOUNTING ANGLE
12 9020-6023 1 WIPER MOTOR
13 8850-1004 1 HEX NUT, 1/4-20
14 9020-0680 1 DEFROSTER FAN
15 8832-1025 4 SELF TAPPPING SCREW, #8-32X3/4
16 8820-1031 2 HEX HD CAPSCREW, 3/8-16X1/2,
17 8855-1011 2 LOCKWASHER, 3/8-16X1/2
18 9020-6613 1 ANGLE
19 9020-5846 1 RIGHT SIDE WINDOW
20 9040-3034 1 TOP WINDOW
21 9040-3035 1 REAR WINDOW
KG
down bar)
GR5
GR5
* Added item 41.
Item Part No. Qty. Description Of Part
22 9040-3032 1 DOOR TROUGH
23 8830-1309 4 FLAT HD MACHINE SCREW,
1/4-20X3/4
24 8850-1004 4 HEX NUT,1/4-20
25 9040-3082 1 DOOR POST
26 9103-1360 1 L. WINDOW TOP HOLD DOWN BAR
27 9040-3033 1 LEFT SIDE WINDOW
28 9020-6100 AR RUBBER GLAZING STRIP
29 9020-5888 1 PLUNGER SOCKET
30 9020-5886 1 DOOR HOLD PLUNGER
31 8820-1309 4 HEX HD CAPSCREW, 3/8-16X2, GR5
32 8850-1006 4 HEX NUT, 3/8-16
33 9041-0229 1 DOOR WINDOW
34 8366-1145 AR RUBBER GLAZING STRIP (8' long)
35 9080-1238 1 DOOR ASSY
36 9020-3627 1 HANDLE
37 8820-1031 2 HEX HD CAPSCREW, 3/8-16X1/2,
GR5
38 9020-3840 1 DOOR PULL HANDLE
39 8832-1039 2 SELF TAPPING SCREW, #10-32X1/2
40 9103-1362 1 WINDOW HOLD DOWN BAR
41 9103-4033 1 LATCH ASSY
2-2
CHASSIS & ATTACHING PARTS
Cab Heater & Hoses
Starting Serial No. 0155299S
Original Issue 3-90
Item Part No. Qty. Description Of Part
1 9020-6134 1 JUMPER WIRE
2 9103-4098 1 HEATER SWITCH (furnished with
heater)
3 9020-6133 1 JUMPER WIRE
4 9020-6131 1 CIRCUIT BREAKER
5 9020-5731 2 HEATER MOUNTING BRACKET
6 8820-1005 8 HEX HD CAPSCREW 1/4-20X1, GR5
7 9020-0679 1 HEATER (includes item 2)
8 AR HOSE, 5/8 I.D.
9 8850-1004 4 HEX NUT, 1/4-20
10 2464-1328 2 SHUT-OFF VALVE
11 8871-1383 2 REDUCING BUSHING, 1/2X3/8
12 8668-3193 4 HOSE CLAMP
2-3
CHASSIS & ATTACHING PARTS
Front Axle Cradle & Attaching Parts
Starting Serial No. 0155299S
Original Issue 3-90
Item Part No. Qty. Description Of Part
1 9080-1303 1 FRONT AXLE CRADLE
2 9020-6847 1 SWAY CYLINDER ROD PIN
3 8820-1106 1 HEX HD CAPSCREW, 5/8-11X4-1/2
GR5
4 8850-1010 1 HEX NUT, 5/8-11
5 9020-5891 2 SPACER
6 9103-1014 AR SHIM
7 9103-1096 2 BUSHING
8 8320-1107 8 HEX HD CAPSCREW (lubricate and
torque to 545-595 ft. lbs.)
9 9002-7475 8 WASHER
10 8852-1216 8 HEX LOCKNUT, 1-8
11 8852-1016 1 HEX LOCKNUT, 1-8 (Stover)
12 9103-1243 1 FRAME PIN
13 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
14 8320-1031 1 HEX HD CAPSCREW
15 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
2-4
CHASSIS & ATTACHING PARTS
Rear Steering Axle & Attaching Parts
Starting Serial No. 0155299S
Original Issue 6-93
Revised 6-1-99
* Changed Description on Steering Knuckle Kit; changed Part No. on item 42; added
items 64 & 65; added service note and revised illustration.
PCN 980725, 980730 - JH
2-5
CHASSIS & ATTACHING PARTS
Rear Steering Axle & Attaching Parts
Starting Serial No. 0155299S
Original Issue 6-93
Revised 6-1-99
NOTE: All machines must bore out Steering Knuckles to use items 64 & 65. Unless you have purchased
new Steering Knuckles part number 9112-0003 & 9112-0004. See engineering print that comes with the
Steering Knuckle Kit for details.
Item Part No. Qty. Description Of Part
9103-5240 AR STEERING KNUCKLE KIT, (includes
*
9104-5152 AR STEERING CYLINDER PIN KIT,
1 9104-6114 1 AXLE FRAME ASSY, (includes items 2
2 9112-3028 2 FRAME UPPER BUSHING
3 9112-3027 2 FRAME LOWER BUSHING
4 9112-3031 2 FRAME AXLE PIN BUSHING
5 9104-1489 1 FRAME AXLE STABILIZER BUSHING
6 8867-1022 6 LUBE FITTING, 90 DEGREES, 1/8
7 8820-1065 2 HEX HD CAPSCREW, 1/2-13X1, GR5
8 8855-1013 2 LOCKWASHER, 1/2
9 9108-1461 2 WASHER
10 9108-1384 2 STEERING CYLINDER PIVOT PIN
11 9020-1918 2 WASHER
12 8822-1701 2 SOCKET SET SCREW, 3/8-16X1/2,
13 9002-0247 2 HEX HD CAPSCREW
14 9103-1440 1 AXLE MOUNTING PIN
15 8856-1119 1 FLAT WASHER, 1-1/4
16 8510-1098 1 HEX NUT
17 9020-6846 AR SHIM, (1/8 thick)
18 9103-1009 AR SHIM, (1/4 thick)
19 9002-2234 1 HEX LOCKNUT
20 9112-3030 4 BACK-UP RING
21 8859-1032 4 O-RING
22 8692-1268 2 LIP SEAL
23 8821-1121 2 SOCKET HD CAPSCREW,
8852-1208 2 HEX LOCKNUT, 1/2
24 9108-1693 2 UPPER KING PIN
25 8852-1312 2 HEX LOCKNUT, 3/4-10
26 9108-1415 2 DIRT SHIELD
27 9104-1732 2 SPACER
28 8859-1104 2 O-RING
*
29 9104-1481 2 STEERING CYLINDER PIN
30 9104-1459 2 WASHER
31 8850-1416 2 HEX JAM NUT, 1-14, (lubricate &
32 8850-1006 4 HEX NUT, 3/8-16
items 2, 3, 4 pieces of item 6, items 20
thru 24, 26, 27, 28, 47 thru 55, 63,
64, & 65, one kit will do both sides)
(includes one each of items 25 thru 31,
one kit needed for each side)
thru 5)
SELF-LOCKING, (cup point)
1/2-13X6-1/2, GR8
torque to 425-475 ft.lbs.)
Item Part No. Qty. Description Of Part
33 8855-1011 8 LOCKWASHER, 3/8
34 9002-7470 4 HARDENED WASHER
35 8652-1144 2 CLAM P
36 9108-1387 2 TUBE SUPPORT
37 8820-1035 4 HEX HD CAPSCREW, 3/8-16X1, GR5
38 9020-2343 4 TUBE CLAMP
39 8820-1036 4 HEX HD CAPSCREW, 3/8-16X1-1/4,
40 Ref WHEEL DRIVE ASSY, (see page 6-17
41 8850-1110 2 HEAVY HEX JAM NUT, 5/8-11
42 9112-0003 1 STEERING KNUCKLE, LH
*
9112-0004 1 STEERING KNUCKLE, RH
43 9104-1403 4 MODIFIED WASHER
44 9104-3222 4 CAPSCREW, 12PT. HD, 3/4-10X2,
45 8668-1572 12 HARDENED WASHER, 3/4
46 8320-1006 12 HEX HD CAPSCREW, 3/4-10X2, GR8
47 8821-2321 2 SOCKET HD CAPSCREW,
48 8858-1323 2 RETAINING RING
49 9114-1424 2 LOWER KING PIN
50 8855-1153 2 LOCKWASHER, (hi-collar) 5/8
51 8821-2321 2 SOCKET HD CAPSCREW,
52 9104-1450 4 SHIM, (.0478 thick, use as required)
9104-1449 4 SHIM, (.060 thick, use as required)
9104-1451 6 SHIM, (.106 thick, use as required)
9104-1596 4 SHIM, (20 gauge, use as required)
53 9112-3029 2 O-RING
54 8859-1104 2 O-RING
55 9112-1091 2 THRUST BEARING
56 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
57 9116-6063 1 TIE ROD ASSY, (includes item 58)
58 9104-3247 2 SELF-ALIGNING BUSHING
59 9104-1439 2 TIE ROD PIN
60 8852-1306 2 HEX LOCKNUT, 3/8-16
61 8624-1716 2 HEX HD CAPSCREW, 3/8-16X3, GR8
62 2460-1570 2 LIP SEAL
63 8859-1019 2 O-RING
64 9112-1239 2 BUSHING
*
65 9112-1240 4 BUSHING
*
GR5
for details)
(lubricate & torque to 270-290 ft.lbs.)
(lubricate & torque to 270-290 ft.lbs.)
5/8-11X3-3/4, GR8
5/8-11X3-3/4, GR8
* Changed Description on Steering Knuckle Kit; changed Part No. on item 42; added
items 64 & 65; added service note and revised illustration.
PCN 980725, 980730 - JH
2-5
CHASSIS & ATTACHING PARTS
Rear Steering Axle & Attaching Parts
Starting Serial No. 0155369
Original Issue 6-93
Revised 6-1-99
NOTE: All machines must bore out Steering Knuckles to use items 62 & 63. Unless you
have purchased new Steering Knuckles part number 9112-0003 & 9112-0004. See
engineering print that comes with the Steering Knuckle Kit for details.
Item Part No. Qty. Description Of Part
9103-5240 1 STEERING KNUCKLE KIT, (includes
*
9104-5152 AR STEERING CYLINDER PIN KIT,
1 1 DRIVE HUB, (see page 6-17 for details)
2 9112-0004 1 R.H. STEERING KNUCKLE
*
3 8821-2321 2 SOCKET HD CAPSCREW,
4 8320-1006 12 HEX HD CAPSCREW, 3/4-10X2, GR8,
5 9104-3222 4 CAPSCREW, 12 PT. 3/4-10X2,
6 8668-1572 12 HARDENED WASHER, 3/4
7 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
8 9104-6114 1 REAR AXLE WELDMENT, (includes
9 9103-1440 1 REAR AXLE MOUNTING PIN
10 9002-0247 1 HEX HD CAPSCREW, 1-1/4-7X6
11 8856-1119 1 FLAT WASHER, 1-1/4
12 8510-1098 1 HEX NUT, 1-1/4-7
13 9020-6846 AR SHIM, (1/8 thick)
14 9103-1009 AR SHIM, (1/4 thick)
15 9002-2234 1 HEX LOCKNUT
16 8850-1006 2 HEX NUT, 3/8-16
17 8855-1011 2 LOCKWASHER, 3/8
18 8320-1144 2 HEX HD CAPSCREW, 3/8-16X5-3/4,
19 9108-1695 2 STEERING CYLINDER PIVOT PIN
20 8871-1280 2 PIPE PLUG
21 8867-1033 4 LUBE FITTING,STRAIGHT,1/4-28
22 9104-1598 AR SHIM
23 2 STEERING CYLINDER ASSY, (see page
24 9020-1918 AR SHIM, (10 gauge thick)
25 8852-1312 2 HEX LOCKNUT, 3/4-10
26 9108-1415 2 DIRT SHIELD
27 9104-1732 2 SPACER
PCN 980725, 980730 - JH
items 26, 27, 29, 31, 32, 33, 34,
35, 38, 39, 43 thru 54, 62, & 63, one kit
will do both sides)
(includes one each of items 25, 26, 27,
29, 30, 36, & 37, one kit needed for each
side)
5/8-11X3-3/4, GR8
(lubricate and torque to 270-290 ft. lbs.)
(lubricate and torque to 270-290 ft. lbs.)
items 33, 49, & 59)
GR5
10-7 for details)
* Changed Description on Steering Knuckle Kit; changed Part No. on items 2 & 55;
added items 62 & 63; added service note and revised illustration.
Item Part No. Qty. Description Of Part
28 9103-3445 2 LUBE FITTING
29 8859-1019 2 O-RING
30 9104-1481 2 STEERING CYLINDER PIN
31 9112-3030 4 BACK-UP RING
32 8859-1032 4 O-RING
33 9112-3028 2 BUSHING
34 8692-1268 2 LIP SEAL
35 8821-1121 2 SOCKET HD CAPSCREW,
8852-1208 2 HEX LOCKNUT, 1/2
36 9104-1459 2 WASHER
37 8850-1416 2 HEX JAM NUT, 1-14, (lubricate &
38 8867-1022 4 LUBE FITTING, 30 DEGREES, 1/8
39 9108-1693 2 UPPER KING PIN
40 9104-1439 2 TIE ROD PIN
41 8320-1140 2 HEX HD CAPSCREW, 3/8-16X2-3/4,
42 8852-1306 2 LOCKNUT, 3/8-16
43 8858-1323 2 RETAINING RING
44 9108-1382 2 LOWER KING PIN
45 9104-1596 4 SHIM, (20 gauge, use as required)
46 9104-1449 4 SHIM, (.060 thick, use as required)
47 9104-1450 4 SHIM, (.0478 thick, use as required)
48 9104-1451 6 SHIM, (.106 thick, use as required)
49 9112-3027 2 BUSHING
50 9112-3029 2 O-RING
51 8821-2321 2 SLOT HD CAPSCREW,
52 8855-1153 2 LOCKWASHER, 5/8
53 8859-1104 2 O-RING
54 9112-1091 2 THRUST BUSHING
55 9112-0003 1 L.H. STEERING KNUCKLE
*
56 9116-6063 1 TIE ROD, (includes item 57)
57 9104-3247 2 SELF-ALIGNING BUSHING
58 2460-1570 2 LIP SEAL
59 9112-3031 2 BUSHING
60 8850-1110 2 HEAVY HEX JAM NUT, 5/8-11
61 9103-3444 2 STREET ELBOW
62 9112-1239 2 BUSHING
*
63 9112-1240 4 BUSHING
*
1/2-13X6-1/2, GR8
torque to 425-475 ft. lbs.)
GR8
5/8-11X3-3/4, GR8
2-5
CHASSIS & ATTACHING PARTS
Outrigger & Attaching Parts
Starting Serial No. 0155299S
Original Issue 3-90
Revised 9-91
PCN L-8581
Item Part No. Qty. Description Of Part
1 8643-1005 16 HEX HD CAPSCREW (lubricate and
torque to 795-845 ft. lbs.)
2 0510-1441 16 HEAT TREATED WASHER
3 9103-6029 1 OUTRIGGER BRACKET, L.H.
9103-6030 1 OUTRIGGER BRACKET, R.H.
4 8320-1073 6 HEX HD CAPSCREW
5 9103-1141 4 SHOE PIN
6 8852-1206 6 HEX LOCKNUT, 3/8-16
7 8867-1001 8 LUBE FITTING, STRAIGHT, 1/8
8 9104-3258 2 DUAL P.O. CHECK VALVE
9 8820-1040 6 HEX HD CAPSCREW, 3/8-16X2-1/4,
GR5
10 8855-1011 6 LOCK WASHER, 3/8
11 Ref OUTRIGGER CYLINDER ASSY (see
page 10-9 for details)
12 9103-6032 2 OUTRIGGER SHOE
13 9103-6041 2 ARM WELDMENT
14 9103-1140 2 ARM PIN
2-6
11"
2 RAD.
16
(TYP)
30
15"
64
STANDARD
CHASSIS & ATTACHING PARTS
CAB GLASS
Starting Serial No. 0155390S
Original Issue 2-94
Revised 6-8-94
11"
2 RAD.
REAR WINDOW
16
(TYP)
1"
29
4
5"
38
16
39
17"
64
RIGHT SIDE WINDOW
CAB GLASS CAN ONLY BE SHIPPED
WITH THE COMPLETE CAB ENCLOSURE
OPTION. IF GLASS BREAKAGE OCCURS
IN THE FIELD IT MUST BE REPLACED
LOCALLY USING THE DIMENSIONS GIVEN.
WITH THE EXCEPTION OF THE DOOR SLIDING
WINDOW ASSY WHICH MAY BE PURCHASED
THROUGH THE PARTS DEPARTMENT.
OPTIONAL
5"
28
8
3"
21
16
NOTE: ALL LAMINATED SAFETY GLASS,
TINTED FOR 73% LIGHT
TRANSMISSION SEAMED EDGES,
7/32" THICK.
11"
2 RAD.
16
(TYP)
11"
2 RAD.
16
(TYP)
28
5"
8
31
7"
8
24
7"
8
KG
3"
24
16
1"
=
3 RAD.
8
(6) PLACES
1"
24
4
FRONT WINDOW
10"
15
32
5"
22
32
1"
29
16
3"
32
LEFT SIDE
WINDOW
=
(2) PLACES
3"
4
7"
11
8
7"
2 RAD.
8
TOP WINDOW
DOOR SLIDING WINDOW
(9104-3437)
2-7
BOOMS
1st Boom Section
Starting Serial No. 0155299S
Original Issue 3-90
Revised 1-15-98
Item Part No. Qty. Description Of Part
1 9104-6079 1 FIRST BOOM SECTION WELDMENT
2 8820-1564 4 HEX HD CAPSDCREW, 1/2-20X1,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
3 1238-1025 24 HARDENED WASHER
4 9104-1277 8 SPACER
5 9104-1276 10 SHIM
6 9104-1278 6 SPACER
7 9104-3180 2 BEARING PAD
8 9104-3177 4 BEARING PAD
9 8820-1069 2 HEX HD CAPSCREW, 1/2-13X2, GR5
10 8855-1013 2 LOCKWASHER, 1/2
11 9104-1009 1 CYLINDER SUPPORT PLATE
12 9104-3164 4 BEARING PAD
13 9104-1265 4 SPACER
14 9104-1006 12 SHIM
* Removed incorrect part number, and added reference to item 18.
KG
Item Part No. Qty. Description Of Part
15 9104-1007 4 SPACER
16 8820-1566 12 HEX HD CAPSCREW, 1/2-20X1-1/12,
17 8820-1562 8 HEX HD CAPSCREW, 1/2-20X3/4, GR5
18 Ref CROWD CYLINDER ASSY (see page
*
19 9002-8935 2 RETAINING RING
20 9020-7352 1 PIN
21 8852-1010 1 HEX LOCKNUT, 5/8-11
22 9103-1371 2 BUSHING
23 9103-1389 1 PIN
24 8348-1645 1 HEX HD CAPSCREW
25 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
GR5 (lubricate and torque to 68-78 ft.
lbs.)
(lubricate and torque to 68-78 ft. lbs.)
10-2 for details)
3-1
BOOMS
2nd Boom Section
Starting Serial No. 0155299S
Original Issue 3-90
Item Part No. Qty. Description Of Part
1 9104-6018 1 SECOND BOOM SECTION
WELDMENT
2 8820-1563 16 HEX HD CAPSCREW, 1/2-20X7/8,
GR5 (lubricate and torque to 69-78 ft.
lbs.)
3 1238-1025 32 HARDENED WASHER
4 9104-1277 12 SPACER
5 9104-1276 12 SHIM
6 9104-3180 2 BEARING PAD
7 9104-1278 10 SPACER
8 9104-3177 8 BEARING PAD
9 9104-3164 4 BEARING PAD
10 9104-1265 2 SPACER
Item Part No. Qty. Description Of Part
11 9104-1006 6 SHIM
12 9104-1007 2 SPACER
13 8820-1562 16 HEX HD CPASCREW, 1/2-20X3/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
14 8820-1535 4 HEX HD CAPSCREW, 3/8-24X1-1/4,
GR5 (lubricate and torque to 30-35 ft.
lbs.)
15 1200-1234 4 HARDENED WASHER
16 9103-1234 2 SHIM
17 9020-7029 6 SHIM
18 9103-3188 2 BEARING PAD
3-2
BOOMS
3rd Boom Section
Starting Serial No. 0155299S
Original Issue 3-90
Item Part No. Qty. Description Of Part
1 9104-6019 1 THIRD BOOM SECTION WELDMENT
2 8820-1563 4 HEX HD CAPSCREW, 1/2-20X7/8,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
3 1238-1025 8 HARDENED WASHER
4 9104-1277 10 SPACER
5 9104-1276 12 SHIM
6 9104-1278 10 SPACER
7 9104-3180 2 BEARING PAD
8 8820-1562 16 HEX HD CAPSCREW, 1/2-20X3/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
9 1238-1025 24 HARDENED WASHER
10 9104-3164 4 BEARING PAD
11 8820-1567 6 HEX HD CPASCREW, 1/2-20X1-3/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
Item Part No. Qty. Description Of Part
12 9104-3177 8 BEARING PAD
13 9104-1265 2 SPACER
14 9104-1006 4 SHIM
15 9104-1007 2 SPACER
16 8820-1565 6 HEX HD CPASCREW, 1/2-20X1-1/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
17 8820-1535 4 HEX HD CAPSCREW, 3/8-24X1-1/4,
GR5 (lubricate and torque to 30-35 ft.
lbs.)
18 1200-1234 4 HARDENED WASHER
19 9103-1234 2 SHIM
20 9020-7029 6 SHIM
21 9103-3188 2 BEARING PAD
3-3
BOOMS
4th Boom Section
Starting Serial No. 0155299S
Original Issue 3-90
Item Part No. Qty. Description Of Part
1 9104-6020 1 FOURTH BOOM SECTION
WELDMENT (includes item 2)
2 9103-1136 2 BUSHING
3 9104-6008 1 SWITCH ACTUATOR
4 8856-1004 2 FLAT WASHER, 3/8
5 8855-1011 2 LOCK WASHER, 3/8
6 8850-1035 2 HEX HD CAPSCREW, 3/8-16X1, GR5
7 9104-3177 2 BEARING PAD
8 9104-1278 2 SPACER
9 9104-1276 4 SHIM
10 9104-1277 2 SPACER
11 1238-1025 10 HARDENED WASHER
12 8820-1563 2 HEX HD CAPSCREW, 1/2-20X7/8,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
13 8824-1029 4 SOCKET FLAT HD CAPSCREW 1/4-
20X1/2
14 9104-3099 2 BEARING PAD
15 9104-6006 1 SUPPORT WELDMENT
16 8820-1065 2 HEX HD CAPSCREW, 1/2-13X1-1/4,
GR5
Item Part No. Qty. Description Of Part
17 8855-1013 2 LOCK WASHER, 1/2
18 9104-3164 2 BEARING PAD
19 9104-1007 2 SPACER
20 9104-1265 2 SPACER
21 8820-1565 6 HEX HD CAPSCREW, 1/2-20X1-1/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
22 8820-1562 2 HEX HD CAPSCREW, 1/2-20X3/4,
GR5 (lubricate and torque to 68-78 ft.
lbs.)
23 8820-1538 4 HEX HD CAPSCREW, 3/8-24X2, GR5
(lubricate and torque 30-35 ft. lbs.)
24 1200-1234 4 HARDENED WASHER
25 9104-1134 2 BEARING BLOCK
26 9104-1005 2 SPACER
27 9104-1004 6 SHIM
28 9104-1264 2 SPACER
29 9104-3059 2 BEARING PAD
3-4
!
NOTE: When purchasing item (1) Push
Beam W eldment (9104-6049), the
rub pads may need to be hand
ground for proper fit when
installing the sheave assy.
BOOMS
Push Beam & Cables
Starting Serial No. 0155299
Original Issue 3-90
Revised 5-6-97
Item Part No. Qty. Description Of Part
1 9104-6049 1 PUSH BEAM WELDMENT
2 9104-3418 1 EXTENSION CABLE (includes
*
3 9104-5126 1 SHEAVE ASSY (includes item 4)
4 1 BUSHING
5 9002-1608 1 CLEVIS PIN
6 9104-1232 1 SHEAVE PIN
7 8867-1002 1 LUBE FITTING, STRAIGHT, 1/8
8 8863-1310 1 COTTER PIN, 3/32X1
9 9104-6052 1 CABLE ANCHOR
10 9104-3099 1 BEARING PAD
11 8824-1030 2 SOCKET FLAT HD CAPSCREW,
12 8320-1003 6 HEX HD CAPSCREW, 5/8-11X1-3/4
13 7714-1077 6 HARDENED WASHER
14 9104-3062 1 CABLE PIN
15 9104-3047 1 RETRACTION CABLE
16 8856-1013 1 FLAT WASHER
17 8863-1339 1 COTTER PIN, 3/16X2
18 8855-1011 4 LOCKWASHER, 3/8
19 8850-1006 8 HEX NUT, 3/8-16
20 9104-1012 2 HOSE RETAINER STUD
21 9104-1404 3 HOSE RETAINER PLATE
22 9104-1406 2 RETAINER ROLLER, 5" LONG
23 9104-1405 2 RETAINER ROLLER, 8-1/2" LONG
24 9020-3039 2 THRUST WASHER
mounting hardware)
1/4-20X5/8
(nylok) GR8
Item Part No. Qty. Description Of Part
25 9020-3040 1 THRUST WASHER
26 9104-3101 1 SHEAVE
27 9020-0253 4 THRUST WASHER
28 9104-1013 1 STRONGBACK PLATE
29 8540-1340 2 HARDENED WASHER
30 8855-1013 6 LOCKWASHER, 1/2
31 8820-1071 2 HEX HD CAPSCREW, 1/2-13X2-1/2,
32 9002-8965 2 FLANGE HALF
33 8850-1116 2 HEX JAM NUT, 1"-8
34 1 BUSHING
35 9103-5147 1 SHEAVE ASSY (includes item 34)
36 9104-3100 1 SHEAVE
37 8856-1109 6 FLAT WASHER, 3/8
*
38 8820-1033 6 HX HD CAPSCREW, 3/8-16X3/4
39 8820-1044 1 HEX HD CAPSCREW, 3/8-16X3-1/4,
40 9104-1008 1 PUSH BEAM PIN
41 8867-1008 2 LUBE FITTING, STRAIGHT, 1/4-28
42 8852-1006 1 HEAVY HEX JAM LOCKNUT, 3/8-16
*
43 9104-3261 1 BEARING PAD
*
44 8830-1339 2 FLAT HD MACHINE SCREW,
*
45 9104-1510 1 BOOM CABLE GUARD
46 8820-1067 4 HEX HD CAPSCREW, 1/2-13X1-1/2,
GR5
GR5
3/8-16X1
GR5
NOTE: ONLY ITEMS WITH PART
NUMBERS ARE AVAILABLE FOR
SERVICE.
KG
* Changed part numbers on items 2, 43 & 44, changed quantities on items 37 &
42, and removed items 47 & 48.
3-5
BOOMS
Quick Switch Assembly
Starting Serial No. 0155299S thru 0155421S
Original Issue 3-90
Revised 3-9-98
PCN 940033-JH
Item Part No. Qty. Description Of Part
9104-5095 1 QUICK SWITCH ASSEMBLY
1 9108-6074 1 QUICK SWITCH WELDMENT
*
2 9108-6073 1 PLUNGER WELDMENT
3 9020-7902 1 QUICK RELEASE PIN
4 9103-3038 1 JACK CHAIN, 8" LONG, SIZE 12
5 8863-1509 1 ROLL PIN, 1/4"X2
6 8867-1008 1 LUBE FITTING, STRAIGHT, 1/4-28
7 9104-6020 REF FOURTH BOOM SECTION
8 9103-1136 REF BUSHING
9 8864-1057 1 HEX HD CAPSCREW
10 9104-1365 1 HEAD PIN
11 8852-1010 1 HEX LOCKNUT, 5/8-11
12 9020-7046 1 TILT CYLINDER ROD END PIN
13 8820-1065 2 HEX HD CAPSCREW, 1/2-13X1, GR5
14 8855-1013 2 LOCKWASHER, 1/2
15 8830-1090 1 RD. HD MACH SCREW, #10-24X1/2
16 8856-1105 1 FLAT WASHER #10
WELMENT
* Changed part number on item 1.
3-6
BOOMS
Quick Switch Assembly
Starting Serial No. 0155422S
Original Issue 2-98
JH
Item Part No. Qty. Description Of Part
9108-5049 Ref QUICK SWITCH OPTION ( includes
9108-5091 plus items 9,10, 11, &17)
9108-5091 1 QUICK SWITCH ASSY (includes items 1
thru 6, 15 & 16)
1 9108-6152 1 QUICK SWITCH WELDMENT
2 9108-6151 1 PLUNGER WELDMENT
3 9020-7902 1 QUICK RELEASE PIN
4 9103-3038 1 JACK CHAIN, 5" LONG, SIZE 12
5 8863-1509 1 ROLL PIN, 1/4"X2
6 8867-1008 1 LUBE FITTING, STRAIGHT, 1/4-28
7 Ref THIRD BOOM SECTION (see page 3-3)
8 9103-1136 2 BUSHING
9 9112-1308 1 HEX HD CAPSCREW, 5/8-11X5, GR5
10 9104-1365 1 PIN
11 9112-1309 1 HEX NUT, 5/8-11 (torque to 185-200 ft. lbs.)
12 9116-6062 1 TILT CYLINDER PIN
13 8320-1123 2 HEX HD CAPSCREW, 1/2-13X1, GR8
14 8856-1111 2 WASHER, 1/2
15 8830-1193 1 ROUND HD MACHINE SCREW,
#10-32X1/2
16 8856-1105 1 FLAT WASHER, #10
17 9112-1310 2 WASHER, 5/8
3-6
ATTACHMENTS & ACCESSORIES
Sand Bucket & Carriages
Starting Serial No. 0155299S
Original Issue 3-90
Revised 11-22-00
Item Part No. Qty. Description Of Part
1 9080-1332 1 SAND BUCKET
Item Part No. Qty. Description Of Part
9045-5007 1 48" CARRIAGE ASSY, (includes all
1 9080-1315 1 48" CARRIAGE WELDMENT
2 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5
3 9020-0003 2 COLLAR
4 8852-1310 2 HEX LOCKNUT, 5/8-11
5 9040-2477 1 FORK PIN
6 9015-3001 1 SERIAL NUMBER PLATE
*
7 8834-1022 4 DRIVE SCREW, #10X3/8
*
items)
Item Part No. Qty. Description Of Part
9045-5008 1 66" CARRIAGE ASSY, (includes all
1 9080-1314 1 66" CARRIAGE WELDMENT
2 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5
3 9020-0003 2 COLLAR
4 8852-1310 2 HEX LOCKNUT, 5/8-11
5 9040-2478 1 FORK PIN
6 9015-3001 1 SERIAL NUMBER PLATE
*
7 8834-1022 4 DRIVE SCREW, #10X3/8
*
SVC
items)
* Revised illustration and fork note; added items 6 & 7.
NOTE:MANY DIFFERENT FORK
ASSEMBLIES ARE AVAILABLE
FOR THE CARRIAGE
ASSEMBLIES ON THE 544B.
PLEASE SEE FORK
INFORMATION PAGE, (4-3) FOR
LIST OF FORKS.
Item Part No. Qty. Description Of Part
9055-5008 1 72" CARRIAGE ASSY, (includes all
1 9055-6003 1 72" CARRIAGE WELDMENT
2 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5
3 9020-0003 2 COLLAR
4 8852-1310 2 HEX LOCKNUT, 5/8-11
5 9055-1013 1 FORK PIN
6 9015-3001 1 SERIAL NUMBER PLATE
*
7 8834-1022 4 DRIVE SCREW, #10X3/8
*
items)
Item Part No. Qty. Description Of Part
9045-5038 1 80" CARRIAGE ASSY, (includes all
1 9045-6003 1 80" CARRIAGE WELDMENT
2 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5
3 9020-0003 2 COLLAR
4 8852-1310 2 HEX LOCKNUT, 5/8-11
5 9045-1011 1 FORK PIN
6 9015-3001 1 SERIAL NUMBER PLATE
*
7 8834-1022 4 DRIVE SCREW, #10X3/8
*
items)
4-1
ATTACHMENTS
(9130-5016) 66" Slope Piler Carriage
Starting Serial No. 0155299S
Original Issue 8-94
Revised 6-19-06
Item Part No. Qty. Description Of Part
9130-5016 Ref 66" SLOPE PILER CARRIAGE,
(includes all items)
9103-3426 1 CAPACITY DECAL
1 9130-6030 1 CARRIAGE WELDMENT
2 9108-6122 1 ADAPTER WELDMENT
*
3 Ref SWAY CYLINDER, (see page 13-19 for
4 9108-3248 1 BUSHING
5 3423263 2 PIN
*
6 9020-4007 1 TUBE
7 9103-3186 2 BEARING PAD
8 9108-1577 1 TAP BOLT
9 9108-1594 1 THRUST WASHER
10 9020-5870 AR SHIM
*
11 9103-1236 2 SPACER
12 8820-1535 4 HEX HD CAPSCREW, 3/8-24X1-1/4,
*
13 8820-1534 4 HEX HD CAPSCREW, 3/8-24X1, GR5
*
14 9108-1313 3 KEEPER PLATE
15 8820-1065 6 HEX HD CAPSCREW, 1/2-13X1, GR5
16 8855-1013 6 LOCKWASHER, 1/2
17 8852-1016 1 HEX LOCKNUT, 1-8
18 8867-1022 2 LUBE FITTING, 90 DEGREES, 1/8
*
19 8856-1109 4 FLAT WASHER, 3/8
20 8850-1016 1 HEX NUT, 1-8
21 0510-1441 1 WASHER, 1-1/16
22 9108-1622 1 PIN
23 8471-6434 2 HOSE ASSY
24 8366-1316 2 CONNECTOR
ER 46361, 48269, 49530,
details)
GR5
* Revised illustration & parts list.
49939, 50170 LK
Item Part No. Qty. Description Of Part
25 8866-1010 2 CONNECTOR, (Before S/N
*
8866-2018 2 CONNECTOR, (S/N 2005283-01 &
26 9116-3138 1 MALE QUICK DISCONNECT, (Before
*
9140-3414 1 MALE QUICK DISCONNECT, (S/N
27 9116-3139 1 FEMALE QUICK DISCONNECT,
*
9140-3413 1 FEMALE QUICK DISCONNECT, (S/N
28 8834-1022 4 DRIVE SCREW, #10X3/8
29 9015-3001 1 SERIAL NUMBER PLATE
30 9104-3125 1 DUST PLUG
31 9104-3126 1 DUST CAP
32 8866-2105 2 ELBOW, 90 DEGREES, (swivel nut)
*
33 Ref DUAL P.O. CHECK VALVE, (see page
34 8820-1040 3 HEX HD CAPSCREW, 3/8-16X2-1/4,
35 8855-1011 3 LOCKWASHER, 3/8
36 9130-1083 1 FORK PIN
37 9020-0003 2 COLLAR
38 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5
39 8852-1310 2 LOCKNUT, 5/8-11
40 8452-1062 1 SUPPORT CLAMP
*
41 7714-3015 1 WHIZ-LOK NUT, 3/8-16
*
2005283-01)
After)
S/N 2005283-01)
2005283-01 & After)
(Before S/N 2005283-01)
2005283-01 & After)
13-20 for details)
GR5
4-2
Loading...