Illustrated Parts Manual

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1 Illustrated Parts Manual Model 544C-10 S/N P/N Revised February 23, 2007

2 INTRODUCTION Table of Contents Original Issue Revised SECTION 1 INTRODUCTION Table of Contents thru 1-4 Alphabetical Index thru 1-8 Service Kits , 1-10 * Part Number Index thru 1-23 SECTION 2 CHASSIS & ATTACHING PARTS Frame Shrouding & Trim Rear Axle & Attaching Parts Front Axle Mounting Cab Glass Outrigger Mounting SECTION 3 BOOM First Boom Section Second Boom Section Third Boom Section Fourth Boom Section Boom Cross Section/Push Beam Pin Extension Chains Retraction Chains Quick Switch Assembly SECTION 4 ATTACHMENTS Buckets Carriage Assembly Truss Boom Truss Boom W/Winch Ft. Vertical Mast " Slope Piler Carriage " Slope Piler Carriage Degree Swing Fork Quick Hook Ft. Swing Mast W/Side Shift Degree Drywall Swing Fork Assembly Swinging Slope Piler Degree Swing Frame SECTION 5 ENGINE & ATTACHING PARTS Engine Left Side View Engine Right Side View Fuel Tank & Lines Radiator & Hoses Oil Cooler GH * Changed page numbers to section one. 1-1

3 INTRODUCTION Table of Contents Original Issue SECTION 5 ENGINE & ATTACHING PARTS (continued) Revised Air Cleaner Piping Air Cleaner Exhaust System SECTION 6 DRIVE TRAIN Front Axle Assembly Front Axle Front Axle Housing Brake Assembly Front Axle Differential Carrier Rear Steering Axle Drive Hub Wheels & Tires SECTION 7 CONTROLS Tilt & Sway Control Brake & Inching Linkage Accelerator Linkage Floor Plate Assy Steering Column & Attaching Parts SECTION 8 BRAKE CIRCUITS Service Brake Lines SECTION 9 HYDRAULIC CIRCUITS Oil Supply & Pressure Lines Dump Circuit Front Drive Circuit Rear Drive Circuit Boom Hydraulics Sub-Assy Lift Cylinder Crowd Cylinder Tilt & Tilt Compensating Cylinder Sway Cylinder Steering Cylinder Joystick Circuit Stabilizer Cylinder Outrigger Cylinder * Hose Clamp Locations ( rear) SECTION 10 HYDRAULIC COMPONENTS Tilt Cylinder Crowd Cylinder Lift Cylinder KG * Added page 9-14, hose clamp locations. 1-2

4 INTRODUCTION Table of Contents Original Issue SECTION 10 HYDRAULIC COMPONENTS (Continued) Compensating Cylinder Sway Cylinder Steering Cylinder Stabilizer Cylinder Outrigger Cylinder Flow Divider Assembly Brake Valve Solenoid Valve Thermal Bypass Valve Inching Valve Main Hydraulic Control Valve Hydraulic Reservoir & Filters Front Drive Motor Main Hydraulic Pump Hydrostatic Transmission Pump Sway Cylinder Valve / Outrigger Cylinder Valve Joystick Assembly Traction Lock Valve Rear Drive Motor Stabilizer Valve Outrigger Valve SECTION 11 ELECTRICAL Gauge Panel Assembly Dash Panel Battery & Cables Stabilizer Proximaty Sensor SECTION 12 MISCELLANEOUS Frame Decals Boom Decals SECTION 13 OPTIONAL EQUIPMENT Block Heater Winch Installation Work Light Auxiliary Hydraulics W/Electrics Vandal Kit Glow Plug Installation R.H. Tilt Sway Auxiliary Hydraulics KG 1-3

5 INTRODUCTION Table of Contents Original Issue Revised SECTION 13 OPTIONAL EQUIPMENT (Continued) Cab Enclosure Tilt on Joystick Sway Cylinder Dual P.O. Check Valve Swing Cylinder Ether Start Kit Swing Valve Assy Truss Boom Winch Winch Motor Crossover Valve Rear Axle Rework Kit Rear Axle Advantage Kit Button Handle ( ) * Pintle Hook ( ) * Work Light Package SVC * Added Pintle Hook (13-22) & Work Light Package(13-23). 1-4

6 INTRODUCTION Alphabetical Index Original Issue ACCELERATOR CABLE , 7-3 ACCELERATOR PEDAL AIR CLEANER AIR CLEANER ELEMENT AIR CLEANER SERVICE INDICATOR ALTERNATOR ATTACHMENTS thru 4-13 BACK-UP ALARM BATTERY BATTERY HOLD DOWN BATTERY CABLES BEARING PADS (Boom Sections) thru 3-4 BLOCK HEATER BOOM DECALS BOOM SECTIONS thru 3-4 BRAKE PEDAL BRAKE VALVE BRAKE WARNING LIGHT BREATHER (Filler cap) BUCKETS BOOM CROSS SECTION BOOM HYDRAULICS SUB-ASSY CARRIAGES , 4-6, 4-7 COMPENSATING CYLINDER COMPENSATING CYLINDER HYDRAULIC CIRCUIT CONTROL VALVES thru 10-14, 10-19, 10-21, 10-23, CROWD CYLINDER CROWD CYLINDER HYDRAULIC CIRCUIT DECALS , 12-2 DECK DRIVE CIRCUIT , 9-4 DUAL P.O. CHECK VALVE DUMP CIRCUIT ELECTRICAL SYSTEMS thru 11-4 ENGINE LEFT SIDE ENGINE MOUNT KG 1-5

7 INTRODUCTION Alphabetical Index Original Issue ENGINE RIGHT SIDE ENGINE THROTTLE CONTROL EXHAUST PIPE EXHAUST SYSTEM EXTENSION CHAINS FAN BELT FIRST BOOM SECTION FIRST BOOM SECTION MOUNTING PIN FILTERS , 5-2, FILTER ELEMENT FLOORPLATE ASSY FLOW DIVIDER ASSY , 9-2, 10-9 FOOT SWITCH FORWARD-NEUTRAL-REVERSE SHIFTER FOURTH BOOM SECTION FRAME FRAME SHROUDING & TRIM FRONT AXLE thru 6-5 FRONT AXLE MOUNTING FRONT AXLE DIFFERENTIAL CARRIER FRONT AXLE DRIVE MOTOR FRONT AXLE HOUSING FRONT AXLE SHAFT & PLANETARY WHEEL END FUEL FILTERS , 5-2 FUEL GAUGE FUEL LEVEL SENDER FUEL LINES , 5-3 FUEL TANK & CAP GAUGE PANEL ASSEMBLY GEAR PUMP GLOW PLUG HOOD HORN HORN WIRING , 11-2 HOURMETER HYDRAULIC CIRCUITS thru 9-13 HYDROSTATIC TRANSMISSION PUMP KG 1-6

8 INTRODUCTION Alphabetical Index Original Issue Revised IGNITION SWITCH INCHING VALVE , INSTRUMENT PANEL , 11-2 JOYSTICK JOYSTICK HYDRAULIC CIRCUIT KITS LIFT CYLINDER LIFT CYLINDER HYDRAULIC CIRCUIT MAIN BOOM SECTIONS thru 3-4 MAIN CONTROL VALVE MAIN HYDRAULIC PUMP , MISCELLANEOUS ELECTRICAL COMPONENTS thru 11-4 MUFFLER NEGATIVE BATTERY CABLE , 11-3 OIL COOLER , 9-2 OIL FILTER , OIL PRESSURE GAUGE OIL PRESSURE SENDER OIL RESERVOIR OIL SUPPLY & PRESSURE LINES * PINTLE HOOK POSITIVE BATTERY CABLE , 11-3 QUICK HOOK QUICK SWITCH ASSEMBLY RADIATOR & HOSES REAR AXLE REAR AXLE MOUNTING PIN REAR DRIVE MOTOR REAR STEERING AXLE DRIVE HUB REGULATOR REPAIR KITS RESERVOIR & FILTERS SVC * Added Pintle Hook, (13-22). 1-7

9 INTRODUCTION Alphabetical Index Original Issue RETRACTION CHAINS R.H. TILT/SWAY SEAT SEAT BELT SECOND BOOM SECTION SERVICE BRAKE LINES SERVICE KITS SIX FOOT MAST SLOPE PILER CARRIAGE , 4-7 SOLENOID VALVE STARTER STARTER SOLENOID STEERING COLUMN STEERING CYLINDER STEERING CYLINDER HYDRAULIC CIRCUIT STEERING KNUCKLES STEERING ORBITROL STEERING WHEEL SUPPLY HYDRAULIC CIRCUIT SWAY CONTROL HANDLE & LINKAGE SWAY CYLINDERS , SWAY CYLINDER HYDRAULIC CIRCUIT SWING CYLINDER THERMAL BYPASS VALVE , 9-2, THIRD BOOM SECTION TIE ROD ARM TILT CONTROL HANDLE & LINKAGE TILT CYLINDER TILT CYLINDER HYDRAULIC CIRCUIT TILT ON JOYSTICK WATER TEMPERATURE GAUGE WATER TEMPERATURE SENDER WHEELS & TIRES WIRING HARNESS , 11-1, 11-2 KG 1-8

10 INTRODUCTION Service Kits Original Issue SECTION PAGE NO. PART NUMBER DESCRIPTION Steering Knuckle Kit Steering Cylinder Pin Kit Engine Filter Kit Brake Piston Plate Kit Brake Plate & Seal Kit Piston Brake Shim Kit Limited Slip Plate Stack Kit Pinion Cage Shim Kit Drive Pinion Shim Kit Limited Slip Shim Kit Drive Hub Repair Kit Cable Support Bracket Kit Cable Attach Kit Boot Kit Heel Rest Kit Steering Control Unit Seal Kit Tilt Cylinder Seal Kit Crowd Cylinder Seal Kit Lift Cylinder Seal Kit Compensating Cylinder Seal Kit Sway Cylinder Seal Kit Steering Cylinder Seal Kit Stabilizer Cylinder Seal Kit Outrigger Cylinder Seal Kit Flow Divider Valve Seal Kit Brake Valve Repair Kit Thermal Bypass Valve Element Kit Main Control Valve Seal Kit MCV Section Seal Kit MCV Work Section Seal Kit MCV Main Relief Seal Kit MCV Spool Positioner Kit KG 1-9

11 INTRODUCTION Service Kits Original Issue SECTION PAGE NO. PART NUMBER DESCRIPTION Check Valve Kit (Front Drive Motor) DA 1 Control Kit Front Drive Motor Seal Kit Hyd. Pump Shaft Seal Kit Hyd. Pump Seal Kit Hydrostatic Transmission Seal Kit Valve Seal Kit (Sway & Outrigger) Joystick Seal Kit Traction Lock Valve Seal Kit Rear Drive Motor Check Valve Kit Rear Drive Motor Seal Kit Check Valve Seal Kit (Stabilizer) Solenoid Valve Seal Kit (Stabilizer) Outrigger Valve Section Seal Kit Handle Kit (Outrigger Valve) Decal Kit Vandal Kit Sway Cylinder Seal Kit ( ) Dual P.O. Check Valve Seal Kit Swing Cylinder Seal Kit Winch Seal Kit Swing Valve Seal Kit Check Valve Seal Kit Counterbalance Valve Seal Kit Shaft Seal Kit (Winch Motor) 1-10

12 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 4-7, , 13-4, , , , , , , , 9-7, 9-12, , , 9-4, 9-7, 9-10, , 9-14, , 9-14, , 4-10, 4-11, 4-12, , 9-12, 9-13, , , 4-12, 8-1, , , 4-11, 9-5, , 9-13, , 4-10, 4-11, , , , , 9-4, 9-7, , 9-12, , 9-5, 9-13, , , 9-4, 9-5, , 9-10, 9-12, , 9-14, , 9-1, , 7-4, , 7-4, , 5-4, 9-11, , , , 5-4, 9-11, , 11-2, 11-3, , , 10-12, , 13-3, 13-6, , , 13-3, 13-6, , * Complete revision of index , 13-9, , , , , 13-3, 13-9, ,

13 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , , 4-10, 4-11, , 4-10, 4-11, , , 5-2, 9-3, , , , 9-3, , , , , 4-7, , , , , , 5-2, 9-3, , , , 9-1, , , , , , , , 9-1, * Complete revision of index , , , , 9-1, , , 13-2, 13-4, , , 13-4, , 13-4, , , , 5-3,

14 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 4-7, , 3-6, 3-7, , , , , , 5-1, 7-4, , 13-9, , 4-10, 4-11, , 7-4, 8-1, 9-1, , , 12-2, , , 5-4, , , , 9-4, 9-7, , 9-12, 9-14, , , , , 13-4, , , 4-3, 4-4, 5-5, , 9-4, 9-5, , 13-16, , 4-4, 5-2, , 10-12, 10-15, 13-4, , , 5-4, , 4-7, 4-12, , 9-13, , , , , 3-6, 3-7, 3-8, , 4-7, 4-12, 5-1, , 10-3, 10-4, , 3-2, 3-3, 4-4, , , , 13-4, , , 4-6, 4-7, 4-8, , , , 3-2, 3-3, , 4-6, 4-7, , 4-7, , , , , , , 13-19, , 7-4, , 13-19, , 9-11, , , * Complete revision of index , , , 13-3, , 4-2, 4-3, 4-4, , 4-6, 4-7, 4-8, 4-9, , 4-11, 4-12, , , 9-2, 9-11, , , 4-4, 4-10, , 5-1, 5-4, 7-2, 7-4, , 13-4, , 4-3, 4-4, 4-5, , 9-12, 10-14, , 11-12, 13-3, 13-4, , 13-16, , , 4-4, 5-1,...9-7, 9-8, 9-13, 13-2, , 13-8, , 4-7, , , 13-2, 13-4, , , , , , , 7-4, , , , , , , 4-6, 4-7, , 5-4, , 13-4, , 5-5, 9-5, , 13-8,

15 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 4-6, 4-7, , 4-11, , , , 5-1, 7-3, 7-4, , 9-1, 9-2, 9-4, , 13-10, , 4-10, 4-12, 5-1, , 5-7, 7-2, 7-4, , 12-2, 13-4, , , 2-5, 4-5, 4-6, , 4-9, 4-11, 4-12, , 5-2, 5-4, 7-5, , 9-4, 9-5, 9-8, , 9-12, 9-13, 10-12, , 10-15, 13-3, 13-4, , 13-16, , 5-2, 9-1,...9-3, 9-4, , 3-1, 3-2, 3-3, , 3-7, 3-8, 4-6,...4-7, 4-12, 5-2, 9-3, 9-7,...9-8, 9-13, 10-1, 10-3, , 10-7, 13-4, , 13-19, , 9-4, , 4-9, 4-10, , , 5-4, , , 9-5, 9-8, , 10-15, 13-4, , , 7-4, 8-1, , 13-9, , 4-10, 4-12, , , 3-2, 3-3, 3-4, , 4-7, 4-12, 5-2, 5-4, , 9-5, 13-3, 13-4, , 3-2, 3-3, 3-8, , 5-2, 5-4, 10-1, , , 4-10, 4-11, , 13-19, , 9-13, , , , , 13-19, , , 9-10, , 4-10, 4-11, 4-12, , 5-2, 6-1, 7-4, , 9-1, 9-2, 9-3,...9-4, 9-10, 9-11, 9-13, , , 4-10, 4-11, , 6-1, 7-4, 9-10, 9-12, , , 5-1, 6-1, 7-4, , 9-2, 9-4, 9-8, , 9-2, 9-3, , 9-6, 9-7, 9-8, 9-9, , 10-9, 13-4, , 10-9, , 5-4, 9-1, , 9-10, , 3-7, 13-4, , 4-11, , , 4-5, 4-6,...4-7, 4-8, 4-10, 4-11, , 4-13, , 9-13, , 13-4, , 4-12 * Complete revision of index , , , 6-1, 9-1, , 9-3, 9-4, , , 4-12, 6-1, , 9-10, , 9-4, 9-6, , , , 4-10, , 4-12, , 7-4,...9-2, , 9-9, 13-4, , , 9-1, 9-2, , , 9-10, , 4-12, 4-13,...7-4, 8-1, 9-2, 9-4, 9-10, , 10-9, , 9-12, , , 4-11, 9-11, , 4-10, 4-11, 4-12, , 8-1, 9-1, 9-10, , 9-13, , 4-10, 4-11, 4-12, , 9-4, 9-10, 13-2, 13-4, , 9-6, , , 9-2, , 9-10,

16 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 4-10, 4-11, , , 6-1, 9-1, , , 9-1, 9-2, 9-4, , , , 2-5, 3-6, 3-7, , 4-4, 4-9, 10-1, , 10-5, 13-16, , 3-8, 4-8, 4-10, , 4-12, , 3-1, 3-4, 4-6, , 4-8, 4-10, 4-11, , 10-3, , 3-3, , , , , , , , 13-4, , 5-2, 9-4,...9-5, 9-10, 9-11, 11-4, , 13-4, 13-8, , , , 3-2, , 3-2, 3-3, , , 3-7, 5-1, , , , 13-7, , , , , , 4-3, 4-5,...4-6, 4-7, 4-8, 4-9, 4-10, , , 4-6, 4-7, , 4-11, , * Complete revision of index , , 4-7, , 4-10, 4-11, , 4-5, 4-6,...4-7, 4-8, 4-9, 4-10, 4-11, , 4-13, 13-2, , , 4-6, 4-7, 4-8, , 4-10, 4-11, 4-12, , 13-2, 13-4, , 5-2, 9-3, , 3-2, 3-3, , 4-6, 4-7, , , , , 9-8, 13-2, , , 9-8, 13-4, , , , ,

17 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , , , , , , , , , * Complete revision of index , , , , , 3-2, 3-3, , 4-6, 4-7, , 4-8, 4-10, , , 4-10, 4-11, , , 3-2, 3-3, , 4-7, , 3-2,

18 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , 10-2, 10-3, , , 4-10, 4-11, , 4-10, 4-11, , 4-11, , 4-10, 4-11, , 4-10, 4-11, , 4-10, 4-11, , 4-10, 4-11, , , 4-10, 4-11, , 3-6, 3-7, , 13-4, , 3-6, 3-7, , 13-4, 13-8, , 3-6, 3-7, , 13-4, 13-8, , 3-6, 3-7, , 13-4, , , , 4-7, 4-8, 4-9, , 4-11, 4-12, 4-13, , 13-4, , 4-5, 4-6, , 4-8, 4-9, 4-10, , 4-12, 4-13, , 13-4, , , 4-10, 4-11, , , , 4-10, 4-11, , , * Complete revision of index , 4-10, 4-11, , 9-3, , 11-4, , 9-3, , , , 3-6, 3-7, 4-6, , 4-12, 10-3, , , 7-4, , 4-7, , 4-7, , 4-7, , , 5-2, 9-3,

19 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 7-4, 13-4, , , 13-2, 13-4, , , 9-1, , 4-7, , , , 9-1, , * Complete revision of index , , , ,

20 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 13-2, 13-4, , , , , 13-19, , 13-19, , 13-19, , 13-19, , 13-2, 13-4, , , 10-6, , , , , 3-3, , 3-3, , 4-10, 4-11, , , 13-19, , 13-4, , , 9-1 * Complete revision of index , , , , , , , , 9-1,

21 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , 10-4, , , 10-3, 10-4, , , , , 10-6, 10-7, , * Complete revision of index

22 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , 4-10, 4-11, , , 4-10, 4-11, , , * Complete revision of index , , , , 13-4, , , , , , 3-3, ,

23 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , , 13-4, , 13-4, , , , , , , 9-1, , 9-3, , , , , , 13-4, , 3-3, 3-4 * Complete revision of index , , 3-3, , 9-3, ,

24 INDEX INTRODUCTION Part Number Index Original Issue Revised PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE JJ , , , , , , 10-1, , , 13-4, , 9-12, , , * Complete revision of index

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