JLG 544D-10 Parts Manual

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Page 1

An Oshkosh Corporation Company

Illustrated Parts Manual

Model

544D

S/N 0355001 thru 0455362

& 0160000192 & After

91364001

Revised

April 3, 2014

Page 2

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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

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EFFECTIVITY PAGE

544D 91364001ii

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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

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TABLE OF CONTENTS

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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

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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

Page 8

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

Page 9

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

Page 10

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

544D 91364001viii

Page 11

SECTION 1

FRAME & ATTACHING PARTS

91364001 544D

Page 12

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Trim

S/N 0355001 thru 0455362 &

0160000192 thru 0160000973

544D 913640011-2

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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

Page 29

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

Page 30

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

Page 31

S/N 0160000192 & After

FRAME & ATTACHING PARTS

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

Item Part Number Qty. Description Rev.

91364001 544D 1-21

Page 32

FRAME & ATTACHING PARTS

ROCKWELL

Figure 1-3 Front Axle Mounting

S/N 0355001 thru 0455362

544D 913640011-22

Page 33

S/N 0355001 thru 0455362

FRAME & ATTACHING PARTS

Figure 1-3 Front Axle Mounting

Item Part Number Qty. Description Rev.

14404793 AR UNION 76 MEGAPLEX GREASE 1 Ref FRONT AXLE ASSY, (see Figure 5-1 for details) 2 91081176 1 FRONT SWAY PIN 3 90205891 2 SPACER 4 91031014 2 SHIM WASHER 5 83201172 1 HEX HD CAPSCREW, 1-8 x 5, GR8 6 88521016 1 HEX LOCKNUT, 1-8 7 91083480 1 SHIM WASHER

91364001 544D 1-23

Page 34

FRAME & ATTACHING PARTS

PAP21670

3 17

CARRARO

Figure 1-4 Front Axle Mounting

S/N 0160000192 & After

544D 913640011-24

Page 35

S/N 0160000192 & After

FRAME & ATTACHING PARTS

Figure 1-4 Front Axle Mounting

Item Part Number Qty. Description Rev.

1 Ref FRONT AXLE ASSY, (see Figure 5-6 for details) 2 3423248 1 FRONT SWAY PIN 3 90205891 AR SPACER 4 91031014 AR SHIM WASHER 5 83201172 1 HEX HD CAPSCREW, 1-8X5, GR8 6 88521016 1 HEX LOCKNUT, 1-8 7 91083480 AR SHIM WASHER

17 14404793 AR UNION 76 MEGAPLEX GREASE

91364001 544D 1-25

Page 36

FRAME & ATTACHING PARTS

PAP17700

FOR SERVICE ONLY

Figure 1-5 Outrigger Mounting

Before S/N 0160015062

544D 913640011-26

Page 37

Before S/N 0160015062

FRAME & ATTACHING PARTS

Figure 1-5 Outrigger Mounting

Item Part Number Qty. Description Rev.

1 88671001 4 STRAIGHT LUBE FITTING, 1/8 2 Ref OUTRIGGER CYLINDER VALVE, (see Figure 9-19 for details) 3 88211083 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8 4 91161080 2 SHOE PIN 5 3300143 4 HEX LOCKNUT, 3/8-16 6 91161069 2 ARM PIN 7 Ref OUTRIGGER CYLINDER ASSY, (see Figure 9-8 for details) 8 91166008 2 ARM WELDMENT 9 91166011 2 OUTRIGGER SHOE

10 88201065 4 HEX HD CAPSCREW, 1/2-13X1, GR5 11 83793054 2 HEX HD CAPSCREW, 3/8-16X4-1/4 12 91161016 2 OUTRIGGER CYLINDER PIN 13 91081313 2 KEEPER, (see Figure 9-13 for details) 14 88551013 4 LOCKWASHER, 1/2 15 91163014 4 BUSHING 16 Ref ADAPTOR, (includes o-ring), (see Figure 9-8 for details)

91364001 544D 1-27

Page 38

FRAME & ATTACHING PARTS

15 16

PAL3390

15 16

Figure 1-5 Outrigger Mounting

S/N 0160015062 & After

544D 913640011-28

Page 39

S/N 0160015062 & After

FRAME & ATTACHING PARTS

Figure 1-5 Outrigger Mounting

Item Part Number Qty. Description Rev.

Ref OUTRIGGER INSTALLATION, (includes all items) 2 91566050 2 ARM WELDMENT 3 91566051 2 OUTRIGGER HOSE 4 Ref OUTRIGGER CYLINDER, (see Figure 9-8 for details)

Ref OUTRIGGER VALVE, (see Figure 9-19 for details)

Ref OUTRIGGER CYLINDER & VALVE, (see Figure 9-8 for details) 5 91163014 4 BUSHING 6 91563197 2 OUTRIGGER CYLINDER PIN 7 91563198 2ARM PIN 8 91563199 2SHOE PIN 9 91081313 2 KEEPER

10 0641634 2 HEX HD CAPSCREW, 3/8-16X4-1/4, GR5 11 0641808 4 HEX HD CAPSCREW, 1/2-13X1, GR5 12 3300143 4 HEX LOCKNUT, 3/8-16 13 3931672 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8 14 4761800 4 LOCKWASHER, 1/2 15 2160002 4 STRAIGHT LUBE FITTING, 1/8

16 0100011 AR

LOCTITE

17 Ref HOSE ASSY, (not shown), (see Figure 8-15 for details)

242

91364001 544D 1-29

Page 40

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

544D 913640011-30

Page 41

SECTION 2

BOOM

91364001 544D

Page 42

BOOM

NOTES:

1. ADD BEARING PAD SHIMS & SPACERS AS REQUIRED TO SHIM BOOM TO WITHIN 1/16 IN OF A TIGHT FIT. AMOUNTS OF SHIMS CAN VARY AT EACH SHIM POINT. WHENEVER A SHIM IS USED WITH A PAD, A SPACER MUST BE INSERTED BETWEEN PAD & SHIM. NO PADS SHALL SIT DIRECTLY ON SLOTTED SURFACE OF SHIMS.

2. ADD, 14404793, MYSTIK TETRIMOLY GREASE TO ALL BEARING PADS & BEARING SLIDE AREAS.

3. T HE LEN GTH OF PAD BOL TS DEPEND ON T HE AMOUNT OF SHIMS USED. BOLT CANNOT EXTEND PAST CHAMFER ON BEARING.

4. BEARING PAD BOLT TORQUES, 3/8 IN BOLTS = 32-37 LB-FT, 1/2 IN BOLTS = 76-86 LB-FT

Figure 2-1 First Boom Section

544D 913640012-2

Page 43

BOOM

Figure 2-1 First Boom Section

Item Part Number Qty. Description Rev.

1 91166014 1 FIRST BOOM SECTION 2 88201066 2 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5, (Before S/N 0160012437)

0651618 2 HEX HD CAPSCREW, 0.375-24X2.25, LG, (S/N 0160012437 & After) 3 88551013 2 LOCKWASHER, 1/2 4 88201536 2 HEX HD CAPSCREW, 3/8-24X1-1/2, GR5, (Before S/N 0160012437)

0651612 2 HEX HD CAPSCREW, 0.375-24X1.5, LG, (S/N 0160012437 & After) 5 90027470 10 HARDENED WASHER, 3/8 6 0651606 8 HEX HD CAPSCREW, 3/8-24X3/4, GR5

0651605 AR HEX HD CAPSCREW, 0.375-24X0.62, LG

0651607 AR HEX HD CAPSCREW, 0.375-24X0.88, LG 7 88201537 AR HEX HD CAPSCREW, 3/8-24X1-3/4, GR5, (Before S/N 0160012437)

0651614 AR HEX HD CAPSCREW, 0.375-24X1.75, LG, (S/N 0160012437 & After) 8 91361048 6 SHIM 9 91031236 6 SPACER

10 91033186 4 BEARING PAD 11 91161171 2 BEARING PAD SUPPORT 12 91033189 2 BEARING PAD 13 1001117653 2 BEARING PAD 14 91161183 2 SPACER 15 91361050 2 SHIM, (Before S/N 0160012437)

91161184 2 SHIM, (S/N 0160012437 & After) 16 91161167 2 BEARING PAD SUPPORT 17 90027471 AR HARDENED WASHER, 1/2 18 88201570 6 HEX HD CAPSCREW, 1/2-20X2-1/2, GR5, (Before S/N 0160012437)

0651820 6 HEX HD CAPSCREW, 0.5-20 X 2.5, LG, (S/N 0160012437 & After)

0651822 AR HEX HD CAPSCREW, 0.5-20 X 2.75, LG, (S/N 0160012437 & After) 19 91141301 2 BUSHING 20 88671001 2 LUBE FITTING 21 91141122 1 BOOM BASE PIN, (Before S/N 0160018546)

3423247 1 BOOM BASE PIN, (S/N 0160018546 & After) 22 83481645 1 HEX HD CAPSCREW, 5/8-11X6, GR8, (Before S/N 0160018546)

88212287 1 HEX HD CAPSCREW, 3/4-16X6, GR8, (S/N 0160018546 & After)

23 88521010 1 HEX NUT, 5/8-11, (Before S/N 0160018546)

8310067 1 HEX LOCKNUT, 3/4-10, (S/N 0160018546 & After) 24 88561111 2 FLAT WASHER, 1/2

91364001 544D 2-3

Page 44

BOOM

NOTES:

2. ADD, 14404793, MYSTIK TETRIMOLY GREASE TO ALL BEARING PADS & BEARING SLIDE AREAS.

3. ADD, 14404595, MYSTIK TETRIMOLY GREASE ON ALL BEARING PAD GREASE FITTINGS AT REAR OF BOOM.

4. THE LENGTH OF PAD BOLTS DEPEND ON THE AMOUNT OF SHIMS USED. BOLT CANNOT EXTEND PAST CHAMFER ON BEARING.

5. BEARING PAD BOLT TORQUES, 3/8 IN BOLTS = 32-37 LB-FT, 1/2 IN BOLTS = 76-86 LB-FT, HOLLOW 3/8 IN BOLTS = 20-25 LB-FT, HOLLOW 1/2 IN BOLTS = 45-50 LB-FT

Figure 2-2 Second Boom Section

544D 913640012-4

Page 45

BOOM

Figure 2-2 Second Boom Section

Item Part Number Qty. Description Rev.

1 91166015 1 SECOND BOOM SECTION 2 91033189 2 BEARING PAD 3 91031236 8 SPACER 4 91361048 6 SHIM 5 91161170 2 BEARING PAD SUPPORT 6 90027470 20 HARDENED WASHER, 3/8 7 88201539 4 HEX HD CAPSCREW, 3/8-24X2-1/4, GR5, (Before S/N 0160012437)

0651618 AR HEX HD CAPSCREW, 0.375-24X2.25, LG, (S/N 0160012437 & After)

8 88551013 2 LOCKWASHER, 1/2 9 88201066 2 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5, (Before S/N 0160012437)

0651620 AR HEX HD CAPSCREW, 0.375-24X2.25, LG, (S/N 0160012437 & After) 10 91161168 1 BEARING PAD SUPPORT 11 90027473 2 HARDENED WASHER, 3/4 12 88201108 2 HEX HD CAPSCREW, 3/4-10X1-1/4, GR5, (Before S/N 0160012437)

0642210 2 HEX HD CAPSCREW, 0.75-10X1.25, LG, (S/N 0160012437 & After) 13 90027471 18 HARDENED WASHER, 1/2 14 0651812 8 HEX HD CAPSCREW, 1/2-20X1-1/2, GR5

0651816 AR HEX HD CAPSCREW, 500-20X2.00, LG

0651808 AR HEX HD CAPSCREW, 500-20X1.00, LG

0651806 1 HEX HD CAPSCREW, 500-20X0.75, LG 15 91141302 2 SHIM 16 91141303 2 SPACER 17 1001117652 2 BEARING PAD 18 91033186 4 BEARING PAD 19 90205870 2 SHIM 20 0651606 10 HEX HD CAPSCREW, 3/8-24X3/4, GR5

0651605 AR HEX HD CAPSCREW, 0.375-24X0.62, LG

0651607 AR HEX HD CAPSCREW, 0.375-24X0.88, LG 21 1001117653 2 BEARING PAD 22 91161183 2 SPACER 23 91161184 2 SHIM 24 88201564 2 HEX HD CAPSCREW, 1/2-20X1, GR5 25 88201538 2 HEX HD CAPSCREW, 3/8-24X2, GR5, (Before S/N 0160012437)

0651616 2 HEX HD CAPSCREW, 0.375-24X2, LG, (S/N 0160012437 & After) 26 91163214 2 BEARING PAD 27 91511094 2 SPACER 28 91121082 4 SHIM 29 88561111 2 FLAT WASHER, 1/2 30 88671027 6 GREASE FITTING, 90 DEGREE 31 91161248 2 HOLLOW HEX HD CAPSCREW, 3/8-24X3/4, (torque to 20-25 lb-ft),

(Before S/N 0160012437)

91361045 2 HOLLOW HEX HD CAPSCREW, 0.375-24X0.875, (torque to 20-25 ft.lbs),

(S/N 0160012437 & After)

91361044 2 HOLLOW HEX HD CAPSCREW, 0.375-24X0.625, (torque to 20-25 lb-ft),

(S/N 0160012437 & After)

32 91161222 2 HOLLOW HEX HD CAPSCREW, 1/2-20X1-1/2, (torque to 20-25 lb-ft) 33 91163188 2 BEARING PAD 34 91161278 2 HOLLOW HEX HD CAPSCREW, 3/8-24X2, (torque 20-25 lb-ft),

(Before S/N 0160012437)

91361046 2 HOLLOW HEX HD CAPSCREW, 0.375-24X2.25, (torque 20-25 lb-ft),

(S/N 0160012437 & After)

91364001 544D 2-5

Page 46

BOOM

NOTES:

2. ADD, 14404793, MYSTIK TETRIMOLY GREASE TO ALL BEARING PADS & BEARING SLIDE AREAS.

3. ADD, 14404595, MYSTIK TETRIMOLY GREASE ON ALL BEARING PAD GREASE FITTINGS AT REAR OF BOOM.

4. THE LENGTH OF PAD BOLTS DEPEND ON THE AMOUNT OF SHIMS USED. BOLT CANNOT EXTEND PAST CHAMFER ON BEARING.

5. BEARING PAD BOLT TORQUES; 3/8” BOLTS = 32-37 LB-FT, 1/2” BOLTS = 76-86 LB-FT, HOLLOW 3/8” BOLTS = 20-25 LB-FT, HOLLOW 1/2” BOLTS = 45-50 LB-FT

Figure 2-3 Third Boom Section

544D 913640012-6

Page 47

BOOM

Figure 2-3 Third Boom Section

Item Part Number Qty. Description Rev.

1 91166016 1 THIRD BOOM SECTION 2 91161169 1 BEARING PAD SUPPORT 3 88201093 2 HEX HD CAPSCREW, 5/8-11X1, GR5, (Before S/N 0160012437)

0642008 2 HEX HD CAPSCREW, 0.625-11X1.00, LG, (S/N 0160012437 & After)

4 77141077 2 HARDENED WASHER, 5/8 5 88201564 6 HEX HD CAPSCREW, 1/2-20X1, GR5, (Before S/N 0160012437)

0651816 AR HEX HD CAPSCREW, 500-20X2, LG, (S/N 0160012437 & After)

0651808 AR HEX HD CAPSCREW, 500-20X1, LG, (S/N 0160012437 & After)

0651806 1 HEX HD CAPSCREW, 500-20X0.75, LG, (S/N 0160012437 & After)

6 90027471 AR HARDENED WASHER, 1/2 7 91141302 6 SHIM 8 91141303 6 SPACER 9 1001117652 6 BEARING PAD

10 88201539 2 HEX HD CAPSCREW, 3/8-24X2-1/4, GR5, (Before S/N 0160012437)

0651618 AR HEX HD CAPSCREW, 0.375-24X2.25, LG, (S/N 0160012437 & After) 11 88201066 2 HEX HD CAPSCREW, 1/2-13X1-1/4, GR5, (Before S/N 0160012437)

0651620 AR HEX HD CAPSCREW, 0.375-24X2.25, LG, (S/N 0160012437 & After) 12 90027470 AR HARDENED WASHER, 3/8 13 88551013 2 LOCKWASHER, 1/2 14 91161170 2 BEARING PAD SUPPORT 15 91361048 8 SHIM 16 91031236 8 SPACER 17 91033189 2 BEARING PAD 18 91033186 4 BEARING PAD 19 91163188 2 BEARING PAD 20 0651606 10 HEX HD CAPSCREW, 3/8-24X3/4, GR5

0651605 AR HEX HD CAPSCREW, 0.375-24X0.62, LG

0651607 AR HEX HD CAPSCREW, 0.375-24X0.88, LG 21 0651814 6 HEX HD CAPSCREW, 1/2-20X1-3/4, GR5

0651810 6 HEX HD CAPSCREW, 0.50-20 X 1.50, LG 22 88201565 2 HEX HD CAPSCREW, 1/2-20X1-1/4, GR5

0651808 2 HEX HD CAPSCREW, 1/2-20X1

0651810 2 HEX HD CAPSCREW, 1/2-20X1-1/4

0651806 2 HEX HD CAPSCREW, 1/2-20X3/4 23 91161277 2 HOLLOW HEX HD CAPSCREW, 1/2-20X2, (torque to 20-25 lb-ft),

(Before S/N 0160012437)

91361047 2 HOLLOW HEX HD CAPSCREW, 0.50-20X1.50, (torque to 20-25 lb-ft),

(S/N 0160012437 & After)

24 88561111 3 FLAT WASHER, 1/2 25 88671027 6 GREASE FITTING, 90 DEGREE 26 91161248 2 HOLLOW HEX HD CAPSCREW, 3/8-24X3/4, (torque to 20-25 lb-ft),

(Before S/N 0160012437)

91361045 2 HOLLOW HEX HD CAPSCREW, 0.375-24X0.875, (torque to 20-25 ft.lbs),

(S/N 0160012437 & After)

27 91161221 2 HOLLOW HEX HD CAPSCREW, 1/2-20X1-3/4, (torque to 20-25 lb-ft)

91361047 2 HOLLOW HEX HD CAPSCREW, 1/2-20X1-3/4, (torque to 20-25 lb-ft)

91364001 544D 2-7

Page 48

BOOM

NOTES:

2. ADD 14404793, MYSTIK TETRIMOLY GREASE TO ALL BEARING PADS & BEARING SLIDE AREAS.

3. ADD 14404595, MYSTIK TETRIMOLY GREASE ON ALL BEARING PADS.

4. THE LENGTH OF PAD BOLTS DEPEND ON THE AMOUNT OF SHIMS USED. BOLT CANNOT EXTEND PAST CHAMFER ON BEARING.

5. BEARING PAD BOLT TORQUES, 3/8 IN BOLTS = 32-37 LB-FT, 1/2 IN BOLTS = 76-86 LB-FT, HOLLOW 3/8 IN BOLTS = 20-25 FT.LBS, HOLLOW 1/2 IN BOLTS = 45-50 LB-FT

Figure 2-4 Fourth Boom Section

544D 913640012-8

Page 49

BOOM

Figure 2-4 Fourth Boom Section

Item Part Number Qty. Description Rev.

1 91166017 1 FOURTH BOOM SECTION, (Before S/N 0160037689)

1001099331 1 FOURTH BOOM SECTION, (S/N 0160037689 & After) 2 1001117652 4 BEARING PAD 3 91141303 4 SPACER 4 91141302 8 SHIM 5 90027471 AR HARDENED WASHER, 1/2 6 0651814 6 HEX HD CAPSCREW, 1/2-20X1-3/4, GR5, (torque to 76-86 lb-ft)

0651816 AR HEX HD CAPSCREW, 500-20X2.00, LG 0651808 AR HEX HD CAPSCREW, 500-20X1.00, LG

0651806 1 HEX HD CAPSCREW, 500-20X0.750, LG 7 91161221 2 HOLLOW HEX HD CAPSCREW, 1/2-20X1-3/4, (torque to 20-25 lb-ft) 8 88671027 4 GREASE FITTING, 90 DEGREE 9 91161248 2 HOLLOW HEX HD CAPSCREW, 3/8-24X3/4, (torque to 20-25 lb-ft),

(Before S/N 0160012437)

91361045 2 HOLLOW HEX HD CAPSCREW, 0.375-24X0.875, (torque to 20-25 ft.lbs),

(S/N 0160012437 & After)

91361044 AR HOLLOW HEX HD CAPSCREW, 3/8-24X3/4, (torque to 20-25 lb-ft) 10 90027470 AR HARDENED WASHER, 3/8 11 0651606 10 HEX HD CAPSCREW, 3/8-24X3/4, GR5

0651605 AR HEX HD CAPSCREW, 0.375-24X0.62, LG

0651607 AR HEX HD CAPSCREW, 0.375-24X0.88, LG 12 91361048 2 SHIM 13 91031236 2 SPACER 14 91163188 2 BEARING PAD 15 0651812 2 HEX HD CAPSCREW, 1/2-20X1-1/2, GR5, (torque to 76-87 ft.lbs)

0651810 2 HEX HD CAPSCREW, 0.5-20X1.5, LG 16 72088049 12 in NYLON TUBE, 1/4 IN OD 17 86881276 2 ELBOW, 90 DEGREE 18 91161274 2 HOLLOW HEX HD CAPSCREW, 1/2-20X1-3/4, (torque to 20-25 lb-ft) 19 88671018 2 LUBE FITTING, 45 DEGREE, 1/8 20 86881273 2 STRAIGHT THREAD CONNECTOR 21 91166065 2 BRACKET 22 91166039 1 BRACKET ASSY 23 4761600 2 LOCKWASHER, 3/8 24 0641606 2 HEX HD CAPSCREW, 3/8-16X3/4

91364001 544D 2-9

Page 50

BOOM

NOTES:

1. USE ITEM 101 ON ITEM 8.

2. BOOM SECTIONS SHOWN SEPARATELY FOR CLARIFICATION.

Figure 2-5 Extension Chains

544D 913640012-10

Page 51

BOOM

Figure 2-5 Extension Chains

Item Part Number Qty. Description Rev.

1 Ref FIRST BOOM SECTION, (see Figure 2-1 for details) 2 88501314 6 HEX NUT, 7/8-14, (torque to 100 lb-ft) 3 91161218 3 SPECIAL WASHER 4 91163163 3 SPRING 5 91166044 1 CHAIN ANCHOR 6 1360296 3 CHAIN CLEVIS 7 88581112 12 RETAINING RING, 3/8 8 91413122 6 CHAIN PIN

9 91163036 3 CHAIN, 193 IN 10 91165022 3 CHAIN ROLLER, (includes items 20 & 21) 11 Ref SECOND BOOM SECTION, (see Figure 2-2 for details) 12 88501414 6 JAM NUT, (torque to 100 lb-ft) 13 1360297 3 CHAIN CLEVIS 14 91166045 1 ROLLER BRACKET 15 91161266 1 CHAIN SHEAVE PIN 16 91081313 2 PIN KEEPER 17 4761800 4 LOCKWASHER, 1/2 18 88201065 4 HEX HD CAPSCREW, 1/2-13X1, GR5 19 88671001 2 GREASE FITTING 20 91163204 3 BUSHING 21 86921268 6 SEAL 22 91041451 6 THRUST WASHER, (0.106 in thick)

91041450 AR THRUST WASHER, (0.0478 in thick) 91041449 AR THRUST WASHER, (0.060 in thick)

91041596 AR THRUST WASHER, (0.0359 in thick) 23 Ref THIRD BOOM SECTION, (see Figure 2-3 for details) 24 91166025 1 ROLLER BRACKET 25 91161267 1 CHAIN SHEAVE PIN 26 Ref FOURTH BOOM SECTION, (see Figure 2-4 for details) 27 Ref BOOM HYD. SUB ASSY, (see Figure 8-6 for details)

101 8522012 AR ANTI-SEIZE LUBE, (not shown) 151 88581157 2 RETAINING RING, (not shown)

91364001 544D 2-11

Page 52

BOOM

PAP21640

151

NOTES:

1. USE ITEM 101 ON ITEM 8.

2. BOOM SECTIONS SHOWN SEPARATELY FOR CLARIFICATION.

Figure 2-6 Retraction Chains

544D 913640012-12

Page 53

BOOM

Figure 2-6 Retraction Chains

Item Part Number Qty. Description Rev.

1 88501412 1 HEX JAM NUT, 3/4-16, (torque to 100 lb-ft) 2 88501312 3 HEX NUT, 3/4-16, (torque to 100 lb-ft) 3 90027473 2 HARDENED WASHER, 3/4 4 Ref FOURTH BOOM SECTION, (see Figure 2-4 for details) 5 1360293 1 CHAIN CLEVIS 6 91163037 1 CHAIN, 167-1/4 IN 7 91413129 2 CHAIN PIN 8 88581157 2 RETAINING RING, 5/16

9 91166027 1 ANCHOR BRACKET 10 88501414 1 HEX JAM NUT, 7/8-14, (torque to 100 lb-ft) 11 88501314 3 HEX NUT, 7/8-14, (torque to 100 lb-ft) 12 Ref THIRD BOOM SECTION, (see Figure 2-3 for details) 13 1360297 1 CHAIN CLEVIS 14 91163036 1 CHAIN, 193 IN 15 91413122 2 CHAIN PIN 16 91081313 2 PIN KEEPER 17 4761800 4 LOCKWASHER, 1/2 18 88201065 4 HEX HD CAPSCREW, 1/2-13X1, GR5 19 88671001 2 GREASE FITTING 20 91161267 2 CHAIN SHEAVE PIN 21 91166026 1 ROLLER BRACKET 22 91165022 2 CHAIN ROLLER, (includes items 23 & 24) 23 91163204 2 BUSHING 24 86921268 4 SEAL 25 91041451 4 THRUST WASHER

91041450 AR THRUST WASHER 91041449 AR THRUST WASHER

91041596 AR THRUST WASHER 26 Ref SECOND BOOM SECTION, (see Figure 2-2 for details) 27 91166022 1 ROLLER BRACKET 28 1360292 1 CHAIN CLEVIS 29 91161214 1 STOP BAR 30 83201061 8 HEX HD CAPSCREW, 3/4-10X1-3/4, GR5, (torque to 340-365 lb-ft),

(Before S/N 0160012437)

0682214 8 HEX HD CAPSCREW, 0.750-10X1.750, LG, (S/N 0160012437 & After) 31 90027473 8 HARDENED WASHER, 3/4 32 91161212 1 CABLE ADJUSTMENT BLOCK 33 91163162 1 SPRING 34 Ref FIRST BOOM SECTION, (see Figure 2-1 for details) 35 1360296 1 CHAIN CLEVIS 36 91161213 1 STOP BAR 37 91161211 1 CABLE ADJUSTMENT BLOCK 38 91163161 1 SPRING 39 91033187 1 BEARING PAD 40 88201536 2 HEX HD CAPSCREW, 3/8-24X1-1/2, GR5 41 90027470 AR HARDENED WASHER, 3/8 42 88581112 4 RETAINING RING, 3/8

101 8522012 AR ANTI-SEIZE LUBE, (not shown) 151 91161180 1 KEEPER PLATE 152 88581157 2 RETAINING RING, (not shown)

91364001 544D 2-13

Page 54

BOOM

NOTES:

1. USE EXTREME PRESSURE GREASE WITH THE FOLLOWING PROCEDURE: A. CLEAN ID OF BUSHINGS B. COAT ID OF BUSHINGS WITH GREASE ALL THE WAY AROUND C. INSTALL PIN & QUICK SWITCH WITHOUT RETAINING BOLT, (ITEM 9) D. GREASE BOTH BUSHINGS UNTIL GREASE COMES OUT E. ROTATE PIN 180 DEGREES F. GREASE BOTH BUSHINGS A SECOND TIME G. INSTALL RETAINING BOLT, (ITEM 9)

Before S/N 0160037689

Figure 2-7 Quick Switch Assembly

544D 913640012-14

Page 55

Before S/N 0160037689

BOOM

Figure 2-7 Quick Switch Assembly

Item Part Number Qty. Description Rev.

91085091 1 QUICK SWITCH ASSY, (includes items 1 thru 6, 16 & 17) C 1 91086152 1 QUICK SWITCH WELDMENT 2 91086151 1 PLUNGER WELDMENT 3 90207902 1 QUICK RELEASE PIN 4 91033038 1 JACK CHAIN, 5 IN LONG, SIZE 12 5 3440832 1 ROLL PIN, 1/4X2 6 88671008 1 STRAIGHT LUBE FITTING, 1/4-28 7 Ref FOURTH BOOM SECTION, (includes item 8), (see Figure 2-4 for details) 8 91363085 2 BUSHING 9 91121308 1 HEX HD CAPSCREW, 5/8-11X5, L-9

10 91041365 1 PIN 11 91121309 1 HEX LOCKNUT, 5/8-11, L-9, (torque to 185-200 lb-ft, do not substitute lesser

grade hardware for L-9 parts) 12 91166062 1 TILT CYLINDER PIN 13 83201123 2 HEX HD CAPSCREW, 1/2-13X1, GR5, (nylok) 14 4712000 2 FLAT WASHER, 5/8, L-9 15 4711800 2 FLAT WASHER, 1/2 16 88301193 1 ROUND HD MACHINE SCREW, #10-32X1/2 17 88561105 1 FLAT WASHER, #10

91364001 544D 2-15

Page 56

BOOM

PY2050

122

121

116

120

103

114 301

304

302

115

113

S/N 0160037689 & After

Figure 2-7 Quick Switch Assembly

544D 913640012-16

Page 57

S/N 0160037689 & After

BOOM

Figure 2-7 Quick Switch Assembly

Item Part Number Qty. Description Rev.

3 Ref FOURTH BOOM SECTION, (see Figure 2-4 for details)

71 Ref TILT CYLINDER, (see Figure 9-1 for details)

103 8310067 1 LOCKNUT, 3/4-10 113 2160002 2 STRAIGHT GREASE FITTING 114 1001098383 1 QUICK SWITCH COUPLING ASSY, (includes items 301 thru 304) D 115 1001098233 1 PIVOT PIN

8307916 AR WASHER, SHIM, (not shown) 8307917 AR WASHER, SHIM, (not shown)

116 1001098492 1 PIN WELDMENT

8307904 AR WASHER, SHIM, (not shown) 8310093 AR WASHER, SHIM, (not shown)

8307918 AR WASHER, SHIM, (not shown) 120 0682244 1 HEX HD CAPSCREW, 3/4-10X5-1/2, GR8 121 4740003 1 WASHER, 1/2 122 0641808 1 HEX HD CAPSCREW, 1/2-13X1, GR5 301 1001100755 1 QUICK SWITCH COUPLER 302 1001143692 1 POPPIN PIN ASSY 304 1001105441 1 QUICK SWITCH LOCK PIN

91364001 544D 2-17

Page 58

BOOM

This Page Intentionally Left Blank

544D 913640012-18

Page 59

SECTION 3

ATTACHMENTS

91364001 544D

Page 60

ATTACHMENTS

Figure 3-1 Buckets

544D 913640013-2

Page 61

ATTACHMENTS

Figure 3-1 Buckets

Item Part Number Qty. Description Rev.

1 90455049 1 60 IN BUCKET, 3/4³ YARD, (Before S/N 0160037689) D 1 1001100822 1 72 IN BUCKET, 1.0³ YARD, (S/N 0160037689 & After) B 1 90555020 1 74 IN BUCKET, 1-1/4³ YARD, (Before S/N 0160037689) D 1 90453039 1 74 IN BUCKET, 2.0³ YARD, (Before S/N 0160037689) B 1 1001100823 1 96 IN BUCKET, 1.5³ YARD, (S/N 0160037689& After) B 1 1001100824 1 102 IN BUCKET, 2.0³ YARD, (S/N 0160037689 & After) B 1 91123115 1 CONCRETE HOPPER, 3/4³ YARD, (Before S/N 0160037689) C 2 NSS 1 S/N PLATE

91364001 544D 3-3

Page 62

ATTACHMENTS

Before S/N 0160023515

Figure 3-2 Tilt Carriage

544D 913640013-4

Page 63

Before S/N 0160023515

ATTACHMENTS

Figure 3-2 Tilt Carriage

Item Part Number Qty. Description Rev.

90455051 1 48 IN CARRIAGE ASSY, (includes items 1 thru 7) H 90455052 1 66 IN CARRIAGE ASSY, (includes items 1 thru 7) G

90555008 1 72 IN CARRIAGE ASSY, (includes items 1 thru 7) G 1 NSS 1 CARRIAGE WELDMENT 2 88201105 2 HEX HD CAPSCREW, 5/8-11X4, GR5 3 90200003 2 COLLAR 4 88521310 2 HEX LOCKNUT, 5/8-11 5 90451058 1 FORK PIN, (48 in carriage)

90402478 1 FORK PIN, (66 in carriage)

90551013 1 FORK PIN, (72 in carriage) 6 NSS 1 S/N PLATE 7 88341022 4 DRIVE SCREW, #10X3/8 8 Ref FORKS, (see Figure 3-17 for details)

91364001 544D 3-5

Page 64

ATTACHMENTS

PY0430

S/N 0160023515 & After

Figure 3-2 Tilt Carriage

544D 913640013-6

Page 65

S/N 0160023515 & After

ATTACHMENTS

Figure 3-2 Tilt Carriage

Item Part Number Qty. Description Rev.

1170020 1 50 IN TILT CARRIAGE, (Before S/N 0160037689), (includes all items) C 1170021 1 50 IN TILT CARRIAGE, (S/N 0160037689 & After), (includes all items) D 1170023 1 60 IN TILT CARRIAGE, (Before S/N 0160037689), (includes all items) C 1170024 1 60 IN TILT CARRIAGE, (S/N 0160037689 & After), (includes all items) D 1170026 1 72 IN TILT CARRIAGE, (Before S/N 0160037689), (includes all items) C 1170027 1 72 IN TILT CARRIAGE, (S/N 0160037689 & After), (includes all items),

(no longer available, use 1001132514 for service)

1001132514 1 72 IN TILT CARRIAGE, (S/N 0160037689 & After), (includes all items) A 1 0642032 2 HEX HD CAPSCREW, 5/8-11X4, GR5 2 NSS 1 TILT CARRIAGE 3 3300240 2 LOCKNUT, 5/8-11 4 3423275 1 50 IN FORK PIN

3423242 1 60 IN FORK PIN

3423276 1 72 IN FORK PIN 5 90200003 2 COLLAR 6 NSS 1 S/N PLATE

91364001 544D 3-7

Page 66

ATTACHMENTS

PAP19460

19 18

Before S/N 0160037689

Figure 3-3 Truss Boom

544D 913640013-8

Page 67

Before S/N 0160037689

ATTACHMENTS

Figure 3-3 Truss Boom

Item Part Number Qty. Description Rev.

90455011 1 10 FT TRUSS BOOM, (includes all items) K 1 NSS 1 TRUSS BOOM WELDMENT 2 90453040 1 SWIVEL HOOK

91164440 1 SAFETY LATCH KIT 3 90451047 2 SPACER 4 90451053 1 HANGER 5 90453041 1 SHACKLE, (includes attachment hardware)

NSS 1 BOLT NSS 1 NUT

NSS 1 COTTER PIN 6 90402948 1 PIN 7 88671001 1 STRAIGHT LUBE FITTING, 1/8 8 88201073 1 HEX HD CAPSCREW, 1/2-13X3, GR5 9 88501008 1 HEX NUT, 1/2-13

10 90602905 1 SLIDER BRACKET 11 90602904 1 SLIDER BRACKET 12 90403437 2 SLIDER BAR 13 88201036 8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 14 88501006 8 HEX NUT, 3/8-16 15 90207884 2 LOCKING CLAMP 16 88201021 8 HEX HD CAPSCREW, 5/16-18X1-1/4, GR5 17 88501005 8 HEX NUT, 5/16-18 18 88201035 2 HEX HD CAPSCREW, 3/8-16X1, GR5 19 88501106 2 HEAVY HEX JAM NUT, 3/8-16 20 NSS 1 S/N PLATE

91364001 544D 3-9

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ATTACHMENTS

PY1540

S/N 0160037689 & After

Figure 3-3 Truss Boom

544D 913640013-10

Page 69

S/N 0160037689 & After

ATTACHMENTS

Figure 3-3 Truss Boom

Item Part Number Qty. Description Rev.

1001099902 1 12 FT TRUSS BOOM, (includes all items) A

1001099901 1 15 FT TRUSS BOOM, (includes all items) A 1 4110422 2 DANGER SWINGING LOADS DECAL 2 NSS 1 S/N PLATE 3 NSS 1 TRUSS BOOM

91364001 544D 3-11

Page 70

ATTACHMENTS

PAP21530

33 34

Before S/N 0160037689

Figure 3-4 Truss Boom With Winch

544D 913640013-12

Page 71

Before S/N 0160037689

ATTACHMENTS

Figure 3-4 Truss Boom With Winch

Item Part Number Qty. Description Rev.

90455012 1 10 FT TRUSS BOOM ASSY WITH WINCH, (includes all items) Q 1 NSS 1 TRUSS BOOM WELDMENT 2 Ref WINCH WITH MOTOR, (see Figures 12-5 & 12-12 for details) 3 88201096 4 HEX HD CAPSCREW, 5/8-11X1-3/4, GR5 4 88501010 4 HEX NUT, 5/8-11 5 88561113 8 FLAT WASHER, 5/8 8 90451047 2 SPACER 9 Ref CROSSOVER VALVE, (see Figure 12-21 for details)

10 88201027 2 HEX HD CAPSCREW, 5/16-18X2-3/4, GR5 11 88561108 2 FLAT WASHER, 5/16 12 88501005 10 HEX NUT, 5/16-18 13 83451104 4 ADAPTER 14 1001094695 2 ADAPTER 15 90205121 2 HOSE ASSY 16 2220973 2 ELBOW, 90 DEGREE, (swivel nut) 17 2220898 2 ADAPTER 18 90207880 2 FLOW LIMITER 19 2220374 4 ADAPTER, (includes item 46) 20 84717644 2 HOSE ASSY 21 88661013 2 MALE CONNECTOR, 1/2X1/2, (Before S/N 2005283-01)

2220373 2 ADAPTER, (S/N 2005283-01 & After), (includes 8859-1205 o-ring)

22 91163138 1 MALE TIP COUPLER, (Before S/N 2005283-01)

91403414 1 MALE TIP COUPLER, (S/N 2005283-01 & After)

23 91043126 1 DUST CAP 24 91163139 1 FEMALE COUPLER, (Before S/N 2005283-01)

91403413 1 FEMALE COUPLER, (S/N 2005283-01 & After)

25 91043125 1 DUST PLUG 26 90403056 1 SHEAVE 28 90402948 1 PIN 29 88201073 1 HEX HD CAPSCREW, 1/2-13X3, GR5 30 88501008 1 HEX NUT, 1/2-13 31 88671001 1 STRAIGHT LUBE FITTING, 1/8 32 90207882 1 WIRE ROPE, 3/8 IN DIAMETER 33 91403448 1 SWIVEL HOOK 34 90026965 1 THIMBLE 35 90028990 2 WIRE ROPE CLIP 36 90602905 1 SLIDER BRACKET 37 90602904 1 SLIDER BRACKET 38 90403437 2 SLIDER BAR 39 88201036 8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 40 88501006 8 HEX NUT, 3/8-16 41 90207884 2 LOCKING CLAMP 42 88201021 8 HEX HD CAPSCREW, 5/16-18X1-1/4, GR5 43 88201035 2 HEX HD CAPSCREW, 3/8-16X1, GR5 44 88501106 2 HEAVY HEX JAM NUT, 3/8-16 45 NSS 1 S/N PLATE 46 88591206 4 O-RING

91364001 544D 3-13

Page 72

ATTACHMENTS

PAP3440

S/N 0160037689 & After

Figure 3-4 Truss Boom With Winch

544D 913640013-14

Page 73

S/N 0160037689 & After

ATTACHMENTS

Figure 3-4 Truss Boom With Winch

Item Part Number Qty. Description Rev.

1001099351 1 12 FT TRUSS BOOM WITH WINCH, (includes all items) F 1 NSS 1 TRUSS BOOM FRAME 2 90554016 1 USA DECAL 3 NSS 1 S/N PLATE 4 70021349 4 HEX HD CAPSCREW, 3/8X1

90554042 4 LOCKWASHER, 3/8 5 70021921 1 TRUSS BOOM WINCH MOTOR 6 NSS 2 HEX HD CAPSCREW, 1/2X1.75

90554020 2 LOCKWASHER, 1/2

90554054 2 HEX NUT, 1/2 7 70021415 2 CONNECTOR 8 70021977 2 HOSE ASSY, 3/8X32 9 NSS 1 ELBOW, 90 DEGREE

10 7029692 1 MALE QUICK COUPLER 11 90554062 1 DUST CAP 12 70021342 1 FEMALE QUICK COUPLER 13 90554076 1 DUST COVER 15 70021978 1 BALL SWIVEL WITH SAFETY HOOK 16 70021979 1 SOCKET ASSY 17 NSS 1 PIN 18 NSS 1 COTTER PIN 19 NSS 2 CLAMP 20 70021935 1 PULLEY 21 70022028 1 CABLE 22 4110422 2 WARNING SWINGING LOADS DECAL 23 NSS 1 PIN 24 NSS 2 FLAT WASHER, 1 25 NSS 2 SNAP RING

91364001 544D 3-15

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ATTACHMENTS

Before S/N 0160037689

Figure 3-5 6 Ft Vertical Mast

544D 913640013-16

Page 75

RAIL ASSEMBLY

RAIL CYLINDER

ASSEMBLY

CARRIAGE ASSEMBLY

Before S/N 0160037689

ATTACHMENTS

Figure 3-5 6 Ft Vertical Mast (Continued)

91364001 544D 3-17

Page 76

Before S/N 0160037689

ATTACHMENTS

Figure 3-5 6 Ft Vertical Mast

Item Part Number Qty. Description Rev.

90455035 1 MAST ASSY, (48 in carriage), (includes all items) R

90455037 1 MAST ASSY, (66 in carriage), (includes all items) R 1 NSS 1 CARRIAGE, (includes items 301 thru 310) 2 NSS 1 ADAPTER WELDMENT 3 84717640 1 HOSE ASSY 4 91163138 1 MALE HYDRAULIC COUPLING, (Before S/N 2005283-01)

91403414 1 MALE HYDRAULIC COUPLING, (S/N 2005283-01 & After) 5 91043126 1 DUST CAP 6 24431386 2 CLAMP 7 88201037 2 HEX HD CAPSCREW, 3/8-16X1-1/2, GR5 8 88561004 2 FLAT WASHER, 3/8 9 88661013 1 MALE ADAPTER, 1/2X1/2 TUBE, (Before S/N 2005283-01)

2220373 1 ADAPTER, (S/N 2005283-01 & After), (includes o-ring) 10 88661016 1 MALE CONNECTOR, 5/8X1/2 TUBE 11 88661180 1 FEMALE ELBOW, 90 DEGREE, 1/2X1/2 TUBE 12 88501006 2 HEX NUT, 3/8-16 13 88551011 2 LOCKWASHER, 3/8 14 NSS 1 S/N PLATE 15 NSS 4 DRIVE SCREW, #10X3/8 16 90451039 1 STOP TUBE 17 91034372 2 RETAINING RING 18 91034373 2 CHAIN ROLLER 19 91034374 6 LOAD ROLLER, (inside carriage frame) 20 91034375 AR SHIM 21 91034376 4 SIDE THRUST ROLLER, (small outside roller) 22 91034377 2 SCREW 23 91031271 4 GUSSET 24 90453030 1 6 FT MAST, (includes items 101 thru 125) B

101 91034431 1 OUTER RAIL ASSY 102 91034394 1 CYLINDER ASSY, (3-5/8 OD)

00078041 1 SEAL KIT 91034404 1 CYLINDER ASSY, (3-3/4 OD), (includes items 201 thru 211)

00083046 1 SEAL KIT, (includes items 206 thru 211) 103 91034423 1 CYLINDER RETAINING RING ASSY 104 91034422 2 NUT 105 91034393 1 FREE LIFT CYLINDER HEAD 106 91034373 2 CHAIN SHIEVE 107 91034372 2 RETAINING RING 108 91034421 2 GUARD 109 91034420 4 LOCKWASHER 110 91034419 4 SCREW 111 8033686 1 LOCKWASHER 112 91034424 1 SCREW 113 91034417 2 CHAIN ASSY, (includes items 114 thru 118) 114 8033693 4 NUT 115 8033690 4 CHAIN ANCHOR 116 8033691 4 CHAIN CONNECT PIN 117 8033692 8 COTTER PIN 118 91034392 2 CHAIN

544D 913640013-18

Page 77

Before S/N 0160037689

ATTACHMENTS

Figure 3-5 6 Ft Vertical Mast (Continued)

Item Part Number Qty. Description Rev.

119 91034428 1 FLOW VALVE 120 91034427 1 FITTING 121 91034426 1 TUBE 122 91034429 1 RETAINING RING 123 91034430 2 BOLT 124 91034433 2 LOCKWASHER 125 91034434 2 SCREW 126 91034418 2 PLUG 201 91034405 1 OUTER TUBE ASSY 202 91034408 1 PISTON & RAM ASSY 203 91034409 1 GLAND NUT 204 91034407 1 CHECK VALVE 205 91034406 1 RETAINING RING 206 NSS 1 WIPER 207 NSS 1 U-CUP, (gland nut) 208 NSS 1 BACK-UP RING, (gland nut) 209 NSS 1 O-RING, (gland nut) 210 NSS 1 U-CUP, (piston) 211 NSS 1 WEAR RING 301 NSS 1 CARRIAGE WELDMENT 302 91034410 1 SHAFT, (48 in carriage)

91034432 1 SHAFT, (66 in carriage) 303 91034376 4 THRUST ROLLER 304 8033698 2 NUT 305 8033686 2 LOCKWASHER 306 91034413 2 NUT 307 91034377 2 FLAT HD SCREW 308 91034414 2 GREASE FITTING 309 91034415 2 BOLT 310 91034416 2 END RING

91364001 544D 3-19

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ATTACHMENTS

4 14 15 16 18 22

4 14 15 16

40 41

26 31

27 30

24 32

5 14 15 16

6 8 17 20 21

34 35

36 37 38 39

7 10 11 12 13 19

PAP20090

Before S/N 0160037689

Figure 3-6 48 In Slope Piler Carriage

544D 913640013-20

Page 79

Before S/N 0160037689

ATTACHMENTS

Figure 3-6 48 In Slope Piler Carriage

Item Part Number Qty. Description Rev.

91085058 Ref 48 IN SLOPE PILER CARRIAGE, (includes all items) U 1 NSS 1 CARRIAGE WELDMENT 2 NSS 1 ADAPTER WELDMENT 3 Ref SWAY CYLINDER, (see Figure 12-14 for details) 4 91083248 1 BUSHING 5 3423263 2 PIN 6 90204007 1 TUBE 7 91033186 2 BEARING PAD 8 91081577 1 TAP BOLT 9 91081594 1 THRUST WASHER

10 90205870 AR SHIM 11 91031236 2 SPACER 12 88201535 4 HEX HD CAPSCREW, 3/8-24X1-1/4, GR5 13 88201534 4 HEX HD CAPSCREW, 3/8-24X1, GR5 14 91081313 3 KEEPER PLATE 15 88201065 6 HEX HD CAPSCREW, 1/2-13X1, GR5 16 88551013 6 LOCKWASHER, 1/2 17 88521016 1 HEX LOCKNUT, 1-8 18 88671022 2 LUBE FITTING, 90 DEGREE, 1/8 19 88561109 4 FLAT WASHER, 3/8 20 88501016 1 HEX NUT, 1-8 21 05101441 1 WASHER, 1-1/16 22 91081622 1 PIN 23 84716434 2 HOSE ASSY 24 2220603 2 ADAPTER 25 88661010 2 ADAPTER, (Before S/N 2005283-01)

2220372 2 ADAPTER, (S/N 2005283-01 & After)

26 91163138 1 MALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403414 1 MALE QUICK DISCONNECT, (S/N 2005283-01 & After)

27 91163139 1 FEMALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403413 1 FEMALE QUICK DISCONNECT, (S/N 2005283-01 & After)

29 NSS 1 S/N PLATE 30 91043125 1 DUST PLUG 31 91043126 1 DUST CAP 32 8760268 2 ELBOW, 90 DEGREE, (swivel nut) 33 Ref DUAL P.O. CHECK VALVE, (see Figure 12-15 for details) 34 88201040 3 HEX HD CAPSCREW, 3/8-16X2-1/4, GR5 35 88551011 3 LOCKWASHER, 3/8 36 90451058 1 FORK PIN 37 90200003 2 COLLAR 38 88201105 2 HEX HD CAPSCREW, 5/8-11X4, GR5 39 88521310 2 LOCKNUT, 5/8-11 40 84521062 1 SUPPORT CLAMP 41 77143015 1 WHIZ-LOCKNUT, 3/8-16

91364001 544D 3-21

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ATTACHMENTS

4 14 15 16 18 22

4 14 15 16

40 41

26 31

27 30

24 32

5 14 15 16

6 8 17 20 21

34 35

36 37 38 39

7 10 11 12 13 19

PAP20100

Before S/N 0160037689

Figure 3-7 66 In Slope Piler Carriage

544D 913640013-22

Page 81

Before S/N 0160037689

ATTACHMENTS

Figure 3-7 66 In Slope Piler Carriage

Item Part Number Qty. Description Rev.

91305016 Ref 66 IN SLOPE PILER CARRIAGE, (includes all items) U 1 NSS 1 CARRIAGE WELDMENT 2 NSS 1 ADAPTER WELDMENT 3 Ref SWAY CYLINDER, (see Figure 12-14 for details) 4 91083248 1 BUSHING 5 3423263 2 PIN 6 90204007 1 TUBE 7 91033186 2 BEARING PAD 8 91081577 1 TAP BOLT 9 91081594 1 THRUST WASHER

10 90205870 AR SHIM 11 91031236 2 SPACER 12 88201535 4 HEX HD CAPSCREW, 3/8-24X1-1/4, GR5 13 88201534 4 HEX HD CAPSCREW, 3/8-24X1, GR5 14 91081313 3 KEEPER PLATE 15 88201065 6 HEX HD CAPSCREW, 1/2-13X1, GR5 16 88551013 6 LOCKWASHER, 1/2 17 88521016 1 HEX LOCKNUT, 1-8 18 88671022 2 LUBE FITTING, 90 DEGREE, 1/8 19 88561109 4 FLAT WASHER, 3/8 20 88501016 1 HEX NUT, 1-8 21 05101441 1 WASHER, 1-1/16 22 91081622 1 PIN 23 84716434 2 HOSE ASSY 24 83661316 2 CONNECTOR 25 88661010 2 CONNECTOR, (Before S/N 2005283-01)

2220372 2 CONNECTOR, (S/N 2005283-01 & After)

26 91163138 1 MALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403414 1 MALE QUICK DISCONNECT, (S/N 2005283-01 & After)

27 91163139 1 FEMALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403413 1 FEMALE QUICK DISCONNECT, (S/N 2005283-01 & After)

29 NSS 1 S/N PLATE 30 91043125 1 DUST PLUG 31 91043126 1 DUST CAP 32 8760268 2 ELBOW, 90 DEGREE, (swivel nut) 33 Ref DUAL P.O. CHECK VALVE, (see Figure 12-15 for details) 34 88201040 3 HEX HD CAPSCREW, 3/8-16X2-1/4, GR5 35 88551011 3 LOCKWASHER, 3/8 36 91301083 1 FORK PIN 37 90200003 2 COLLAR 38 88201105 2 HEX HD CAPSCREW, 5/8-11X4, GR5 39 88521310 2 LOCKNUT, 5/8-11 40 84521062 1 SUPPORT CLAMP 41 77143015 1 WHIZ-LOCKNUT, 3/8-16

91364001 544D 3-23

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ATTACHMENTS

SECTION B-B

NOTE:

USE LOCTITE

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

SECTION A-A

Before S/N 0160037689

Figure 3-8 100 Degree Swing Fork

544D 913640013-24

Page 83

Before S/N 0160037689

ATTACHMENTS

Figure 3-8 100 Degree Swing Fork

Item Part Number Qty. Description Rev.

90455044 1 100 DEGREE SWING FORK ASSY, (includes all items) Q 1 91043126 1 DUST CAP 2 91163138 1 MALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403414 1 MALE QUICK DISCONNECT, (S/N 2005283-01 & After) 3 88661013 2 MALE ADAPTER, 1/2X1/2 TUBE, (Before S/N 2005283-01)

2220373 2 ADAPTER, (S/N 2005283-01 & After), (includes 88591205 o-ring) 4 91043125 1 DUST CAP 5 91163139 1 FEMALE QUICK DISCONNECT, (Before S/N 2005283-01)

91403413 1 FEMALE QUICK DISCONNECT, (S/N 2005283-01 & After) 6 84718067 2 HOSE ASSY 7 91411073 2 LOCKING PLATE 8 83201024 4 HEX HD CAPSCREW, 3/8-16X1, SELF-LOCKING, GR8, (nylok) 9 91083249 1 CLAMP SET

10 77133140 1 COVER PLATE 11 77133177 1 HEX HD CAPSCREW, 5/16X1-3/8 12 91041324 2 PIVOT PIN 13 88671008 2 STRAIGHT LUBE FITTING, 1/4-28 14 91041325 2 PIVOT PIN 15 88671022 2 LUBE FITTING, 90 DEGREE 16 91041327 2 BUSHING 17 91041322 2 LOCKING PLATE 18 83201026 4 HEX HD CAPSCREW, 1/2-13X1-1/2, GR8 19 Ref SWING CYLINDER, (see Figure 12-4 for details) 20 8760268 6 ELBOW, 90 DEGREE, (swivel nut) 21 2220372 2 ADAPTER, (includes item 48) 22 91041326 2 PIVOT PIN 23 88581136 4 RETAINING RING 24 NSS 1 CARRIAGE WELDMENT 25 90200003 2 COLLAR 26 90551013 1 FORK PIN 27 88201105 2 HEX HD CAPSCREW, 5/8-11X4, GR5 28 88521310 2 LOCKNUT 29 91041356 6 SPACER 30 NSS 1 PIVOT WELDMENT 31 NSS 4 DRIVE SCREW 32 NSS 1 S/N PLATE 33 91033039 2 CHAIN CONNECTOR 34 91033038 24 in CHAIN 35 88631449 2 ROLL PIN, 1/8X1-1/2 36 91141350 2 PIN 37 91146053 1 LH SUPPORT BRACKET 38 91146054 1 RH SUPPORT BRACKET 39 91043221 2 DETENT PIN 40 91043186 1 DOUBLE PILOT CHECK VALVE 41 88561002 2 FLAT WASHER, 1/4 42 88201008 2 HEX HD CAPSCREW, 1/4-20X1-3/4, GR5 43 90204097 2 HOSE ASSY 44 2220501 2 ELBOW, 45 DEGREE, (includes item 45) 45 NSS 4 O-RING

91364001 544D 3-25

Page 84

Before S/N 0160037689

ATTACHMENTS

Figure 3-8 100 Degree Swing Fork (Continued)

Item Part Number Qty. Description Rev.

46 77133201 2 HOSE ASSY 47 91041361 2 FITTING 48 NSS 2 O-RING 49 91041362 2 ORIFICE FITTING 50 2220899 2 TEE FITTING, (includes item 45) 51 91143282 2 PINCH POINT DECAL 52 8765204 2 ELBOW, 90 DEGREE, (swivel nut)

544D 913640013-26

Page 85

Before S/N 0160037689

ATTACHMENTS

Figure 3-8 100 Degree Swing Fork (Continued)

Item Part Number Qty. Description Rev.

91364001 544D 3-27

Page 86

ATTACHMENTS

18 19 20

21 22 23

14 15

16 17

1 2

4 5

31 32 33

PAP20110

Before S/N 0160037689

Figure 3-9 Quick Hook Assembly

544D 913640013-28

Page 87

Before S/N 0160037689

ATTACHMENTS

Figure 3-9 Quick Hook Assembly

Item Part Number Qty. Description Rev.

91085056 Ref QUICK HOOK ASSY, (includes all items) J 1 88551011 8 LOCKWASHER, 3/8 2 88201034 8 HEX HD CAPSCREW, 3/8-16X7/8, GR5 3 88671001 2 STRAIGHT LUBE FITTING, 1/8 4 91081574 1 PIN 5 88631343 2 COTTER PIN 6 91081573 1 ROLLER 7 91083368 1 WIRE ROPE, (7/16 in Dia.) 8 91083367 1 WINCH 9 NSS 1 QUICK HOOK WELDMENT

10 NSS 1 S/N PLATE 12 90205126 2 HOSE ASSY 13 77363079 2 STRAIGHT THREAD CONNECTOR, (Before S/N 2005283-01)

2220373 2 CONNECTOR, (S/N 2005283-01 & After), (includes 88591205 o-ring) 14 91043125 1 DUST CAP 15 91163139 1 FEMALE HYDRAULIC COUPLING, (Before S/N 2005283-01)

91403413 1 FEMALE HYDRAULIC COUPLING, (S/N 2005283-01 & After) 16 91043126 1 DUST CAP 17 91163138 1 MALE HYDRAULIC COUPLING, (Before S/N 2005283-01)

91403414 1 MALE HYDRAULIC COUPLING, (S/N 2005283-01 & After) 18 77133136 1 STAUFF CLAMP SET 19 77133137 1 STAUFF COVER PLATE 20 88201023 1 HEX BOLT 21 77133270 1 STAUFF CLAMP SET 22 88561002 1 STAUFF COVER PLATE 23 88201005 1 HEX BOLT 24 91143276 1 TUBE ASSY 25 91143275 1 TUBE ASSY 26 88661110 2 MALE ELBOW, 90 DEGREE, 3/8X1/2 TUBE 27 90029999 1 WIRE ROPE CLAMP, 7/16 28 90201443 1 HOOK & BALL 29 91143277 1 L-HANDLE 30 91081737 1 WEDGE 31 91063040 2 CLAMP SET 32 91063039 2 COVER PLATE 33 88201006 4 HEX BOLT

91364001 544D 3-29

Page 88

ATTACHMENTS

PAL4560

Figure 3-10 Fork Mounted Lifting Hook

544D 913640013-30

Page 89

ATTACHMENTS

Figure 3-10 Fork Mounted Lifting Hook

Item Part Number Qty. Description Rev.

91565094 1 FORK MOUNTED LIFTING HOOK, (includes all items) F 1 7029520 2 HAIRPIN CLIP 2 1001093171 2 PIN 3 70020555 1 SPRING BUSHING 4 90554080 1 SLING HOOK 5 7029521 1 CHAIN SHACKLE, 12,000LB 6 90554080 1 LIFTING HOOK 7 NSS 1 S/N PLATE

91364001 544D 3-31

Page 90

ATTACHMENTS

31 33 34 35

43 92 93 94 95 96

27 28 29 48 49

21 45 47 50

21 91

32 37 47

9 10 12

16 17 18 19

15 16 17 18

3 4 5

7 11

21 32 91

30 36

13 14

21 41 42

21 23 57

54 55 56

77 78 79 80

64 88

63 89

69 76 90

83 84 97

72 73 74

WARNING

Before S/N 0160037689

Figure 3-11 6 Ft Swing Mast With Side Shift

544D 913640013-32

Page 91

23 85 86

20 23 61

22 61

SOLENOID VALVE

DUAL COUNTERBALANCE VALVE

SWING

CYLINDER

MAST

CYLINDER

SIDE SHIFT CYLINDER

SOLENOID VALVE BANK

AUX HYD. LINES

HYDRAULIC SCHEMATIC

.094

SWING

VIEW B-B

SECTION A-A

52 53

VIEW C-C

Before S/N 0160037689

ATTACHMENTS

Figure 3-11 6 Ft Swing Mast With Side Shift (Continued)

91364001 544D 3-33

Page 92

Before S/N 0160037689

ATTACHMENTS

Figure 3-11 6 Ft Swing Mast With Side Shift

Item Part Number Qty. Description Rev.

90455047 Ref 6 FT SWING MAST WITH SIDE SHIFT, (includes all items) Z 1 NSS 1 MAST WELDMENT 2 NSS 1 SWING FORK PIVOT WELDMENT 3 91041325 2 PIVOT PIN 4 88671018 2 LUBE FITTING, 45 DEGREE, 1/8 5 91041327 2 BUSHING 6 91411073 2 LOCKING PLATE 7 83201026 4 HEX HD CAPSCREW, 1/2-13X1-1/2, GR8 8 Ref HYDRAULIC CYLINDER, (see Figure 12-4 for details) 9 91041324 2 PIVOT PIN

10 88671008 2 STRAIGHT LUBE FITTING, 1/4-28 11 91041322 2 LOCKING PLATES 12 83201024 4 HEX HD CAPSCREW, 3/8-16X1, GR8 13 91041326 2 PIVOT PIN 14 88581136 4 SNAP RING 15 91146053 1 LH SUPPORT BRACKET 16 91141350 2 PIN 17 88631449 2 ROLL PIN, 1/8X1-1/2 18 91043221 2 DETENT PIN 19 91146054 1 RH SUPPORT BRACKET 20 2220899 2 TEE FITTING, (includes item 61) 21 NSS 7 O-RING 22 2220473 2 ELBOW, 90 DEGREE, (includes item 61) 23 8760268 6 ELBOW, 90 DEGREE, (swivel nut) 24 77133201 2 HOSE ASSY 25 90204097 2 HOSE ASSY 26 90451060 1 FRONT COVER, (solenoid valve) 27 90453043 1 SOLENOID VALVE 28 88201007 2 HEX HD CAPSCREW, 1/4-20X1-1/2, GR5 29 88551009 2 LOCKWASHER, 1/4 30 91034399 2 HOSE SHEAVE 31 88551010 2 LOCKWASHER, 5/16 32 8765204 2 ELBOW, 90 DEGREE, (swivel nut) 33 90453019 1 SOLENOID VALVE BANK 34 88201025 2 HEX HD CAPSCREW, 5/16-18X2-1/4, GR5 35 88561108 2 FLAT WASHER, 5/16 36 91034400 2 SHOULDER BOLT 37 2220362 1 TEE FITTING 38 77143013 5 WHIZ-LOCKNUT, 1/4-20 39 77133269 1 HOSE ASSY 40 90453023 1 WIRING HARNESS 41 90203384 1 ADAPTER 42 91041362 1 ORIFICE FITTING 43 91345026 1 DIODE ASSY, (includes items 92 thru 96) C 44 90453044 1 WIRING HARNESS 45 84718047 1 HOSE ASSY 46 77133458 1 HOSE ASSY 47 2220385 2 ADAPTER 48 2220726 2 ELBOW, 90 DEGREE

544D 913640013-34

Page 93

Before S/N 0160037689

ATTACHMENTS

Figure 3-11 6 Ft Swing Mast With Side Shift (Continued)

Item Part Number Qty. Description Rev.

49 90207719 1 JUMPER WIRE 50 2220596 1 ELBOW, 90 DEGREE, (includes item 21) 51 90451061 1 BACK COVER, (solenoid valve) 52 80673023 2 SUPPORT CLAMP 53 77143006 2 WHIZ-LOCKNUT, 5/16-18 54 90453018 1 DUAL COUNTERBALANCE VALVE 55 88201008 2 HEX HD CAPSCREW, 1/4-20X1-3/4, GR5 56 88561002 2 FLAT WASHER, 1/4 57 2220372 2 ADAPTER, (includes item 21) 58 90453021 1 TUBE ASSY 59 90453020 1 TUBE ASSY 60 84717778 1 HOSE ASSY 61 NSS 4 O-RING 62 88661013 2 MALE ADAPTER, 1/2X1/2 TUBE, (Before S/N 2005283-01)

2220373 2 ADAPTER, (S/N 2005283-01 & After), (includes o-ring)

63 91163138 1 HYD COUPLING, MALE TIP, (Before S/N 2005283-01)

91403414 1 HYD COUPLING, MALE TIP, (S/N 2005283-01 & After) 64 91043125 1 DUST CAP 65 90453046 1 WIRING HARNESS 66 90207662 1 6 CONTACT PLUG 67 91033039 2 CHAIN CONNECTION 68 91033038 24 in CHAIN 69 NSS 4 DRIVE SCREW, #10X3/8 70 91041356 6 SPACER 71 84717871 2 HOSE ASSY 72 77133497 2 CLAMP 73 77133498 2 COVER PLATE 74 77133499 4 HEX HD CAPSCREW, 1/4-20X1-5/16 75 91143282 2 PINCH POINT DECAL 76 91343053 1 ATTENTION DECAL 77 77133168 1 CLAMP SET 78 77133140 2 COVER PLATE 79 88201024 1 HEX HD CAPSCREW, 5/16-18X2, GR5 80 88501005 1 HEX NUT, 5/16-18 81 Ref FORKS, (see Figure 3-17 for details) 82 90453033 1 66 IN S.S. CARRIAGE

90454001 1 CYLINDER

90454002 1 PACKING KIT 83 91034374 6 LOAD ROLLER 84 91034375 12 SHIM 85 84717537 2 HOSE ASSY 86 2230024 2 ADAPTER 87 77133146 1 HOSE ASSY 88 91163139 1 HYD COUPLING, FEMALE, (Before S/N 2005283-01)

91403413 1 HYD COUPLING, FEMALE, (S/N 2005283-01 & After) 89 91043126 1 DUST CAP 90 NSS 1 S/N PLATE 91 2220373 4 ADAPTER, (includes item 21) 92 77385131 1 DIODE ASSY

91364001 544D 3-35

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Before S/N 0160037689

ATTACHMENTS

Figure 3-11 6 Ft Swing Mast With Side Shift (Continued)

Item Part Number Qty. Description Rev.

93 91043440 2 PIGGYBACK CONNECTOR 94 86661147 3 in BLACK WIRE, 16 GA. 95 86683480 1 BUTT CONNECTOR 96 83683549 AR HEAT SHRINK TUBING 97 91034377 2 SCREW 98 90454003 2 BRONZE GUIDE

544D 913640013-36

Page 95

Before S/N 0160037689

ATTACHMENTS

Figure 3-11 6 Ft Swing Mast With Side Shift (Continued)

Item Part Number Qty. Description Rev.

91364001 544D 3-37

Page 96

ATTACHMENTS

SECTION A-A

SECTION B-B

Before S/N 0160037689

Figure 3-12 100 Degree Drywall Swing Carriage

544D 913640013-38

Page 97

Before S/N 0160037689

ATTACHMENTS

Figure 3-12 100 Degree Drywall Swing Carriage

Item Part Number Qty. Description Rev.

90555013 1 100 DEGREE DRYWALL SWING CARRIAGE, (includes all items) Q

1 NSS 1 DRYWALL CARRIAGE WELDMENT 2 91041326 2 PIVOT PIN 3 88581136 4 EXTERNAL RETAINING RING 4 Ref SWING CYLINDER ASSY, (see Figure 12-4 for details) 5 91041324 2 PIVOT PIN 6 88671008 2 STRAIGHT LUBE FITTING, 1/4-28 7 91411073 2 LOCKING PLATE 8 83201024 4 HEX HD CAPSCREW, 3/8-16X1, GR8 9 91043125 1 DUST CAP

10 91163139 1 FEMALE HYDRAULIC COUPLER, (Before S/N 2005283-01)

91403413 1 FEMALE HYDRAULIC COUPLER, (S/N 2005283-01 & After) 11 88661013 2 MALE CONNECTOR, 1/2X1/2 TUBE, (Before S/N 2005283-01)

2220373 2 CONNECTOR, (S/N 2005283-01 & After), (includes 88591205 o-ring) 12 91043126 1 DUST CAP 13 91163138 1 MALE HYDRAULIC COUPLER, (Before S/N 2005283-01)

91403414 1 MALE HYDRAULIC COUPLER, (S/N 2005283-01 & After) 14 84718067 2 HOSE ASSY 15 91041325 2 PIVOT PIN 16 91041327 2 BUSHING 17 88671022 2 LUBE FITTING, 90 DEGREE, 1/8 18 91041322 2 LOCKING PLATE 19 83201026 4 HEX HD CAPSCREW, 1/2-13X1-1/2, GR8 20 88201008 2 HEX HD CAPSCREW, 1/4-20X1-3/4, GR5 21 88561002 2 FLAT WASHER, 1/4 22 91043186 1 DOUBLE PILOT CHECK VALVE 23 91041361 2 FITTING 24 91041362 2 ORIFICE FITTING 25 88591205 2 O-RING 26 2220501 2 ELBOW, 45 DEGREE, (includes item 27) 27 88591204 2 O-RING 28 90204097 2 HOSE ASSY 29 77133201 2 HOSE ASSY 30 8760268 6 ELBOW, 90 DEGREE, (swivel nut) 31 2220372 2 CONNECTOR, (includes item 32) 32 88591205 2 O-RING 33 2220899 2 BRANCH TEE, (includes item 34) 34 88591204 2 O-RING 35 88201105 4 HEX HD CAPSCREW, 5/8-11X4, GR5 36 88521310 4 HEX LOCKNUT, 5/8-11 37 90200003 4 COLLAR 38 90453013 2 DRYWALL FORK 39 90451020 2 FORK PIN 40 91041356 6 SPACER 41 NSS 1 PIVOT WELDMENT 42 91033038 1 CHAIN, 24 IN 43 91033039 2 CHAIN CONNECTION 44 88631449 2 ROLL PIN, 1/8X1-1/2 45 91141350 2 PIN

91364001 544D 3-39

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ATTACHMENTS

Figure 3-12 100 Degree Drywall Swing Carriage (Continued)

Item Part Number Qty. Description Rev.

46 91146053 1 LH SUPPORT BRACKET

91146054 1 RH SUPPORT BRACKET 47 91043221 2 DETENT PIN 48 NSS 1 S/N PLATE 49 NSS 4 DRIVE SCREW, #10X3/8 50 90553012 2 SIDE DRYWALL GUARD 51 88241053 14 SOCKET FLAT HD CAPSCREW, 3/8-16X1-1/2 52 88551011 8 LOCKWASHER, 3/8 53 88501006 8 HEX NUT, 3/8-16 54 90553013 2 BOTTOM DRYWALL GUARD 55 91083249 1 CLAMP SET 56 77133140 1 COVER PLATE 57 77133177 1 HEX HD CAPSCREW, 5/16-18X1-3/8 58 91143282 2 PINCH POINT DECAL 59 8765204 2 ELBOW, 90 DEGREE, (swivel nut)

544D 913640013-40

Page 99

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ATTACHMENTS

Figure 3-12 100 Degree Drywall Swing Carriage (Continued)

Item Part Number Qty. Description Rev.

91364001 544D 3-41

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ATTACHMENTS

2 3 4

101

102 103 104 105

106

107

PY1510

LEFT SIDE SHOWN, RIGHT SIDE

OPPOSITE

S/N 0160037689 & After

Figure 3-13 Sheet Material Handler

544D 913640013-42

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

Figure 1-3 Front Axle Mounting

Figure 1-4 Front Axle Mounting

Figure 1-5 Outrigger Mounting

Figure 2-1 First Boom Section

Figure 2-2 Second Boom Section

Figure 2-3 Third Boom Section

Figure 2-4 Fourth Boom Section

Figure 2-5 Extension Chains

Figure 2-6 Retraction Chains

Figure 2-7 Quick Switch Assembly

Figure 3-1 Buckets

Figure 3-2 Tilt Carriage

Figure 3-3 Truss Boom

Figure 3-4 Truss Boom With Winch

Figure 3-5 6 Ft Vertical Mast

Figure 3-6 48 In Slope Piler Carriage

Figure 3-7 66 In Slope Piler Carriage

Figure 3-8 100 Degree Swing Fork

Figure 3-9 Quick Hook Assembly

Figure 3-10 Fork Mounted Lifting Hook

Figure 3-11 6 Ft Swing Mast With Side Shift

Figure 3-12 100 Degree Drywall Swing Carriage

Figure 3-13 Sheet Material Handler