GRADALL 544D Forklift TELEHandLER Parts Manual
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91364001 544D 3
TABLE OF CONTENTS
91364001 544D 5
SECTION 1 - FRAME AND ATTACHING PARTS.............................................................................................................................. 11
FIGURE 1-1. FRAME SHROUDING AND TRIM (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........... 12
FIGURE 1-2. FRAME SHROUDING AND TRIM (SN 0160000976 through 0160034720, Including 0160035922) ........................ 16
FIGURE 1-3. FRAME SHROUDING AND TRIM (SN 0160035037 to Present, Excluding 0160035922) ....................................... 20
FIGURE 1-4. REAR AXLE AND ATTACHING PARTS (SN 0355001 through 0455362)................................................................ 24
FIGURE 1-5. REAR AXLE AND ATTACHING PARTS (SN 0160000192 to Present) .................................................................... 28
FIGURE 1-6. FRONT AXLE MOUNTING (SN 0355001 through 0455362) .................................................................................... 32
FIGURE 1-7. FRONT AXLE MOUNTING (SN 0160000192 to Present)......................................................................................... 34
FIGURE 1-8. OUTRIGGER MOUNTING (Prior to SN 0160015062) .............................................................................................. 36
FIGURE 1-9. OUTRIGGER MOUNTING (SN 0160015062 to Present) ......................................................................................... 38
SECTION 2 - BOOM .......................................................................................................................................................................... 41
FIGURE 2-1. FIRST BOOM SECTION ........................................................................................................................................... 42
FIGURE 2-2. SECOND BOOM SECTION ...................................................................................................................................... 44
FIGURE 2-3. THIRD BOOM SECTION .......................................................................................................................................... 48
FIGURE 2-4. FOURTH BOOM SECTION ...................................................................................................................................... 52
FIGURE 2-5. EXTENSION CHAINS ............................................................................................................................................... 54
FIGURE 2-6. RETRACTION CHAINS ............................................................................................................................................ 56
FIGURE 2-7. QUICK SWITCH ASSEMBLY (Prior to SN 0160037689).......................................................................................... 60
FIGURE 2-8. QUICK SWITCH ASSEMBLY (SN 0160037689 to Present) ..................................................................................... 62
SECTION 3 - ATTACHMENTS .......................................................................................................................................................... 65
FIGURE 3-1. BUCKETS ................................................................................................................................................................. 66
FIGURE 3-2. TILT CARRIAGE (Prior to SN 0160023515) ............................................................................................................. 68
FIGURE 3-3. TILT CARRIAGE (SN 0160023515 to Present) ........................................................................................................ 70
FIGURE 3-4. TRUSS BOOM (Prior to SN 0160037689) ................................................................................................................ 72
FIGURE 3-5. TRUSS BOOM (SN 0160037689 to Present) ........................................................................................................... 74
FIGURE 3-6. TRUSS BOOM WITH WINCH (Prior to SN 0160037689) ......................................................................................... 76
FIGURE 3-7. TRUSS BOOM WITH WINCH (SN 0160037689 to Present) .................................................................................... 78
FIGURE 3-8. 6 FT VERTICAL MAST (Prior to SN 0160037689) ................................................................................................... 80
FIGURE 3-9. 48 IN SLOPE PILER CARRIAGE (Prior to SN 0160037689) .................................................................................... 84
FIGURE 3-10. 66 IN SLOPE PILER CARRIAGE (Prior to SN 0160037689) .................................................................................. 86
FIGURE 3-11. 100, SWING FORK (Prior to SN 0160037689) ....................................................................................................... 88
FIGURE 3-12. QUICK HOOK ASSEMBLY (Prior to SN 0160037689) ........................................................................................... 92
FIGURE 3-13. FORK MOUNTED LIFTING HOOK ......................................................................................................................... 94
FIGURE 3-14. 6 FT SWING MAST WITH SIDE SHIFT (Prior to SN 0160037689) ........................................................................ 96
FIGURE 3-15. 100, DRYWALL SWING CARRIAGE (Prior to SN 0160037689) .......................................................................... 102
FIGURE 3-16. SHEET MATERIAL HANDLER (SN 0160037689 to Present) ............................................................................... 106
FIGURE 3-17. SIDE TILT CARRIAGE (SN 0160037689 to Present) ........................................................................................... 108
FIGURE 3-18. 180, SWING CARRIAGE (Prior to SN 0160000976)............................................................................................. 110
FIGURE 3-19. 180, SWING CARRIAGE (SN 0160000976 through 0160023514) ....................................................................... 114
FIGURE 3-20. 180, SWING CARRIAGE (SN 0160023515 through 0160037688) ....................................................................... 118
FIGURE 3-21. 180, SWING CARRIAGE (SN 0160037689 to Present) ........................................................................................ 122
FIGURE 3-22. 90, SWING CARRIAGE (SN 0160037689 to Present) .......................................................................................... 126
FIGURE 3-23. FORKS.................................................................................................................................................................. 128
FIGURE 3-24. PERSONNEL PLATFORM (Prior to SN 0160037689) .......................................................................................... 130
FIGURE 3-25. FORK MOUNTED PLATFORM............................................................................................................................. 134
FIGURE 3-26. FORK PIN LOCK INSTALLATION (SN 0160037689 to Present) ......................................................................... 138
FIGURE 3-27. GRAPPLE BUCKET (SN 0160037689 to Present) ............................................................................................... 140
FIGURE 3-28. 8 FT STANDARD MAST (SN 0160037689 to Present)......................................................................................... 142
FIGURE 3-29. 8 FT SIDE TILT ELECTRIC MAST (SN 0160037689 to Present) ......................................................................... 146
FIGURE 3-30. 66 IN DRYWALL CARRIAGE (Prior to SN 0160037689) ...................................................................................... 152
SECTION 4 - ENGINE AND ATTACHING PARTS .......................................................................................................................... 155
FIGURE 4-1. ENGINE ASSEMBLY, LH VIEW (SN 0355001 through 0355069) .......................................................................... 156
FIGURE 4-2. ENGINE ASSEMBLY, LH VIEW (SN 0355070 through 0355140) .......................................................................... 160
FIGURE 4-3. ENGINE ASSEMBLY, LH VIEW (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ............ 164
FIGURE 4-4. ENGINE ASSEMBLY, LH VIEW (SN 0160000976 through 0160034720, Including 0160035922) ......................... 168
FIGURE 4-5. ENGINE ASSEMBLY, LH VIEW (SN 0160035037 to Present, Excluding 0160035922) ........................................ 172
FIGURE 4-6. ENGINE ASSEMBLY, RH VIEW (SN 0355001 through 0355069) ......................................................................... 176
FIGURE 4-7. ENGINE ASSEMBLY, RH VIEW (SN 0355070 through 0355140) ......................................................................... 180
FIGURE 4-8. ENGINE ASSEMBLY, RH VIEW (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ............ 184
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6 544D 91364001
FIGURE 4-9. ENGINE ASSEMBLY, RH VIEW (SN 0160000976 through 0160034720, Including 0160035922) ......................... 188
FIGURE 4-10. ENGINE ASSEMBLY, RH VIEW (SN 0160035037 to Present, Excluding 0160035922) ...................................... 192
FIGURE 4-11. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355001 through 0355069) ...................................... 196
FIGURE 4-12. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355070 through 0355140) ...................................... 198
FIGURE 4-13. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355141 through 0455362, SN 0160000192 through
0160000973) ................................................................................................................................................................................. 200
FIGURE 4-14. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0160000976 through 0160034720, Including
0160035922) ................................................................................................................................................................................. 202
FIGURE 4-15. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0160035037 to Present, Excluding 0160035922) .... 204
FIGURE 4-16. JOHN DEERE ENGINE (SN 0160000976 through 0160008588) .......................................................................... 206
FIGURE 4-17. JOHN DEERE ENGINE (SN 0160008590 through 0160034720, Including 0160035922)..................................... 208
FIGURE 4-18. CUMMINS ENGINE (SN 0160035037 to Present, Excluding 0160035922) .......................................................... 210
FIGURE 4-19. FUEL TANK AND LINES (Prior to SN 0160035037, Including 0160035922) ........................................................ 212
FIGURE 4-20. FUEL TANK AND LINES (SN 0160035037 to Present, Excluding 0160035922) .................................................. 214
FIGURE 4-21. RADIATOR ASSEMBLY (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ....................... 216
FIGURE 4-22. RADIATOR ASSEMBLY (SN 0160000976 through 0160034720, Including 0160035922).................................... 218
FIGURE 4-23. RADIATOR ASSEMBLY (SN 0160035037 to Present, Excluding 0160035922) ................................................... 220
FIGURE 4-24. AIR CLEANER PIPING (SN 0355001 through 0355579) ...................................................................................... 222
FIGURE 4-25. AIR CLEANER PIPING (SN 0355580 through 0455362, SN 0160000192 through 0160000973) ......................... 224
FIGURE 4-26. AIR CLEANER PIPING (SN 0160000976 through 0160034720, Including 0160035922) ..................................... 226
FIGURE 4-27. AIR CLEANER PIPING (SN 0160035037 to Present, Excluding 0160035922) ..................................................... 228
FIGURE 4-28. AIR CLEANER (SN 0355001 through 0355579) ................................................................................................... 230
FIGURE 4-29. AIR CLEANER (SN 0355580 through 0455362, SN 0160000192 through 0160034720, Including 0160035922) . 232
FIGURE 4-30. AIR CLEANER (SN 0160035037 to Present, Excluding 0160035922) .................................................................. 234
FIGURE 4-31. EXHAUST SYSTEM (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ............................. 236
FIGURE 4-32. EXHAUST SYSTEM (SN 0160000976 through 0160034720, Including 0160035922) .......................................... 238
FIGURE 4-33. EXHAUST SYSTEM (SN 0160035037 to Present, Excluding 0160035922) ......................................................... 240
SECTION 5 - DRIVE TRAIN ............................................................................................................................................................. 243
FIGURE 5-1. FRONT AXLE ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) ........................................................... 244
FIGURE 5-2. FRONT AXLE - ROCKWELL (SN 0355001 through 0455362)................................................................................ 246
FIGURE 5-3. LEFT/RIGHT HOUSING AND AXLE SHAFT AND WHEEL FLANGE ASSEMBLY - ROCKWELL (SN 0355001
through 0455362) .......................................................................................................................................................................... 248
FIGURE 5-4. BRAKE ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) ...................................................................... 250
FIGURE 5-5. CARRIER ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) .................................................................. 252
FIGURE 5-6. FRONT AXLE ASSEMBLY - CARRARO (SN 0160000192 to Present) .................................................................. 256
FIGURE 5-7. FRONT AXLE - CARRARO (SN 0160000192 to Present)....................................................................................... 258
FIGURE 5-8. AXLE HOUSING ASSEMBLY - CARRARO (SN 0160000192 to Present) .............................................................. 260
FIGURE 5-9. BRAKE ASSEMBLY - CARRARO (SN 0160000192 to Present)............................................................................. 262
FIGURE 5-10. CARRIER ASSEMBLY - CARRARO (SN 0160000192 to Present) ....................................................................... 264
FIGURE 5-11. REAR STEERING AXLE DRIVE HUB (SN 0355001 through 0455362) ............................................................... 268
FIGURE 5-12. REAR STEERING AXLE DRIVE HUB (SN 0160000192 to Present) .................................................................... 270
FIGURE 5-13. TIRES AND RIMS (Prior to SN 0160000192) ........................................................................................................ 272
FIGURE 5-14. TIRES AND RIMS (SN 0160000192 to Present) ................................................................................................... 274
SECTION 6 - CAB ............................................................................................................................................................................ 277
FIGURE 6-1. OPEN CAB (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding 0160012298) ....... 278
FIGURE 6-2. OPEN CAB (SN 0160012437 to Present, Including 0160012298) .......................................................................... 280
FIGURE 6-3. CAB ENCLOSURE KIT INSTALLATION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) 282
FIGURE 6-4. CAB ENCLOSURE KIT INSTALLATION (SN 0160000976 through 0160012366, Excluding 0160012298) ........... 286
FIGURE 6-5. CAB ENCLOSURE KIT INSTALLATION (SN 0160012437 to Present, Including 0160012298) ............................. 290
FIGURE 6-6. CAB ENCLOSURE KIT (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding
0160012298) ................................................................................................................................................................................. 294
FIGURE 6-7. CAB ENCLOSURE KIT (SN 0160012437 to Present, Including 0160012298) ........................................................ 300
FIGURE 6-8. DASH PANEL ASSEMBLY (SN 0355001 through 0355039) .................................................................................. 304
FIGURE 6-9. DASH PANEL ASSEMBLY (SN 0355040 through 0355069) .................................................................................. 306
FIGURE 6-10. DASH PANEL ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ................... 308
FIGURE 6-11. DASH PANEL ASSEMBLY (SN 0160000976 to Present) ..................................................................................... 310
FIGURE 6-12. GAUGE PANEL ASSEMBLY (SN 0355001 through 0355069) ............................................................................. 312
FIGURE 6-13. GAUGE PANEL ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ................ 314
FIGURE 6-14. GAUGE PANEL ASSEMBLY (SN 0160000976 to Present) .................................................................................. 316
FIGURE 6-15. WINDSHIELD/TOP WINDOW KIT INSTALLATION .............................................................................................. 318
FIGURE 6-16. SKYLIGHT WIPER INSTALLATION ...................................................................................................................... 322
SECTION 7 - CONTROLS ................................................................................................................................................................ 325
TABLE OF CONTENTS
91364001 544D 7
FIGURE 7-1. BRAKE AND INCHING LINKAGE (SN 0355001 through 0455362, SN 0160000192 through 0160000238) .......... 326
FIGURE 7-2. BRAKE AND INCHING LINKAGE (SN 0160000239 through 0160000973)............................................................ 330
FIGURE 7-3. BRAKE AND INCHING LINKAGE (SN 0160000976 through 0160012366, Excluding 0160012298) ..................... 334
FIGURE 7-4. BRAKE AND INCHING LINKAGE (SN 01600122437 to Present, Including 0160012298) ..................................... 338
FIGURE 7-5. ACCELERATOR PEDAL ASSEMBLY (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ... 342
FIGURE 7-6. ACCELERATOR PEDAL ASSEMBLY (SN 0160000976 to Present) ...................................................................... 344
FIGURE 7-7. STEERING COLUMN AND ATTACHING PARTS .................................................................................................. 346
FIGURE 7-8. CAB RIGHT SIDE CONTROLS .............................................................................................................................. 348
FIGURE 7-9. JOYSTICK ASSEMBLY .......................................................................................................................................... 350
FIGURE 7-10. CAB LEFT SIDE CONTROLS (SN 0160024648 to Present) ................................................................................ 352
FIGURE 7-11. CYBERTECH 5-BUTTON JOYSTICK CONTROLLER (SN 0160024648 to Present) ........................................... 358
SECTION 8 - HYDRAULIC CIRCUITS............................................................................................................................................. 361
FIGURE 8-1. OIL SUPPLY AND PRESSURE LINES (SN 0355001 through 0355140) ............................................................... 362
FIGURE 8-2. OIL SUPPLY AND PRESSURE LINES (SN 0355141 through 0455362, SN 0160000192 through 0160000973).. 366
FIGURE 8-3. OIL SUPPLY AND PRESSURE LINES (SN 0160000976 to Present) .................................................................... 370
FIGURE 8-4. DUMP CIRCUIT (SN 0355001 through 0355140) ................................................................................................... 374
FIGURE 8-5. DUMP CIRCUIT (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ..................................... 378
FIGURE 8-6. DUMP CIRCUIT (SN 0160000976 to Present) ....................................................................................................... 382
FIGURE 8-7. FRONT DRIVE CIRCUIT ........................................................................................................................................ 386
FIGURE 8-8. REAR DRIVE CIRCUIT (SN 0355001 through 0355140) ....................................................................................... 388
FIGURE 8-9. REAR DRIVE CIRCUIT (SN 0355141 through 0455362) ....................................................................................... 392
FIGURE 8-10. REAR DRIVE CIRCUIT (SN 0160000192 to Present) .......................................................................................... 396
FIGURE 8-11. SERVICE/PARKING BRAKE ................................................................................................................................ 400
FIGURE 8-12. BOOM HYDRAULICS SUB-ASSY (Prior to SN 0160024648) .............................................................................. 402
FIGURE 8-13. BOOM HYDRAULICS SUB-ASSY (SN 0160024648 to Present) ......................................................................... 404
FIGURE 8-14. AUXILIARY HYDRAULICS (SN 0160024648 through 0160037688) .................................................................... 406
FIGURE 8-15. AUXILIARY HYDRAULICS (SN 0160037689 to Present) ..................................................................................... 408
FIGURE 8-16. LIFT CYLINDER.................................................................................................................................................... 410
FIGURE 8-17. CROWD CYLINDER ............................................................................................................................................. 412
FIGURE 8-18. TILT CYLINDER AND TILT COMPENSATING CYLINDER .................................................................................. 414
FIGURE 8-19. SWAY CYLINDER ................................................................................................................................................ 416
FIGURE 8-20. STEERING CIRCUIT (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........................... 418
FIGURE 8-21. STEERING CIRCUIT (SN 0160000976 through 0160001769, Excluding 0160001766) ....................................... 420
FIGURE 8-22. STEERING CIRCUIT (SN 0160001770 to Present, Including 0160001766) ......................................................... 422
FIGURE 8-23. JOYSTICK CIRCUIT ............................................................................................................................................. 424
FIGURE 8-24. STABILIZER CYLINDER (SN 0355001 through 0355496) ................................................................................... 426
FIGURE 8-25. STABILIZER CYLINDER (SN 0355497 through 0455362, SN 0160000192 to Present) ...................................... 428
FIGURE 8-26. OUTRIGGER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160000973) .................... 430
FIGURE 8-27. OUTRIGGER CYLINDER (SN 0160000976 to Present) ....................................................................................... 432
FIGURE 8-28. HOSE CLAMP LOCATIONS, (REAR) (SN 0355001 through 0355140) ............................................................... 434
FIGURE 8-29. HOSE CLAMP LOCATIONS, (REAR) (SN 0355141 through 0455362, SN 0160000192 through 0160000973) .. 436
FIGURE 8-30. HOSE CLAMP LOCATIONS, (REAR) (SN 0160000976 to Present) .................................................................... 438
SECTION 9 - HYDRAULIC COMPONENTS .................................................................................................................................... 441
FIGURE 9-1. TILT CYLINDER (Prior to SN 0160033224) ............................................................................................................ 442
FIGURE 9-2. TILT CYLINDER (SN 0160033224 through 0160037688) ...................................................................................... 444
FIGURE 9-3. TILT CYLINDER (SN 0160037689 to Present) ....................................................................................................... 446
FIGURE 9-4. CROWD CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .............................. 448
FIGURE 9-5. CROWD CYLINDER (SN 0160017525 to Present) ................................................................................................ 450
FIGURE 9-6. LIFT CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .................................... 452
FIGURE 9-7. LIFT CYLINDER (SN 0160017525 to Present) ....................................................................................................... 454
FIGURE 9-8. COMPENSATING CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160032630) ............... 456
FIGURE 9-9. COMPENSATING CYLINDER (SN 0160033224 to Present) ................................................................................. 458
FIGURE 9-10. SWAY CYLINDER (Prior to SN 0160033224)....................................................................................................... 460
FIGURE 9-11. SWAY CYLINDER (SN 0160033224 to Present) .................................................................................................. 462
FIGURE 9-12. STEERING CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160001769, Excluding
0160001766) ................................................................................................................................................................................ 464
FIGURE 9-13. STEERING CYLINDER (SN 0160001770 through 0160033083, Including 0160001766, Excluding 0160032250,
0160032591, 0160032630, 0160032644 and 0160032679) ......................................................................................................... 466
FIGURE 9-14. STEERING CYLINDER (SN 0160033224 to Present, Including 0160032250, 0160032591, 0160032630,
0160032644 and 0160032679) ..................................................................................................................................................... 468
FIGURE 9-15. STABILIZER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) ..................... 470
FIGURE 9-16. STABILIZER CYLINDER (SN 0160017525 to Present) ........................................................................................ 472
FIGURE 9-17. OUTRIGGER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .................... 474
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8 544D 91364001
FIGURE 9-18. OUTRIGGER CYLINDER (SN 0160017525 through 0160038794) ....................................................................... 476
FIGURE 9-19. OUTRIGGER CYLINDER (FOR SERVICE ONLY) ............................................................................................... 478
FIGURE 9-20. FLOW DIVIDER ASSEMBLY ................................................................................................................................ 480
FIGURE 9-21. BRAKE VALVE (SN 0355001 through 0355947) ................................................................................................... 482
FIGURE 9-22. BRAKE VALVE (SN 0355948 through 0455362) ................................................................................................... 484
FIGURE 9-23. BRAKE VALVE (SN 0160000239 to Present) ....................................................................................................... 486
FIGURE 9-24. SOLENOID VALVE ............................................................................................................................................... 488
FIGURE 9-25. THERMAL BYPASS VALVE ASSEMBLY ............................................................................................................. 490
FIGURE 9-26. INCHING VALVE (SN 0355001 through 0455362, SN 0160000192 through 0160000238) .................................. 492
FIGURE 9-27. INCHING VALVE (SN 0160000239 to Present) .................................................................................................... 494
FIGURE 9-28. MAIN CONTROL VALVE (Prior to SN 0160037689) ............................................................................................. 496
FIGURE 9-29. MAIN CONTROL VALVE (SN 0160037964 to Present) ........................................................................................ 500
FIGURE 9-30. HYDRAULIC RESERVOIR AND FILTERS ............................................................................................................ 504
FIGURE 9-31. FRONT DRIVE MOTOR ........................................................................................................................................ 506
FIGURE 9-32. MAIN HYDRAULIC PUMP ..................................................................................................................................... 508
FIGURE 9-33. HYDROSTATIC TRANSMISSION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........ 510
FIGURE 9-34. HYDROSTATIC TRANSMISSION (SN 0160000976 to Present) .......................................................................... 512
FIGURE 9-35. SWAY AND OUTRIGGER CYLINDER VALVES ................................................................................................... 514
FIGURE 9-36. TRACTION LOCK VALVE ..................................................................................................................................... 516
FIGURE 9-37. REAR DRIVE MOTOR .......................................................................................................................................... 518
FIGURE 9-38. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355001 through 0355496) ................................................... 520
FIGURE 9-39. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355497 through 0455362, SN 0160000192 to Present) ...... 522
FIGURE 9-40. OUTRIGGER VALVE ............................................................................................................................................ 524
FIGURE 9-41. QUICK START CYLINDER AND VALVE ASSEMBLY (SN 035507 through 0160000973) ................................... 526
FIGURE 9-42. 180, SWING CARRIAGE CYLINDER .................................................................................................................... 528
FIGURE 9-43. 72 IN 90, SWING CARRIAGE CYLINDER ............................................................................................................ 530
FIGURE 9-44. SIDE TILT CARRIAGE CYLINDER ....................................................................................................................... 532
FIGURE 9-45. SIDE TILT CARRIAGE CYLINDER ....................................................................................................................... 534
FIGURE 9-46. GRAPPLE BUCKET CYLINDER ........................................................................................................................... 536
SECTION 10 - ELECTRICAL............................................................................................................................................................ 539
FIGURE 10-1. BATTERY AND CABLES (Prior to SN 0160035037, Including 0160035922)........................................................ 540
FIGURE 10-2. BATTERY AND CABLES (SN 0160035037 to Present, Excluding 0160035922) .................................................. 542
FIGURE 10-3. STABILIZER PROXIMITY SENSOR ..................................................................................................................... 544
FIGURE 10-4. DASH HARNESS ASSEMBLY (SN 0355001 through 0355069) ........................................................................... 546
FIGURE 10-5. DASH HARNESS ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ............. 548
FIGURE 10-6. DASH HARNESS ASSEMBLY (SN 0160000976 to Present)................................................................................ 550
FIGURE 10-7. ENGINE HARNESS ASSEMBLY (SN 0355001 through 0355140) ....................................................................... 552
FIGURE 10-8. ENGINE HARNESS ASSEMBLY (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ......... 554
FIGURE 10-9. ENGINE HARNESS ASSEMBLY (SN 0160000976 through 0160034720, Including 0160035922) ...................... 556
FIGURE 10-10. ENGINE HARNESS ASSEMBLY (SN 0160035037 to Present, Excluding 0160035922).................................... 558
FIGURE 10-11. ECU ENGINE HARNESS (SN 0160000976 through 0160034720, Including 0160035922) ................................ 560
FIGURE 10-12. ECU ENGINE HARNESS (SN 0160035037 to Present, Excluding 0160035922) ............................................... 562
FIGURE 10-13. AUXILIARY ELECTRICAL INSTALLATION (SN 0160024648 to Present) .......................................................... 564
FIGURE 10-14. AUXILIARY ELECTRICAL HARNESSES (SN 0160024648 to Present) ............................................................. 568
FIGURE 10-15. COLD START (SN 0160035037 to Present, Excluding 0160035922) ................................................................. 570
SECTION 11 - DECALS ................................................................................................................................................................... 573
FIGURE 11-1. FRAME DECALS (SN 0355001 through 0455362, SN 0160000192 through 0160000973) .................................. 574
FIGURE 11-2. FRAME DECALS (SN 0160000976 through 0160003956, Excluding 0160003856) ............................................. 578
FIGURE 11-3. FRAME DECALS (SN 0160003969 to Present, Including 0160003856) ............................................................... 582
FIGURE 11-4. BOOM DECALS (SN 0355001 through 0455362, SN 0160000192 through 0160012544) ................................... 586
FIGURE 11-5. BOOM DECALS (SN 0160012602 to Present, Including 0160012298) ................................................................. 588
SECTION 12 - OPTIONS.................................................................................................................................................................. 591
FIGURE 12-1. HYDRAULIC RESERVOIR HEATER INSTALLATION .......................................................................................... 592
FIGURE 12-2. WINCH INSTALLATION ........................................................................................................................................ 594
FIGURE 12-3. STOP LIGHT INSTALLATION ............................................................................................................................... 598
FIGURE 12-4. SWING CYLINDER ............................................................................................................................................... 602
FIGURE 12-5. TRUSS BOOM WINCH (Prior to SN 0160037689) ................................................................................................ 604
FIGURE 12-6. LH SWAY ASSEMBLY (Prior to SN 0160024648) ................................................................................................ 608
FIGURE 12-7. AUXILIARY HYDRAULIC FIELD KIT (Prior to SN 0160024648) ........................................................................... 610
FIGURE 12-8. AUXILIARY HYDRAULICS AND SWAY ASSEMBLY (Prior to SN 0160024648) .................................................. 614
FIGURE 12-9. AUXILIARY ELECTRICS ASSEMBLY (Prior to SN 0160024648) ......................................................................... 618
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91364001 544D 9
FIGURE 12-10. OVERHEAD WINDOW ....................................................................................................................................... 622
FIGURE 12-11. TILT ON JOYSTICK INSTALLATION ................................................................................................................. 624
FIGURE 12-12. WINCH MOTOR.................................................................................................................................................. 628
FIGURE 12-13. ENGINE BLOCK HEATER (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ................. 630
FIGURE 12-14. ENGINE BLOCK HEATER (SN 0160000976 to Present) ................................................................................... 632
FIGURE 12-15. SWAY CYLINDER .............................................................................................................................................. 634
FIGURE 12-16. DUAL P.O. CHECK VALVE ................................................................................................................................ 636
FIGURE 12-17. SWING VALVE KIT ............................................................................................................................................. 638
FIGURE 12-18. SWING VALVE KIT ............................................................................................................................................. 640
FIGURE 12-19. LH TILT/SWAY ASSEMBLY (Prior to SN 0160024648)...................................................................................... 642
FIGURE 12-20. LH TILT ASSEMBLY (Prior to SN 0160024648) ................................................................................................. 644
FIGURE 12-21. ETHER START (SN 0355001 through 0355069) ................................................................................................ 646
FIGURE 12-22. WORK LIGHT PACKAGE (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding
0160012298) ................................................................................................................................................................................ 648
FIGURE 12-23. WORK LIGHT PACKAGE (SN 0160012437 to Present, Including 0160012298) ............................................... 654
FIGURE 12-24. CROSSOVER RELIEF VALVE ........................................................................................................................... 658
FIGURE 12-25. FOAM TIRE OPTION .......................................................................................................................................... 660
FIGURE 12-26. AUX. HYDRAULICS/ELECTRIC W/LH TILT AND SWAY (Prior to SN 0160024648) ......................................... 662
FIGURE 12-27. REAR AXLE ADVANTAGE KIT (SN 0355001 through 0455362) ....................................................................... 668
FIGURE 12-28. REAR AXLE ADVANTAGE KIT (SN 0160000192 to Present) ............................................................................ 672
FIGURE 12-29. R.H. AUX. HYDRAULIC ASSEMBLY (Prior to SN 0160024648) ........................................................................ 676
FIGURE 12-30. 5-BUTTON AUXILIARY HANDLE ASSEMBLY (Prior to SN 0160024648) ......................................................... 680
FIGURE 12-31. RH AUX/TILT ON JOYSTICK (Prior to SN 0160024648).................................................................................... 682
FIGURE 12-32. AUXILIARY HYDRAULIC ASSEMBLY (Prior to SN 0160024648) ...................................................................... 686
FIGURE 12-33. CAB HEATER OPTION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ..................... 690
FIGURE 12-34. CAB HEATER OPTION (SN 0160000976 through 0160035922) ....................................................................... 694
FIGURE 12-35. CAB HEATER OPTION (SN 0160036260 to Present) ........................................................................................ 698
FIGURE 12-36. ADJUSTABLE TILT ON JOYSTICK .................................................................................................................... 702
FIGURE 12-37. FUEL/WATER SEPARATOR INSTALLATION ................................................................................................... 706
FIGURE 12-38. BEACON LIGHT PACKAGE (SN 0355001 through 0455497, SN 0160000192 through 0160012665, Excluding
0160012298) ................................................................................................................................................................................ 708
FIGURE 12-39. BEACON LIGHT PACKAGE (SN 0160012842 to Present, Including 0160012298) ........................................... 710
FIGURE 12-40. CAB REPLACEMENT SERVICE KIT.................................................................................................................. 712
FIGURE 12-41. STARTER KIT (SN 0160008321 to Present) ...................................................................................................... 714
FIGURE 12-42. PINTLE HOOK INSTALLATION.......................................................................................................................... 716
FIGURE 12-43. COLD START INSTALLATION (SN 0160000976 through 0160034720, Including 0160035922) ....................... 718
SECTION 13 - RECOMMENDED SPARE PARTS .......................................................................................................................... 721
FIGURE 13-1. RECOMMENDED SPARE PARTS ....................................................................................................................... 722
PART NUMBER INDEX ................................................................................................................................................................... 725
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