Manual

ManualsBrandsSkyTrak ManualsSpecial machinery10054

Illustrated Parts Manual

Service and Maintenance Manual

ANSI

Model

8042

10042

10054

8990187-003

FEBRUARY 2000

Summary of content (412 pages)

PAGE 1
Illustrated Parts Manual Service and Maintenance Manual Model 8042 10042 10054 8990187-003 FEBRUARY 2000 ANSI
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Table of Contents Page SECTION 1 – MAIN FRAME AND GUARDS Main Frame .................................................................. 2 Hoods and Guards ....................................................... 4 SECTION 2 – OPERATOR’S CAB AND CONTROLS Operator’s Cab - Open ................................................. 6 Operator’s Cab - Closed (Optional) .............................. 8 Cab Door .................................................................... 10 Operator’s Seat .....................
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Page Page SECTION 6 – HYDRAULIC COMPONENTS SECTION 8 – DECALS AND PAINT Hydraulic Reservoir .................................................. 162 Main Pump (S/N 9908 & Before) .............................. 164 Main Pump (S/N 9909 & After) ................................. 166 Boom Extend Cylinder (Early Production) ................ 168 Boom Extend Cylinder (Current Production) ............ 170 Boom Hoist Cylinder (S/N 5818 & Before) ............... 172 Boom Hoist Cylinder (S/N 5819 & After) ..........
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SECTION 1 MAIN FRAME AND GUARDS The parts information in this publication is based on data available at the time it was printed. Because of continual improvement and advancing product design, your vehicle may not be identical to the parts information shown. Whenever there is a question, obtain the latest parts information available from your local dealer.
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SECTION 1 MAIN FRAME Locate the fracture in bearing outer race at the clock position shown for each application (Items 5 & 7).
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SECTION 1 MAIN FRAME Item No. 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 Part Number Qty.
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SECTION 1 HOODS AND GUARDS 14 15 13 20 3 26 21 20 8 16 3 31 S/N 9908 & Before 11 32 11 12 22 17 18 18 19 28 27 9 7 17 18 29 12 28 8 26 2 24 30 4 9 25 11 12 1 12 6 8 29 If Gap at top exceeds .06", shim Lower Pivot with Item 8. 11 16 7 11 12 14 15 13 20 23 5 10 18 19 33 11 12 PF0810 Apply Item 33 to Item 10 PH1330 4 8042/10042/10054 Rev.
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SECTION 1 HOODS AND GUARDS Item No. 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 Part Number 7098262 7084792 7111164 7150393 NLA 7138614 7095452 7097174 8344010 8307110 8303034 7111473 8307002 8305004 8303656 8307203 8307004 8305906 8342807 8342808 8342416 5746241 8580213 8582413 8303729 7084821 8310136 7082311 8304660 8307005 5724742 7094682 8581007 8307202 8526035 8042/10042/10054 Rev. 2/00 Qty.
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SECTION 2 OPERATOR S CAB AND CONTROLS SECTION 2 OPERATOR’S CAB - OPEN Torque to 13 - 16 lb/ft (18 - 22 Nm) 3 12 4 Torque to 50 lb/ft (68 Nm) 9 18 17 16 15 5 3 14 Frame 37 13 36 Torque to 210 lb/ft (285 Nm) 2 Places 35 1 31 25 10 11 24 42 2 40 26 26 3 2 20 21 8 19 23 27 22 32 6 7 30 34 33 33 Torque to 515 lb/ft (698 Nm) 2 Places 28 29 39 14 38 41 PH0532 6 8042/10042/10054 Rev.
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SECTION 2 OPERATOR’S CAB - OPEN Item No. 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 38 39 40 41 42 Part Number Qty.
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SECTION 2 OPERATOR’S CAB - CLOSED (Optional) 47 48 47 42 41 15 See also “Skylight Windshield Wiper” 43 49 44 17 16 5 18 46 45 18 38 35 34 20 4 7 20 19 4 37 32 31 6 34 35 36 24 33 50 12 16 14 13 30 26 20 27 24 20 8 29 10 1 2 25 28 9 25 24 40 22 11 3 51 23 21 39 Kit PF0791 PF0810 See “Cab Door” PH0482 8 8042/10042/10054 Rev.
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SECTION 2 OPERATOR’S CAB - CLOSED (Optional) Item No. 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 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Part Number Qty.
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SECTION 2 CAB DOOR 9 10 4 9 1 5 11 28 8 2 7 6 16 17 30 18 36 27 12 37 3 14 13 35 31 22 15 32 29 24 25 26 19 26 20 34 24 33 21 23 PH0552 10 8042/10042/10054 Rev.
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SECTION 2 CAB DOOR Item No. 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 Number 8346008 8033844 8033845 8033843 8033842 8033841 8034544 8034545 8034546 8034547 8034548 8033846 8033847 8033848 8033849 8033850 8033851 8033852 8033853 8033854 8033855 8033856 8033857 8033858 8033859 8033860 8033861 8037206 8033862 8033863 8033864 8033865 8033866 8033867 8033868 8033869 8342808 8042/10042/10054 Rev. 2/00 Qty.
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SECTION 2 OPERATOR’S SEAT 1 2 6 20 10 7 5 13 9 12 18 11 4 8 19 12 13 3 15 16 14 17 21 22 Kit Kit PF0791 PA0064 12 8042/10042/10054 Rev.
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SECTION 2 OPERATOR’S SEAT Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number 8864037 8864044 8864041 8864045 8864046 8864039 8864040 NSS 8864043 8303604 7090751 8303697 8307006 8864036 8307106 8305626 7083963 8305008 8307005 8303534 8305006 8303745 8307113 Qty.
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SECTION 2 CONTROL CONSOLE 1 11 2 3 8 7 9 4 5 10 6 0900 17 13 11 12 14 18 21 16 20 19 15 PH0543 14 8042/10042/10054 Rev.
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SECTION 2 CONTROL CONSOLE Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 7084902 7082292 8464212 8466305 8469030 8467014 8305004 8307002 8303034 8223442 8580312 8223405 8580311 8033201 8223220 7099352 7150371 7111842 7150472 7099332 7111832 4107971 4107981 8223445 8223444 7135942 8042/10042/10054 Rev. 2/00 Qty.
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SECTION 2 TRANSMISSION SHIFT CONTROLS (S/N 9908 & Before) 3 2 1 4 5 6 11 11 13 9 Speed Control Connection Torque to 19 - 23 lb/ft (26 - 31 Nm) 12 Directional Control Connection 10 8 15 Transmission Control Valve 14 7 PA0085 16 8042/10042/10054 Rev.
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SECTION 2 TRANSMISSION SHIFT CONTROLS (S/N 9908 & Before) Item No. Part Number Qty. 1 2 3 4 5 6 7 8160205 8034694 8580111 8032753 8160042 8305402 8160417 1 1 2 1 2 2 1 8 9 10 11 12 13 14 15 8033240 8033241 8303540 8033242 8033243 8305601 8303106 8307005 4 2 4 2 2 4 4 4 8042/10042/10054 Rev.
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SECTION 2 TRANSMISSION SHIFT CONTROLS (S/N 9909 & After) 1 PH1201 18 8042/10042/10054 Origin 2/00
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SECTION 2 TRANSMISSION SHIFT CONTROLS (S/N 9909 & After) Item No. 1 Part Number 1319283 8042/10042/10054 Origin 2/00 Qty.
PAGE 24
SECTION 2 BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL 4 2 3 1 5 Boom Raise/Lower Spool Section Boom Extend/Retract Spool Section 9 8 9 8 7 7 6 Front PH0522 20 8042/10042/10054 Rev.
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SECTION 2 BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL Item No. 1 2 3 4 5 6 7 8 9 Part Number 8224027 8580110 8160419 8310143 8310144 8160062 8305402 8301439 8302470 8042/10042/10054 Rev. 2/00 Qty. 1 1 1 4 4 2 4 2 2 Description Joystick (Includes Items 2 and 3) Knob Boot TRHCS #10-24 Nut, Prop.
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SECTION 2 FRAME LEVEL & ATTACHMENT TILT CONTROL 12 2 3 13 1 6 4 Front 5 7 8 9 8 8 Attachment Tilt Spool Section 11 10 9 8 Frame Tilt Spool Section PH0512 22 8042/10042/10054 Rev.
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SECTION 2 FRAME LEVEL & ATTACHMENT TILT CONTROL Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number 8224026 8580110 8160419 8303540 8310001 7098142 8160060 8305005 8160617 8301443 8302470 8303034 8307109 8042/10042/10054 Rev. 2/00 Qty.
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SECTION 2 THROTTLE PEDAL CONTROL 10 1 2 7 6 13 3 22 23 14 9 20 8 26 16 21 3 S/N 1598 and Before 6 4 13 5 6 14 10 11 7 24 17 9 25 18 15 19 8 12 13 PH0592 24 8042/10042/10054 Rev.
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SECTION 2 THROTTLE PEDAL CONTROL Item No. 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 Part Number 8162003 8033178 8303742 8307002 8305004 8160046 8160610 8305002 8307003 8303837 7127102 8340034 8305402 8307109 7127091 8700116 8303799 8307024 8305650 7088522 8301002 8302449 8301402 8303790 8307025 8305624 8042/10042/10054 Rev. 6/98 Qty.
PAGE 30
SECTION 2 SERVICE BRAKE PEDAL CONTROL See “Directional Control Valves” 14 12 3 4 13 17 15 18 7 1 6 Torque to 30 lb/ft (41 Nm) 5 6 8 13 2 10 11 16 9 PG0531 26 8042/10042/10054 Rev.
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SECTION 2 SERVICE BRAKE PEDAL CONTROL Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number 7111203 7081031 7080891 8305410 8310257 8307104 8310258 8700120 8303742 8305004 8307002 8303534 8305405 8307005 8310170 8307110 7111191 8302406 8042/10042/10054 Rev. 12/97 Qty.
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SECTION 2 FRONT WINDSHIELD WIPER L H P S X 25 26 27 28 35 24 10 43 44 37 36 9 2 15 14 3 41 42 11 8 6 7 5 4 38 24 1 12 13 18 17 45 29 20 22 19 Torque to 16 23 21 17 180 - 200 lb/in (20 - 23 Nm) Kit 32 40 PF0791 Skylight Wiper Washer Reservoir (Ref.) 31 Seat Riser (Ref.) 30 39 34 33 Existing Hardware from Cab Heater PH0492 Front 28 8042/10042/10054 Rev.
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SECTION 2 FRONT WINDSHIELD WIPER Item No. 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 38 39 40 41 42 43 44 45 Part Number 8866492 NSS NSS NSS NSS NSS NSS NSS NSS 8866382 8033105 8034815 NSS 8307052 8303839 NSS NSS 8033104 8305006 8866437 NSS 8310002 7112511 8033102 8220073 8303835 8305002 8307046 NSS 8033065 7118941 8303540 8307109 8305624 8866381 8034801 8034802 8033110 8033075 8033103 NSS 8310029 NSS 8305005 8307203 8042/10042/10054 Rev.
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SECTION 2 CAB HEATER (Optional) 4 Seat Riser (Ref.) 5 5 1 2 3 11 12 8 6 7 HI 12 11 13 14 15 LO F OF 19 10 11 9 18 16 19 17 PG0561 30 8042/10042/10054 Rev.
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SECTION 2 CAB HEATER (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part Number 8360008 8032793 8032794 8303776 8307002 8223024 8580309 8303995 7075191 7124531 8405007 7125251 8430048 8540023 8360005 8584001 8584003 8220008 7125271 8042/10042/10054 Rev. 2/00 Qty. 1 1 1 2 4 1 1 2 2 2 4 2 1 1 1 1 6 1 1 Description Heater (Includes Items 2 and 3) Motor, Heater - 12 VDC Fan, Heater HHCS, 1/4-20 x 1/2" Washer, Lock 1/4" Switch Kit Cap HHCS, #10-24 x 1-1/4" Spacer, 3/4" Conduit, 1/4 I.D.
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SECTION 2 AUX. HYDRAULIC CONTROL (Optional) 5 2 11 6 3 12 1 13 14 6 12 7 4 15 Auxiliary Spool Control 9 11 10 Front PH0501 32 8042/10042/10054 Rev.
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SECTION 2 AUX. HYDRAULIC CONTROL (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 8160406 8580110 8160418 8303758 4105621 8305004 7091323 8305906 8307004 8303697 8160059 8305402 8160617 8302470 8301443 8042/10042/10054 Rev. 12/97 Qty.
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SECTION 2 MIRRORS Torque to 10 lb/ft (14 Nm) Front 1 3 2 Cab (Ref.) Torque to 23 lb/ft (31 Nm) Front 4 5 PG0591 34 8042/10042/10054 Rev.
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SECTION 2 MIRRORS Item No. Part Number Qty. 1 2 3 4 8866347 8866350 8866364 8866348 1 1 1 1 5 8866351 1 8042/10042/10054 Rev. 12/97 Description Mirror Assembly, 6.5" x 10", Left Side Cab - Flat Glass (Includes Items 2 and 3) Lens, 6.5" x 10" Flat Glass Replacement Loop Assembly Mirror Assembly, 6.5" x 10" Right Side - Convex Glass (Includes Item 5 and mounting hardware) Lens, 6.
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SECTION 2 SKYLIGHT WINDSHIELD WIPER (Optional) 12 11 10 5 8 7 1 6 9 5 4 22 3 2 13 14 17 18 15 2 14 19 Seat Riser (Reference) 5 16 21 20 Front Windshield Wiper/Washer Reservoir (Reference) Existing Hardware from Cab Heater Front PH0811 36 8042/10042/10054 Rev.
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SECTION 2 SKYLIGHT WINDSHIELD WIPER (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 8034797 8033075 8034798 8034799 8034800 8034801 8034802 8034803 8034804 8034805 8034806 8034807 8034808 8034809 7137132 8034810 8034811 8303540 8033065 7118941 8307109 8305624 8034817 8042/10042/10054 Rev. 2/00 Qty.
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SECTION 2 SOFT CAB ENCLOSURE (Optional) 4 1 2 5 7 6 3 PG1090 8 PG1080 Kit PF0791 PH1400 38 8042/10042/10054 Origin 2/00
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SECTION 2 SOFT CAB ENCLOSURE (Optional) Item No. 1 2 3 4 5 6 7 8 Part Number 8866525 8866526 8866527 8033081 8033479 8585155 8585156 8585133 8042/10042/10054 Origin 2/00 Qty. 1 1 1 1 1 1 1 1 Description Soft Cab Enclosure Kit - Complete (Includes Items 2 thru 7 plus Installation Instructions) Rear Window Enclosure - Soft Door Section - Soft Glass - Top Glass - Front 1" Hook Strip Material - 10 ft. 2" Hook Strip Material - 10 ft.
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SECTION 3 DRIVE TRAIN SECTION 3 CONVERTER AND TRANSMISSION HOUSINGS (S/N 9908 & Before) 5 1 7 4 3 21 20 19 6 6 1 18 2 22 23 24 11 10 9 13 14 15 17 16 12 25 29 28 24 26 27 23 45 30 33 43 42 34 46 26 40 44 47 31 32 18 39 38 37 W LO 36 X A X 37 V U 36 V 48 37 62 Y 63 61 W 60 36 35 57 24 41 56 Z 55 54 Y 37 51 52 53 U 49 3R 50 D LU 64 65 BE 59 58 W A Z PB0183 40 8042/10042/10054 Rev.
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SECTION 3 CONVERTER AND TRANSMISSION HOUSINGS (S/N 9908 & Before) Item No.
PAGE 46
SECTION 3 CONVERTER GROUP (S/N 9908 & Before) 14 7 3 4 13 5 6 8 9 2 1 3 19 18 16 17 15 20 11 3 10 10 29 3 21 12 24 32 22 23 28 31 29 25 30 27 26 41 40 39 38 37 35 36 56 34 42 44 55 33 43 47 45 56 46 48 55 49 50 57 58 59 60 53 52 42 51 54 PB0192 42 8042/10042/10054 Rev.
PAGE 47
SECTION 3 CONVERTER GROUP (S/N 9908 & Before) Item No.
PAGE 48
SECTION 3 FORWARD, REVERSE, LOW AND 2ND (S/N 9908 & Before) 37 RD WA R FO 38 18 26 13 34 33 27 12 21 39 40 11 36 35 25 24 23 22 14 41 31 28 29 42 31 30 18 16 15 W LO 32 30 15 16 17 18 20 19 14 12 9 1 2 3 4 5 6 7 6 10 13 SE ER V RE & D 2N 11 8 PB0201 44 8042/10042/10054 Rev.
PAGE 49
SECTION 3 FORWARD, REVERSE, LOW AND 2ND (S/N 9908 & Before) Item No.
PAGE 50
SECTION 3 OUTPUT, IDLER AND THIRD (S/N 9908 & Before) 19 17 15 16 15 28 14 13 11 12 8 9 10 7 18 20 21 22 23 24 25 26 30 29 27 27 D 3R See “Emergency Brake” 1 2 3 4 5 6 39 38 37 36 43 45 46 33 32 31 47 44 35 42 41 34 47 31 32 40 33 PH0250 46 8042/10042/10054 Rev.
PAGE 51
SECTION 3 OUTPUT, IDLER AND THIRD (S/N 9908 & Before) Item No.
PAGE 52
SECTION 3 TRANSMISSION CLUTCH GROUPS (S/N 9908 & Before) 8 LOW 7 6 5 4 3 2 1 W LO 16 15 13 12 11 10 9 20 19 18 17 FORWARD 14 D AR W R FO 24 21 22 23 3RD D 3R 32 31 29 28 27 26 25 2ND & REVERSE 30 SE ER V RE D 2N 39 38 37 36 35 34 33 PH0630 48 8042/10042/10054 Rev.
PAGE 53
SECTION 3 TRANSMISSION CLUTCH GROUPS (S/N 9908 & Before) Item No.
PAGE 54
SECTION 3 CONTROL VALVE ASSEMBLY (S/N 9908 & Before) 17 1 18 22 3 2 16 19 23 20 21 24 4 13 8 5 14 9 9 25 15 12 6 10 11 15 7 PB0232 50 8042/10042/10054 Rev.
PAGE 55
SECTION 3 CONTROL VALVE ASSEMBLY (S/N 9908 & Before) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Part Number 8032666 8307005 8033239 8032672 8032673 8032676 8032679 8032674 8032675 8825174 8032678 8032680 8032682 8032681 8032676 8841314 8033202 8033203 8033204 8033205 8033238 8033890 8032669 8032670 8303987 8042/10042/10054 Rev. 12/97 Qty.
PAGE 56
SECTION 3 EMERGENCY BRAKE (S/N 9908 & Before) 1 Apply Loctite #242 to Threads and Torque 15 - 20 lb/ft (20 - 27 Nm) 3 5 2 4 Apply Loctite #242 to Threads and Torque 35 - 40 lb/ft (47 - 54 Nm) 7 6 *9 10 12 8 13 14 *9 15 16 22 11 Kit 21 17 23 20 Kit 8 PF0791 18 19 Apply Loctite #242 to Threads and Torque 85 - 90 lb/ft (115 - 122 Nm) Kit Kit * Earlier models did not include dowel pins (Item 9).
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SECTION 3 EMERGENCY BRAKE (S/N 9908 & Before) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part Number 8033791 8033774 8033775 See Kits See Kits See Kits 8033776 See Kits 8033777 8033778 See Kits 8033779 See Kits See Kits See Kits See Kits 8033780 8033781 8033782 Qty.
PAGE 58
SECTION 3 TRANSMISSION MOUNTING (S/N 9908 & Before) 1 4 9 5 10 2 3 6 11 7 12 8 13 Frame PH0241 54 8042/10042/10054 Rev.
PAGE 59
SECTION 3 TRANSMISSION MOUNTING (S/N 9908 & Before) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number 8841025 8307010 8303664 7095342 8310051 8278017 7096471 8310116 7111952 8303724 8278007 7054351 8310067 8042/10042/10054 Rev. 7/99 Qty.
PAGE 60
SECTION 3 ENGINE CONNECT (S/N 9909 & After) 2 8 10 5 6 4 11 3 14 13 12 15 1 7 9 PH1040 56 8042/10042/10054 Origin 7/99
PAGE 61
SECTION 3 ENGINE CONNECT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 1319203 1319204 10732095 1319205 1319206 1319207 1319208 10731748 10731751 1319209 1319210 1319211 1319212 1319213 10731702 8042/10042/10054 Origin 7/99 Qty.
PAGE 62
SECTION 3 CONVERTER AND LAYSHAFT (S/N 9909 & After) 6 1 4 5 2 3 4 Torque Limit 58.
PAGE 63
SECTION 3 CONVERTER AND LAYSHAFT (S/N 9909 & After) Item No. 1 2 3 4 5 6 Part Number 10732110 10732111 10732112 10732113 10732114 10732115 10732116 10732117 10732118 10732119 10732120 10732121 10732122 10731704 8042/10042/10054 Rev. 2/00 Qty.
PAGE 64
SECTION 3 OIL PRESSURE PUMP (S/N 9909 & After) 3 1 2 Torque Limit 17 lb/ft (23 Nm) 4 5 6 PH1060 60 8042/10042/10054 Origin 7/99
PAGE 65
SECTION 3 OIL PRESSURE PUMP (S/N 9909 & After) Item No. 1 2 3 4 5 6 Part Number 10731705 10731706 10731707 1319214 10731710 10731709 8042/10042/10054 Origin 7/99 Qty.
PAGE 66
SECTION 3 INPUT SHAFT (S/N 9909 & After) 4 7 3 5 8 2 6 1 7 PH1070 62 8042/10042/10054 Origin 7/99
PAGE 67
SECTION 3 INPUT SHAFT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 Part Number 10731711 10731712 10731713 1319215 10731715 1319216 1319217 10731716 10731717 10731718 10731719 10731720 10731721 10731722 10731723 10731724 10731725 10731726 10731727 10731728 10731729 10731730 10731731 10731732 1319218 10731734 8042/10042/10054 Rev. 2/00 Qty.
PAGE 68
SECTION 3 GEARBOX HOUSING (S/N 9909 & After) 11 22 21 20 1 17 10 Torque Limit 4.4 lb/ft (6 Nm) 2 19 14 7 12 25 16 12 3 16 15 13 26 PH0940 OIL LE VE L 18 5 4 8 24 9 23 8 9 7 6 NOTE: Apply Item 26 to all Item 6. Torque limit 17 lb/ft (23 Nm).
PAGE 69
SECTION 3 GEARBOX HOUSING (S/N 9909 & After) Item No. 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 Part Number 1319219 10731736 10731737 10731738 10731739 1319220 10731741 10731742 10731743 10731744 10731745 10731746 10731747 10731748 10731749 10731750 10731751 10731752 10731753 10731754 1319221 10731756 1319222 10731758 10731759 8526052 8042/10042/10054 Rev. 2/00 Qty.
PAGE 70
SECTION 3 CLUTCH PACK 1ST GEAR - 1 OF 2 (S/N 9909 & After) 33 32 15 29 30 31 13 19 14 1 5 4 3 6 7 8 9 10 14 12 2 8 11 13 21 12 22 8 20 25 23 24 26 17 16 28 24 27 37 15 16 17 18 36 35 34 38 PH1100 66 8042/10042/10054 Origin 7/99
PAGE 71
SECTION 3 CLUTCH PACK 1ST GEAR - 1 OF 2 (S/N 9909 & After) Item No.
PAGE 72
SECTION 3 CLUTCH PACK 1ST GEAR - 2 OF 2 (S/N 9909 & After) 33 32 15 29 30 31 13 19 14 1 5 4 3 6 7 8 9 10 14 12 2 8 11 13 21 12 22 8 20 25 23 24 26 17 16 28 24 27 37 15 16 17 18 36 35 34 38 PH1100 68 8042/10042/10054 Origin 7/99
PAGE 73
SECTION 3 CLUTCH PACK 1ST GEAR - 2 OF 2 (S/N 9909 & After) Item No. 8 (cont.
PAGE 74
SECTION 3 CLUTCH PACK 2ND GEAR - 1 OF 2 (S/N 9909 & After) 26 28 26 27 26 30 29 14 1 6 19 4 5 3 16 17 10 7 8 13 2 11 9 12 15 14 24 22 21 15 23 20 16 18 17 25 11 13 9 18 34 32 35 31 33 31 31 PH1110 70 8042/10042/10054 Origin 7/99
PAGE 75
SECTION 3 CLUTCH PACK 2ND GEAR - 1 OF 2 (S/N 9909 & After) Item No. Part Number Qty.
PAGE 76
SECTION 3 CLUTCH PACK 2ND GEAR - 2 OF 2 (S/N 9909 & After) 26 28 26 27 26 30 29 14 1 6 19 4 5 3 16 17 10 7 8 13 2 11 9 12 15 14 24 22 21 15 23 20 16 18 17 25 11 13 9 18 34 32 35 31 33 31 31 PH1110 72 8042/10042/10054 Origin 7/99
PAGE 77
SECTION 3 CLUTCH PACK 2ND GEAR - 2 OF 2 (S/N 9909 & After) Item No.
PAGE 78
SECTION 3 CLUTCH PACK 3RD GEAR - 1 OF 2 (S/N 9909 & After) 1 9 6 5 8 7 15 16 13 14 17 2 10 3 4 12 11 42 38 39 40 41 18 19 18 28 17 27 26 19 24 22 23 21 20 20 21 36 37 28 35 22 31 32 34 30 33 25 29 46 45 44 43 47 PH1120 74 8042/10042/10054 Origin 7/99
PAGE 79
SECTION 3 CLUTCH PACK 3RD GEAR - 1 OF 2 (S/N 9909 & After) Item No.
PAGE 80
SECTION 3 CLUTCH PACK 3RD GEAR - 2 OF 2 (S/N 9909 & After) 1 9 6 5 8 7 15 16 13 14 17 2 10 3 4 12 11 42 38 39 40 41 18 19 18 28 17 27 26 19 24 22 23 21 20 20 21 36 37 28 35 22 31 32 34 30 33 25 29 46 45 44 43 47 PH1120 76 8042/10042/10054 Origin 7/99
PAGE 81
SECTION 3 CLUTCH PACK 3RD GEAR - 2 OF 2 (S/N 9909 & After) Item No.
PAGE 82
SECTION 3 OUTPUT SHAFT (S/N 9909 & After) 56 7 8 2 Torque Limit 25 lb/ft (34 Nm) OIL LE VE L 10 9 11 10 12 1 6 5 8 7 4 12 3 PH1130 78 8042/10042/10054 Origin 7/99
PAGE 83
SECTION 3 OUTPUT SHAFT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number 10731953 10731954 10731955 10731956 10839156 10731957 10731958 10731959 10731960 10731961 10731962 10731963 10731964 10731965 10731966 10731967 10731968 10731969 10731970 10731971 10731972 10731973 10731974 10731975 10731976 10731977 8042/10042/10054 Rev. 2/00 Qty.
PAGE 84
SECTION 3 PARKING BRAKE (S/N 9909 & After) 22 15 PH0940 16 12 11 10 NOTE: Apply Item 22 to all Item 14. Torque limit 7 lb/ft (9,5 Nm).
PAGE 85
SECTION 3 PARKING BRAKE (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 10731981 10731982 10731983 10731984 10731985 10731986 10731987 10731988 10732097 10732093 10732094 10732095 1319237 10731980 10731751 10732098 10732099 10732099 10732101 10731978 10731979 8526052 8042/10042/10054 Rev. 2/00 Qty.
PAGE 86
SECTION 3 POWER TAKE-OFF SHAFT (S/N 9909 & After) 8 3 7 4 7 5 6 9 10 2 1 OIL LE VE L PH1150 82 8042/10042/10054 Origin 7/99
PAGE 87
SECTION 3 POWER TAKE-OFF SHAFT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 10731989 1319238 1319218 1319240 10731992 10731993 10731994 10731995 10731996 10731997 10731998 10731999 10732000 10732001 10732002 10732003 10732004 1319241 1319242 1319243 1319244 1319245 1319246 1319247 1319248 1319249 1319250 1319251 1319252 10732005 10731845 1319253 1319254 1319255 8042/10042/10054 Rev. 2/00 Qty.
PAGE 88
SECTION 3 GEARSHIFT SYSTEM (S/N 9909 & After) 7 8 9 11 12 1 11 10 2 Torque Limit 17 lb/ft (23 Nm) 3 4 19 18 17 21 20 16 15 14 13 6 5 PH1160 84 8042/10042/10054 Origin 7/99
PAGE 89
SECTION 3 GEARSHIFT SYSTEM (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 1319256 10732007 1319257 10732009 1319220 10731710 10732011 10732012 10732013 1319259 10731710 1319260 10732017 10731709 1319261 10837660 10732021 10732022 10732023 10732024 10732025 8042/10042/10054 Origin 7/99 Qty.
PAGE 90
SECTION 3 CONTROL VALVE (S/N 9909 & After) 1 49 47 48 43 Torque Limit 4 lb/ft (5,5 Nm) 42 39 40 29 41 28 36 19 31 20 38 35 37 34 33 32 44 30 22 46 45 2 10 11 4 3 9 5 17 8 51 50 18 21 12 53 54 7 23 52 55 6 13 15 16 14 24 25 27 26 Torque Limit 4 lb/ft (5,5 Nm) PH1170 86 8042/10042/10054 Origin 7/99
PAGE 91
SECTION 3 CONTROL VALVE (S/N 9909 & After) Item No.
PAGE 92
SECTION 3 TRANSMISSION FILTER & DIPSTICK (S/N 9909 & After) 11 12 11 12 7 9 8 11 12 15 10 17 18 11 12 14 12 11 13 16 OIL LE VE L Torque Limit 17 lb/ft (23 Nm) 2 5 6 4 3 88 1 3 PH1180 8042/10042/10054 Origin 7/99
PAGE 93
SECTION 3 TRANSMISSION FILTER & DIPSTICK (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number 10731923 10731924 10731925 10731926 1319271 1319272 1319273 10732071 1319274 10732083 10732076 10732018 10732078 8035733 8035734 10731743 10732081 10732082 8042/10042/10054 Rev. 2/00 Qty.
PAGE 94
SECTION 3 OIL TUBES (S/N 9909 & After) 9 8 7 11 10 2 2 1 6 8 1 2 1 9 2 1 1 5 2 4 2 1 1 2 3 2 1 PH1210 90 8042/10042/10054 Origin 7/99
PAGE 95
SECTION 3 OIL TUBES (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 Part Number 1319275 10732085 1319276 1319277 1319278 1319279 10732089 10732090 10732091 10732092 10732085 8042/10042/10054 Origin 7/99 Qty.
PAGE 96
SECTION 3 TRANSMISSION MOUNTING (S/N 9909 & After) Torque to 48 lb/ft (65 Nm) Torque to 35 lb/ft (47 Nm) 17 16 18 1 4 Front Torsion Coupler 29 3 13 Torque to 32 - 37 lb/ft (43 - 50 Nm) Torque to 34 lb/ft (46 Nm) 14 15 20 21 19 26 22 27 2 13 19 11 25 24 23 15 Torque to 302 lb/ft (409 Nm) 12 28 6 Torque to 34 lb/ft (46 Nm) 9 Torque to 32 - 37 lb/ft (43 - 50 Nm) 8 12 11 Torque to 302 lb/ft (409 Nm) 5 7 10 PH1240 92 8042/10042/10054 Origin 2/00
PAGE 97
SECTION 3 TRANSMISSION MOUNTING (S/N 9909 & After) Item No. 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 Part Number 8841040 7150192 7150182 7150202 7138186 7150082 7054351 8278007 8303724 8310067 8310427 8307047 8882009 7138208 8880218 8310425 8307006 8880219 8302470 8303519 8307025 8307220 10136599 10701363 10701562 10238805 10138907 10715335 8630016 8042/10042/10054 Origin 2/00 Qty.
PAGE 98
SECTION 3 DRIVE SHAFT - ENGINE TO TRANSMISSION (S/N 9908 & Before) To Engine 8 1 2 Cap Retaining Ring Felt Seal 5 4 6 3 Torque to 55 - 60 lb/ft (75 - 81 Nm) 7 PH0452 94 8042/10042/10054 Rev.
PAGE 99
SECTION 3 DRIVE SHAFT - ENGINE TO TRANSMISSION (S/N 9908 & Before) Item No. 1 2 3 4 5 6 7 8 Part Number 7096592 8033798 8033009 8033797 8033007 8033796 8880218 6619261 8042/10042/10054 Rev. 7/99 Qty.
PAGE 100
SECTION 3 DRIVE SHAFT - ENGINE TO TRANSMISSION (S/N 9909 & After) 16 To Engine 15 1 Torque to 48 lb/ft (65 Nm) 7 4 2 6 5 3 11 13 12 9 10 8 4 6 Torque to 35 lb/ft (47 Nm) 5 14 PH2040 96 8042/10042/10054 Origin 7/99
PAGE 101
SECTION 3 DRIVE SHAFT - ENGINE TO TRANSMISSION (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number 7150202 8035618 8034593 8035620 8035628 8035622 8033652 8035617 8033003 8033004 8035623 8035624 8035625 8880219 8310425 8307006 8042/10042/10054 Origin 7/99 Qty.
PAGE 102
SECTION 3 DRIVE SHAFT - FRONT AND REAR (S/N 9908 & Before) 9 1 2 Torque to 55 - 60 lb/ft (75 - 81 Nm) 4 3 8 7 6 Cap Retaining Ring Felt Seal 5 4 10 Torque to 32 - 37 lb/ft (43 - 50 Nm) PH0421 98 8042/10042/10054 Rev.
PAGE 103
SECTION 3 DRIVE SHAFT - FRONT AND REAR (S/N 9908 & Before) Item No. Part Number Qty. 1 2 7096632 7099832 1 1 3 4 5 6 7 8 9 10 8033097 8033009 8033006 8033007 8033008 8033098 8880218 8882009 1 2 1 1 1 1 2 2 8042/10042/10054 Rev.
PAGE 104
SECTION 3 DRIVE SHAFT - FRONT AND REAR (S/N 9909 & After) 2 1 2 2 2 3 PH1340 100 8042/10042/10054 Origin 2/00
PAGE 105
SECTION 3 DRIVE SHAFT - FRONT AND REAR (S/N 9909 & After) Item No. 1 2 3 Part Number 7150192 8035778 7150182 8042/10042/10054 Origin 2/00 Qty.
PAGE 106
SECTION 3 DIFFERENTIAL CARRIER ASSEMBLY 44 43 39 37 1 2 10* 3 35 31** 43 40 44 6 36 42 30** 25** 34** 10* 4 27** 29** 29** 38 5 34** 7 33** 28** 45 41 34** 11* 33** 29** 28** 26** 32** 9* 31** 3 2 15 *Item 8 Includes These Parts **Item 24 Includes These Parts ITEM 14 SPACER, PINION BEARING CHART PART NO. THICKNESS 8034506 .5135" 8034507 .5165" 8034508 .5195" 8034509 .5225" 8034510 .5245" 8034511 .5255" 8034512 .5265" 8034513 .5275" 8034514 .5285" 8034515 .5295" 8034516 .
PAGE 107
SECTION 3 DIFFERENTIAL CARRIER ASSEMBLY Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number Qty.
PAGE 108
SECTION 3 AXLE STEERING JOINTS 18 19 20 21 8 14 7 13 15 21 5 16 17 20 4 19 10 9 18 6 2 11 1 3 12 Torque to 80 - 100 lb/ft (109 - 136 Nm) 17 16 15 14 13 PH0270 104 8042/10042/10054 Rev.
PAGE 109
SECTION 3 AXLE STEERING JOINTS Item No. Part Number Qty. Description NOTE: Quantities are for one axle. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 8033815 8033816 8033817 8033818 8033805 8033009 8033804 8033820 8033821 8033822 8033823 8032876 8032875 8032877 8033824 8032880 8032881 8032882 8032979 8032883 8032885 8032886 8042/10042/10054 Rev.
PAGE 110
SECTION 3 AXLE WHEEL ENDS (S/N 0460 & Before) 28 29 26 1 31 30 44 40 37 41 43 25 Torque to 450 - 500 lb/ft (610 - 678 Nm) 38 24 39 42 35 PH0920 PH0910 46 36 23 45 34 22 33 32 21 20 PH0910 19 47 14 27 10 17 Torque to 45 - 50 lb/ft (61 - 67 Nm) 13 11 12 3 11 10 8 9 7 18 4 5 16 6 15 50 49 48 2 Kit Kit PF0791 PF0791 Torque to 90 - 100 lb/ft (122 - 136 Nm) Kit PF0791 PH0642 106 8042/10042/10054 Rev.
PAGE 111
SECTION 3 AXLE WHEEL ENDS (S/N 0460 & Before) Item No. 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 Part Number Qty.
PAGE 112
SECTION 3 AXLE WHEEL ENDS (S/N 0461 & After) 29 30 1 26 31 32 45 38 44 41 25 42 39 24 Torque to 450 - 500 lb/ft (610 - 678 Nm) 40 43 PH0920 PH0910 36 46 47 37 23 35 22 34 33 21 PH0910 20 48 19 3 14 17 28 10 27 13 11 12 11 Torque to 130 - 140 lb/ft (176 - 190 Nm) 10 8 9 7 18 4 5 16 15 50 49 Kit PF0791 6 51 Kit PF0791 2 Torque to 90 - 100 lb/ft (122 - 136 Nm) Kit PF0791 PH0643 108 8042/10042/10054 Rev.
PAGE 113
SECTION 3 AXLE WHEEL ENDS (S/N 0461 & After) Item No. 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 Part Number Qty.
PAGE 114
SECTION 3 TIE ROD AND STEERING CYLINDER MOUNTING See “Steering Cylinder” 11 10 9 5 3* 11 10 4 9 6 2 ACTUAL SIZE 6 1 8 7* 9 1-1/8-16 Item #3 P/N 8033962 Front 1-1/8-12 Item #7 P/N 8033964 *IMPORTANT: When replacing Socket Assembly (Items #3 or 7) measure the threads per inch to ensure ordering the correct socket. The tie rod is symetrical and could be assembled to the axle opposite as shown above. PH0282 110 8042/10042/10054 Rev.
PAGE 115
SECTION 3 TIE ROD AND STEERING CYLINDER MOUNTING Item No. Part Number Qty. Description NOTE: Quantities listed are for one axle. 1 2 3 8033960 8033961 8033962 1 1 1 4 5 6 7 8033963 8033965 8032930 8033964 1 1 2 1 8 9 10 11 8033963 8033965 8340025 8032816 1 3 2 AR 8042/10042/10054 Rev.
PAGE 116
SECTION 3 WHEELS AND TIRES - 8042 ! Warning Mis-Matched tire sizes or mixing of tire types (Radial and Bias ply) may compromise vehicle stability and may result in vehicle tipover. 5 17 25 34 44 1 13 21 29 39 33 38 43 48 7 19 27 36 45 6 18 26 35 46 4 8 16 47 20 24 28 32 37 42 2 14 22 30 41 3 15 23 31 40 11 9 10 12 PH0461 112 8042 Rev.
PAGE 117
SECTION 3 WHEELS AND TIRES - 8042 Item No. Part Number Qty.
PAGE 118
SECTION 3 WHEELS AND TIRES - 10042/10054 ! Warning Mis-Matched tire sizes or mixing of tire types (Radial and Bias ply) may compromise vehicle stability and may result in vehicle tipover. 3 7 6 4 8 2 5 1 10 14 15 11 14 10 12 & 16 9 13 18 22 23 19 22 18 20 & 24 21 114 17 PH0651 10042/10054 Rev.
PAGE 119
SECTION 3 WHEELS AND TIRES - 10042/10054 Item No. 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 Number 7099532 7098733 8780037 8786514 7099522 7098733 8780037 8786514 7099702 7110333 8780035 8786559 7099692 7110333 8780035 8786559 7110352 7110333 8780037 8786559 7110342 7110333 8780037 8786559 10042/10054 Rev. 12/97 Qty. 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 Description Tire & Wheel Ass’y, Right Side - 17.5 x 25, 12 Ply (Includes Items 2 thru 4) Wheel, 1325LR x 1.
PAGE 120
SECTION 4 POWER PLANT SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (S/N 0118 & Before) 2 3 4 12 67 1 Left Side Engine Mount 14 15 16 17 5 13 Left Side of Engine 6 7 10 8 9 63 44 64 11 66 65 19 20 59 58 58 44 41 43 44 42 56 55 54 50 18 62 21 57 61 11 10 22 60 48 56 23 58 24 25 47 51 52 47 46 39 46 26 32 53 37 49 38 33 34 39 35 41 28 36 45 40 44 31 30 29 27 42 43 44 69 PS0940 116 10 11 68 PS0950 PH0077 8042/10042 Rev.
PAGE 121
SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (S/N 0118 & Before) Item No.
PAGE 122
SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (S/N 0119 thru 1598) 2 3 4 12 65 Left Side Engine Mount 1 13 14 15 16 17 5 Left Side of Engine 10 7 6 8 61 11 62 9 64 63 43 20 58 57 19 57 18 43 41 42 43 55 53 54 40 11 10 22 50 60 55 48 55 57 45 51 52 47 46 26 37 39 55 41 42 67 PS0940 25 32 35 36 28 31 43 24 11 10 33 34 38 46 45 49 44 23 59 46 47 21 56 44 30 29 27 66 PS0950 PH0076 118 8042/10042/10054 Rev.
PAGE 123
SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (S/N 0119 thru 1598) Item No.
PAGE 124
SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (EPA) (S/N 1599 & After) Left Side Engine Mount 2 3 4 1 12 60 14 15 16 17 5 13 Left Side of Engine 56 54 6 10 7 38 11 8 55 20 19 57 50 49 18 9 49 38 46 35 37 10 22 47 36 45 44 53 47 21 48 52 58 59 51 11 49 47 42 11 38 23 27 24 25 41 39 61 32 11 26 16 40 41 39 28 33 43 29 34 36 37 38 30 63 62 PS0940 PS0940 120 64 31 52 47 10 PS0950 PH0075 8042/10042/10054 Rev.
PAGE 125
SECTION 4 ENGINE, RADIATOR AND OIL COOLER MOUNTING (EPA) (S/N 1599 & After) Item No. 1 Part Number Qty.
PAGE 126
SECTION 4 TORSION COUPLER (S/N 9909 & After) 1 2 3 4 5 To Engine 6 PH1230 122 8042/10042/10054 Origin 7/99
PAGE 127
SECTION 4 TORSION COUPLER (S/N 9909 & After) Item No. 1 2 3 4 5 6 Part Number 7137643 8035555 8035556 8035557 8035558 8035559 8042/10042/10054 Origin 7/99 Qty. 1 1 1 6 6 1 Description Coupling Assembly, Torsion (Includes Items 2 thru 6) Assembly, Shaft and Bearing Housing, Protective Bolt, Hex Hd.
PAGE 128
SECTION 4 EXHAUST SYSTEM To Turbo Charger 1 2 5 6 8 3 4 7 9 4 10 11 10 PH0091 124 8042/10042/10054 Rev.
PAGE 129
SECTION 4 EXHAUST SYSTEM Item No. 1 2 3 4 5 6 7 8 9 10 11 Part Number 8275240 7126953 7088283 8275247 8275212 8275248 8275212 8303621 8307204 8305645 7127022 7110022 7126962 7086742 7126992 7097452 7126922 7079162 8042/10042/10054 Rev. 2/00 Qty. 1 1 1 1 1 2 2 2 2 2 1 1 1 1 2 2 1 1 Description Clamp, V-Band Pipe, Exhaust (S/N 1599 & After) Pipe, Exhaust (S/N 1598 & Before) Clamp, Muffler 3.00" (S/N 1599 & After) Clamp, Muffler 2.50" (S/N 1598 & Before) Clamp, Muffler 2.
PAGE 130
SECTION 4 AIR CLEANER 4 5 3 7 1 2 8 18 6 9 19 10 16 11 14 17 13 15 14 12 PH0081 126 8042/10042/10054 Rev.
PAGE 131
SECTION 4 AIR CLEANER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part Number 7097323 8273240 7095302 8303697 8307203 8305626 8303618 8307025 8273241 8273013 8032764 8273237 8273238 8273272 8032762 8405307 7095393 8405404 8405305 8042/10042/10054 Rev. 2/00 Qty. 1 2 1 4 4 4 2 2 1 1 1 1 1 2 1 1 1 1 1 Description Scoop, Air Intake Band, Air Cleaner Mounting Bracket, Air Cleaner Mounting HHCS, 0.31 x 0.
PAGE 132
SECTION 4 FUEL SYSTEM (S/N 1598 & Before) Engine Is Turned Around 180° From Mounted Position For Clarity 10 9 11 8 5 4 7 6 10 3 12 2 1 19 Fuel Supply 22 10 14 13 20 13 15 16 Fuel Return 10 17 10 22 21 18 PH0031 128 8042/10042/10054 Rev.
PAGE 133
SECTION 4 FUEL SYSTEM (S/N 1598 & Before) Item No. Part Number Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7136034 7138209 NLA 7138714 NLA 8305626 7118222 8310163 8430007 8410009 7127881 8274022 7127871 7125421 8640903 8541435 8430034 8430035 1 1 1 1 1 4 1 5 1 4 1 1 1 1 1 1 1 1 19 20 21 22 8320250 8320253 8630012 8405009 1 1 2 2 8042/10042/10054 Rev.
PAGE 134
SECTION 4 FUEL SYSTEM (EPA) (S/N 1599 & After) Engine Is Turned Around 180° From Mounted Position For Clarity 9 10 11 8 5 4 7 6 10 12 3 2 20 10 14 13 1 21 Fuel Supply 13 15 16 Fuel Return 10 17 14 20 19 18 PH0032 130 8042/10042/10054 Rev.
PAGE 135
SECTION 4 FUEL SYSTEM (EPA) (S/N 1599 & After) Item No. 1 2 3 4 5 Part Number Qty. 6 7 8 9 10 11 12 13 14 15 16 17 18 7136034 7138209 NLA 7138714 NLA 8322029 8305626 7118222 8310163 8430007 8410009 7127881 8274022 7127871 7127081 8640903 8541435 8430034 8430064 1 1 1 1 1 1 4 1 5 1 4 1 1 1 1 1 1 1 1 19 20 21 8630012 8405009 8320270 2 2 1 8042/10042/10054 Rev.
PAGE 136
SECTION 5 HYDRAULIC CIRCUITS SECTION 5 POWER STEERING CIRCUIT (S/N 9908 & Before) 32 36 24 23 To Port “CF” 33 1 39 Load Sense Port 41 19 To Port “EF” Outlet Port 42 38 25 1 26 2 2 4 To Port “T” To Port “LS” 28 33 20 17 18 8 35 5 37 12 L T L P R T 7 13 P 21 Front Steering Cylinders Main Control Valve (Rotated For Clarity) 10 16 11 34 35 7 7 P R 11 8 T L 15 14 9 12 17 19 20 21 14 To Port “3” 1 Inlet Port 4 6 7 2 9 18 Front 14 29 4 32 28 To Port “1”
PAGE 137
SECTION 5 POWER STEERING CIRCUIT (S/N 9908 & Before) Item No.
PAGE 138
SECTION 5 POWER STEERING CIRCUIT (S/N 9909 & After) 22 To Port “CF” 31 35 Load Sense Port 32 46 38 23 13 47 43 To Port “EF” To Port “T” To Port “LS” 44 42 18 24 1 25 2 2 6 To Port “2” 26 21 27 To Port “1” 13 16 5 19 7 11 16 P R Main Control Valve (Rotated For Clarity) 7 34 4 36 11 L 34 T L P R T 12 P 20 Front Steering Cylinders 6 9 15 10 T 6 6 8 1 Inlet Port 17 33 20 13 To Port “3” 32 L 10 13 6 8 18 14 48 49 27 31 3 Front Rear Steering Cylinders 5
PAGE 139
SECTION 5 POWER STEERING CIRCUIT (S/N 9909 & After) Item No.
PAGE 140
SECTION 5 CONTROL VALVES CIRCUIT (S/N 9908 & Before) See “Hydraulic Reservoir” Main Pump 5 28 19 Control Drain Port 21 26 2 3 18 20 5 4 2 27 22 19 Inlet Port Main Control Valve 2 1 See “Main Pump” 12 7 8 Load Sense Port 11 13 Inlet Port 1 6 7 Front 8 14 9 6 10 17 12 Outlet Port 16 24 15 T P Axle Stabilizer Valve P Port “P” 22 23 13 See “Secondary Control Valve” 21 21 25 See “Main Control Valve” (Rotated For Clarity) BR K 2 29 Underneath View of Valve Plate See “Valve
PAGE 141
SECTION 5 CONTROL VALVES CIRCUIT (S/N 9908 & Before) Item No. 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 Part Number 2713292 2712942 8760117 8770015 2713442 2711872 8760401 8760504 8760482 8760118 8760474 6605202 2711972 8760457 8760141 8760107 8760493 7121013 8304624 7099072 8307206 8307007 8310337 8305012 8310178 8640405 8307206 8584007 6604882 8042/10042/10054 Rev. 2/00 Qty. 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 6 1 7 5 1 3 2 1 AR 1 1 Description Hose, .75 I.D.
PAGE 142
SECTION 5 CONTROL VALVES CIRCUIT (S/N 9909 & After) See “Hydraulic Reservoir” 26 2 3 25 1 38 37 19 36 Main Pump Inlet Port 35 2 2 17 21 18 4 11 4 6 12 7 8 Load Sense Port 33 13 1 32 10 31 34 9 30 Front 29 5 16 15 12 28 20 23 14 20 24 21 22 T P See “Secondary Control Valve” 11 5 Port “P” P BR Axle Stabilizer Valve See “Main Control Valve” (Rotated For Clarity) K 2 27 Underneath View of Valve Plate See “Valve Plate Assembly” 138 To Priority Valve “P” Port Tee PH1370
PAGE 143
SECTION 5 CONTROL VALVES CIRCUIT (S/N 9909 & After) Item No.
PAGE 144
SECTION 5 BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT (S/N 9908 & Before) 18 9 3 2 17 4 16 Boom 15 1 10054 Only 6 7 8 Extend Port Retract Port 5 11 Raise Port 12 Lower Port Front 10 14 13 A - Boom Extend Port B - Boom Retract Port C - Boom Raise Port Extend D - Boom Lower Port Retract D B Lower Port 10 4 4 9 Raise Port Main Control Valve (Rotated for Clarity) 9 C A PH0161 140 8042/10042/10054 Rev.
PAGE 145
SECTION 5 BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT (S/N 9908 & Before) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number Qty. 7133802 7133812 8760039 2713262 8760305 8305626 8769128 8769127 8760109 1 1 2 2 2 1 1 1 4 8760109 3 2713282 2711852 8584007 8760111 8760483 8770030 8902251 8770012 8760317 2 2 1 2 2 1 1 1 1 8042/10042/10054 Rev. 2/00 Description Tube, Boom Ext. Cyl. Tube, Boom Ext. Cyl. Union, Bulkhead, Straight, SAE 12 - male JIC 37° Hose, .62 I.D.
PAGE 146
SECTION 5 BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT (S/N 9909 & After) 5 5 3 4 13 Boom 15 17 14 16 2 5 1 10054 Only 6 7 8 Extend Port Retract Port 5 10 18 12 19 Front 11 A - Boom Extend Port B - Boom Retract Port C - Boom Raise Port Extend D - Boom Lower Port Retract 12 D 18 19 4 4 14 9 5 14 B Lower Port 5 Raise Port Main Control Valve (Rotated for Clarity) C A PH1380 142 8042/10042/10054 Origin 2/00
PAGE 147
SECTION 5 BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part Number 7133802 7133812 8760039 7150452 8760305 8305626 8769128 8769127 2711852 8584007 8760111 8760483 8902251 8770157 8760134 8760138 2716516 7150442 7150432 8042/10042/10054 Origin 2/00 Qty. 1 1 2 2 5 1 1 1 2 1 2 2 1 2 1 1 1 1 1 Description Tube, Boom Ext. Cyl. Tube, Boom Ext. Cyl. Union, Bulkhead, Straight, SAE 12 - male JIC 37° Hose, .62 I.D.
PAGE 148
SECTION 5 ATTACHMENT TILT AND SLAVE CIRCUIT 22 23 25 24 3 12 8 4 PH0940 5 1 26 2 28 11 NOTE: Secure Items 10 & 12 with Item 28 8 27 20 10 9 6 8 7 Retract Port 6 14 13 20 Retract Port Extend Port 20 15 Extend Port 15 18 23 23 21 16 20 21 17 18 10054 Only 18 18 19 Extend Port Secondary Control Valve Retract Port T P Front 20 29 P Extend Port Kit PF0791 BR K Retract Port 18 Underneath View of Valve Plate See “Valve Plate Assembly” PH0172 144 8042/10042/10054 R
PAGE 149
SECTION 5 ATTACHMENT TILT AND SLAVE CIRCUIT Item No. 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 Part Number Qty.
PAGE 150
SECTION 5 FRAME TILT AND STABILIZER CIRCUIT Retract Port 3 4 5 5 Extend Port 4 4 7 5 2 Retract Port Extend Port 1 5 1 1 1 1 Front 6 To Port “TC” Secondary Control Valve 5 Pressure Reducing Valve T P To Port “SB” Stabilizer Valve See Page 205 Steer Select Valve P BR 5 K To Port “SR” Underneath View of Valve Plate PH0181 146 8042/10042/10054 Rev.
PAGE 151
SECTION 5 FRAME TILT AND STABILIZER CIRCUIT Item No. 1 2 3 4 5 6 7 Part Number 2711892 8770012 8760276 8760134 2713332 8760110 8760268 8042/10042/10054 Rev. 12/97 Qty. 2 1 1 3 2 1 1 Description Hose, .38 I.D. x 130" Long Elbow, 90° SAE 6-4 - male JIC 37° x male str. thd. o-ring Elbow, 45°, SAE 6 - male JIC 37° x female JIC 37° swivel Connector, Straight, SAE 6-4 - male JIC 37° x male str. thd. o-ring Hose, .38 I.D. x 96" Long Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd.
PAGE 152
SECTION 5 SERVICE BRAKE AND DE-CLUTCH CIRCUIT Hydraulic Reservoir 10 11 12 13 5 14 18 8 6 9 7 9 7 6 4 9 19 3 2 1 6 10 7 17 15 16 11 7 9 3 Front Pressure Reducing Valve Port “C1” 10 P BR To Transmission De-Clutch K Port “C2” To Port “BRK” 11 To Transmission Emergency Brake 3 Underneath View of Valve Plate - See “Valve Plate Assembly” PH0193 148 8042/10042/10054 Rev.
PAGE 153
SECTION 5 SERVICE BRAKE AND DE-CLUTCH CIRCUIT Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part Number NLA 7119813 8902222 8760110 2712332 2705122 6604972 8760455 8406105 6605772 2712092 6611752 6604712 8760011 8760113 8584007 8760501 8430046 8430032 6605772 2712012 8760276 8042/10042/10054 Rev. 2/00 Qty.
PAGE 154
SECTION 5 VALVE PLATE ASSEMBLY (Without Outriggers 8042 Only) 12 13 34 33 11 7 32 6 17 14 5 9 24 13 3 2 37 To Control Valve “P” Port Tee 10 24 16 20 35 26 V S R S B T C T P 3 4 36 1 8 25 15 12 19 22 20 18 35 To Priority Valve “P” Port Tee 27 T 21 23 NOTE: O-rings must be replaced whenever replacing Item 16 or Item 21. Return to Tank 28 29 30 31 Front Valve Plate Shown as Mounted for Clarity PH0122 150 8042 Rev.
PAGE 155
SECTION 5 VALVE PLATE ASSEMBLY (Without Outriggers 8042 Only) Item No. 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 8042 Rev. 2/00 Part Number Qty.
PAGE 156
SECTION 5 VALVE PLATE ASSEMBLY (With Outriggers 10042/10054 Only) 35 39 32 35 20 40 38 37 39 38 12 13 40 43 7 39 32 20 6 3 33 34 11 35 36 13 24 5 9 2 To Control Valve “P” Port Tee 14 10 17 16 26 3 24 23 41 4 3 P BR K P 1 32 43 19 22 8 8 15 25 To Priority Valve “P” Port Tee 27 28 42 18 41 21 23 NOTE: O-rings must be replaced whenever replacing Item 16 or Item 21. Return to Tank 29 30 31 Front Valve Plate Shown as Mounted for Clarity PH0112 152 10042/10054 Rev.
PAGE 157
SECTION 5 VALVE PLATE ASSEMBLY (With Outriggers 10042/10054 Only) Item No. 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 38 39 40 41 42 43 Part Number Qty.
PAGE 158
SECTION 5 TRANSMISSION COOLING CIRCUIT (S/N 9908 & Before) Transmission Transmission Oil Cooler 2 2 2 2 1 4 3 PH0202 154 8042/10042/10054 Rev.
PAGE 159
SECTION 5 TRANSMISSION COOLING CIRCUIT (S/N 9908 & Before) Item No. 1 2 3 4 Part Number 6604912 8760109 7124471 8584007 8042/10042/10054 Rev. 2/00 Qty. 2 4 2 2 Description Hose, .75 I.D. x 113" Long Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring Conduit, 1 I.D. x 12.5" Tie, plastic, .5 x 20.
PAGE 160
SECTION 5 TRANSMISSION COOLING CIRCUIT (S/N 9909 & After) 6 7 1 3 1 2 2 Transmission Oil Cooler 2 5 4 7 5 4 Transmission PH1390 156 8042/10042/10054 Origin 2/00
PAGE 161
SECTION 5 TRANSMISSION COOLING CIRCUIT (S/N 9909 & After) Item No. 1 2 3 4 5 6 7 Part Number 7150282 8760254 8760305 8630017 8770158 8770157 8760431 8042/10042/10054 Origin 2/00 Qty. 2 3 1 2 2 1 2 Description Hose, .75 I.D. x 105" Long Elbow, 90°, SAE 12 - male JIC 37° x female JIC 37° swivel Elbow, 90° SAE 12 - male JIC 37° x male str. thd. o-ring O-Ring, 23mm x 2mm Connector, M26 x 12 - 37° Flare Elbow, Long, 90° SAE 12-12 - male JIC 37° x male str. thd. o-ring Plug, Hex Hd., SAE 12 - male str. thd.
PAGE 162
SECTION 5 AUXILIARY HYDRAULIC CIRCUIT (Optional) 12 31 28 4 5 30 1 2 29 11 3 10 6 8 13 9 7 7 14 20 21 27 15 26 22 23 24 25 19 17 Port “B” 16 Port “A” 18 32 Kit Underneath View of Valve Plate See “Valve Plate Assembly” PF0791 PH0212 158 8042/10042/10054 Rev.
PAGE 163
SECTION 5 AUXILIARY HYDRAULIC CIRCUIT (Optional) Item No. 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 Part Number 8310081 8307004 8307203 7111402 8303679 8303622 8769161 8750003 2713082 8769122 8303757 7133843 7133853 8760037 2713212 8760264 2712872 8760107 8760143 8420055 8420053 8430006 8640029 8430005 8640029 8640028 8640032 8760142 8760045 7112452 NSS 8584001 2713642 Qty.
PAGE 164
SECTION 5 OUTRIGGER HYDRAULIC CIRCUIT (10042/10054 Only) 5 1 6 4 1 2 3 5 Extend Port 1 Retract Port 2 Retract Port 1 Extend Port 3 Front Port “B2” 6 Outrigger Valve Secondary Control Valve Port “B1” To Left Cylinder Extend Port Port “A1” To Left Cylinder Retract Port Port “A2” Steer Select Valve Pressure Reducing Valve To Right Cylinder Extend Port To Right Cylinder Retract Port Stabilizer Cylinder Valve Underneath View of Valve Plate See “Valve Plate Assembly” PH0412 160 10042/1005
PAGE 165
SECTION 5 OUTRIGGER HYDRAULIC CIRCUIT (10042/10054 Only) Item No. 1 2 3 4 5 6 Part Number 2711982 8760311 8584001 8584003 8760029 2712952 10042/10054 Rev. 12/97 Qty. 4 4 2 1 4 4 Description Hose Assembly, 3/8" I.D. Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring Tie Wrap (10054 Only) Tie Wrap Union, SAE 6 - male JIC 37° Hose Assembly, 3/8" I.D.
PAGE 166
SECTION 6 HYDRAULIC COMPONENTS SECTION 6 HYDRAULIC RESERVOIR 9 16 5 6 10 19 18 13 17 7 20 11 4 12 13 3 8 14 1 S/N 9499 & Before 2 15 25 2 Torque to 4 - 5 lb/ft (5 - 7 Nm) 9 See “Fuel Tank” 1 24 In 21 Hydraulic Reservoir 16 19 18 Drain Out 11 12 26 13 14 17 13 To Brake Valve 23 2 To Main Pump Inlet 22 6 PH0103 162 8042/10042/10054 Rev.
PAGE 167
SECTION 6 HYDRAULIC RESERVOIR Item No. 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 Part Number NLA 7136034 NLA 7138209 NLA NLA 7138714 NLA 8322029 8305626 8305626 7094562 8320265 8464012 8760118 8640903 8541435 8760110 8760110 8760501 8760351 8223217 8223226 8310129 8307009 8305014 7098271 8760102 7138164 8324029 8760419 8760451 8760107 8042/10042/10054 Rev. 2/00 Qty.
PAGE 168
SECTION 6 MAIN PUMP (S/N 9908 & Before) 55 2 3 4 5 6 7 8 15 14 13 9 18 16 22 17 12 11 19 23 24 45 10 21 25 26 53 52 9 51 48 49 50 47 27 54 28 29 30 31 8 20 9 46 33 32 40 39 34 37 36 38 35 41 41 44 37 38 39 41 36 42 40 1 42 57 56 41 58 43 PF0760 Kit PF0791 164 Torque to 80 lb/ft (108 Nm) Kit PH0292 8042/10042/10054 Rev.
PAGE 169
SECTION 6 MAIN PUMP (S/N 9908 & Before) Item No. Part Number Qty.
PAGE 170
SECTION 6 MAIN PUMP (S/N 9909 & After) *Item 2 3 7 9 10 17 47 55 56 58 60 1 33 6 32 5 4 34 56* 13 18 60* 61 17* 19 20 21 59 Torque values 13.3-17.8 lb/ft (18-24 Nm) 192.4-222 lb/ft (280-300 Nm) 21.5-23.7 lb/ft (29-32 Nm) 76.2-94 lb/ft (103-127 Nm) 76.2-94 lb/ft (103-127 Nm) 55.5-61.4 lb/ft (75-83 Nm) 2.7-3.3 lb/ft (3-4 Nm) 76.2-94 lb/ft (103-127 Nm) 23-27.4 lb/ft (31-37 Nm) 9.6-11 lb/ft (13-15 Nm) 11.1-11.
PAGE 171
SECTION 6 MAIN PUMP (S/N 9909 & After) Item No. 1 2 3 Part Number Qty.
PAGE 172
SECTION 6 BOOM EXTEND CYLINDER (Early Production) VENDOR STAMPING IMPORTANT: There are two similar but distinctly different Boom Extend Cylinders. Make sure you know which version you have before ordering replacement parts. On “Early Production” cylinders, the gland is installed flush with the cylinder tube and has “TJB” stamped on the gland. On the “Current Production” cylinders, the gland has a lip that bottoms out against the cylinder tube.
PAGE 173
SECTION 6 BOOM EXTEND CYLINDER (Early Production) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number NLA NSS 8902261 See Kits See Kits See Kits 8033734 8033735 See Kits See Kits 8033732 See Kits See Kits See Kits 8033733 8033737 8033738 Qty.
PAGE 174
SECTION 6 BOOM EXTEND CYLINDER (Current Production) IMPORTANT: VENDOR STAMPING There are two similar but distinctly different Boom Extend Cylinders. Make sure you know which version you have before ordering replacement parts. On Early Production cylinders, the gland is installed flush with the cylinder tube and has TJB stamped on the gland. On the Current Production cylinders, the gland has a lip that bottoms out against the cylinder tube.
PAGE 175
SECTION 6 BOOM EXTEND CYLINDER (Current Production) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part Number 2716173 NSS 8035800 8035539 8035616 8035615 8035536 8035315 8035514 See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits 8520013 Qty.
PAGE 176
SECTION 6 BOOM HOIST CYLINDER (S/N 5818 & Before) Torque to 45 - 50 lb/ft (61 - 68 Nm) 1 4 3 12 11 2 10 9 8 7 6 15 5 14 13 Torque to 600 lb/ft (814 Nm) and Stake 4 Places 16 17 PF0760 PH0231 172 8042/10042/10054 Rev.
PAGE 177
SECTION 6 BOOM HOIST CYLINDER (S/N 5818 & Before) Item No. Part Number Qty.
PAGE 178
SECTION 6 BOOM HOIST CYLINDER (S/N 5819 & After) 1 Retract Port 3 Extend Port 2 14 4 13 16 7 16 8 10 12 17 Torque to 45 - 50 lb/ft (61 - 68 Nm) 6 11 11 10 17 6 9 16 7 16 5 18 14 15 13 19 Loctite and Torque to 1750 - 2000 lb/ft (2373 - 2712 Nm) PF0760 20 PH2010 174 8042/10042/10054 Origin 7/99
PAGE 179
SECTION 6 BOOM HOIST CYLINDER (S/N 5819 & After) Item No. Part Number Qty.
PAGE 180
SECTION 6 FRAME TILT CYLINDER 3 15 7 Torque to 30 - 35 lb/ft (41 - 48 Nm) PF0760 16 6 PF0760 9 14 1 10 2 Extend Port 11 Retract Port 12 8 13 Apply Loctite # 271 to Threads 4 5 Torque to 450 lb/ft (610 Nm) and Stake 4 Places PH0362 176 8042/10042/10054 Rev.
PAGE 181
SECTION 6 FRAME TILT CYLINDER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number 7115662 2713853 NSS 8902511 8032726 See Kits See Kits 8033745 8033744 See Kits See Kits 8032728 See Kits See Kits 8033746 Qty.
PAGE 182
SECTION 6 STABILIZER CYLINDER 3 Sol. 2 Torque to 30 - 35 lb/ft (41 - 48 Nm) 1 Sol. 6 7 8 4 17 5 9 6 10 2 11 12 Extend Port 18 19 PF0760 13 16 Retract Port 14 15 Sol. 1 20 PF0760 Sol. 5 PF0760 PH0351 178 8042/10042/10054 Rev.
PAGE 183
SECTION 6 STABILIZER CYLINDER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 2713333 NSS 8902511 8033755 8033704 8033715 8032726 See Kits 8033745 See Kits See Kits See Kits 8032728 See Kits See Kits 8033744 8033721 Qty. 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 2 Description Cylinder, Stabilizer (Includes Items 2 thru 17) Tube, Cylinder (Serviced Only in Item 1) Valve, Pilot Check (See Kits) Solenoid Valve (See Kits) Solenoid Valve (See Kits) Orifice, .060 Dia.
PAGE 184
SECTION 6 SLAVE CYLINDER (Early Production) VENDOR STAMPING IMPORTANT: There are two similar but distinctly different Slave Cylinders. Make sure you know which version you have before ordering replacement parts. On “Early Production” cylinders, the gland is installed flush with the cylinder tube and has “TJB” stamped on the gland. On the “Current Production” cylinders, the gland has a lip that bottoms out against the cylinder tube.
PAGE 185
SECTION 6 SLAVE CYLINDER (Early Production) Item No. Part Number Qty.
PAGE 186
SECTION 6 SLAVE CYLINDER (Current Production) VENDOR STAMPING IMPORTANT: There are two similar but distinctly different Slave Cylinders. Make sure you know which version you have before ordering replacement parts. On “Early Production” cylinders, the gland is installed flush with the cylinder tube and has “TJB” stamped on the gland. On the “Current Production” cylinders, the gland has a lip that bottoms out against the cylinder tube.
PAGE 187
SECTION 6 SLAVE CYLINDER (Current Production) Item No. Part Number Qty. 1 2714973 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 NSS 8035613 8035612 8035611 8035547 See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 Description Cylinder, Slave (Includes Items 2 thru 17) NOTE: Quantities Listed Below Are For 1 Cylinder Only Tube, Cylinder (Serviced Only in Item 1) Piston Gland, Head Rod Nut, Lock 1.
PAGE 188
SECTION 6 ATTACHMENT TILT CYLINDER 3 Apply Loctite #271 to Threads 1 2 9 10 12 13 Torque to 600 lb/ft (814 Nm) and Stake 4 Places Retract Port Extend Port 11 4 14 10 Torque to 40 - 50 lb/ft (61 - 68 Nm) 9 15 13 12 8 7 6 17 5 16 PF0760 PF0760 PH0221 184 8042/10042/10054 Rev.
PAGE 189
SECTION 6 ATTACHMENT TILT CYLINDER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 2712973 NSS 8032714 8902260 See Kits 8033724 See Kits 8033725 See Kits See Kits 8033722 See Kits See Kits 8033723 7089722 Qty.
PAGE 190
SECTION 6 OUTRIGGER CYLINDER (S/N 10881 & Before) Torque to 400 lb/ft (542 Nm) and Stake 4 Places Apply Loctite #271 to Threads 1 2 4 5 3 Torque to 30 - 35 lb/ft (41 - 48 Nm) 14 Torque to 30 - 35 lb/ft (41 - 48 Nm) 5 Retract Port 13 12 11 Extend Port 10 9 4 12 9 10 7 6 13 8 15 16 PF0760 PF0760 PH0382 186 8042/10042/10054 Rev.
PAGE 191
SECTION 6 OUTRIGGER CYLINDER (S/N 10881 & Before) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number NLA NSS 8032702 See Kits 8902511 See Kits 8033750 See Kits See Kits See Kits 8033748 See Kits See Kits 8033749 Qty.
PAGE 192
SECTION 6 OUTRIGGER CYLINDER (S/N 10882 & After) Torque to 25 - 38 lb/ft (34 - 41 Nm) 1 2 6 8 8 15 Torque to 30 - 35 lb/ft (41 - 47 Nm) 13 10 18 16 12 4 Torque to 300 - 400 lb/ft (407 - 542 Nm) 11 9 17 12 11 14 17 16 9 3 17 Apply Loctite and Torque to 1300 - 1500 lb/ft (1762 - 2034 Nm) 14 17 5 7 10 18 15 13 PF0760 19 PF0760 20 PH1260 188 8042/10042/10054 Origin 2/00
PAGE 193
SECTION 6 OUTRIGGER CYLINDER (S/N 10882 & After) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number 2716163 NSS 8035727 8035728 8035729 8035730 8035322 8035731 See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits See Kits Qty. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 2 Description Cylinder, Outrigger (Includes Items 2 thru 18) Tube, Weldment (Serviced Only in Item 1) Piston Gland, Head Rod, Weldment Plug, SAE No. 4 Steel Hex Head Nut, Lock UNF 1.
PAGE 194
SECTION 6 SWING CARRIAGE CYLINDER 3 2 1 4 Torque to 250 lb/ft (339 Nm) Apply Loctite #271 to Inside Threads Retract Port 6 14 “X” Port Extend Port 11 5 7 8 13 9 10 Torque to 30 - 35 lb/ft (41 - 48 Nm) Torque to 30 - 35 lb/ft (41 - 48 Nm) 12 15 PF0760 17 16 PF0760 PF0760 PH0441 190 8042/10042/10054 Rev.
PAGE 195
SECTION 6 SWING CARRIAGE CYLINDER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number 2713363 NSS See Kits See Kits 8033783 See Kits See Kits 8033784 See Kits See Kits 8033785 8033786 8902842 8033788 Qty.
PAGE 196
SECTION 6 SIDE TILT CARRIAGE CYLINDER 4 14 13 1 5 12 11 9 10 3 15 6 Torque to 30 - 35 lb/ft (41 - 48 Nm) Apply Loctite #271 to Threads Torque to 350 lb/ft (475 Nm) and Stake 4 Places 8 2 7 16 15 Retract Port Extend Port 17 PF0760 PF0760 PH0800 192 8042/10042/10054 Rev.
PAGE 197
SECTION 6 SIDE TILT CARRIAGE CYLINDER Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 2711613 NSS 8902511 8205545 8205546 8205547 8205548 8205514 See Kits See Kits See Kits See Kits See Kits See Kits 8520013 Qty.
PAGE 198
SECTION 6 STEERING CYLINDER (S/N 1167 & Before) 1 2 Extend Port 6 3 11 13 Retract Port 10 4 9 9 5 12 8 8 7 12 7 14 PF0760 PH0621 194 8042/10042/10054 Rev.
PAGE 199
SECTION 6 STEERING CYLINDER (S/N 1167 & Before) Item No. Part Number Qty.
PAGE 200
SECTION 6 STEERING CYLINDER (S/N 1168 & After) 1 Extend Port 2 11 13 13 Retract Port 14 10 Torque to 160 lb/ft (217 Nm) 4 6 3 13 9 14 11 10 PF0760 15 13 16 12 15 9 7 5 8 8 12 7 PH0900 196 8042/10042/10054 Rev.
PAGE 201
SECTION 6 STEERING CYLINDER (S/N 1168 & After) Item No. Part Number Qty. 1 8034684 4 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NSS 8034821 8034822 8034823 8034824 See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Description Steering Cylinder (Includes Items 2 thru 15) NOTE: Quantities Listed Below Are For 1 Cylinder Only Barrel Assembly (Serviced Only in Item 1) Piston Rod - 17.
PAGE 202
SECTION 6 MAIN CONTROL VALVE 30 3 10 1 9 11 8 19 B 18 A 11 6 6 4 7 12 12 20 5 BO OM 6 EX B A TE ND 17 2 BO OM 34 16 20 7 8 9 16 15 HO IST 32 14 13 31 33 32 21 25 21 20 29 22 23 30 28 37 38 26 35 36 27 Kit PF0791 PF0760 25 24 23 PH1250 198 8042/10042/10054 Rev.
PAGE 203
SECTION 6 MAIN CONTROL VALVE Item No. 1 Part Number Qty.
PAGE 204
SECTION 6 SECONDARY CONTROL VALVE 1 29 25 31 33 26 27 32 30 28 14 24 42 35 40 39 3 12 23 24 13 6 15 16 5 17 9 18 19 41 2 18 10 22 4 12 13 8 7 21 7 40 39 7 FR AM ET ILT 7 23 AU X. H 20 YD. 8 AT TA CH .T ILT 20 37 9 36 10 11 38 34 37 35 43 44 46 45 47 Kit PF0760 PF0760 PF0760 Kit PF0791 PH0472 200 8042/10042/10054 Rev.
PAGE 205
SECTION 6 SECONDARY CONTROL VALVE Item No. 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 38 39 40 41 42 Part Number Qty.
PAGE 206
SECTION 6 DIRECTIONAL CONTROL VALVES 1 OF 2 9 7 2 10 10 6 12 11 Torque to 65 lb/ft (88 Nm) P T C1 S T 8 Torque to 35 lb/ft (48 Nm) 1 V1 13 14 Torque to 35 lb/ft (48 Nm) 5 3 3 4 2 1 19 15 16 18 17 PF0760 PH0950 202 8042/10042/10054 Rev.
PAGE 207
SECTION 6 DIRECTIONAL CONTROL VALVES 1 OF 2 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number NLA 7119813 8902222 8902137 8904047 8902838 8902846 8902141 8902193 8902140 8904049 8304631 8640017 8902251 8034558 8034559 8034560 Qty.
PAGE 208
SECTION 6 DIRECTIONAL CONTROL VALVES 2 OF 2 3 3 Torque to 35 lb/ft (48 Nm) 2 2 Torque to 35 lb/ft (48 Nm) 1 4 Torque to 35 lb/ft (48 Nm) S/N 0653 & Before 4 S R S B T C T P 10 V 9 Torque to 35 lb/ft (48 Nm) Torque to 35 lb/ft (48 Nm) 8 8 11 5 T 6 7 Torque to 35 lb/ft (48 Nm) 7 S/N 0653 & Before Torque to 35 lb/ft (48 Nm) 9 16 17 18 19 20 Discard Check Valve Kit PF0791 6 12 13 14 15 S/N 0654 thru 2194 PF0760 PH0960 204 8042/10042/10054 Rev.
PAGE 209
SECTION 6 DIRECTIONAL CONTROL VALVES 2 OF 2 Item No. 1 2 3 4 5 6 7 8 9 10 11 Part Number Qty.
PAGE 210
SECTION 7 ELECTRICAL SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 0291 & Before) 4 CIRCULATION FAN OPT. ENCL. CAB WIPER MOTOR OPT. ENCL.
PAGE 211
SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 0291 & Before) Item No.
PAGE 212
SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 0292 thru 9908) 25 32 43 29 19 20 21 35 26 DEFOG FAN OPT. ENCL. CAB 18 30 5 44 4 FRONT WIPER - OPT. ENCL.
PAGE 213
SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 0292 thru 9908) Item No.
PAGE 214
SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 9909 and After) 20 19 21 31 23 5 4 39 FRT. WIPER OPT. SWITCH BLK MOTOR 20C 1 RED GRN 2 SKYLIGHT WIPER OPT. MOTOR BLK YELLOW RED/BLK 32 5 5 B B 1 W 4 2 3 W 18 DEFOG FAN OPT.
PAGE 215
SECTION 7 ELECTRICAL SYSTEM - CAB HARNESS (S/N 9909 and After) Item No.
PAGE 216
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-0206 & Before and 10042-0211 & Before) 32 BLACK WIRE BLUE WIRE BROWN WIRE 16 17 18 19 HYDRAULIC TANK 6 10 12 13 15 25 21 15 18 44 NOT USED 33 14 27 19 36 38 2 18 6 20 25 NOT USED 35 1 31 37 14 2 23 19 31 34 20 15 FRAME GRD 29 5 2 44 1 21 14 17 SEE VIEW A-A 36 NOT USED 28 2 47 2 29 30 24 37 27 5 6 10 16 17 31 34 1 31 34 38 22 7 8 9 2 18 35 35 20 2 10 35 16 NOT USED FRAME GRD 25 20 29 26 30 27 SEE
PAGE 217
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-0206 & Before and 10042-0211 & Before) Item No.
PAGE 218
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-0207 thru 1598, 10042-0212 thru 1598, 10054-1598 & Before) 11 BLACK WIRE TO BOOM EXTEND SENSOR (10054 ONLY) (NOT USED ON 8042 OR 10042) BLUE WIRE 49 23 2 BROWN WIRE 16 17 18 19 HYDRAULIC TANK 15 15 18 44 49 23 12 14 13 6 NOT USED 27 19 36 38 2 35 25 18 6 20 25 NOT USED 35 1 31 37 14 2 23 24 37 27 6 20 29 30 25 NOT USED 19 31 34 5 10 16 17 2 31 34 1 10 21 (NOT USED ON 8042 OR 10042) 38 22 7 8 9 18 TO LOGIC
PAGE 219
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-0207 thru 1598, 10042-0212 thru 1598, 10054-1598 & Before) Item No. 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 Part Number 7126684 8270014 7114542 7098762 8310202 8270602 8270617 8305004 8307002 8584001 7099882 8307023 8303987 8305438 8223217 8310041 8305201 8220073 8223510 8223217 8223216 8033406 8034813 8277162 8033340 8270221 8307022 8305043 7118222 8310077 8310078 8042/10042/10054 Rev. 2/00 Qty.
PAGE 220
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-1599 to 5234, 10042-1599 to 5250, 10054-1599 to 5274) 11 TO BOOM EXTEND SENSOR (10054 ONLY) (NOT USED ON 8042 OR 10042) 22 BLUE WIRE 49 23 2 18 TO LOGIC HARNESS (10054 ONLY) 16 17 18 19 1 10 21 (NOT USED ON 8042 OR 10042) 12 14 13 6 27 30A 36 38 2 18 6 20 25 NOT USED 35 1 31 37 14 2 20 6 23 24 19 15 1 21 17 20 NOT USED 29 2 44 NOT USED 28 2 14 47 2 36 TO STABILIZER HARNESS 28 5 19 31 27 2 31 NOT USED 37 34 16 10
PAGE 221
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (S/N 8042-1599 to 5234, 10042-1599 to 5250, 10054-1599 to 5274) Item No. 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 Part Number 7126684 8270014 7114542 7098762 8310202 8270602 8270617 8305004 8307002 8584001 7099882 8307023 8303987 8305438 8223217 8310041 8305201 8220073 8223610 8223217 8223216 8033406 8034813 8277162 8033340 8270221 8307022 8305043 7118222 8310077 8310078 8042/10042/10054 Rev. 2/00 Qty.
PAGE 222
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (EPA) (S/N 8042-5235, 10042-5251, 10054-5275 thru 9908) 12 23 TO BOOM EXTEND SENSOR (10054 ONLY) (NOT USED ON 8042 OR 10042) BLUE WIRE 49 23 2 18 TO LOGIC HARNESS (10054 ONLY) 49 1 11 22 6 7 (NOT USED ON 8042 OR 10042) 27 30A 36 38 2 18 6 20 25 NOT USED 35 1 31 37 14 2 25 19 15 1 21 17 20 NOT USED 29 2 44 NOT USED 28 2 14 47 2 36 TO STABILIZER HARNESS 28 5 21 6 24 37 27 2 31 NOT USED 10 31 34 16 19 16 17 2 10 35 44 13 15
PAGE 223
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (EPA) (S/N 8042-5235, 10042-5251, 10054-5275 thru 9908) Item No. Part Number Qty.
PAGE 224
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (EPA) (S/N 9909 and After) 31 109 D E F A BC 1 2 3 4 5 TO BACKUP ALARM 100 101 102 103 104 105 111 110 100 107 A B 108 100 87 86 111 102 108 113 105 107 103 11 A B C D 85 87 86 108 110 104 106 BLACK WIRE 101 114 TO BOOM EXTEND SENSOR (10054 ONLY) 114 102 114 112 A B C D 86 100 30 85 87 30 85 100 109 30 TO STARTER RELAY 106 112 104 111 GREEN WIRE ENGINE HARNESS 30 32 2 113 113 14 HYDRAULIC TANK BROWN WIRE 1
PAGE 225
SECTION 7 ELECTRICAL SYSTEM - ENGINE HARNESS (EPA) (S/N 9909 and After) Item No. 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 Part Number 7134894 8270134 7129392 7129382 8310202 8270625 8270617 8305004 8307002 8584001 7099882 8307023 8305438 8223217 8310041 8305201 8220073 8223610 8223217 8223216 8035276 8277162 8033340 8270221 8307022 8305043 7118222 8310077 8310078 7150402 8035805 8035806 8305038 7150521 8042/10042/10054 Origin 2/00 Qty.
PAGE 226
SECTION 7 LIGHTING SYSTEM Torque Item 5 to 120 lb/ft (163 Nm) 4 Places 19 25 27 21 7 5 4 6 18 4 5 6 7 18 19 25 27 2 28 2 22 25 21 22 2 17 20 24 4 5 6 7 18 3 25 27 29 2 15 16 3 25 27 29 1 10 11 12 13 14 8 9 23 2 28 BOOM LIGHT 2 15 IGN. SW. 2 1 RIGHT FRONT RIGHT REAR 5 4 3 3 19 10 11 3 2 2 5 54 9 2 8 12 TO FUEL GAUGE 9 6 T 4 3 7 2 6 2 2 1 7 11 8 5 H 10 17 54 14 B 15 26 34 2 11 15 4 2 34 15 1 14 STOP LIGHT SW.
PAGE 227
SECTION 7 LIGHTING SYSTEM Item No. 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 Part Number 7098973 5721202 8500036 7112302 8303632 8307009 8307207 8223025 7111191 8223424 8500201 8303837 8305627 8307111 8223419 7124331 8223016 8305014 8500009 8584018 8584003 8584001 8305405 7058372 8307206 8229235 8220050 7110782 8310058 8042/10042/10054 Rev. 2/00 Qty.
PAGE 228
SECTION 7 OUTRIGGER ELECTRICAL HARNESS (10042/10054 Only) TOGGLE SWITCHES 4 GREY/PURPLE L.H. TOP TOP R.H. PURPLE/WHITE RED/GREY 62 61 BLACK 2 64 60 63 RED/GREY 61 2 YELLOW/ GREEN 63 BLACK 2 3 BROWN/ YELLOW BROWN/YELLOW BROWN/YELLOW 64 1 YELLOW/GREEN OUTRIGGER VALVE 60 6AMP YELLOW/GREEN GREY/PURPLE BLACK PURPLE/WHITE BLACK 2 50 62 60 18 2 20 BLACK 10AMP BLACK Kit 20 PH0791 For Units w/Circuit Breakers 10042 Only 16 1 57 50 R.H.
PAGE 229
SECTION 7 OUTRIGGER ELECTRICAL HARNESS (10042/10054 Only) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 7099923 7115114 8220882 8688026 8223221 7112592 7138469 7099882 7112582 7138468 8303738 8307005 8310113 8225117 8229233 8307111 8305002 8307003 8223525 8307106 Qty.
PAGE 230
SECTION 8 DECALS AND PAINT SECTION 8 DECALS AND PAINT ® 1 4 13 2 3 12 11 14 Low Engine Idle Setting (No Load) 1050 ±50 RPM 4107901 33 23 4108302 10 5 See “Control Console” 22 29 36 15 16 4107462 21 19 - + ® 35 25 Only Use an Approved Work Platform. 60 75 Only Lift or Lower personnel when using a work platform Never move machine with personnel on the work platform.
PAGE 231
SECTION 8 DECALS AND PAINT Item No.
PAGE 232
SECTION 9 BOOM AND ATTACHMENTS SECTION 9 OUTER BOOM 34 35 4 2 5 36 6 3 39 36 1 37 11 38 23 24 28 20 22 12 8 13 7 21 11 17 16 18 9 8 21 7 22 20 12 32 15 8 28 30 31 20 8 9 29 20 13 15 7 8 19 15 14 8 20 22 26 22 22 14 9 7 23 24 10 25 27 33 PH0940 NOTE: Apply Item 33 to All screws that secure wear pads and torque to 31 ± 3 lb/ft (42 ± 4 Nm). S/N 0884 & Before Only PH0053 228 8042/10042/10054 Rev.
PAGE 233
SECTION 9 OUTER BOOM Item No. Part Number Qty.
PAGE 234
SECTION 9 INTERMEDIATE BOOM - 8042 AND 10042 41 30 25 41 32 24 28 23 33 S/N 0481 & Before-Complete Early Model Hose Reel Assemblies Are No Longer Available, Order Item 22.
PAGE 235
SECTION 9 INTERMEDIATE BOOM - 8042 AND 10042 Item No. 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 38 39 40 41 Part Number Qty.
PAGE 236
SECTION 9 INNER BOOM - 8042 AND 10042 4 5 6 9 3 7 8 1 10 3 1 11 3 2 S/N 8042-0866 or 10042-0880 & Before (No Longer Available) 7 8 5 25 13 4 5 4 24 22 PH0940 14 NOTE: Apply Item 24 to All screws that secure wear pads and torque to 31 ± 3 lb/ft (42 ± 4 Nm). 21 22 12 23 17 12 19 20 16 15 15 26 27 28 18 PH0063 232 8042/10042 Rev.
PAGE 237
SECTION 9 INNER BOOM - 8042 AND 10042 Item No. 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 Part Number Qty. 7118662 1 7117113 1 8303679 8307005 7082311 7111572 7096882 7082362 7082342 8303675 8303681 8307204 7095312 7096702 8520021 8520013 8305644 7083992 8305643 7095352 8303666 7095522 8642224 8303772 8526036 7125811 8307918 8310093 8307904 6 16 16 7 2 AR AR 2 8 8 2 1 1 3 1 1 1 1 1 1 2 1 AR 1 2 AR AR 8042/10042 Rev.
PAGE 238
SECTION 9 QUICK ATTACH 1 2 3 8 7 6 5 4 PA0746 234 8042/10042/10054 Rev.
PAGE 239
SECTION 9 QUICK ATTACH Item No. 1 2 3 4 5 6 7 8 Part Number 7085102 7120742 8305619 7085552 7085571 7085562 8307104 8303638 8042/10042/10054 Rev. 2/00 Qty.
PAGE 240
SECTION 9 CARRIAGE 48" 2 3 1 4 2 3 4 6 7 8 5 9 10 PA0744 236 8042/10042/10054 Rev.
PAGE 241
SECTION 9 CARRIAGE 48" Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7083054 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128772 7097523 7097543 7097533 7085073 8042/10042/10054 Rev. 7/98 Qty. 1 2 2 2 1 1 1 1 1 2 2 2 6 Description Carriage, 48" HHCS, 5/8-11 x 4" Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer, .51 x 1.88 x 1.25" Bolt, Eye 1/2 x 13 x 2" Length Shank Shaft, 48" Fork, Pallet 48" x 4" x 2" (4,000 lb. Rating) - 8042 Only Fork, Pallet 48" x 4" x 2.
PAGE 242
SECTION 9 CARRIAGE 60" (Optional) 2 3 4 1 2 3 4 6 7 9 8 5 10 PA0744 238 8042/10042/10054 Rev.
PAGE 243
SECTION 9 CARRIAGE 60" (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7086304 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128792 7097523 7097543 7097533 7085073 8042/10042/10054 Rev. 7/98 Qty. 1 2 2 2 1 1 1 1 1 2 2 2 6 Description Carriage, 60" HHCS, 5/8-11 x 4" Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer, .51 x 1.88 x 1.25" Bolt, Eye 1/2 x 13 x 2" Length Shank Shaft, 60" Fork, Pallet 48" x 4" x 2" (4,000 lb.
PAGE 244
SECTION 9 CARRIAGE 72" (Optional) 2 3 4 1 2 3 4 6 7 8 5 9 10 PA0744 240 8042/10042/10054 Rev.
PAGE 245
SECTION 9 CARRIAGE 72" (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7090814 8303634 7086471 8305643 7118892 7118882 8310276 8310266 7128802 7097523 7097543 7097533 7085073 8042/10042/10054 Rev. 7/98 Qty. 1 2 2 2 1 1 1 1 1 2 2 2 6 Description Carriage, 72" HHCS, 5/8-11 x 4" Collar Nut, Hex Lock 5/8-11 Pin, Lock (Includes Items 6 thru 8) Pin Washer, .51 x 1.88 x 1.25" Bolt, Eye 1/2 x 13 x 2" Length Shank Shaft, 72" Fork, Pallet 48" x 4" x 2" (4,000 lb.
PAGE 246
SECTION 9 SIDE TILT CARRIAGE - EARLY PRODUCTION (Optional) IMPORTANT: There are two similar but distinctly different Side Tilt Carriages. Make sure you know which version you have before ordering replacement parts. All reference to the right or left side are given from the operator's seat looking forward. An "Early Production" Carriage has its hydraulic cylinder attached on the operator's left side.
PAGE 247
SECTION 9 SIDE TILT CARRIAGE - EARLY PRODUCTION (Optional) Item No.
PAGE 248
SECTION 9 SIDE TILT CARRIAGE - CURRENT PRODUCTION (Optional) IMPORTANT: There are two similar but distinctly different Side Tilt Carriages. Make sure you know which version you have before ordering replacement parts. All reference to the right or left side are given from the operator's seat looking forward. An "Early Production" Carriage has its hydraulic cylinder attached on the operator's left side.
PAGE 249
SECTION 9 SIDE TILT CARRIAGE - CURRENT PRODUCTION (Optional) Item No.
PAGE 250
SECTION 9 OUTRIGGERS (10042/10054 Only) 1 2 3 4 5 3 6 7 9 10 18 See also “Outrigger Cylinder” 17 13 11 12 1 14 8 19 20 21 22 15 16 27 17 21 28 23 25 24 26 21 PH0402 246 10042/10054 Rev.
PAGE 251
SECTION 9 OUTRIGGERS (10042/10054 Only) Item No. 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 Part Number 8305643 7115432 7110002 8769159 8769160 8769158 8307107 8303717 7124491 8303655 8065063 7090832 8307912 8307913 8303794 8310067 7090634 8520013 2716163 8310151 7090871 8305644 7091373 7090891 7090822 8303629 7090951 8303628 7125801 10042/10054 Rev. 2/00 Qty.
PAGE 252
SECTION 9 SWING CARRIAGE (Optional) 24 16 17 23 L.H. Cylinder 12 18 19 20 21 X 40 E R R.H. Cylinder 27 27 38 38 28 39 R 14 13 37 37 E X 42 12 29 2 3 5 33 35 See “Swing Carriage Cylinder” 8 9 33 31 32 6 4 33 41 42 32 25 32 11 8 9 9 22 15 10 1 36 8 7 25 12 8 10 Attach to Port “R” R.H. Cylinder 9 26 Attach to Port “R” L.H. Cylinder 4 12 30 33 32 31 34 PH0560 248 8042/10042/10054 Rev.
PAGE 253
SECTION 9 SWING CARRIAGE (Optional) Item No.
PAGE 254
SECTION 9 SHEET MATERIAL HANDLER (Optional) 3 4 5 6 4 3 4 8 5 6 1 10 7 5 9 4 8 7 2 10 9 5 PK0042 250 8042/10042/10054 Rev.
PAGE 255
SECTION 9 SHEET MATERIAL HANDLER (Optional) Item No. 1 2 3 4 5 6 7 8 9 10 Part Number 7112533 7112523 7112642 8303626 8307007 8305012 8301456 7114941 8305644 8307112 8042/10042/10054 Rev. 2/00 Qty.
PAGE 256
SECTION 9 UTILITY BUCKET (Optional) 1 2 PA0782 252 8042/10042/10054 Rev.
PAGE 257
SECTION 9 UTILITY BUCKET (Optional) Item No. 1 2 Part Number 7110744 4106561 8042/10042/10054 Rev. 6/94 Qty. 1 1 Description Bucket, Utility, 1-1/4 cu. yd.
PAGE 258
SECTION 9 PRIMARY INTERMEDIATE BOOM - 10054 45 46 13 44 44 45 42 41 43 40 14 39 38 S/N 0481 & Before Complete Early Model Hose Reel Assemblies Are No Longer Available, Order Item 22.
PAGE 259
SECTION 9 PRIMARY INTERMEDIATE BOOM - 10054 Item No. Part Number Qty.
PAGE 260
SECTION 9 SECONDARY INTERMEDIATE BOOM - 10054 11 10 9 4 8 Hose Carrier (Reference Only) 7 22 6 1 3 2 24 12 6 5 22 25 24 13 12 6 23 14 17 6 17 15 18 6 28 16 18 27 20 7 10 8 7 8 10 11 10 11 20 10 19 18 11 6 11 21 PH0940 26 10 29 30 NOTE: Apply Item 26 to All screws that secure wear pads and torque to 31 ± 3 lb/ft (42 ± 4 Nm). Kit PF0791 PH0683 256 10054 Rev.
PAGE 261
SECTION 9 SECONDARY INTERMEDIATE BOOM - 10054 Item No. Part Number Qty.
PAGE 262
SECTION 9 INNER BOOM - 10054 4 S/N 1933 & After 30 37 37 31 5 6 7 8 30 24 25 26 3 10 25 12 31 32 3 25 29 26 2 9 3 Hose Carrier (Reference Only) 10 23 28 1 7 8 4 5 5 4 13 21 PH0940 27 NOTE: Apply Item 27 to All screws that secure wear pads and torque to 31 ± 3 lb/ft (42 ± 4 Nm). 20 21 22 33 11 15 11 16 19 18 14 34 35 14 17 36 PH0662 258 10054 Rev.
PAGE 263
SECTION 9 INNER BOOM - 10054 Item No. Part Number Qty.
PAGE 264
SECTION 9 BOOM EXTEND CHAINS - 8042 AND 10042 4 12 5 6 2 2 6 3 7 1 8 Outer Boom (Ref.) Inner Boom (Ref.) 10 11 3 Outer Boom (Ref.) Intermediate Boom (Ref.) 2 9 1 2 Inner Boom (Ref.) 13 Kit PF0791 PH0821 260 8042/10042 Rev.
PAGE 265
SECTION 9 BOOM EXTEND CHAINS - 8042 AND 10042 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number Qty. NLA 2 8127014 8642237 8124126 8310019 8310020 7089781 8305645 8305644 NLA 7119362 8307104 8305646 NLA 7119372 2 8 4 2 1 2 2 1 2 2 2 2 2 2 Description Chain, 4 x 6 Link - 194.25" Long (S/N 11144 & Before) (For Service, Order Kit P/N 7138738) Chain, 6 x 6 Link (S/N 11145 & After) Retaining Ring, 1/4" Dia.
PAGE 266
SECTION 9 BOOM RETRACT CHAIN - 8042 AND 10042 (S/N 1084 & Before) 2 3 1 Outer Boom (Ref.) Inner Boom (Ref.) Inner Boom (Ref.) 2 4 7 6 Outer Boom (Ref.) 2 3 1 Intermediate Boom (Ref.) 2 Inner Boom (Ref.) 5 4 6 PH0851 262 8042/10042 Rev.
PAGE 267
SECTION 9 BOOM RETRACT CHAIN - 8042 AND 10042 (S/N 1084 & Before) Item No. Part Number Qty. 1 7120191 1 2 3 4 5 6 7 8642237 8124126 7119362 8307104 8305646 8305018 4 2 2 1 2 1 8042/10042 Origin 12/97 Description Kit, 6 x 6 Retract Chain (Includes 6 x 6 chain, 4 of Item 2, 2 of Item 3 & 2 of Item 4) Retaining Ring, 1/4" Dia.
PAGE 268
SECTION 9 BOOM RETRACT CHAIN - 8042 AND 10042 (S/N 1085 & After) 2 3 1 8 Inner Boom (Ref.) 7 2 5 7 9 Outer Boom (Ref.) Inner Boom (Ref.) Intermediate Boom (Ref.) Outer Boom (Ref.) 2 3 1 2 4 6 10 PH0831 264 8042/10042 Rev.
PAGE 269
SECTION 9 BOOM RETRACT CHAIN - 8042 AND 10042 (S/N 1085 & After) Item No. Part Number Qty. 1 7119351 1 2 3 4 5 6 7 8 9 10 8642237 8124126 7119362 7119372 8305646 7117031 8310019 8305645 8307104 4 2 1 1 1 2 2 2 1 8042/10042 Origin 12/97 Description Kit, 6 x 6 Retract Chain (Includes 6 x 6 chain, 4 of Item 2, 2 of Item 3, 1 Item 4 & 1 Item 5) Retaining Ring, 1/4" Dia.
PAGE 270
SECTION 9 BOOM EXTEND CHAINS - 10054 Extend Chains (Ref.) FRONT SIDE 5 6 4 2 VIEW OF BOOM 3 2 18 3 9 2 6 1 1 20 19 2 7 8 Outer Boom (Ref.) Secondary Intermediate Boom (Ref.) m oo B ter Ou te dia e erm Int om y ar Bo im Pr Primary Intermediate Boom (Ref.) om Bo r e Inn te dia e rm nte I ary om nd Bo o c Se 13 12 15 16 17 10 11 21 13 12 Kit 14 PF0791 Inner Boom (Ref.) PH0861 266 10054 Rev.
PAGE 271
SECTION 9 BOOM EXTEND CHAINS - 10054 Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Qty. NLA 2 8127014 8642237 8124126 8310019 8310020 7089781 8305645 8305644 NLA 7119372 8310205 7113982 8127009 8124131 8305643 7113952 8310066 8310210 NLA 7119362 8307104 8305646 2 8 4 2 1 2 2 1 2 2 1 1 1 2 1 1 1 1 2 2 2 2 Description Chain, 4 x 6 Link - 194.25" Long (S/N 11144 & Before) (For Service, Order Kit 7138738) Chain, 6 x 6 Link - 194.
PAGE 272
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 0884 & Before) FRONT SIDE VIEW Inner Boom (Ref.) OF 2 BOOM 4 3 Secondary Intermediate Boom (Ref.) 3 2 6 2 2 5 ary om nd e Bo o c t Se edia m er Int 1 9 om Bo r e Inn ary im r P 10 1 9 om Bo e iat ed m er Int 3 4 2 Outer Boom (Ref.) 2 ter Ou 2 7 9 3 6 om Bo 8 2 10 11 8 9 Kit PF0791 268 PH0891 10054 Rev.
PAGE 273
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 0884 & Before) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 8305018 8642237 8124126 NLA NLA 8127008 NLA 8307104 8305646 7119362 Qty. 1 8 4 1 2 1 1 2 4 2 Description Nut, Hex Jam 3/4-16 Retaining Ring, 1/4" Pin, Chain Clevis Chain, 4 x 6 - 164.25" Long (For Service, Order Kit P/N 7120191) Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7120191) Chain, 6 x 6 - 164.
PAGE 274
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 0885 thru 1084) Retract Chains (Ref.) FRONT SIDE VIEW Inner Boom (Ref.) OF 5 BOOM 6 9 5 6 7 Secondary 1 1 Intermediate Boom (Ref.) 5 5 4 2 ary om nd e Bo o c t Se edia erm Int 3 e Inn 5 m oo B r 8 2 3 m oo B te dia e rm nte I ary im r P 6 7 Outer Boom (Ref.) ter Ou 5 12 10 11 5 om Bo 6 9 5 13 14 11 12 Kit PF0791 270 PH0870 10054 Rev.
PAGE 275
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 0885 thru 1084) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 8310019 7117031 8305645 NLA 8642237 8124126 NLA 7119372 8127008 NLA 8307104 8305646 7119362 Qty. 4 4 4 1 8 4 1 1 1 1 2 2 1 Description Bolt, Shoulder 3/8-16 x 1-1/2 Link Nut, Hex Lock Elastic 3/8-16 Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7119351) Retaining Ring, 1/4" Pin, Chain Clevis Chain, 4 x 6 - 164.
PAGE 276
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 1085 & After) Retract Chains (Ref.) FRONT SIDE VIEW Inner Boom (Ref.) OF 5 BOOM 6 5 7 6 9 Secondary 1 1 Intermediate Boom (Ref.) 4 2 5 5 ary om nd e Bo o c t Se edia erm Int 3 e Inn m oo B r P 5 rm nte I ary rim 8 2 3 om Bo e iat ed 6 7 Outer Boom (Ref.) 5 ter Ou 10 12 5 om Bo 6 9 5 11 13 11 14 12 Kit PF0791 272 PH0870 10054 Rev.
PAGE 277
SECTION 9 BOOM RETRACT CHAINS - 10054 (S/N 1085 & After) Item No. Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 Qty.
PAGE 278
SECTION 9 TRUSS BOOM 12 AND 15 FT. (Optional) 12 ft. Truss Boom 8042 Only 6 8 1 7 9 5 2 4 3 Torque to 85 lb/ft (115 Nm) 15 ft.
PAGE 279
SECTION 9 TRUSS BOOM 12 AND 15 FT. (Optional) Item No. 1 2 3 4 5 6 7 8 9 Part Number 7113024 7112804 8382017 8310195 8307112 8305644 4107182 4107822 4107832 4107812 8042/10042/10054 Origin 12/97 Qty. 1 1 1 4 4 4 2 2 2 2 Description 12' Truss Boom - 8042 (Includes Items 2 thru 9) 15' Truss Boom - 10042 &10054 (Includes Items 2 thru 9) Pintle Hook HHCS, 1/2-13 x 1.
PAGE 280
276
PAGE 281
SECTION 10 GENERAL TROUBLESHOOTING HYDRAULIC Hydraulic Diagnostic Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 8042 Hydraulic Diagram & Testing (S/N 1167 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 - 291 8042 Hydraulic Diagram & Testing (S/N 1168 thru 2194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 - 293 8042 Hydraulic Diagram & Testing (S/N 2195 thru 9908) . . . . . . .
PAGE 282
8042/10042/10054 Lighting System Circuit (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8042/10042/10054 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8042/10042/10054 Cranking Circuit (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8042/10042/10054 Cranking Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 283
SECTION 10 SECTION 10 Hydraulic Diagnostic Test Equipment OmniQuip Parts Worldwide is pleased to announce the availability of two valuable diagnostic tools. The Sky Trak Pressure Test Kit and Flowmeter Kit. Both kits feature a durable polyethylene carrying case for demanding field service conditions. For price and availability, call OmniQuip Parts Worldwide at (888) 872-5123.
PAGE 284
SECTION 10 8042 Hydraulic Diagram (S/N 1167 & Before) ATTACHMENT TILT CYLINDER AUXILIARY HYDRAULICS (Optional) FEMALE ATTACHMENT TILT BACK MALE 6 9 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE ATTACHMENT TILT FORWARD FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE T A P R P L T 2 7 POWER STEERING UNIT STEER SELECT VALVE T EF 2 1 LS T 3 P CONTROL VALVE P B A T T Frame Tilt FUEL TANK Boom Ext. EXTEND CYLINDER Aux. Hyd.
PAGE 285
SECTION 10 8042 Hydraulic Testing (S/N 1167 & Before) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . .
PAGE 286
SECTION 10 8042 Hydraulic Diagram 8042 HYDRAULIC 1168 & After) (S/NDIAGRAM 1168 thru(S/N 2194) ATTACHMENT TILT CYLINDER AUXILIARY HYDRAULICS (Optional) FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL.
PAGE 287
SECTION 10 8042 Hydraulic Testing (S/N 1168 thru 2194) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 288
SECTION 10 8042 Hydraulic Diagram (S/N 2195 thru 9908) 8042 HYDRAULIC DIAGRAM (S/N 1168 & After) ATTACHMENT TILT CYLINDER AUXILIARY HYDRAULICS (Optional) FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL.
PAGE 289
SECTION 10 8042 Hydraulic Testing (S/N 2195 thru 9908) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 290
SECTION 10 8042 Hydraulic Diagram (S/N 9909 & After) ATTACHMENT TILT CYLINDER AUXILIARY HYDRAULICS (Optional) FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 5 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE T A P R P L T STEER SELECT VALVE T CONTROL VALVE P SHUTTLE VALVE P B EF 2 1 LS T 3 T P FUEL TANK Boom Hoist Attach Tilt Boom Ext. EXTEND CYLINDER Aux. Hyd.
PAGE 291
SECTION 10 8042 Hydraulic Testing (S/N 9909 & After) Equipment Needed To Perform Tests From Kit P/N 7133413 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 292
SECTION 10 10042 Hydraulic Diagram (S/N 1167 & Before) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE 6 9 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE ATTACHMENT TILT FORWARD FRAME TILT CYLINDER STEER CYL. STEER CYL.
PAGE 293
SECTION 10 10042 Hydraulic Testing (S/N 1167 & Before) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . .
PAGE 294
SECTION 10 10042 Diagram (S/N (S/N 11681168 thru&2194) 10042Hydraulic HYDRAULIC DIAGRAM After) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL.
PAGE 295
SECTION 10 10042 Hydraulic Testing (S/N 1168 thru 2194) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 296
SECTION 10 10042 HYDRAULIC DIAGRAM (S/N 1168 & After) 10042 Hydraulic Diagram (S/N 2195 thru 9908) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL.
PAGE 297
SECTION 10 10042 Hydraulic Testing (S/N 2195 thru 9908) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 298
SECTION 10 10042 Hydraulic Diagram (S/N 9909 & After) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 5 OPERATOR'S CAB LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE T A P BRAKE VALVE R P L T STEER T SELECT VALVE CONTROL VALVE LS T 3 2 P T T Frame Tilt FUEL TANK Boom Hoist Attach Tilt EXTEND CYLINDER Boom Ext. Aux. Hyd.
PAGE 299
SECTION 10 10042 Hydraulic Testing (S/N 9909 & After) Equipment Needed To Perform Tests From Kit P/N 7133413 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . . .47.3 gal.
PAGE 300
SECTION 10 10054 Hydraulic Diagram (S/N 1167 & Before) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE 6 9 OPERATOR'S CAB BRAKE VALVE LEFT FRONT BRAKE ATTACHMENT TILT FORWARD FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE T A P R P L T 7 POWER STEERING UNIT 2 EF 2 1 STEER T SELECT VALVE CONTROL VALVE LS T 3 P CF P 1 SHUTTLE VALVE 2 A B PRIORITY VALVE P P T T Frame Tilt C1 T Aux. Hyd.
PAGE 301
SECTION 10 10054 Hydraulic Testing (S/N 1167 & Before) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . .
PAGE 302
SECTION 10 10054 Hydraulic Diagram (S/N 1168 thru 2194) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE LEFT FRONT BRAKE T A P BRAKE VALVE R P L T 7 POWER STEERING UNIT 2 EF 2 STEER SELECT VALVE 1 T LS T 3 P P 1 SHUTTLE VALVE CONTROL VALVE 2 A B PRIORITY VALVE CF P P T T Frame Tilt C1 T Aux. Hyd.
PAGE 303
SECTION 10 10054 Hydraulic Testing (S/N 1168 thru 2194) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . 59.5 gal.
PAGE 304
SECTION 10 10054 Hydraulic Diagram (S/N 2195 thru 9908) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 6 OPERATOR'S CAB FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE LEFT FRONT BRAKE T A P BRAKE VALVE R P L T 7 POWER STEERING UNIT 2 EF 2 STEER SELECT VALVE T 1 SHUTTLE VALVE P LS T 3 PRIORITY VALVE CF P 1 CONTROL VALVE 2 A B P P T T Frame Tilt C1 T Aux. Hyd.
PAGE 305
SECTION 10 10054 Hydraulic Testing (S/N 2195 thru 9908) Equipment Needed To Perform Tests From Kit P/N 7118782 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . 59.5 gal.
PAGE 306
SECTION 10 10054 Hydraulic Diagram (S/N 9909 & After) LEFT OUTRIGGER CYL. AUXILIARY HYDRAULICS RIGHT OUTRIGGER CYL. ATTACHMENT TILT CYLINDER FEMALE ATTACHMENT TILT BACK MALE ATTACHMENT TILT FORWARD 5 OPERATOR'S CAB LEFT FRONT BRAKE FRAME TILT CYLINDER STEER CYL. STEER CYL. RIGHT FRONT BRAKE T A P BRAKE VALVE R P L T STEER SELECT VALVE T CONTROL VALVE P 2 T T Aux. Hyd.
PAGE 307
SECTION 10 10054 Hydraulic Testing (S/N 9909 & After) Equipment Needed To Perform Tests From Kit P/N 7133413 Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm Circuit Gauge Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter) Capacity - System . . . . . . . . . . . . 59.5 gal.
PAGE 308
SECTION 10 8042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram (S/N 9908 & Before) OUTPUT PORT LOAD SENSE PORT (PARKER) HYDRAULIC PUMP LOAD SENSE HOSEREMOVED FROM SHUTTLE VALVE FLOW METER Webster Model DH CR 250 PRESSURE GAUGE FLOW 21.125.0 LOAD CONTROL VALVE OUTPUT HOSE REMOVED FROM PRIORITY VALVE RESET TACH TACH EXT. FLOW } INT. FLOW EXT.
PAGE 309
SECTION 10 8042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram (S/N 9909 & After) LOAD SENSE PORT OUTPUT PORT LOAD SENSE HOSEREMOVED FROM SHUTTLE VALVE (VICKERS) HYDRAULIC PUMP FLOW METER Webster Model DH CR 250 PRESSURE GAUGE FLOW 21.125.0 LOAD CONTROL VALVE RESET TACH TACH ROTARY SELECTOR SWITCH OUTPUT HOSE REMOVED FROM PRIORITY VALVE EXT. FLOW } INT. FLOW EXT.
PAGE 310
SECTION 10 8042/10042 Hoist and Extend Circuits (S/N 8540 & Before) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE P FUEL TANK Boom Hoist Boom Ext. LS HYDRAULIC RESERVOIR MAIN FILTER Park Brake LOAD SENSE (LS) IN MAIN PUMP Trans. DeClutch CONTROL DRAIN OUT TRANSMISSION LS COUNTER BALANCE VALVE LOCATIONS HOIST CYLINDERS – Base Side EXTEND CYLINDER – Rod and Base Sides LEFT HOIST CYLINDER 316 RIGHT HOIST CYLINDER MH0091 Rev.
PAGE 311
SECTION 10 8042/10042 Hoist and Extend Schematic (S/N 8540 & Before) HOIST CYLINDER - R.H. HOIST CYLINDER - L.H. HIGH PRESSURE HIGH PRESSURE EXTEND CYLINDER HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE TEMP.
PAGE 312
SECTION 10 8042/10042 Hoist and Extend Circuits (S/N 8541 thru 9908) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE P FUEL TANK Boom Hoist Boom Ext. LS HYDRAULIC RESERVOIR MAIN FILTER Park Brake LOAD SENSE (LS) IN MAIN PUMP Trans. DeClutch CONTROL DRAIN OUT TRANSMISSION LS COUNTER BALANCE VALVE LOCATIONS HOIST CYLINDERS – Base Side EXTEND CYLINDER – Rod and Base Sides LEFT HOIST CYLINDER 318 RIGHT HOIST CYLINDER MH0091 Rev.
PAGE 313
SECTION 10 8042/10042 Hoist and Extend Schematic (S/N 8541 thru 9908) HOIST CYLINDER - R.H. HOIST CYLINDER - L.H. HIGH PRESSURE HIGH PRESSURE EXTEND CYLINDER HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE X TEMP.
PAGE 314
SECTION 10 8042/10042 Hoist and Extend Circuits (S/N 9909 & After) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE P FUEL TANK Boom Hoist Boom Ext.
PAGE 315
SECTION 10 8042/10042 Hoist and Extend Schematic (S/N 9909 & After) HOIST CYLINDER - L.H. HIGH PRESSURE HOIST CYLINDER - R.H. EXTEND CYLINDER LOW PRESSURE HIGH PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE X 0-45 GPM SHUTTLE VALVE TP X OUTRIGGER VALVE X 25 PSI STEERING VALVE 2450-2550 PSI 3000 PSI RESERVOIR 500 / 600 PSI STANDBY TEMP.
PAGE 316
SECTION 10 10054 Hoist and Extend Circuits (S/N 8540 & Before) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE BOOM EXTEND LOCKOUT VALVE P FUEL TANK Boom Hoist C1 Boom Ext. T LS HYDRAULIC RESERVOIR MAIN FILTER IN Park Brake MAIN PUMP Trans.
PAGE 317
SECTION 10 10054 Hoist and Extend Schematic (S/N 8540 & Before) HOIST CYLINDER - R.H. HOIST CYLINDER - L.H. HIGH PRESSURE HIGH PRESSURE EXTEND CYLINDER HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE TEMP.
PAGE 318
SECTION 10 10054 Hoist and Extend Circuits (S/N 8541 thru 9908) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE BOOM EXTEND LOCKOUT VALVE P FUEL TANK Boom Hoist C1 Boom Ext. T LS HYDRAULIC RESERVOIR MAIN FILTER IN Park Brake MAIN PUMP Trans.
PAGE 319
SECTION 10 10054 Hoist and Extend Schematic (S/N 8541 thru 9908) HOIST CYLINDER - R.H. HOIST CYLINDER - L.H. HIGH PRESSURE HIGH PRESSURE EXTEND CYLINDER HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE X TEMP.
PAGE 320
SECTION 10 10054 Hoist and Extend Circuits (S/N 9909 & After) EXTEND CYLINDER SHUTTLE VALVE CF EF 2 1 LS 3 T P PRIORITY VALVE CONTROL T VALVE BOOM EXTEND LOCKOUT VALVE P FUEL TANK Boom Hoist C1 Boom Ext.
PAGE 321
SECTION 10 10054 Hoist and Extend Schematic (S/N 9909 & After) HOIST CYLINDER - L.H. HIGH PRESSURE HOIST CYLINDER - R.H. EXTEND CYLINDER LOW PRESSURE HIGH PRESSURE HIGH PRESSURE LOW PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE MAIN CONTROL VALVE 3200 PSI 3200 PSI HOIST VALVE EXTEND RETRACT VALVE X 0-45 GPM SHUTTLE VALVE TP X OUTRIGGER VALVE X 25 PSI STEERING VALVE 2450-2550 PSI 3000 PSI RESERVOIR 500 / 600 PSI STANDBY TEMP.
PAGE 322
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 2194 & Before) PILOT OPERATED CHECK VALVE LOCATIONS: FRAME TILT CYLINDER - Rod & Base Sides ATTACHMENT CYLINDER - Base Side AUXILIARY COUNTER BALANCE VALVE LOCATION: HYDRAULICS ATTACHMET CYLINDER - Base Side (optional) ATTACHMENT TILT CYLINDER LOAD SENSE (LS) FRAME TILT CYLINDER FEMALE MALE ATTACHMENT TILT FORWARD ATTACHMENT TILT BACK PRIORITY VALVE EF CF 2 1 OPERATOR'S CAB LS T 3 SHUTTLE VALVE CONTROL VALV
PAGE 323
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2194 & Before) FRAME TILT CYLINDER .070 SLAVE CYLINDER - L.H. SLAVE CYLINDER - R.H. AUX. QUICK DISCONNECT COUPLERS ATTACH. TILT CYLINDER HIGH PRESSURE .070 LOW PRESSURE RELIEF VALVES OPTIONAL 3200 PSI 3200 PSI ORIFICES IN FRAME TILT CYLINDER FOR S/N -266 & BEFORE FRAME TILT VALVE ATTACH. TILT VALVE 3200 PSI 3200 PSI AUX.
PAGE 324
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 2195 thru 9908) PILOT OPERATED CHECK VALVE LOCATIONS: FRAME TILT CYLINDER - Rod & Base Sides ATTACHMENT CYLINDER - Base Side AUXILIARY COUNTER BALANCE VALVE LOCATION: HYDRAULICS ATTACHMET CYLINDER - Base Side (optional) ATTACHMENT TILT CYLINDER LOAD SENSE (LS) FRAME TILT CYLINDER FEMALE MALE ATTACHMENT TILT FORWARD ATTACHMENT TILT BACK PRIORITY VALVE EF CF 2 1 OPERATOR'S CAB LS T 3 SHUTTLE VALVE CONTROL VAL
PAGE 325
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2195 thru 9908) FRAME TILT CYLINDER .070 SLAVE CYLINDER - L.H. SLAVE CYLINDER - R.H. AUX. QUICK DISCONNECT COUPLERS ATTACH. TILT CYLINDER HIGH PRESSURE .070 LOW PRESSURE RELIEF VALVES OPTIONAL 3200 PSI 3200 PSI ORIFICES IN FRAME TILT CYLINDER FOR S/N -266 & BEFORE FRAME TILT VALVE ATTACH. TILT VALVE 3200 PSI 3200 PSI AUX.
PAGE 326
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 9909 & After) PILOT OPERATED CHECK VALVE LOCATIONS: FRAME TILT CYLINDER - Rod & Base Sides ATTACHMENT CYLINDER - Base Side AUXILIARY COUNTER BALANCE VALVE LOCATION: HYDRAULICS ATTACHMET CYLINDER - Base Side (optional) ATTACHMENT TILT CYLINDER LOAD SENSE (LS) FEMALE MALE PRIORITY VALVE OPERATOR'S CAB EF CF 2 1 LS T 3 CONTROL VALVE FRAME TILT CYLINDER ATTACHMENT TILT BACK ATTACHMENT TILT FORWARD P SHUTTLE V
PAGE 327
SECTION 10 8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 9909 & After) FRAME TILT CYLINDER SLAVE CYLINDER - L.H. SLAVE CYLINDER - R.H. AUX. QUICK DISCONNECT COUPLERS ATTACH. TILT CYLINDER HIGH PRESSURE LOW PRESSURE RELIEF VALVES OPTIONAL 3200 PSI 3200 PSI 3200 PSI FRAME TILT VALVE AUX. VALVE ATTACH.
PAGE 328
SECTION 10 8042/10042/10054 Steering Circuit (S/N 9908 & Before) RIGHT FRONT BRAKE LEFT FRONT BRAKE STEER CYL. STEER CYL. POWER STEERING UNIT P R L T 1 T B P A LS T 3 P STEER SELECT VALVE T Frame Tilt P SHUTTLE VALVE P T FUEL TANK Boom Hoist Attach Tilt PRIORITY VALVE EF CF 2 Boom Ext. Aux. Hyd. CONTROL VALVE HYDRAULIC RESERVOIR CONTROL VALVE MAIN FILTER OPERATOR'S CAB Park Brake IN MAIN PUMP Trans. DeClutch CONTROL DRAIN OUT TRANSMISSION LOAD SENSE (LS) STEER CYL.
PAGE 329
SECTION 10 8042/10042/10054 Steering Schematic (S/N 9908 & Before) STEERING CYLINDER - R.H. - REAR 4-W STEERING CYLINDER - L.H. - REAR 2-W CRAB STEERING CYLINDER L.H. - FRONT STEERING CYLINDER R.H. - FRONT TEMP. SWITCH 210° F TEST PORT SHUTTLE VALVE 2900-3000 PSI CONTROL VALVES 500-600 PSI 2450-2550 PSI 25 PSI RESERVOIR PRESSURE REDUCING VALVE PRIORITY VALVE PUMP 46 GPM REAR AXLE VALVE PRESSURE REDUCING VALVE MH0331 Rev.
PAGE 330
SECTION 10 8042/10042/10054 Steering Circuit (S/N 9909 & After) RIGHT FRONT BRAKE LEFT FRONT BRAKE STEER CYL. STEER CYL. POWER STEERING UNIT P R L T 1 T B P A LS T 3 P STEER SELECT VALVE T Frame Tilt P SHUTTLE VALVE P T FUEL TANK Boom Hoist Attach Tilt PRIORITY VALVE EF CF 2 Boom Ext. Aux. Hyd. CONTROL VALVE HYDRAULIC RESERVOIR CONTROL VALVE MAIN FILTER OPERATOR'S CAB LS OUT CONTROL DRAIN MAIN PUMP PARK BRAKE LOAD SENSE (LS) STEER CYL.
PAGE 331
SECTION 10 8042/10042/10054 Steering Schematic (S/N 9909 & After) STEERING CYLINDER - R.H. - REAR STEERING CYLINDER - L.H. - REAR 4-W 2-W CRAB STEERING CYLINDER L.H. - FRONT STEERING CYLINDER R.H. - FRONT SHUTTLE VALVE TP X 0-45 GPM CONTROL VALVES X 25 PSI 2450-2550 PSI 3000 PSI RESERVOIR 500 / 600 PSI STANDBY CONTROL VALVES PRIORITY VALVE TEMP.
PAGE 332
SECTION 10 8042/10042/10054 Service Brake & De-Clutch Circuits (S/N 9908 & Before) RIGHT FRONT BRAKE LEFT FRONT BRAKE OPERATOR'S CAB PRIORITY VALVE EF CF LS T P BRAKE VALVE PRESSURE REDUCING VALVE BLOCK P T Boom Hoist (Valve is bolted to Axle Stabilizer Valve Block) CONTROL VALVE FUEL TANK Boom Ext. HYDRAULIC RESERVOIR MAIN FILTER BRK P C2 T C1 PRESSURE REDUCING VALVE Park Brake IN MAIN PUMP Trans.
PAGE 333
SECTION 10 8042/10042/10054 Service Brake & De-Clutch Schematic (S/N 9908 & Before) CONTROL VALVES 400-450 PSI PRESSURE REDUCING VALVE BRAKE VALVE S/N 1167 & BEFORE 500-525 PSI S/N 1168 & AFTER PARK BRAKE .035 ORIFICE (S/N 882 & BEFORE ONLY) TRANS. DECLUTCH 200 PSI FRAME TILT VALVE 100 PSI S/N 001-654 + S/N -1167 & AFTER REAR AXLE STABILIZER CYLINDER REAR AXLE VALVE S/N -655 THRU -1166 MAX. PRESSURE 350 PSI TEST PORT CONTROL VALVES TEMP.
PAGE 334
SECTION 10 8042/10042/10054 Service Brake Circuit (S/N 9909 & After) RIGHT FRONT BRAKE LEFT FRONT BRAKE OPERATOR'S CAB PRIORITY VALVE EF CF LS T P BRAKE VALVE PRESSURE REDUCING VALVE BLOCK P T (Valve is bolted to Axle Stabilizer Valve Block) Boom Hoist CONTROL VALVE FUEL TANK Boom Ext.
PAGE 335
SECTION 10 8042/10042/10054 Service Brake Schematic (S/N 9909 & After) 400-450 PSI PRESSURE REDUCING VALVE BRAKE VALVE S/N 1167 & BEFORE 500-525 PSI S/N 1168 & AFTER PARK BRAKE 200 PSI FRAME TILT VALVE REAR AXLE VALVE S/N 001-654 + S/N -1167 & AFTER REAR AXLE STABILIZER CYLINDER S/N 655 THRU 1166 MAX.
PAGE 336
SECTION 10 10042/10054 Outrigger Schematic (S/N 10881 & Before) OUTRIGGER CYLINDER - R.H. OUTRIGGER CYLINDER - L.H. Pressure Switch 1500 PSI 10054 Only OPTIONAL OUTRIGGER VALVE Pressure Switch 1500 PSI 10054 Only OPTIONAL OUTRIGGER VALVE SHUTTLE VALVE HYDRAULIC RESERVOIR CONTROL VALVES MH0351 342 Rev.
PAGE 337
SECTION 10 10042/10054 Outrigger Schematic (S/N 10882 & After) OUTRIGGER CYLINDER - R.H. OUTRIGGER CYLINDER - L.H.
PAGE 338
3 38 BLK 32 CIRCUIT BREAKER 10 AMP 24 45 45 NOT USED 2 RED 42 22 BRAKE PEDAL SWITCH CAB HEATER (Opt.) ORG 7 1 42 22 24 12 12 WARNING LIGHTS L S S G I 38 G 45 14 41 HORN BUTTON HOURMETER I FUEL GAUGE DK. BLUE/ORG EMERGENCY BRAKE SWITCH 46 12 2 15 6 24 45 46 25 BLACK 2 17 16 18 2 13 40 2 BULB TEST BUTTON SPLICE 35 WASHER BOTTLE (Opt.) 33 RED/GRAY PURPLE WHITE BROWN LIGHTING PACKAGE (Opt.
PAGE 339
WHITE 45 CAB HEATER (Opt.
PAGE 340
WHITE 7.5 AMP BLK RED GRN 7 NOT USED 22 45 1 2 3 4 BRAKE PEDAL SW.
PAGE 341
11 7 45 45 NOT USED 2 RED 39 46 42 WHT L I 38 G G S 14 45 46 24 HORN BUTTON HOURMETER S I FUEL GAUGE EMERGENCY BRAKE SWITCH 24 12 12 22 WARNING LIGHTS 12 35 2 13 45 25 41 26 BLK BLK 43 BLK STABILIZER LIGHT WHITE/BLUE BLUE/WHITE RED 1 41 40 NOT USED NOT USED PRESSURE REDUCING VALVE 31 ORANGE/BLACK BROWN/GREEN ORANGE YELLOW YELLOW/RED LT. BLUE GRAY BROWN LT.GRN/ BLACK LT.
PAGE 342
LETTER N G U P R Y K S B BW OR UO UW RED GRAY NUMBER COLOR 101 BROWN 105 GREEN 103 BLUE 108 VIOLET 111 RED 104 YELLOW 102 PINK 112 GREY 100 BLACK 109 BLACK/WHITE 110 ORANGE/RED 106 BLUE/ORANGE 107 BLUE/WHITE 113 RED 114 GRAY BOOM EXTEND SENSOR .
PAGE 343
SECTION 10 10042 Outrigger Logic Circuit TOGGLE SWITCHES 50 GREY/PURPLE YELLOW/GREEN BROWN/YELLOW 61 RED/GREY 2 BLACK BROWN/YELLOW 63 OUTRIGGER VALVE 64 7.5 AMP* BLACK 2 62 BLACK 60 PURPLE/WHITE GREY/PURPLE 60 64 63 BLACK RED/GREY PURPLE/WHITE YELLOW/ GREEN BROWN/YELLOW L.H. TOP TOP R.H. 62 61 BLACK 2 2 20 *7.5 AMP - S/N 0292 & After 6.0 AMP - S/N 0291 & Before YELLOW/GREEN 60 10 AMP BLACK 20 FOR UNITS WITH CIRCUIT BREAKERS MH0181 Rev.
PAGE 344
SECTION 10 10054 Outrigger Logic Circuit (S/N 9908 & Before) PRESSURE SWITCH 57 50 R.H. OUTRIGGER CYLINDERS 57 L.H. 56 BROWN/ YELLOW 67 PRESSURE SWITCH BOOM SENSOR 2 23 GREY/ PURPLE 64 ENGINE HARNESS 49 YELLOW/ GREEN 60 L.H. 58 OUTRIGGER SWITCHES 49 23 YELLOW/GREEN 2 R.H. 68 BOOM EXTEND SOLENOID RED/GREY PURPLE/WHITE 62 49 23 51 2 3 68 63 23 10A 51 49 10 67 60 2B 61 45 3 56 2A 2C 58 50 10 2 10 GRD.
PAGE 345
SECTION 10 10054 Outrigger Logic Circuit (S/N 9909 & After) PRESSURE SWITCH 57 50 R.H. OUTRIGGER CYLINDERS 57 L.H. 56 67 PRESSURE SWITCH 64 BROWN/ YELLOW BOOM SENSOR 2 23 GREY/ PURPLE ENGINE HARNESS 49 YELLOW/ GREEN 60 35 7 YELLOW/GREEN L.H. 58 OUTRIGGER SWITCHES 49 23 2H R.H. 35 7 68 BOOM EXTEND SOLENOID RED/GREY PURPLE/WHITE 62 49 23 51 2K 2 7 56 3 68 63 23 51 49 67 60 2B 61 45 3 2A 2C 58 50 2 3 TRANSMISSION WIRE HARNESS BRAKE SWITCH PARK BRAKE SOLENOID GRD.
PAGE 346
SECTION 10 8042/10042/10054 Lighting System Circuit (Optional) BOOM LIGHT RIGHT FRONT LEFT FRONT 7 8 6 9 2 2 1 2 3 TURN SIGNAL SWITCH 4 6 9 54 11 8 5 TO FUEL GAUGE 7 15 T 10 H B IGNITION SWITCH LIGHT SWITCH 3 12 4 FLASHER FUSE 20 AMP 1 2 5 3 34 14 1 STOP LIGHT SWITCH 12 2 54 14 12 2 2 11 5 34 34 3 4 2 15 LEFT REAR 15 10 RIGHT REAR MH0201 352 Rev.
PAGE 347
SECTION 10 8042/10042/10054 Charging Circuit BATTERY CAB FRAME GROUND "BAT" TERMINAL 19 RED/WHITE TO STARTER RELAY BATTERY 27 CAB FRAME GROUND "BAT" TERMINAL STARTER S/N 0292 & Before 27 TO STARTER RELAY STARTER RED ALTERNATOR CHARGING LIGHT TO IGNITION SWITCH YELLOW RED/WHITE 19 6 6 27 RED 29 TO STARTER RELAY 5 YELLOW ALTERNATOR 38 TO HOURMETER W D+ B+ WARNING LIGHTS 6 6 2 TO FRAME GROUND YELLOW MH0211 Rev.
PAGE 348
SECTION 10 8042/10042/10054 Cranking Circuit (S/N 9908 & Before) BATTERY CAB FRAME GROUND 19 BATTERY CAB FRAME GROUND 37 STARTER 19 RED/WHITE S/N 0292 & Before NOTE: 40 AMP Circuit Breaker replaced with 40 AMP sealed fuse 40 AMP S/N 8739 & After. STARTER RELAY STARTER 29 2 RED RED BLACK 27 26 RED 27 RED 27 29 1 3 2 4 5 RED/BLACK 34 IGNITION SWITCH RED/BLACK 34 2 FUEL RUN SOLENOID 20 WHITE BLACK 1 FRAME GROUND 14 EMERGENCY BRAKE SWITCH WHITE/ BLUE WHITE/ BLUE 14 37 DK.
PAGE 349
SECTION 10 8042/10042/10054 Cranking Circuit (S/N 9909 & After) BATTERY CAB FRAME GROUND 106 19 RED/WHITE STARTER RELAY STARTER RED 2 RED/WHITE 30A RED 40 AMP 29 BLACK 27 26 RED 27 RED 27 29 1 3 2 5 RED/BLACK 34 RED/BLACK 34 2 1 IGNITION SWITCH WHITE FUEL RUN SOLENOID RED 111 114 EMERGENCY BRAKE SWITCH GREY FRAME GROUND TO SHIFTER 100 BLACK 20 BLUE/ORANGE 4 106 NEUTRAL (N) START RELAY MH0700 Origin 2/00 355
PAGE 350
SECTION 10 8042/10042 Steer Select Circuit (S/N 0291 & Before) BATTERY FRAME GROUND 27 STARTER RED CIRCUIT BREAKER 40 AMP 26 27 RED RED LT. GREEN/ 1 WHITE 2 2 8 11 9 RED 27 29 2 1 STEER SELECT SWITCH LT. GREEN 27 LT. GREEN/ BLACK TO STARTER RELAY 2 STEER SELECT VALVE 5 2 2 11 TO ALTERNATOR 46 CIRCUIT BREAKER 6 AMP 20 39 7 CIRCUIT BREAKER 6 AMP CIRCUIT BREAKER MOUNTING STUD 26 3 3 4 1 2 5 PURPLE IGNITION SWITCH MH0231 356 Rev.
PAGE 351
SECTION 10 8042/10042/10054 Steer Select Circuit (S/N 0292 & After) BATTERY FRAME GROUND 27 STARTER RED 27 RED 26 LT. GREEN/ 1 WHITE 11 9 11 STEER SELECT SWITCH 46 2 27 LT. GREEN/ BLACK RED 29 27 2 1 2 TO STARTER RELAY 5 2 STEER SELECT VALVE 2 TO ALTERNATOR RED 7.5 A 27 2 8 LT. GREEN RED NOTE: 40 AMP Circuit Breaker replaced with 40 AMP sealed fuse S/N 8739 & After. 40 AMP 26 20 1 3 PURPLE 3 2 4 5 IGNITION SWITCH CIRCUIT BREAKER MOUNTING STUD MH0241 Rev.
PAGE 352
SECTION 10 8042/10042 Stabilizer Circuit (S/N 0291 & Before) SOL 3 45 2 47 PUR/BLK BROWN TAN PURPLE/WHITE BOOM RELAY 2 2 47 40 10 48 28 2 39 STABILIZER VALVE 28 47 28 47 SOL 5 SOL 1 SOL 6 SOL 2 STABILIZER CYLINDER DK.
PAGE 353
SECTION 10 8042/10042 Stabilizer Circuit (S/N 0292 thru S/N 9908) SOL 3 45 PUR/BLK 39 BROWN TAN PURPLE/WHITE BOOM RELAY 2 2 47 2 47 40 10 48 28 2 STABILIZER VALVE 28 47 28 47 SOL 5 SOL 1 SOL 6 SOL 2 STABILIZER CYLINDER DK. BLUE/ORANGE 28 SOL 4 STABILIZER LOCK RELAY BLUE BLK + (-) BLK BLK BLACK BOOM SENSOR 35 RED/GRAY BROWN 7 35 SPLICE NOTE: 40 AMP Circuit Breaker replaced with 40 AMP sealed fuse S/N 8739 & After. CIRCUIT BREAKER 7.
PAGE 354
SECTION 10 8042/10042 Stabilizer Circuit (S/N 9909 & After) SOL 3 45 PUR/BLK 39 BOOM SENSOR BROWN TAN PURPLE/WHITE BOOM RELAY 2 2 47 2 47 40 10 48 28 2 STABILIZER VALVE 28 47 28 47 SOL 5 SOL 1 SOL 6 SOL 2 STABILIZER CYLINDER DK. BLUE/ORANGE 28 SOL 4 STABILIZER LOCK RELAY BLK + (-) BLK BLK BLACK BLUE 35 RED/GRAY BROWN 7 35 SPLICE 10 10 7.5 AMP RED 46 35 35 27 27 BROWN/WHITE 27 RED 2 26 3 2 4 5 3 BLK 7.
PAGE 355
SECTION 10 10054 Stabilizer Circuit (S/N 9908 & Before) SOL 3 PUR/BLK 2 47 40 TAN 28 47 BOOM RELAY 10 28 47 SOL 5 SOL 1 SOL 6 SOL 2 10 BLUE BLK PURPLE/WHITE BROWN 35 SPLICE NOTE: 40 AMP Circuit Breaker replaced with 40 AMP sealed fuse RED S/N 8739 & After. CIRCUIT BREAKER 7.5 AMP 46 (-) 2 10 TAN 10 10 35 35 27 27 BROWN/WHITE 40 AMP 27 RED 2 26 3 2 4 5 3 BLK 2 2 BLK BLK IGNITION SWITCH CIRCUIT BREAKER 7.
PAGE 356
SECTION 10 10054 Stabilizer Circuit (S/N 9909 & After) SOL 3 45 2 47 BROWN TAN FROM LOGIC HARNESS 28 47 10 28 47 SOL 1 SOL 6 SOL 2 10 BLUE BLK PURPLE/WHITE 40 AMP SEALED FUSE RED 7.5 AMP 27 46 10 35 35 RED 27 27 BLK BATTERY L S I G 40 40 RED 2 2 BLACK 46 S HOURMETER 20 2 G CIRCUIT BREAKER MOUNTING STUD 20 20 42 45 108 112 TO LOGIC HARNESS 45 EMERGENCY BRAKE SWITCH 114 113 NEUTRAL START RELAY RED GRAY DK.
PAGE 357
SECTION 10 NOTES 363
PAGE 358
SECTION 10 Stabil-TRAK System The following information explains the difference between a typical telescopic handler and the benefits that the Stabil-TRAK System provides. Most telescopic handlers operate within a 3 point stability triangle, as defined by points A, B, and C in the illustration to the right. Point 1 in the illustration represents the center of gravity of an unloaded vehicle. The load has its own center of gravity indicated by Point 3.
PAGE 359
SECTION 10 Stabil-TRAK System Angle Of Stabil-TRAK Activation 40° FREE PIVOT MODE Stabil-TRAK Light "OFF" MH0362 Free Pivot Mode Boom Angles are below 40°. Rear Axle is allowed to pivot freely. Rev.
PAGE 360
SECTION 10 Stabil-TRAK System Angle Of 40° Stabil-TRAK Activation FINAL POSITIONING MODE Stabil-TRAK Light "OFF" FREE PIVOT MODE Stabil-TRAK Light "OFF" Travel MH0372 Final Positioning Mode Boom Angles are above 40° with vehicle traveling. Rear axle is unlocked and is allowed to pivot, but will respond SLOWLY to changes in terrain. 366 Rev.
PAGE 361
SECTION 10 Stabil-TRAK System Angle Of 40° Stabil-TRAK Activation LOCKED MODE Stabil-TRAK Light "ON" FREE PIVOT MODE Stabil-TRAK Light "OFF" MH0382 Locked Mode Boom Angles are above 40°. Rear axle is locked so it is rigid with the frame. Activated by one or more of these functions: • Engaging the Emergency Brake Switch • Placing Travel Select Lever in NEUTRAL • Depressing and holding the Service Brake Pedal Rev.
PAGE 362
SECTION 10 8042/10042 Stabil-TRAK System Troubleshooting (S/N 9908 & Before) ) )5 5 ( ( ( ( 3 3, , 9 9 2 2 7 7 0 0 2 2' ' ( ( ) ), , 1 1 $ $ / / 3 32 2 6 6 , , 7, 7, 2 2 1 1 , , 1 1 * * 0 0 2 2' ' ( ( / /2 2 & & . . ( ( ' ' 0 0 2 2' ' ( ( ) )5 5 ( ( ( ( 3 3, , 9 9 2 2 7 7 0 0 2 2' ' ( ( ) ), , 1 1 $ $ / / 3 32 2 6 6 , , 7, 7, 2 2 1 1 , , 1 1 * * 0 0 2 2' ' ( ( / /2 2 & & . .
PAGE 363
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Ignition “OFF” (S/N 9908 & Before) , , J J Q Q L L W W L L R RQ Q ´2 ´2) )) )µ µ , , J J Q Q L L W W L L R RQ Q ´2 ´2) )) )µ µ See NOTE A 40 Amp DE See NOTE D IGN. SWITCH 35 B See NOTE 39 BOOM SWITCH RELAY C DE O 10 42 45 1 BOOM UP 28 FUEL SHUTOFF Fwd/Rev NEU. SWITCH PARK BRAKE SWITCH STABILIZER LOCK BOOM RELAY SERVICE BRAKE SWITCH 14 41 NEUTRAL START SWITCH 48 PARK BRAKE/ DECLUTCH SOLENOID 47 SOL. 6 SOL.
PAGE 364
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Free Pivot Mode (S/N 9908 & Before) ) ) U U H HH H 3 3 L L Y Y R R W W 0 0 R R G G H H ) ) U U H HH H 3 3 L L Y Y R R W W 0 0 R R G G H H & & R R Q Q G G L L W WL L R R Q Q V V & & R R Q Q G G L L W WL L R R Q Q V V 1. Ignition “ON” 4. 2. Transmission in Fwd. or Rev. 5. 3. Boom Below 40° 6. SB & PB Released See NOTE A 40 Amp See NOTE D IGN.
PAGE 365
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Free Pivot Mode (S/N 9908 & Before) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 .029 E SOL. 2 E SOL. 1 R R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP 46 GPM SOL. 3 500 - 525 PSI TP 200 +/- 25 PSI STABILIZER VALVE BLOCK S B BR K T TP *100 PSI CONTROL VALVE (located on valve plate under cab) T C SOLENOID 4 *60 PSI P P V SOL.
PAGE 366
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Final Positioning Mode (S/N 9908 & Before) ) ) L L Q Q D D O O 3 3 R R V V L L W WL L R R Q Q L L Q Q J J 0 0 R R G G H H ) ) L L Q Q D D O O 3 3 R R V V L L W WL L R R Q Q L L Q Q J J 0 0 R R G G H H 1. Ignition “ON” 4. 2. Transmission in Fwd. or Rev. 5. 3. Boom Above 40° 6.
PAGE 367
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Final Positioning Mode (S/N 9908 & Before) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 .029 E E SOL. 2 SOL. 1 R R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP 46 GPM SOL. 3 500 - 525 PSI TP 200 +/- 25 PSI FRAME TILT VALVE SECTION STABILIZER VALVE BLOCK P T T B S C T R P V SOL.
PAGE 368
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Locked Mode (S/N 9908 & Before) / / R R F F N NH HG G 0 0 R R G G H H / / R R F F N NH HG G 0 0 R R G G H H & & R R Q Q G G L L W WL L R R Q Q V V & & R R Q Q G G L L W WL L R R Q Q V V 1. Ignition “ON” 4. 2. Transmission in Neutral 5. 3. Boom Above 40° 6. SB & PB Applied See NOTE A See NOTE 40 Amp See NOTE D DE B C IGN. SWITCH 39 BOOM SWITCH RELAY 35 O 10 42 45 FUEL SHUTOFF BOOM UP 28 1 Fwd/Rev NEU.
PAGE 369
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Locked Mode (S/N 9908 & Before) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 E .029 R E SOL. 2 SOL. 1 R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP 46 GPM SOL. 3 500 - 525 PSI TP 200 +/- 25 PSI FRAME TILT VALVE SECTION STABILIZER VALVE BLOCK T S B T C P V SOL.
PAGE 370
SECTION 10 8042/10042 Stabil-TRAK System Troubleshooting (S/N 9909 & After) ) )5 5 ( ( ( ( 3 3, , 9 9 2 2 7 7 0 0 2 2' ' ( ( ) ), , 1 1 $ $ / / 3 32 2 6 6 , , 7, 7, 2 2 1 1 , , 1 1 * * 0 0 2 2' ' ( ( / /2 2 & & . . ( ( ' ' 0 0 2 2' ' ( ( ) )5 5 ( ( ( ( 3 3, , 9 9 2 2 7 7 0 0 2 2' ' ( ( ) ), , 1 1 $ $ / / 3 32 2 6 6 , , 7, 7, 2 2 1 1 , , 1 1 * * 0 0 2 2' ' ( ( / /2 2 & & . .
PAGE 371
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Ignition “OFF” (S/N 9909 & After) , , J J Q Q L L W W L L R RQ Q ´2 ´2) )) )µ µ , , J J Q Q L L W W L L R RQ Q ´2 ´2) )) )µ µ A 40 Amp DE B D 35 C IGN. SWITCH 46 DE 39 BOOM SWITCH RELAY 10 O 45 1 FUEL SHUTOFF 48 45 STABILIZER LOCK BOOM RELAY PARK BRAKE SWITCH SERVICE BRAKE SWITCH 45 112 47 111 PARK BRAKE DE DE 113 100 SOL. 5 SOL. 6 SOL. 4 DE PROXIMITY SWITCH DOWN 40 41 107 114 BOOM UP 28 46 SOL.
PAGE 372
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Free Pivot Mode (S/N 9909 & After) ) ) U U H HH H 3 3 L L Y Y R R W W 0 0 R R G G H H ) ) U U H HH H 3 3 L L Y Y R R W W 0 0 R R G G H H & & R R Q Q G G L L W WL L R R Q Q V V & & R R Q Q G G L L W WL L R R Q Q V V 1. Ignition “ON” 4. 2. Transmission in Fwd. or Rev. 5. 3. Boom Below 40° 6. SB & PB Released A 40 Amp E B D 35 C IGN.
PAGE 373
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Free Pivot Mode (S/N 9909 & After) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 .029 E SOL. 2 E SOL. 1 R R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP LS 45 GPM LS 500 - 525 PSI SOL.
PAGE 374
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Final Positioning Mode (S/N 9909 & After) ) ) L L Q Q D D O O 3 3 R R V V L L W W L L R R Q Q L L Q Q J J 0 0 R R G G H H ) ) L L Q Q D D O O 3 3 R R V V L L W W L L R R Q Q L L Q Q J J 0 0 R R G G H H & & R R Q Q G G L L W WL L R R Q Q V V & & R R Q Q G G L L W WL L R R Q Q V V 1. Ignition “ON” 4. 2. Transmission in Fwd. or Rev. 5. 3. Boom Above 40° 6. SB & PB Released A 40 Amp DE B D C IGN.
PAGE 375
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Final Positioning Mode (S/N 9909 & After) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 .029 E E SOL. 2 SOL. 1 R R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP LS 45 GPM LS SOL.
PAGE 376
SECTION 10 8042/10042 Stabil-TRAK Electrical Circuit Locked Mode (S/N 9909 & After) / / R R F F N NH HG G 0 0 R R G G H H / / R R F F N NH HG G 0 0 R R G G H H & & R R Q Q G G L L W WL L R R Q Q V V & & R R Q Q G G L L W WL L R R Q Q V V 1. Ignition “ON” 4. 2. Transmission in Neutral 5. 3. Boom Above 40° 6. SB & PB Applied A 40 Amp DE B D C BOOM 39 SWITCH RELAY IGN.
PAGE 377
SECTION 10 8042/10042 Stabil-TRAK Hydraulic Circuit Locked Mode (S/N 9909 & After) STABILIZER CYLINDER FRAME TILT CYLINDER SOLENOID 2 .029 E .029 R E SOL. 2 SOL. 1 R SOLENOID 6 .060 SOLENOID 5 SOLENOID 1 SOL. 6 SOL. 5 PRESSURE REDUCING VALVE BLOCK SOL. 4 VARIABLE DISPLACEMENT PUMP LS 45 GPM LS SOL.
PAGE 378
SECTION 10 6 6 6 6 W W D DE E L L W W D DE E L L O O 75 75 $ $ . . O O 75 75 $ $ . .
PAGE 379
SECTION 10 6 6 6 6 W W D DE E L L W W D DE E L L O O O O 7 7 5 5 7 7 5 5 $ $ . . $ $ . .
PAGE 380
– White Stabilizer Light Sol. 5&6 47 48 52 2 45 Stabilizer Lock Relay DE 45 Fwd/Rev Neutral Switch Tan Relay Block located under Dash on left side of the Steering Wheel Switch Power 7.5 Amp Outrigger Pressure Proximity Switch Power 7.5 Amp Outrigger and Extend Sol. 3&4 40 To Starter Interlock Solenoid Coil Neutral Start Switch Dk. Bl/Red Red Red/Blk Park Brake Switch 42 Purple Dk.
PAGE 381
Red/Blk Red 47 2 45 Stabilizer Lock Relay DE 45 Relay Block located under Dash on left side of the Steering Wheel Outrigger Lockout Relay Boom Extend Lockout Relay RELAY LOCATIONS Park Brake Interlock B Right Outrigger Lockout Relay Stabilizer Interlock Relay Stabilizer Lock-Up Relay Left Outrigger Lockout Relay DE 2 Black Black 2 59 2 Boom Sensor DE 10 2 Stabilizer Lock Relay Boom Switch Relay RELAY LOCATIONS F E D C 67 2 Left Outrigger "Up" Solenoid 63 Left Outrigger
PAGE 382
– White Stabilizer Light Sol. 5&6 2 45 E Stabilizer Lock Relay 45 Fwd/Rev Neutral Switch Tan 47 48 52 Purple Relay Block located under Dash on left side of the Steering Wheel Switch Power 7.5 Amp Outrigger Pressure Proximity Switch Power 7.5 Amp Outrigger and Extend Sol. 3&4 40 To Starter Interlock Solenoid Coil Neutral Start Switch Dk.
PAGE 383
2 Stabilizer Lock Relay DE Relay Block located under Dash on left side of the Steering Wheel Boom Extend Lockout Relay Outrigger Lockout Relay RELAY LOCATIONS Park Brake Interlock B Stabilizer Interlock Relay Stabilizer Lock-Up Relay Left Outrigger Lockout Relay Black 2 59 2 DE 10 2 Stabilizer Lock Relay Boom Switch Relay F E D C 2 Left Outrigger "Up" Solenoid 63 Left Outrigger Lockout Relay 2 40 Amp Ignition Switch Feed Yel/Grn DE Left Outrigger 2 "Down" Solenoid 64 7.
PAGE 384
– White 2 45 DE Stabilizer Lock Relay 45 Fwd/Rev Neutral Switch Tan 47 Stabilizer Light Sol. 5&6 48 52 Purple Relay Block located under Dash on left side of the Steering Wheel Switch Power 7.5 Amp Outrigger Pressure Proximity Switch Power 7.5 Amp Outrigger and Extend Sol. 3&4 40 To Starter Interlock Solenoid Coil Dk.
PAGE 385
Red/Blk Red Relay Block located under Dash on left side of the Steering Wheel Switch Power 7.
PAGE 386
– White 2 45 E Stabilizer Lock Relay 45 Fwd/Rev Neutral Switch Tan 47 Stabilizer Light Sol. 5&6 48 52 Purple Relay Block located under Dash on left side of the Steering Wheel Switch Power 7.5 Amp Outrigger Pressure Proximity Switch Power 7.5 Amp Outrigger and Extend Sol. 3&4 40 To Starter Interlock Solenoid Coil Neutral Start Switch Dk.
PAGE 387
Red 47 2 Relay Block located under Dash on left side of the Steering Wheel Switch Power Right Outrigger Lockout Relay Outrigger Lockout Relay Boom Extend Lockout Relay RELAY LOCATIONS Park Brake Interlock B Black Boom Extend Interlock Park Brake Applied Stabilizer Interlock Relay Stabilizer Lock-Up Relay Left Outrigger Lockout Relay DE 2 Black Black 2 59 2 Boom Sensor DE 10 2 Stabilizer Lock Relay Boom Switch Relay RELAY LOCATIONS F E D C 67 2 Left Outrigger "Up" Solenoid
PAGE 388
– White Stabilizer Light Sol.
PAGE 389
SECTION 10 NOTES 395
PAGE 390
SECTION 10 6 6 6 6 % % 2 2 2 20 0 % % 2 2 2 20 0 W W D D E E L L W W D D E E L L O O O O 7 7 5 5 7 7 5 5 ( ( ; ; 7( 7( 1 1 ( ( ; ; 7( 7( 1 1 $ $ . . $ $ . .
PAGE 391
SECTION 10 6 6 6 6 W W D D E E L L W W D D E E L L O O 75 75 O O 75 75 $ $ . . $ $ . .
PAGE 392
Sol. 3&4 47 42 Purple 45 107 7.5 Amp Outrigger and Extend Proximity Switch Power 7.5 Amp Outrigger Pressure Switch Power Black Green Blue Violet Red Yellow Pink Gray A B C D A B C D Park Brake Interlock B A O Park Brake Interlock Dk.
PAGE 393
Sol. 3&4 47 Purple Tan 45 108 46 107 A B C D A B C D Park Park Brake Interlock Dk.
PAGE 394
40 Sol. 3&4 47 42 Purple 45 46 107 Black Green Blue Violet Red Yellow Pink Gray 2 A B C D A B C D DE Park Brake Interlock Dk. Blue Org/Black 114 104 Not Used 101 Brown 108 7.5 Amp Outrigger Pressure Switch Power 7.
PAGE 395
Sol. 3&4 47 Purple 42 Tan 45 46 107 A B C D A B C D Park Brake Interlock Dk.
PAGE 396
Sol. 3&4 47 42 Purple 45 46 107 7.5 Amp Outrigger and Extend Proximity Switch Power 7.5 Amp Outrigger Pressure Switch Power Black Green Blue Violet Red Yellow Pink Gray Park Brake Interlock Dk.
PAGE 397
40 Sol.
PAGE 398
40 Sol. 3&4 47 42 Purple 45 107 7.5 Amp Outrigger and Extend Proximity Switch Power 7.5 Amp Outrigger Pressure Switch Power 108 46 Black Green Blue Violet Red Yellow Pink Gray A B C D A B C D Park Brake Interlock Dk.
PAGE 399
40 Sol.
PAGE 400
40 Sol. 3&4 47 42 Purple 45 107 7.5 Amp Outrigger and Extend Proximity Switch Power 7.
PAGE 401
PART NUMBER INDEX Part Number 10136599 10138907 10238805 10701363 10701562 10715335 10731702 10731704 10731705 10731706 10731707 10731709 10731710 10731711 10731712 10731713 10731715 10731716 10731717 10731718 10731719 10731720 10731721 10731722 10731723 10731724 10731725 10731726 10731727 10731728 10731729 10731730 10731731 10731732 10731734 10731736 10731737 10731738 10731739 10731741 10731742 10731743 10731744 10731745 10731746 10731747 10731748 10731749 10731750 10731751 10731752 10731753 10731754 10731
PAGE 402
PART NUMBER INDEX Part Number 10731957 10731958 10731959 10731960 10731961 10731962 10731963 10731964 10731965 10731966 10731967 10731968 10731969 10731970 10731971 10731972 10731973 10731974 10731975 10731976 10731977 10731978 10731979 10731980 10731981 10731982 10731983 10731984 10731985 10731986 10731987 10731988 10731989 10731992 10731993 10731994 10731995 10731996 10731997 10731998 10731999 10732000 10732001 10732002 10732003 10732004 10732005 10732007 10732009 10732011 10732012 10732013 10732015 10732
PAGE 403
PART NUMBER INDEX Part Number 2712973 2712993 2713054 2713222 2713242 2713262 2713282 2713292 2713332 2713333 2713363 2713432 2713442 2713452 2713642 2713803 2713853 2714973 2714993 2716163 2716173 2716516 2716545 4105621 4106561 4107182 4107232 4107692 4107702 4107712 4107812 4107822 4107832 4107971 4107981 4108161 4108232 4108302 4110123 4110124 4110125 5721202 5724284 5724302 5724622 5724742 5746241 5746411 6604662 6604712 6604882 139 6604972 6604982 6605202 6605772 6608621 6611752 Page ...............
PAGE 404
PART NUMBER INDEX Part Number Page 7113952 ...................... 267 7113982 ...................... 267 7114032 ...................... 257 7114112 .............. 231, 255 7114542 .............. 215, 217 7114604 ...................... 209 7114612 ...................... 213 7114754 .............. 209, 211 7114763 ...................... 207 7114922 ...................... 259 7114941 ...................... 251 7115114 ...................... 225 7115163 ...................... 207 7115432 .....................
PAGE 405
PART NUMBER INDEX Part Number 8032595 8032604 8032605 8032606 8032607 8032608 8032609 8032611 8032612 8032613 8032614 8032615 8032616 8032617 8032620 8032622 8032623 8032624 8032625 8032626 8032627 8032628 8032629 8032631 8032632 8032633 8032634 8032635 8032637 8032638 8032640 8032641 8032642 8032643 8032644 8032645 8032646 8032647 8032648 8032649 8032650 8032651 8032652 8032653 8032654 8032655 8032656 8032657 8032658 8032659 8032661 8032663 8032665 8032666 8032669 8032670 8032672 8032673 Page ...........
PAGE 406
PART NUMBER INDEX Part Number 8033704 8033715 8033721 8033722 8033723 8033724 8033725 8033726 8033727 8033728 8033729 8033730 8033731 8033732 8033733 8033734 8033735 8033736 8033737 8033738 8033740 8033741 8033742 8033744 8033745 8033746 8033747 8033748 8033749 8033750 8033751 8033753 8033755 8033756 8033760 8033761 8033763 8033768 8033769 8033770 8033771 8033772 8033773 8033774 8033775 8033776 8033777 8033778 8033779 8033780 8033781 8033782 8033783 8033784 8033785 8033786 8033788 8033789 282 Page ......
PAGE 407
PART NUMBER INDEX Part Number 8033992 8033993 8033994 8033995 8033996 8033997 8033998 8033999 8034500 8034501 8034502 8034503 8034504 8034505 8034527 8034528 8034530 8034531 8034532 8034534 8034538 8034539 8034540 8034541 8034542 8034543 8034544 8034545 8034546 8034547 8034548 8034549 8034550 8034551 8034552 8034554 8034555 8034556 8034557 8034558 8034559 8034560 8034561 8034562 8034569 8034570 8034571 8034575 8034577 8034578 8034580 8034581 8034584 8034585 8034586 8034590 8034593 8034684 Page ...........
PAGE 408
PART NUMBER INDEX Part Number Page 8220073 29, 213, 215, 217, 219, 221 8220882 ..... 207, 209, 211, 225 8223016 ...................... 223 8223024 31, 207, 209, 211 8223025 ..... 207, 209, 211, 223 8223216 ..... 213, 215, 217, 219, 221 8223217 ..... 163, 213, 215, 217, 219, 221 8223220 15, 207, 209, 211 8223221 ...................... 225 8223226 ...................... 163 8223405 15, 207, 209, 211 8223419 ...................... 223 8223424 ...................... 223 8223436 ...... 207, 209, 211 8223438 ..
PAGE 409
PART NUMBER INDEX Part Number Page 8307109 . 7, 23, 25, 29, 37, 117, 119, 121, 207, 209 8307110 .... 5, 27, 117, 121 8307111 ..... 209, 211, 223, 225 8307112 .............. 251, 275 8307113 ............ 9, 13, 229 8307201 .......................... 9 8307202 .......................... 5 8307203 ... 5, 29, 119, 121, 127, 245 8307204 . 9, 119, 125, 229, 231, 233, 255, 257, 259 8307206 . 9, 137, 139, 223, 231, 255 8307207 .................. 9, 223 8307220 ................ 93, 139 8307222 ......
PAGE 410
PART NUMBER INDEX Part Number Page 8760254 ...................... 157 8760268 ...................... 147 8760276 ...... 139, 147, 149 8760302 ...................... 139 8760303 ...................... 133 8760305 ...... 141, 143, 157 8760307 .............. 135, 145 8760308 ...................... 139 8760311 ..... 133, 135, 139, 249 8760313 ...... 133, 135, 249 8760317 .............. 139, 141 8760351 ...................... 163 8760401 ..... 133, 135, 137, 139 8760407 ...................... 135 8760409 .....
PAGE 411
PAGE 412
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.