Parts Manual Owner's manual

ManualsBrandsGradall ManualsHoist544B

544B

9104-4337

August 25, 2006

Starting Serial No.

0155299S

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 (180 pages)

PAGE 1
® ® PART MANUAL ® 544B 9104-4337 August 25, 2006 Starting Serial No. 0155299S 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.
PAGE 2
INTRODUCTION Table of Contents Starting Serial No. 0155299S Original Issue 3-90 Revised 1-19-96 SECTION 1 - INTRODUCTION Table of Contents ...................................................................................................... 1-1 thru 1-4 Alphabetical Index ................................................................................................... 1-5 thru 1-10 Service Kits ..............................................................................................................
PAGE 3
INTRODUCTION Table of Contents Starting Serial No. 0155299S Original Issue 3-90 Revised 12-16-94 SECTION 6 - DRIVE TRAIN (Continued) Propeller Shaft ...................................................................................................................... 6-11 Front Axle Assembly ............................................................................................................. 6-12 Front Axle Housing ....................................................................................
PAGE 4
INTRODUCTION Table of Contents Starting Serial No. 0155299S Original Issue 3-90 Revised 12-16-94 SECTION 10 - HYDRAULIC COMPONENTS (continued) Outrigger Cylinder ................................................................................................................ 10-9 Main Control Valve ............................................................................................................. 10-10 Priority Flow Contrlol Valve ...................................................................
PAGE 5
INTRODUCTION Table of contents Starting Serial No. 0155299S Original Issue 3-90 Revised 6-1-99 SECTION 13 - OPTIONAL EQUIPMENT (continued) Winch Assembly.......................................................................................................13-12, 13-13 Hydraulic Cylinder (Jarp) .................................................................................................... 13-14 Hydraulic Cylinder (Iowa) ...................................................................................
PAGE 6
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 ACCELERATOR CABLE ........................................................................................................7-3 ACCELERATOR PEDAL .........................................................................................................7-3 ACCUMULATOR .....................................................................................................................8-4 ACCUMULATOR CHARGE VALVE ..
PAGE 7
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 DOOR .....................................................................................................................................2-2 DOOR HANDLES ...................................................................................................................2-2 DRIVE BELT ...........................................................................................................................
PAGE 8
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 HEATER ................................................................................................................................. 2-3 HEAT SHIELD ........................................................................................................................ 5-9 HEATER SWITCH ..................................................................................................................
PAGE 9
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 PARKING BRAKE LINES ....................................................................................................... 8-2 PARKING BRAKE VALVE .................................................................................................. 10-20 PILOT PUMP ..................................................................................................................... 10-23 POSITIVE BATTERY CABLE ..
PAGE 10
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 STABILIZER CYLINDER ..................................................................................................... 10-8 STABILIZER CYLINDER HYDRAULIC CIRCUIT ................................................................. 9-16 STABILIZER VALVE ........................................................................................................... 10-15 STARTER BUTTON ...............................
PAGE 11
INTRODUCTION Alphabetical Index Starting Serial No. 0155299S Original Issue 3-90 Revised 12-19-94 WEATHER STRIP ...................................................................................................................2-2 WHEELS & TIRES ............................................................................................................... 6-16 WINDOWS ..............................................................................................................................
PAGE 12
INTRODUCTION Service Kits Starting Serial No. 0155299S Original Issue 3-90 Revised 3-30-95 SECTION PAGE NO. PART NO.
PAGE 13
CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Starting Serial No. 0155299S Original Issue 3-90 Revised 2-12-97 Item Part No. Qty.
PAGE 14
CHASSIS & ATTACHING PARTS Cab Enclosure, Wiper & Defroster Starting Serial No. 0155299S Original Issue 3-90 Revised 2-7-97 Item Part No. Qty.
PAGE 15
CHASSIS & ATTACHING PARTS Cab Heater & Hoses Starting Serial No. 0155299S Original Issue 3-90 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.
PAGE 16
CHASSIS & ATTACHING PARTS Front Axle Cradle & Attaching Parts Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 17
CHASSIS & ATTACHING PARTS Rear Steering Axle & Attaching Parts Starting Serial No. 0155299S Original Issue 6-93 Revised 6-1-99 * Changed Description on Steering Knuckle Kit; changed Part No. on item 42; added items 64 & 65; added service note and revised illustration.
PAGE 18
CHASSIS & ATTACHING PARTS Rear Steering Axle & Attaching Parts Starting Serial No. 0155299S Original Issue 6-93 Revised 6-1-99 NOTE: All machines must bore out Steering Knuckles to use items 64 & 65. Unless you have purchased new Steering Knuckles part number 9112-0003 & 9112-0004. See engineering print that comes with the Steering Knuckle Kit for details. Item Part No.
PAGE 19
CHASSIS & ATTACHING PARTS Rear Steering Axle & Attaching Parts Starting Serial No. 0155369 Original Issue 6-93 Revised 6-1-99 NOTE: All machines must bore out Steering Knuckles to use items 62 & 63. Unless you have purchased new Steering Knuckles part number 9112-0003 & 9112-0004. See engineering print that comes with the Steering Knuckle Kit for details. Item Part No. Qty.
PAGE 20
CHASSIS & ATTACHING PARTS Outrigger & Attaching Parts Starting Serial No. 0155299S Original Issue 3-90 Revised 9-91 Item Part No. Qty. 1 8643-1005 16 2 3 0510-1441 9103-6029 9103-6030 8320-1073 9103-1141 8852-1206 8867-1001 9104-3258 8820-1040 4 5 6 7 8 9 PCN L-8581 10 11 8855-1011 12 13 14 9103-6032 9103-6041 9103-1140 Description Of Part HEX HD CAPSCREW (lubricate and torque to 795-845 ft. lbs.) 16 HEAT TREATED WASHER 1 OUTRIGGER BRACKET, L.H. 1 OUTRIGGER BRACKET, R.H.
PAGE 21
CHASSIS & ATTACHING PARTS CAB GLASS Starting Serial No. 0155390S Original Issue 2-94 Revised 6-8-94 STANDARD 2 11" RAD. 16 (TYP) 30 15" 64 REAR WINDOW 1" 29 4 28 5" 8 38 5" 16 21 39 17" 64 2 11" RAD. 16 (TYP) 3" 16 NOTE: ALL LAMINATED SAFETY GLASS, TINTED FOR 73% LIGHT TRANSMISSION SEAMED EDGES, 7/32" THICK. RIGHT SIDE WINDOW CAB GLASS CAN ONLY BE SHIPPED WITH THE COMPLETE CAB ENCLOSURE OPTION. IF GLASS BREAKAGE OCCURS IN THE FIELD IT MUST BE REPLACED LOCALLY USING THE DIMENSIONS GIVEN.
PAGE 22
BOOMS 1st Boom Section Starting Serial No. 0155299S Original Issue 3-90 Revised 1-15-98 Item Part No. Qty. 1 2 9104-6079 8820-1564 1 4 3 4 5 6 7 8 9 10 11 12 13 14 1238-1025 9104-1277 9104-1276 9104-1278 9104-3180 9104-3177 8820-1069 8855-1013 9104-1009 9104-3164 9104-1265 9104-1006 24 8 10 6 2 4 2 2 1 4 4 12 Description Of Part FIRST BOOM SECTION WELDMENT HEX HD CAPSDCREW, 1/2-20X1, GR5 (lubricate and torque to 68-78 ft. lbs.
PAGE 23
BOOMS 2nd Boom Section Starting Serial No. 0155299S Original Issue 3-90 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 4 5 6 7 8 9 10 1238-1025 9104-1277 9104-1276 9104-3180 9104-1278 9104-3177 9104-3164 9104-1265 32 12 12 2 10 8 4 2 SECOND BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X7/8, GR5 (lubricate and torque to 69-78 ft. lbs.
PAGE 24
BOOMS 3rd Boom Section Starting Serial No. 0155299S Original Issue 3-90 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 Description Of Part THIRD BOOM SECTION WELDMENT HEX HD CAPSCREW, 1/2-20X7/8, GR5 (lubricate and torque to 68-78 ft. lbs.) HARDENED WASHER SPACER SHIM SPACER BEARING PAD HEX HD CAPSCREW, 1/2-20X3/4, GR5 (lubricate and torque to 68-78 ft. lbs.
PAGE 25
BOOMS 4th Boom Section Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 26
BOOMS Push Beam & Cables ! Starting Serial No. 0155299 Original Issue 3-90 Revised 5-6-97 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. Description Of Part Item Part No. Qty.
PAGE 27
BOOMS Quick Switch Assembly Starting Serial No. 0155299S thru 0155421S Original Issue 3-90 Revised 3-9-98 Item Part No. Qty.
PAGE 28
BOOMS Quick Switch Assembly Starting Serial No. 0155422S Original Issue 2-98 Item JH Part No. Qty.
PAGE 29
ATTACHMENTS & ACCESSORIES Sand Bucket & Carriages Starting Serial No. 0155299S Original Issue 3-90 Revised 11-22-00 Item Part No. Qty. 1 9080-1332 1 Item Part No. Qty. Description Of Part 9045-5007 1 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 Part No. Qty.
PAGE 30
ATTACHMENTS (9130-5016) 66" Slope Piler Carriage Starting Serial No. 0155299S Original Issue 8-94 Revised 6-19-06 Item Part No. Qty.
PAGE 31
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 32
ENGINE & ATTACHING PARTS Engine Left Side View Starting Serial No. 0155299S Original Issue 3-90 Revised 12-29-95 Item Part No. 1 9104-3175 2 3 4 5 6 7 8 9 7713-4059 8820-1067 8540-1340 8855-1013 2464-1328 8871-1383 8871-2034 8820-1036 10 11 12 13 14 15 16 17 18 19 20 8855-1011 8471-1369 9105-3345 8503-1525 7713-3089 8859-1204 9105-3344 8366-1304 8471-1333 9020-7719 9020-6739 21 22 23 8367-4109 8367-4110 8319-1007 Qty.
PAGE 33
ENGINE & ATTACHING PARTS Engine Right Side View Starting Serial No.
PAGE 34
ENGINE & ATTACHING PARTS Engine Right Side View Starting Serial No. 0155299S Original Issue 3-90 Revised 12-29-95 Item Part No. Qty.
PAGE 35
ENGINE & ATTACHING PARTS Fuel Tank & Lines Starting Serial No. 0155299S Original Issue 3-90 Revised 10-16-96 Item Part No. Qty.
PAGE 36
ENGINE & ATTACHING PARTS Radiator & Hoses Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 37
ENGINE & ATTACHING PARTS Ether Starting Kit Starting Serial No. 0155299S Original Issue 3-90 Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 9002-5075 9020-5767 8850-1005 9040-3110 8820-1003 9002-1454 9002-1903 9020-0308 9020-6316 Qty.
PAGE 38
(9020-5663) ENGINE & ATTACHING PARTS Air Cleaner Piping Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 39
ENGINE & ATTACHING PARTS Air Cleaner Starting Serial No. 0155299S Original Issue 3-90 Revised 10-21-96 Item 1 2 3 4 5 Part No. Qty. 9020-5663 9020-6606 9020-6262 9020-1414 9020-0807 1 1 1 1 1 1 Description Of PartAIR CLEANER (includes items 1 thru 5) COVER W/NUT ELEMENT WING NUT W/SEAL VACUATOR BODY ( not sold separately order P/N 9020-5663) * Corrected artwork.
PAGE 40
ENGINE & ATTACHING PARTS Exhaust System CUMMINS ENGINE Item Part No. Qty.
PAGE 41
DRIVE TRAIN Transmission Mounting & Controls Starting Serial No. 0155299S Original Issue 3-90 Revised 11-8-95 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 42
DRIVE TRAIN Transmission Flex Plate & Torque Converter Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 43
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No.
PAGE 44
DRIVE TRAIN Transmission Case & Converter Housing Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 45
DRIVE TRAIN Transmission Drive Gearing Starting Serial No. 0155299S Original Issue 3-90 Revised 2-93 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 46
DRIVE TRAIN Transmission Clutch & Gearing (Reverse 2nd and Low) Starting Serial No. 0155299S Original Issue 3-90 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 47
DRIVE TRAIN Transmission Clutch & Gearing (Forward, Output and Third) Starting Serial No. 0155299S Original Issue 3-90 3RD UT & P T U O 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 Qty.
PAGE 48
DRIVE TRAIN Transmission Clutch Assemblies Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 49
DRIVE TRAIN Transmission Modulator Valve Starting Serial No. 0155299S Original Issue 3-90 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 VAVLE (part of valve assy.
PAGE 50
DRIVE TRAIN Transmission Control Valve Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. Qty.
PAGE 51
DRIVE TRAIN Propeller Shaft Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 52
DRIVE TRAIN Propeller Shaft Starting Serial No. 0155309S Original Issue 7-90 Item PCN L-8938 Part No. Qty.
PAGE 53
DRIVE TRAIN Front Axle Assembly Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. 9104-3291 1 1 9104-4444 1 2 9104-4448 1 3 4 5 1 8319-3009 9104-3146 4 24 Description Of Part FRONT AXLE ASSY (includes items 1 thru 4) AXLE HOUSING ASSY (see page 6-13 for details) DIFFERENTIAL CARRIER ASSY (see page 6-14 for details) AXLE SHAFT & PLANETARY WHEEL END ASSY (see page 6-15 for details) FITTING LUG NUT (lubricate and torque to 350-400 ft. lbs.
PAGE 54
DRIVE TRAIN Front Axle Assembly Starting Serial No. 0155309S Original Issue 7-90 Revised 8-90 Item PCN L-8938 Part No. Qty.
PAGE 55
DRIVE TRAIN Front Axle Housing Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 Part No. Qty.
PAGE 56
DRIVE TRAIN Front Axle Housing Starting Serial No. 0155309S Original Issue 7-90 PCN L-8938 Item Part No. Qty.
PAGE 57
DRIVE TRAIN Front Axle Differential Carrier Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 58
DRIVE TRAIN (9103-4328) Front Axle Differential Carrier Starting Serial No.
PAGE 59
DRIVE TRAIN (9103-4328) Front Axle Differential Carrier Starting Serial No. 0155309S Original Issue 7-90 Revised 2-92 Item Part No.
PAGE 60
DRIVE TRAIN Front Axle Shaft & Planetary Wheel End Starting Serial No. 0155309S Original Issue 7-90 Item Part No. Qty.
PAGE 61
DRIVE TRAIN Front Axle Shaft & Planetary Wheel End Starting Serial No. 0155299S Original Issue 3-90 Revised 4-30-96 Item Part No. Qty.
PAGE 62
DRIVE TRAIN Wheels & Tires Starting Serial No. 0155299S Original Issue 3-90 Revised 4-3-95 NEW STYLE OLD STYLE * REAR-STANDARD FRONT-STANDARD Item Part No. Qty. 1 9104-3276 1 *1 2 9104-3430 9104-3146 1 12 3 9020-0339 1 *3 9108-3385 9020-0561 9020-0772 9020-1615 9103-3104 1 1 1 1 1 4 5 6 7 Description Of Part RIM, 8.00 TG X 24 ** NOTE: (NO LONGER AVAILABLE, REPLACED BY 9104-3430) RIM, 9.00 X 24 (New One Piece Style) LUG NUT (lubricate and torque to 350400 ft. lbs.
PAGE 63
DRIVE TRAIN Wheels & Tires Starting Serial No. 0155309S Original Issue 7-90 Revised 4-3-95 REAR-STANDARD FRONT-STANDARD Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part 1 2 9104-3298 9104-3146 1 12 1 2 9104-3298 9104-3146 1 12 3 9108-3385 9104-3084 2 1 RIM, 9.00 X 24 LUG NUT (lubricate & torque to 350400 ft.lbs.) VALVE (air/liquid) TIRE, 14.00 X 24, 12 PLY (G-2 Grader tubeless)(not illustrated) 3 9108-3385 9104-3084 2 1 RIM, 9.
PAGE 64
DRIVE TRAIN (9104-3328) Rear Steering Axle Planetary Wheel Drive Starting Serial No. 0155299S Original Issue 3-90 Revised 4-7-95 ! * 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, PART NUMBER 9104-3472. Item Part No. Qty.
PAGE 65
DRIVE TRAIN (9104-3472) Rear Steering Axle Planetary Wheel Drive Starting Serial No. 0155410S Original Issue 4-95 Revised 2-26-96 ! Item * NOTE! To service item 17 locknut, a special wrench is required, order P/N 9114-4325 wrench. Part No. Qty.
PAGE 66
DRIVE TRAIN Front Axle Service Brakes Starting Serial No. 0155309S Original Issue 7-90 Item Part No. Qty.
PAGE 67
DRIVE TRAIN Front Axle Parking Brakes Starting Serial No. 0155309S Original Issue 7-90 Item 1 2 3 4 5 6 7 8 9 10 11 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 68
CONTROLS Forward & Reverse, Speed Selector Starting Serial No. 0155299S Original Issue 3-90 Revised 11-04-05 JD * Revised illustration and parts list.
PAGE 69
CONTROLS Forward & Reverse, Speed Selector Starting Serial No. 0155299S Original Issue 3-90 Revised 11-04-05 Item Part No. Qty.
PAGE 70
CONTROLS Tilt & Sway Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 71
CONTROLS Acceleration Linkage Starting Serial No. 0155299S Original Issue 3-90 Revised 5-5-97 Item Part No. Qty.
PAGE 72
CONTROLS Steering Column Starting Serial No. 0155299S Original Issue 3-90 Revised 9-91 Item Part No. Qty.
PAGE 73
BRAKES Hydraulics & Parking Brake Lines Starting Serial No. 0155299S Original Issue 3-90 TO PARKING BRAKE VALVE (SEE PAGE 8-2) Item Part No. Qty.
PAGE 74
BRAKES Hydraulics & Parking Brake Lines Starting Serial No. 0155309S Original Issue 7-90 TO PARKING BRAKE VALVE (SEE PAGE 8-2) SEE PAGE 6-12 FOR CONTINUATION OF SERVICE AND PARKING BRAKE LINES. PCN L-8938 Item Part No. 1 8471-7524 2 3 4 5 6 7 8 9 10 11 7713-3177 7713-3140 7713-3139 8471-7987 9103-3032 9104-3091 9104-3227 8471-7523 9002-7187 9108-3154 12 13 14 8859-1205 8866-2018 8866-2105 Qty.
PAGE 75
BRAKES Hydraulics & Service Brake Lines Starting Serial No. 0155309S Original Issue 7-90 TO ACCUMULATOR CHARGE VALVE (SEE PAGE 8-4) TO HYDRAULIC TANK TEE (SEE PAGE 9-3) TO FRONT AXLE PARKING BREAK (SEE PAGE 8-1) Item Part No. 1 9108-3154 2 3 8859-1205 8866-2065 4 5 6 7 8 9 10 11 8866-2106 8471-7842 8866-2018 8866-2239 9104-3163 7713-3089 8471-7317 8471-7508 PCN L-8938 Qty.
PAGE 76
BRAKES Hydraulics & Service Brake Lines Starting Serial No. 0155299S Original Issue 3-90 TO TEE IN DIRECTIONAL CONTROL VALVE (SEE PAGE 9-3) TO HYDRAULIC TANK TEE (SEE PAGE 9-3) FROM HYDRAULIC CONTROLLER (SEE PAGE 9-14) TO DIRECTIONAL CONTROL VALVE (SEE PAGE 9-5) TO FRONT AXLE BRAKES (SEE PAGE 8-1) TO HYDRAULIC TANK TEE (SEE PAGE 9-3) TO ACCUMULATOR CHARGE VALVE (SEE PAGE 8-4) TO FRONT AXLE PARKING BRAKES (SEE PAGE 8-1) Item Part No.
PAGE 77
BRAKE Brake Pedal & Inching Linkage Starting Serial No. 0155299S Original Issue 3-90 Revised 4-92 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 78
BRAKE Brake Pedal & Inching Linkage Starting Serial No. 0155309S Original Issue 7-90 Revised 4-92 Item Part No. Qty.
PAGE 79
BRAKES Accumulator, Charging Valve & Lines Starting Serial No. 0155299S Original Issue 3-90 Revised 8-21-95 TO DUMP CIRCUIT (SEE PAGE 9-3) FROM PILOT PUMP (SEE PAGE 9-1) TO ELBOW 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 80
BRAKES Accumulator, Charging Valve & Lines Starting Serial No. 0155309S Original Issue 7-90 Revised 8-21-95 TO DUMP CIRCUIT (SEE PAGE 9-3) FROM PILOT PUMP (SEE PAGE 9-1) TO ELBOW 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 81
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No.
PAGE 82
HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Starting Serial No. 0155299S Original Issue 3-90 Revised 10-92 Item Part No.
PAGE 83
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No.
PAGE 84
HYDRAULIC CIRCUITS Dump Circuit Starting Serial No. 0155299S Original Issue 3-90 Item Part No. 1 2 3 4 5 6 8471-7842 8866-2225 9020-7599 8866-1245 9020-6739 7 8 9 10 11 12 13 14 15 16 8471-7520 9020-5776 9002-8482 9020-7365 9104-3144 8866-1365 7713-3447 8866-2105 8366-1316 17 18 19 20 21 8471-7797 9020-5793 8866-1364 8471-7900 22 23 7713-3167 24 25 26 8471-7526 8859-1204 8866-2064 Qty.
PAGE 85
HYDRAULIC CIRCUITS Rear Drive Starting Serial No.
PAGE 86
HYDRAULIC CIRCUITS Rear Drive Starting Serial No. 0155299S Original Issue 3-90 Revised 6-12-06 Item Part No. 1 Qty. Description Of Part Item Part No. Qty.
PAGE 87
HYDRAULIC CIRCUITS Steering Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 88
HYDRAULIC CIRCUITS Lift Cylinder Starting Serial No. 0155299S Original Issue 3-90 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 Qty.
PAGE 89
HYDRAULIC CIRCUITS Crowd Cylinder Starting Serial No.
PAGE 90
HYDRAULIC CIRCUITS Crowd Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 1-91 Item Part No. Qty.
PAGE 91
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 8-18-00 DS * Revised part number on items 31 & 52.
PAGE 92
HYDRAULIC CIRCUITS Tilt Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 8-18-00 Item Part No. 1 Qty. Description Of Part Item Part No. Qty. Description Of Part Ref TILT CYLINDER ASSY (see page 10-4 for details) TUBE ASSY ELBOW - 90 DEGREES (includes item 4) O-RING COUNTERBALANCE VALVE O-RING HEX HD CAPSCREW, 1/2-13X2-1/2, GR5 (lubricate & torque to 68-78 ft. lbs.
PAGE 93
HYDRAULIC CIRCUITS Sway Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 11-29-93 Item Part No. 1 2 3 4 8859-1012 9104-1387 5 8820-1041 6 7 8 9 10 8855-1011 8867-1008 8866-2006 8859-1205 9020-7727 9020-7728 9020-7729 9020-7730 Qty. Description Of Part Ref SWAY CYLINDER (see page 10-6 for details) 2 O-RING 2 ORIFICE PLUG 1 DUAL P.O.
PAGE 94
HYDRAULIC CIRCUITS Sway Cylinder Starting Serial No. 0155299S Original Issue 7-90 Revised 11-29-93 Item Part No. 1 2 3 4 8859-1012 9104-1387 5 8820-1041 6 7 8 9 10 8855-1011 8867-1008 8866-2006 8859-1205 9020-7727 9020-7728 9020-7729 9020-7730 Qty. Description Of Part Ref SWAY CYLINDER (see page 10-6 for details) 2 O-RING 2 ORIFICE PLUG 1 DUAL P.O.
PAGE 95
HYDRAULIC CIRCUITS Joystick Starting Serial No. 0155299S Original Issue 3-90 TO DUMP CIRCUIT (see page 9-3) PRESSURE FROM TEE IN PILOT CIRCUIT (see page 9-1) Item Part No. Qty.
PAGE 96
HYDRAULIC CIRCUITS Outrigger Cylinder Starting Serial No. 0155299S Original Issue 3-90 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 Qty.
PAGE 97
HYDRAULIC CIRCUITS Stabilizer Cylinder Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 98
HYDRAULIC COMPONENTS (9104-3302) Lift Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 8-93 Item Part No. Qty. 9104-3302 2 9103-4278 1 2 3 9104-4318 9020-5414 8867-1027 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 9103-4280 9103-4281 9104-4319 9103-4282 9104-4369 9103-1372 8867-1033 Description Of Part LIFT CYLINDER ASSY (includes all items) 1 SEAL KIT (includes items 5-8, 11, 12, 14 and 15) 1 TUBE ASSY 1 BUSHING 1 LUBE FITTING, 90 DEGREES, 1/4-28 1 LOCKNUT (torque to 1100 ft.
PAGE 99
HYDRAULIC COMPONENTS Crowd Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 1-91 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. Qty. Description Of Part 9104-3300 1 9103-4290 1 9104-4326 9103-4286 1 1 2 1 1 1 1 1 1 1 1 1 1 1 CROWD CYLINDER ASSY (includes all items) SEAL KIT (includes items 3, 4, 5, 6, 9, 10, 12 & 13) TUBE ASSY LOCKNUT (torque to 590 ft. lbs.
PAGE 100
HYDRAULIC COMPONENTS (9104-3306) Crowd Extension Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 10-91 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No. Qty. Description Of Part 9104-3306 1 9104-4320 1 9104-4321 9103-4303 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 CROWD EXTENSION CYLINDER ASSY (includes all items) SEAL KIT (includes items 3, 4, 5, 6, 8, 9, 11 & 12) TUBE ASSY LOCK NUT (torque to 235 ft. lbs.
PAGE 101
HYDRAULIC COMPONENTS (9104-3482) Crowd Extension Cylinder FOR SERVICE ONLY Original Issue 5-99 Item 1 2 3 4 5 6 7 8 9 Part No. Qty. Description Of Part Item Part No. Qty. 9104-3482 1 1 9108-4347 9104-4543 9114-4017 9120-4460 1 1 1 1 2 1 1 2 1 10 11 12 13 14 15 16 17 18 9104-4544 9104-4508 CROWD EXTENSION CYLINDER ASSY (includes all items) SEAL KIT (includes items 5 thru 9, 11, 12, 13, 15, 16, & 17) COUNTERBALANCE VALVE CASE ASSY CAPSCREW, 8X32X.
PAGE 102
HYDRAULIC COMPONENTS (9104-3301) Tilt Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 10-91 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 9104-3301 1 9104-4278 1 9104-4329 9108-4176 8867-1018 9103-4280 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 TILT CYLINDER CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 11, 13, & 14) TUBE ASSY (includes item 2) BUSHING LUBE FITTING, 45 DEGREES, 1/8 LOCK NUT (torque to 1100 ft. lbs.
PAGE 103
HYDRAULIC COMPONENTS Compensating Cylinder Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty. Description Of Part 9104-3304 1 9103-4278 1 9104-4313 9108-4176 8867-1033 9103-4280 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 COMPENSATING CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 11, 13, & 14) TUBE ASSY (includes item 2) BUSHING LUBE FITTING, STRAIGHT 1/4-28 LOCK NUT (torque to 1100 ft. lbs.
PAGE 104
HYDRAULIC COMPONENTS Sway Cylinder Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty. Description Of Part 9104-3367 1 9103-4297 1 9104-4298 9108-4176 8867-1033 9103-4286 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 SWAY CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 11, 13, & 14) TUBE ASSY (includes item 2) BUSHING LUBE FITTING, STRAIGHT 1/4-28 LOCK NUT (torque to 590 ft. lbs.
PAGE 105
HYDRAULIC COMPONENTS Steering Cylinder Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No. Qty. Description Of Part 9104-3316 2 9103-4301 1 9103-4302 9108-4194 8867-1033 9103-4303 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 STEERING CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 12, & 13 ) TUBE ASSY BUSHING LUBE FITTING, STRAIGHT 1/4-28 LOCK NUT (torque to 235 ft. lbs.
PAGE 106
HYDRAULIC COMPONENTS (9103-3478) Steering Cylinder Starting Serial No. 0155382S Original Issue 2-97 Revised 4-4-97 Item * 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No. Qty. Description Of Part 9103-3478 2 9103-4301 1 STEERING CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 12, & 13 ) TUBE ASSY BUSHING LUBE FITTING, 90 DEGREE LOCK NUT (torque to 235 ft. lbs.
PAGE 107
HYDRAULIC COMPONENTS Stabilizer Cylinder Starting Serial No. 0155299S Original Issue 3-90 Revised 4-7-06 Item Part No. Qty. Description Of Part 9104-3303 1 * 9104-4330 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 9104-4334 9103-4286 1 1 2 1 1 1 1 1 1 1 1 1 1 1 STABLIZER CYLINDER ASSY (includes all items) SEAL KIT (includes items 3, 4, 5, 6, 8, 10 & 11) TUBE ASSY LOCK NUT (torque to 590 ft. lbs.
PAGE 108
HYDRAULIC COMPONENTS Outrigger Cylinder Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty. Description Of Part 9104-3305 2 9103-4278 1 9104-4316 9104-4371 8867-1018 9103-4280 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 OUTRIGGER CYLINDER ASSY (includes all items) SEAL KIT (includes items 5, 6, 7, 8, 10, 11, 13, & 14) TUBE ASSY BUSHING LUBE FITTING, 45 DEGREES, 1/8 LOCK NUT (torque to 1100 ft. lbs.
PAGE 109
HYDRAULIC COMPONENTS (9104-3065) Main Control Valve Assembly * Starting Serial No. 0155299S Original Issue 8-86 Revised 2-5-97 KG * Changed items included in kits, fixed starting serial number & added notes.
PAGE 110
HYDRAULIC COMPONENTS (9104-3065) Main Control ValveAssembly * Starting Serial No. 0155299S Original Issue 8-86 Revised 2-5-97 ARTWORK ON PREVIOUS PAGE Item Part No. Qty.
PAGE 111
HYDRAULIC COMPONENTS Priority Flow Control Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 112
HYDRAULIC COMPONENTS Forward-Reverse Control Valve Starting Serial No. 0155299S Original Issue 3-90 Revised 10-17-03 Item GP Part No. Qty.
PAGE 113
HYDRAULIC COMPONENTS Series-Parallel Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 114
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 Part No. Qty.
PAGE 115
HYDRAULIC COMPONENTS Stabilizer Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part 9111-3003 1 9104-4002 STABILIZER VALVE ASSY (includes itesm 1 thru 5) SEAL KIT VALVE BODY RELIEF VALVE ASSY SOLENOID VALVE ASSY (includes item 4) SOLENOID COIL CHECK VALVE ASSY 1 2 3 9104-4346 9104-4347 AR 1 1 1 4 5 9104-4012 9104-4348 1 4 NOTE: SEAL KIT IS APPLICABLE TO ITEMS 2, 3 & 5.
PAGE 116
HYDRAULIC COMPONENTS Outrigger Control Valve Starting Serial No. 8655105G Starting Serial No. 0155299S Original Issue 3-90 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 Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 117
HYDRAULIC COMPONENTS Accumulator Charge Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 118
HYDRAULIC COMPONENTS Accumulator Charge Valve Starting Serial No. 0155309S Original Issue 7-90 PCN L-9005 Item Part No. Qty.
PAGE 119
HYDRAULIC COMPONENTS (9103-4308) Counterbalance Valve Starting Serial No. 0155299S Original Issue 3-90 Revised 5-31-05 Item Part No. Qty. 1 9103-4308 9104-4524 1 1 * JD Description Of Part COUNTERBALANCE VALVE COUNTERBALANCE VALVE SEAL KIT * Changed part number on seal kit.
PAGE 120
HYDRAULIC COMPONENTS Brake Valve Starting Serial No. 0155309S Original Issue 7-90 PCN L-8769 Item Part No. 1 9108-3154 9106-4057 Qty.
PAGE 121
HYDRAULIC COMPONENTS Brake Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 122
HYDRAULIC COMPONENTS Parking Brake Valve Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 Part No. Qty.
PAGE 123
HYDRAULIC COMPONENTS Directional Control Valve Starting Serial No. 0155299S Original Issue 3-90 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 MOUNTING BOLT Item 11 12 13 14 15 16 17 Part No. 9103-4014 9103-4015 9103-4016 9103-4017 Qty.
PAGE 124
HYDRAULIC COMPONENTS Main Hydraulic Pump Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. Qty.
PAGE 125
HYDRAULIC COMPONENTS Pilot Pump Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part 9104-3259 1 9104-4354 1 9103-4019 1 1 8820-1038 4 2 3 4 9103-4058 9103-4059 9104-4355 4 1 1 PILOT PUMP ASSY (includes all items) MAJOR KIT (includes items, 7, 8, 11, 12, 13 & 16) SEAL KIT (includes items 7, 12, 13 & 16) HEX HD CAPSCREW, 3/8-16X1-3/4, GR5 (lubricate and torque to 34-38 ft.lbs.
PAGE 126
HYDRAULIC COMPONENTS Rear Drive Motor Starting Serial No. 0155299S Original Issue 3-90 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 127
HYDRAULIC COMPONENTS Oil Reservoir Filter Starting Serial No. 0155299S Original Issue 3-90 Revised 7-92 UNIT WITH INDICATOR UNIT WITH POP-UP INDICATOR Item Part No. Qty.
PAGE 128
HYDRAULIC COMPONENTS Hydraulic Oil Reservoir Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 129
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 Part No. Qty.
PAGE 130
HYDRAULIC COMPONENTS Solenoid Valve Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 Part No. Qty.
PAGE 131
HYDRAULIC COMPONENTS (9103-3482) Joystick Assembly Starting Serial No. 0155384S Original Issue 12-94 Revised 4-29-96 KG * Added item 17, spring to spool assembly listing.
PAGE 132
HYDRAULIC COMPONENTS (9103-3482) Joystick Assembly Starting Serial No. 0155384S Original Issue 12-94 Revised 4-29-96 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 KG Part No. Qty.
PAGE 133
HYDRAULIC COMPONENTS Hydraulic Controller Starting Serial No. 0155299S Original Issue 3-90 Revised 1-3-96 Item KG Part No. Qty.
PAGE 134
HYDRAULIC COMPONENTS Dual P.O. Check Valve Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part 1 3 1 1 1 1 1 1 1 1 DUAL P.O.
PAGE 135
HYDRAULIC COMPONENTS Dual P.O. Check Valve Starting Serial No. 0155299S Original Issue 3-90 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 136
ELECTRICAL Instrument Panel & Wiring Harness Starting Serial No.0155299S Original Issue 3-90 TO OIL TEMERATURE SENDER TO FRAME HARNESS Item Part No. Qty.
PAGE 137
ELECTRICAL Instrument Panel & Wiring Harness Starting Serial No. 0155382S Original Issue 1-96 Item 1 2 3 4 5 6 7 8 9 Part No. Qty. 9103-5068 1 9103-3112 9103-3111 8855-4917 8850-1613 9020-5688 9020-5687 9020-5685 9020-5686 9103-3247 1 2 4 4 1 1 1 1 1 Description Of Part INSTRUMENT PANEL ASSY (includes all items except items 15 thru 21) INSTRUMENT PANEL HARNESS CIRCUIT BREAKER LOCKWASHER, #10X.062X.047 HEX NUT, #10-32 HOURMETER WATER TEMP. GAUGE AMMETER FUEL GAUGE OIL PRESSURE GAUGE Item Part No.
PAGE 138
ELECTRICAL Batteries & Cables Starting Serial No. 0155299S Original Issue 3-90 Revised 5-31-05 Item JD Part No. Qty. *1 8097-3021 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 volt, 1000 amps), TOP STUD, 3/8-16 UNC THREAD, BCI GROUP 31 BATTERY HOLD DOWN LOCK NUT SUPPORT CLAMP HOLD DOWN STUD NEGATIVE BATTERY CABLE POSITIVE BATTERYCABLE GROUND CABLE * Added part number & changed description on item 1.
PAGE 139
ELECTRICAL Boom Section Wiring Starting Serial No. 0155299S Original Issue 3-90 Revised 11-04-05 Item Part No. Qty.
PAGE 140
ELECTRICAL Miscellaneous Electrical Components Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 141
MISCELLANEOUS Frame Decals Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty. 1 2 9020-7488 8830-2128 1 2 3 4 5 6 7 8 9 9104-3033 9100-3040 9106-3047 7733-3027 9100-3039 9103-3362 9104-3171 1 1 1 1 1 1 1 10 11 12 13 7702-3007 9103-3089 9104-3215 9104-3172 1 1 1 1 14 15 9103-3024 9103-3090 1 1 16 9103-3011 1 Description Of Part MOUNTING PLATE ROUND HD MACHINE SCREW, 1/4-20X1 LIFT CAPACITY DECAL FORWARD-REVERSE DECAL WARNING DECAL MADE IN U.S.A.
PAGE 142
MISCELLANEOUS Boom Decals Starting Serial No. 0155299S Original Issue 3-90 Revised 2-6-97 9' 1 1/2" (109 1/2") 7' 1 1/2" (85 1/2") 37 1/2" 8 7/8" (TYP) 9' 3 3/8" (111 3/8") 7' 7" (91") 67" 41" 37" 19" 19 5/8" 12 1/2" (TYP) 20 1/2" (TYP) 6 5/8" (TYP) 10" (TYP) 18" 1" (TYP) 6 7/8" R Item Part No. Qty.
PAGE 143
OPTIONAL EQUIPMENT Dual Hose Reel Assembly Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. Qty.
PAGE 144
OPTIONAL EQUIPMENT Dual Hose Reel & Hydraulic System Starting Serial No. 0155299S Original Issue 3-90 Revised 12-1-93 TO CONTROL VALVE TOP VIEW FRONT Item Part No.
PAGE 145
OPTIONAL EQUIPMENT Sway, Auxiliary & Tilt Controls Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 146
OPTIONAL EQUIPMENT 100 Degree Swing Fork Assembly Starting Serial No. 0155299S Original Issue 3-90 SIDE VIEW B A A B SECTION A-A Item Part No. Qty.
PAGE 147
OPTIONAL EQUIPMENT 100 Degree Drywall Swing Fork Assembly Starting Serial No.
PAGE 148
OPTIONAL EQUIPMENT 100 Degree Drywall Swing Fork Assembly Starting Serial No. 0155299S Original Issue 3-90 Revised 7-13-06 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 149
OPTIONAL EQUIPMENT 180 Degree Swing Frame Assembly Starting Serial No.
PAGE 150
OPTIONAL EQUIPMENT 180 Degree Swing Frame Assembly Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 151
OPTIONAL EQUIPMENT (9055-3007 & 9055-3016) Swing Valve Assembly Original Issue 3-90 Revised 10-22-96 Item * Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 152
OPTIONAL EQUIPMENT Single Hose Reel & Hydraulic System Starting Serial No. 0155299S Original Issue 3-90 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 153
OPTIONAL EQUIPMENT Winch & Hydraulic System Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 154
OPTIONAL EQUIPMENT (9104-3165) Single Hose Reel Assembly Starting Serial No. 0155299S Original Issue 3-90 Revised 10-22-96 Item 1 2 3 4 5 6 * 7 8 9 10 11 12 13 14 15 16 17 18 KG Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 155
OPTIONAL EQUIPMENT (9103-3196) Winch Assy Starting Serial No.
PAGE 156
OPTIONAL EQUIPMENT (9103-3196) Winch Assy Starting Serial No. 0155299S Original Issue 3-90 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 157
OPTIONAL EQUIPMENT (9080-1313) Hydraullic Cylinder Assembly (Jarp) Starting Serial No. 0155299S Original Issue 3-90 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No. Qty.
PAGE 158
OPTIONAL EQUIPMENT (9103-3291) Hydraulic Cylinder Assembly (Iowa) Starting Serial No. 0155299S Original Issue 3-90 Item Part No. Qty.
PAGE 159
OPTIONAL EQUIPMENT Electrics for Auxiliary Hydraulics Starting Serial No.
PAGE 160
OPTIONAL EQUIPMENT Electrics for Auxiliary Hydraulics Starting Serial No. 0155299S Original Issue 3-90 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 161
OPTIONAL EQUIPMENT (9103-5082) Chassis Auxiliary Electrics Starting Serial No. 0155299S Original Issue 3-90 BLACK YELLOW TO BOOM ASSEMBLY YELLOW RED YELLOW BLACK CIRCUIT BREAKER WHITE ELECTRIC SCHEMATIC Item Part No.
PAGE 162
ATTACHMENTS (9108-5058) 48" Slope Piler Carriage Original Issue 12-91 Revised 6-19-06 Item Part No. Qty.
PAGE 163
OPTIONAL EQUIPMENT (9108-3286) Sway Cylinder * Starting Serial No. 0155299S thru 0155481 Original Issue 12-91 Revised 1-15-98 Item Part No. Qty.
PAGE 164
OPTIONAL EQUIPMENT (9108-3471) Sway Cylinder Starting Serial No. 0155482 Original Issue 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 ASSY CAPSCREW, #8X32X.
PAGE 165
HYDRAULIC COMPONENTS (9108-3262) Dual P.O. Check Valve Original Issue 12-94 Revised 1-18-96 Item Part No. Qty. 9108-3262 9104-4002 1 2 7713-3248 1 Ref 1 2 3 4 * 5 9108-4227 9108-4228 8859-1009 2 2 2 Description Of Part 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 NOTE: ONLY ITEMS WITH PART NUMBERS ARE AVAILABLE FOR SERVICE. KG * Added item 5.
PAGE 166
ATTACHMENTS (9045-5035) & (9045-5037) 6 Ft. Vertical Mast Original Issue 12-91 Revised 7-06-06 Item Part No. Qty. Description Of Part Item Part No. Qty.
PAGE 167
OPTIONAL EQUIPMENT (9103-5220) Auxiliary Controls Assembly Original Issue 11-93 STANDARD AUXILIARY CONTROLS HANDLE A C VIEW C-C C A B VIEW A-A SECTION THRU CAB THIS OPTION DRAWS APPROX. 2 AMPS. TOTAL #2 WIRE (SIDE SHIFT) B VIEW B-B GREEN/YELLOW WIRE (GROUND) #1 WIRE (MAST) #3 WIRE (SWING) #5 WIRE (EXTRA) TO IGN.
PAGE 168
#16 OPTIONAL EQUIPMENT (9103-5220) Auxiliary Controls Assembly Original Issue 11-93 IGNITION START SWITCH #16 N.O. RELAY AMMETER #16 10 AMP. CIRCIUT BREAKER (6) HANDLE COMMON 5 BUTTON HANDLE SW-1 PUSHBUTTON SPOT MOMENTARY SW-2 PUSHBUTTON SPOT MOMENTARY SW-3 PUSHBUTTON SPOT MOMENTARY SW-4 PUSHBUTTON SPOT MOMENTARY SW-5 PUSHBUTTON SPOT MOMENTARY N.O. (1) N.O. (2) N.O. (3) N.O. (4) N.O.
PAGE 169
OPTIONAL EQUIPMENT (9103-5266) Tilt On Joystick Original Issue 11-93 Item Part No. 9103-5266 1 2 3 12 8866-1306 8471-8323 8866-2035 8859-1204 8866-2105 7713-3196 9130-3038 8820-1009 8856-1107 8855-1009 8850-1004 8866-2005 8859-1204 8866-2064 13 14 15 16 17 8859-1204 9108-5071 9020-7719 8866-2239 7713-3447 8471-7956 4 5 6 7 8 9 10 11 Qty.
PAGE 170
OPTIONAL EQUIPMENT (9103-5261) Cab Enclosure Original Issue 11-93 TOP VIEW HEATER FAN WIPER MOTOR WIRING SCHEMATIC 85" SECTION A-A 13-24
PAGE 171
OPTIONAL EQUIPMENT (9103-5261) Cab Enclosure Original Issue 11-93 Item Part No. 9103-5261 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 9103-6119 9002-7315 9002-7319 9020-0506 8850-1613 8855-4917 8698-3188 9020-3376 8668-3480 9103-1486 9108-1599 7738-3744 9020-6134 9103-1494 9103-1490 9103-1521 8820-1005 21 22 23 24 25 26 9104-3429 9100-3053 7714-3004 7714-3006 27 28 29 30 31 9103-1507 1440-3190 9020-5888 8830-1309 Qty.
PAGE 172
OPTIONAL EQUIPMENT (9104-3353) Engine Block Heater Original Issue 6-94 ! REPLACES FROST PLUG ON RIGHT SIDE OF ENGINE. Item KG Part No. Qty.
PAGE 173
OPTIONAL EQUIPMENT (9104-5129) Steer Axle Advantage Kit FOR SERVICE ONLY Original Issue 2-97 Revised 1-12-99 1 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. 2 21 3 22 4 20 19 12 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".
PAGE 174
OPTIONAL EQUIPMENT (9104-5129) Steer Axle Advantage Kit FOR SERVICE ONLY Original Issue 2-97 Revised 1-12-99 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.
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OPTIONAL EQUIPMENT (9103-3499) Steering Cylinder Steer Axle Advantage Kit (Only) FOR SERVICE ONLY Original Issue 1-99 1 19 NOTE: FOR STEER AXLE ADVANTAGE KIT ONLY SEE PAGE 13-26 FOR DETAILS. 2 3 4 18 5 3 1 17 6 16 7 15 14 13 12 11 10 8 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part No. Qty.
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OPTIONAL EQUIPMENT (9114-5136) Rear Axle Rework Kit FOR SERVICE ONLY Original Issue 6-99 Revised 5-31-05 FRONT OF MACHINE Item JD Part No. Qty.
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OPTIONAL EQUIPMENT (9103-5253) Work Light Package Starting Serial No. 0155299S Original Issue 10-00 GREEN WIRE IS FOR BACKUP ALARM, RED WIRE IS FOR STOP LIGHT & BLACK WIRE IS FOR TAIL LIGHT. 26 27 28 29 30 31 32 33 34 NOTE: ATTACH GROUND WIRE TO SERIES/PARALLEL VALVE MOUNTING BOLT.
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OPTIONAL EQUIPMENT (9103-5253) Work Light Package 11 41 11 41 41 43 I IGNITION-START SWITCH + I TO WORK,GAUGE LIGHTS 11 41 TO IGN. SWITCH TO AMMETER 19 46 A S TO STOP-LIGHT SWITCH 11 41 43 (#10) 30 86 S 14 N.O. RELAY AMMETER 85 87 87A 16 16 (#10) 6 AMP. CIRCUIT BREAKER 16 35 36 37 38 40 42 44 45 A. 10 G B TO BACK-UP ALARM A. 16 G (#16) Starting Serial No. 0155299S Original Issue 10-00 TO BACK-UP LIGHT GA . GA . GA . GA 39 39 36 35 . BUSS BAR 20 AMP.
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OPTIONAL EQUIPMENT (9104-5154) Deluxe Light Package Starting Serial No. 0155299S Original Issue 10-00 10 12 13 10 11 13 6 7 8 14 15 16 17 1 2 3 4 5 9 9 22 31 33 TO BACK-UP ALARM 3A C B A 19 22 23 20 18 21 23 26 14 15 16 17 19 22 23 C B A GRAY BLACK BROWN RED/GREEN END VIEW OF SHROUD (L.H. HEADLIGHT) GRAY BLACK BROWN RED END VIEW OF SHROUD I AMTR 24 TORQ TEMP AUX G BATT FUEL S BATT 42 AUX 24 (R.H. HEADLIGHT) S I S I + TEMP I S H G O U AUX R M G S TO N.O.
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OPTIONAL EQUIPMENT (9104-5154) Deluxe Light Package Starting Serial No. 0155299S Original Issue 10-00 BRAKE SWITCH INSTALLATION 34 TO 25B IN ENGINE HARNESS TO 25B IN REVERSE SWITCH CONNECTION 16 46 47 36 TO STOPLIGHT SWITCH TO FLASHER TO HEADLIGHT SWITCH DIMMER SWITCH MOUNTING ON FLOOR PLATE TO SPOTLIGHTS 35 GREEN 30 86 FLASHER N.O.