Gradall 544B User Manual

0 (0)

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

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

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

* 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

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

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

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

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

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

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

* 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

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

down bar)

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.

(TYP)

15"

STANDARD

CHASSIS & ATTACHING PARTS

CAB GLASS

Starting Serial No. 0155390S

Original Issue 2-94

Revised 6-8-94

11"

2 RAD.

REAR WINDOW

(TYP)

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

NOTE: ALL LAMINATED SAFETY GLASS, TINTED FOR 73% LIGHT TRANSMISSION SEAMED EDGES, 7/32" THICK.

11"

2 RAD.

(TYP)

11"

2 RAD.

(TYP)

5" 8

7" 8

3 RAD.

(6) PLACES

FRONT WINDOW

10"

LEFT SIDE WINDOW

(2) PLACES

3" 4

2 RAD.

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.

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

3/8-16X1

GR5 NOTE: ONLY ITEMS WITH PART

NUMBERS ARE AVAILABLE FOR SERVICE.

* 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

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

+ 150 hidden pages