JLG 544D-10 Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Model

544D

S/N 0355001 thru 0455362

& 0160000192 & After

91364001

Revised

April 3, 2014

October 8, 2004 - A - Revised Manual

December 30, 2004 - B - Revised Manual

September 30, 2005 - C - Revised Manual

April 24, 2006 - D - Revised Manual

August 25, 2006 - E - Revised Manual

February 23, 2007 - F - Revised Manual

July 06, 2007 - G - Revised Manual

May 16, 2008 - H - Revised Manual

November 26, 2008 - I - Revised Manual

September 3, 2009 - J - Revised Manual

August 8, 2012 - K - Revised Manual

January 3, 2013 - L - Revised Manual

April 3, 2014 - M - Revised Manual

EFFECTIVITY PAGE

91364001 544D i

EFFECTIVITY PAGE

544D 91364001ii

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Rear Axle & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-3 Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-4 Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-5 Outrigger Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

SECTION 2 –

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-5 Extension Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-6 Retraction Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-7 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

SECTION 3 –

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-5 6 Ft Vertical Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-6 48 In Slope Piler Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-7 66 In Slope Piler Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-8 100 Degree Swing Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-9 Quick Hook Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-10 Fork Mounted Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-11 6 Ft Swing Mast With Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-12 100 Degree Drywall Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-13 Sheet Material Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-14 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-15 180 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-16 90 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

3-17 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3-18 Personnel Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3-19 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3-20 Fork Pin Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

3-21 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3-22 8 Ft Standard Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

3-23 8 Ft Side Tilt Electric Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

3-24 66 In Drywall Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

91364001 544D iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 4 –

ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 Engine Assembly, LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Engine Assembly, RH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-3 Engine Pump Mount & Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-4 John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

4-5 Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

4-6 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4-7 Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

4-8 Air Cleaner Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

4-9 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

4-10 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

SECTION 5 –

DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 Front Axle Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Front Axle - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 Left/Right Housing & Axle Shaft & Wheel Flange Assembly - Rockwell . . . . . . . . . . . . . . . . . . . 5-6

5-4 Brake Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 Carrier Assembly - Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 Front Axle Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-7 Front Axle - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-8 Axle Housing Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-9 Brake Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-10 Carrier Assembly - Carraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-11 Rear Steering Axle Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-12 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

SECTION 6 –

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 Open Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Cab Enclosure Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 Cab Enclosure Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-4 Dash Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-5 Gauge Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-6 Windshield/Top Window Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-7 Skylight Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

SECTION 7 –

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 Brake & Inching Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-3 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-4 Cab Right Side Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

544D 91364001iv

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

7-5 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7-6 Cab Left Side Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7-7 Cybertech 5-Button Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

SECTION 8 –

HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 Oil Supply & Pressure Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-3 Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-4 Rear Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8-5 Service/Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

8-6 Boom Hydraulics Sub-Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

8-7 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

8-8 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

8-9 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

8-10 Tilt Cylinder & Tilt Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

8-11 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

8-12 Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

8-13 Joystick Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

8-14 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62

8-15 Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66

8-16 Hose Clamp Locations, (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

SECTION 9 –

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-3 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9-5 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9-6 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9-7 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9-8 Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9-9 Flow Divider Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40

9-10 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

9-11 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48

9-12 Thermal Bypass Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50

9-13 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

9-14 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56

9-15 Hydraulic Reservoir & Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

9-16 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66

9-17 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68

9-18 Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70

9-19 Sway & Outrigger Cylinder Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74

9-20 Traction Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-76

91364001 544D v

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

9-21 Rear Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-78

9-22 Optional Stabilizer Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-80

9-23 Outrigger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84

9-24 Quick Start Cylinder & Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86

9-25 180 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88

9-26 72 In 90 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90

9-27 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92

9-28 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94

SECTION 10 –

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 Battery & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 Stabilizer Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-3 Dash Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10-4 Engine Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

10-5 ECU Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

10-6 Auxiliary Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

10-7 Auxiliary Electrical Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

10-8 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

SECTION 11 –

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

SECTION 12 –

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-1 Hydraulic Reservoir Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-2 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-3 Stop Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12-4 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

12-5 Truss Boom Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

12-6 LH Sway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

12-7 Aux. Hydraulic Field Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

12-8 Aux. Hydraulics & Sway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

12-9 Auxiliary Electrics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

12-10 Overhead Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32

12-11 Tilt on Joystick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

12-12 Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-38

12-13 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40

12-14 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44

12-15 Dual P.O. Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46

12-16 Swing Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48

12-17 LH Tilt/Sway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52

544D 91364001vi

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

12-18 LH Tilt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54

12-19 Ether Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-56

12-20 Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58

12-21 Crossover Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-68

12-22 Foam Tire Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

12-23 Aux. Hydraulics/Electric w/LH Tilt & Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-72

12-24 Rear Axle Advantage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-78

12-25 RH Aux. Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-86

12-26 5-Button Auxiliary Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90

12-27 RH Aux/Tilt on Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-92

12-28 Aux. Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96

12-29 Cab Heater Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-100

12-30 Adjustable Tilt on Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112

12-31 Fuel/Water Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-116

12-32 Beacon Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-118

12-33 Cab Replacement Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-122

12-34 Starter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-124

12-35 Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-126

12-36 Cold Start Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-128

SECTION 13 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

91364001 544D vii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

544D 91364001viii

SECTION 1

FRAME & ATTACHING PARTS

91364001 544D

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim

S/N 0355001 thru 0455362 &

0160000192 thru 0160000973

544D 913640011-2

S/N 0355001 thru 0455362 & 0160000192 thru 0160000973

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.

91166058 Ref FRAME WELDMENT 14404645 AR T-9 METAL PROTECTANT, (12oz.)

14404646 AR T-9 METAL PROTECTANT, (1 gal.) 1 91143051 2 BUSHING 2 90206196 61 in TRIM-LOCK 3 14402248 AR ADHESIVE 4 83683291 1 MIRROR 5 91146103 1 RADIATOR COVER, (S/N 0355001 thru 0355023)

91366003 1 RADIATOR COVER, (S/N 0355024 thru 0160000973) 6 91143346 1 RUBBER AIR DAM 7 90200755 24 in WEATHER STRIP 8 77143003 52 WHIZ-LOCK SCREW, 5/16-18X5/8 9 90207458 2 DRAW LATCH

10 88301193 8 ROUND HD MACHINE SCREW, #10-32X1/2 11 88551007 12 LOCKWASHER, #10 12 88501613 4 HEX NUT, #10-32 13 91366004 1 TANK COVER WELDMENT 14 85211088 2 RUBBER BUMPER 15 88301073 2 ROUND HD MACHINE SCREW, #8-32X3/4 16 88521604 2 HEX LOCKNUT, #8-32 17 91083173 4 RUBBER HD SCREW BUMPER 18 88501612 4 HEX NUT, #10-24 19 91141218 1 HINGE 20 91143348 1 CLAMP BAR 21 88561003 9 FLAT WASHER, 5/16 22 91123124 4 WHIZ-LOCK SCREW, 5/16-18X1/2 23 91366017 1 REAR ENGINE COVER 24 91303021 2 T-HANDLE, (S/N 0355001 thru 0160000323)

91363210 2 T-HANDLE, (S/N 0160000339 thru 0160000973)

25 91146050 1 REAR COVER WELDMENT 26 91366002 1 REAR COVER CENTER 27 91403574 1 BACK-UP ALARM 28 88201016 2 HEX HD CAPSCREW, 5/16-18X1/2, GR5 29 91140001 1 COUNTERWEIGHT 30 88201143 4 HEX HD CAPSCREW, 1-8X5, GR5, (torque to 545-595 lbs-ft) 31 88561011 4 WASHER, 1 32 91161282 1 REAR CAB COVER 33 88201050 2 HEX HD CAPSCREW, 7/16-14X1, GR5 34 91033029 1 SEAT BELT, (not used with optional seat) 35 88501007 2 HEX NUT, 7/16-14 36 91033485 1 SEAT WITH ARMREST, (std.)

91124107 1 SLIDE ADJ. KIT, (use with std. seat)

91043237 1 GRAMMER SEAT, (opt.)

88201020 4 HEX HD CAPSCREW, 5/16-18X1, GR5, (use with opt. seat)

37 77143006 8 WHIZ-LOCKNUT, 5/16-18 38 91081475 1 HEATER COVER PLATE 39 91141329 1 VALVE ACCESS COVER 40 91361005 1 BELLY PAN 41 91083533 10 FENDER WASHER, 1-1/2, OD

FRAME & ATTACHING PARTS

91364001 544D 1-3

S/N 0355001 thru 0455362 &

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

42 91403230 1 MANUAL CASE 43 77143013 4 WHIZ-LOCKNUT, 1/4-20 44 77143006 2 WHIZ-LOCKNUT, 5/16-18, (not shown), (use with item 58) 45 91033320 Ref TILT GAUGE, (no longer available; use 8466306 for replacement)

8466306 1 TILT GAUGE, (with adhesive) 46 88204912 1 HEX HD CAPSCREW, 1/4-20X1 47 88561107 1 FLAT WASHER 48 88521204 1 LOCKNUT, 1/4-20 49 Ref OPEN CAB, (see Figure 6-1 for details) 50 91141463 1 DECK COVER, (S/N 0355001 thru 0355023)

91361007 1 DECK COVER, (S/N 0355024 thru 0160000973) 51 91143357 1 HORN ASSY 54 77133177 2 HEX HD CAPSCREW, 5/16-18X1-3/8, GR5 55 77133168 2 CLAMP SET 56 77133140 2 COVER PLATE 57 91363018 8 WHIZ-LOCK SCREW, 5/16-18X1 58 91166074 1 HOSE GUARD, (not shown), (located under dash panel, beneath steering

column), (S/N 0355035 thru 0355039)

91363065 1 HOSE GUARD, (not shown), (located under dash panel, beneath steering

column), (S/N 0355040 thru 0160000973) 59 85941016 1 SUPPORT CLAMP, (not shown), (use with item 58) 60 86683122 1 TIE WRAP 61 88261014 4 SOCKET BUTTON HD CAPSCREW, 1/4-20X1/2 62 91146081 1 DIPSTICK COVER 63 83201158 4 HEX HD CAPSCREW, 7/8-9X1-3/4, (torque to 450-475 lb-ft) 64 4892500 4 HARDENED WASHER, 7/8

0160000192 thru 0160000973

544D 913640011-4

S/N 0355001 thru 0455362 & 0160000192 thru 0160000973

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

FRAME & ATTACHING PARTS

91364001 544D 1-5

FRAME & ATTACHING PARTS

PAP21511

2 3

9 10 11 12

13 14 15 16

14 15 16

11 17 18

5 6 8

45 46 47 48

2 3

51 54 55 56

40 41

38 39

36 79 80 81 82 83 84 85 86 87

29 30 31 78

27 28 60 72 73 74 75

76 77

42 43

65 66 67

2 3

21 22

Figure 1-1 Frame Shrouding & Trim

S/N 0160000976 thru 0160034720

including 0160035922

544D 913640011-6

S/N 0160000976 thru 0160034720 including 0160035922

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.

91556001 1 FRAME WELDMENT, (S/N 0355001 thru 0455362 & 0160000192 thru

016001615, excluding 0160015296, 0160015297 & 0160015492)

91556019 1 FRAME WELDMENT, (S/N 0160015710 thru 0160034720 including

0160015296, 0160015297, 0160015492 & 0160035922)

14404645 AR T-9 METAL PROTECTANT, (12oz.)

14404646 AR T-9 METAL PROTECTANT, (1 gal.) 1 91143051 2 BUSHING 2 90206196 59 in TRIM-LOCK 3 14402248 AR ADHESIVE 4 83683291 1 MIRROR 5 91556015 1 RADIATOR COVER 6 91553043 1 RUBBER AIR DAM 7 90200755 24 in WEATHER STRIP 8 77143003 53 WHIZ-LOCK SCREW, 5/16-18X5/8 9 90207458 2 DRAW LATCH

10 88301193 8 ROUND HD MACHINE SCREW, #10-32X1/2 11 88551007 10 LOCKWASHER, #10 12 88501613 4 HEX NUT, #10-32 13 91366004 1 TANK COVER WELDMENT 14 85211088 4 RUBBER BUMPER 15 88301073 4 ROUND HD MACHINE SCREW, #8-32X3/4 16 88521604 4 HEX LOCKNUT, #8-32 17 91083173 2 RUBBER HD SCREW BUMPER 18 88501612 2 HEX NUT, #10-24 19 91551023 1 HINGE 20 91551024 1 HINGE 21 88561003 9 FLAT WASHER, 5/16 22 91123124 4 WHIZ-LOCK SCREW, 5/16-18X1/2 23 91556014 1 REAR ENGINE COVER 24 91363210 2 T-HANDLE 25 91146050 1 REAR COVER WELDMENT 26 91556016 1 REAR COVER CENTER 27 1 BACK-UP ALARM, (Before S/N 0160016754), (no longer available, order kit

2915184 for service)

8270621 1 BACK-UP ALARM, (S/N 0160016754 & After) 28 0641406 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5, (S/N 0160016754 & After) 29 91140001 1 COUNTERWEIGHT, (no pintle hook)

1001091458 1 COUNTERWEIGHT, (with pintle hook) 30 88201143 4 HEX HD CAPSCREW, 1-8X5, GR5, (torque to 545-595 lb-ft) 31 88561011 4 WASHER, 1 32 91161282 1 REAR CAB COVER, (S/N 0160000976 thru 0160012366 excluding

0160012298)

Ref REAR CAB COVER, (S/N 0160012437 & After including 0160012298),

(see Figure 6-1 for details)

33 88201050 2 HEX HD CAPSCREW, 7/16-14X1, GR5, (Before S/N 0160016097 excluding

0160015710, 0160015711 & 0160015915)

34 91033029 1 SEAT BELT, (not used with optional seat), (Before S/N 0160016097 excluding

0160015710, 0160015711 & 0160015915)

35 88501007 2 HEX NUT, 7/16-14, (Before S/N 0160016097 excluding 0160015710,

0160015711 & 0160015915)

FRAME & ATTACHING PARTS

91364001 544D 1-7

S/N 0160000976 thru 0160034720

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

36 91033485 1 SEAT WITH ARMREST, (std.), (Before S/N 0160016097 excluding

0160015710, 0160015711 & 0160015915)

91563158 1 SUSPENSION SEAT WITH 2 IN SEAT BELT,

(S/N 0160016097 & After including 0160015710, 0160015711 & 0160015915)

1001101085 1 SUSPENSION SEAT WITH 2 IN SEAT BELT, (includes items 81 thru 87)

7026904 1 ARMREST KIT

91124107 1 SLIDE ADJ. KIT, (use with std. seat), (Before S/N 0160016097 excluding

0160015710, 0160015711 & 0160015915)

91043237 1 GRAMMER SEAT, (opt.), (Before S/N 0160016097 excluding 0160015710,

0160015711 & 0160015915)

88201020 4 HEX HD CAPSCREW, 5/16-18X1, GR5, (use with opt. seat), (Before

S/N 0160016097 excluding 0160015710, 0160015711 & 0160015915)

37 77143006 8 WHIZ-LOCKNUT, 5/16-18 38 91081475 1 HEATER COVER PLATE, (S/N 0160000976 thru 0160012366 excluding

0160012298)

Ref HEATER COVER PLATE, (S/N 0160012437 & After including 0160012298),

(see Figure 6-1 for details)

39 91141329 1 VALVE ACCESS COVER, (S/N 0160000976 thru 0160012366 excluding

0160012298)

Ref VALVE ACCESS COVER, (S/N 0160012437 & After including 0160012298),

(see Figure 6-1 for details)

40 91361005 1 BELLY PAN, (S/N 0160000976 thru 0160012366 excluding 0160012298)

Ref BELLY PAN, (S/N 0160012437 & After including 0160012298),

(see Figure 6-1 for details) 41 91083533 10 FENDER WASHER, 1-1/2, OD 42 91403230 1 MANUAL CASE 43 77143013 4 WHIZ-LOCKNUT, 1/4-20 44 77143006 2 WHIZ-LOCKNUT, 5/16-18, (use with item 58), (not shown) 45 1 TILT GAUGE, (S/N 0160000976 thru 0160005687), (no longer available, use

8466306 for service)

8466306 1 TILT GAUGE, (with adhesive), (S/N 016005766 & After) 46 88204912 1 HEX HD CAPSCREW, 1/4-20X1, (S/N 0160000976 thru 0160005687) 47 88561107 1 FLAT WASHER, (S/N 0160000976 thru 0160005687) 48 88521204 1 LOCKNUT, 1/4-20, (S/N 0160000976 thru 0160005687) 49 Ref OPEN CAB, (see Figure 6-1 for details) 50 91361007 1 DECK COVER 51 91143357 1 HORN ASSY 54 77133177 1 HEX HD CAPSCREW, 5/16-18X1-3/8, GR5 55 77133139 1 CLAMP SET 56 77133140 1 COVER PLATE 57 91363018 8 WHIZ-LOCK SCREW, 5/16-18X1 58 91363065 1 HOSE GUARD, (not shown), (located under dash panel, beneath steering

column) 59 4892500 4 HARDENED WASHER, 7/8 60 86683122 1 TIE WRAP 64 88261020 4 SOCKET BUTTON HD CAPSCREW, 5/16-18X1/2 65 91143348 2 CLAMP BAR 66 91551034 1 AIR DAM SUPPORT 67 91551033 1 AIR DAM SUPPORT 68 83201158 4 HEX HD CAPSCREW, 7/8-9X1-3/4, (torque to 450-475 lb-ft)

including 0160035922

544D 913640011-8

S/N 0160000976 thru 0160034720 including 0160035922

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

69 88201021 4 HEX HD CAPSCREW, 5/16-18X1-1/4, (S/N 0160012437 & After including

0160012298)

70 4751500 4 FLAT WASHER, 5/16, (S/N 0160012437 & After including 0160012298) 71 Ref FENDER, (see Figure 6-1 for details) 72 8305624 2 LOCKNUT, 1/4-20 73 3576433 1 MOUNTING BAR 74 4711400 2 FLAT WASHER, 1/4 75 86683480 2 BUTT CONNECTOR 76 91556017 1 SHEET METAL SUPPORT 77 77143006 4 WHIZ-LOCKNUT, 5/16-18

78 0100019 AR

79 3311505 4 HEX LOCKNUT, 5/16-18, (S/N 0160016097 & After including 0160015710,

80 4711500 4 FLAT WASHER, 5/16, (S/N 0160016097 & After including 0160015710,

81 7026900 1 BACK CUSHION KIT 82 7026902 1 BACK PANEL KIT 83 7026905 1 SEAT BELT

91565064 1 SEAT BELT, 3 IN, (California Only), (not included with std. seat) 84 7026906 1 TETHER KIT 85 7026901 1 SEAT CUSHION KIT 86 7026799 1 KNOB KIT 87 7026798 1 SLIDE KIT

LOCTITE

0160015711 & 0160015915)

271

FRAME & ATTACHING PARTS

K1 2915184 1 BACK-UP ALARM SERVICE KIT, (includes items 27, 28 & 72 thru 75) A

91364001 544D 1-9

FRAME & ATTACHING PARTS

PAP21390

215 218

217

220

219

330 334

450

445

515

513

512

618

617

614

615

616

28 76

801

106

116

2 30

9 10 45

4 20 21

9 10 45

7 18 27

28 34 41

50 77 78

60 61

701 702 703 704 705 706 707

283

Figure 1-1 Frame Shrouding & Trim

S/N 0160035037 & After

excluding 0160035922

544D 913640011-10

S/N 0160035037 & After excluding 0160035922

Figure 1-1 Frame Shrouding & Trim

Item Part Number Qty. Description Rev.

1 1001099036 1 DECK COVER 2 1001091065 1 REAR ENGINE COVER 3 1001099034 1 RADIATOR COVER 4 91366004 1 TANK COVER WELDMENT 5 1001093467 1 RUBBER AIR DAM 6 90207458 2 DRAW LATCH 7 91083173 2 RUBBER BUMPER

9 88301073 4 ROUND HD MACHINE SCREW, #8-32X3/4 10 88521604 4 HEX LOCKNUT, #10-32 15 91556016 1 REAR CENTER COVER 16 91363210 2 T-HANDLE 17 88301193 8 ROUND HD CAPSCREW, #10-32X1/2 18 4761000 10 LOCKWASHER, #10 19 88501613 4 HEX NUT, #10-32 20 90206196 AR TRIM-LOCK 21 14402248 AR 3M ADHESIVE 27 88501612 2 HEX NUT, #10-24 28 0791505 70 WHIZ-LOCK SCREW, 5/16-18X5/8 29 91146050 1 REAR COVER WELDMENT 30 90200755 24 in WEATHER STRIP 34 4751500 26 FLAT WASHER, 5/16 35 0791504 4 WHIZ-LOCK SCREW, 5/16-18X1/2 37 14404645 AR T-9 METAL PROTECTION, (12 oz. spray), (not shown) 38 14404646 AR T-9 METAL PROTECTION, (1 gal.), (not shown) 39 83683291 1 MIRROR 40 91141218 1 HINGE 41 91143348 2 CLAMP BAR 43 91531021 1 AIR DAM SUPPORT 44 0630467 4 HEX SOCKET BUTTON HD CAPSCREW, 5/16-18X1/2 45 85211088 4 RUBBER BUMPER 50 91563158 1 SUSPENSION SEAT WITH 2 IN SEAT BELT F

1001101085 1 SUSPENSION SEAT WITH 2 IN SEAT BELT, (includes items 701 thru 707) B

7026904 1 ARMREST KIT 60 77143013 4 WHIZ-LOCKNUT, 1/4-20 61 91403230 1 MANUAL HOLDER 65 8466306 1 TILT ANGLE GAUGE 76 77143006 4 WHIZ-LOCKNUT 77 3311505 4 HEX LOCKNUT, 5/16-18 78 4711500 4 FLAT WASHER, 5/16

106 0682414 4 HEX HD CAPSCREW, 7/8-9X1-3/4, GR8 116 4892500 4 HARDENED WASHER, 7/8 215 86683122 1 TIE WRAP 217 0641406 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5 218 8270621 1 BACK-UP ALARM 219 4711400 2 FLAT WASHER, 1/4 220 8305624 2 HEX LOCKNUT, 1/4-20 283 1001116274 1 MOLDED RESISTOR 330 91143357 1 HORN ASSY 334 0791504 1 WHIZ-LOCK SCREW, 5/16-18X1/2

FRAME & ATTACHING PARTS

91364001 544D 1-11

S/N 0160035037 & After

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

445 77143006 4 WHIZ-LOCKNUT, 5/16 450 1001091086 1 SHEET METAL SUPPORT 512 0642640 4 HEX HD CAPSCREW, 1-8X5 513 4752600 4 FLAT WASHER, 1 515 91140001 1 COUNTERWEIGHT 614 Ref REAR PANEL COVER, (see Figure 6-1 for details) 615 Ref HEATER PANEL COVER, (see Figure 6-1 for details) 616 Ref VALVE ACCESS COVER, (see Figure 6-1 for details) 617 Ref CAB BELLY PAN COVER, (see Figure 6-1 for details) 618 Ref FRONT FENDER, (see Figure 6-1 for details) 701 7026900 1 BACK CUSHION KIT 702 7026902 1 BACK PANEL KIT 703 7026905 1 SEAT BELT KIT

91563164 1 SEAT BELT, 3 IN, (California Only), (not included with standard seat) 704 7026906 1 TETHER KIT 705 7026901 1 SEAT CUSHION KIT 706 7026799 1 KNOB KIT 707 7026798 1 SLIDE KIT 708 70023040 1 SHOCK ABSORBER KIT, (not shown), (includes one shock absorber, two shock

pins & two hex nuts) 709 70023041 1 SPRING & SADDLE KIT, (not shown) 801 1001091067 1 FRAME WELDMENT

excluding 0160035922

K1 70023139 1 SEAT BELT KIT, 3 IN, (California only), (includes retractor & female end)

544D 913640011-12

S/N 0160035037 & After excluding 0160035922

Figure 1-1 Frame Shrouding & Trim (Continued)

Item Part Number Qty. Description Rev.

FRAME & ATTACHING PARTS

91364001 544D 1-13

FRAME & ATTACHING PARTS

PAP19650

UPPER

LOWER

RIGHT

SIDE

LEFT

SIDE

FRONT OF

37 38

28 30

UPPER

ENLARGED VIEW

MACHINE

21 22

KNUCKLE LAYOUT FOR BORING OUT HOLES FOR BUSHINGS SEE NOTE #3 FOR DETAILS (RH KNUCKLE SHOWN)

(3)HOLES

2.377 DIA

2.378

125

NEW HOLES

BOTTOM HOLE

LOCATE NEW BORES THRU BOTTOM HOLE. NEW BORES MUST BE IN LINE WITH EXISTING BOTTOM BORE. HOLES MUST ACCEPT A 2.375 DIA. SHAFT THRU ALL 4 HOLES.

K1 K2

NOTES:

1. CYLINDER BASE END MUST BE FREE TO ROTATE. SHIM STEERING CYLINDER BASE END AS REQUIRED TO MAINTAIN A TOTAL MAX. GAP OF 1/16 IN.

2. SHIM BOTTOM KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/32 IN MOVEMENT.

SHIM TOP KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/16 IN GAP. MUST HAVE A MINIMUM OF ONE SHIM.

3. ALL MACHINES (BEFORE S/N 0355258) NEED TO BORE STEERING KNUCKLES TO USE ITEMS 4 & 7.

4. SEE FIGURE 12-24 FOR DETAILS ON THE REAR AXLE ADVANTAGE KIT.

5. USE LOCTITE

242TM (P/N 14403364) ON ALL BOLT THREADS.

Figure 1-2 Rear Axle & Attaching Parts

S/N 0355001 thru 0455362

544D 913640011-14

S/N 0355001 thru 0455362

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts

Item Part Number Qty. Description Rev.

1 88521312 2 HEX LOCKNUT, 3/4-10, (torque to 160-175 lb-ft) 2 91081415 2 DIRT SHIELD 3 91041481 2 STEERING CYLINDER PIN 4 91121239 2 BUSHING 5 91041439 2 TIE ROD PIN 6 88521306 2 LOCKNUT, 3/8-16 7 91121240 4 BUSHING 8 91123030 4 BACK-UP RING

9 88591032 4 O-RING 10 91123027 2 BUSHING 11 91123029 2 O-RING 12 88591104 4 O-RING 13 91121091 2 THRUST BUSHING 14 91041733 AR SHIM 15 91166013 1 REAR AXLE WELDMENT, (includes items 10, 17, 61 & 63) 16 86921268 2 LIP SEAL 17 91123028 2 BUSHING 18 91081693 2 UPPER KING PIN 19 88581323 4 RETAINING RING 20 88671022 4 LUBE FITTING, 90 DEGREE, 1/8 21 91041732 2 SPACER, (3/16 thick) 22 91041438 AR SPACER 23 88591019 2 O-RING 24 91041459 2 WASHER 25 88501416 2 HEX JAM NUT, 1-14, (torque to 225-250 lb-ft) 26 83201140 2 HEX HD CAPSCREW, 3/8-16x2-3/4, GR8 27 91141424 2 LOWER KING PIN 28 91041449 AR SHIM, (0.060 thick, see note #2) 29 91041450 AR SHIM, (0.0478 thick, see note #2) 30 91041451 AR SHIM, (0.106 thick, see note #2) 31 91041596 AR SHIM, (20 ga, see note #2) 32 Ref DRIVE HUB, (see Figure 5-11 for details) 33 91120004 1 RH STEERING KNUCKLE, (see note #3) 34 88501006 2 HEX NUT, 3/8-16 35 88551011 6 LOCKWASHER, 3/8 36 83201144 2 HEX HD CAPSCREW, 3/8-16X5-3/4, GR8 37 88671001 6 STRAIGHT LUBE FITTING, 1/8 38 91081695 2 STEERING CYLINDER PIVOT PIN 39 91403066 AR SHIM, (0.060 thick, see note #1) 40 Ref STEERING CYLINDER ASSY, (see Figure 9-6 for details) 41 91166056 1 LH TUBE SUPPORT

91166055 1 RH TUBE SUPPORT 42 88201035 4 HEX HD CAPSCREW, 3/8-16X1, GR5 43 88211121 2 SOCKET HD CAPSCREW, 1/2-13X6-1/2, GR8 44 91120003 1 LH STEERING KNUCKLE, (see note #3) 45 91043247 2 SELF-ALIGNING BUSHING 46 86681572 12 HARDENED WASHER, 3/4 47 83201006 12 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 270-290 lb-ft) 48 88521208 2 HEX LOCKNUT, 1/2-13

91364001 544D 1-15

S/N 0355001 thru 0455362

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts (Continued)

Item Part Number Qty. Description Rev.

49 91043222 4 CAPSCREW, 12PT, 3/410X2, GR8, (torque to 270-290 ft lbs.) 50 91403065 AR SHIM, (10 ga., see note #1) 51 88551153 2 LOCKWASHER, 5/8 52 88212321 4 SOCKET HD CAPSCREW, 5/8-11X3-3/4, GR8 53 91081177 1 REAR AXLE MOUNTING PIN 54 85101098 1 HEX NUT, 1-1/4-7 55 91166063 1 TIE ROD, (includes items 45 & 2 of item 37) 56 91161066 AR SHIM, (0.0598 thick) 57 91161067 AR SHIM, (0.1046 thick) 58 91161068 AR SHIM, (0.1345 thick) 59 90020247 1 HEX HD CAPSCREW, 1-1/4-7X6, GR5 60 24601570 2 LIP SEAL 61 91123031 2 BUSHING 62 88501110 2 HEX NUT, 5/8-11 63 91163019 2 BUSHING, (stabilizer support), (not shown)

K1 91145099 1 STEERING KNUCKLE KIT, (includes items 2, 4, 7, 8, 9, 11 thru 14, 16, 18 thru

23, 27 thru 31, 51 & two of item 52, one kit does both sides)

K2 91045152 AR STEERING CYLINDER PIN KIT, (includes one each of items 1, 2, 3, 12, 21 thru

25, one kit needed for each side)

544D 913640011-16

S/N 0355001 thru 0455362

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts (Continued)

Item Part Number Qty. Description Rev.

91364001 544D 1-17

PAP21550

ENLARGED VIEW

37 38

102

104 105

103

K1 K2

34 67 68

36 66

LOWER

UPPER

LOWER

42 64

K3 K4

NOTES:

1. CYLINDER BASE END MUST BE FREE TO ROTATE. SHIM STEERING CYLINDER BASE END AS REQUIRED TO MAINTAIN ATOTAL MAX. GAP OF 1/16 IN.

2. SHIM BOTTOM KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/32 IN MOVEMENT. SHIM TOP KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/16 IN GAP. MUST HAVE A MINIMUM ONE SHIM.

3. INSTALL 5/8 LONG THREAD ON STUD INTO DRIVE HUB, (SHORTEST LENGTH THREADS ON STUD).

4. USE GREASE P/N 1440-4595 ON ALL PINS & SURFACES INDICATED BEFORE ASSEMBLY.

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts

S/N 0160000192 & After

544D 913640011-18

S/N 0160000192 & After

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts

Item Part Number Qty. Description Rev.

1 88521312 2 LOCKNUT, 3/4-10, (torque to 160-175 lb-ft) 2 91081415 2 DIRT SHIELD 3 91041732 2 SPACER 4 80933066 2 O-RING 5 3790226 2 O-RING 6 91343052 2 ROD END STEER CYLINDER PIN 8 1001099173 2 FLANGE NUT, (torque to 280-305 lb-ft)

9 91403082 2 TIE ROD PIN 10 4761600 4 LOCKWASHER, 3/8 11 83201021 2 HEX HD CAPSCREW, 3/8-16X3 12 88521306 2 HEX LOCKNUT, 3/8-16, (nylok) 13 91403145 8 WIPER SEAL 14 91403034 2 LOWER BUSHING 15 91403146 2 O-RING 16 88591108 2 O-RING 17 91401081 2 THRUST BUSHING 18 91346009 1 REAR AXLE WELDMENT, (includes items 14, 23, 56, 69) I 19 91403163 AR KING PIN SHIM, (see note #2)

91403164 AR KING PIN SHIM, (see note #2) 91403165 AR KING PIN SHIM, (see note #2)

91403166 AR KING PIN SHIM, (see note #2) 20 91403078 2 LOWER KING PIN 21 91403067 2 RETAINING WASHER 22 88211068 2 SOCKET HD CAPSCREW, 3/8-16X5/8, GR8 23 91403031 2 UPPER BUSHING 24 91403079 2 UPPER KING PIN 25 88581325 2 SNAP RING 26 91123092 8 STUD, (see note #3) 27 85401340 8 HARD WASHER 28 91083449 8 HEX NUT, 1/2-13 29 Ref DRIVE HUB, (see Figure 5-11 for details) 30 Use Kit K3 1 RH KNUCKLE 31 88501110 2 HEX NUT, 5/8-11 32 88212321 2 SOCKET HD CAPSCREW, 5/8-11X3-3/4, GR8 33 90028740 2 FEMALE GREASE FITTING 34 88701021 2 NIPPLE, 1/8X2 35 88501006 2 HEX NUT, 3/8-16 36 83201144 2 HEX HD CAPSCREW, 3/8-16X5-3/4 37 91403372 2 BASE END STEER CYLINDER PIN 38 88711280 2 HEX SOCKET PIPE PLUG, 1/8 39 91403065 AR KING PIN SHIM, (see note #1)

91403066 AR KING PIN SHIM, (see note #1) 40 Ref STEERING CYLINDER, (see Figure 9-6 for details) 41 91406098 1 LH TUBE SUPPORT

91406099 1 RH TUBE SUPPORT 42 0641608 4 HEX HD CAPSCREW, 3/8-16X1, GR5 43 4761600 4 LOCKWASHER, 3/8 44 88212272 2 SOCKET HD CAPSCREW, 5/8-11X8, GR8 45 88521210 2 HEX LOCKNUT, 5/8, (nylok)

91364001 544D 1-19

S/N 0160000192 & After

FRAME & ATTACHING PARTS

Figure 1-2 Rear Axle & Attaching Parts (Continued)

Item Part Number Qty. Description Rev.

46 Use Kit K4 1 LH KNUCKLE 47 8050001 2 SELF-ALIGNING BUSHING, (tie rod) 48 88671001 2 STRAIGHT LUBE FITTING, 1/8 49 91406021 1 TIE ROD WELDMENT, (includes items 47 & 48) 50 86681572 12 HARDENED WASHER, 3/4 51 83201006 12 HEX HD CAPSCREW, 3/4-10X2 52 91043222 4 12 POINT SCREW, 3/4-10X2 53 88551154 2 LOCKWASHER, 3/4, (hi-collar) 54 88212285 2 SOCKET HD CAPSCREW, 3/4-10X5, GR8 55 91403145 2 WIPER SEAL 56 91403033 2 PIVOT TUBE BUSHING 57 88671001 1 LUBE FITTING - STRAIGHT, 1/8, (rear) 58 91081177 1 REAR AXLE PIN 59 90020247 1 HEX HD CAPSCREW, 1-1/4-7X6 60 88521020 1 LOCKNUT, 1-1/4-7 61 91161068 AR SHIM, (0.135 thick) 62 91161067 AR SHIM, (0.100 thick) 63 91161066 AR SHIM, (0.060 thick) 64 14404793 AR UNION 76 MEGAPLEX GREASE 65 4711600 4 PLAIN WASHER, 3/8 66 14404595 AR MYSTIK TETRIMOLY GREASE 67 14404082 AR LOCTITE PIPE SEALANT

277

641

68 14404102 AR

LOCTITE

69 91163019 2 BUSHING 102 91403354 2 BUSHING 103 91403355 1 BUSHING 104 91551039 1 BUSHING 105 14404978 AR

LOCTITE

K1 91415039 1 STEERING KNUCKLE KIT, (includes items 2 thru 5, 13 thru 17, 19 thru 25, 44,

45, 53 & 54)

K2 91415040 1 STEERING CYLINDER PIN KIT, (includes one each of items 1 thru 8, one kit

needed for each side) K3 91555032 AR RH KNUCKLE KIT, (includes items 8, 30 & 102 thru 105) K4 91555031 AR LH KNUCKLE KIT, (includes items 8, 46 & 102 thru 105)

544D 913640011-20

+ 700 hidden pages

JLG 544D-10 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EFFECTIVITY PAGE

TABLE OF CONTENTS

Figure 1-1 Frame Shrouding & Trim

Figure 1-2 Rear Axle & Attaching Parts