Instruction Manual

ManualsBrandsGradall ManualsHoist544

544

9104-1280

August 25, 2006

Starting Serial No.

8655105G

PART MANUAL

CORPORATE OFFICE

JLG INDUSTRIES, INC.

1 JLG DRIVE

McConnellsburg, PA

17233-9533

USA

Telephone: (717) 485-5161

Fax: (717) 485-6417

GRADALL DIVISION

JLG INDUSTRIES, INC.

406 Mill Avenue S.W.

New Philadelphia, OH

44663

USA

Telephone: (330) 339-2211

Fax: (330) 339-8458

Summary of content (209 pages)

PAGE 1
® ® PART MANUAL ® 544 9104-1280 August 25, 2006 Starting Serial No. 8655105G CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. 1 JLG DRIVE McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES, INC. 406 Mill Avenue S.W.
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INTRODUCTION Table of Contents Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 SECTION 1 - INTRODUCTION Table of Contents ...................................................................................................... 1-1 thru 1-4 Alphabetical Index ................................................................................................... 1-5 thru 1-10 Service Kits .................................................................................................................
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INTRODUCTION Table of Contents Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 SECTION 6 - DRIVE TRAIN (Continued) Modulator Valve .......................................................................................................................6-9 Control Valve ........................................................................................................................ 6-10 Propeller Shaft .......................................................................................
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INTRODUCTION Table of Contents Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 SECTION 10 - HYDRAULIC COMPONENTS (continued) Outrigger Cylinder ................................................................................................................ 10-9 Main Control Valve ............................................................................................................. 10-10 Priority Flow Contrlol Valve .......................................................................
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INTRODUCTION Table of contents Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 SECTION 13 - OPTIONAL EQUIPMENT (continued) Winch Assembly.......................................................................................................13-12, 13-13 Hydraulic Cylinder (Jarp) .................................................................................................... 13-14 Hydraulic Cylinder (Iowa) .....................................................................................
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INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 ACCELERATOR CABLE ........................................................................................................ 7-3 ACCELERATOR PEDAL ......................................................................................................... 7-3 ACCUMULATOR .................................................................................................................... 8-4 ACCUMULATOR CHARGE VALVE ....
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INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 DOOR .................................................................................................................................... 2-2 DOOR HANDLES ................................................................................................................... 2-2 DRIVE BELT ...........................................................................................................................
PAGE 9
INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 HEATER ..................................................................................................................................2-3 HEAT SHIELD .........................................................................................................................5-9 HEATER SWITCH ..................................................................................................................2-3 HOOD ..
PAGE 10
INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 PARKING BRAKE LINES ....................................................................................................... 8-2 PARKING BRAKE VALVE ................................................................................................... 10-20 PILOT PUMP ...................................................................................................................... 10-23 POSITIVE BATTERY CABLE ....
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INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 STABILIZER CYLINDER ..................................................................................................... 10-8 STABILIZER CYLINDER HYDRAULIC CIRCUIT ................................................................ 9-17 STABILIZER VALVE ........................................................................................................... 10-15 STARTER BUTTON ....................................
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INTRODUCTION Alphabetical Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 WEATHER STRIP .................................................................................................................. 2-2 WHEELS & TIRES ............................................................................................................... 6-16 WINDOWS .............................................................................................................................
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INTRODUCTION Service Kits Starting Serial No. 8655105G Original Issue 8-86 Revised 8-97 SECTION PAGE NO. PART NO.
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 0510-1411 ....................................... 2-6 0510-1441 ........................................ 4-2 1200-1234 ............................ 3-2, 3-3, ................................................ 3-4, 5-3 1238-1025 ............................ 3-1, 3-2, ................................................ 3-3, 3-4 2460-1570 .................................. 13-19 2464-1328 ......................
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 7713-3342 ................... 8-2, 9-5, 9-6 7713-3389 .................................. 9-15 7713-3390 .................................. 9-15 7713-3440 ................................... 9-10 7713-3447 ............................ 9-3, 9-4 7713-3497 .................................. 13-9 7713-3498 ........................ 9-1, 9-2, .............................. 9-15, 13-9, 13-16 7713-3499 .........
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 8666-1083 .................................... 11-1 8666-1084 .................................... 11-4 8667-1112 ...................................... 5-2 8667-1164 ............................. 2-1, 5-3 8667-1609 ...................................... 5-5 8668-1572 .................................. 13-19 8668-3106 ...................................... 5-4 8668-3117 ...........................
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 8830-1339 ..................................... 3-5 8830-2128 ................................... 12-1 8832-1008 ................................. 13-16 8832-1015 ...................................... 7-1 8832-1019 ..................................... 7-1 8832-1025 ...................................... 2-2 8832-1039 ..................................... 2-2 8832-1048 .................................
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 8859-1202 ................. 8-4, 9-5, 9-6, ................................ 9-8, 9-10, 9-12 8859-1204 ................ 8-1, 8-2, 9-1, ................................... 9-2, 9-3, 9-4, ................................... 9-5, 9-7, 9-8, ............................. 9-13, 9-14, 9-16, ........................... 10-18, 13-4, 13-5, ......................................... 13-6, 13-7 8859-1205 ............
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 8874-3055 ...................................... 6-1 8882-1003 ............................ 6-1, 7-1 8882-1004 .................. 7-2, 8-3, 13-3 8998-1036 ..................................... 5-1 9002-0115 ......................... 13-6, 13-7 9002-0489 ................................... 13-3 9002-1454 ..................................... 5-6 9002-1552 .......................... 7-2, 13-3 9002-1553 ..
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9020-2372 ..................... 10-22, 10-24 9020-2376 ..................... 10-22, 10-24 9020-2377 .................................. 10-24 9020-2378 .................................. 10-24 9020-2379 ..................... 10-22, 10-24 9020-2382 .................................. 10-24 9020-2383 .................................. 10-22 9020-2389 .................................. 10-24 9020-2390 ......
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9020-5783 ............................. 9-1, 9-2 9020-5792 ................... 9-1, 9-2, 9-10 9020-5793 ............................. 9-3, 9-4 9020-5846 ....................................... 2-2 9020-5870 ...................................... 4-2 9020-5886 ...................................... 2-2 9020-5888 ...................................... 2-2 9020-5891 ......................................
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INTRODUCTION Parts Index Starting Serial No.
PAGE 23
INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9103-1067 ...................................... 2-1 9103-1074 ....................................... 2-1 9103-1075 ...................................... 2-1 9103-1077 .................................. 13-10 9103-1085 ...................................... 8-3 9103-1086 ............................. 9-5, 9-6 9103-1087 ...................................... 7-3 9103-1088 ..............................
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INTRODUCTION Parts Index Starting Serial No.
PAGE 25
INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9103-4264 ...................................... 6-9 9103-4272 .................................. 10-31 9103-4273 .................................. 10-31 9103-4276 .................................. 10-32 9103-4301 .................................. 13-19 9103-4326 ...................................... 6-1 9103-4327 ...................................... 6-1 9103-4329 .................................
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9104-3063 ...................................... 2-1 9104-3064 .................................. 10-29 9104-3065 .................................. 10-10 9104-3066 .................................... 10-4 9104-3067 .................................... 10-1 9104-3069 ....................................... 9-8 9104-3070 ...................................... 9-8 9104-3071 ..............................
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INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9104-4014 ......................... 10-1, 10-4 9104-4015 ......................... 10-1, 10-4 9104-4016 ........................ 10-1, 10-2, .................................. 10-3, 10-4, 10-8 9104-4017 .................................... 10-1 9104-4018 ......................... 10-1, 10-4 9104-4019 .................................... 10-1 9104-4020 ....................................
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INTRODUCTION Parts Index Starting Serial No.
PAGE 29
INTRODUCTION Parts Index Starting Serial No. 8655105G Original Issue 8-86 Revised 8-87 Part Number Page 9104-4518 .................................. 10-10 9104-4519 .................................. 10-10 9104-4520 .................................. 10-10 9104-4521 .................................. 10-10 9104-4522 .................................. 10-10 9104-4523 .................................... 6-17 9104-4525 .................................. 10-29 9104-4526 ..................................
PAGE 30
CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Starting Serial No. 8655105G Original Issue 7-86 Revised 7-88 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 31
CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Starting Serial No. 0155173 Original Issue 3-88 Revised 3-89 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 32
CHASSIS & ATTACHING PARTS Cab Enclosure, Wiper & Defroster Starting Serial No. 8655105G Original Issue 7-86 Revised 2-92 Item Part No. Qty.
PAGE 33
CHASSIS & ATTACHING PARTS Cab Heater & Hoses Starting Serial No. 8655105G Original Issue 4-86 Revised 6-89 Item Part No. Qty. Description Of Part 1 2 9020-6134 9103-4098 1 1 3 4 5 6 7 8 9 10 11 12 9020-6133 9020-6131 9020-5731 8820-1005 9020-0679 1 1 2 8 1 AR 4 2 2 4 JUMPER WIRE HEATER SWITCH (furnished with heater) JUMPER WIRE CIRCUIT BREAKER HEATER MOUNTING BRACKET HEX HD CAPSCREW, 1/4-20X1, GR5 HEATER (includes item 2) HOSE, 5/8 I.D.
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CHASSIS & ATTACHING PARTS Front Axle Cradle & Attaching Parts Starting Serial No. 8655105G Original Issue 4-86 Revised 9-89 PCN L-8797 Item Part No. Qty.
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CHASSIS & ATTACHING PARTS Rear Steering Axle & Attaching Parts Starting Serial No. 8755124G Original Issue 9-87 Revised 9-89 Item Part No. Qty.
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CHASSIS & ATTACHING PARTS Rear Steering Axle & Attaching Parts Starting Serial No. 8655105G Original Issue 4-86 Revised 4-23-97 Item Part No. Qty.
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CHASSIS & ATTACHING PARTS Outrigger & Attaching Parts Starting Serial No. 8655105G Original Issue 4-86 Revised 9-91 Item Part No. Qty. Description Of Part 1 8643-1005 16 2 3 0510-1411 9103-6029 9103-6030 8320-1073 9103-1141 8852-1206 8867-1001 9104-3258 8820-1040 16 1 1 6 4 6 8 2 6 10 11 8855-1011 6 Ref 12 13 14 9103-6032 9103-6041 9103-1140 2 2 2 HEX HD CAPSCREW (lubricate and torque to 795-845 ft. lbs.) HEAT TREATED WASHER OUTRIGGER BRACKET, L.H. OUTRIGGER BRACKET, R.H.
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BOOMS 1st Boom Section Starting Serial No. 0155173 Original Issue 3-88 Revised 9-88 Item Part No. Qty. Description Of Part Item Part No. Qty. 1 2 9104-6079 8820-1564 1 4 16 8820-1566 12 3 1238-1025 4 9104-1277 5 9104-1276 6 9104-1278 7 9104-3180 8 9104-3177 9 8820-1069 10 8855-1013 11 9104-1009 12 9104-3164 13 9104-1265 14 9104-1006 15 9104-1007 PCN L-8616 24 8 10 6 2 4 2 2 1 4 4 12 4 FIRST BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X1, GR5 (lubricate and torque to 68-78 ft. lbs.
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BOOMS 1st Boom Section Starting Serial No. 8655105G Original Issue 5-86 Revised 3-86 Item Part No. Qty. Description Of Part Item Part No. Qty. 1 2 9104-6017 8820-1564 1 4 16 8820-1566 12 3 1238-1025 4 9104-1277 5 9104-1276 6 9104-1278 7 9104-3180 8 9104-3177 9 8820-1069 10 8855-1013 11 9104-1009 12 9104-3164 13 9104-1265 14 9104-1006 15 9104-1007 PCN L-8419 24 8 14 6 2 4 2 2 1 4 4 12 4 FIRST BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X1, GR5 (lubricate and torque to 68-78 ft. lbs.
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BOOMS 2nd Boom Section Starting Serial No. 8655105G Original Issue 5-86 Revised 9-88 Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part 1 9104-6018 1 2 8820-1563 16 11 12 13 9104-1006 9104-1007 8820-1562 6 2 16 3 1238-1025 4 9104-1277 5 9104-1276 6 9104-3180 7 9104-1278 8 9104-3177 9 9104-3164 10 9104-1265 PCN L-8616 32 12 12 2 10 8 4 2 SECOND BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X7/8, GR5 (lubricate and torque to 68-78 ft. lbs.
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BOOMS 3rd Boom Section Starting Serial No. 8655105G Original Issue 5-86 Revised 9-88 Item Part No. Qty. 1 2 9104-6019 8820-1563 1 4 3 4 5 6 7 8 1238-1025 9104-1277 9104-1276 9104-1278 9104-3180 8820-1562 8 10 12 10 2 16 9 10 11 1238-1025 9104-3164 8820-1567 24 4 6 PCN L-8616 Description Of Part THIRD BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X7/8, GR5 (lubricate and torque to 68-78 ft. lbs.
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BOOMS 4th Boom Section Starting Serial No. 8655105G Original Issue 5-86 Revised 11-86 Item Part No. Qty.
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BOOMS Push Beam & Cables Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty.
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BOOMS Push Beam & Cables Starting Serial No. 8755156G Original Issue 11-87 Revised 12-15-93 Item Part No. Qty. Description Of Part Item Part No. Qty.
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BOOMS Push Beam & Cables *Starting Serial No. 0155250 ! NOTE: When purchasing item (1) Push Beam Weldment (9104-6049), the rub pads may need to be hand ground for proper fit when installing the sheave assy. Item Part No. Qty.
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BOOMS Quick Switch Assembly Starting Serial No. 8655105G Original Issue 6-86 Revised 4-24-97 Item Part No. Qty.
PAGE 47
BOOMS Quick Switch Assembly Starting Serial No. 0155269 Original Issue 7-89 Item 1 2 3 4 5 6 7 PCN L-8854 Part No. Qty.
PAGE 48
ATTACHMENTS & ACCESSORIES Sand Bucket & Carriages Starting Serial No. 8655105G Original Issue 1-87 Revised 11-29-00 Item Part No. Qty. 1 9080-1332 1 Item Part No. Qty. Description Of Part 9045-5007 1 1 2 3 4 5 *6 *7 9080-1315 8820-1105 9020-0003 8852-1310 9040-2477 9015-3001 8834-1022 1 2 2 2 1 1 4 48" CARRIAGE ASSY, (includes all items) 48" CARRIAGE WELDMENT HEX HD CAPSCREW, 5/8-11X4, GR5 COLLAR HEX LOCKNUT, 5/8-11 FORK PIN SERIAL NUMBER PLATE DRIVE SCREW, #10X3/8 Item Part No. Qty.
PAGE 49
ATTACHMENTS & ACCESSORIES (9130-5016) 66" Slope Piler Carriage Starting Serial No. 8655105G Original Issue 8-94 Revised 6-16-06 Item Part No. Qty.
PAGE 50
ATTACHMENTS & ACCESSORIES Fork Information Original Issue 11-00 Revised 7-5-02 NOTE: FORKS RATED LESS THAN THE ATTACHMENT OR MACHINE’S CAPACITY DECREASE CAPACITY OF THE ATTACHMENT OR MACHINE TO THAT OF THE FORKS. FORKS RATED MORE THAN THE ATTACHMENT OR MACHINE’S CAPACITY DO NOT INCREASE ATTACHMENT OR MACHINE’S CAPACITY. NOTE: PLEASE CONSULT THE GRADALL PARTS DEPARTMENT TO DETERMINE THE CORRECT FORKS APPLICABLE TO YOUR SPECIFIC CARRIAGE ASSEMBLY AND APPLICATION. Item TT Part No. Qty.
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ENGINE & ATTACHING PARTS Engine Left Side View Starting Serial No. 8655105G Original Issue 5-86 Revised 11-86 Item Part No. 1 2 3 7713-4059 8820-1067 4 5 6 7 8540-1340 8855-1013 8471-1369 8820-1036 8 9 10 11 12 13 14 15 8855-1011 9105-3345 8503-1525 7713-3089 8471-1333 8366-1304 9105-3344 16 8652-1144 17 8820-1031 L-8027 Qty.
PAGE 52
ENGINE & ATTACHING PARTS Engine Right Side View Starting Serial No. 8655105G Original Issue 4-86 Revised 8-88 Item Item Part No. Qty. Description Of Part 9103-5141 1 9020-6262 9103-4006 9103-4005 9020-4732 1 1 1 1 PERKINS ENGINE/TRANSMISSION FILTER KIT (includes all items) AIR FILTER OIL FILTER FUEL FILTER TRANSMISSION FILTER Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 53
ENGINE & ATTACHING PARTS Engine Mounting Starting Serial No. 8655105G Original Issue 4-86 Revised 5-89 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 54
ENGINE & ATTACHING PARTS Fuel Tank & Lines Starting Serial No. 8655105G Original Issue 5-86 Revised 11-86 Item L-7949 Part No. Qty.
PAGE 55
ENGINE & ATTACHING PARTS Fuel Tank & Lines Starting Serial No. 0155251 Original Issue 5-89 Item PCN L-8813 Part No. Qty.
PAGE 56
ENGINE & ATTACHING PARTS Radiator & Hoses Starting Serial No. 8655105G Original Issue 4-86 Revised 8-86 Item Part No. Qty.
PAGE 57
ENGINE & ATTACHING PARTS Ether Starting Kit Starting Serial No. 8655105G Original Issue 4-86 Item Part No. 1 Qty.
PAGE 58
ENGINE & ATTACHING PARTS Air Cleaner Piping Starting Serial No. 8655105G Original Issue 4-86 Revised 4-88 Item Part No. 1 PCN L-8553 Qty.
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ENGINE & ATTACHING PARTS Air Cleaner Starting Serial No. 8655105G Original Issue 4-86 Revised 10-21-96 Item 1 2 3 4 5 KG Part No. Qty. 9020-5663 9020-6606 9020-6262 9020-1414 9020-0807 1 1 1 1 1 1 * Corrected artwork.
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ENGINE & ATTACHING PARTS Exhaust System Starting Serial No. 8655105G Original Issue 4-86 Revised 6-27-97 PERKINS ENGINE Item KG Part No. Qty.
PAGE 61
DRIVE TRAIN Transmission Mounting & Controls Starting Serial No. 8655105G Original Issue 4-86 Revised 11-3-95 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 62
DRIVE TRAIN Transmission Mounting & Controls Starting Serial No. 0155173G Original Issue 8-88 Revised 11-3-95 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 63
DRIVE TRAIN Transmission Flex Plate & Torque Converter Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 64
DRIVE TRAIN Transmission Flex Plate & Torque Converter Starting Serial No. 0155173G Original Issue 8-88 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 65
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No.
PAGE 66
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 67
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No.
PAGE 68
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No. 0155173G Original Issue 8-88 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 69
DRIVE TRAIN Transmission Drive Gearing Starting Serial No. 8655105G Original Issue 5-86 Revised 2-93 USED WITH AUX PUMP Item Part No. 1 2 8820-1036 3 4 5 6 7 8 9 10 11 12 13 9020-4733 9020-4734 9020-4735 9020-4793 9020-4737 9020-4730 7710-4048 9020-4731 9103-4331 7710-4085 9002-8641 8820-1062 14 15 16 17 18 19 20 7710-4204 9020-4732 7710-4181 9020-4740 9020-4741 9020-4738 9020-5047 Qty.
PAGE 70
DRIVE TRAIN Transmission Drive Gearing Starting Serial No. 0155173G Original Issue 8-88 Revised 2-93 USED WITH AUX PUMP Item Part No. 1 2 9103-4247 3 4 5 6 7 8 9 10 11 12 13 9020-4733 9020-4734 9020-4735 9020-4793 9020-4737 9020-4730 7710-4048 9020-4731 9103-4331 7710-4085 9002-8641 8820-1062 14 15 16 17 18 19 20 7710-4204 9020-4732 7710-4181 9020-4740 9020-4741 9020-4738 9020-5047 Qty.
PAGE 71
DRIVE TRAIN Transmission Clutch & Gearing (Reverse 2nd & Low) Starting Serial No. 8655105G Original Issue 5-86 REV ERS 2ND E& LOW Item Part No. 1 2 3 4 7710-4207 7710-4208 5 6 7 8 7710-4187 7710-4186 7710-4185 7710-4231 9 10 11 12 13 14 7710-4184 7710-4232 7710-4219 7710-4220 7710-4221 7710-4222 15 16 7710-4223 7710-4224 Qty.
PAGE 72
DRIVE TRAIN Transmission Clutch & Gearing (Reverse 2nd & Low) Starting Serial No. 0155173G Original Issue 8-88 REV ERS 2ND E& LOW Item Part No. 1 2 3 4 7710-4207 7710-4208 5 6 7 8 7710-4187 7710-4186 7710-4185 7710-4231 9 10 11 12 13 14 15 7710-4184 9103-4255 9020-4855 7710-4219 7710-4220 7710-4221 7710-4222 16 17 7710-4223 7710-4224 Qty.
PAGE 73
DRIVE TRAIN Transmission Clutch & Gearing (Forward, Output and Third) Starting Serial No. 8655105G Original Issue 5-86 OUT PUT D & 3R D WAR FOR Item Part No. 1 2 3 4 5 6 7 8 9 9020-4866 9020-4864 9020-4862 7710-4185 7710-4186 7710-4187 7710-4198 10 11 12 13 14 7710-4205 7710-4206 7710-4207 7710-4208 15 16 17 18 19 7710-4211 7710-4212 7710-4213 7710-4214 7710-4215 Qty.
PAGE 74
DRIVE TRAIN Transmission Clutch & Gearing (Forward, Output and Third) Starting Serial No. 0155173G Original Issue 8-88 OUT PUT D & 3R D WAR FOR Item Part No. 1 2 3 4 5 6 7 8 9 10 9103-4257 9103-4255 7710-4217 9020-4862 7710-4185 7710-4186 7710-4187 7710-4198 11 12 13 14 15 7710-4205 7710-4206 7710-4207 7710-4208 16 17 18 19 7710-4211 7710-4212 7710-4213 9103-4258 PCN L-8546 Qty.
PAGE 75
DRIVE TRAIN Transmission Clutch Assemblies Starting Serial No. 8655105G Original Issue 5-86 LOW FORWARD 3RD REVERSE 2ND Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 76
DRIVE TRAIN Transmission Clutch Assemblies Starting Serial No. 0155173G Original Issue 8-88 LOW FORWARD 3RD REVERSE 2ND Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 77
DRIVE TRAIN Transmission Modular Valve Starting Serial No. 0155173G Original Issue 8-88 Revised 6-89 Item 1 2 3 4 Part No. Qty. 9020-4990 1 9103-4263 9020-4992 1 1 1 2 5 6 7 8 9020-5056 9020-5057 9103-4264 4 4 2 2 9 9020-4820 1 Description Of Part MODULATOR VALVE (includes items 1 thru 8) VALVE HOUSING ACCUMULATOR SPRING (inner) ACCUMULATOR SPRING (outer) ACCUMULATOR VALVE (part of valve assy.) O-RING SPOOL STOP PLUG (includes item 6) REGULATOR SPRING REGULATOR SPOOL (part of valve assy.
PAGE 78
DRIVE TRAIN Transmission Modular Valve Starting Serial No. 8655105G Original Issue 5-86 Item 1 2 3 4 5 6 7 8 9 Part No. Qty. Description Of Part 9023-8085 1 MODULATOR VALVE ASSY (includes all items) VALVE HOUSING ACCUMULATOR INNER SPRING ACCUMULATOR OUTER SPRING VALVE SPOOL STOP PLUG (includes item 6) O-RING REGULATOR SPRING REGULATOR SPOOL GASKET 9020-4991 9020-4992 9020-5057 9020-5056 9020-4822 9020-4820 1 2 2 2 4 4 2 2 1 NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 79
DRIVE TRAIN Transmission Control Valve Starting Serial No. 8655105G Original Issue 5-86 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 80
DRIVE TRAIN Transmission Control Valve Starting Serial No. 0155173G Original Issue 8-88 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 81
DRIVE TRAIN Propeller Shaft Starting Serial No. 8655105G Original Issue 4-86 Revised 5-19-97 Item 1 *2 3 4 5 6 7 8 9 10 Part No. Qty.
PAGE 82
DRIVE TRAIN Front Axle Assy Starting Serial No. 8655105G Original Issue 8-86 Revised 7-89 Item PCN L-8744 Part No. Qty.
PAGE 83
DRIVE TRAIN Front Axle Assy Starting Serial No. 0155259 Original Issue 1-98 Item KG Part No. Qty.
PAGE 84
DRIVE TRAIN Front Axle Housing Starting Serial No. 8655105G Original Issue 8-86 Item Part No. Qty.
PAGE 85
DRIVE TRAIN Front Axle Housing Starting Serial No. 0155259 Original Issue 1-98 Item 1 2 3 4 5 6 7 8 9 KG Part No. Qty.
PAGE 86
DRIVE TRAIN Front Axle Differential Carrier Starting Serial No. 8655105G Original Issue 8-86 Item Part No. Qty.
PAGE 87
DRIVE TRAIN Front Axle Differential Carrier Starting Serial No. 0155259 Original Issue 1-98 Item KG Part No. Qty.
PAGE 88
DRIVE TRAIN (9104-4165) Front Axle Shaft & Planetary Wheel End Starting Serial No. 8655105G Original Issue 8-86 Revised 4-30-96 Item Part No. Qty.
PAGE 89
DRIVE TRAIN (9103-4309) Front Axle Shaft & Planetary Wheel End Starting Serial No. 0155259 Original Issue 2-98 Item Part No. Qty.
PAGE 90
DRIVE TRAIN Wheels & Tires Starting Serial No. 8655105G Original Issue 4-86 Revised 4-3-95 NEW STYLE OLD STYLE REAR-STANDARD FRONT-STANDARD Item Part No. Qty. 1 9104-3080 1 * 1 2 9103-3469 9104-3146 1 10 3 9020-0339 1 *3 9108-3385 9020-0561 9020-0772 9020-1615 9104-3084 1 1 1 1 1 4 5 6 7 Description Of Part RIM, 8.00 TG X 24 ** NOTE: (NO LONGER AVAILABLE REPLACED BY 9103-3469) RIM, 9.00 X 24 (New One Piece Style) LUG NUT (lubricate and torque to 350400 ft.lbs.
PAGE 91
DRIVE TRAIN (9104-3277) Rear Steering Axle Planetary Hub Starting Serial No. 8655105G Original Issue 7-86 Revised 7-30-04 ! Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DS NOTE: AS OF 4-7-95, THE SPINDLE (ITEM 6) IS OBSOLETE AND STOCK IS LIMITED. WHEN STOCK IS DEPLETED, YOU WILL NEED TO PURCHASE A NEW WHEEL DRIVE ASSEMBLY, P/N 9104-3489. Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 92
DRIVE TRAIN (9104-3489) Rear Steering Axle Drive Hub FOR SERVICE ONLY Original Issue 4-95 Revised 7-30-04 ! Item * 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 DS NOTE: TO SERVICE ITEM 17, A SPECIAL WRENCH IS REQUIRED. ORDER P/N 9114-4325 WRENCH. Part No. Qty.
PAGE 93
CONTROLS Forward & Reverse Speed Selector Starting Serial No. 8655105G Original Issue 6-86 Revised 11-04-05 JD * Revised illustration and parts list.
PAGE 94
CONTROLS Forward & Reverse Speed Selector Starting Serial No. 8655105G Original Issue 6-86 Revised 11-04-05 JD Item Part No. Qty.
PAGE 95
CONTROLS Tilt & Sway Starting Serial No. 8655105G Original Issue 6-86 Revised 4-87 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 96
CONTROLS Accelerator Linkage Starting Serial No. 8655105G Original Issue 4-86 Revised 12-86 Item Part No. Qty.
PAGE 97
CONTROLS Steering Column Starting Serial No. 8655105G Original Issue 4-86 Revised 9-91 Item Part No. Qty.
PAGE 98
BRAKES Hydraulics & Service Brake Lines Starting Serial No. 8655105G Original Issue 4-86 Revised 3-89 TO PARKING BRAKE VALVE (SEE PAGE 8-2) PCN L-8301 Item Part No. Qty.
PAGE 99
BRAKES Hydraulics & Parking Brake Lines Starting Serial No. 0155238 Original Issue 5-89 TO PARKING BRAKE VALVE (SEE PAGE 8-2) PCN L-8769 Item Part No. Qty.
PAGE 100
BRAKES Hydraulics & Parking Brake Lines * Starting Serial No. 0155221 Original Issue 3-90 ! NOTE: THIS PAGE, STARTING SERIAL NO. 0155221, ORIGINAL ISSUE 3-90, REPLACES PAGE STARTING SERIAL NO. 0155238, ORIGINAL ISSUE 5-89. THIS SERIAL NO. WAS INCORRECT FOR DATA ON THIS PAGE. TO PARKING BRAKE VALVE (SEE PAGE 8-2) PCN L-8688 Item Part No. Qty.
PAGE 101
BRAKES Hydraulics & Parking Brake Lines Starting Serial No. 8655105G Original Issue 4-86 Revised 3-88 FROM HYDRAULIC CONTROLLER (SEE PAGE 9-14) TO DUMP CIRCUIT (SEE PAGE 9-3) TO TEE IN DIRECTIONAL CONTROL VALVE (SEE PAGE 9-3) TO DIRECTIONAL CONTROL VALVE (SEE PAGE 9-8) TO ACCUMULATOR CHARGE VALVE (SEE PAGE 8-4) TO FRONT AXLE PARKING BRAKES (SEE PAGE 8-1) Item Part No.
PAGE 102
BRAKES Hydraulics & Parking Brake Lines Starting Serial No. 0155238 Original Issue 5-89 TO TEE IN DIRECTIONAL CONTROL VALVE (SEE PAGE 9-3) TO DUMP CIRCUIT (SEE PAGE 9-3) FROM HYDRAULIC CONTROLLER (SEE PAGE 9-14) TO DIRECTIONAL CONTROL VALVE (SEE PAGE 9-5) TO HYDRAULIC TANK TEE (SEE PAGE 9-3) TO FRONT AXLE BRAKES (SEE PAGE 8-1) TO ACCUMULATOR CHARGE VALVE (SEE PAGE 8-4) TO FRONT AXLE PARKING BRAKES (SEE PAGE 8-1) Item Part No. 1 Qty.
PAGE 103
BRAKES Hydraulics & Parking Brake Lines ! TO TEE IN DIRECTIONAL CONTROL VALVE (SEE PAGE 9-3) Starting Serial No. 0155221 Original Issue 3-90 NOTE: THIS PAGE, STARTING SERIAL NO. 0155221, ORIGINAL ISSUE 3-90, REPLACES PAGE STARTING SERIAL NO. 0155238, ORIGINAL ISSUE 5-89. THIS SERIAL NO. WAS INCORRECT FOR DATA ON THIS PAGE.
PAGE 104
BRAKES Brake Pedal & Inching Linkage Starting Serial No. 8655105G Original Issue 4-86 Revised 6-4-97 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 105
BRAKES Brake Pedal & Inching Linkage Starting Serial No. 0155188G Original Issue 7-88 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 106
BRAKES Brake Pedal & Inching Linkage Starting Serial No. 0155238 Original Issue 5-89 Revised 7-89 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 107
BRAKES Accumulator, Charging Valve & Lines Starting Serial No. 8655105G Original Issue 4-86 Revised 8-21-95 TO DUMP CIRCUIT (SEE PAGE 9-3) FROM PILOT PUMP (SEE PAGE 9-1) TO TEE IN PILOT CIRCUIT (SEE PAGE 9-1) TO DUMP CIRCUIT (SEE PAGE 9-3) TO BRAKE VALVE (SEE PAGE 8-2) Item Part No. Qty.
PAGE 108
BRAKES Accumulator, Charging Valve & Lines Starting Serial No. 0155238 Original Issue 5-89 Revised 8-21-95 TO DUMP CIRCUIT (SEE PAGE 9-3) FROM PILOT PUMP (SEE PAGE 9-1) TO TEE IN PILOT CIRCUIT (SEE PAGE 9-1) TO DUMP CIRCUIT (SEE PAGE 9-3) TO BRAKE VALVE (SEE PAGE 8-2) Item Part No. Qty.
PAGE 109
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No.
PAGE 110
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No. 8655105G Original Issue 6-86 Revised 10-92 Item Part No.
PAGE 111
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No.
PAGE 112
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No. 0155238 Original Issue 5-89 Revised 10-92 Item Part No.
PAGE 113
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No.
PAGE 114
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No. 8655105G Original Issue 6-86 Revised 1-89 Item Part No. 1 2 3 4 9020-7599 8866-1145 5 6 7 8 9 10 11 8471-7520 9020-5776 9002-8482 9020-7365 9104-3144 8866-1365 12 13 14 15 16 17 18 8366-1316 8866-2105 8471-7842 8471-7797 9020-5793 7713-3447 8820-1008 19 20 21 22 23 9002-9915 8871-1282 8850-1004 8856-1107 24 25 26 8471-7526 8866-2064 27 28 8859-1204 7713-3167 PCN L-8741 Qty.
PAGE 115
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No.
PAGE 116
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No. 0155238 Original Issue 5-89 Item Part No. 1 2 3 4 9020-7599 8866-1145 5 6 7 8 9 10 11 8471-7520 9020-5776 9002-8482 9020-7365 9104-3144 8866-1365 12 13 14 15 16 17 18 8366-1316 8866-2105 8471-7842 8471-7797 9020-5793 7713-3447 8820-1008 19 20 21 22 23 9002-9915 8871-1282 8850-1004 8856-1107 24 25 26 8471-7526 8866-2064 27 28 8859-1204 7713-3167 PCN L-8769 Qty.
PAGE 117
HYDRAULIC CIRCUITS Rear Drive Starting Serial No.
PAGE 118
HYDRAULIC CIRCUITS Rear Drive Starting Serial No. 8655105G Original Issue 6-86 Revised 12-86 Item Part No.
PAGE 119
HYDRAULIC CIRCUITS Rear Drive Starting Serial No.
PAGE 120
HYDRAULIC CIRCUITS Rear Drive Starting Serial No. 0155238 Original Issue 2-90 Revised 2-3-94 Item Part No. 1 2 3 4 5 6 7 8 9 9104-3113 9104-3116 9020-7290 9002-7187 9104-3308 9104-3309 9020-2343 8820-1033 10 11 8856-1109 12 13 14 15 16 17 18 19 20 8471-7900 9104-3312 9104-3311 9104-3307 9104-3310 9104-3115 9002-7372 8471-1342 8820-1067 21 22 23 24 25 26 27 9020-7372 9104-3114 9020-0482 8850-1008 9002-7471 9103-3481 PCN 930685-KG Qty.
PAGE 121
HYDRAULIC CIRCUITS Steering Starting Serial No. 8655105G Original Issue 6-86 Revised 8-86 Item Part No. Qty.
PAGE 122
HYDRAULIC CIRCUITS Lift Cylinder Starting Serial No. 8655105G Original Issue 6-86 Revised 5-87 Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 8859-1207 8866-2038 8866-2108 8866-2008 9104-3095 9104-3096 8471-6448 8820-1035 9020-0483 8850-1006 8471-7799 14 8820-1104 15 16 17 18 9020-6892 8850-1010 8859-1202 8866-2062 19 20 9104-3070 9104-3069 PCN L-8684 Qty.
PAGE 123
HYDRAULIC CIRCUITS Lift Cylinder Starting Serial No. 8755147G Original Issue 11-87 Revised 2-89 Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8859-1207 8866-2038 8866-2108 8866-2008 9104-3095 9104-3096 8471-6448 8820-1035 9020-0483 8850-1006 8471-7799 8867-1008 8820-1104 15 9020-6892 PCN L-8684 Qty.
PAGE 124
HYDRAULIC CIRCUITS Lift Cylinder Starting Serial No. 0155220 Original Issue 2-89 Revised 7-89 Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8859-1207 8866-2038 8866-2108 8866-2008 9104-3095 9104-3096 8471-6448 8820-1035 9020-0483 8850-1006 8471-7799 8867-1008 8820-1104 15 9020-6892 PCN L-8821 Qty.
PAGE 125
HYDRAULIC CIRCUITS Crowd Cylinder Starting Serial No.
PAGE 126
HYDRAULIC CIRCUITS Crowd Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 7-89 Item Part No. Qty.
PAGE 127
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 8-18-00 DS * Revised part number on items 31 & 52.
PAGE 128
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 8-18-00 Item Part No. 1 2 3 9104-3174 8866-2062 4 5 6 7 8859-1202 9104-3232 8859-1106 8820-1071 8 9 10 11 12 13 14 15 8855-1013 9104-3157 8471-7588 8852-1010 9020-6892 8320-1044 8471-7487 8866-1206 16 17 18 19 8471-7486 7713-3136 7713-3137 8820-1023 20 21 9104-3098 8820-1038 22 23 24 25 26 8856-1109 9104-1226 8855-1011 8850-1006 8820-1003 27 28 29 30 9104-3093 8855-1009 8866-1065 8820-1037 DS Qty.
PAGE 129
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 0155283 Original Issue 11-89 Revised 8-18-00 DS * Revised part number on items 28 & 47.
PAGE 130
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 0155283 Original Issue 11-89 Revised 8-18-00 Item Part No. 1 2 3 4 5 6 7 8 8867-1008 8867-1027 9020-6892 8320-1044 8852-1010 8866-2106 8866-2020 9 10 11 12 13 14 8859-1207 8471-7916 8866-1065 8471-7486 7713-3136 8820-1023 15 16 17 7713-3137 9104-3098 8820-1038 18 19 20 21 22 23 8856-1109 9104-1226 8855-1011 8850-1006 9104-3093 8820-1003 24 25 8856-1107 8820-1037 26 27 8471-7494 8855-1009 DS Qty.
PAGE 131
HYDRAULIC CIRCUITS Sway Cylinder Starting Serial No. 8655105G Original Issue 6-86 Revised 12-88 Item Part No. Qty. 9104-5032 1 1 2 3 4 8859-1012 9104-1387 9105-3354 5 8820-1041 6 7 8 9 10 8855-1011 8867-1008 8866-2006 8859-1205 9020-7727 9020-7728 9020-7729 9020-7730 PCN L-8776 Description Of Part SWAY CYLINDER ASSY (includes items 1 thru 9) Ref SWAY CYLINDER (see page 10-6 for details) 2 O-RING 2 ORIFICE PLUG 1 DUAL P.O.
PAGE 132
HYDRAULIC CIRCUITS Joystick Starting Serial No. 8655105G Original Issue 6-86 Revised 12-86 TO DUMP CIRCUIT (see page 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (SEE PAGE 9-1) L-8008, L-8067 Item Part No. Qty.
PAGE 133
HYDRAULIC CIRCUITS Joystick Starting Serial No. 0155238 Original Issue 5-89 TO DUMP CIRCUIT (see page 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (SEE PAGE 9-1) PCN L-8769 Item Part No. Qty.
PAGE 134
HYDRAULIC CIRCUITS Outrigger Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 11-30-93 Item Part No. 1 2 3 9103-3201 8866-2085 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 8859-1205 8471-7527 8471-7528 9002-7187 7713-3168 7713-3140 7713-3177 9103-3141 9103-3198 7713-3499 7713-3498 9103-3138 9103-3199 9103-3200 9103-3140 7713-3177 7713-3140 7713-3168 7713-3390 7713-3389 KG Qty.
PAGE 135
HYDRAULIC CIRCUITS Outrigger Cylinder Starting Serial No. 0155283 Original Issue 11-89 Revised 11-30-93 Item Part No. 1 2 3 9103-3201 8866-2085 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 8859-1205 8471-7527 8471-7528 9002-7187 7713-3168 7713-3140 7713-3177 9103-3141 9103-3198 7713-3499 7713-3498 9103-3138 9103-3199 9103-3200 9103-3140 7713-3177 7713-3140 7713-3168 7713-3390 7713-3389 KG Qty.
PAGE 136
HYDRAULIC CIRCUITS Stabilizer Cylinder Starting Serial No. 8655105G Original Issue 6-86 Revised 2-89 TO DUMP CIRCUIT (SEE PAGE 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (SEE PAGE 9-1) Item Part No. 1 PCN L-8641 2 3 4 5 6 7 8858-1140 9104-1227 8867-1008 9104-1228 8859-1205 8866-2065 8 9 10 11 12 8471-7584 8471-7578 8471-7485 9020-0483 8820-1036 13 14 15 16 17 18 7713-3167 9104-1202 8866-2005 8859-1204 8697-1355 8866-2084 19 8820-1029 20 21 8856-1108 22 23 9002-7187 9104-5035 Qty.
PAGE 137
HYDRAULIC CIRCUITS Stabilizer Cylinder Starting Serial No. 0155216 Original Issue 2-89 TO DUMP CIRCUIT (SEE PAGE 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (SEE PAGE 9-1) Item Part No. 1 PCN L-8641 2 3 4 5 6 7 8858-1140 9104-1227 8867-1008 9104-1489 8859-1205 8866-2065 8 9 10 11 12 8471-7584 8471-7578 8471-7485 9020-0483 8820-1036 13 14 15 16 17 18 7713-3167 9104-1202 8866-2005 8859-1204 8697-1355 8866-2084 19 8820-1029 20 21 8856-1108 22 23 24 9002-7187 9104-5035 8867-1027 Qty.
PAGE 138
HYDRAULIC CIRCUITS Stabilizer Cylinder Starting Serial No. 0155238 Original Issue 5-89 TO DUMP CIRCUIT (SEE PAGE 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (SEE PAGE 9-1) Item Part No. 1 PCN L-8769 2 3 4 5 6 7 8858-1140 9104-1227 8867-1008 9104-1489 8859-1205 8866-2065 8 9 10 11 12 8471-7584 8471-7578 8471-7485 9020-0483 8820-1036 13 14 15 16 17 18 7713-3167 9104-1202 8866-2005 8859-1204 8697-1355 8866-2084 19 8820-1029 20 21 8856-1108 22 23 24 9002-7187 9104-5035 8867-1027 Qty.
PAGE 139
HYDRAULIC COMPONENTS Lift Cylinder Starting Serial No. 8655105G Original Issue 5-86 Item 1 2 3 4 5 6 7 8 9 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 140
HYDRAULIC COMPONENTS Crowd Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 7-88 Item Part No. Qty.
PAGE 141
HYDRAULIC COMPONENTS Crowd Extension Cylinder Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 142
HYDRAULIC COMPONENTS Tilt Cylinder Starting Serial No. 8655105G Original Issue 5-86 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty. Description Of Part 9104-3066 1 9104-4014 1 9104-4015 1 9104-4039 9020-6793 9104-4040 9020-6793 9104-4040 2 1 1 1 2 1 2 1 9104-4018 1 2 1 TILY CYLINDER ASSY (includes all items) SEAL KIT (includes items 2, 3, 4, 10, 11, 13, 14, 15, 16) PISTON ASSY (includes items 2 thru 4; lubricate and torque to 1,450-1,550 ft. lbs.
PAGE 143
HYDRAULIC COMPONENTS Compensating Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 11-86 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part No. Qty.
PAGE 144
HYDRAULIC COMPONENTS (9104-3139) Sway Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 3-3-97 Item Part No. Qty.
PAGE 145
HYDRAULIC COMPONENTS Steering Cylinder Starting Serial No. 8655105G Original Issue 5-86 Revised 12-88 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No. Qty.
PAGE 146
HYDRAULIC COMPONENTS Stabilizer Cylinder Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty.
PAGE 147
HYDRAULIC COMPONENTS Outrigger Cylinder Starting Serial No. 8655105G Original Issue 5-86 Item Part No. Qty.
PAGE 148
HYDRAULIC COMPONENTS (9104-3065) Main Control Valve Assembly Starting Serial No. 8655105G Original Issue 8-86 Revised 2-5-97 KG * Entire page redrawn to include more service parts breakdown.
PAGE 149
HYDRAULIC COMPONENTS (9104-3065) Main Control Valve Assembly Starting Serial No. 8655105G Original Issue 8-86 Revised 2-5-97 ARTWORK ON PREVIOUS PAGE Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 KG Qty.
PAGE 150
HYDRAULIC COMPONENTS Priority Flow Control Valve Starting Serial No. 8655105G Original Issue 4-86 Revised 11-88 Item L-7899 Part No. Qty.
PAGE 151
HYDRAULIC COMPONENTS Priority Flow Control Valve Starting Serial No. 8655105G Original Issue 4-86 Revised 5-87 Item L-7899 Part No. Qty.
PAGE 152
HYDRAULIC COMPONENTS Forward-Reverse Control Valve Starting Serial No. 8655105G Original Issue 4-86 Revised 10-17-03 Item GP Part No. Qty.
PAGE 153
HYDRAULIC COMPONENTS Series-Parallel Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 3 4 5 6 7 8 9 10 Part No. Qty. 9020-6738 1 9020-8060 9020-8058 9020-8065 9020-8062 9020-8064 9020-8061 9020-8059 9020-8063 1 1 2 2 4 2 2 2 2 4 Description Of Part SERIES-PARALLEL VALVE ASSY (includes all items) HOUSING SPOOL O-RING PLUG O-RING SPACER SPRING TUBE CAP HEX HD CAPSCREW NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 154
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 8655105G Original Issue 4-86 Revised 5-90 Item 1 2 3 4 5 Part No. Qty. Description Of Part 9020-6739 1 9104-4001 9020-8066 9020-8067 7738-4267 9020-8071 9020-8072 1 1 1 1 1 1 SOLENOID VALVE ASSY, THREE WAY - TWO POSITION (includes all items) SEAL KIT NUT NAME PLATE SOLENOID COIL ASSY VALVE ASSY VALVE BODY NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 155
HYDRAULIC COMPONENTS Rear Drive Main Relief Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part No. Qty.
PAGE 156
HYDRAULIC COMPONENTS Outrigger Control Valve Starting Serial No. 8655105G Original Issue 8-87 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Part No. Qty.
PAGE 157
HYDRAULIC COMPONENTS (9104-3296) Accumulator Charge Valve Starting Serial No. 8655105G Original Issue 6-86 Revised 3-5-97 Item Part No. Qty. Description Of Part 1 2 3 4 9104-3296 9104-4538 9104-4539 9104-4540 1 1 1 1 ACCUMULATOR CHARGE VALVE LG. SPRING REPAIR KIT SPOOL & SM. SPRING REPAIR KIT ELEMENT & SEAL KIT NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE. KG * 9104-3079 Accumulator charge valve supercedes to 9104-3296.
PAGE 158
HYDRAULIC COMPONENTS Series-Parallel Control Valve Starting Serial No. 8655105G Original Issue 5-86 Revised 11-86 Item Part No. Qty.
PAGE 159
HYDRAULIC COMPONENTS Brake Valve Starting Serial No. 8655105G Original Issue 6-86 Item Part No. Qty.
PAGE 160
HYDRAULIC COMPONENTS Brake Valve Starting Serial No. 0155238 Original Issue 5-89 PCN L-8769 Item Part No. Qty.
PAGE 161
HYDRAULIC COMPONENTS Parking Brake Valve Starting Serial No. 8655105G Original Issue 8-86 Revised 6-89 Item 1 2 3 4 5 6 7 PCN L-8899 Part No. Qty.
PAGE 162
HYDRAULIC COMPONENTS Directional Control Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 3 4 5 6 7 8 9 10 Part No. Qty. 9103-3097 1 9103-4011 9103-4012 9103-4013 4 1 1 2 2 2 1 1 1 4 Description Of Part DIRECTIONAL CONTROL VALVE ASSY (includes all items) SCREW NAME PLATE GASKET SCREW TERMINAL BLOCK SCREW TERMINAL BOX GASKET GROUND SCREW MOUNTING BOLT Item 11 12 13 14 15 16 17 Part No. 9103-4014 9103-4015 9103-4016 9103-4017 Qty.
PAGE 163
HYDRAULIC COMPONENTS Main Hydraulic Pump Starting Serial No. 8655105G Original Issue 4-86 Revised 5-88 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty.
PAGE 164
HYDRAULIC COMPONENTS Pilot Pump Starting Serial No. 8655105G Original Issue 6-86 Item 1 2 3 4 5 6 7 8 Part No. Qty. 9103-3122 1 9103-4019 1 8820-1038 4 9103-4058 9103-4059 9103-4060 9103-4061 9103-4062 9103-4063 4 1 1 2 2 1 1 Description Of Part PILOT PUMP ASSY (includes all items) SEAL KIT (includes items 7, 12, 13, 16, 17) HEX HD CAPSCREW, 3/8-16X1-3/4, GR5 (lubricate and torque to 34-38 ft. lbs.
PAGE 165
HYDRAULIC COMPONENTS Rear Drive Motor Starting Serial No. 8655105G Original Issue 4-86 Revised 5-88 Item 1 2 3 4 5 6 7 8 9 10 Part No. Qty. 9020-6748 2 9020-2371 9020-2372 9020-5716 9020-8193 9020-2435 9020-2376 9002-7736 9020-2377 9020-2378 9020-2379 1 1 1 1 2 2 8 2 2 1 Description Of Part REAR DRIVE MOTOR ASSY (includes all items) OUTER SHAFT SEAL SNAP RING INNER SHAFT SEAL FLANGE (includes bushings) BALL DOWEL HEX HD CAPSCREW CHECK BALL BALL CHECK RETAINER O-RING Item Part No. Qty.
PAGE 166
HYDRAULIC COMPONENTS Oil Reservoir Filter Starting Serial No. 8655105G Original Issue 4-86 Revised 7-92 UNIT WITH POP-UP INDICATOR UNIT WITHOUT INDICATOR Item Part No. Qty.
PAGE 167
HYDRAULIC COMPONENTS Hydraulic Oil Reservoir Starting Serial No. 8655105G Original Issue 4-86 Item Part No. Qty.
PAGE 168
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 4 6 7 Part No. Qty. 9104-3108 1 9104-4002 9104-4003 1 1 1 1 1 1 7738-4267 9104-4004 7738-3338 Description Of Part SOLENOID VALVE ASSY, TWO-WAY, NORMALLY OPEN (includes all items) SEAL KIT NUT NAME PLATE SOLENOID COIL VALVE ASSY VALVE BODY NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 169
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 3 4 5 6 7 Part No. Qty. 9104-3108 1 9104-4002 9104-4003 1 1 1 1 1 1 1 1 9020-8068 7738-4267 9020-8070 9104-4004 7738-3338 Description Of Part SOLENOID VALVE ASSY, TWO-WAY, NORMALLY OPEN (includes all items) SEAL KIT NUT NAME PLATE COIL HOUSING SOLENOID COIL COVER PLATE VALVE ASSY VALVE BODY NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 170
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 8655105G Original Issue 4-86 Item 1 2 3 4 5 6 7 Part No. Qty. 9104-3107 1 9104-4005 9020-8066 1 1 1 1 1 1 1 1 9020-8068 7738-4267 9020-8070 9104-4006 9104-4007 Description Of Part SOLENOID VALVE ASSY, TWO-WAY, NORMALLY CLOSED (includes all items) SEAL KIT NUT NAME PLATE COIL HOUSING SOLENOID COIL COVER PLATE VALVE ASSY VALVE BODY NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 171
HYDRAULIC COMPONENTS Hydraulic Controller Starting Serial No. 8655105G Original Issue 8-86 Revised 1-3-96 Item Part No. Qty. 9104-3064 1 9900-7524 4 1 2 3 4 5 6 9104-4131 9104-4132 9104-4133 9104-4134 9104-4135 9104-4136 1 1 1 1 1 1 7 9104-4474 1 *8 9104-4525 1 * Added item 8.
PAGE 172
HYDRAULIC COMPONENTS Dual P.O. Check Valve Starting Serial No. 8655105G Original Issue 6-87 Revised 12-88 Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part 1 3 1 1 1 1 1 1 1 DUAL P.O.
PAGE 173
HYDRAULIC COMPONENTS Dual P.O. Check Valve Starting Serial No. 8655105G Original Issue 12-88 Item 1 2 3 4 5 6 7 8 9 10 11 12 Part No. Qty. Description Of Part 9105-3354 2 9103-4272 8855-1011 9103-4110 9103-4111 9103-4112 9103-4113 9103-4114 9103-4115 9103-4116 9103-4117 9103-4273 8820-1041 1 3 1 1 1 1 1 1 1 1 2 3 DUAL P.O.
PAGE 174
HYDRAULIC COMPONENTS Counterbalance Control Valve Starting Serial No. 0155220 Original Issue 7-89 PCN L-8821 Item Part No. Qty.
PAGE 175
ELECTRICAL (9103-5068) Instrument Panel & Wiring Harness Starting Serial No. 8655105G Original Issue 5-86 Revised 9-88 TO OIL TEMERATURE SENDER TO FRAME HARNESS Item Part No. Qty.
PAGE 176
ELECTRICAL Batteries & Cables Starting Serial No. 8655105G Original Issue 7-86 Revised 5-31-05 Item JD Part No. Qty. *1 9020-3359 2 2 3 4 5 6 7 8 9040-3432 7714-3006 8584-1094 9020-0382 9103-3042 9103-3086 9020-0811 1 2 1 2 1 1 1 Description Of Part BATTERY (12 volts, 590 amps), TOP STUD, BCI GROUP 27 BATTERY HOLD DOWN LOCK NUT SUPPORT CLAMP HOLD DOWN STUD NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE GROUND CABLE * Added part number & changed description on item 1.
PAGE 177
ELECTRICAL Boom Section Wiring Starting Serial No. 8655105G Original Issue 2-90 Revised 12-15-93 Item Part No. Qty.
PAGE 178
ELECTRICAL Miscellaneous Eliectrical Components Starting Serial No. 8655105G Original Issue 8-86 Revised 12-87 PCN L-8301 Item Part No. Qty.
PAGE 179
MISCELLANEOUS Frame Decals Starting Serial No. 8655105G Original Issue 5-86 Revised 11-87 Item Part No. Qty.
PAGE 180
MISCELLANEOUS Frame Decals Starting Serial No. 0155253 Original Issue 6-89 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 181
MISCELANEOUS Boom Decals Starting Serial No. 8655105G Original Issue 5-86 Revised 12-86 Item Part No. Qty.
PAGE 182
MISCELLANEOUS Boom Decals Starting Serial No. 0155253 Original Issue 6-89 Item Part No. Qty.
PAGE 183
OPTIONAL EQUIPMENT (9104-3106) Dual Hose Reel Assy Starting Serial No. 8655105G Original Issue 5-87 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. Qty.
PAGE 184
OPTIONAL EQUIPMENT Dual Hose Reel & Hydraulic System Starting Serial No. 8655105G Original Issue 5-87 Revised 12-1-93 TO CONTROL VALVE TOP VIEW FRONT Item Part No. 1 Qty.
PAGE 185
OPTIONAL EQUIPMENT Sway, Auxiliary & Tilt Controls Starting Serial No. 8655105G Original Issue 5-87 Item Part No. Qty.
PAGE 186
OPTIONAL EQUIPMENT (9104-5030) 100 Degree Swing Fork Assy Starting Serial No. 8655105G Original Issue 5-87 Revised 7-88 B A SIDE VIEW A B SECTION B-B SECTION A-A Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 187
OPTIONAL EQUIPMENT (9055-5013) 100 Degree Swing Fork Assy Starting Serial No.
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OPTIONAL EQUIPMENT (9055-5013) 100 Degree Swing Fork Assy Starting Serial No. 8655105G Original Issue 5-87 Revised 7-13-06 Item Part No. Qty.
PAGE 189
OPTIONAL EQUIPMENT (9055-3004) 180 Degree Swing Frame Assy Starting Serial No.
PAGE 190
OPTIONAL EQUIPMENT (9055-3004) 180 Degree Swing Frame Assy Starting Serial No. 8655105G Original Issue 11-87 Item Part No. Qty. Description Of Part Item Part No.
PAGE 191
OPTIONAL EQUIPMENT (9055-3004) 180 Degree Swing Frame Assy Starting Serial No.
PAGE 192
OPTIONAL EQUIPMENT (9055-3004) 180 Degree Swing Frame Assy Starting Serial No. 8655105G Original Issue 7-87 Revised 11-87 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 193
OPTIONAL EQUIPMENT (9055-3007) Swing Valve Assy Starting Serial No. 8655105G Original Issue 11-87 Revised 8-88 Item * Part No. Qty.
PAGE 194
OPTIONAL EQUIPMENT Single Hose Reel & Hydraulic System Starting Serial No. 8655105G Original Issue 11-87 Revised 2-14-95 SEE PAGE 13-2 FOR DUAL HOSE REEL & HYDRAULIC SYSTEM REAR VIEW OF BOOM AUXILIARY VIEW OF SOLENOID VALVE ON ENGINE KG Item Part No. Qty.
PAGE 195
OPTIONAL EQUIPMENT (9104-5025) Winch & Hydrualic System Starting Serial No. 8655105G Original Issue 11-87 Revised 8-88 Item Part No. Qty.
PAGE 196
OPTIONAL EQUIPMENT (9104-3165) Single Hose Reel Assy Starting Serial No. 8655105G Original Issue 11-87 Revised 11-30-93 Item 1 2 3 4 5 6 * 7 8 9 10 11 12 13 14 15 16 17 18 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 197
OPTIONAL EQUIPMENT (9103-3196) Winch Assy Starting Serial No.
PAGE 198
OPTIONAL EQUIPMENT (9103-3196 Winch Assy Starting Serial No. 8655105G Original Issue 11-87 Revised 8-5-97 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Part No. Qty.
PAGE 199
OPTIONAL EQUIPMENT (9080-1313) (Jarp) Hydraulic Cylinder Assy Starting Serial No. 8655105G Original Issue 7-88 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PCN L-8566 Part No. Qty.
PAGE 200
OPTIONAL EQUIPMENT (9103-3291) (Iowa) Hydraulic Cylinder Assy Starting Serial No. 8655105G Original Issue 7-88 Item Part No. Qty.
PAGE 201
OPTIONAL EQUIPMENT Electrics for Auxiliary Hydraulics Original Issue 3-89 13-16
PAGE 202
OPTIONAL EQUIPMENT Electrics for Auxiliary Hydraulics Original Issue 3-89 Item Part No. 9104-5067 1 2 3 4 5 6 7 9020-7470 9002-8955 9002-8957 9002-8978 9020-4263 9104-6093 8820-1064 8 9 10 8855-1013 9104-3265 8820-1037 11 12 13 14 8856-1004 8855-1011 8850-1006 9106-1115 Qty.
PAGE 203
OPTIONAL EQUIPMENT Auxiliary Hydraulics Original Issue 3-89 BLACK YELLOW TO BOOM ASSEMBLY YELLOW CIRCUIT BREAKER RED YELLOW BLACK WHITE ELECTRIC SCHEMATIC Item Part No. Qty.
PAGE 204
OPTIONAL EQUIPMENT Pintle Hook Original Issue 4-90 Item Part No. 9103-5101 PCN L-8698 1 2 9020-0602 8320-1120 3 8855-1013 Qty.
PAGE 205
OPTIONAL EQUIPMENT (9104-5129) Steer Axle Advantage Kit FOR SERVICE ONLY Original Issue 3-96 Revised 2-27-97 NOTE #1: CUSTOMER TO USE EXISTING WHEEL HUBS & HARDWARE, DRIVE MOTORS, DRIVE MOTOR TUBE ASSEMBLIES, AND DRAIN LINE HOSES OR ORDER SEPARATELY IF REPLACEMENT IS REQUIRED NOTE #2: CYLINDER BASE END MUST BE FREE TO ROTATE. SHIM STEER CYLINDER BASE END AS REQUIRED TO MAINTAIN A TOTAL MAX. GAP OF 1/16". * NOTE #3: SHIM BOTTOM KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/32" MOVEMENT.
PAGE 206
OPTIONAL EQUIPMENT (9104-5129) Steer Axle Advantage Kit FOR SERVICE ONLY Original Issue 3-96 Revised 2-27-97 NOTE #1: CUSTOMER TO USE EXISTING WHEEL HUBS & HARDWARE, DRIVE MOTORS, DRIVE MOTOR TUBE ASSEMBLIES, AND DRAIN LINE HOSES OR ORDER SEPARATELY IF REPLACEMENT IS REQUIRED NOTE #2: CYLINDER BASE END MUST BE FREE TO ROTATE. SHIM STEER CYLINDER BASE END AS REQUIRED TO MAINTAIN A TOTAL MAX. GAP OF 1/16". * NOTE #3: SHIM BOTTOM KNUCKLES AS REQUIRED TO MAINTAIN NO MORE THAN 1/32" MOVEMENT.
PAGE 207
OPTIONAL EQUIPMENT (9108-3286) Sway Cylinder Starting Serial No. 8655105G Original Issue 1-98 Item KG Part No. Qty.
PAGE 208
OPTIONAL EQUIPMENT (9108-3471) Sway Cylinder Original Issue 6-06 Item Part No. Qty. 9108-3471 1 9108-4308 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 9106-4016 9114-4128 9112-4083 9114-4017 9103-4156 9112-4084 9112-4085 9112-4086 Description Of Part SWAY CYLINDER ASSY, (includes all items) Ref SEAL KIT, (includes items 6 thru 9, 11, 12 & 14 thru 16) 2 BUSHING 2 GREASE FITTING 1 CASE ASSY 1 CAPSCREW, #8X32X.375 1 LOCKNUT, (lubricate & torque to 350-400 ft.lbs.
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OPTIONAL EQUIPMENT (9108-3262) Dual P.O. Check Valve Starting Serial No. 8655105G Original Issue 6-06 Item Part No. Qty. Description Of Part 9108-3262 9104-4002 DUAL P.O. CHECK VALVE ASSY SEAL KIT, (includes items 3 and 4) BODY CHECK VALVE, (includes items 3 and 4) O-RING O-RING O-RING 1 2 7713-3248 1 Ref 1 2 3 4 5 9108-4227 9108-4228 8859-1009 2 2 2 NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.