Manual

ManualsBrandsGradall ManualsHoist544C-10

Illustrated Parts Manual

Model

544C-10

S/N 0255001

P/N - 91164001

Revised

February 23, 2007

Summary of content (171 pages)

PAGE 1
Illustrated Parts Manual Model 544C-10 S/N 0255001 P/N - 91164001 Revised February 23, 2007
PAGE 2
INTRODUCTION Table of Contents Starting Serial No. 0255001 Original Issue 11-96 Revised 1-6-98 SECTION 1 – INTRODUCTION Table of Contents .................................................................................................................. 1-1 thru 1-4 Alphabetical Index ................................................................................................................. 1-5 thru 1-8 Service Kits ......................................................................................
PAGE 3
INTRODUCTION Table of Contents Starting Serial No. 0255001 Original Issue 11-96 Revised 3-7-97 SECTION 5 – ENGINE & ATTACHING PARTS (continued) Air Cleaner Piping .............................................................................................................................. 5-5 Air Cleaner ......................................................................................................................................... 5-6 Exhaust System ................................................
PAGE 4
INTRODUCTION Table of Contents Starting Serial No. 0255001 Original Issue 11-96 SECTION 10 – HYDRAULIC COMPONENTS (Continued) Compensating Cylinder .................................................................................................................... 10-4 Sway Cylinder ................................................................................................................................... 10-5 Steering Cylinder ........................................................................
PAGE 5
INTRODUCTION Table of Contents Starting Serial No. 0255001 Original Issue 11-96 Revised 7-26-00 SECTION 13 – OPTIONAL EQUIPMENT (Continued) Cab Enclosure .................................................................................................................................. 13-9 Tilt on Joystick ................................................................................................................................ 13-10 Sway Cylinder .......................................................
PAGE 6
INTRODUCTION Alphabetical Index Starting Serial No. 0255001 Original Issue 11-96 ACCELERATOR CABLE ............................................................................................................. 5-1, 7-3 ACCELERATOR PEDAL .................................................................................................................... 7-3 AIR CLEANER ....................................................................................................................................
PAGE 7
INTRODUCTION Alphabetical Index Starting Serial No. 0255001 Original Issue 11-96 ENGINE RIGHT SIDE ........................................................................................................................ 5-2 ENGINE THROTTLE CONTROL ....................................................................................................... 5-1 EXHAUST PIPE..................................................................................................................................
PAGE 8
INTRODUCTION Alphabetical Index Starting Serial No. 0255001 Original Issue 11-96 Revised 5-11-00 IGNITION SWITCH ........................................................................................................................... 11-2 INCHING VALVE ..................................................................................................................... 7-2, 10-13 INSTRUMENT PANEL .............................................................................................................
PAGE 9
INTRODUCTION Alphabetical Index Starting Serial No. 0255001 Original Issue 11-96 RETRACTION CHAINS ...................................................................................................................... 3-7 R.H. TILT/SWAY ............................................................................................................................... 13-7 SEAT ........................................................................................................................................
PAGE 10
INTRODUCTION Service Kits Starting Serial No. 0255001 Original Issue 11-96 SECTION KG PAGE NO.
PAGE 11
INTRODUCTION Service Kits Starting Serial No. 0255001 Original Issue 11-96 SECTION PAGE NO. PART NUMBER DESCRIPTION 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10-16 10-16 10-16 10-17 10-17 10-18 10-19 10-20 10-21 10-22 10-22 10-23 10-23 10-24 10-24 8091-4235 9109-4033 9109-4025 9101-4058 9114-4174 9108-4317 9116-4056 8093-4226 9108-4284 9114-4418 9114-4414 9116-4054 9116-4056 9020-6417 9115-4006 Check Valve Kit (Front Drive Motor) DA 1 Control Kit Front Drive Motor Seal Kit Hyd.
PAGE 12
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 0510-1441 ..................... 4-6, 4-7, 4-12 1201-0717 .................................... 13-10 1440-2248 ................. 2-1, 13-4, 13-14 1440-3190 ..................................... 13-9 1440-3416 ...................................... 11-3 1440-4793 ........................... 13-4, 13-8 2443-1386 ...................................... 4-5 2460-1570 ............................ 2-2, 13-20 2464-1328 .....................................
PAGE 13
INTRODUCTION Part Number Index Starting Serial No. 0255001 Original Issue 12-96 Revised 7-23-99 INDEX PART NUMBER PAGE 8319-1010 ............................... 5-1, 5-2 8319-1013 ...................................... 5-2 8319-1021 ...................................... 5-2 8319-1032 ............................... 5-1, 5-2 8319-1039 ...................................... 5-1 8319-1059 ...................................... 7-5 8320-1006 ...................................... 2-2 8320-1024 ...........
PAGE 14
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 8688-3260 ..................................... 13-3 8688-3327 ...................................... 5-4 8688-3469 ..................... 4-6, 4-7, 4-12 8692-1268 ...................... 2-2, 3-6, 3-7, .......................................... 13-19, 13-20 8696-1044 ..................................... 13-5 8697-1355 ..................................... 4-13 8698-1533 ...................................... 5-5 8698-3188 .............................
PAGE 15
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 8852-1310 ...................... 4-2, 4-6, 4-7, .................................... 4-8, 4-11, 4-12 8852-1312 ............................ 2-2, 13-20 8852-1408 ...................................... 9-5 8852-1604 ..................................... 13-9 8855-1007 ............................. 2-1, 11-4 8855-1009 ................ 4-10, 5-1, 7-3, 7-4, ............................. 8-1, 9-1, 9-2, 9-4, ...............................
PAGE 16
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 8866-2144 ..................................... 10-9 8866-2152 .................. 4-8, 4-10, 4-11, .............................................. 4-12, 7-4 8866-2175 ..................................... 4-12 8866-2194 ...................................... 6-1 8866-2224 ............... 5-2, 6-1, 9-1, 9-4 8866-2225 ..................................... 13-2 8866-2237 ................................ 9-1, 9-4 8866-2239 .....
PAGE 17
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 9020-7880 ...................................... 4-4 9020-7881 ...................................... 4-4 9020-7882 ............................. 4-4, 13-2 9020-7884 ............................... 4-3, 4-4 9020-7902 ...................................... 3-8 9020-8066 ................................... 10-11 9020-8142 ................................... 13-16 9020-8143 ................................... 13-16 9020-8144 .............................
PAGE 18
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 9103-3485 ...................................... 2-1 9103-3487 ................................... 13-10 9103-4070 ................................... 10-14 9103-4107 ................................... 10-19 9103-4118 ................................... 10-19 9103-4139 ........................... 10-1, 10-4 9103-4153 ................. 10-1, 10-2, 10-3, ............................................ 10-4, 10-8 9103-4276 .................................
PAGE 19
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 9108-3107 ...................................... 7-1 9108-3128 ...................................... 5-5 9108-3136 .................... 7-2, 7-4, 13-4, ............................................ 13-7, 13-8 9108-3155 ..................................... 13-9 9108-3159 ...................................... 2-1 9108-3161 ...................................... 2-1 9108-3173 ...................................... 2-1 9108-3200 ........................
PAGE 20
INTRODUCTION Part Number Index Starting Serial No. 0255001 Original Issue 12-96 Revised 7-23-99 INDEX PART NUMBER PAGE 9112-1083 ...................................... 3-2 9112-1091 ...................................... 2-2 9112-1134 .......... 9-8, 13-2, 13-4, 13-8 9112-1139 ..................................... 13-4 9112-1145 ..................................... 13-3 9112-1146 ..................................... 13-3 9112-1151 ..................................... 13-3 9112-1159 ...................
PAGE 21
INTRODUCTION Part Number Index Starting Serial No. 0255001 Original Issue 12-96 Revised 7-23-99 INDEX PART NUMBER PAGE 9114-3292 ..................................... 12-1 9114-4002 ................................... 10-18 9114-4004 ................. 10-1, 10-4, 10-8 9114-4005 ........................... 10-5, 10-7 9114-4006 ..................................... 10-6 9114-4008 ...................................... 5-4 9114-4009 ................................... 10-21 9114-4010 .......................
PAGE 22
INTRODUCTION Part Number Index INDEX PART NUMBER 9114-4352 9114-4353 9114-4354 9114-4356 9114-4357 9114-4358 9114-4359 9114-4360 9114-4361 9114-4362 9114-4363 9114-4364 9114-4365 9114-4367 9114-4368 9114-4371 9114-4372 9114-4373 9114-4374 9114-4375 9114-4376 9114-4377 9114-4378 9114-4379 9114-4380 9114-4381 9114-4382 9114-4383 9114-4384 9114-4385 9114-4386 9114-4387 9114-4388 9114-4389 9114-4390 9114-4391 9114-4392 9114-4393 9114-4394 9114-4395 9114-4396 9114-4397 9114-4398 9114-4399 9114-4400 9114-4401 9
PAGE 23
INTRODUCTION Part Number Index INDEX PART NUMBER PAGE 9116-1277 ...................................... 3-3 9116-1278 ...................................... 3-2 9116-1283 ................................... 13-14 9116-1379 ..................................... 9-12 9116-3001 ...................................... 5-1 9116-3008 ..................................... 10-3 9116-3011 ...................................... 5-1 9116-3012 ...................................... 7-5 9116-3013 ......................
PAGE 24
INTRODUCTION Part Number Index Starting Serial No. 0255001 Original Issue 12-96 Revised 7-23-99 INDEX PART NUMBER PAGE 9116-4049 ................................... 10-17 9116-4050 ................................... 10-17 9116-4051 ................................... 10-17 9116-4052 ..................................... 10-2 9116-4053 ................................... 10-23 9116-4054 ................................... 10-23 9116-4055 ................................... 10-23 9116-4056 ...............
PAGE 25
CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Starting Serial No. 0255001 Original Issue 6-96 Revised 2-10-97 KG * Added item 58.
PAGE 26
CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Starting Serial No. 0255001 Original Issue 6-96 Revised 2-10-97 Item Part No. Qty. Description Of Part Item Part No.
PAGE 27
CHASSIS & ATTACHING PARTS Rear Axle & Attaching Parts Starting Serial No. 0255001 Original Issue 6-96 Revised 5-1-99 1 2 21 22 23 (3)HOLES 125 2.377 DIA 2.378 3 4 20 19 12 18 20 19 8 9 17 24 25 5 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.
PAGE 28
CHASSIS & ATTACHING PARTS Rear Axle & Attaching Parts Starting Serial No. 0255001 Original Issue 6-96 Revised 5-1-99 NOTE #1: 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 #2: Shim bottom knuckles as required to maintain no more than 1/32" movement. Shim top knuckles as required to maintain no more than 1/16" gap. Must have a minimum of one shim. NOTE #3: All machines need to bore Steering Knuckles to use items 4 & 7.
PAGE 29
CHASSIS & ATTACHING PARTS Front Axle Mounting Starting Serial No. 0255001 Original Issue 6-96 Item Part No. 1 2 3 4 5 6 7 KG 9108-1176 9020-5891 9103-1014 8320-1031 8852-1016 9108-3480 Qty.
PAGE 30
CHASSIS & ATTACHING PARTS CAB GLASS 211/16 Rad. Typ. 3511/16 Starting Serial No. 0255001 Original Issue 6-96 211/16 Rad. Typ. 265/8 RIGHT SIDE WINDOW LEFT SIDE WINDOW (STANDARD ON ALL UNITS) 411/2 103/8 421/4 34 2811/16 2611/16 231/2 DOOR SLIDING WINDOW ASSY (9130-3067) 1611/16 FRONT WINDOW 111/2 263/4 417/8 NOTE 3: TOP WINDOW IS LEXAN MR50T4-112. 1/4 THICK. 413/8 313/8 101/2 1/ 2 NOTE 1: CAB GLASS CAN ONLY BE SHIPPED WITH THE COMPLETE CAB ENCLOSURE OPTION.
PAGE 31
CHASSIS & ATTACHING PARTS Outrigger Mounting Starting Serial No. 0255001 Original Issue 6-96 Revised 2-4-97 Item Part No. 1 2 8867-1001 3 8821-1083 4 5 6 9116-1016 8852-1206 8820-1047 7 8855-1011 PCN 960866-KG Qty. Description Of Part 4 LUBE FITTING, STRAIGHT, 1/8 Ref DUAL P.O. CHECK VALVE (see 13-12 for details) 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2 2 OUTRIGGER CYLINDER PIN 4 HEX LOCKNUT, 3/8-16 6 HEX HD CAPSCREW, 3/8-16X4, GR5 6 LOCKWASHER, 1/2 * Added item 17. Item Part No.
PAGE 32
BOOM First Boom Section Starting Serial No. 0255001 Original Issue 6-96 Revised 2-4-97 SERVICE NOTES: 1). 2). 3). 4). Add bearing pad shims & spacers as required to shim boom to within 1/16" 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. Add 1440-4595 Union 76 Mega Plex to all bearing pads and bearing slide areas.
PAGE 33
BOOM Second Boom Section Starting Serial No. 0255001 Original Issue 6-96 Revised 5-12-97 SERVICE NOTES: 1). 2). 3). 4). Add bearing pad shims & spacers as required to shim boom to within 1/16" 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. Add 1440-4595 Union 76 Mega Plex to all bearing pads and bearing slide areas.
PAGE 34
BOOM Third Boom Section Starting Serial No. 0255001 Original Issue 6-96 Revised 2-1-97 SERVICE NOTES: 1). 2). 3). 4). Add bearing pad shims & spacers as required to shim boom to within 1/16" 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. Add 1440-4595 Union 76 Mega Plex to all bearing pads and bearing slide areas.
PAGE 35
BOOM Fourth Boom Section Starting Serial No. 0255001 Original Issue 6-96 Revised 1-31-97 SERVICE NOTES: 1). 2). 3). 4). Add bearing pad shims & spacers as required to shim boom to within 1/16" 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. Add 1440-4595 Union 76 Mega Plex to all bearing pads and bearing slide areas.
PAGE 36
BOOM Boom Cross Section Starting Serial No.
PAGE 37
BOOM Extension Chains Starting Serial No. 0255001 Original Issue 11-96 Revised 5-7-97 SERVICE NOTES: 1). Item A chain wear gage, part number 9116-4084, is now available to check if your boom chain has been stretched beyond spec. Part No. 1 2 3 4 5 6 7 8 9 10 8850-1314 9116-1218 9116-3163 9116-6044 9116-3170 8863-1302 9116-3123 9116-3036 9116-5022 11 12 13 14 15 KG 8850-1414 9116-3171 9116-6045 9116-1266 Qty.
PAGE 38
BOOM Retraction Chains Starting Serial No. 0255001 Original Issue 11-96 Revised 5-7-97 SERVICE NOTES: 1). KG A chain wear gage, part number 9116-4084, is now available to check if your boom chain has been stretched beyond spec. * Added service note.
PAGE 39
BOOM Retraction Chains Starting Serial No. 0255001 Original Issue 11-96 Revised 5-7-97 SERVICE NOTES: 1). A chain wear gage, part number 9116-4084, is now available to check if your boom chain has been stretched beyond spec. Item Part No. Qty.
PAGE 40
BOOM Quick Switch Assembly Starting Serial No. 0255001 Original Issue 11-96 Item KG Part No. Qty.
PAGE 41
ATTACHMENTS Buckets Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty. 1 9045-5049 1 KG Description Of Part 60" BUCKET (3/4 yard capacity) Item Part No. Qty.
PAGE 42
ATTACHMENTS (9045-5051) & (9045-5052) Carriage Assemblies Starting Serial No. 0255001 Original Issue 7-96 Revised 11-29-00 NOTE: Item Part No. Qty.
PAGE 43
ATTACHMENTS (9045-5011) Truss Boom Starting Serial No. 0255001 Original Issue 7-96 Revised 6-29-01 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 44
ATTACHMENTS (9045-5012) Truss Boom W/Winch Starting Serial No. 0255001 Original Issue 7-96 Revised 7-06-06 Item Part No. Qty.
PAGE 45
ATTACHMENTS 6 Ft. Vertical Mast Starting Serial No. 0255001 Original Issue 7-96 Revised 7-06-06 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 46
ATTACHMENTS (9108-5058) 48" Slope Piler Carriage Starting Serial No. 0255001 Original Issue 7-96 Revised 6-19-06 Item Part No. 9108-5058 1 2 3 9108-6121 9108-6122 4 9108-3248 3423263 9020-4007 9103-3186 9108-1577 9108-1594 9020-5870 9103-1236 8820-1535 *5 6 7 8 9 *10 11 *12 *13 14 15 16 17 18 19 20 21 22 23 24 8820-1534 9108-1313 8820-1065 8855-1013 8852-1016 8867-1022 8856-1109 8850-1016 0510-1441 9108-1622 8471-6434 8366-1316 Qty.
PAGE 47
ATTACHMENTS (9130-5016) 66" Slope Piler Carriage Starting Serial No. 0255001 Original Issue 7-96 Revised 6-19-06 Item Part No. 9130-5016 1 2 3 9130-6030 9108-6122 4 9108-3248 3423263 9020-4007 9103-3186 9108-1577 9108-1594 9020-5870 9103-1236 8820-1535 *5 6 7 8 9 10 * 11 * 12 * 13 14 15 16 17 * 18 19 20 21 22 23 24 8820-1534 9108-1313 8820-1065 8855-1013 8852-1016 8867-1022 8856-1109 8850-1016 0510-1441 9108-1622 8471-6434 8366-1316 Qty.
PAGE 48
ATTACHMENTS (9045-5044) 100 Degree Swing Fork Starting Serial No. 0255001 Original Issue 7-96 Revised 7-10-06 Item Part No. 9045-5044 1 2 9104-3126 9116-3138 9140-3414 3 8866-1013 8866-2006 4 5 9104-3125 9116-3139 9140-3413 6 7 8 8471-8067 9141-1073 8320-1024 9 10 11 12 13 14 15 16 17 18 9108-3249 7713-3140 7713-3177 9104-1324 8867-1008 9104-1325 8867-1022 9104-1327 9104-1322 8320-1026 19 Qty.
PAGE 49
ATTACHMENTS (9108-5056) Quick Hook Assembly Starting Serial No. 0255001 Original Issue 7-96 Revised 7-24-06 Item Part No. 9108-5056 1 2 8855-1011 8820-1034 3 4 5 6 7 8 9 10 11 8867-1001 9108-1574 8863-1343 9108-1573 9108-3368 9108-3367 9108-6119 9015-3001 8834-1022 12 13 9020-5126 7736-3079 8866-2006 14 15 9104-3125 9116-3139 9140-3413 Qty.
PAGE 50
ATTACHMENTS (9045-5047) 6' Swing Mast W/Side Shift 6 9 10 12 Starting Serial No. 0255001 Original Issue 7-96 Revised 7-11-06 2 16 17 18 19 15 16 17 18 21 41 42 3 4 5 7 11 B 21 32 91 8 13 14 B 25 30 36 27 28 46 29 48 49 1 51 31 33 34 35 26 25 43 92 93 94 95 96 39 44 38 52 53 SECTION A-A C 64 88 62 70 75 A 59 A AUX HYD. LINES 62 77 78 79 80 69 76 90 SOLENOID VALVE 39 87 65 V1 .
PAGE 51
ATTACHMENTS (9045-5047) 6' Swing Mast W/Side Shift Starting Serial No. 0255001 Original Issue 7-96 Revised 7-11-06 Item 1 2 3 4 5 6 7 Part No. Qty.
PAGE 52
ATTACHMENTS (9055-5013) 100 Degree Drywall Swing Fork Asembly Original Issue 7-96 Revised 7-13-06 LK 4-11
PAGE 53
ATTACHMENTS (9055-5013) 100 Degree Drywall Swing Fork Asembly Original Issue 7-96 Revised 7-13-06 Item Part No. Qty.
PAGE 54
ATTACHMENTS (9130-5021) Swinging Slope Piler Starting Serial No.
PAGE 55
ATTACHMENTS (9130-5021) Swinging Slope Piler Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty.
PAGE 56
ATTACHMENTS (9055-3011) 180 Degree Swing Frame Starting Serial No. 0255001 Original Issue 7-96 Revised 11-19-00 SVC * Revised part list.
PAGE 57
ATTACHMENTS (9055-3011) 180 Degree Swing Frame Starting Serial No. 0255001 Original Issue 7-96 Revised 11-19-00 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 58
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.
PAGE 59
ENGINE & ATTACHING PARTS (9116-5003) Engine Left Side View Starting Serial No. 0255001 Original Issue 7-96 Revised 5-16-00 544C-10 (9116-3001 CUMMINS ENGINE) Part No. Description Of Part 9116-5020 ENGINE FILTER KIT, (includes the following items) AIR FILTER OIL FILTER FUEL FILTER, (primary) FUEL FILTER, (secondary) FUEL FILTER, (I/L) 9115-4001 9108-4001 7738-3202 7738-3203 9108-3218 SVC * Added item number 74.
PAGE 60
ENGINE & ATTACHING PARTS (9116-5003) Engine Left Side View Starting Serial No. 0255001 Original Issue 7-96 Revised 5-16-00 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 61
ENGINE & ATTACHING PARTS (9116-5003) Engine Right Side View Starting Serial No.
PAGE 62
ENGINE & ATTACHING PARTS (9116-5003) Engine Right Side View Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty.
PAGE 63
ENGINE & ATTACHING PARTS Fuel Tank & Lines Starting Serial No. 0255001 Original Issue 7-96 Revised 6-22-01 Item * 1 2 3 4 5 6 7 8 9 10 Part No. Qty. Description Of Part Item 9108-5016 1 FUEL TANK ASSY, (includes items 1 thru 6, 9, 10 & 14) FUEL TANK, (includes items 4 & 14) FUEL LEVEL SENDER, (includes item 3) SCREW FUEL TANK CAP, (w/chain) REDUCING BUSHING, 1/2X1/8 HOSE NIPPLE HOSE CLAMP FUEL LINE HOSE, 7/32 I.D.
PAGE 64
ENGINE & ATTACHING PARTS (9116-5019) Radiator Assembly Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 65
ENGINE & ATTACHING PARTS Air Cleaner Piping Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty.
PAGE 66
ENGINE & ATTACHING PARTS (9115-3006) Air Cleaner Starting Serial No.0255001 Original Issue 7-96 Item 1 2 3 4 5 KG Part No. Qty.
PAGE 67
ENGINE & ATTACHING PARTS Exhaust System Starting Serial No. 0255001 Original Issue 7-96 Revised 10-19-99 * NOTE: In order to improve the product life of item 5, we have developed a muffler mounting kit for service replacement. Order part number 9116-5045 which includes two 9116-1290 muffler mounts and two 2492-1332 muffler clamps. Item Part No. Qty.
PAGE 68
DRIVE TRAIN (9116-5004) Front Axle Assembly Starting Serial No. 0255001 Original Issue 6-96 TO BRAKE LINE SEE PAGE 8-1 Item Part No. Qty.
PAGE 69
DRIVE TRAIN (9116-3015) Front Axle Starting Serial No. 0255001 Original Issue 6-96 Revised 4-12-04 SERVICE NOTE: When servicing this axle, it is recommended that on machines with starting serial numbers prior to 0255070, that you: 1). Replace the old style cover plate with the new cover plate kit, p/n 9114-5130. 2). Then refill the axle with 40 pints of mobil 424 fluid instead of 33 pints. Item Qty.
PAGE 70
DRIVE TRAIN (9114-4339) (9114-4337) Left/Right Housing Assembly (9114-4333) (9114-4335) Axle Shaft and Wheel Flange Assembly Starting Serial No. 0255001 Original Issue 6-96 Revised 5-7-97 Item Part No. Qty.
PAGE 71
DRIVE TRAIN Brake Assembly Starting Serial No. 0255001 Original Issue 6-96 Revised 5-26-05 Part No. Qty.
PAGE 72
DRIVE TRAIN Carrier Assembly Starting Serial No. 0255001 Original Issue 6-96 Revised 10-24-03 Item Part No. Qty.
PAGE 73
DRIVE TRAIN (9104-3472) Rear Steering Axle Drive Hub Starting Serial No. 0255001 Original Issue 7-96 ! Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 KG *NOTE! To service item 17 locknut, a special wrench is required, order P/N 9114-4325 wrench. Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 74
DRIVE TRAIN Wheels & Tires Starting Serial No. 0255001 Original Issue 7-96 Item KG Part No. Qty. Description Of Part 9116-5024 1 9116-5025 1 1 2 9104-3298 9104-3146 2 48 3 4 9108-3385 9104-3084 2 2 R.H. TIRE ASSY(includes items 1, 3 and 4) L.H. TIRE ASSY(includes items 1, 3 and 4) RIM LUG NUT (lubricate and torque to 350-400 ftlbs.) VALVE TIRE (not shown) 14.
PAGE 75
CONTROLS Tilt & Sway Starting Serial No. 0255001 Original Issue 7-96 Revised 8-30-02 Item TT Part No. Qty. * 1 9108-3107 1 2 8826-1022 4 3 4 5 6 7 8 9 9116-3132 9108-6089 8852-1304 9114-3191 9112-3062 9108-4282 8821-1044 2 1 3 3 2 1 4 * 10 9108-4359 1 Description Of Part REMOTE CONTROL VALVE, (includes item 10) HEX SOC. BUT.
PAGE 76
CONTROLS Brake & Inching Linkage Starting Serial No. 0255001 Original Issue 7-96 KG Item Part No. Qty.
PAGE 77
CONTROLS (9114-3118) Accelerator Pedal Assembly Starting Serial No. 0255001 Original Issue 7-96 Revised 1-18-02 VIEW SHOWN WITH BOOT & PIN REMOVED 9 13 14 6 7 8 10 11 13 14 15 17 13 14 15 1 2 3 4 5 16 12 ! Item 1 2 3 4 5 6 7 SVC TO ENGINE THIS ASSEMBLY COMES WITH A DIFFERENT CABLE SUPPORT, (item 1, not shown). THE CABLE SUPPORT SHOWN IS THE PROPER REPLACEMENT AND NEEDS TO BE ORDERED SEPARATELY. Part No. Qty.
PAGE 78
CONTROLS (9116-5103) Floorplate Assy Starting Serial No. 0255001 Original Issue 7-96 Revised 1-18-02 SECTION A - A SVC * Revised illustration, description on items 5, 8, 10, 11 & 18, quantity on items 19 & 32 and revised item 49; removed item 55.
PAGE 79
CONTROLS (9116-5103) Floorplate Assy Starting Serial No. 0255001 Original Issue 7-96 Revised 1-18-02 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 80
CONTROLS Steering Column & Attaching Parts Starting Serial No. 0255001 Original Issue 7-96 Revised 8-2-00 NOTE: WHEN ITEM 9 IS ORDERED, REPLACE SCREWS PROVIDED FROM VENDOR WITH ITEM 11. Item Part No. Qty.
PAGE 81
BRAKES Service/Parking Brake Lines Starting Serial No. 0255001 Original Issue 9-96 Item Part No. 1 2 8471-8759 3 8820-1008 4 5 6 8855-1009 8856-1107 8866-2064 7 8 9 8859-1204 7713-3136 7713-3137 KG Qty. Description Of Part 1 HOSE ASSY Ref SOLENOID VALVE (see page 10-11 for details) 2 HEX HD CAPSCREW, 1/4-20X1 3/4, GR5 2 LOCKWASHER, 1/4 2 FLAT WASHER, 1/4 1 ELBOW, 90 DEGREES (includes item 7) 1 O-RING 3 CLAMP SET, 3/4-3/4 3 COVER PLATE Item Part No. Qty.
PAGE 82
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No. 0255001 Original Issue 9-96 Revised 6-24-97 KG * Corrected art at hydraulic tank, changed part number on item 5.
PAGE 83
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No. 0255001 Original Issue 9-96 Revised 6-24-97 Item Part No. 1 Qty. Description Of Part Item Part No. Qty.
PAGE 84
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No. 0255001 Original Issue 10-96 Revised 1-29-97 PCN 960926-KG * Changed part number on item 4.
PAGE 85
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No. 0255001 Original Issue 10-96 Revised 1-29-97 Item Part No. 1 2 3 * 4 5 8471-8979 8471-8748 8471-8968 8866-2070 6 7 8 9 10 9114-3273 9116-3140 7713-3053 7713-3052 8820-1010 11 12 13 14 15 16 8850-1004 8855-1009 8856-1107 8471-8999 9105-3450 17 18 19 7713-3076 7713-3075 8820-1011 20 21 22 23 24 25 26 8471-8947 8866-1364 8471-8635 8471-8745 8471-8956 8471-8746 8471-8743 PCN 960926-KG Qty.
PAGE 86
HYDRAULIC CIRCUITS Front Drive Circuit Starting Serial No. 0255001 Original Issue 10-96 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 87
HYDRAULIC CIRCUITS Rear Drive Circuit Starting Serial No. 0255001 Original Issue 10-96 Revised 5-17-00 RIG HT T LEF R FR SVC ON F TO MA C T IGH RE E HIN * Revised part number on items 1 & 23.
PAGE 88
HYDRAULIC CIRCUITS Rear Drive Circuit Starting Serial No. 0255001 Original Issue 10-96 Revised 5-17-00 REAR DRIVE HOSE CLAMP LOCATIONS Item Part No. Qty.
PAGE 89
HYDRAULIC CIRCUITS (9116-5007) Boom Hydraulics Sub-Assy Starting Serial No. 0255001 Original Issue 10-96 Revised 10-19-99 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 90
HYDRAULIC CIRCUITS Lift Cylinder Starting Serial No. 0255001 Original Issue 10-96 Item Part No. 1 2 3 4 5 6 7 KG Qty. Ref 8859-1207 8866-2008 9116-3220 9116-3219 8471-8893 8471-8894 6 4 1 1 1 1 Description Of Part LIFT CYLINDER ASSY (see page 10-3 for details) O-RING CONNECTOR (includes item 2) TUBE ASSY TUBE ASSY HOSE ASSY HOSE ASSY Item Part No. 8 9 8866-2107 10 11 12 13 14 8866-2108 9116-3218 9116-3217 8471-8948 8866-2022 Qty.
PAGE 91
HYDRAULIC CIRCUITS Crowd Cylinder Starting Serial No. 0255001 Original Issue 10-96 Item Part No. 1 2 3 4 5 6 7 8 9 8859-1207 8866-2022 8471-8684 9020-7464 9020-7463 9116-3095 9116-3094 8820-1023 10 7713-3136 KG Qty. Description Of Part Ref CROWD CYLINDER ASSY (see page 10-2 for details) 4 O-RING 2 CONNECTOR (includes item 2) 2 HOSE ASSY 2 HOSE SUPPORT 2 CUSHION CLAMP 1 TUBE ASSY 1 TUBE ASSY 2 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5 4 CLAMP SET Item Part No. Qty.
PAGE 92
HYDRAULIC CIRCUITS Tilt Cylinder & Tilt Compensating Cylinder Starting Serial No. 0255001 Original Issue 10-96 Revised 10-19-99 PCN 990426-KG * Changed part number on item 20.
PAGE 93
HYDRAULIC CIRCUITS Tilt Cylinder & Tilt Compensating Cylinder Starting Serial No. 0255001 Original Issue 10-96 Revised 10-19-99 Item Part No. 1 PCN 990426-KG Qty.
PAGE 94
HYDRAULIC CIRCUITS Sway Cylinder Starting Serial No. 0255001 Original Issue 10-96 Item Part No. Qty. 1 8820-1040 3 2 3 8855-1011 4 5 8859-1012 8866-2082 KG Description Of Part HEX HD CAPSCREW, 3/8-16X2-1/4, GR5 3 LOCKWASHER, 3/8 Ref SWAY CYLINDER VALVE (see page 10-19 for details) 2 O-RING 2 CONNECTOR (includes item 4) Item Part No. 6 7 8 9 10 11 8471-8675 8866-1341 8866-1406 8866-2020 8859-1207 Qty.
PAGE 95
HYDRAULIC CIRCUITS Steering Circuit Starting Serial No.
PAGE 96
HYDRAULIC CIRCUITS Steering Circuit Starting Serial No. 0255001 Original Issue 10-96 Item Part No. Qty.
PAGE 97
HYDRAULIC CIRCUITS Joystick Circuit Starting Serial No. 0255001 Original Issue 10-96 Item Part No. Qty.
PAGE 98
HYDRAULIC CIRCUITS Stabilizer Cylinder Starting Serial No. 0255001 Original Issue 10-96 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 99
HYDRAULIC CIRCUITS Outrigger Cylinder Starting Serial No. 0255001 Original Issue 10-96 Revised 3-7-97 Item Qty.
PAGE 100
HYDRAULIC CIRCUITS Hose Clamp Locations (rear) Starting Serial No. 0255001 Original Issue 3-97 Item Part No. Qty. 1 2 3 4 5 6 7 8093-3140 7713-3168 7713-3306 7713-3140 7713-3177 7713-3390 9121-3002 1 1 5 4 4 5 4 KG Description Of Part CLAMP SET, 13/16 - 1-1/4 CLAMP SET, 1/2-1/2 STACK BOLT COVER PLATE BOLT SAFETY CLIP CLAMP SET, 3/4-1/2 Item Part No. Qty.
PAGE 101
HYDRAULIC COMPONENTS (9114-3214) Tilt Cylinder Starting Serial No. 0255001 Original Issue 7-96 Revised 11-07-05 Item Part No. Qty.
PAGE 102
HYDRAULIC COMPONENTS (9116-3225) Crowd Cylinder Starting Serial No. 0255001 Original Issue 7-96 Revised 1-11-99 Item * 1 * 2 3 4 5 6 7 8 9 10 JH Part No. Qty.
PAGE 103
HYDRAULIC COMPONENTS (9116-3008) Lift Cylinder Starting Serial No. 0255001 Original Issue 7-96 Revised 1-12-99 Item * 1 2 3 4 * 5 6 7 8 9 10 11 12 * 13 JH Part No. Qty.
PAGE 104
HYDRAULIC COMPONENTS (9114-3003) Compensating Cylinder Starting Serial No. 0255001 Original Issue 7-96 Item 1 2 3 4 5 6 7 8 9 10 11 KG Part No. Qty. Description Of Part Item 9114-3003 1 COMPENSATING CYLINDER ASSY (includes items 1 thru 18) SEAL KIT (includes items 6, 7, 8, 9, 11, 12 & 14 thru 17) BUSHING GREASE FITTING CASE ASSY CAPSCREW, #8X32X.375 LOCKNUT (torque 1300-1350 ft.lbs.
PAGE 105
HYDRAULIC COMPONENTS (9114-3007) Sway Cylinder Assembly Starting Serial No. 0255001 Original Issue 7-96 Item 1 2 3 4 5 6 7 8 9 10 KG Part No. Qty. Description Of Part Item 9114-3007 1 9114-4005 1 9106-4016 8867-1001 9114-4032 9114-4017 9106-4017 3 2 1 1 1 2 1 1 1 1 SWAY CYLINDER (includes items 1 thru 18) SEAL KIT (includes items 6, 7, 8, 9, 11, 12 & 14 thru 17) BUSHING GREASE FITTING CASE ASSY CAPSCREW, #8X32X.375 LOCKNUT (torque 650-700 ft.lbs.
PAGE 106
HYDRAULIC COMPONENTS (9116-3178) Steering Cylinder Starting Serial No. 0255001 Original Issue 7-96 Revised 9-7-05 3 1 5 9 6 9 10 11 7 8 3 14 15 12 13 4 16 17 2 18 19 20 21 Item Part No. Qty.
PAGE 107
HYDRAULIC COMPONENTS (9116-3045) Stabilizer Cylinder Starting Serial No. 0255001 Original Issue 7-96 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 108
HYDRAULIC COMPONENTS (9116-3016) Outrigger Cylinder Starting Serial No. 0255001 Original Issue 7-96 Item 1 2 3 4 5 6 7 8 9 10 11 12 KG Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 109
HYDRAULIC COMPONENTS (9116-5023) Flow Divider Assy Starting Serial No. 0255001 Original Issue 8-96 Revised 5-17-00 Item Part No. Qty.
PAGE 110
HYDRAULIC COMPONENTS (9114-3201) Brake Valve Starting Serial No. 0255001 Original Issue 7-96 Item 1 2 Part No. Qty.
PAGE 111
HYDRAULIC COMPONENTS (9104-3446) Solenoid Valve Starting Serial No. 0255001 Original Issue 7-96 Item 1 2 3 4 KG Part No. Qty.
PAGE 112
HYDRAULIC COMPONENTS (9114-5067) Thermal Bypass Valve Assy Starting Serial No. 0255001 Original Issue 9-96 Item Part No. Qty.
PAGE 113
HYDRAULIC COMPONENTS (9114-3140) Inching Valve Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty. Description Of Part 1 2 3 4 5 6 9114-3140 8093-4423 8093-4202 1 1 1 1 1 2 INCHING VALVE (includes all items) O-RING O-RING ACTIVATING LEVER SOCKET HD CAPSCREW SOCKET HD CAPSCREW 8821-2228 NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 114
HYDRAULIC COMPONENTS (9116-3222) Main Control Valve Starting Serial No.
PAGE 115
HYDRAULIC COMPONENTS (9116-3222) Main Control Valve Starting Serial No. 0255001 Original Issue 11-96 Item Part No. Qty.
PAGE 116
HYDRAULIC COMPONENTS (9116-5013) Hydraulic Reservoir & Filters Starting Serial No. 0255001 Original Issue 7-96 Revised 10-19-99 MPC3868-KG * Added item 30.
PAGE 117
HYDRAULIC COMPONENTS (9116-5013) Hydraulic Reservoir & Filters Starting Serial No. 0255001 Original Issue 7-96 Revised 10-19-99 Item Part No. Qty.
PAGE 118
HYDRAULIC COMPONENTS (9116-3044) Front Drive Motor Starting Serial No. 0255001 Original Issue 7-96 FOR OUR APPLICATION THIS DRIVE MOTOR IS UTILIZED IN A 180 DEGREE INVERSION. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 KG Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 119
HYDRAULIC COMPONENTS (9116-3068) Main Hydraulic Pump Starting Serial No. 0255001 Original Issue 8-96 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 KG Part No. Qty.
PAGE 120
HYDRAULIC COMPONENTS (9116-3048) Hydrostatic Transmission Starting Serial No. 0255001 Original Issue 7-96 Revised 9-17-97 KG * Corrected part number and art on item 39, thru charge pump.
PAGE 121
HYDRAULIC COMPONENTS (9116-3048) Hydrostatic Transmission Starting Serial No. 0255001 Original Issue 7-96 Revised 9-17-97 Item 1 2 3 4 5 6 7 8 9 10 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 122
HYDRAULIC COMPONENTS (9116-3027) Sway Cylinder Valve (9116-3245) Outrigger Cylinder Valve Starting S/N 0255001 Original Issue 11-96 Revised 8-21-00 Item Item 1 2 3 4 5 Part No. Qty. 9116-3027 1 9116-4061 9116-4056 9116-4062 8859-1012 2 2 1 2 1 Description Of Part SWAY CYLINDER VALVE (includes items 1, 2, 3 & 5) VALVE CARTRIDGE VALVE SEAL KIT PISTON O-RING VALVE BODY (not sold separately, order P/N 9116-3027) NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 123
HYDRAULIC COMPONENTS (9130-3037) Joystick Assembly Starting Serial No. 0255001 Original Issue 7-96 Revised 11-03-05 1 2 8 9 7 3 10 2 16 4 11 12 13 17 5 14 15 6 ! NOTE: THE BOSCH REXROTH CORPORATION JOYSTICK HANDLE SWITCH IS NOT A FIELD SERVICEABLE COMPONENT. ANY ATTEMPT BY NON-FACTORY AUTHORIZED PERSONNEL TO REPAIR OR REPLACE THE SWITCH WILL VOID THE WARRANTY AND CAN RESULT IN A JOYSTICK MALFUNCTION. Item 1 2 3 4 5 6 *7 8 9 10 JD Part No. Qty.
PAGE 124
HYDRAULIC COMPONENTS (9114-3049) Traction Lock Valve Starting Serial No. 0255001 Original Issue 7-96 Revised 10-17-03 1 4 12 16 3 2 5 15 13 14 14 17 10 11 18 20 8 19 9 7 2 3 4 21 22 6 23 5 1 25 26 24 27 29 30 28 31 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 125
HYDRAULIC COMPONENTS (9116-3023) Rear Drive Motor Starting Serial No. 0255001 Original Issue 7-96 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 126
HYDRAULIC COMPONENTS (9116-5031) Stabilizer Valve Assembly Original Issue 11-96 Item Part No. Qty.
PAGE 127
HYDRAULIC COMPONENTS (9114-3161) Outrigger Valve Starting Serial No. 0255001 Original Issue 7-96 Item KG Part No. Qty.
PAGE 128
ELECTRICAL (9114-5031) Gauge Panel Assembly Starting Serial No.
PAGE 129
ELECTRICAL (9114-5031) Gauge Panel Assembly Starting Serial No. 0255001 Original Issue 8-96 ON OFF BEACON PULL ON ON OFF LIGHTS HIGH OFF LOW HEATER 12 12 12 123 123 123 123 123 123 PARK BRAKE ON ALT 4X4 ON OFF PARK BRAKE 4X4 AUX LIGHT ON OFF STARTING AID DATCON HOURS 1/10 HORN 4X2 3/32 Min. 1/8 Max. With lockwasher under panel, bushing extention above panel must not exceed .125" or the seal may be cut.
PAGE 130
ELECTRICAL (9116-1208) Dash Panel Starting Serial No. 0255001 Original Issue 8-96 PARTIAL VIEW FROM ABOVE DASH WITH PANEL REMOVED FOR CLARITY PARTIAL VIEW FROM UNDER DASH TO PARK BRAKE VALVE TO TRACTION LOCK FOOT SWITCH STEERING COLUMN MOUNT GND-2 GND-3 TO F-N-R SHIFTER IGN-C PRK IGN ACC-A ACC-B IGN-A IGN-B ALT EXC-A ACC-A BAT START-A IGN-C IGN-A ENLARGED VIEW OF IGNITION SWITCH CONNECTION Item Part No. 1 2 9116-1208 3 4 9116-3020 5 6 7714-3003 7714-3006 KG Qty.
PAGE 131
ELECTRICAL Battery & Cables Starting Serial No. 0255001 Original Issue 8-96 Revised 5-31-06 2 2 3 4 5 8 9 10 5 7 8 1 6 Item Part No. Qty.
PAGE 132
BOOM (9116-5006) Stabilizer Proximity Sensor Starting Serial No. 0255001 Original Issue 11-96 NOTE: ADJUST STABILIZER SENSOR TO OPERATE WHEN + 2 DEGREES BOOM ANGLE IS 45 _ Item KG Part No. Qty.
PAGE 133
MISCELLANEOUS Frame Decals Starting Serial No. 0255001 Original Issue 8-96 Item Part No. Qty. 9116-5037 1 1 2 3 4 5 6 7 9108-3341 9116-3212 9116-3087 9116-3184 9116-3074 9116-3075 8826-1017 1 1 2 1 1 1 2 8 9116-3215 1 9 10 11 12 13 14 15 16 17 KG 9114-3120 9108-3314 9116-3028 9108-3494 9108-3497 9104-3210 9103-3011 7734-3018 9108-3510 1 1 1 1 1 1 1 1 1 Description Of Part 544C-10 DECAL KIT (std.
PAGE 134
MISCELLANEOUS Boom Decals Starting Serial No. 0255001 Original Issue 8-96 Revised 2-5-97 53 1/2" 5" 17" 53 1/2" 5" 7" 7" 17" 6 7/8" RAD. 16 5/8" 9" 7" TYP. 12 1/4" TYP. 4 1/4" 11" 24" 37" 50" 63" 69 5/8" TYP. 6' 4" (76") 7' 5" (89") 8' 6" (102") 9' 7" (115") 10' 8" (128") KG 5" TYP. * Added dimensions to decals.
PAGE 135
MISCELLANEOUS Boom Decals Starting Serial No. 0255001 Original Issue 8-96 Revised 2-5-97 Item Part No. Qty.
PAGE 136
OPTIONAL EQUIPMENT (9104-3353) Block Heater Starting Serial No. 0255001 Original Issue 8-96 ! REPLACES FROST PLUG ON RIGHT SIDE OF ENGINE. Item KG Part No. Qty.
PAGE 137
OPTIONAL EQUIPMENT (9116-5011) Winch Installation Starting Serial No.
PAGE 138
OPTIONAL EQUIPMENT (9116-5011) Winch Installation Starting Serial No. 0255001 Original Issue 9-96 Revised 8-1-06 Item Part No. 9116-5011 1 2 3 4 5 6 7 8 9 9108-3535 9002-7187 8471-6148 8471-8046 9020-7882 9020-1443 9002-8990 9136-3079 8820-1070 10 11 12 13 14 15 * 16 9002-7471 8850-1008 8471-9474 8471-8959 9108-3217 9020-7463 8866-1085 17 18 19 9116-3064 7713-3389 7713-3139 Qty.
PAGE 139
OPTIONAL EQUIPMENT (9114-5021) Work Light Package Starting Serial No.
PAGE 140
OPTIONAL EQUIPMENT (9114-5021) Work Light Package Starting Serial No. 0255001 Original Issue 9-96 Revised 10-5-00 ON OFF BEACON 41 PULL ON AUX LIGHT HIGH 40 4X4 ON OFF STARTING AID PARK BRAKE ON ALT DATCON 0 0 0 0 0 0 4X4 HOURS 1/10 4X2 HORN ACC-C GND-3 TO L.H.FRT CAB LIGHT PARK BRAKE TO R.H.
PAGE 141
OPTIONAL EQUIPMENT (9116-5010) Auxiliary Hydraulics W/Electric Starting Serial No. 0255001 Original Issue 9-96 Revised 10-5-01 1 2 3 4 5 6 7 8 9 10 15 5 14 103 11 12 13 5 11 52 VIEW D-D 17 18 19 20 7 16 21 D 50 35 51 52 53 54 102 55 56 L/DN 57 58 61 62 63 64 42 43 44 45 46 49 42 43 44 46 47 48 3 4 40 41 39 38 4 25 57 58 R/UP 59 60 2 16 24 38 104 105 106 26 27 28 29 30 31 32 E 22 23 24 25 D 33 34 E . THIS OPTION DRAWS APPROXIMATELY 2 AMPS. TOTAL.
PAGE 142
OPTIONAL EQUIPMENT (9116-5010) Auxiliary Hydraulics W/Electric Starting Serial No. 0255001 Original Issue 9-96 Revised 10-5-01 B 77 A R/UP B 70 71 72 73 A 41 65 66 24 67 68 69 L/DN 10 78 C C 5 76 74 2 75 96 3 1 4 5 76 84 83 24 68 69 85 LIFT 82 CROWD TILT FV 41 65 86 87 98 80 81 88 89 90 79 VIEW A-A SWAY AUX 93 94 95 92 93 94 91 SECTION C-C 6 CONTACT SOCKET CONNECT TO SPL ACC FROM DASH HARNESS. "TM" EXTRA (ORANGE) "A" OPEN 99 5 BUTTON HANDLE SW-1 N.O.
PAGE 143
OPTIONAL EQUIPMENT (9116-5010) Auxiliary Hydraulics W/Electric Starting Serial No. 0255001 Original Issue 9-96 Revised 10-5-01 Item 1 Part No. Qty.
PAGE 144
OPTIONAL EQUIPMENT (9114-5032) Vandal Kit Starting Serial No. 0255001 Original Issue 9-96 KG Item Part No. Qty.
PAGE 145
OPTIONAL EQUIPMENT (9115-5004) Glow Plug Installation Starting Serial No.0255001 Original Issue 9-96 PARTIAL VIEW FROM ABOVE DASH PARTIAL VIEW FROM UNDER DASH PARTIAL VIEW - ENGINE LEFT SIDE Item 1 2 3 4 5 6 7 8 9 10 11 12 KG Part No. Qty.
PAGE 146
OPTIONAL EQUIPMENT (9116-5012) R.H. Tilt/Sway Starting Serial No. 0255001 Original Issue 9-96 Revised 6-1-99 C A A PARTIAL VIEW A - A B ITEM 11 (USE HOLES WITH 1-5/16" SPACING) B C VIEW C - C VIEW B - B Item Part No. Qty. 1 2 3 4 5 6 9116-5012 9108-1480 8863-1338 9002-8662 8856-1113 9114-6043 9108-3136 Ref 1 1 3 9 1 4 PCN 980660 - JH Description Of Part R.H. TILT/SWAY (includes all items) COVER PLATE COTTER PIN WAVE BEND WASHER WASHER, 5/8 SWAY LEVER BUSHING Item 7 8 9 10 *11 12 Part No.
PAGE 147
OPTIONAL EQUIPMENT (9116-5009) Auxiliary Hydraulics Assembly Starting Serial No.
PAGE 148
OPTIONAL EQUIPMENT (9116-5009) Auxiliary Hydraulics Assembly Starting Serial No. 0255001 Original Issue 9-96 Revised 7-25-06 Item 1 Part No. Qty.
PAGE 149
OPTIONAL EQUIPMENT (9116-5050) Cab Enclosure Starting Serial No. 0255001 Original Issue 9-96 Revised 5-7-97 VIEW B-B VIEW OF INSIDE OF CAB DOOR VIEW A-A KG * Added items 58 thru 63.
PAGE 150
OPTIONAL EQUIPMENT (9116-5050) Cab Enclosure Starting Serial No. 0255001 Original Issue 9-96 Revised 5-7-97 VIEW C-C ENGINE FRONT VIEW WIRING SCHEMATIC ENGINE REAR VIEW Item Part No. Qty.
PAGE 151
OPTIONAL EQUIPMENT (9116-5116) Tilt On Joystick Starting Serial No.
PAGE 152
OPTIONAL EQUIPMENT (9116-5116) Tilt On Joystick Starting Serial No. 0255001 Original Issue 9-96 VIEW B-B VIEW A-A Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 KG Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 153
OPTIONAL EQUIPMENT (9108-3471) Sway Cylinder Starting Serial No. 0255001 Original Issue 9-96 Revised 1-15-98 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty. 9108-3471 1 9108-4308 Ref 9106-4016 9114-4128 9112-4083 9114-4017 9103-4156 2 2 1 1 1 9112-4084 9112-4085 9112-4086 2 1 1 1 1 1 1 1 1 1 1 1 Description Of Part SWAY CYLINDER ASSY, (includes all items) SEAL KIT, (includes items 6 thru 9, 11, 12 & 14 thru 16) BUSHING GREASE FITTING CASE ASSEMBLY CAPSCREW, #8X32X.
PAGE 154
OPTIONAL EQUIPMENT (9108-3262) Dual P.O. Check Valve Starting Serial No. 0255001 Original Issue 9-96 Item Part No. Qty. 9108-3262 1 9104-4002 1 2 3 4 5 7713-3248 9108-4227 9108-4228 8859-1009 Description Of Part DUAL P.O. CHECK VALVE ASSY (includes all items) Ref SEAL KIT (includes items 3 & 4) 1 BODY 2 CHECK VALVE 2 O-RING 2 O-RING 2 O-RING NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 155
OPTIONAL EQUIPMENT (9103-3366) Swing Cylinder Starting Serial No. 0255001 Original Issue 9-96 Item Part No. Qty.
PAGE 156
OPTIONAL EQUIPMENT (9045-3034) Swing Cylinder Assembly Original Issue 7-10-06 1 2 9 9 11 14 18 15 13 12 16 3 6 7 5 4 6 8 10 17 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 10 Part No. Qty.
PAGE 157
OPTIONAL EQUIPMENT (9116-5028) Ether Start Starting Serial No. 0255001 Original Issue 9-96 Revised 2-5-97 Item Part No. Qty.
PAGE 158
OPTIONAL EQUIPMENT (9055-3016) SWING VALVE ASSEMBLY Starting Serial No. 0255001 Original Issue 9-96 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 159
OPTIONAL EQUIPMENT (9045-3050) Truss Boom Winch Starting Serial No.
PAGE 160
OPTIONAL EQUIPMENT (9045-3050) Truss Boom Winch Starting Serial No. 0255001 Original Issue 7-96 Revised 7-06-06 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 161
OPTIONAL EQUIPMENT (9020-7879) Winch Motor Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty.
PAGE 162
OPTIONAL EQUIPMENT (9060-2706) Crossover Valve Starting Serial No. 0255001 Original Issue 7-96 Item Part No. Qty. 9060-2706 1 1 9020-3440 2 2 3 4 5 9020-3437 9020-3438 9020-3439 4 2 2 1 Description Of Part CROSSOVER RELIEF VALVE (includes all items) RELIEF CARTRIDGE (includes items 2 thru 4) BACKUP RING (2/cartridge) O-RING (1/cartridge) O-RING (1/cartridge) BODY NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE.
PAGE 163
OPTIONAL EQUIPMENT (9114-5136) Rear Axle Rework Kit FOR SERVICE ONLY Original Issue 3-99 Revised 5-31-05 FRONT OF MACHINE Item JD Part No. Qty.
PAGE 164
OPTIONAL EQUIPMENT (9114-5042) Rear Axle Advantage Kit FOR SERVICE ONLY Original Issue 3-99 1 2 20 3 21 4 19 18 12 7 17 19 8 9 16 22 23 5 18 24 25 6 UPPER 26 27 28 29 14 15 7 8 LOWER 39 40 33 9 14 LEFT SIDE 10 12 11 38 13 35 36 ENLARGED VIEW NOTE: STABILIZER SUPPORT NOT SHOWN. SEE ITEM 56 FOR BUSHING.
PAGE 165
OPTIONAL EQUIPMENT (9114-5042) Rear Axle Advantage Kit FOR SERVICE ONLY Original Issue 3-99 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 166
OPTIONAL EQUIPMENT (9103-3387) 5-Button Handle Starting Serial No. 0255001 Original Issue 6-99 Item 1 2 3 4 5 6 7 8 KG Part No. Qty. 9103-3387 1 9136-4015 9136-4016 9136-4017 9136-4018 9136-4019 9136-4020 9136-4021 9136-4022 3 5 1 5 1 1 1 1 Description Of Part 5-BUTTON HANDLE (includes all items) FACEPLATE SCREW PUSHBUTTON BOOT FACEPLATE PUSHBUTTON SWITCH FACEPLATE GASKET HOUSING CABLE STOP CABLE (2.75 ft.
PAGE 167
OPTIONAL EQUIPMENT (9103-5101) Pintle Hook Starting Serial No. 0255001 Original Issue 9-00 3 3/8 13 3/16 15 3/4 1 3/4 1 2 3 Item SVC Part No. Qty.
PAGE 168
OPTIONAL EQUIPMENT (9114-5098) Work Light Package Starting Serial No.
PAGE 169
OPTIONAL EQUIPMENT (9114-5098) Work Light Package Starting Serial No. 0255016 Original Issue 10-00 OIL PRESS. GAUGE GND GAUGE LIGHT ACC-C LT VOLTMETER ACC-A FUEL GAUGE 15 AMP FUSE WATER TEMP. GAUGE GND I A B S ACC-C/ACC-B DASH SHOWN FLAT FOR CLARITY 15 AMP FUSE IGNITION-START SWITCH 15 AMP FUSE TEMP GAUGE LIGHT FUEL AUXLT DOME LIGHT SWITCH ACC-C OIL 86 DOME LIGHT 30 RELAY WORK LIGHT SWITCH 85 87A 87 STOP LIGHT SWITCH FROM REV SWITCH REV AUXLT TO REAR TAIL LIGHT TO L.H.
PAGE 170
PAGE 171
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 265 811 111 Fax: (61) 265 810 122 JLG Latino Americana Ltda. Rua Eng.