parts service maintenance skytrack 8042-10042-10054

Illustrated Parts ManualService and Maintenance Manual

ANSI

Model

80421004210054

8990187-003FEBRUARY 2000

Page Page

Table of Contents

8042/10042/10054 Origin 2/00 T of C 1© 2000 JLG Industries, Inc.

SECTION 1 – MAIN FRAME AND GUARDS

Main Frame .................................................................. 2Hoods and Guards ....................................................... 4

SECTION 2 – OPERATOR’S CAB AND CONTROLS

Operator’s Cab - Open ................................................. 6Operator’s Cab - Closed (Optional) .............................. 8Cab Door .................................................................... 10Operator’s Seat .......................................................... 12Control Console.......................................................... 14Transmission Shift Controls (S/N 9908 & Before) ...... 16Transmission Shift Controls (S/N 9909 & After) ......... 18Boom Raise/Lower & Extend/Retract Control ............ 20Frame Level & Attachment Tilt Control ...................... 22Throttle Pedal Control ................................................ 24Service Brake Pedal Control ...................................... 26Front Windshield Wiper .............................................. 28Cab Heater (Optional) ................................................ 30Aux. Hydraulic Control (Optional) ............................... 32Mirrors ........................................................................ 34Skylight Windshield Wiper (Optional) ......................... 36Soft Cab Enclosure (Optional).................................... 38

SECTION 3 – DRIVE TRAIN

Converter and Transmission Housings(S/N 9908 & Before)............................................. 40

Converter Group (S/N 9908 & Before) ....................... 42Forward, Reverse, Low and 2nd

(S/N 9908 & Before)............................................. 44Output, Idler and Third (S/N 9908 & Before) .............. 46Transmission Clutch Groups (S/N 9908 & Before)..... 48Control Valve Assembly (S/N 9908 & Before)............ 50Emergency Brake (S/N 9908 & Before) ..................... 52Transmission Mounting (S/N 9908 & Before)............. 54Engine Connect (S/N 9909 & After) ........................... 56Converter and Layshaft (S/N 9909 & After)................ 58Oil Pressure Pump (S/N 9909 & After) ....................... 60Input Shaft (S/N 9909 & After).................................... 62Gearbox Housing (S/N 9909 & After) ......................... 64Clutch Pack 1st Gear - 1 of 2 (S/N 9909 & After) ....... 66Clutch Pack 1st Gear - 2 of 2 (S/N 9909 & After) ....... 68Clutch Pack 2nd Gear - 1 of 2 (S/N 9909 & After)...... 70Clutch Pack 2nd Gear - 2 of 2 (S/N 9909 & After)...... 72Clutch Pack 3rd Gear - 1 of 2 (S/N 9909 & After) ...... 74Clutch Pack 3rd Gear - 2 of 2 (S/N 9909 & After) ...... 76Output Shaft (S/N 9909 & After) ................................. 78Parking Brake (S/N 9909 & After) .............................. 80Power Take-Off Shaft (S/N 9909 & After) .................. 82Gearshift System (S/N 9909 & After) ......................... 84Control Valve (S/N 9909 & After) ............................... 86

Transmission Filter & Dipstick (S/N 9909 & After) ......88Oil Tubes (S/N 9909 & After) ......................................90Transmission Mounting (S/N 9909 & After) ................92Drive Shaft - Engine to Transmission

(S/N 9908 & Before) .............................................94Drive Shaft - Engine to Transmission

(S/N 9909 & After) ................................................96Drive Shaft - Front and Rear (S/N 9908 & Before) .....98Drive Shaft - Front and Rear (S/N 9909 & After) ......100Differential Carrier Assembly ....................................102Axle Steering Joints ..................................................104Axle Wheel Ends (S/N 0460 & Before) .....................106Axle Wheel Ends (S/N 0461 & After) ........................108Tie Rod and Steering Cylinder Mounting ..................110Wheels and Tires - 8042...........................................112Wheels and Tires - 10042/10054..............................114

SECTION 4 – POWER PLANT

Engine, Radiator and Oil Cooler Mounting(S/N 0118 & Before) ...........................................116

Engine, Radiator and Oil Cooler Mounting(S/N 0119 thru 1598) ..........................................118

Engine, Radiator and Oil Cooler Mounting (EPA)(S/N 1599 & After) ..............................................120

Torsion Coupler (S/N 9909 & After) ..........................122Exhaust System ........................................................124Air Cleaner ................................................................126Fuel System (S/N 1598 & Before).............................128Fuel System (EPA) (S/N 1599 & After) .....................130

SECTION 5 – HYDRAULIC CIRCUITS

Power Steering Circuit (S/N 9908 & Before) .............132Power Steering Circuit (S/N 9909 & After) ................134Control Valves Circuit (S/N 9908 & Before) ..............136Control Valves Circuit (S/N 9909 & After) .................138Boom Raise/Lower & Extend/Retract Circuit

(S/N 9908 & Before) ...........................................140Boom Raise/Lower & Extend/Retract Circuit

(S/N 9909 & After) ..............................................142Attachment Tilt and Slave Circuit ..............................144Frame Tilt and Stabilizer Circuit ................................146Service Brake and De-Clutch Circuit ........................148Valve Plate Assembly

(Without Outriggers 8042 Only)..........................150Valve Plate Assembly

(With Outriggers 10042/10054 Only)..................152Transmission Cooling Circuit (S/N 9908 & Before) ...154Transmission Cooling Circuit (S/N 9909 & After) ......156Auxiliary Hydraulic Circuit (Optional) ........................158Outrigger Hydraulic Circuit (10042/10054 Only) .......160

8042/10042/10054 Origin 2/00

Page Page

T of C 2 © 2000JLG Industries, Inc.

SECTION 6 – HYDRAULIC COMPONENTS

Hydraulic Reservoir .................................................. 162Main Pump (S/N 9908 & Before) .............................. 164Main Pump (S/N 9909 & After) ................................. 166Boom Extend Cylinder (Early Production) ................ 168Boom Extend Cylinder (Current Production) ............ 170Boom Hoist Cylinder (S/N 5818 & Before) ............... 172Boom Hoist Cylinder (S/N 5819 & After) .................. 174Frame Tilt Cylinder ................................................... 176Stabilizer Cylinder..................................................... 178Slave Cylinder (Early Production)............................. 180Slave Cylinder (Current Production)......................... 182Attachment Tilt Cylinder ........................................... 184Outrigger Cylinder (S/N 10881 & Before) ................. 186Outrigger Cylinder (S/N 10882 & After) .................... 188Swing Carriage Cylinder........................................... 190Side Tilt Carriage Cylinder........................................ 192Steering Cylinder (S/N 1167 & Before)..................... 194Steering Cylinder (S/N 1168 & After)........................ 196Main Control Valve ................................................... 198Secondary Control Valve.......................................... 200Directional Control Valves 1 of 2 .............................. 202Directional Control Valves 2 of 2 .............................. 204

SECTION 7 – ELECTRICAL

Electrical System - Cab Harness(S/N 0291 & Before)........................................... 206

Electrical System - Cab Harness(S/N 0292 thru 9908) ......................................... 208

Electrical System - Cab Harness(S/N 9909 and After) .......................................... 210

Electrical System - Engine Harness(S/N 8042-0206 & Before and 10042-0211 & Before)........................................ 212

Electrical System - Engine Harness(S/N 8042-0207 thru 1598, 10042-0212 thru 1598, 10054-1598 & Before).............................. 214

Electrical System - Engine Harness(S/N 8042-1599 to 5234, 10042-1599 to 5250, 10054-1599 to 5274)................................ 216

Electrical System - Engine Harness (EPA)(S/N 8042-5235, 10042-5251, 10054-5275 thru 9908) ...................................... 218

Electrical System - Engine Harness (EPA)(S/N 9909 and After) .......................................... 220

Lighting System........................................................ 222Outrigger Electrical Harness (10042/10054 Only).... 224

SECTION 8 – DECALS AND PAINT

Decals and Paint ...................................................... 226

SECTION 9 – BOOM AND ATTACHMENTS

Outer Boom.............................................................. 228Intermediate Boom - 8042 and 10042...................... 230Inner Boom - 8042 and 10042 ................................. 232Quick Attach............................................................. 234Carriage 48" ............................................................. 236Carriage 60" (Optional) ............................................ 238Carriage 72" (Optional) ............................................ 240Side Tilt Carriage - Early Production (Optional) ....... 242Side Tilt Carriage - Current Production (Optional) ... 244Outriggers (10042/10054 Only)................................ 246Swing Carriage (Optional)........................................ 248Sheet Material Handler (Optional)............................ 250Utility Bucket (Optional)............................................ 252Primary Intermediate Boom - 10054 ........................ 254Secondary Intermediate Boom - 10054 ................... 256Inner Boom - 10054 ................................................. 258Boom Extend Chains - 8042 and 10042 .................. 260Boom Retract Chain - 8042 and 10042

(S/N 1084 & Before) .......................................... 262Boom Retract Chain - 8042 and 10042

(S/N 1085 & After) ............................................. 264Boom Extend Chains - 10054 .................................. 266Boom Retract Chains - 10054

(S/N 0884 & Before) .......................................... 268Boom Retract Chains - 10054

(S/N 0885 thru 1084) ......................................... 270Boom Retract Chains - 10054 (S/N 1085 & After) ... 272Truss Boom 12 and 15 Ft. (Optional)....................... 274

PART NUMBER INDEX........................................... 277

SECTION 10 – GENERAL TROUBLESHOOTING . 287

1

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.

SECTION 1 MAIN FRAME AND GUARDS

2

SECTION 1

MAIN FRAME

1

23

4

5

6

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

2324

25

26

27

28

21

105

5

5

23

4

6

6

10

32

4

32

4

10

6

128

86

22

19

20

15

14

16

13

3

3

17

4

6

6

2

Boom PivotFrame Tilt CylinderStabilizer CylinderHoist CylinderSlave Cylinder

121

2

3

4

56

7

8

9

10

11

Locate the fracture in bearing outer race at the clock position shown for each

application (Items 5 & 7).

18

18

PH0012

510

510

��

PF0791

29

��

30

��

31

8042/10042/10054 Rev. 2/00

3

SECTION 1

Item No. Part Number Qty. Description

MAIN FRAME

1 Consult Factory 1 Weldment, Frame2 7092292 8 Pin, Hoist, Slave, Tilt, and Stabilizer Cylinders 3 8303782 8 HHCS, 1/2-13 x 4"4 8305644 8 Nut, Hex Lock Elastic 1/2-135 8065640 8 Bearing, 2" I.D.’6 6620531 AR Conduit, 1 x 5' - Cut to Fit7 8065641 2 Bearing, 2-3/4" I.D.8 7124331 AR Conduit, 1/2 x 5' - Cut to Fit9 7125861 AR Conduit, 3/4 x 5' - Cut to Fit

10 8520013 8 Fitting, Grease11 8520021 2 Fitting, Grease 90°12 8303724 8 HHCS, 3/4-10 x 3-1/2"13 8310111 8 Washer, Flat .81 x 2 x .15"14 8310067 8 Nut, Hex Lock Elastic 3/4-1015 7079442 2 Pin, Axle Pivot16 8307913 AR Spacer, Washer .12" Thick17 8307912 AR Spacer, Washer .06" Thick18 8310259 AR Spacer, Washer .09" Thick19 8303655 2 HHCS, 5/8-11 x 4-1/2"20 8305643 2 Nut, Hex Lock Elastic 5/8-1121 7099312 2 Anchor, Cylinder22 8040258 2 Axle23 7098563 1 Counterweight24 8305021 4 Nut, Hex 1"-825 5724302 2 Washer, Shim .06" Thick26 8307012 4 Washer, Lock 1"27 8310066 2 Washer, Flat .134" Thick28 8310051 4 HHCS, 1-8 x 4"

KITS

29 7138302 1 Kit, Cylinder Anchor (Includes 1 of Item 5, 1 of Item 10 and 1 of Item 21)30 7129313 1 Kit, Hoist Cylinder Pivot Left Side (Includes 1 of Item 2, 1 of Item 5 and 1 of Item 10)31 7129323 1 Kit, Hoist Cylinder Pivot Right Side (Includes 1 of Item 2, 1 of Item 5 and 1 of Item 10)

8042/10042/10054 Rev. 2/00

4

SECTION 1

HOODS AND GUARDS

1

2

3

4

5

6

7

8

9

10

1112

1314

15

16

1718

19

20

21

22

23

24

25

26

2728

29

3029

26

28

16

1112

9

1112

1112

18

1112

1718

13

1415

8

8

1918

If Gap at topexceeds .06", shim

Lower Pivot with Item 8.

PH1330

20

20

S/N 9908 & Before

Apply Item 33 to Item 10

31 312

11

32

7

PF0810

33

8042/10042/10054 Rev. 2/00

5

SECTION 1


HOODS AND GUARDS

1 7098262 1 Cover, Tool Box2 7084792 1 Cover, Fuel Tank3 7111164 1 Cover, Transmission (S/N 9908 & Before)

7150393 1 Cover, Transmission (S/N 9909 & After)4 NLA 1 Cover, Fuel/Hydraulic Tank (S/N 11020 & Before) For Service, Order P/N 7138614

7138614 1 Cover, Fuel/Hydraulic Tank (S/N 11021 & After)5 7095452 2 Cover, Side Access6 7097174 1 Cover, Radiator7 8344010 3 Hinge8 8307110 AR Washer, Flat 3/8"9 8303034 8 TRHDCS, 1/4-20 x 3/4"

10 7111473 1 Cover11 8307002 18 Washer, Lock 1/4"12 8305004 18 Nut, Hex 1/4-2013 8303656 6 HHCS, 5/16-18 x 7/8"14 8307203 6 Washer, Flat 5/16"15 8307004 6 Washer, Lock 5/16"16 8305906 6 Nut, Retaining 5/16"17 8342807 2 Lock w/Key18 8342808 AR Key Set19 8342416 3 Latch, w/Lock and Key20 5746241 4 Tape, Foam - 38" (Cut to Fit)21 8580213 2 Grommet22 8582413 2 Plug, Bumper23 8303729 6 HHCS, 1/4-20 x 5/8"24 7084821 1 Shim25 8310136 4 TRHDCS, 1/4-20 x 1-1/4"26 7082311 2 Insert27 8304660 2 SHCS, 3/8-16 x 3/4"28 8307005 2 Washer, Lock 3/8"29 5724742 2 Gasket30 7094682 2 Hinge, Side Access Cover31 8581007 AR Tape, Foam - 170" (Cut to Fit)32 8307202 6 Washer, Flat 1/4"33 8526035 AR Caulk, Clear RTV-08

8042/10042/10054 Rev. 2/00

6

SECTION 2

SECTION 2 OPERATOR S CAB AND CONTROLS

OPERATOR’S CAB - OPEN

PH0532

1

2

3

5

6

7

8

9

12

19

32

33

34

353613

15

2322

4

30

2

29

2827

26

33

316

1817

37

40

3125101124

20 21

14

14

41

38

39

Torque to13 - 16 lb/ft

(18 - 22 Nm)

Torque to50 lb/ft

(68 Nm)

Torque to210 lb/ft

(285 Nm)2 Places

Torque to515 lb/ft

(698 Nm)2 Places

26

Frame

42

3

8042/10042/10054 Rev. 2/00

7

SECTION 2


OPERATOR’S CAB - OPEN

1 7099742 1 Cab Assembly, Operator’s Protective Structure Orange, Open - 10042/10054(Right Rear Corner Post Reinforced)

7112102 1 Cab Assembly, Operator’s Protective Structure Orange, Open - 80422 8033050 2 Panel, Lower3 8303034 20 THMS, Torx, 1/4-20 x 3/4"4 8033052 1 Panel, Right Front Console5 8033053 1 Panel, Side Console6 8033031 1 Gasketing, Sponge Rubber, 25-1/4"7 8033022 1 Cover, Battery8 8342807 1 Lock, Cam9 8033051 1 Panel, Left Front Console (S/N 9908 & Before)

7150361 1 Panel, Left Front Console (S/N 9909 & After)10 8307002 3 Washer, Lock 1/4"11 8307109 3 Washer, Flat 1/4"12 8466306 1 Gauge, Tilt Angle13 8721023 1 Column, Steering (S/N 9908 & Before)

7150382 1 Column, Steering (S/N 9909 & After)14 8307005 8 Washer, Lock 3/8"15 8303534 4 FHCS, 3/8-16 x 1-1/4"16 8720014 1 Wheel, Steering17 8305916 1 Nut, Steering Column18 8720015 1 Cap, Steering Wheel19 8864038 1 Arm Rest20 8065639 1 Bushing, Sleeve21 8302147 1 Pin, Roll22 7098342 1 Bracket, Arm Rest23 8303705 2 Scr. FLHDC 1/4-20 x 3/4"24 8990147 1 Holder, Manual25 8303729 2 HHCS, 1/4-20 x 5/8"26 7124331 1 Conduit, 1/2 I.D. x 5' - Cut to Fit27 8310344 AR Bolt, Carriage 3/8-16 x 10"28 7129261 1 Bar, Single Battery Hold Down (Current Production)

7082971 1 Bar, Double Battery Hold Down (Early Production)29 7125521 AR Hose, 3/8 x 8.0"30 8305645 2 Nut, Lock 3/8-1631 8305624 2 Nut, Lock 1/4-2032 8310050 1 HHCS, 1-8 x 6"33 8307012 2 Washer, Lock 1"34 8310049 1 HHCS, 1-8 x 2-3/4"35 8310112 1 HHCS, 3/4-10 x 6"36 8307010 2 Washer, Lock 3/4"37 8303638 1 HHCS, 3/4-10 x 2-3/4"38 8305008 4 Nut, Hex 3/8-1639 8310070 4 Retainer - 3/8"40 8310036 4 Bolt, Carriage 3/8-16 x 1-1/4"41 7097233 1 Guard, Bottom42 7125691 2 Rope Caulk, 0.2 Dia. x 3.0"

8042/10042/10054 Rev. 2/00

8

SECTION 2

OPERATOR’S CAB - CLOSED(Optional)

��

12

3

4

5

6

7

8

9

10

11

121314

15

1617

18

19

20

21

22

23

24

28

29

3031

32

33

343536

37

38

39

40

4142

43

4445

46

47 48

49

50

51

16

18

47

20

24

20

204

3435

25

25

2627

24

See also “Skylight Windshield Wiper”

See“Cab Door”

PH0482

PF0791

PF0810

8042/10042/10054 Rev. 12/97

9

SECTION 2


OPERATOR’S CAB - CLOSED(Optional)

1 7112092 1 Cab, Enclosed - Complete (Includes Cab Door; 10042 & 10054 Reinforced, Orange)7099324 1 Cab, Enclosure Kit minus Cab Door (Includes Items 3 thru 49 on this page

and all parts on pages 29 and 37)7127282 1 Cab Assembly, Operator’s Protective Structure Enclosed Orange - Optional

Includes: 7099324 - Cab Enclosure Kit8346008 - Door Assembly7112102 - Cab Assembly, Operator’s Protective Structure Orange, Open

2 See page 7 Cab Assembly3 8307207 1 Washer, Flat 5/8"4 8033079 2 Window, Wing5 8033081 1 Window, Skylight w/o Wiper Assembly6 8033092 4 HHCS, #10-24 x 3/4"7 8033072 1 Seal, Rubber, 120"8 8307113 1 Washer, Flat 7/16"9 8305647 1 Nut, Hex Lock 7/16-14

10 8307206 AR Washer, Flat 1/2"11 8346010 1 Bolt, Striker12 8307003 4 Washer, Lock #1013 8307201 4 Washer, Flat 3/16"14 8033085 2 Hinge, Spring15 8033084 1 Window, Rear16 8033086 8 Nut, Well17 8033087 4 Washer, Nylon18 8033088 8 Screw, Phil. Hd, #10-32 x 3/4"19 8033044 1 Window Hold Slide Assembly, w/Hardware20 8585135 3 Tape, Butyl, 1/4" sq. x 15' Roll21 8303540 2 HHCS, 1/4-20 x 1"22 8342413 1 Strap23 8033090 1 Bracket, Door Mounting24 8305601 6 Nut, Hex Lock 1/4-2025 8303982 4 Screw, Self Tap 1/4-20 x 3/4"26 8346011 1 Panel, Rear Foam27 8585138 1 Weldment, Latch Bracket28 8580315 1 Plug, Hole29 8033479 1 Window, Front30 8033076 1 Wire Assembly, Fan31 8033078 1 Fan, Defroster32 8033077 2 Connector, Wire33 8033094 1 Bracket, Circulation Fan34 8585139 2 Washer, Flat Plastic 3/8"35 8307204 2 Washer, Flat 3/8"36 8580115 1 Knob37 8303776 2 HHCS, 1/4-20 x 1/2"38 8303540 2 HHCS, 1/4-20 x 1"39 8585134 AR Sealant, Urethene, 10 oz. Cartridge 40 8307002 2 Washer, Lock 1/4"41 8346009 1 Window, Right Side Sliding (Includes Items 42 thru 49)42 8033833 1 Glass Assembly - Front43 8033834 1 Glass Assembly - Rear44 8033835 1 Frame Assembly45 8033836 1 Trim, Stop - Front46 8033837 1 Trim, Stop - Rear47 8033838 2 Rubber, Flkd48 8033839 1 Rubber, Flkd49 8033840 1 Rubber, Flkd50 8033082 1 Window, Right Side (Optional) 51 8585133 1 Window Glue Kit (Includes Items 20, 39, four setting blocks and installation instructions)

8042/10042/10054 Rev. 2/00

10

SECTION 2

CAB DOOR

1

2

3

4

5

6

7

8

910

11

12

13

2526

27

29

30

31

32

33

34

35

36

14

15

16

17

18

19 20

37

21

22

23

24

9

2624

PH0552

28

8042/10042/10054 Rev. 2/00

11

SECTION 2


CAB DOOR

1 8346008 1 Door Assembly (Includes Items 2 thru 36)2 8033844 1 Door Weldment3 8033845 1 Sliding Window Assembly (Includes Items 4 thru 11)4 8033843 1 Glass Assembly - Front5 8033842 1 Glass Assembly - Rear6 8033841 1 Frame Assembly7 8034544 1 Trim, Stop - Front8 8034545 1 Trim, Stop - Rear9 8034546 2 Rubber, Flkd

10 8034547 1 Rubber, Flkd11 8034548 1 Rubber, Flkd12 8033846 1 Paddle Latch13 8033847 4 Nut, Hex Locking 1/4-2014 8033848 1 Grab Handle15 8033849 2 Screw, Self Tapping 1/4 x 3/4"16 8033850 1 Door Release17 8033851 2 Screw, Self Tapping #10-24 x 1/2"18 8033852 1 Bezel19 8033853 1 Latch Trip20 8033854 1 Spring21 8033855 1 Cam Latch - Right Side22 8033856 4 Bolt, 1/4-20 x 3/4"23 8033857 1 Bolt, Hex Hd. 5/16 x 3/4"24 8033858 2 Nut, Hex Locking 5/16"25 8033859 1 Shoulder Bolt26 8033860 2 Washer, Nylon27 8033861 1 Seal, Rubber (17’)28 8037206 1 Seal, Bulb “D” .216 x .354 (9.5’) 29 8033862 3 Hole Plug30 8033863 1 Rubber Grip31 8033864 1 Soundproofing - Upper Door32 8033865 1 Soundproofing - Lower Door33 8033866 1 Bolt, Hex Hd. 3/8 x 3/4"34 8033867 1 Nut, Hex Locking 3/8"35 8033868 1 Striker Bolt36 8033869 1 Washer, Lock 3/8"37 8342808 1 Key Set (Not Shown)

8042/10042/10054 Rev. 2/00

12

SECTION 2

OPERATOR’S SEAT

��

2

2010

7

13

8

19

4

3

1

6

5

18

13

14

15

16

17

11

912

12

PA0064

��

2221

PF0791

8042/10042/10054 Rev. 2/00

13

SECTION 2


OPERATOR’S SEAT

1 8864037 1 Seat Assembly - Vinyl (Includes Items 2 thru 5)8864044 1 Seat Assembly - Cloth 2 Piece (Includes Items 2 thru 5)

2 8864041 1 Cushion, Seat - Vinyl (one piece)8864045 1 Cushion, Seat - Cloth8864046 1 Seat Back - Cloth

3 8864039 1 Slide, w/Handle4 8864040 1 Slide, w/o Handle5 NSS 4 Screw6 8864043 1 Belt, Seat7 8303604 2 HHCS, 7/16-20 x 1-1/4"8 7090751 2 Mount, Seat9 8303697 4 HHCS, 5/16-18 x 3/4"

10 8307006 2 Washer, Lock 7/16"11 8864036 1 Suspension12 8307106 8 Washer, Flat 5/16"13 8305626 12 Nut, Hex Lock Elastic 5/16-1814 7083963 1 Support, Suspension15 8305008 4 Nut, Hex 3/8-1616 8307005 4 Washer, Lock 3/8"17 8303534 4 FLHDCS 3/8-16 x 1-1/4"18 8305006 4 Nut, Hex 5/16-1819 8303745 4 HHCS, 5/16-18 x 5/8"20 8307113 2 Washer, Flat 7/16"

KITS

21 7143900 1 Kit, Seat Belt non-retractable 3"22 7144000 1 Kit, Seat Belt retractable 3"

8042/10042/10054 Rev. 2/00

14

SECTION 2

CONTROL CONSOLE

��

1

23

45

678

911

10

17 13

12

14

191516

18

PH0543

21

20

8042/10042/10054 Rev. 2/00

15

SECTION 2


CONTROL CONSOLE

1 7084902 1 Plate, Gauge Mounting2 7082292 1 Cover3 8464212 1 Gauge, Fuel4 8466305 1 Gauge, Warning Lights (Includes Item 5)5 8469030 4 Bulb (Not Shown)6 8467014 1 Hourmeter7 8305004 4 Nut, Hex, 1/4-208 8307002 4 Washer, Lock 1/4"9 8303034 4 TRHCS, Torx 1/4-20 x 3/4"

10 8223442 1 Switch Test11 8580312 1 Cap, Seal12 8223405 1 Button, Horn13 8580311 1 Cap, Seal14 8033201 1 Switch, Washer/Wiper Front (Optional)15 8223220 1 Switch, Steer Select16 7099352 1 Overlay, Left Console - Domestic (S/N 9908 & Before)

7150371 1 Overlay, Left Console - Domestic (S/N 9909 & After)7111842 1 Overlay, Left Console - Export (S/N 9908 & Before)7150472 1 Overlay, Left Console - Export (S/N 9909 & After)

17 7099332 1 Overlay, Right Console - Domestic7111832 1 Overlay, Right Console - Export

18 4107971 1 Decal, Outrigger Contact - Domestic (10054 Only)4107981 1 Decal, Outrigger Contact - Export (10054 Only)

19 8223445 1 Guard, Switch20 8223444 1 Emergency Brake Switch21 7135942 1 Switch, Skylight Wiper (Optional)

8042/10042/10054 Rev. 2/00

16

SECTION 2

TRANSMISSION SHIFT CONTROLS(S/N 9908 & Before)

1

3

5 6

8

9

10

11

11

12

13

1415

7

Speed ControlConnection

Directional ControlConnection

TransmissionControl Valve

2

4

PA0085


(26 - 31 Nm)

8042/10042/10054 Rev. 2/00

17

SECTION 2


TRANSMISSION SHIFT CONTROLS(S/N 9908 & Before)

1 8160205 1 Shifter, Transmission (Includes Items 2 thru 4)2 8034694 1 Gate Plate3 8580111 2 Knob4 8032753 1 Decal Kit (Contains F-N-R & 3-2-1 Decals)5 8160042 2 Cable, Control6 8305402 2 Nut, Hex Jam 1/4-287 8160417 1 Transmission Connector Kit (Includes Items 8 thru 15 plus all other parts not

identified with an Item number)8 8033240 4 Spacer9 8033241 2 Clamp

10 8303540 4 HHCS, 1/4-20 x 1"11 8033242 2 Swivel12 8033243 2 Pin, Clevis13 8305601 4 Nut, Lock14 8303106 4 HHCS, 3/8-16 x 2-1/2"15 8307005 4 Washer, Lock 3/8"

8042/10042/10054 Rev. 2/00

18

SECTION 2

TRANSMISSION SHIFT CONTROLS(S/N 9909 & After)

PH1201

1

8042/10042/10054 Origin 2/00

19

SECTION 2


TRANSMISSION SHIFT CONTROLS(S/N 9909 & After)

1 1319283 1 Shifter, Transmission Range Selector

8042/10042/10054 Origin 2/00

20

SECTION 2

BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL

2

1

3

5

4

6

8 9

8

Boom Raise/LowerSpool Section Boom Extend/Retract

Spool Section

Front

77

9

PH0522

8042/10042/10054 Rev. 2/00

21

SECTION 2


BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL

1 8224027 1 Joystick (Includes Items 2 and 3)2 8580110 1 Knob3 8160419 1 Boot4 8310143 4 TRHCS #10-245 8310144 4 Nut, Prop. Tee #10-246 8160062 2 Cable, Control7 8305402 4 Nut, Hex Jam 1/4-288 8301439 2 Clevis, with Pin and Cotter9 8302470 2 Pin, Hair 1/16"

8042/10042/10054 Rev. 2/00

22

SECTION 2

FRAME LEVEL & ATTACHMENT TILT CONTROL

2

3

1

7

8

8

6

11

10 9

4

5

13

8

12

Front

Attachment Tilt Spool Section

Frame TiltSpool Section

8

9

PH0512

8042/10042/10054 Rev. 2/00

23

SECTION 2


FRAME LEVEL & ATTACHMENT TILT CONTROL

1 8224026 1 Joystick, With Gate (Includes Items 2 and 3)2 8580110 1 Knob3 8160419 1 Boot4 8303540 4 HHCS, 1/4-20 x 1"5 8310001 8 Nut, Retainer 1/4-206 7098142 2 Spacer7 8160060 2 Cable, Control8 8305005 4 Nut, Hex 1/4-289 8160617 2 Clevis, Cable

10 8301443 2 Pin, Clevis 3/16 x 1"11 8302470 2 Pin, Hair 1/16"12 8303034 4 TRHCS, Torx 1/4-20 x 3/4"13 8307109 4 Washer, Flat 1/4"

8042/10042/10054 Rev. 2/00

24

SECTION 2

THROTTLE PEDAL CONTROL

1

3

4

5

2

6

10

15

16

12

14

9

8

11

17

3

13

18

137

8

23

21

2014

22

S/N 1598 and Before

6

6

26

19 13

924

2510

7

PH0592

8042/10042/10054 Rev. 2/00

25

SECTION 2


THROTTLE PEDAL CONTROL

1 8162003 1 Pedal, Throttle (Includes Item 2)2 8033178 1 Bellows, Throttle Pedal3 8303742 3 FLHDCS 1/4-20 x 1" (Qty 3 for EPA Engines, Qty 5 for Pre-EPA Engines)4 8307002 3 Washer, Lock 1/4"5 8305004 3 Nut, Hex 1/4-206 8160046 1 Cable, Throttle7 8160610 1 Clamp, Cable8 8305002 2 Nut, Hex #10-249 8307003 2 Washer, Lock #10

10 8303837 2 Screw, Round Hd. #10-24 x 3/4"11 7127102 1 Bracket, Throttle Cable (EPA Engines)12 8340034 1 Rod End13 8305402 2 Nut, Jam .25 NF14 8307109 AR Washer, Flat SAE 1/4"15 7127091 1 Extension, Throttle Lever16 8700116 1 Spring17 8303799 2 HHCS, M6 x 14mm18 8307024 2 Washer, Lock M619 8305650 1 Nut, Lock .25 NF20 7088522 1 Bracket, Throttle Cable (Pre-EPA Engines)21 8301002 1 Clevis22 8302449 1 Pin, Cotter23 8301402 1 Pin, Yoke24 8303790 2 HHCS, M12 x 30mm25 8307025 2 Washer, Lock M1226 8305624 2 Nut, Hex Lock Elastic

8042/10042/10054 Rev. 6/98

26

SECTION 2

SERVICE BRAKE PEDAL CONTROL

1

34

7

6

5

6

8

14

12

2

1110

13

15

16

9

17

13

See “Directional Control Valves”

Torque to30 lb/ft

(41 Nm)

18

PG0531

8042/10042/10054 Rev. 2/00

27

SECTION 2


SERVICE BRAKE PEDAL CONTROL

1 7111203 1 Pedal, Brake2 7081031 1 Shaft3 7080891 1 Rod, Push4 8305410 1 Nut, Jam 1/2-205 8310257 1 Yoke6 8307104 2 Washer, Flat 3/4"7 8310258 1 Pin, Clevis8 8700120 1 Spring9 8303742 1 FLHDCS, 1/4-20 x 1-1/4"

10 8305004 1 Nut, Hex 1/4-2011 8307002 1 Washer, Lock 1/4"12 8303534 2 FLHDCS, 3/8-16 x 1-1/4"13 8305405 2 Nut, Jam 3/8-1614 8307005 2 Washer, Lock 3/8"15 8310170 1 Screw, Set 3/8-16 x 1-3/4"16 8307110 2 Washer, Flat 3/8"17 7111191 1 Plate, Actuator18 8302406 1 Cotter Pin, 1/8" x 1"

8042/10042/10054 Rev. 12/97

28

SECTION 2

FRONT WINDSHIELD WIPER

�

�

�

��

1

2 3

4 5 6 78

9

10

11

12 13

1415

16

1718

19

20

25262728

29

30

31

32

3334

35

3637

38

39

40

41 42

4344

2122

24

45

17Torque to

180 - 200 lb/in(20 - 23 Nm)

SkylightWiper Washer

Reservoir -(Ref.)

Seat Riser -(Ref.)

Existing Hardwarefrom Cab Heater

24

PH0492

��

PF0791

23

8042/10042/10054 Rev. 2/00

Front

29

SECTION 2


FRONT WINDSHIELD WIPER

1 8866492 1 Pivot Arm and Shaft Assembly (Includes Items 2 thru 9) 2 NSS 1 Nut, Acorn 3/8-243 NSS 1 Washer, Internal Tooth Lock 3/8"4 NSS 1 Driver, Knurled5 NSS 1 Cap, Rubber6 NSS 1 Nut, Hex Jam 11/16-247 NSS 1 Washer, Metal8 NSS 1 Washer, Cardboard9 NSS 1 Shaft Assembly

10 8866382 1 Wiper Arm - 22" 11 8033105 1 Spacer 12 8034815 1 Panto Adapter Kit (Includes Items 13, 38, 41 & 42)13 NSS 1 Gasket, Panto (Order P/N 8034815)14 8307052 2 Washer, External Tooth Lock #1015 8303839 2 Screw, Slotted Pan Head #10-32 x 1/2"16 NSS 2 Clip, Spring (Order P/N 8033102)17 NSS 2 Washer, Special Flat .5600 x .2510 x .015 (Order Item 24)18 8033104 1 Link, Connecting 19 8305006 1 Nut, Hex Flanged 5/16-1820 8866437 1 Drive Arm21 NSS 3 Screw, Slotted Hex Head Cap 1/4-28 x 3/4" (Order Item 24)22 8310002 3 Washer, External Tooth Lock 1/4"23 7112511 1 Wiper Motor Kit (Includes Items 20, 24 thru 29)24 8033102 1 Wiper Motor Assembly (Includes mounting bracket, motor, link and hardware)25 8220073 1 Adapter, 1/4" Male Blade26 8303835 1 Screw, Pan Head #10-24 x 1/2"27 8305002 1 Nut, Hex #10-2428 8307046 1 Washer, Internal Tooth Lock #10 29 NSS 1 Bracket, Wiper Motor (Order Item 24)30 8033065 1 Washer Reservoir Assembly w/washer pump31 7118941 1 Bracket, Washer Bottle Mounting32 8303540 3 HHCS, 1/4-20 x 1"33 8307109 3 Washer, Flat 1/4"34 8305624 3 Nut, Lock 1/4-2035 8866381 1 Wiper Blade - 22"36 8034801 1 Spray Nozzle37 8034802 1 Nozzle Tip 38 8033110 2 HHCS, 1/4-28 x 3/4"39 8033075 1 Hose, Washer 120"40 8033103 1 Cable, Wiper41 NSS 1 Nut, Acorn 1/4-28 (Order Item 12)42 8310029 1 Washer, Internal Tooth Lock 1/4"43 NSS 1 Pin, Shoulder (Order Item 1)44 8305005 1 Nut, Hex 1/4-2845 8307203 3 Washer, Flat 5/16"

8042/10042/10054 Rev. 2/00

30

SECTION 2

CAB HEATER(Optional)

��

��

��

123

4 5

67

8

9

10

111213 14 15

161811

125

Seat Riser - (Ref.)

19

19

17

11

PG0561

8042/10042/10054 Rev. 12/97

31

SECTION 2


CAB HEATER(Optional)

1 8360008 1 Heater (Includes Items 2 and 3)2 8032793 1 Motor, Heater - 12 VDC3 8032794 1 Fan, Heater 4 8303776 2 HHCS, 1/4-20 x 1/2"5 8307002 4 Washer, Lock 1/4"6 8223024 1 Switch Kit7 8580309 1 Cap8 8303995 2 HHCS, #10-24 x 1-1/4"9 7075191 2 Spacer, 3/4"

10 7124531 2 Conduit, 1/4 I.D. x 5"11 8405007 4 Clamp12 7125251 2 Hose, 5/8 I.D. x 120"13 8430048 1 Hose Fitting, Beaded, SAE 10-8P - hose I.D. x male NPT14 8540023 1 Reducer, 3/8" NPT x 1/2" NPT15 8360005 1 Valve, Shut-off16 8584001 1 Tie Wrap, .2 wide x 6.7"17 8584003 6 Tie Wrap, .3 wide x 14.8"18 8220008 1 Terminal, #1019 7125271 1 Hose, 5/8 I.D. x 156"

8042/10042/10054 Rev. 2/00

32

SECTION 2

AUX. HYDRAULIC CONTROL(Optional)

2

3

1

4

6

7

6

91011

11

12

12

13

14

15

AuxiliarySpool

Control

5

Front

PH0501

8042/10042/10054 Rev. 2/00

33

SECTION 2


AUX. HYDRAULIC CONTROL(Optional)

1 8160406 1 Controller (Includes Items 2 and 3)2 8580110 1 Knob3 8160418 1 Boot4 8303758 2 HHCS, 1/4-20 x 2"5 4105621 1 Decal, Auxiliary Control6 8305004 2 Nut, Hex 1/4-207 7091323 1 Support, Controller8 8305906 3 Nut, Retaining 5/16-189 8307004 3 Washer, Lock 5/16"

10 8303697 3 HHCS, 5/16-18 x 3/4"11 8160059 1 Cable, Control12 8305402 2 Nut, Jam 1/4-2813 8160617 1 Clevis14 8302470 1 Pin, Cotter15 8301443 1 Pin, Clevis

8042/10042/10054 Rev. 12/97

34

SECTION 2

MIRRORS

1

2

3

4

5

Cab -(Ref.)

Front

PG0591

FrontTorque to

10 lb/ft(14 Nm)

Torque to23 lb/ft

(31 Nm)

8042/10042/10054 Rev. 2/00

35

SECTION 2


MIRRORS

1 8866347 1 Mirror Assembly, 6.5" x 10", Left Side Cab - Flat Glass (Includes Items 2 and 3)2 8866350 1 Lens, 6.5" x 10" Flat Glass Replacement3 8866364 1 Loop Assembly4 8866348 1 Mirror Assembly, 6.5" x 10" Right Side - Convex Glass

(Includes Item 5 and mounting hardware)5 8866351 1 Lens, 6.5" x 10" Convex Glass Replacement

8042/10042/10054 Rev. 12/97

36

SECTION 2

SKYLIGHT WINDSHIELD WIPER(Optional)

1

2

3

4

5

6

78

9

1011

12

13

14

15

16

1718

19

2021

22

5

14

5

2

Front WindshieldWiper/Washer

Reservoir - (Reference) Existing Hardware

from Cab Heater

Seat Riser - (Reference)

FrontPH0811

8042/10042/10054 Rev. 2/00

37

SECTION 2


SKYLIGHT WINDSHIELD WIPER(Optional)

1 8034797 1 Window, Skylight 2 8033075 1 Hose, Washer 120" (cut to length)3 8034798 2 Nut, Hex 5/16-184 8034799 2 Washer, Lock 5/16"5 8034800 3 Washer, Black Nylon 5/16"6 8034801 1 Spray Nozzle7 8034802 1 Nozzle Tip8 8034803 1 Grommet, T-Style9 8034804 1 Washer, Weather Tight

10 8034805 1 Nut, Acorn #10-2411 8034806 1 Wiper Blade - 20"12 8034807 1 Wiper Arm, 15-19" Adjustable13 8034808 1 Spacer, Nylon14 8034809 1 Wiper Cover Assembly15 7137132 1 Kit, Wiper Motor and Switch w/Breaker (S/N P6931A - P8239B)

8034810 1 Skylight Wiper Motor Kit, WWF Auto-SP (S/N P8239C & After)16 8034811 1 Screw, #10-24 x 7/8" 17 8303540 3 HHCS, 1/4-20 x 1" 18 8033065 1 Washer Reservoir Assembly (Includes washer pump)19 7118941 1 Bracket, Washer Bottle Mounting 20 8307109 3 Washer, Flat 1/4" 21 8305624 3 Nut, Lock 1/4-20 22 8034817 1 Wire Harness, Skylight Wiper

8042/10042/10054 Rev. 2/00

38

SECTION 2

SOFT CAB ENCLOSURE(Optional)

PH1400

1 4

2

5

36

7

8PG1090

��

PF0791

PG1080

8042/10042/10054 Origin 2/00

39

SECTION 2


SOFT CAB ENCLOSURE(Optional)

1 8866525 1 Soft Cab Enclosure Kit - Complete (Includes Items 2 thru 7 plus Installation Instructions)2 8866526 1 Rear Window Enclosure - Soft3 8866527 1 Door Section - Soft4 8033081 1 Glass - Top5 8033479 1 Glass - Front6 8585155 1 1" Hook Strip Material - 10 ft.7 8585156 1 2" Hook Strip Material - 10 ft.8 8585133 1 Window Glue Kit

8042/10042/10054 Origin 2/00

40

SECTION 3

SECTION 3 DRIVE TRAIN

CONVERTER AND TRANSMISSION HOUSINGS(S/N 9908 & Before)

1

2

3 4

5

6

7 1

910

1112

1314

15

16

21

22

2324

25

2627

2829

30

31

32

3334

35

3641

42 4344

4546

47

48

49

50

5152

53

54

55

56

17

18

19 20

37

38

39

40

57

5859

6061

6263

6

23 24

36

37

37

37

36

18

24

26

64 65

XXLOW

A

V

U

V

Y

W

Z

YU 3RD

WZ

LUBE

A

PB0183

8042/10042/10054 Rev. 12/97

41

SECTION 3


CONVERTER AND TRANSMISSION HOUSINGS(S/N 9908 & Before)

1 8032510 1 Pump Mounting Stud2 8032511 1 Pump Mounting Stud3 8032500 1 Gasket, Pump To Converter Housing4 8032501 1 O-Ring5 8032502 1 Charging Pump Assembly6 8032503 5 Washer, Lock7 8032504 1 Screw8 8032505 2 Screw9 8032506 2 Nut, Stud

10 8320254 1 Filter Assembly11 8032541 2 Screw12 8307005 2 Washer, Lock13 8032542 1 Support, Bearing14 8032543 1 Retaining Ring15 8033199 1 Bearing, Pump Drive Gear16 8032545 1 Ring, Locating17 8032546 1 Gear, Drive18 8033886 2 Pipe Plug19 8032509 1 Air Breather20 8307005 11 Washer, Lock21 8032547 11 Screw22 8032548 1 Housing, Converter23 8032515 2 Pipe Plug24 8032516 3 Pipe Plug25 8032517 1 Sleeve, Converter Housing26 8033887 36 Washer, Lock27 8033888 16 Screw28 8032519 1 Gasket, Screen Assembly29 8032518 1 Screen Assembly30 8032549 1 Gasket, Front Cover31 8033188 1 Drain Hose Assembly32 8033189 1 Hose Adaptor33 8033193 1 Cover, Converter Housing Front34 8033198 1 Oil Seal, Front Cover35 8032537 1 Gasket, Housing To Case36 8032523 4 O-Ring37 8032522 4 Tube Sleeve38 8032501 1 O-Ring39 8032538 1 Tube, Low Speed Clutch Pressure40 8033889 20 Screw41 8033314 1 Transmission Case Assembly (Includes Items 37, 39, 54 thru 59, 60, 62 & 63)42 8033303 1 Bore Plug43 8033302 1 Gasket, Rear Cover To Case44 8032521 2 Dowel Pin45 8033349 1 Rear Cover & Plug Assembly (Includes one of Item 24)46 8033299 1 Low Shaft Rear Bearing Cap Assembly (Includes Item 47)47 8032526 1 Plug48 8032539 1 Pipe Plug49 8032528 2 Magnetic Drain Plug50 8033311 1 Oil Baffle51 8033312 1 Screw52 8032503 1 Washer, Lock53 8033313 1 Clip, Suction Tube54 8032532 1 O-Ring55 8033304 1 Suction Tube Assembly56 8032535 2 Washer, Lock57 8032536 2 Screw58 8033305 1 Clutch Lube Tube59 8033306 1 3rd Speed Tube60 8033307 1 Tube Sleeve61 8032521 1 Dowel Pin62 8032532 1 O-Ring63 8033308 1 Plug64 8033309 1 Dipstick Tube Assembly65 8033310 1 Dipstick

8042/10042/10054 Rev. 2/00

42

SECTION 3

CONVERTER GROUP(S/N 9908 & Before)

12

3

45 6

7

89

10

1112

1314

1516

1718

2324

25

2627

28

29

30

31

32

3334

3536

37

38

3940

4546

47

4849

50

51

5253

1920

2122

41

4243

44

54

5556

5758

5960

5556

103

3

3

29

42

PB0192

8042/10042/10054 Rev. 12/97

43

SECTION 3


CONVERTER GROUP(S/N 9908 & Before)

1 8032541 2 Screw2 8307005 2 Washer, Lock3 8032545 4 Ring, Locating4 8032542 1 Support, Pump Drive Bearing5 8032550 1 Ring, Retaining6 8032551 1 Bearing, Gear7 8032552 1 Pump Drive Gear8 8032554 1 Lockball, Stub Shaft9 8032555 1 Shaft, Stub

10 8032543 2 Ring, Retaining11 8033199 1 Bearing, Shaft12 8032553 1 Pump Drive Idler Gear13 8032568 1 Turbine Shaft Assembly (Includes Item 14)14 8032620 1 Ring, Retaining15 8032567 1 Bearing, Turbine Shaft16 8032566 1 Washer, Locating17 8032565 1 Ring, Retaining18 8032564 1 Ring, Piston19 8032563 1 Ring, Snap20 8032560 1 Support, Stator21 8303620 6 Screw22 8307005 6 Washer, Lock23 8032559 1 Spring, Expander24 8032558 1 Ring, Piston25 8032556 1 Oil Baffle Assembly26 8033190 1 Shaft, Reverse Idler27 8033191 1 O-Ring28 8033192 1 Lockball29 8033194 2 Plate, Thrust30 8032574 1 Reverse Idler Gear Bearing Assembly31 8033195 1 Nut, Bearing Retaining Plate32 8032573 1 Gear, Reverse Idler33 8032578 1 Ring, Retaining34 8032579 1 Member, Reaction35 8032580 1 Spacer36 8032581 8 Screw37 8032582 4 Lock Tab38 8032583 1 Impeller39 8032584 1 O-Ring40 8032585 1 Gear, Impeller Hub41 8032586 1 Bearing, Impeller Hub Gear42 8032587 2 Ring, Retaining43 8032588 1 Hub, Turbine44 8032589 1 Turbine45 8033196 1 Screw Ring, Turbine To Hub46 8033197 12 Screw47 8032595 1 O-Ring48 8032592 1 Locating Ring, Turbine Hub Bearing49 8032593 1 Bearing, Turbine Hub50 8033384 1 Impeller Cover51 8032594 1 Retaining Washer, Bearing52 8033385 1 O-Ring53 8033386 1 Input Shaft54 8033373 1 Bearing, Input Shaft55 8303620 34 Screw56 8307005 34 Washer57 8033885 1 Flange58 8033318 1 O-Ring59 8032612 1 Washer60 8032613 1 Nut

8042/10042/10054 Rev. 6/94

44

SECTION 3

FORWARD, REVERSE, LOW AND 2ND(S/N 9908 & Before)

12

34

56

78

910

11

1213

1415

1617

18

1920

21

22

2324

25

26

27

2829

3031

32

3334

3536

37

38

39

40

41 42

1112

1415

1618

13

18

3031

6

FORWARD

LOW

REVERSE & 2ND

PB0201

8042/10042/10054 Rev. 2/00

45

SECTION 3


FORWARD, REVERSE, LOW AND 2ND(S/N 9908 & Before)

1 8032652 3 Ring, Piston2 8032651 1 Ring, Retaining3 8032650 1 Snap Ring4 8032649 1 Bearing, Front5 8032648 1 Bearing, Gear6 8032645 2 Ring, Retaining7 8032647 1 Spacer, Bearing8 8032646 1 Reverse Clutch Gear & Retaining Ring Assembly (Includes Item 9)9 8032620 1 Ring, Retaining

10 8032644 1 Bearing, Gear11 8032640 2 Snap Ring12 8033348 2 Disc Spring Assembly (Contains 5 Pcs.)13 8032638 2 Spacer, Piston Return Spring14 8032615 2 Piston Return Spring15 8032616 2 Spring Retainer16 8032617 2 Snap Ring17 8032643 1 Bearing, Reverse & 2nd Shaft18 8032623 3 Snap Ring19 8032642 1 2nd Clutch Disc Hub & Retaining Ring Assembly (Includes Item 20)20 8032620 1 Ring, Retaining21 8032641 1 Pilot Bearing22 8032637 3 Ring, Piston23 8033355 1 Ring, Retaining24 8032635 1 Sleeve, Piston Ring25 8032634 1 Bearing, Forward Shaft26 8033356 1 Ring, Retaining27 8033357 1 Gear, Forward Shaft28 8032633 1 Bearing, Low Speed Clutch29 8032632 1 Spacer, Bearing30 8032628 2 Bearing, Gear31 8032629 2 Locating Ring32 8032631 1 Spacer, Gear33 8032622 1 Bearing, Low Speed Shaft34 8032566 1 Washer, Rear Bearing Support35 8032614 1 Ring, Piston36 8032624 1 O-Ring37 8032626 4 Stud, Cap38 8032503 4 Washer, Lock39 8032506 4 Nut, Stud40 8032625 1 O-Ring41 8033358 1 Low Shaft Gear, Hub & Retaining Ring Assembly (Includes Item 42)42 8032620 1 Ring, Retaining

8042/10042/10054 Rev. 6/94

46

SECTION 3

OUTPUT, IDLER AND THIRD(S/N 9908 & Before)

12

3 45 6

78

910

1112

1314

1516

2324

2526

27

2829

30

3132

33

3435

3637

38

17

18

19

2021

22

39

4041

42

43

44

45 46

47

15

27

See “Emergency

Brake”

3132

33

47

3RD

PH0250

8042/10042/10054 Rev. 2/00

47

SECTION 3


OUTPUT, IDLER AND THIRD(S/N 9908 & Before)

1 8033870 1 Roll Pin, Outer Race2 8033871 1 Piston Ring Outer Race3 8032652 2 Ring, Piston4 8033872 1 Ring, Retaining5 8032628 1 Bearing6 8033351 1 Ring, Locating7 8032615 1 Spring, Return8 8032616 1 Retainer, Spring9 8032617 1 Ring, Snap

10 8032643 1 Bearing, Pilot11 8033359 1 3rd Clutch Disc Hub & Retaining Ring Assembly (Includes Item 12)12 8032620 1 Ring, Retaining13 8033360 1 Carrier, Bearing14 8033361 1 Ring, Locating15 8033362 2 Ring, Locating16 8033363 1 Bearing, 3rd Clutch Disc Hub17 8033364 1 Ring, Retaining18 8033365 1 Bearing19 8033873 1 Idler Shaft & Gear Assembly (46T)20 8033368 1 O-Ring21 8033874 1 Seal, Brake Housing To Brake Disc Hub22 8033875 1 Hub, Brake Disc23 8033876 1 Ring, Snap24 8033877 1 O-Ring25 8033878 1 Plug, Brake Disc Hub26 8033879 1 Ring, Snap27 8033880 2 O-Ring28 8033881 4 Stud, Brake Housing To Rear Cover29 8033882 4 Washer, Lock30 8033883 4 Nut, Stud31 8033372 2 Nut, Flange32 8033371 2 Washer, Flange33 8032611 2 O-Ring34 8033198 1 Oil Seal, Output Shaft35 8033373 1 Bearing36 8033376 1 Spacer, Output Gear37 8033375 1 Gear, Output Shaft (46T)38 8033374 1 Spacer, Output Gear39 8033884 1 Shaft, Output40 8032604 1 Bearing41 8032605 1 Oil Seal, Rear Bearing Cap42 8032606 1 Gasket, Rear Bearing Cap43 8032627 4 Stud, Bearing Cap44 8032607 1 Bearing Cap45 8032608 4 Washer, Lock46 8032609 4 Nut, Stud47 8033885 2 Flange, Output

8042/10042/10054 Rev. 6/94

48

SECTION 3

TRANSMISSION CLUTCH GROUPS(S/N 9908 & Before)

1234

56

7

8

9101112

1314

15

16

17181920

2122

23

24

25262728

2930

31

32

333435

36373839

LOW

FORWARD

3RD

2ND & REVERSE

LOW

FORWARD

3RD

REVERSE

2ND

PH0630

8042/10042/10054 Rev. 6/94

49

SECTION 3


TRANSMISSION CLUTCH GROUPS(S/N 9908 & Before)

1 8032653 1 Ring, Snap2 8032654 1 Backing Plate3 8032655 8 Disc, Clutch Inner4 8032656 8 Disc, Clutch Outer5 8032657 1 Piston, Clutch6 8032658 1 Ring, Outer Piston7 8032659 1 Seal, Inner Piston8 8033387 1 Low Clutch Shaft Drum & Bleed Valve Assembly9 8032653 1 Ring, Snap

10 8032654 1 Backing Plate11 8032661 8 Disc, Clutch Inner12 8032656 8 Disc, Clutch Outer13 8032657 1 Piston, Clutch14 8032658 1 Ring, Outer Piston15 8032659 1 Seal, Inner Piston16 8033347 1 Forward Shaft, Drum & Plug Assembly17 8032653 1 Ring, Snap18 8032654 1 Backing Plate19 8032661 6 Disc, Clutch Inner20 8032656 6 Disc, Clutch Outer21 8032663 1 Clutch Piston Assembly22 8032658 1 Ring, Outer Piston23 8032659 1 Seal, Inner Piston24 8033344 1 3rd Clutch Shaft, Drum & Plug Assembly25 8032653 1 Ring, Snap26 8032654 1 Backing Plate27 8032661 8 Disc, Clutch Inner28 8032656 8 Disc, Clutch Outer29 8032657 1 Piston, Clutch30 8032658 1 Ring, Outer Piston31 8032659 1 Seal, Inner Piston32 8032665 1 Rev. & 2nd Shaft, Drum & Plug Assembly33 8032659 1 Seal, Inner Piston34 8032658 1 Ring, Outer Piston35 8032663 1 Piston, Clutch36 8032656 6 Disc, Clutch Outer37 8032661 6 Disc, Clutch Inner38 8032654 1 Backing Plate39 8032653 1 Ring, Snap

8042/10042/10054 Rev. 6/94

50

SECTION 3

CONTROL VALVE ASSEMBLY(S/N 9908 & Before)

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

9

15

PB0232

8042/10042/10054 Rev. 6/94

51

SECTION 3


CONTROL VALVE ASSEMBLY(S/N 9908 & Before)

1 8032666 9 Screw2 8307005 9 Washer, Lock3 8033239 1 Control Valve Assembly (Includes Items 4 thru 7 and Item 16)4 8032672 1 Valve Spool5 8032673 1 Spring, Control Valve6 8032676 1 Stop, Valve Spool7 8032679 1 Control Valve Housing Assembly (Includes Items 8 thru 15)8 8032674 1 Valve Spool, Forward & Reverse9 8032675 2 Oil Seal

10 8825174 1 Switch, Neutral11 8032678 1 Switch Actuating Pin12 8032680 3 Pipe Plug13 8032682 1 Speed Selector Spool & Plug Assembly (Includes Item 14)14 8032681 1 Plug15 8032676 2 Stop, Valve Spool16 8841314 1 Hydraulic Actuator Assembly (Includes Items 17 thru 21)17 8033202 1 O-Ring18 8033203 1 Balance Spring & Pin Kit19 8033204 1 Piston Seal20 8033205 1 Piston21 8033238 1 Glyd. Ring Assembly22 8033890 1 Gasket, Control Valve23 8032669 2 Detent Ball24 8032670 2 Detent Spring25 8303987 2 Screw, #8-32 x 1/4" Slotted Pan Hd.

8042/10042/10054 Rev. 12/97

52

SECTION 3

EMERGENCY BRAKE(S/N 9908 & Before)

��

1

2

3

4

7

8

*910

11

12

13

14

15

16

17

18

19

5

6

*9

8

Apply Loctite #242to Threads and

Torque 35 - 40 lb/ft(47 - 54 Nm)

Apply Loctite #242to Threads and Torque

15 - 20 lb/ft(20 - 27 Nm)

* Earlier models did not include dowel pins (Item 9).For earlier models, all tabs on stator discs (Item 6)must line up over shoulder bolts (Item 3).

Apply Loctite #242to Threads and Torque

85 - 90 lb/ft(115 - 122 Nm)

��

��

21

20 23

PF0791

PH0131

��

22

8042/10042/10054 Rev. 2/00

53

SECTION 3


EMERGENCY BRAKE(S/N 9908 & Before)

1 8033791 1 Emergency Brake Assembly (Includes Items 2 thru 19)2 8033774 1 Cover3 8033775 4 Shoulder Bolt4 See Kits 1 Disc, Primary5 See Kits 7 Disc, Rotor6 See Kits 7 Disc, Stator7 8033776 4 HHCS, Socket Head 8 See Kits 2 Case Gasket9 8033777 4 Dowel Pin

10 8033778 1 Spring Plate11 See Kits 12 Spring, Red12 8033779 1 Piston13 See Kits 1 Back-up Ring14 See Kits 1 O-Ring15 See Kits 1 Back-up Ring16 See Kits 1 O-Ring17 8033780 1 Bleeder Screw18 8033781 1 Pressure Plate19 8033782 4 HHCS, Socket Head

KITS

20 7131852 1 Kit, Repair Park Brake (Includes Items 3, 21, 22 & 23)21 8033771 1 Rotor and Stator Disc Kit (Includes Items 4 thru 6 & 8)22 8033772 1 O-Ring and Back-up Ring Kit (Includes Items 8 & 13 thru 16)23 8033773 1 Spring Kit (Includes Items 8 & 11)

8042/10042/10054 Rev. 2/00

54

SECTION 3

TRANSMISSION MOUNTING(S/N 9908 & Before)

1

23

45

6

7

8

910

11

12

13Frame

PH0241

8042/10042/10054 Rev. 2/00

55

SECTION 3


TRANSMISSION MOUNTING(S/N 9908 & Before)

1 8841025 1 Transmission2 8307010 8 Washer, Lock 3/4"3 8303664 8 HHCS, 3/4-10 x 1-1/2"

Items 4 thru 8 for Machines Model 8042 S/N 8042-0058 & BeforeItems 4 thru 8 for Machines Model 10042 S/N 10042-0057 & Before

4 7095342 2 Mount, Transmission5 8310051 4 HHCS, 1-8 x 4"6 8278017 4 Isolator7 7096471 4 Washer, Rebound8 8310116 4 Nut, Hex Lock Elastic 1-8

Items 9 thru 13 for Machines Model 8042 S/N 8042-0059 thru 9908Items 9 thru 13 for Machines Model 10042 S/N 10042-0058 thru 9908Items 9 thru 13 for Machines Model 10054

9 7111952 2 Mount, Transmission10 8303724 4 HHCS, 3/4-10 x 3-1/2"11 8278007 4 Isolator12 7054351 4 Washer, Rebound13 8310067 4 Nut, Hex Lock Elastic 3/4"

8042/10042/10054 Rev. 7/99

56

SECTION 3

ENGINE CONNECT(S/N 9909 & After)

PH1040

1

2 3

45 6

7

8

9

1011

12

13

14

15

8042/10042/10054 Origin 7/99

57

SECTION 3


ENGINE CONNECT(S/N 9909 & After)

1 1319203 1 Diaphragm2 1319204 4 HHCS, M10 x 18mm3 10732095 4 Washer, 10,54 1319205 1 Washer5 1319206 2 HHCS, M8 x 50mm6 1319207 1 Washer7 1319208 1 Cover8 10731748 12 HHCS, M10 x 45mm9 10731751 12 Nut, Hex M10

10 1319209 1 Bearing11 1319210 1 Ring, Retaining 90 x 312 1319211 1 Flange, Input13 1319212 1 Shaft, Input14 1319213 1 Washer15 10731702 8 HHCS, M10 x 16mm

8042/10042/10054 Origin 7/99

58

SECTION 3

CONVERTER AND LAYSHAFT(S/N 9909 & After)

1

PH1050

2

3

4 5

6

4

Torque Limit 58.3 lb/ft(79 Nm)

8042/10042/10054 Origin 7/99

59

SECTION 3


CONVERTER AND LAYSHAFT(S/N 9909 & After)

1 10732110 1 Axle2 10732111 1 Gear, Idler3 10732112 1 HHCS, M12 x 115mm4 10732113 2 Bearing, Roller5 10732114 1 Bushing, 7,20mm

10732115 1 Bushing, 7,25mm10732116 1 Bushing, 7,30mm10732117 1 Bushing, 7,35mm10732118 1 Bushing, 7,40mm10732119 1 Bushing, 7,45mm10732120 1 Bushing, 7,50mm10732121 1 Bushing, 7,55mm10732122 1 Bushing, 7,60mm

6 10731704 1 Converter

8042/10042/10054 Rev. 2/00

60

SECTION 3

OIL PRESSURE PUMP(S/N 9909 & After)

12

3

4

PH1060

5 6Torque Limit

17 lb/ft(23 Nm)

8042/10042/10054 Origin 7/99

61

SECTION 3


OIL PRESSURE PUMP(S/N 9909 & After)

1 10731705 1 Pump2 10731706 1 Seal, Shaft3 10731707 1 O-Ring, 192 x 34 1319214 8 SHCS, M8 x 40mm5 10731710 8 Washer, 8,46 10731709 8 O-Ring, 8 x 1,5

8042/10042/10054 Origin 7/99

62

SECTION 3

INPUT SHAFT(S/N 9909 & After)

1

23

4

56

7

8

PH1070

7

8042/10042/10054 Origin 7/99

63

SECTION 3


INPUT SHAFT(S/N 9909 & After)

1 10731711 1 Shaft, Turbine2 10731712 1 Bearing, Roller3 10731713 1 Gear, Input4 1319215 1 Bearing, Roller5 10731715 1 Washer, 1,2mm

1319216 1 Washer, 1,25mm1319217 1 Washer, 1,35mm10731716 1 Washer, 0.5mm10731717 1 Washer, 0,6mm10731718 1 Washer, 0,7mm10731719 1 Washer, 0,8mm10731720 1 Washer, 0,9mm10731721 1 Washer, 1,0mm10731722 1 Washer, 1,1mm10731723 1 Washer, 1,3mm10731724 1 Washer, 1,4mm10731725 1 Washer, 1,5mm10731726 1 Washer, 0,65mm10731727 1 Washer, 0,75mm10731728 1 Washer, 0,85mm10731729 1 Washer, 0,95mm10731730 1 Washer, 1,05mm10731731 1 Washer, 1,15mm

6 10731732 1 Ring, Snap7 1319218 2 Ring, Piston8 10731734 1 Flange, Oil Feed

8042/10042/10054 Rev. 2/00

64

SECTION 3

GEARBOX HOUSING(S/N 9909 & After)

OIL LEVEL

1

2

3

45

67

8

10

11

12

13

14

15

16

17

18

1920

21 22

23

24

25

PH1080

12

7

8

16

9

9

Torque Limit4.4 lb/ft(6 Nm)

PH0940

26

NOTE: Apply Item 26 to all Item 6. Torque limit

17 lb/ft (23 Nm).

8042/10042/10054 Origin 7/99

65

SECTION 3


GEARBOX HOUSING(S/N 9909 & After)

1 1319219 1 Housing2 10731736 1 O-Ring, 150 x 33 10731737 1 Housing, Gearbox4 10731738 1 Sheet, Screen5 10731739 1 Sheet, Screen6 1319220 3 SHCS, M8 x 35mm7 10731741 5 Cap, Sealing8 10731742 2 Plug, M33 x 29 10731743 2 O-Ring, 30 x 2,5

10 10731744 1 Breather11 10731745 1 Bracket12 10731746 3 HHCS, M10 x 55mm13 10731747 17 HHCS, M10 x 32mm14 10731748 3 HHCS, M10 x 45mm15 10731749 2 HHCS, M10 x 85mm16 10731750 3 HHCS, M10 x 70mm17 10731751 6 Nut, Hex M1018 10731752 1 Pin, M6 x 35mm19 10731753 1 Sheet, Cover20 10731754 1 O-Ring, 294 x 321 1319221 8 HHCS, M8 x 20mm22 10731756 8 Washer, M823 1319222 1 Plate, Type24 10731758 4 Stud 3 x 525 10731759 1 Ball26 8526052 AR Threadlocker, High Strength

8042/10042/10054 Rev. 2/00

66

SECTION 3

CLUTCH PACK 1ST GEAR - 1 OF 2(S/N 9909 & After)

12

345

6 7 8 9 1011

12

13 14

15

1617

18

19

202122

232425

2627 28

29

3031

32

33

34

35

8

812

1314

15 16 17

24

36

38

37

PH1100

8042/10042/10054 Origin 7/99

67

SECTION 3



1 1319223 1 Shaft2 10731761 2 Ball3 10731762 1 Bearing, Ball4 10731763 1 Shim, 0,9mm

10731764 1 Shim, 0,95mm10731765 1 Shim, 1,00mm10731766 1 Shim, 1,05mm10731767 1 Shim, 1,1mm10731768 1 Shim, 1,15mm10731769 1 Shim, 1,2mm10731770 1 Shim, 1,25mm10731771 1 Shim, 1,3mm10731772 1 Shim, 1,35mm10731773 1 Shim, 1,4mm10731774 1 Shim, 1,45mm10731775 1 Shim, 1,5mm10731776 1 Shim, 1,55mm10731777 1 Shim, 1,6mm10731778 1 Shim, 1,65mm10731779 1 Shim, 1,7mm10731780 1 Shim, 1,75mm10731781 1 Shim, 1,8mm10731782 1 Shim, 1,85mm10731783 1 Shim, 1,9mm10731784 1 Shim, 1,95mm10731785 1 Shim, 2,0mm10731786 1 Shim, 2,05mm10731787 1 Shim, 2,1mm1319285 1 Shim, 2,15mm1319286 1 Shim, 2,2mm1319287 1 Shim, 2,25mm1319288 1 Shim, 2,3mm

5 1319224 3 Ring, Piston 45 x 2,56 10731789 1 Ring, Retaining 45 x 1,757 10731790 1 Bearing, Ball8 10731791 4 Shim, 1,3mm

10731792 4 Shim, 1,35mm10731793 4 Shim, 1,4mm10731794 4 Shim, 1,45mm10731795 4 Shim, 1,5mm10731796 4 Shim, 1,55mm10731797 4 Shim, 1,6mm10731798 4 Shim, 1,65mm10731799 4 Shim, 1,7mm10731800 4 Shim, 1,75mm10731801 4 Shim, 1,8mm10731802 4 Shim, 1,85mm10731803 4 Shim, 1,9mm10731804 4 Shim, 1,95mm10731805 4 Shim, 2,0mm10731806 4 Shim, 2,05mm10731807 4 Shim, 2,1mm10731808 4 Shim, 2,15mm10731809 4 Shim, 2,2mm10731810 4 Shim, 2,25mm

continued on next parts list

8042/10042/10054 Rev. 2/00

68

SECTION 3


12

345

6 7 8 9 1011

12

13 14

15

1617

18

19

202122

232425

2627 28

29

3031

32

33

34

35

8

812

1314

15 16 17

24

36

38

37

PH1100

8042/10042/10054 Origin 7/99

69

SECTION 3



8 10731811 4 Shim, 2,3mm(cont.) 10731812 4 Shim, 2,35mm

10731813 4 Shim, 2,4mm10731814 4 Shim, 2,45mm10731815 4 Shim, 2,5mm10731816 4 Shim, 2,55mm10731817 4 Shim, 2,6mm10731818 4 Shim, 2,65mm10731819 4 Shim, 2,7mm10731820 4 Shim, 2,75mm10731821 4 Shim, 2,8mm

9 10731822 1 Bush10 10731823 1 Gear, Spur Z=4411 10731824 1 Bearing, Ball12 10731825 10 Spring, Cup13 10731826 2 Ring, Snap14 10731827 2 Shim, End15 10731828 2 O-Ring, 60 x 316 10731829 2 O-Ring, 120 x 317 10731830 2 Piston18 10731831 1 Carrier, Disc19 10731832 1 Ring, Snap20 10731833 1 Bearing, Snap21 10731834 1 Shim, 0,8mm

10731835 1 Shim, 0,9mm1319225 1 Shim, 0,95mm10731836 1 Shim, 1,0mm10731837 1 Shim, 1,1mm10731838 1 Shim, 1,2mm10731839 1 Shim, 1,3mm

22 10732107 1 Ring, Retaining 77 x 2,523 10731841 1 Cage, Needle24 10731842 2 Bush25 10731843 1 Gear, Spur Z=2726 10731844 1 Ring, Internal27 10731845 1 Ring, Retaining 40 x 1,7528 10731846 1 Bearing, Ball29 10731847 5 Disc, Inner Clutch30 10731848 2 Disc, Inner Clutch31 10731847 1 Disc, Inner Clutch 2,0mm

10731848 1 Disc, Inner Clutch 1,5mm10731849 1 Disc, Inner Clutch 2,5mm

32 10731850 8 Disc, Outer Clutch33 10731851 1 Disc, Outer Clutch34 10731847 3 Disc, Inner Clutch35 10731748 2 Disc, Inner Clutch36 10731747 1 Disc, Inner Clutch 2,0mm


37 10731750 6 Disc, Outer Clutch38 10731751 1 Disc, Outer Clutch

8042/10042/10054 Rev. 2/00

70

SECTION 3

CLUTCH PACK 2ND GEAR - 1 OF 2(S/N 9909 & After)

12

34 5

6

7 8

9

1011

1213

14 15

16171820

2122 23

2425

2627

28

29

30

31

32

33

34

35

1916 17

1815 14

13 9 11

26

26

31

31

PH1110

8042/10042/10054 Origin 7/99

71

SECTION 3



1 1319226 1 Shaft2 10731761 2 Ball3 1319227 1 Bearing, Roller4 10731854 1 Washer, 0,8mm

10731855 1 Washer, 0,85mm10731856 1 Washer, 0,9mm10731857 1 Washer, 0,95mm10731858 1 Washer, 1,0mm10731859 1 Washer, 1,05mm10731860 1 Washer, 1,1mm10731861 1 Washer, 1,15mm10731862 1 Washer, 1,2mm10731863 1 Washer, 1,25mm10731864 1 Washer, 1,3mm10731865 1 Washer, 1,35mm10731866 1 Washer, 1,4mm10731867 1 Washer, 1,45mm10731868 1 Washer, 1,5mm10731869 1 Washer, 1,55mm10731870 1 Washer, 1,6mm10731871 1 Washer, 1,65mm10731872 1 Washer, 1,7mm10731873 1 Washer, 1,75mm10731874 1 Washer, 1,8mm10731875 1 Washer, 1,85mm10731876 1 Washer, 1,9mm10731877 1 Washer, 1,95mm10731878 1 Washer, 2,0mm10731879 1 Washer, 2,05mm10731880 1 Washer, 2,1mm10731881 1 Washer, 2,15mm10731882 1 Washer, 2,2mm10731883 1 Washer, 2,25mm10731884 1 Washer, 2,3mm10731885 1 Washer, 2,35mm10731886 1 Washer, 2,4mm

5 10731789 1 Ring, Retaining 45 x 1,756 1319224 3 Ring, Piston 45 x 2,57 1319215 1 Bearing, Roller8 10731791 1 Shim, 1,3mm

10731792 1 Shim, 1,35mm10731793 1 Shim, 1,4mm10731794 1 Shim, 1,45mm10731795 1 Shim, 1,5mm10731796 1 Shim, 1,55mm10731797 1 Shim, 1,6mm10731798 1 Shim, 1,65mm10731799 1 Shim, 1,7mm10731800 1 Shim, 1,75mm10731801 1 Shim, 1,8mm10731802 1 Shim, 1,85mm10731803 1 Shim, 1,9mm10731804 1 Shim, 1,95mm10731805 1 Shim, 2,0mm10731806 1 Shim, 2,05mm10731807 1 Shim, 2,1mm10731808 1 Shim, 2,15mm10731809 1 Shim, 2,2mm10731810 1 Shim, 2,25mm10731811 1 Shim, 2,3mm10731812 1 Shim, 2,35mm10731813 1 Shim, 2,4mm10731814 1 Shim, 2,45mm10731815 1 Shim, 2,5mm10731816 1 Shim, 2,55mm10731817 1 Shim, 2,6mm10731818 1 Shim, 2,65mm10731819 1 Shim, 2,7mm10731820 1 Shim, 2,75mm10731821 1 Shim, 2,8mm

9 10731805 2 Shim10 10731887 1 Bush11 10731888 2 Bearing, Roller


8042/10042/10054 Rev. 2/00

72

SECTION 3


12

34 5

6

7 8

910

1112

13

14 15

16171820

2122 23

2425

2627

28

29

30

31

32

33

34

35

1916 17

1815 14

13 9 11

26

26

31

31

PH1110

8042/10042/10054 Origin 7/99

73

SECTION 3



12 10731889 1 Gear, Spur Z=4413 10731825 10 Spring, Cup14 10731826 2 Ring, Snap15 10731827 2 Shim, End16 10731828 2 O-Ring, 60 x 317 10731829 2 O-Ring, 120 x 318 10731830 2 Piston19 10731831 1 Carrier, Disc20 10731832 1 Ring, Snap 4821 10731890 1 Gear, Spur22 10731891 1 Bearing, Roller23 10731892 1 Bearing, Roller24 10731893 1 Shim, 1,0mm

10731894 1 Shim, 1,05mm10731895 1 Shim, 1,1mm10731896 1 Shim, 1,15mm10731897 1 Shim, 1,2mm10731898 1 Shim, 1,25mm10731899 1 Shim, 1,3mm10731900 1 Shim, 1,35mm10731901 1 Shim, 1,4mm10731902 1 Shim, 1,45mm10731903 1 Shim, 1,5mm10731904 1 Shim, 1,55mm10731905 1 Shim, 1,6mm10731906 1 Shim, 1,65mm10731907 1 Shim, 1,7mm10731908 1 Shim, 1,75mm10731909 1 Shim, 1,8mm

25 10731910 1 Nut, Slotted26 10731847 5 Disc, Inner Clutch27 10731848 2 Disc, Inner Clutch28 10731847 1 Disc, Inner Clutch 2,0mm





8042/10042/10054 Rev. 2/00

74

SECTION 3

CLUTCH PACK 3RD GEAR - 1 OF 2(S/N 9909 & After)

12

3

4

56

78

910

1112

13 14 15 16 17

18

19

20

21

22

23

24

25

2627

28

29

17

18

19

20

2122

28

3031

3233 34

35 36 37

38

3940

41

42

43

4445

46

47

PH1120

8042/10042/10054 Origin 7/99

75

SECTION 3



1 10731911 1 Shaft2 10731761 2 Ball3 10731912 1 Bearing, Ball4 10731913 1 Ring, Snap 1005 1319230 1 Washer6 1319220 2 HHCS, M8 x 35mm7 10731789 1 Ring, Retaining 45 x 1,758 1319224 3 Ring, Piston 45 x 2,59 10732103 1 Gear, Spur Z=29

10 10732104 1 Cage, Needle11 10732105 1 Ring, Internal12 10732106 1 Bush13 10731824 1 Bearing, Ball14 10731834 1 Shim, 0,8mm

10731835 1 Shim, 0,9mm1319225 1 Shim, 0,95mm10731836 1 Shim, 1,0mm10731837 1 Shim, 1,1mm10731838 1 Shim, 1,2mm10731839 1 Shim, 1,3mm

15 10732107 1 Ring, Retaining 77 x 2,516 10731791 2 Shim, 1,3mm

10731792 2 Shim, 1,35mm10731793 2 Shim, 1,4mm10731794 2 Shim, 1,45mm10731795 2 Shim, 1,5mm10731796 2 Shim, 1,55mm10731797 2 Shim, 1,6mm10731798 2 Shim, 1,65mm10731799 2 Shim, 1,7mm10731800 2 Shim, 1,75mm10731801 2 Shim, 1,8mm10731802 2 Shim, 1,85mm10731803 2 Shim, 1,9mm10731804 2 Shim, 1,95mm10731805 2 Shim, 2,0mm10731806 2 Shim, 2,05mm10731807 2 Shim, 2,1mm10731808 2 Shim, 2,15mm10731809 2 Shim, 2,2mm10731810 2 Shim, 2,25mm10731811 2 Shim, 2,3mm10731812 2 Shim, 2,35mm10731813 2 Shim, 2,4mm10731814 2 Shim, 2,45mm10731815 2 Shim, 2,5mm10731816 2 Shim, 2,55mm10731817 2 Shim, 2,6mm10731818 2 Shim, 2,65mm10731819 2 Shim, 2,7mm10731820 2 Shim, 2,75mm10731821 2 Shim, 2,8mm

17 10731825 10 Spring, Cup18 10731826 2 Ring, Snap19 10731827 2 Shim, End


8042/10042/10054 Rev. 2/00

76

SECTION 3


12

3

4

56

78

910

1112

13 14 15 16 17

18

19

20

21

22

23

24

25

2627

28

29

17

18

19

20

2122

28

3031

3233 34

35 36 37

38

3940

41

42

43

4445

46

47

PH1120

8042/10042/10054 Origin 7/99

77

SECTION 3



20 10731828 2 O-Ring, 60 x 321 10731829 2 O-Ring, 120 x 322 10731830 2 Piston23 10731916 1 Carrier, Disc24 10731832 1 Ring, Snap 4825 10731917 1 Gear, Spur Z=5626 10731918 1 Cage, Roller27 10731919 1 Shim, 3,4mm

10731920 1 Shim, 1,6mm28 10731921 2 Ring, Retaining 48 x 1,7529 1319234 2 Washer, Thrust30 1319235 1 Bearing, Roller31 10731928 1 Ring, Retaining 120 x 432 10731929 1 Washer, 1,0mm

10731930 1 Washer, 1,05mm10731931 1 Washer, 1,1mm10731932 1 Washer, 1,15mm10731933 1 Washer, 1,2mm10731934 1 Washer, 1,25mm10731935 1 Washer, 1,3mm10731936 1 Washer, 1,35mm10731937 1 Washer, 1,4mm

33 10731938 1 Shim, 0,8mm10731839 1 Shim, 0,85mm10731840 1 Shim, 0,9mm10731841 1 Shim, 0,95mm10731842 1 Shim, 1,0mm10731843 1 Shim, 1,05mm10731844 1 Shim, 1,1mm10731845 1 Shim, 1,15mm10731846 1 Shim, 1,2mm10731847 1 Shim, 1,25mm10731848 1 Shim, 1,3mm

34 10731849 1 Ring, Retaining 65 x 2,535 10731850 1 Cage, Needle36 10731851 1 Shim37 10731852 1 Ring, Retaining 30 x 1,538 10731847 3 Disc, Inner Clutch39 10731848 2 Disc, Inner Clutch40 10731847 1 Disc, Inner Clutch 2,0mm





8042/10042/10054 Rev. 2/00

78

SECTION 3

OUTPUT SHAFT(S/N 9909 & After)

��

1

2

345678

101112

9

5 68

10

12

7

PH1130

Torque Limit25 lb/ft

(34 Nm)

8042/10042/10054 Origin 7/99

79

SECTION 3


OUTPUT SHAFT(S/N 9909 & After)

1 10731953 1 Shaft, Output2 10731954 1 Gear, Output3 10731955 1 Bearing, Ball4 10731956 1 Flange, Input5 10839156 2 O-Ring, 38 x 46 10731957 2 Washer7 10731958 2 Washer, Tab8 10731959 4 HHCS, M8 x 25mm9 10731960 1 Bearing, Ball

10 10731961 2 Ring, Retaining 100 x 311 10731962 1 Shim, 1,0mm

10731963 1 Shim, 1,05mm10731964 1 Shim, 1,1mm10731965 1 Shim, 1,15mm10731966 1 Shim, 1,2mm10731967 1 Shim, 1,25mm10731968 1 Shim, 1,3mm10731969 1 Shim, 1,35mm10731970 1 Shim, 1,4mm10731971 1 Shim, 1,45mm10731972 1 Shim, 1,5mm10731973 1 Shim, 1,55mm10731974 1 Shim, 1,6mm10731975 1 Shim, 1,65mm10731976 1 Shim, 1,7mm

12 10731977 2 Seal, Shaft 70 x 100 x 10

8042/10042/10054 Rev. 2/00

80

SECTION 3

PARKING BRAKE(S/N 9909 & After)

1

23

4

5

6 7

8

9

1112

1314

15

16

17

1819

20

21

10

PH1140

19

PH0940

22

NOTE: Apply Item 22 to all Item 14. Torque limit

7 lb/ft (9,5 Nm).

8042/10042/10054 Origin 7/99

81

SECTION 3


PARKING BRAKE(S/N 9909 & After)

1 10731981 1 Shoe, Brake (Includes Items 2 thru 8)2 10731982 1 Shoe, Brake Without Asbestos3 10731983 2 Spring, Tension4 10731984 1 Bolt, Anchor5 10731985 1 Pin6 10731986 1 Washer7 10731987 1 Ring, Retaining 22 x 1,28 10731988 1 Cam, Brake9 10732097 1 Flange, Output

10 10732093 1 Drum, Brake11 10732094 8 HHCS, M10 x 25mm12 10732095 8 Washer, 10,513 1319237 1 Plate, Cover14 10731980 4 SHCS, M6 x 10mm15 10731751 2 Nut, Hex M1016 10732098 1 Plate, Cover17 10732099 1 Washer18 10732099 1 Washer19 10732101 2 HHCS, M10 x 22mm20 10731978 1 O-Ring, 17,3 x 2,421 10731979 1 O-Ring, 25,3 x 2,422 8526052 AR Threadlocker, High Strength

8042/10042/10054 Rev. 2/00

82

SECTION 3

POWER TAKE-OFF SHAFT(S/N 9909 & After)

��

1

2

34

5 6

7

8 910

PH1150

7

8042/10042/10054 Origin 7/99

83

SECTION 3


POWER TAKE-OFF SHAFT(S/N 9909 & After)

1 10731989 1 Shaft, Central2 1319238 1 Bush3 1319218 1 Ring, Piston4 1319240 1 Bearing, Ball5 10731992 1 Shim, 1,0mm

10731993 1 Shim, 1,05mm10731994 1 Shim, 1,1mm10731995 1 Shim, 1,15mm10731996 1 Shim, 1,2mm10731997 1 Shim, 1,25mm10731998 1 Shim, 1,3mm10731999 1 Shim, 1,35mm10732000 1 Shim, 1,40mm10732001 1 Shim, 1,45mm10732002 1 Shim, 1,5mm10732003 1 Shim, 1,55mm10732004 1 Shim, 1,6mm1319241 1 Shim, 1,65mm1319242 1 Shim, 1,70mm1319243 1 Shim, 1,75mm1319244 1 Shim, 1,80mm1319245 1 Shim, 1,85mm1319246 1 Shim, 1,90mm1319247 1 Shim, 1,95mm1319248 1 Shim, 2,00mm1319249 1 Shim, 2,05mm1319250 1 Shim, 2,10mm1319251 1 Shim, 2,15mm1319252 1 Shim, 2,20mm

6 10732005 1 Ring, Retaining 68 x 2,57 10731845 2 Ring, Retaining 40 x 1,758 1319253 1 O-Ring, 104 x 39 1319254 1 Flange, Pump

10 1319255 2 SHCS, M14 x 35mm

8042/10042/10054 Rev. 2/00

84

SECTION 3

GEARSHIFT SYSTEM(S/N 9909 & After)

1

2

3

4

56

7

8

9

1011

12

13

15

171819

20

PH1160

11

16

14

21


(23 Nm)

8042/10042/10054 Origin 7/99

85

SECTION 3


GEARSHIFT SYSTEM(S/N 9909 & After)

1 1319256 1 Gasket2 10732007 1 Plate, Cover3 1319257 1 Gasket4 10732009 1 Plate, Duct5 1319220 11 SHCS, M8 x 35mm6 10731710 11 Washer, 8,47 10732011 1 Gasket8 10732012 1 Plate, Cover9 10732013 1 Gasket

10 1319259 16 SHCS, M8 x 65mm11 10731710 17 Washer, 8,412 1319260 1 SHCS, M8 x 85mm13 10732017 1 Plug, M10 x 114 10731709 1 O-Ring, 8 x 1,515 1319261 1 Plug, M14 x 1,516 10837660 1 O-Ring, 11 x 217 10732021 1 Spool, Valve18 10732022 2 Washer, 6,419 10732023 1 Spring, Compression20 10732024 1 Plug, M20 x 1,521 10732025 1 O-Ring, 17 x 2

8042/10042/10054 Origin 7/99

86

SECTION 3

CONTROL VALVE(S/N 9909 & After)

2

4 5

6

7

8

910

11

13

14

15

16

17

18

19

20

21

22

23

24

25 2627

28

29

30

3132

33

34

353637

38

3940

41

42

43

44

45

46

4748

49

51 5253

54

PH1170

3

12

50

55

1

Torque Limit4 lb/ft

(5,5 Nm)

Torque Limit4 lb/ft

(5,5 Nm)

8042/10042/10054 Origin 7/99

87

SECTION 3


CONTROL VALVE(S/N 9909 & After)

1 10837728 1 Valve Assembly, Control (Includes Items 2 thru 55)2 1319262 1 Housing, Valve3 1319263 1 Sleeve, Screw-In4 10732018 1 O-Ring, 15 x 25 10732027 1 Spring, Compression6 10732028 1 Piston7 10732029 2 Ring, Shim 10 x 16 x 18 10732030 1 Orifice, 0,6mm

10732031 1 Orifice, 0,7mm10732032 1 Orifice, 0,8mm10732033 1 Orifice, 0,65mm10732034 1 Orifice, 0,75mm10732035 1 Orifice, 0,85mm10732036 1 Orifice, 0,90mm1319264 1 Orifice, 0,95mm

9 10731709 1 O-Ring, 8 x 1,510 10732037 1 O-Ring, 6 x 1,511 10732038 1 Piston12 10732039 1 Spring, Compression13 10732040 1 Spring, Compression14 10732041 1 Piston15 10732042 1 Washer16 10732043 1 Ring, Shim 15 x 21 x 2

10732044 1 Ring, Shim 15 x 21 x 110732045 1 Ring, Shim 15 x 21 x 0,5

17 10732046 1 Piston18 10732047 1 Spring, Compression19 10732048 1 Plate, Stop20 10732049 1 Spring, Compression21 10732049 1 Spring, Compression22 10732050 1 Piston23 10732051 1 Piston24 1319265 1 Gasket25 10732053 1 Cover26 10732054 9 SHCS, M6 x 20mm27 10732015 9 Washer, M628 10732049 1 Spring, Compression29 10732050 1 Piston30 10732049 1 Spring, Compression31 10732055 1 Piston32 10732049 1 Spring, Compression33 10732056 1 Piston34 1319266 1 Valve, Reduction35 1319267 1 Ring36 1319268 1 Plate, Fixing37 10732058 1 Spring, Compression38 10732060 2 SHCS, M5 x 12mm39 10732061 10 Ball40 1319269 5 Valve, Solenoid41 10732063 5 Plate, Fixing42 10732064 5 Washer43 10732060 5 SHCS, M5 x 12mm44 10732065 1 Harness, Wiring45 1319270 2 SHCS, M6 x 14mm46 10732067 1 Plate, Fixing47 10732068 1 Cover48 10732069 1 O-Ring, 159,2 x 5,749 10732070 1 Bracket, Clamp50 10732017 8 Plug, M10 x 151 10731709 8 O-Ring, 8 x 1,552 10732071 2 Ball53 10732072 2 Spring, Compression54 10732018 2 O-Ring, 15 x 255 10732076 2 Plug, M18 x 1,5

8042/10042/10054 Rev. 2/00

88

SECTION 3

TRANSMISSION FILTER & DIPSTICK(S/N 9909 & After)

��

1

2

3

56

7

89

10

11

13

14

15

16

17 18

43

11

11

11

11

PH1180

12

12

12

12

12


(23 Nm)

8042/10042/10054 Origin 7/99

89

SECTION 3


TRANSMISSION FILTER & DIPSTICK(S/N 9909 & After)

1 10731923 1 Fixture, Holding2 10731924 1 Cover3 10731925 2 O-Ring, 98 x 44 10731926 1 Filter5 1319271 2 SHCS, M8 x 60mm6 1319272 4 HHCS, M8 x 75mm7 1319273 1 Insert, Valve8 10732071 1 Ball9 1319274 1 Spring, Compression

10 10732083 1 Cap, Sealing11 10732076 5 Plug, M18 x 1,512 10732018 5 O-Ring, 15 x 213 10732078 1 Union, Pipe14 8035733 1 Tube, Oil Level15 8035734 1 Dipstick, Oil16 10731743 1 O-Ring, 30 x 2,517 10732081 1 HHCS, M20 x 20mm18 10732082 1 Washer, M20

8042/10042/10054 Rev. 2/00

90

SECTION 3

OIL TUBES(S/N 9909 & After)

1

3

4

5

6

7

8

10

PH1210

2

1

1

1

1

1

1

8

1

2

22

2

2

2

2

11

9

9

8042/10042/10054 Origin 7/99

91

SECTION 3


OIL TUBES(S/N 9909 & After)

1 1319275 8 Sleeve, Screw-In2 10732085 8 O-Ring, 13 x 23 1319276 1 Pipe4 1319277 1 Pipe5 1319278 1 Pipe6 1319279 1 Pipe7 10732089 1 Tube, Suction8 10732090 2 Union, Pipe9 10732091 2 O-Ring, 38 x 2,5

10 10732092 2 Plug, M16 x 1,511 10732085 2 O-Ring, 13 x 2

8042/10042/10054 Origin 7/99

92

SECTION 3

TRANSMISSION MOUNTING(S/N 9909 & After)

PH1240

1716

18

1

3

14

20 2122

13

2 15

27

28

1926

1911

12

6

9

8

7

10

512

11

4

2524

23


(43 - 50 Nm)

Torque to302 lb/ft

(409 Nm)

Torque to302 lb/ft

(409 Nm)

Torque to34 lb/ft

(46 Nm)

Torque to35 lb/ft

(47 Nm)

Torque to48 lb/ft

(65 Nm)

Torsion Coupler

29

Front

15

Torque to34 lb/ft

(46 Nm)

13


(43 - 50 Nm)

8042/10042/10054 Origin 2/00

93

SECTION 3


TRANSMISSION MOUNTING(S/N 9909 & After)

1 8841040 1 Transmission, ZF 4 WG1002 7150192 1 Shaft, Drive (Front Axle)3 7150182 1 Shaft, Drive (Rear Axle)4 7150202 1 Shaft, Drive (Engine Input)5 7138186 1 Front Mount, Transmission6 7150082 1 Rear Mount, Transmission7 7054351 4 Washer, Rebound8 8278007 4 Mount, Isolation9 8303724 4 HHCS, .75NC x 3.5

10 8310067 4 Nut, Lock .75NC ESNA11 8310427 8 HHCS, M20 x 40mm Long (8.8)12 8307047 8 Washer, Lock M2013 8882009 4 Assembly, U-Bolt14 7138208 1 Pump Assembly15 8880218 2 Kit, Strap16 8310425 4 HHCS, .438 - 20UNF x 1.25 GR817 8307006 4 Washer, Lock .43818 8880219 2 Kit, Fixing 141019 8302470 2 Hair Pin20 8303519 4 HHCS, M12 x 40mm Lg 8.821 8307025 4 Washer, Lock M1222 8307220 4 Washer, Flat M1223 10136599 1 Clevis24 10701363 1 Washer, Star25 10701562 1 Nut, Lock26 10238805 1 Cylinder, Park Brake27 10138907 1 Pin, Clevis28 10715335 1 Pin, Clevis29 8630016 1 O-Ring

8042/10042/10054 Origin 2/00

94

SECTION 3

DRIVE SHAFT - ENGINE TO TRANSMISSION(S/N 9908 & Before)

1

7

2

3

45

6

8

Felt Seal

Retaining Ring

Cap

To Engine

Torque to 55 - 60 lb/ft(75 - 81 Nm)

PH0452

8042/10042/10054 Rev. 7/99

95

SECTION 3


DRIVE SHAFT - ENGINE TO TRANSMISSION(S/N 9908 & Before)

1 7096592 1 Drive Shaft - Engine to Transmission (Inludes Items 2 thru 6)2 8033798 1 Shaft Assembly3 8033009 1 Cross and Bearing Assembly4 8033797 1 Sleeve Assembly5 8033007 1 Fitting, Grease6 8033796 1 Package, Seal7 8880218 2 Kit, Strap (Each Kit Includes 1 Strap and 2 Screws)8 6619261 1 Key, Shaft to Engine

8042/10042/10054 Rev. 7/99

96

SECTION 3

DRIVE SHAFT - ENGINE TO TRANSMISSION(S/N 9909 & After)

PH2040

1

2

3

45

6

7

8

910

11

12

13

14

15

16To Engine

Torque to48 lb/ft

(65 Nm)

Torque to35 lb/ft

(47 Nm)

45

6

8042/10042/10054 Origin 7/99

97

SECTION 3


DRIVE SHAFT - ENGINE TO TRANSMISSION(S/N 9909 & After)

1 7150202 1 Drive Shaft - Engine to Transmission (Includes Items 2 thru 13)2 8035618 1 Tight Joint Assembly (Includes Items 3 thru 7)3 8034593 1 Shaft Assembly4 8035620 2 Cross5 8035628 8 Bearing6 8035622 8 Snap Ring7 8033652 1 Flange Yoke8 8035617 1 Slip Joint Assembly (Includes Items 4 thru 6 and 9 thru 13)9 8033003 1 Slip Yoke

10 8033004 1 Fitting, Grease11 8035623 1 Cap, Dust12 8035624 1 Seal13 8035625 1 Washer14 8880219 2 Kit, Strap (Each Kit Includes 1 Strap and 2 Screws)15 8310425 4 HHCS, 7/16-20UNF x 1.25 Gr.816 8307006 4 Washer, Lock 7/16

8042/10042/10054 Origin 7/99

98

SECTION 3

DRIVE SHAFT - FRONT AND REAR(S/N 9908 & Before)

12

38

4

5

6

7

9

10

4Torque to 55 - 60 lb/ft

(75 - 81 Nm)

RetainingRing

Felt Seal

Torque to 32 - 37 lb/ft

(43 - 50 Nm)

Cap

PH0421

8042/10042/10054 Rev. 7/99

99

SECTION 3


DRIVE SHAFT - FRONT AND REAR(S/N 9908 & Before)

1 7096632 1 Drive Shaft - Front Axle (Includes Items 3 thru 7)2 7099832 1 Drive Shaft - Rear Axle (Includes Items 4 thru 8)

NOTE: Quantities Listed Below Are For One Drive Shaft Assembly3 8033097 1 Shaft Assembly - Front Axle4 8033009 2 Cross and Bearing Assembly5 8033006 1 Sleeve Assembly6 8033007 1 Fitting, Grease7 8033008 1 Seal Package8 8033098 1 Shaft Assembly - Rear Axle9 8880218 2 Kit, Strap (Each Kit Includes 1 Strap and 2 Screws)

10 8882009 2 U-Bolt Assembly

8042/10042/10054 Rev. 7/99

100

SECTION 3

DRIVE SHAFT - FRONT AND REAR(S/N 9909 & After)

PH1340

1

3

2

2

2

2

8042/10042/10054 Origin 2/00

101

SECTION 3


DRIVE SHAFT - FRONT AND REAR(S/N 9909 & After)

1 7150192 1 Drive Shaft - Front (Includes 2 of Item 2)2 8035778 4 Cross and Bearing Kit3 7150182 1 Drive Shaft - Rear (Includes 2 of Item 2)

8042/10042/10054 Origin 2/00

102

SECTION 3

DIFFERENTIAL CARRIER ASSEMBLY

23

45

6

7

9*

10*

11*

12

13

14

15

16

17

1819

20

21

2223

25**

26**

27**

28**

29**

30**

31**

32**

33**

34**

35

36

37

38

39

40

41

42

4344

45

23

43

29**

34**

34**

29**

33**28**

2223

44

10*

*Item 8 Includes These Parts**Item 24 Includes These Parts

ApplyLoctite #271to Threads

31**

46

ITEM 14 SPACER,PINION BEARING CHART

PART NO. THICKNESS8034506 .5135"8034507 .5165"8034508 .5195"8034509 .5225"8034510 .5245"8034511 .5255"8034512 .5265"8034513 .5275"8034514 .5285"8034515 .5295"8034516 .5305"8034517 .5315"8034518 .5325"8034519 .5335"8034520 .5345"8034521 .5355"8034522 .5375"8034523 .5395"8034524 .5405"8034525 .5435"8034526 .5485"

1

PH0261

PF0760

8042/10042/10054 Rev. 7/99

103

SECTION 3


DIFFERENTIAL CARRIER ASSEMBLY

1 8033966 1 Differential Carrier Assembly (Includes Items 2 thru 34)2 8033967 2 Ring, Adjusting3 8033968 2 Cup, Roller Bearing4 8033969 2 Lock, Bearing Adjusting Ring5 8033970 2 Pin, Cotter6 8033971 14 Rivet (Solid)7 8033972 1 Gear and Pinion Assembly (Matched Set)8 8033973 1 Carrier Assembly (Includes Items 9 thru 11)9 NSS 1 Carrier

10 NSS 2 Cap, Differential Bearing11 8033974 4 Bolt, Hex12 8033975 1 Bearing Assembly 13 8033810 1 Nut, Pinion (See Kits)14 See Chart 1 Spacer, Pinion Bearing15 8033976 AR Shim, .010"

8033977 AR Shim, .030"8033978 AR Shim, .005"

16 8033979 6 Bolt, Hex17 8033806 1 Seal, Oil (See Kits)18 8033980 1 Washer19 8033981 1 End Yoke Assembly (Includes Item 20)20 8033982 1 Slinger, Dust21 8033983 1 Cap Assembly, Bearing Retainer (Includes Item 22)22 8033984 2 Cup, Roller Bearing23 8033985 2 Cone, Roller Bearing24 8033986 1 Differential Case Assembly (Includes Items 25 thru 34)25 8033987 1 Flange Half, Differential Case26 8033988 1 Cap Half, Differential Case27 8033989 8 Bolt28 8033990 2 Washer, Thrust (Differential Gear)29 8033991 4 Washer, Thrust (Differential Pinion)30 8033992 1 Shaft, Differential Cross31 8033993 2 Cone, Roller Bearing32 8033994 8 Nut, Lock33 8033995 2 Gear, Differential34 8033996 4 Pinion, Differential35 8033997 1 Plug, Pipe36 8033998 6 Stud, Dowel (2" O.A.L.)

8033999 2 Stud, Dowel (2.38" O.A.L.)8034500 2 Stud, Dowel (2.81" O.A.L.)

37 8034501 1 Housing, Axle38 8032895 1 Plug, Magnetic Pipe39 8034502 1 Grease Fitting40 8033228 1 Breather41 8034503 10 Nut, Flange Lock42 8526044 1 Cartridge, Gasket Eliminator 10.15 fl. oz.43 8034504 2 Bushing, Axle Pivot44 8033809 2 Seal, Oil - Pivot Pin (See Kits)45 8034505 10 Washer, Flat

KITS46 8033802 1 Seal Kit, Axle (Includes the following Items which contains enough

seals to service one complete axle)Oil Seal - Pinion (Item 17, Page 103)Oil Seal - Pivot Pin (Item 44, Page 103)Nut, Pinion (Item 13, Page 103)Oil Seal - Axle Shaft (Item 7, Page 105)Oil Seal - King Pin (Item 18, Page 105)Oil Seal - Wheel Hub (Item 44, )Oil Seal - Spindle (Item 31, Page 107)Seal Kit - Wet Brake (See Kits Page 107)

8042/10042/10054 Rev. 2/00

104

SECTION 3

AXLE STEERING JOINTS

12

3

45

6

7

8

910

11

12

1314

15

1617

18

19

20

21

18

19

20

21

1314

15

16

17Torque to80 - 100 lb/ft

(109 - 136 Nm)

PH0270

8042/10042/10054 Rev. 6/94

105

SECTION 3


AXLE STEERING JOINTS

NOTE: Quantities are for one axle.

1 8033815 2 Shaft & Joint Assembly, Front & Rear Axles (Includes Items 2 thru 6)2 8033816 1 Shaft, Outer3 8033817 1 Slinger, Dust (Outer)4 8033818 1 Shaft, Inner5 8033805 1 Slinger, Dust (Inner)6 8033009 1 Cross and Bearing Kit7 8033804 2 Seal, Oil - Axle Shaft (See Kits Page 103)8 8033820 2 Bushing9 8033821 1 Knuckle Assembly, Left Front, Right Rear (Includes Item 10)

8033822 1 Knuckle Assembly, Not Shown, Right Front, Left Rear (Includes Item 10)10 8033823 24 Stud, Dowell11 8032876 24 Washer, Flat12 8032875 24 Nut, Lock13 8032877 4 Grease Fitting14 8033824 16 HHCS, Hex Head15 8032880 4 Cap, King Pin16 8032881 AR Shim, Formed17 8032882 AR Shim, Formed18 8032979 4 Seal, Oil - King Pin (See Kits Page 103)19 8032883 4 Cone, Roller Bearing20 8032885 4 Cup, Roller Bearing21 8032886 4 Retainer, Grease

8042/10042/10054 Rev. 2/00

106

SECTION 3

AXLE WHEEL ENDS(S/N 0460 & Before)

1

2

3

45

6

78

9

10

1112

13

14

1516

17

18

19

20

21

22

23

24

25

26

27

2829

3031

3233

34

3635

37

38

39

40

41

42

43

44

4546

1110


(610 - 678 Nm)



(122 - 136 Nm)

PH0642

PF0791

PH0920

PH0910

47

PH0910

��

PF0791 PF0791

48 49 50

8042/10042/10054 Rev. 2/00

107

SECTION 3


AXLE WHEEL ENDS(S/N 0460 & Before)

NOTE: Quantities are for one wheel end assembly unless otherwise specified.1 8034814 1 Wheel End Assembly, Front & Rear (Includes Items 2 thru 44)2 8032906 18 Screw, Hex Hd, Self Locking3 8033012 1 Planetary Gear Assembly (Includes Items 4 thru 14)4 8032903 1 Flange, Planetary Drive5 8032895 1 Plug, Pipe6 8032894 1 Plug, Hex Hd7 8032900 3 Pin, Roll8 8032899 3 Shaft, Planet Gear9 8032896 1 Washer, Drive Flange

10 8032901 6 Washer, Keyed11 8032898 150 Bearing, Single Roller12 8032897 3 Washer, Planet Gear13 8032902 3 Gear, Spur14 8032904 1 Plate, Lining Stop15 8033826 1 Ring, Snap16 8033827 1 Gear, Spur17 NSS 4 Plate, Lining Stop (See Kits)18 NSS 4 Disc Assembly (See Kits)19 8032912 1 Piston20 8034692 1 O-Ring (See Kits)21 8034693 1 O-Ring (See Kits)22 8032922 2 O-Ring (See Kits)23 8032923 1 O-Ring (See Kits)24 See Kits 1 Spindle Assembly (Includes Items 25 & 26)25 8033828 1 Bushing, Spindle26 8032826 2 Seat, Insert27 8034581 1 Screw and Washer Kit (Includes six screws & six washers)28 8032984 1 Plug, Bleeder29 8032985 1 O-Ring, Bleeder Plug30 8033829 1 Fitting, Brake31 8033803 1 Seal, Oil - Spindle (See Kits Page 103)32 8032920 1 Retainer, Bearing Adjusting Ring (Includes Item 33)33 8032949 1 Tubing, Brake34 8032972 AR Shim, Adjusting (.010")

8035268 AR Shim, Adjusting (.011")8035269 AR Shim, Adjusting (.012")8035270 AR Shim, Adjusting (.013")8035271 AR Shim, Adjusting (.014")8035272 AR Shim, Adjusting (.015")8032973 AR Shim, Adjusting (.020")8032974 AR Shim, Adjusting (.030")

35 8032910 1 Gear, Planetary Ring36 8032913 1 Cone, Roller37 8033831 1 Hub Assembly (Includes Items 38 thru 41)38 8033832 1 Hub, Planetary39 8032891 1 Cup, Roller Bearing40 8032892 1 Cup, Roller Bearing41 8032893 10 Bolt, Wheel, Right Side42 8786516 10 Nut, Wheel43 8032914 1 Cone, Roller Bearing44 8032983 1 Seal, Oil - Wheel Hub (See Kits Page 103)45 8522043 1 Friction Modifier Fluid (Low Odor) - 32 Oz. (enough to service 4 wheel ends)46 8522045 1 Wheel End Oil 2-1/2 Gal. (enough to service 4 wheel ends)47 8522048 1 Wheel End Oil 1 Gal.

KITS48 8034688 1 Brake Kit (Includes Items 17 thru 18) (this kit services one wheel end)49 8034819 1 Wet Brake Seal Kit (Includes Items 20 thru 23)50 8033799 1 Spindle Kit (Includes Items 24 thru 27)

Identify bolt size before ordering. If 3/8" order similar parts on this page.If 1/2" order similar parts on page 109.

A

A

A

A

A

8042/10042/10054 Rev. 2/00

108

SECTION 3

AXLE WHEEL ENDS(S/N 0461 & After)

25

26

2728

2930

3132

21

34

35

36

37

38

39

40

41

45

43

44

4647

1

2

3

45

6

7

89

10

1112

1314

1516

17

18

19

20

33

23

22

42

1110

24


(176 - 190 Nm)


(610 - 678 Nm)


(122 - 136 Nm)

PH0643

PH0920PH0910

48

PH0910

��

PF0791PF0791PF0791

50 5149

8042/10042/10054 Rev. 2/00

109

SECTION 3


AXLE WHEEL ENDS(S/N 0461 & After)

NOTE: Quantities are for one wheel end assembly unless otherwise specified.1 8034814 1 Wheel End Assembly, Front & Rear (Includes Items 2 thru 45)2 8032906 18 Screw, Hex Hd, Self Locking3 8033012 1 Planetary Gear Assembly (Includes Items 4 thru 14)4 8032903 1 Flange, Planetary Drive5 8032895 1 Plug, Pipe6 8032894 1 Plug, Hex Hd7 8032900 3 Pin, Roll8 8032899 3 Shaft, Planet Gear9 8032896 1 Washer, Drive Flange

10 8032901 6 Washer, Keyed11 8032898 150 Bearing, Single Roller12 8032897 3 Washer, Planet Gear13 8032902 3 Gear, Spur14 8032904 1 Plate, Lining Stop15 8033826 1 Ring, Snap16 8033827 1 Gear, Spur17 NSS 4 Plate, Lining Stop (See Kits)18 NSS 4 Disc Assembly (See Kits)19 8032912 1 Piston20 8034692 1 O-Ring (See Kits)21 8034693 1 O-Ring (See Kits)22 8032922 2 O-Ring (See Kits)23 8032923 1 O-Ring (See Kits)24 See Kits 1 Spindle Assembly (Includes Items 25 & 26)25 8033828 1 Bushing, Spindle26 8032826 2 Seat, Insert27 8034584 6 Screw, 12 Point Cap - 1/2"28 8034585 6 Washer, Flat Hardened 1/2" 29 8032984 1 Plug, Bleeder30 8032985 1 O-Ring, Bleeder Plug31 8033829 1 Fitting, Brake32 8033803 1 Seal, Oil - Spindle (See Kits Page 103)33 8034586 1 Retainer, Bearing Adjusting Ring (Includes Item 34)34 8032949 1 Tubing, Brake35 8032972 AR Shim, Adjusting (.010")

8035268 AR Shim, Adjusting (.011")8035269 AR Shim, Adjusting (.012")8035270 AR Shim, Adjusting (.013")8035271 AR Shim, Adjusting (.014")8035272 AR Shim, Adjusting (.015")8032973 AR Shim, Adjusting (.020")8032974 AR Shim, Adjusting (.030")

36 8032910 1 Gear, Planetary Ring37 8032913 1 Cone, Roller38 8033831 1 Hub Assembly (Includes Items 39 thru 42)39 8033832 1 Hub, Planetary40 8032891 1 Cup, Roller Bearing41 8032892 1 Cup, Roller Bearing42 8032893 10 Bolt, Wheel, Right Side43 8786516 10 Nut, Wheel44 8032914 1 Cone, Roller Bearing45 8032983 1 Seal, Oil - Wheel Hub (See Kits Page 103)46 8522043 1 Friction Modifier Fluid (Low Odor) 32 Oz. (enough to service 4 wheel ends)47 8522045 1 Wheel End Oil 2-1/2 Gal. (enough to service 4 wheel ends)48 8522048 1 Wheel End Oil 1 Gal.

KITS49 8034688 1 Brake Kit (Includes Items 17 & 18) (this kit services one wheel end)50 8034819 1 Wet Brake Seal Kit (Includes Items 20 thru 23)51 8034590 1 Service Kit, Spindle (Includes Items 24 thru 27)

8042/10042/10054 Rev. 2/00

110

SECTION 3

TIE ROD AND STEERING CYLINDER MOUNTING

1

2

3*4

5

6

7*

8

9

10

11

1110

6

See“Steering Cylinder”

9

9

Front

PH0282

*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.

ACTUAL SIZE

1-1/8-16Item #3

P/N 8033962

1-1/8-12Item #7

P/N 8033964

8042/10042/10054 Rev. 2/00

111

SECTION 3


TIE ROD AND STEERING CYLINDER MOUNTING

NOTE: Quantities listed are for one axle.

1 8033960 1 Tie Rod Assembly (Includes Items 2 thru 9)2 8033961 1 Tube, Tie Rod3 8033962 1 Socket Assembly, 1-1/8 - 16 RH Thread

(Includes nut, cotter pin & boot) See “IMPORTANT” Note4 8033963 1 Boot5 8033965 1 Cotter Pin6 8032930 2 Clamp Assembly7 8033964 1 Socket Assembly, 1-1/8 - 12 RH Thread

(Includes nut, cotter pin & boot) See “IMPORTANT” Note8 8033963 1 Boot9 8033965 3 Cotter Pin

10 8340025 2 Socket Assembly, Steer Cylinder (Includes nut, cotter pin & boot)11 8032816 AR Boot

8042/10042/10054 Rev. 7/98

112

SECTION 3

WHEELS AND TIRES - 8042

113212939

214223041

315233140

481647

517253444

618263546

719273645

910

11

12

33384348

! WarningMis-Matched tire sizes or mixing of tire types (Radial and Bias ply) may compromise vehicle stability and may result in vehicle tipover.

202428323742

PH0461

8042 Rev. 2/00

113

SECTION 3


WHEELS AND TIRES - 8042

1 7119642 2 Tire & Wheel Ass’y, Right Side - 13.00 x 24, 12 Ply (Includes Items 2 thru 4) 2 7092533 1 Wheel, 9024 GR3 8780031 1 Tire, 13.00 x 24, 12 Ply4 8786514 1 Stem, Valve5 7119632 2 Tire & Wheel Ass’y, Left Side - 13.00 x 24, 12 Ply (Includes Items 6 thru 8) 6 7092533 1 Wheel, 9024 GR7 8780031 1 Tire, 13.00 x 24, 12 Ply8 8786514 1 Stem, Valve9 7092612 4 Tire & Wheel Ass’y, Left or Right Side - 13.00 R24, 14 Ply (Includes Items 10 thru 12)

10 7092533 1 Wheel, 9024 GR11 8780264 1 Tire, 13.00 R24 Radial12 8786514 1 Stem, Valve13 7110772 2 Tire & Wheel Ass’y, Right Side - 15.5 x 25, 12 Ply (Includes Items 14 thru 16)14 7098733 1 Wheel, 1325LR x 1.5 Offset15 8780036 1 Tire, 15.5 x 25, 12 Ply16 8786514 1 Stem, Valve17 7110762 2 Tire & Wheel Ass’y, Left Side - 15.5 x 25, 12 Ply (Includes Items 18 thru 20)18 7098733 1 Wheel, 1325LR x 1.5 Offset19 8780036 1 Tire, 15.5 x 25, 12 Ply20 8786514 1 Stem, Valve21 7099532 2 Tire & Wheel Ass’y, Right Side - 17.5 x 25, 12 Ply (Includes Items 22 thru 24)22 7098733 1 Wheel, 1325LR x 1.5 Offset23 8780037 1 Tire, 17.5 x 25, 12 Ply24 8786514 1 Stem, Valve25 7099522 2 Tire & Wheel Ass’y, Left Side - 17.5 x 25, 12 Ply (Includes Items 26 thru 28)26 7098733 1 Wheel, 1325LR x 1.5 Offset27 8780037 1 Tire, 17.5 x 25, 12 Ply28 8786514 1 Stem, Valve29 7119662 2 Tire & Wheel Ass’y, Right Side - 13.00 x 24, 12 Ply with Trak Seal

(Includes Items 30 thru 32)30 7092533 1 Wheel, 9024 GR31 8780031 1 Tire, 13.00 x 24, 12 Ply32 8786514 1 Stem, Valve33 4108161 1 Label, Hydrofill34 7119652 2 Tire & Wheel Ass’y, Left Side - 13.00 x 24, 12 Ply with Trak Seal

(Includes Items 35 thru 38)35 7092533 1 Wheel, 9024 GR36 8780031 1 Tire, 13.00 x 24, 12 Ply37 8786514 1 Stem, Valve38 4108161 1 Label, Hydrofill39 7138240 2 Tire & Wheel Ass’y, Right Side - 13.00 x 24, 12 Ply “Yokohama”

(Includes Items 40 thru 43)40 8780045 1 Tire, 13.00 x 24, 12 Ply41 7092533 1 Wheel, 9024 GR42 8786514 1 Stem, Valve43 4108161 1 Label, Hydrofill44 7138241 2 Tire & Wheel Ass’y, Left Side - 13.00 x 24, 12 Ply “Yokohama”

(Includes Items 45 thru 48)45 8780045 1 Tire, 13.00 x 24, 12 Ply46 7092533 1 Wheel, 9024 GR47 8786514 1 Stem, Valve48 4108161 1 Label, Hydrofill

8042 Rev. 2/00

114

SECTION 3

WHEELS AND TIRES - 10042/10054

1

2

348

5

6

7

9

10

11

12 & 1613

14

15

17

1014

18

19

20 & 2421

22

23

1822

! WarningMis-Matched tire sizes or mixing of tire types (Radial and Bias ply) may compromise vehicle stability and may result in vehicle tipover.

PH0651

10042/10054 Rev. 2/00

115

SECTION 3


WHEELS AND TIRES - 10042/10054

1 7099532 2 Tire & Wheel Ass’y, Right Side - 17.5 x 25, 12 Ply (Includes Items 2 thru 4)2 7098733 1 Wheel, 1325LR x 1.5 Offset3 8780037 1 Tire, 17.5 x 25, 12 Ply4 8786514 1 Stem, Valve5 7099522 2 Tire & Wheel Ass’y, Left Side - 17.5 x 25, 12 Ply (Includes Items 6 thru 8)6 7098733 1 Wheel, 1325LR x 1.5 Offset7 8780037 1 Tire, 17.5 x 25, 12 Ply8 8786514 1 Stem, Valve9 7099702 2 Tire & Wheel Ass’y, Right Side - 17.5 R25, 2 Star (Includes Items 10 thru 12)

10 7110333 1 Wheel, 14.00 - 2511 8780035 1 Tire, 17.5 R25, 2 Star, Radial12 8786559 1 Stem, Valve13 7099692 2 Tire & Wheel Ass’y, Left Side - 17.5 R25, 2 Star (Includes Items 14 thru 16)14 7110333 1 Wheel, 14.00 - 2515 8780035 1 Tire, 17.5 R25, 2 Star, Radial16 8786559 1 Stem, Valve17 7110352 2 Tire & Wheel Ass’y, Right Side - 17.5 x 25, 12 Ply (Includes Items 18 thru 20)18 7110333 1 Wheel, 14.00 - 2519 8780037 1 Tire, 17.5 x 25, 12 Ply20 8786559 1 Stem, Valve21 7110342 2 Tire & Wheel Ass’y, Left Side - 17.5 x 25, 12 Ply (Includes Items 22 thru 24)22 7110333 1 Wheel, 14.00 - 2523 8780037 1 Tire, 17.5 x 25, 12 Ply24 8786559 1 Stem, Valve

10042/10054 Rev. 12/97

116

SECTION 4

SECTION 4 POWER PLANT

ENGINE, RADIATOR AND OIL COOLER MOUNTING(S/N 0118 & Before)

1234

12

5

6 7

910

11

14151617 13

58

24

21

23

38

51

50

47

45

49

53

46

10

41

Left SideEngineMount

56

39

4344

42

44

39

37

3640

34

33

32

25

1011

2652

4647

19

444342

44

48

35

11

44

59

58

4156

60

57

58

5554

18

20

61

63

62

64 65

22

66

67

Left Side of Engine

PH0077

8

28

PS0940 PS0950

6968

27

3130

29

8042/10042 Rev. 2/00

117

SECTION 4


ENGINE, RADIATOR AND OIL COOLER MOUNTING(S/N 0118 & Before)

1 7096692 1 Engine, Cummins 4BT 3.9 Turbo8262131 1 Engine, Cummins 4BTA 3.9 After Cooled Turbo

2 8270221 1 Alternator, Bosch3 8270220 1 Fan, Alternator4 8033342 1 Pulley, Alternator5 8272009 1 Fan, Puller 17"6 8310028 4 HHCS, M8 x 70mm7 8307222 4 Washer, Flat M88 8080613 1 Belt, Engine Fan9 7095272 1 Mount, Engine Left Side

10 8303790 14 HHCS, M12 x 30mm11 8307025 14 Washer, Lock M1212 8320262 1 Element, Engine Oil Filter (Also included in Filter Kits 68 and 69)13 8277162 1 Solenoid, Relay for Starter, Sealed14 8303742 2 FLHDCS, 1/4-20 x 1"15 8310002 2 Washer, Lock 1/4" External Teeth16 8307109 2 Washer, Flat 1/4"17 8305624 2 Nut, Hex Lock Elastic 1/4-2018 7054632 1 Cover, Flywheel19 8307023 4 Washer, Lock M1020 8303784 4 HHCS, M10 x 20mm21 7095282 1 Mount, Engine Right Side22 8303702 2 HHCS, 1/2-13 x 3"23 8278012 2 Mount, Vibration24 7095831 2 Washer, Rebound25 8305644 2 Nut, Hex Lock Elastic 1/2-1326 7133022 1 Kit, Engine Mount (Includes Items 27 & 28)27 7127003 1 Mount, Engine28 7132912 1 Kit, Muffler Strap (Includes Items 29 thru 31)29 7127013 1 Bracket, Muffler30 8307025 2 Washer, Lock M1231 8303519 2 HHCS, M12 x 35mm32 8310067 1 Nut, Hex Lock Elastic 3/4-1033 8278007 1 Mount, Vibration34 7054351 1 Washer, Rebound35 8303724 1 HHCS, 3/4-10 x 3-1/2"36 7085422 1 Tank, Radiator Overflow (Includes Item 37)37 8866341 1 Cap w/ Tether38 8305626 4 Nut, Hex Lock Elastic 5/16-1839 8307106 8 Washer, Flat 5/16"40 8406101 1 Support, Hose 5/8"41 8303106 3 HHCS, 3/8-16 x 2-1/2"42 8278008 3 Mount, Vibration43 7057141 3 Washer, Rebound44 8305645 14 Nut, Hex Lock Elastic 3/8-1645 7094592 1 Bar, Radiator Mount46 8307004 10 Washer, Lock 5/16"47 8303744 10 HHCS, 5/16-18 x 1/2"48 2712993 1 Oil Cooler49 8904001 1 Cock, Drain 1/4"50 5724284 1 Radiator (Includes Items 51 thru 54)51 8403224 1 Cap, Connection52 8405104 1 Clamp, Hose 2-1/4"53 8180308 2 Stud, Radiator Mount54 8180307 1 Cap, Radiator55 7099943 1 Shroud, Radiator56 8307110 2 Washer, Flat 3/8"57 8405203 1 Clamp, Hose 3"58 8405104 3 Clamp, Hose 2-1/4"59 7093783 1 Hose, Upper Radiator60 7093772 1 Hose, Lower Radiator61 8303622 1 HHCS, 3/8-16 x 2"62 7099912 1 Support, Upper Radiator63 8303679 8 HHCS, 3/8-16 x 1-3/4"64 7150523 1 Kit, Torsion Dampener Coupling (Includes Coupler, Shaft, Hardware & Instructions)65 8140309 1 Bushing, Split Tapered66 8277161 1 Heater, Coolant

7088352 1 Freeze Plug67 8033340 1 Starter, 12V (Includes Solenoid)68 7138291 1 Kit, 250 Hour Filter (Includes 4 Filters; Engine Oil Filter & 3 Fuel Filters)69 7138301 1 Kit, 1000 Hour Filter (Includes 7 Filters; Engine Oil Filter, 3 Fuel Filters,

Primary Air Filter, Transmission Oil Filter & Hydraulic Oil Filter)

8042/10042 Rev. 2/00

118

SECTION 4

ENGINE, RADIATOR AND OIL COOLER MOUNTING(S/N 0119 thru 1598)

234

1

12

5

67

89

1011

13

14151617


21

23

6143

62

26

32

3334

35

57

58

57

50

48

4547

4649

44

55 4142

3936

37

38

5251

46

1011

56

5957

43

4353

55

44

54

60 55

55

43

41 42

45

47

40

1011

63

20

19

18

22

24

2546

64

65

Left Side of Engine

PH0076

PS0940 PS0950

67 66

28

27

3130

29

8042/10042/10054 Rev. 2/00

119

SECTION 4


ENGINE, RADIATOR AND OIL COOLER MOUNTING(S/N 0119 thru 1598)

1 8262137 1 Engine, Cummins 4BT 3.9 Turbo8262138 1 Engine, Cummins 4BTA 3.9 After Cooled Turbo

2 8270221 1 Alternator, Bosch3 8270220 1 Fan, Alternator4 8033342 1 Pulley, Alternator5 8272009 1 Fan, Puller 17"6 8310028 4 HHCS, M8 x 70mm7 8307222 4 Washer, Flat M88 8080613 1 Belt, Engine Fan9 7095272 1 Mount, Engine Left Side

10 8303790 14 HHCS, M12 x 30mm11 8307025 14 Washer, Lock M1212 8320262 1 Element, Engine Oil Filter (Also included in Filter Kits 66 and 67)13 8277162 1 Solenoid, Relay for Starter14 8303742 2 FLHDCS, 1/4-20 x 1"15 8310002 2 Washer, Lock 1/4" External Teeth16 8307109 5 Washer, Flat 1/4"17 8305624 2 Nut, Hex Lock Elastic 1/4-2018 7054632 1 Cover, Flywheel19 8307023 4 Washer, Lock M1020 8303784 4 HHCS, M10 x 20mm21 7095282 1 Mount, Engine Right Side22 8303702 2 HHCS, 1/2-13 x 3"23 8278012 2 Mount, Vibration24 7095831 2 Washer, Rebound25 8305644 2 Nut, Hex Lock Elastic 1/2-1326 7133022 1 Kit, Engine Mount (Includes Items 27 & 28)27 7127003 1 Mount, Engine28 7132912 1 Kit, Muffler Strap (Includes Items 29 thru 31)29 7127013 1 Bracket, Muffler30 8307025 2 Washer, Lock M1231 8303519 2 HHCS, M12 x 35mm32 8310067 1 Nut, Hex Lock Elastic 3/4-1033 8278007 1 Mount, Vibration34 7054351 1 Washer, Rebound35 8303724 1 HHCS, 3/4-10 x 3-1/2"36 7085422 1 Tank, Radiator Overflow (Includes Item 37)37 8866341 1 Cap w/Tether38 8305626 4 Nut, Hex Lock Elastic 5/16-1839 8406101 1 Support, Hose 5/8"40 8303106 1 HHCS, 3/8-16 x 2-1/2"41 8278008 3 Mount, Vibration42 7057141 3 Washer, Rebound43 8305645 12 Nut, Hex Lock Elastic 3/8-1644 8303622 3 HHCS, 3/8-16 x 2"45 8307004 10 Washer, Lock 5/16"46 8307203 10 Washer, Flat 0.3147 8303697 10 HHCS, 0.31 x 0.75"48 2712993 1 Oil Cooler49 8904001 1 Cock, Drain 1/4"50 7127034 1 Radiator (Includes Items 51 thru 53)51 8403224 1 Cap, Connection52 8405104 1 Clamp, Hose 2-1/4"53 8180307 1 Cap, Radiator54 7127043 1 Shroud, Radiator55 8307204 7 Washer, Flat 3/8" Heavy56 8405203 1 Clamp, Hose 3"57 8405104 3 Clamp, Hose 2-1/4"58 7093783 1 Hose, Upper Radiator59 7093772 1 Hose, Lower Radiator60 7099912 1 Support, Upper Radiator61 8303679 8 HHCS, 3/8-16 x 1-3/4"62 7150523 1 Kit, Torsion Dampener Coupling (Includes Coupler, Shaft, Hardware & Instructions)63 8140309 1 Bushing, Split Tapered64 8277161 1 Heater, Coolant

7088352 1 Freeze Plug65 8033340 1 Starter, 12V (Includes Solenoid)66 7138291 1 Kit, 250 Hour Filter (Includes 4 Filters; Engine Oil Filter & 3 Fuel Filters)67 7138301 1 Kit, 1000 Hour Filter (Includes 7 Filters; Engine Oil Filter, 3 Fuel Filters, Primary Air Filter,

Transmission Oil Filter & Hydraulic Oil Filter)

8042/10042/10054 Rev. 2/00

120

SECTION 4

ENGINE, RADIATOR AND OIL COOLER MOUNTING (EPA)(S/N 1599 & After)


1

11

13

14151617

19

22

25

28

31

234

10

12

68

20

23

26

29

32

5

7

918

21

2427

30

33

61

11 10

11

11 10

35

36

52

40

42

43

4445

46 47

49

50

52

53

54 56

57

58

59

37

41

47

51

55

38

49

47

47

39

38

3941

49

38

48

36

3738

34

16

Left Side of Engine

60

PH0075PS0940 PS0950

PS0940

63 62

64

8042/10042/10054 Rev. 2/00

121

SECTION 4


ENGINE, RADIATOR AND OIL COOLER MOUNTING (EPA)(S/N 1599 & After)

1 8262142 1 Engine, Cummins 4BT 3.9 Turbo (8042)8262143 1 Engine, Cummins 4BTA 3.9 After Cooled Turbo (10042 & 10054)

2 8270221 1 Alternator, Bosch3 8270220 1 Fan, Alternator4 8033342 1 Pulley, Alternator5 8272017 1 Fan6 8303550 4 HHCS, M8 x 60mm7 8307222 4 Washer, Flat M88 8080613 1 Belt, Engine Fan9 7095272 1 Mount, Engine Left Side

10 8303790 14 HHCS, M12 x 30mm11 8307025 14 Washer, Lock M1212 8320262 1 Element, Engine Oil Filter (Also included in Filter Kits 62, 63 and 64)13 8277162 1 Solenoid, Relay for Starter14 8303742 2 FLHDCS, 1/4-20 x 1"15 8310002 2 Washer, Lock 1/4" External Teeth16 8307109 4 Washer, Flat 1/4"17 8305624 2 Nut, Hex Lock Elastic 1/4-2018 7054632 1 Cover, Flywheel19 8307023 4 Washer, Lock M1020 8303784 4 HHCS, M10 x 20mm21 7095282 1 Mount, Engine Right Side22 8303702 2 HHCS, 1/2-13 x 3"23 8278012 2 Mount, Vibration24 7095831 2 Washer, Rebound25 8305644 2 Nut, Hex Lock Elastic 1/2-1326 7127003 1 Mount, Engine27 8310067 1 Nut, Hex Lock Elastic 3/4-1028 8278007 1 Mount, Vibration29 7054351 1 Washer, Rebound30 8303724 1 HHCS, 3/4-10 x 3-1/2"31 7085422 1 Tank, Radiator Overflow (Includes Item 32)32 8866341 1 Cap w/Tether33 8305626 4 Nut, Hex Lock Elastic 5/16-1834 8406101 1 Support, Hose 5/8"35 8303106 3 HHCS, 3/8-16 x 2-1/2"36 8278008 3 Mount, Vibration37 7057141 3 Washer, Rebound38 8305645 14 Nut, Hex Lock Elastic 3/8-1639 8307004 10 Washer, Lock 0.3140 8307106 6 Washer, Flat 0.3141 8303697 10 HHCS, 0.31 x 0.75"42 2712993 1 Oil Cooler (S/N 1599 thru 9908)

2713054 1 Oil Cooler (S/N 9909 & After)43 8904001 1 Cock, Drain 1/4"44 7127034 1 Radiator (Includes Item 45)45 8180307 1 Cap, Radiator46 7127043 1 Shroud, Radiator47 8307110 5 Washer, Flat 3/8"48 8405203 1 Clamp, Hose 3"49 8405104 3 Clamp, Hose 2-1/4"50 7093783 1 Hose, Upper Radiator51 7093772 1 Hose, Lower Radiator52 8303622 3 HHCS, 3/8-16 x 2"53 7099912 1 Support, Upper Radiator54 8303679 8 HHCS, 3/8-16 x 1-3/4"55 7150523 1 Kit, Torsion Dampener Coupling (Includes Coupler, Shaft, Hardware & Instructions)

(S/N 1599 thru 9908)7137643 1 Torsion Dampener Coupling (S/N 9909 & After)

56 8140309 1 Bushing, Split Tapered57 8277161 1 Heater, Coolant58 7127013 1 Bracket, Muffler59 8303519 2 HHCS, M12 x 35mm60 8033340 1 Starter, 12V (Includes Solenoid)61 8307203 6 Washer, Flat62 7138290 1 Kit, 250 Hour Filter (Includes 3 Filters; Engine Oil Filter & Both Fuel Filters)63 7138297 1 Kit, 1000 Hour Filter (Includes 6 Filters; Engine Oil Filter, Both Fuel Filters, Primary Air

Filter, Transmission Oil Filter & Hydraulic Oil Filter) (S/N 1599 thru 9908)64 7138848 1 Kit, 1000 Hour Filter (Includes 6 Filters; Engine Oil Filter, Both Fuel Filters, Primary Air

Filter, Transmission Oil Filter & Hydraulic Oil Filter) (S/N 9909 & After)

8042/10042/10054 Rev. 2/00

122

SECTION 4

TORSION COUPLER(S/N 9909 & After)

PH1230

2

3

45

6

1

To Engine

8042/10042/10054 Origin 7/99

123

SECTION 4


TORSION COUPLER(S/N 9909 & After)

1 7137643 1 Coupling Assembly, Torsion (Includes Items 2 thru 6)2 8035555 1 Assembly, Shaft and Bearing3 8035556 1 Housing, Protective4 8035557 6 Bolt, Hex Hd. M10 x 25mm5 8035558 6 Washer, Flat M106 8035559 1 Element, Torsion Coupling

8042/10042/10054 Origin 7/99

124

SECTION 4

EXHAUST SYSTEM

To TurboCharger

1

2

3

56

7

8

9

10

11

4

4

10

PH0091

8042/10042/10054 Rev. 2/00

125

SECTION 4


EXHAUST SYSTEM

1 8275240 1 Clamp, V-Band2 7126953 1 Pipe, Exhaust (S/N 1599 & After)

7088283 1 Pipe, Exhaust (S/N 1598 & Before)3 8275247 1 Clamp, Muffler 3.00" (S/N 1599 & After)

8275212 1 Clamp, Muffler 2.50" (S/N 1598 & Before)4 8275248 2 Clamp, Muffler 2.75" (S/N 1599 & After)

8275212 2 Clamp, Muffler 2.50" (S/N 1598 & Before)5 8303621 2 HHCS, 3/8-16 x 1-1/2"6 8307204 2 Washer, Flat 3/8" Heavy7 8305645 2 Nut, Hex Lock Elastic 3/8-168 7127022 1 Support, Exhaust Pipe (S/N 1599 & After)

7110022 1 Support, Exhaust Pipe (S/N 1598 & Before)9 7126962 1 Pipe, Tail (S/N 1599 & After)

7086742 1 Pipe, Tail (S/N 1598 & Before)10 7126992 2 Clamp, Band (S/N 1599 & After)

7097452 2 Clamp, Band (S/N 1598 & Before)11 7126922 1 Muffler (S/N 1599 & After)

7079162 1 Muffler (S/N 1598 & Before)

8042/10042/10054 Rev. 2/00

126

SECTION 4

AIR CLEANER

4

5

3

12

8

7

18

9

10

11

6

12

15

16

19

17

13

14

14

PH0081

8042/10042/10054 Rev. 2/00

127

SECTION 4


AIR CLEANER

1 7097323 1 Scoop, Air Intake2 8273240 2 Band, Air Cleaner Mounting3 7095302 1 Bracket, Air Cleaner Mounting4 8303697 4 HHCS, 0.31 x 0.75"5 8307203 4 Washer, Flat 5/16"6 8305626 4 Nut, Hex Lock Elastic 5/16"7 8303618 2 HHCS, M12 x 25mm8 8307025 2 Washer, Lock M129 8273241 1 Indicator, 25" Service

10 8273013 1 Air Cleaner Assembly (Includes Items 11 thru 15)11 8032764 1 Valve, Vacuator12 8273237 1 Element, Primary13 8273238 1 Element, Safety14 8273272 2 Nut, Assembly15 8032762 1 Cover, End16 8405307 1 Clamp, T-Bolt 3-13/16" I.D.17 7095393 1 Hose, Air Intake18 8405404 1 Clamp, T-Bolt Band 4.38" I.D.19 8405305 1 Clamp, T-Bolt Band 3.38" I.D.

8042/10042/10054 Rev. 2/00

128

SECTION 4

FUEL SYSTEM(S/N 1598 & Before)

Engine Is Turned Around 180°From Mounted Position

For Clarity

Fuel Return

Fuel Supply

7

8

6

1516

22

17

9

10

14

12

13

2019

18

1

2

3

4

5

11

21

10

10

10

10

13

22

PH0031

8042/10042/10054 Rev. 2/00

129

SECTION 4


FUEL SYSTEM(S/N 1598 & Before)

1 7136034 1 Tank, Fuel and Hydraulic2 7138209 1 Gasket3 NLA 1 Screen, Fillneck (For Service, Order P/N 8322022)4 7138714 1 Neck, Filler/Breather5 NLA 1 Cap, Fill w/Chain (For Service, Order P/N 8322022)6 8305626 4 Nut, Hex Lock Elastic 5/16-187 7118222 1 Sender, Fuel Level8 8310163 5 THCS, #10 x 5/8"9 8430007 1 Hose Fitting, Long, Barbed, SAE 6-4P - hose I.D. x male NPT, Fits 3/8" Hose

10 8410009 4 Clamp, Hose 1.06 Dia.11 7127881 1 Hose, Fuel Supply .38 x 4"12 8274022 1 Strainer, Fuel13 7127871 1 Hose, Fuel Supply .38 x 100" 14 7125421 1 Hose, Fuel Return .25 x 105" 15 8640903 1 O-Ring16 8541435 1 Plug, Magnetic, Hex Hd., 1" str. thd.17 8430034 1 Hose Fitting, Elbow, 90°, Beaded, SAE 6-6 - hose I.D. x male str. thd. o-ring18 8430035 1 Hose Fitting, Elbow, 90°, Beaded, SAE 4-4 - hose I.D. x male str. thd. o-ring,

Fits 1/4" Hose 19 8320250 1 Element, Fuel Filter - Secondary 20 8320253 1 Element, Fuel Filter - Primary 21 8630012 2 O-Ring22 8405009 2 Clamp, Hose .62

8042/10042/10054 Rev. 2/00

130

SECTION 4

FUEL SYSTEM (EPA)(S/N 1599 & After)

Engine Is Turned Around 180°From Mounted Position

For Clarity

Fuel Return

Fuel Supply

1

2

3

4

5

6

78

9 10 11

10

10

12

20

14 13

21

10

20

14

13

1516

17

19

18

PH0032

8042/10042/10054 Rev. 2/00

131

SECTION 4


FUEL SYSTEM (EPA)(S/N 1599 & After)

1 7136034 1 Tank, Fuel and Hydraulic2 7138209 1 Gasket3 NLA 1 Screen, Fillneck (For Service, Order P/N 8322022)4 7138714 1 Neck, Filler/Breather5 NLA 1 Cap, Fill w/Chain (S/N 9499 & Before) (For Service, Order P/N 8322022)

8322029 1 Cap, Fill w/Chain (S/N 9500 & After)6 8305626 4 Nut, Hex Lock Elastic 5/16-187 7118222 1 Sender, Fuel Level8 8310163 5 THCS, #10 x 5/8"9 8430007 1 Hose Fitting, Long, Barbed, SAE 6-4P - hose I.D. x male NPT, Fits 3/8" Hose

10 8410009 4 Clamp, Hose 1.06 Dia.11 7127881 1 Hose, Fuel Supply .38 x 4"12 8274022 1 Strainer, Fuel13 7127871 1 Hose, Fuel Supply .38 x 100"14 7127081 1 Hose, Fuel Return .31 x 123"15 8640903 1 O-Ring16 8541435 1 Plug, Magnetic, Hex Hd., 1" str. thd.17 8430034 1 Hose Fitting, Elbow, 90°, Beaded, SAE 6-6 - hose I.D. x male str. thd. o-ring18 8430064 1 Hose Fitting, Elbow, 90°, Beaded, SAE 5-6 - hose I.D. x male str. thd. o-ring,

Fits 5/16" Hose19 8630012 2 O-Ring20 8405009 2 Clamp, Hose .6221 8320270 1 Element, Fuel Filter

8042/10042/10054 Rev. 2/00

132

SECTION 5

SECTION 5 HYDRAULIC CIRCUITS

POWER STEERING CIRCUIT(S/N 9908 & Before)

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1

2

3

4

6

78

9

10

11

12

14

15

17

18

19

20

21

22

23 24

26

2728

29

3031

32

3435

36

37

Outlet Port

Load Sense Port

Main Pump

14

RearSteering Cylinders

7

InletPort

Main Control Valve(Rotated For Clarity)

7

33

To Port “CF”

25To Port

“EF”

122To Port

“T”To Port

“LS”4

To Port “3”32

33 1To Port

“2”

To Port “1”

28

4

19

176 18

2014

Underneath View of Valve PlateSee “Valve Plate Assembly”

14

7

FrontSteering Cylinders

7

512

1116

35

10

9

13T

L

RP

Front

8

8

12

35

11

Pressure Reducing

Valve

To Port “B”

Port “T”

Port “P”

T

R

PL

21

To Port “A”

38

39

40

42

PH0142

10To Port “T”

41

8042/10042/10054 Rev. 2/00

133

SECTION 5


POWER STEERING CIRCUIT(S/N 9908 & Before)

1 7150412 2 Hose, .75 I.D. x 18" Long2 8760134 3 Connector, Straight, SAE 6-4 - male JIC 37° x male str. thd. o-ring3 8760118 1 Connector, Straight, SAE 12-16 - male JIC 37° x male str. thd. o-ring4 2713432 2 Hose, .38 I.D. x 18" Long5 8760141 1 Connector, Male Tube End w/Outlet Check, 6-66 8584007 2 Tie Wrap 5"7 2713242 5 Hose, .38 I.D. x 33" Long8 2713332 2 Hose, .38 I.D. x 96" Long9 2711992 1 Hose, .38 I.D. x 31" Long

10 2712942 1 Hose, .38 I.D. x 50" Long11 2711972 1 Hose, .38 I.D. x 53" Long12 2712122 1 Hose, .50 I.D. x 62" Long13 8721029 1 Steering Unit14 8760311 4 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring15 8760140 1 Connector, Male Tube End w/Inlet Check, 8-816 8760143 1 Connector, Long, SAE 8 - male JIC 37° x male str. thd. o-ring17 8760110 2 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring18 2712142 1 Hose, .38 I.D. x 89" Long19 2712112 1 Hose, .50 I.D. x 87" Long20 2710802 1 Hose, .38 I.D. x 105" Long21 8760449 4 Tee, Male Run, SAE 6 - male JIC 37° x male str. thd. o-ring22 8760460 1 Reducer, SAE 8-6 - male str. thd. o-ring x female internal o-ring boss23 8760303 1 Elbow, 90° SAE 8 - male JIC 37° x male str. thd. o-ring24 8904047 1 Priority Valve25 8760109 1 Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring26 8760501 1 Tee, Female Run, SAE 6 - male JIC 37° x female JIC 37° swivel27 8760313 1 Elbow, 90° SAE 6-8 - male JIC 37° x male str. thd. o-ring28 8760449 2 Tee, Male Run, SAE 6 - male JIC 37° x male str. thd. o-ring29 8760488 1 Cap, SAE 6 - JIC 37°30 8902838 1 Valve, Shuttle31 8310158 2 Bolt, Carriage 5/16-18 x 2-1/4"32 8307004 4 Washer, Lock 5/1633 8305006 4 Nut, Hex 5/16-1834 8406105 1 Clamp35 2712012 1 Hose, .38 I.D. x 75" Long36 8310159 2 Bolt, Carriage 5/16-18 x 3-1/2"37 8770016 1 Reducer, SAE 4-6 - male str. thd. o-ring x female internal o-ring boss38 8765204 1 Elbow, 90°, SAE 8 - male JIC 37° x female JIC 37° swivel39 8760474 1 Tee, Male Run, SAE 12 - male JIC 37° x male str. thd. o-ring40 6604882 1 Hose, .50 I.D. x 62" Long41 8760504 1 Reducer, Tube End, SAE 12-8 - JIC 37°42 8760401 1 Nut, SAE 12 - JIC 37°

8042/10042/10054 Rev. 2/00

134

SECTION 5

POWER STEERING CIRCUIT(S/N 9909 & After)

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4613

35

67

8

9

10

11

13

14

16

17

18

19

20

21

22 23

25

2627

28

2930

31

3334

35

36

Outlet Port

Load Sense Port

Main Pump

13

RearSteering Cylinders

6

InletPort

Main Control Valve(Rotated For Clarity)

6

32

To Port “CF”

24To Port

“EF”1 2

2To Port “T”

To Port “LS”

3

To Port “3”31

321

To Port “2”

To Port “1”

27

3

18

165 17

1913


13

6

FrontSteering Cylinders

6

4 11

1015

34

9

8

12T

L

RP

Front

7

7

11

9

10

Pressure Reducing

Valve

To Port “B”

Port “T”

Port “P”

T

R

PL

20

To Port “A”

37

38

39

41

PH1360

9To Port “T”

47

49

50

4842

43

4445 40

8042/10042/10054 Origin 2/00

135

SECTION 5


POWER STEERING CIRCUIT(S/N 9909 & After)

1 7150412 1 Hose, .75 I.D. x 18" Long2 8760134 2 Connector, Straight, SAE 6-4 - male JIC 37° x male str. thd. o-ring3 2713432 2 Hose, .38 I.D. x 18" Long4 8760141 1 Connector, Male Tube End w/Outlet Check, 6-65 8584007 2 Tie Wrap 5"6 2713242 5 Hose, .38 I.D. x 33" Long7 2713332 2 Hose, .38 I.D. x 96" Long8 2711992 1 Hose, .38 I.D. x 31" Long9 2712942 1 Hose, .38 I.D. x 50" Long

10 2711972 1 Hose, .38 I.D. x 53" Long11 2712122 1 Hose, .50 I.D. x 62" Long12 8721029 1 Steering Unit13 8760311 5 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring14 8760140 1 Connector, Male Tube End w/Inlet Check, 8-815 8760143 1 Connector, Long, SAE 8 - male JIC 37° x male str. thd. o-ring16 8760110 2 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring17 2712142 1 Hose, .38 I.D. x 89" Long18 2712112 1 Hose, .50 I.D. x 87" Long19 2710802 1 Hose, .38 I.D. x 105" Long20 8760449 4 Tee, Male Run, SAE 6 - male JIC 37° x male str. thd. o-ring21 8760460 1 Reducer, SAE 8-6 - male str. thd. o-ring x female internal o-ring boss22 8760307 1 Elbow, 45° SAE 8 - male JIC 37° x male str. thd. o-ring23 8904047 1 Priority Valve24 8760109 1 Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring25 8760501 1 Tee, Female Run, SAE 6 - male JIC 37° x female JIC 37° swivel26 8760313 1 Elbow, 90° SAE 6-8 - male JIC 37° x male str. thd. o-ring27 8760449 2 Tee, Male Run, SAE 6 - male JIC 37° x male str. thd. o-ring28 8760488 1 Cap, SAE 6 - JIC 37°29 8902838 1 Valve, Shuttle30 8310158 2 Bolt, Carriage 5/16-18 x 2-1/4"31 8307004 4 Washer, Lock 5/1632 8305006 4 Nut, Hex 5/16-1833 8406105 1 Clamp34 2712012 1 Hose, .38 I.D. x 75" Long35 8310159 2 Bolt, Carriage 5/16-18 x 3-1/2"36 8770016 1 Reducer, SAE 4-6 - male str. thd. o-ring x female internal o-ring boss37 8765204 1 Elbow, 90°, SAE 8 - male JIC 37° x female JIC 37° swivel38 8760474 1 Tee, Male Run, SAE 12 - male JIC 37° x male str. thd. o-ring39 6604882 1 Hose, .50 I.D. x 62" Long40 8760504 1 Reducer, Tube End, SAE 12-8 - JIC 37°41 8760401 1 Nut, SAE 12 - JIC 37°42 8760493 1 Tee, Female Run, SAE 8 - male JIC 37° x female JIC 37° swivel43 8760407 1 Nut, SAE 8 - JIC 37°44 8430037 1 Nipple, Diagnostic45 8430032 1 Plug, Dust46 7150312 1 Hose, .75 I.D. x 25" Long47 8303675 4 Capscrew48 8530030 2 Flange Half, SAE 1649 8640123 1 O-Ring50 8307005 4 Washer, Lock 3/8

8042/10042/10054 Origin 2/00

136

SECTION 5

CONTROL VALVES CIRCUIT(S/N 9908 & Before)

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12

3

6

78

9

10

11

12

13

14

15

16

17

23

24

25

27

2619 21

ControlDrain Port

InletPort

See“Main Pump”

1820

2219

4

5

Load Sense Port

InletPort

5

See “Hydraulic Reservoir”

2

12

See “Secondary

Control Valve”

Port“P”

2

13

87

1

2121

6

See “Main Control Valve”

(Rotated For Clarity)

OutletPort

22

2

Front

Main Pump

Main Control Valve

Axle Stabilizer

Valve

28


To Priority Valve“P” Port Tee

29

8042/10042/10054 Rev. 2/00

PH0152

137

SECTION 5


CONTROL VALVES CIRCUIT(S/N 9908 & Before)

1 2713292 1 Hose, .75 I.D. x 31" Long2 2712942 2 Hose, .38 I.D. x 50" Long3 8760117 1 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring4 8770015 1 Connector, Straight, SAE 24 - male JIC 37° x male str. thd. o-ring5 2713442 1 Hose, 1.50 I.D. x 29-1/2" Long6 2711872 1 Hose, .50 I.D. x 71" Long7 8760401 2 Nut, SAE 12 - JIC 37°8 8760504 2 Reducer, Tube End, SAE 12-8 - JIC 37°9 8760482 1 Tee, Female Run, SAE 12 - male JIC 37° x female JIC 37° swivel

10 8760118 1 Connector, Straight, SAE 12-16 - male JIC 37° x male str. thd. o-ring11 8760474 1 Tee, Male Run, SAE 12 - male JIC 37° x male str. thd. o-ring12 6605202 1 Hose, .50 I.D. x 44-1/2" Long13 2711972 1 Hose, .38 I.D. x 53" Long14 8760457 1 Tee, Male Branch, SAE 6 - male JIC 37° x male str. thd. o-ring15 8760141 1 Connector, Male Tube End w/Outlet Check, 6-616 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring17 8760493 1 Tee, Female Run, SAE 8 - male JIC 37° x female JIC 37° swivel18 7121013 1 Spacer, Pump19 8304624 6 HHCS, 1/2-13 x 2"20 7099072 1 Gasket21 8307206 7 Washer, Flat 1/2"22 8307007 5 Washer, Lock 1/2"23 8310337 1 Bolt, Carriage 1/2-13 x 2-1/2" 24 8305012 3 Nut, Hex 1/2-1325 8310178 2 Bolt, Carriage 1/2-13 x 4"26 8640405 1 O-Ring27 8307206 AR Washer, Flat 1/2"28 8584007 1 Tie Wrap, 5" - Oil Cooler Hose Support29 6604882 1 Hose, .50 I.D. x 62" Long

8042/10042/10054 Rev. 2/00

138

SECTION 5

CONTROL VALVES CIRCUIT(S/N 9909 & After)

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PH1370

1

31

2

2

4

1

19

11

35

9

23

21

25

26

3

38

2

6

30

12

37

20

29

1034

36

33

418

78

1332

285

2420

516

15 1412

11

27

2

InletPort

Load Sense Port

See “Hydraulic Reservoir”

See “Secondary

Control Valve”

Port“P”

See “Main Control Valve”

(Rotated For Clarity)

Front

Main Pump

Axle Stabilizer

Valve

Underneath View of Valve PlateSee “Valve Plate Assembly” To Priority Valve

“P” Port Tee

22

2117

8042/10042/10054 Origin 2/00

139

SECTION 5


CONTROL VALVES CIRCUIT(S/N 9909 & After)

1 7150492 1 Hose, 1 I.D. x 29" Long2 7150502 2 Hose, .50 I.D. x 40" Long3 8760308 1 Elbow, 90° SAE 8-10 - male JIC 37° x male str. thd. o-ring4 7150302 1 Hose, 2" I.D. x 29" Long5 2711872 1 Hose, .50 I.D. x 71" Long6 8760401 1 Nut, SAE 12 - JIC 37°7 8760504 1 Reducer, Tube End, SAE 12-8 - JIC 37°8 8760482 1 Tee, Female Run, SAE 12 - male JIC 37° x female JIC 37° swivel9 8760302 1 Elbow, 45° SAE 16 - male JIC 37° x male str. thd. o-ring

10 8760317 1 Elbow, 45° SAE 12 - male JIC 37° x male str. thd. o-ring11 6604882 1 Hose, .50 I.D. x 62" Long12 2711972 1 Hose, .38 I.D. x 53" Long13 8760501 1 Tee, Female Run, SAE 6 - male JIC 37° x female JIC 37° swivel14 8760141 1 Connector, Male Tube End w/Outlet Check, 6-615 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring16 8760493 1 Tee, Female Run, SAE 8 - male JIC 37° x female JIC 37° swivel17 8546407 2 Flange18 8303626 4 Capscrew19 8640208 1 O-Ring20 8307206 4 Washer, Flat 1/2"21 8307007 7 Washer, Lock 1/2"22 8310337 1 Bolt, Carriage 1/2-13 x 2-1/2" 23 8305012 3 Nut, Hex 1/2-1324 8310178 2 Bolt, Carriage 1/2-13 x 4"25 8630016 1 O-Ring26 8584007 1 Tie Wrap, 5" - Oil Cooler Hose Support27 6604882 1 Hose, .50 I.D. x 62" Long28 8765204 1 Elbow, 90°, SAE 8 - male JIC 37° x female JIC 37° swivel (8042 & 10042)

8760495 1 Tee, Female Branch, SAE 8 - male JIC 37° x female JIC 37° swivel (10054 Only)29 8760415 1 Nut, SAE 16 - JIC 37°30 8770159 1 Reducer, Tube End, SAE 16-8 - JIC 37°31 8760529 1 Tee, Female Run, SAE 16 - male JIC 37° x female JIC 37° swivel32 8760311 1 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring33 8760276 1 Elbow, 45°, SAE 6 - male JIC 37° x female JIC 37° swivel34 8760451 1 Plug, Hex Hd., SAE 6 - male str. thd. o-ring35 8405209 1 Clamp, T-Bolt Band 36 8303519 4 HHCS M12 x 40mm37 8307025 4 Washer, Lock M1238 8307220 4 Washer, Flat M12

8042/10042/10054 Origin 2/00

140

SECTION 5

BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT(S/N 9908 & Before)

1

2 34

5

678

9

10

11 12

1314

15

16

1718

Main Control Valve(Rotated for Clarity)

ExtendPort

10054 Only

Boom

RetractPort

RaisePort

LowerPort

Front

9

9

4 4RaisePort

LowerPort

BD

C A

10

A - Boom Extend PortB - Boom Retract PortC - Boom Raise Port ExtendD - Boom Lower Port Retract

PH0161

8042/10042/10054 Rev. 2/00

141

SECTION 5


BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT(S/N 9908 & Before)

1 7133802 1 Tube, Boom Ext. Cyl.2 7133812 1 Tube, Boom Ext. Cyl.3 8760039 2 Union, Bulkhead, Straight, SAE 12 - male JIC 37°4 2713262 2 Hose, .62 I.D. x 148" Long5 8760305 2 Elbow, 90° SAE 12 - male JIC 37° x male str. thd. o-ring6 8305626 1 Nut, Hex Lock Elastic 5/16-187 8769128 1 Cover, Clamp8 8769127 1 Clamp, Twin (Only half used)9 8760109 4 Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring

(8042/10042 Only)8760109 3 Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring

(10054 Only)10 2713282 2 Hose, .62 I.D. x 52" Long11 2711852 2 Hose, .50 I.D. x 21" Long12 8584007 1 Tie Wrap, Heavy Duty 5"13 8760111 2 Connector, Straight, SAE 8-12 - male JIC 37° x male str. thd. o-ring14 8760483 2 Tee, Male Branch, SAE 12 - male JIC 37° x male str. thd. o-ring15 8770030 1 Union, SAE 12 - male str. thd. o-ring16 8902251 1 Valve, Boom Extend Lockout17 8770012 1 Elbow, 90° SAE 6-4 - male JIC 37° x male str. thd. o-ring18 8760317 1 Elbow, 45° SAE 12 - male JIC 37° x male str. thd. o-ring

8042/10042/10054 Rev. 2/00

142

SECTION 5

BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT(S/N 9909 & After)

12

34

5

678

14

1810

19

15

13

Main Control Valve(Rotated for Clarity)

ExtendPort

10054 Only

Boom

RetractPort

Front

514

4

RaisePort

LowerPort

BD

C A

19

A - Boom Extend PortB - Boom Retract PortC - Boom Raise Port ExtendD - Boom Lower Port Retract

PH1380

5 5

17

5

12

12

11

14

5

4

18

16

9

8042/10042/10054 Origin 2/00

143

SECTION 5


BOOM RAISE/LOWER & EXTEND/RETRACT CIRCUIT(S/N 9909 & After)

1 7133802 1 Tube, Boom Ext. Cyl.2 7133812 1 Tube, Boom Ext. Cyl.3 8760039 2 Union, Bulkhead, Straight, SAE 12 - male JIC 37°4 7150452 2 Hose, .62 I.D. x 148" Long5 8760305 5 Elbow, 90° SAE 12 - male JIC 37° x male str. thd. o-ring6 8305626 1 Nut, Hex Lock Elastic 5/16-187 8769128 1 Cover, Clamp8 8769127 1 Clamp, Twin (Only half used)9 2711852 2 Hose, .50 I.D. x 21" Long

10 8584007 1 Tie Wrap, Heavy Duty 5"11 8760111 2 Connector, Straight, SAE 8-12 - male JIC 37° x male str. thd. o-ring12 8760483 2 Tee, Male Branch, SAE 12 - male JIC 37° x male str. thd. o-ring13 8902251 1 Valve, Boom Extend Lockout14 8770157 2 Elbow, Long, 90° SAE 12-12 - male JIC 37° x male str. thd. o-ring15 8760134 1 Connector, Straight, SAE 6-4 - male JIC 37° x male str. thd. o-ring16 8760138 1 Connector, Straight, SAE 12-12 - male str. thd. o-ring x female JIC 37° swivel17 2716516 1 Hose, .38 I.D. x 16" Long18 7150442 1 Hose, .625 I.D. x 38" Long19 7150432 1 Hose, .625 I.D. x 34.5" Long

8042/10042/10054 Origin 2/00

144

SECTION 5

ATTACHMENT TILT AND SLAVE CIRCUIT

��

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1

2

3 4

5

78

9

11

10

12

1314

1516

17

19 20

21

22 23

24

25

18

18

20

20

6

21

RetractPort

Extend Port

RetractPort

6

23

ExtendPort

20

10054 Only

Front

RetractPort

ExtendPort

ExtendPort

RetractPort

18

20

18

NOTE: Secure Items 10 & 12 with Item 28

2826

27

8

8

18

23

15


PH0172

PH0940

SecondaryControlValve

��

PF0791

29

8042/10042/10054 Rev. 2/00

145

SECTION 5


ATTACHMENT TILT AND SLAVE CIRCUIT

1 8303752 2 HHCS, 5/16-18 x 3-1/2"2 8307004 2 Washer, Lock 5/16"3 8769149 1 Cover Plate, Single Clamp4 8750003 4 Clamp, .62 Dia. Single (8042/10042 Only)

8750003 6 Clamp, .62 Dia. Single (10054 Only)5 8769161 2 Clamp, .75 Dia. Single (8042/10042 Only)6 2713452 2 Hose Assembly, Boom (8042/10042 Only)7 8303739 3 HHCS, 5/16-18 x 1-1/4"8 8769123 5 Cover Plate, Twin9 8769122 3 Clamp, .62 Dia. Twin

10 7133823 1 Tube, Boom Attachment Tilt - Retract11 7133833 1 Tube, Boom Attachment Tilt - Extend12 8760037 2 Union, Bulkhead, Straight, SAE 10 - male JIC 37°13 2713222 2 Hose, .50 I.D. x 34" Long14 6605202 2 Hose, .50 I.D. x 44-1/2" Long15 8760477 2 Tee, Bulkhead, Male Run, SAE 8 - male JIC 37°16 6604982 2 Hose, .50 I.D. x 22" Long17 8760493 2 Tee, Female Run, SAE 8 - male JIC 37° x female JIC 37° swivel18 2712872 2 Hose, .50 I.D. x 153" Long19 8760143 1 Connector, Long, SAE 8 - male JIC 37° x male str. thd. o-ring20 8760107 7 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring

(8042/10042 Only)8760107 5 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring

(10054 Only)21 8760307 2 Elbow, 45° SAE 8 - male JIC 37° x male str. thd. o-ring (10054 Only)22 7112452 1 Hose and Carrier Assembly (Includes Items 23 thru 25)23 2713642 4 Hose Assembly24 NSS 1 Carrier, Hose (For Service, Order Item 22)25 8584001 2 Tie Wrap26 8769140 1 Clamp Set, .675 twin27 8305626 1 Nut, Hex Lock 5/16-1828 8526048 AR Sealant

KITS

29 7117812 1 Kit, Hose Carrier Update

NOTE:Kit Purpose: To bring Early Production Hose Carrier (Item 24) up-to-date with solid bars in every other link instead of in every link, with poly rollers added to bars, and with adhesive patch coated screws instead of liquid sealant application.

8042/10042/10054 Rev. 2/00

146

SECTION 5

FRAME TILT AND STABILIZER CIRCUIT

��

�

��

1

2

3

4

5

6

7

RetractPort

ExtendPort

RetractPort

ExtendPort

To Port“TC”

To Port“SR”

To Port“SB”

Front

4

5

5

4

5

1

11

5

5

1

Stabilizer ValveSee Page 205

Underneath View of Valve Plate

Pressure Reducing

Valve

Secondary Control Valve

Steer Select Valve

PH0181

8042/10042/10054 Rev. 2/00

147

SECTION 5


FRAME TILT AND STABILIZER CIRCUIT

1 2711892 2 Hose, .38 I.D. x 130" Long2 8770012 1 Elbow, 90° SAE 6-4 - male JIC 37° x male str. thd. o-ring3 8760276 1 Elbow, 45°, SAE 6 - male JIC 37° x female JIC 37° swivel4 8760134 3 Connector, Straight, SAE 6-4 - male JIC 37° x male str. thd. o-ring5 2713332 2 Hose, .38 I.D. x 96" Long6 8760110 1 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring7 8760268 1 Elbow, 90°, SAE 6 - male JIC 37° x female JIC 37° swivel

8042/10042/10054 Rev. 12/97

148

SECTION 5

SERVICE BRAKE AND DE-CLUTCH CIRCUIT

��

�

123

4

5

6

7

8

9

1011 12

13

Front

3

10

11

Hydraulic Reservoir

18

97

6

10

11

3

9

7

9

6

To Transmission Emergency Brake

To Transmission De-Clutch

Pressure Reducing Valve

To Port “BRK”

Port “C2”

Port “C1”

14

Underneath View of Valve Plate - See “Valve Plate Assembly”

PH0193

7

19

161517

8042/10042/10054 Rev. 2/00

149

SECTION 5


SERVICE BRAKE AND DE-CLUTCH CIRCUIT

1 NLA 1 Valve, Brake (S/N 0653 & Before) For Service, Order P/N 89022227119813 1 Kit, Brake Valve (S/N 0654 thru 1167)8902222 1 Valve, Brake (S/N 1168 & After)

2 8760110 3 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring3 2712332 1 Hose, .38 I.D. x 50" Long4 2705122 1 Hose, .38 I.D. x 50" Long5 6604972 1 Hose, .38 I.D. x 90" Long6 8760455 3 Tee, Bulkhead, Male Branch, SAE 6 - male JIC 37°7 8406105 4 Clamp8 6605772 1 Hose, .38 I.D. x 66" Long9 2712092 4 Hose, .25 I.D. x 49" Long

10 6611752 1 Hose, .25 I.D. x 52" Long11 6604712 1 Hose, .25 I.D. x 28" Long12 8760011 1 Connector, Straight, SAE 4-2P - male JIC 37° x male NPT13 8760113 1 Connector, Straight, SAE 4 - male JIC 37° x male str. thd. o-ring14 8584007 1 Tie Wrap, 5" (Hose Support)15 8760501 1 Tee, Female Run, SAE 6 - male JIC 37° x female JIC 37° swivel (S/N 9909 & After)16 8430046 1 Nipple, Diagnostic (S/N 9909 & After)17 8430032 1 Plug, Dust (S/N 9909 & After)18 6605772 1 Hose, .38 I.D. x 66" Long (S/N 9908 & Before)

2712012 1 Hose, .38 I.D. x 75" Long (S/N 9909 & After)19 8760276 1 Elbow, 45°, SAE 6 - male JIC 37° x female JIC 37° swivel (S/N 9909 & After)

8042/10042/10054 Rev. 2/00

150

SECTION 5

VALVE PLATE ASSEMBLY(Without Outriggers 8042 Only)

��

��

��

�

1

2

3

4

5

67

8

9

10

11

12

13

15

16

17

181920

21

22

24

25

26

27

28

29

30

31

32

33

34

35

36

37

Front

Valve Plate Shown asMounted for Clarity

24

23

1312

3

14

NOTE: O-rings mustbe replaced

whenever replacingItem 16 or Item 21.

Returnto Tank

20To ControlValve “P”Port Tee

ToPriority Valve“P” Port Tee

PH0122

35

8042 Rev. 2/00

151

SECTION 5


VALVE PLATE ASSEMBLY(Without Outriggers 8042 Only)

1 7098293 1 Plate, Valve Mounting2 8902111 1 Body, Steer Select Valve3 8760110 3 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring4 8760313 1 Elbow, 90° SAE 6-8 - male JIC 37° x male str. thd. o-ring5 8304608 2 SHCS, 5/16-18 x 1-1/2"6 8902137 1 Valve, Steer Select (See Page 203 For Parts Breakdown)7 8304631 4 SCHS, #10-24 x 2"8 8305626 2 Nut, Lock 5/16-189 7115712 1 Kit, Secondary Control Valve (Does Not Include Fittings) S/N 8042-0266 & Before

(See Page 201 For Parts Breakdown)8902152 1 Secondary Control Valve (Does Not Include Fittings) S/N 8042-0267 & After

(See Page 201 For Parts Breakdown)10 8584001 1 Tie Wrap, 3/16" Wide x 6-11/16" Long11 8760303 1 Elbow, 90° SAE 8 - male JIC 37° x male str. thd. o-ring12 6604882 2 Hose, 1/2" I.D. x 62" Long13 6605652 1 Hose, 3/8" I.D. x 19" Long14 8303675 3 HHCS, 3/8-16 x 1-1/4"15 8305645 3 Nut, Lock 3/8-1616 8902255 1 Valve, Pressure Reducing (See Page 205 For Parts Breakdown) (S/N 0653 & Before)

8902266 1 Valve, Pressure Reducing (See Page 205 For Parts Breakdown) (S/N 0654 & After)17 8760419 2 Plug, Hex Hd., SAE 8 - male str. thd. o-ring18 8760113 2 Connector, Straight, SAE 4 - male JIC 37° x male str. thd. o-ring19 8760136 1 Connector, Straight, SAE 4-6 - male JIC 37° x male str. thd. o-ring20 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring21 8902267 1 Valve, Axle Stabilizer (See Page 205 For Parts Breakdown)22 8310137 2 SHCS, 1/4-20 x 2-1/2"23 8760117 4 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring24 8760311 2 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring25 8278008 4 Isolator26 8305624 2 Nut, Lock 1/4-2027 8304042 4 Bolt, Carriage 3/8-16 x 2"28 8310070 4 Bolt, Retainer 3/8"29 7057141 4 Washer, Rebound30 8307005 4 Washer, Lock 3/8"31 8305008 4 Nut, Hex 3/8-1632 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring33 8760458 1 Reducer, Tube End, SAE 8-6 - JIC 37°34 8760407 1 Nut, SAE 8 - JIC 37°35 8630000 2 O-Ring36 8310153 4 SHCS, 1/4-20 x 3"37 8760268 1 Elbow, 90°, SAE 6 - male JIC 37° x female JIC 37° swivel

8042 Rev. 2/00

152

SECTION 5

VALVE PLATE ASSEMBLY(With Outriggers 10042/10054 Only)

��

�

1

2

3 4

5

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

21

22

28

29

30

31

32

33

34

35

36

37

3839

40

41

42

23

24

25

26

27

Front

Valve Plate Shown asMounted for Clarity

3935

40

3932

8

3

23

2435

20

3

13

NOTE: O-rings must bereplaced wheneverreplacing Item 16

or Item 21.Returnto Tank

41

38

To ControlValve “P”Port Tee

ToPriority Valve“P” Port Tee

3243

43

PH0112

10042/10054 Rev. 2/00

153

SECTION 5


VALVE PLATE ASSEMBLY(With Outriggers 10042/10054 Only)

1 7098293 1 Plate, Valve Mounting2 8902111 1 Body, Steer Select Valve3 8760110 5 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring4 8760313 1 Elbow, 90° SAE 6-8 - male JIC 37° x male str. thd. o-ring5 8304608 2 SHCS, 5/16-18 x 1-1/2"6 8902137 1 Valve, Steer Select (See Page 203 For Parts Breakdown)7 8304631 4 SCHS, #10-24 x 2"8 8305626 4 Nut, Lock 5/16-189 7115712 1 Kit, Secondary Control Valve (Does Not Include Fittings) S/N 0266 & Before

(See Page 201 For Parts Breakdown)8902152 1 Secondary Control Valve (Does Not Include Fittings) S/N 0267 & After

(See Page 201 For Parts Breakdown)10 8584001 1 Tie Wrap, 3/16" Wide x 6-11/16" Long11 8760419 2 Plug, Hex Hd., SAE 8 - male str. thd. o-ring12 7111122 1 Tube Assembly (S/N 10881 & Before)

2716545 1 Hose, .38 x 17" (S/N 10882 & After)13 6605652 1 Hose, 3/8" I.D. x 19" Long14 8303675 3 HHCS, 3/8-16 x 1-1/4"15 8305645 3 Nut, Lock 3/8-1616 8902266 1 Valve, Pressure Reducing (See Page 205 For Parts Breakdown)17 8760268 1 Elbow, 90°, SAE 6 - male JIC 37° x female JIC 37° swivel18 8760113 2 Connector, Straight, SAE 4 - male JIC 37° x male str. thd. o-ring19 8760136 1 Connector, Straight, SAE 4-6 - male JIC 37° x male str. thd. o-ring20 8760510 2 Tee, Male Run, SAE 8 - male JIC 37° x male str. thd. o-ring21 8902267 1 Valve, Stabilizer (See Page 205 For Parts Breakdown)22 8310137 2 SHCS, 1/4-20 x 2-1/2"23 8760117 4 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring24 8760311 2 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring25 8278008 4 Isolator26 8305624 2 Nut, Lock 1/4-2027 8304042 4 Bolt, Carriage 3/8-16 x 2"28 8310070 4 Bolt, Retainer 3/8"29 8307204 4 Washer, Flat 3/8"30 8307005 4 Washer, Lock 3/8"31 8305008 4 Nut, Hex 3/8-1632 8760107 3 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring33 8310138 2 SHCS, 5/16-18 x 4" (S/N 10881 & Before)

8310081 2 SHCS, 5/16-18 x 4" (S/N 10882 & After)34 8902141 1 Valve, Outrigger (See Page 203 For Parts Breakdown) (S/N 10881 & Before)

8902193 1 Valve, Outrigger (See Page 203 For Parts Breakdown) (S/N 10882 & After)35 2713322 2 Hose, 1/2" I.D. x 35" Long36 8760459 1 Tee, Female Branch, SAE 6-6 - male JIC 37° x female JIC 37° swivel37 8760117 1 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring (S/N 10881 & Before)

8760141 1 Connector, Male Tube End w/Outlet Check, 6-6 (S/N 10882 & After)38 8760143 2 Connector, Long, SAE 8 - male JIC 37° x male str. thd. o-ring (S/N 10881 & Before)

8760117 2 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring (S/N 10882 & After)39 8760458 3 Reducer, Tube End, SAE 8-6 - JIC 37° (S/N 10881 & Before)

8760460 2 Reducer, SAE 8-6 - male str. thd. o-ring x female internal o-ring boss (S/N 10882 & After)40 8760407 3 Nut, SAE 8 - JIC 37° (S/N 10881 & Before)41 8630000 2 O-Ring42 8310153 4 SHCS, 1/4-20 x 3"43 6604882 2 Hose, 1/2" I.D. x 62" Long

10042/10054 Rev. 2/00

154

SECTION 5

TRANSMISSION COOLING CIRCUIT(S/N 9908 & Before)

1

2

3

Transmission Oil Cooler

Transmission

4

22

2

PH0202

8042/10042/10054 Rev. 2/00

155

SECTION 5


TRANSMISSION COOLING CIRCUIT(S/N 9908 & Before)

1 6604912 2 Hose, .75 I.D. x 113" Long2 8760109 4 Connector, Straight, SAE 12 - male JIC 37° x male str. thd. o-ring3 7124471 2 Conduit, 1 I.D. x 12.5"4 8584007 2 Tie, plastic, .5 x 20.1"

8042/10042/10054 Rev. 2/00

156

SECTION 5

TRANSMISSION COOLING CIRCUIT(S/N 9909 & After)

PH1390

6

1

3

2

1

2

5

4

2

5

4

7

7

TransmissionOil Cooler

Transmission

8042/10042/10054 Origin 2/00

157

SECTION 5


TRANSMISSION COOLING CIRCUIT(S/N 9909 & After)

1 7150282 2 Hose, .75 I.D. x 105" Long2 8760254 3 Elbow, 90°, SAE 12 - male JIC 37° x female JIC 37° swivel3 8760305 1 Elbow, 90° SAE 12 - male JIC 37° x male str. thd. o-ring4 8630017 2 O-Ring, 23mm x 2mm5 8770158 2 Connector, M26 x 12 - 37° Flare6 8770157 1 Elbow, Long, 90° SAE 12-12 - male JIC 37° x male str. thd. o-ring7 8760431 2 Plug, Hex Hd., SAE 12 - male str. thd. o-ring

8042/10042/10054 Origin 2/00

158

SECTION 5

AUXILIARY HYDRAULIC CIRCUIT(Optional)

12

3

4 5

6

7

8

9

10

11

12

13

14

15

1617

18

19

2021

22232425

26

27

28

29

30

31


7

Port“B”

Port“A”

PH0212

��

32

PF0791

8042/10042/10054 Rev. 12/97

159

SECTION 5


AUXILIARY HYDRAULIC CIRCUIT(Optional)

1 8310081 2 HHCS, 5/16-18 x 5"2 8307004 2 Washer, Lock .31"3 8307203 2 Washer, Flat 5/16" Heavy4 7111402 1 Support, Clamp5 8303679 2 HHCS, 3/8-16 x 1-3/4" (8042/10042 Only)

8303622 2 HHCS, 3/8-16 x 2" (10054 Only)6 8769161 2 Clamp, Single .75 I.D. (8042/10042 Only)

8750003 2 Clamp, Single .62 I.D. (10054 Only)7 2713082 2 Hose, .50 I.D. x 426" Long (8042/10042 Only)8 8769122 3 Clamp, Twin .62 I.D. (Two Halves)9 8303757 3 HHCS, 5/16-18 x 2-1/2"

10 7133843 1 Tube Assembly11 7133853 1 Tube Assembly12 8760037 2 Union, Bulkhead, Straight, SAE 10 - male JIC 37°13 2713212 2 Hose, .50 I.D. x 30" Long14 8760264 2 Elbow, 90°, Bulkhead, SAE 8 - male JIC 37°15 2712872 2 Hose, .50 I.D. x 153" Long16 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring17 8760143 1 Connector, Long, SAE 8 - male JIC 37° x male str. thd. o-ring18 8420055 1 Plug, Dust #819 8420053 1 Cap, Dust #820 8430006 1 Quick Disconnect, Male, SAE 8-8ORB - female internal (Includes Item 21)21 8640029 1 Seal, Nose (Not Shown)22 8430005 1 Quick Disconnect, Female, SAE 8-8ORB - female internal (Includes Items 23 thru 25)23 8640029 1 Seal, Nose (Not Shown)24 8640028 1 Seal, Coupler Body (Not Shown)25 8640032 1 Back-Up Ring, Coupler Body Seal (Not Shown)26 8760142 2 Connector, Straight, SAE 8-8 - male str. thd. o-ring x female JIC 37° swivel27 8760045 2 Union, Bulkhead, Straight, SAE 8 - male JIC 37°28 7112452 1 Hose and Carrier Assembly (Includes Items 29 thru 31)29 NSS 1 Carrier, Hose (For Service, Order Item 28)30 8584001 2 Tie Wrap31 2713642 4 Hose Assembly

KITS

32 7117812 1 Kit, Hose Carrier Update

NOTE:Kit Purpose: To bring Early Production Hose Carrier (Item 29) up-to-date with solid bars in every other link instead of in every link, with poly rollers added to bars, and with adhesive patch coated screws instead of liquid sealant application.

8042/10042/10054 Rev. 2/00

160

SECTION 5

OUTRIGGER HYDRAULIC CIRCUIT(10042/10054 Only)

1 2

3

1

2

3

4

5

6

Port“B1”

1

5

1Extend

Port

RetractPort

ExtendPort

RetractPort

Front

To Left CylinderExtend Port

To Left CylinderRetract Port

To Right CylinderExtend Port

To Right CylinderRetract Port

Port“A2”

Port“A1”


Port“B2”

6

Outrigger Valve

Secondary Control Valve

Steer Select Valve

Pressure Reducing Valve

Stabilizer Cylinder Valve

PH0412

10042/10054 Rev. 2/00

161

SECTION 5


OUTRIGGER HYDRAULIC CIRCUIT(10042/10054 Only)

1 2711982 4 Hose Assembly, 3/8" I.D.2 8760311 4 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring3 8584001 2 Tie Wrap (10054 Only)4 8584003 1 Tie Wrap5 8760029 4 Union, SAE 6 - male JIC 37°6 2712952 4 Hose Assembly, 3/8" I.D.

10042/10054 Rev. 12/97

162

SECTION 6

SECTION 6 HYDRAULIC COMPONENTS

HYDRAULIC RESERVOIR

1

8

3

4

5

6

9

7

11

1226

14

23

9

17

1819

21

13


Hydraulic Reservoir

ToBrake Valve

To Main Pump Inlet

See“Fuel Tank”

In

DrainOut

PH0103

16

222

6

24

252

2

16

1020

1819

17

1

13

1514

131211

S/N 9499 & Before

13

8042/10042/10054 Rev. 2/00

163

SECTION 6


HYDRAULIC RESERVOIR

1 NLA 1 Tank, Fuel and Hydraulic (S/N 9499 & Before) (For Service, Order P/N 7136034)7136034 1 Tank, Fuel and Hydraulic (S/N 9500 & After)

2 NLA 2 Gasket (S/N 9499 & Before) (For Service, Order P/N 7138209)7138209 3 Gasket (S/N 9500 & After)

3 NLA 1 Screen, Fill Neck (For Service, Order P/N 8322022)4 NLA 1 Neck, Filler/Breather (S/N 9499 & Before) (For Service, Order P/N 8322022 & 7138714)

7138714 1 Neck, Filler/Breather (S/N 9500 & After)5 NLA 1 Cap, Filler (S/N 9499 & Before) (For Service, Order P/N 8322022)

8322029 1 Cap, Filler (S/N 9500 & After)6 8305626 8 Nut, Hex Lock Elastic 5/16-18 (S/N 9499 & Before)

8305626 12 Nut, Hex Lock Elastic 5/16-18 (S/N 9500 & After)7 7094562 1 Head, Filter (with by-pass)8 8320265 1 Element, Hydraulic Oil Filter9 8464012 1 Gauge, Sight

10 8760118 1 Connector, Straight, SAE 12-16 - male JIC 37° x male str. thd. o-ring (S/N 9499 & Before)11 8640903 1 O-Ring12 8541435 1 Plug, Magnetic, Hex Hd., 1" str. thd.13 8760110 3 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring (S/N 9499 & Before)

8760110 2 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring (S/N 9500 & After)14 8760501 1 Tee, Female Run, SAE 6 - male JIC 37° x female JIC 37° swivel15 8760351 1 Elbow, 45° SAE 24 - male JIC 37° x male str. thd. o-ring (S/N 9499 & Before)16 8223217 1 Switch, Hydraulic Temperature - 210°F (S/N 9499 & Before)

8223226 1 Switch, Hydraulic Temperature - 195°F (S/N 9500 & After)17 8310129 4 Bolt, Carriage 5/8-11 x 2-1/2"18 8307009 4 Washer, Lock 5/8"19 8305014 4 Nut, Hex 5/8-1120 7098271 1 Tee, Swivel #12 Ported (S/N 9499 & Before)21 8760102 1 Connector, Straight, SAE 16 - male JIC 37° x male str. thd. o-ring (S/N 9500 & After)22 7138164 1 Tube Assembly (S/N 9500 & After)23 8324029 1 Strainer (S/N 9500 & After)24 8760419 1 Plug, Hex Hd., SAE 8 - male str. thd. o-ring (S/N 9500 & After)25 8760451 1 Plug, Hex Hd., SAE 6 - male str. thd. o-ring (S/N 9500 & After)26 8760107 1 Connector, Straight, SAE 8 - male JIC 37° x male str. thd. o-ring (S/N 9500 & After)

8042/10042/10054 Rev. 2/00

164

SECTION 6

MAIN PUMP(S/N 9908 & Before)

1

23

45

6

7

8

9

10

1112

1314

25

2627

2829

3031

32

33

3435

363738

49 5051

5253

54

1516

1718

19

20

3940

41

44

21

22

23 2445

46

47

48

43

4142

41

4039

3738

36

89

42

41

56

PH0292

PF0760

9

Torque to80 lb/ft

(108 Nm)

��

PF0791

��

57 58

55

8042/10042/10054 Rev. 2/00

165

SECTION 6


MAIN PUMP(S/N 9908 & Before)

1 8444223 1 Pump, Complete (Includes Items 2 thru 54) (Also must order 7135391 Kit, Relief Valve Hoist/Extend)

2 8033896 1 Snap Ring3 8033897 1 Ball Bearing4 8033898 1 Snap Ring5 8033899 1 Snap Ring6 8033900 1 Shaft Seal7 8033901 1 Shaft, Spline8 8033902 2 Plug9 8033903 3 Plug

10 8033904 1 Housing, Right Side11 8033905 1 O-Ring12 8033906 1 Back-up Ring13 8033907 1 Back-up Ring14 8033908 1 O-Ring15 8033909 1 Back-up Ring16 8033910 1 O-Ring17 8033911 1 Spool18 8033912 1 Sleeve19 8034818 1 Cap & Plug Assembly20 8033914 1 Ball21 8033959 1 O-Ring22 8033916 1 Cap Assembly, Airbleed23 8033917 2 Roll Pin24 8033918 1 O-Ring25 8033919 1 Port Plate, CW26 8033920 1 Barrel27 8033921 2 Retainer28 8033922 1 Spring, Barrel29 8033923 1 Ball Seat30 8033924 1 Retainer, Slipper31 8033925 7 Piston Assembly32 8033926 1 Piston, Servo33 8033927 1 O-Ring34 8033928 1 Swash Plate35 8033929 1 Housing, Trunion36 8033930 2 Thrust Washer37 8033931 2 Trunion Cap38 8033932 2 Needle Bearing39 8033933 2 O-Ring40 8033934 2 Snap Ring41 8033935 4 HHCS42 8033936 2 HHCS43 8033937 1 Plug44 8033938 1 Pin, Trunion45 8033939 1 Plug, Servo46 8034812 1 Screw Assembly, Adjusting47 8033952 1 Cap, Differential48 8033953 AR Shim, Differential49 8033954 AR Shim, Differential50 8033955 1 Piston51 8033956 1 Spring, Modulator52 8033957 1 Spring, Retaining53 8033958 1 Spring, Servo54 8033913 1 O-Ring55 7099072 1 Gasket, Mounting

KITS56 8032752 1 Kit, Seal57 7136374 1 Kit, Retrofits to a Current Production Pump

(Includes Pump, Hoses, Hardware & Instructions) S/N 9499 & Before58 7138340 1 Kit, Retrofits to a Current Production Pump

(Includes Pump, Hoses, Hardware & Instructions) S/N 9500 thru 9908

8042/10042/10054 Rev. 2/00

166

SECTION 6

MAIN PUMP(S/N 9909 & After)

PH1221

1

2*

3* 4

56

7* 89*

10*

11

12

13

14 15

16

17*18

19 20 2122 23 24 25

26

2728 29 30 31

32 33 3435

36

3738 39 40 41

42

4

59

6160*

56*

17*18

43 44 45 4653

58*

47* 48

49 50 51

5254

55*

57

PF0760

63

64

65

66

67

68

69

14

*Item Torque values

2 13.3-17.8 lb/ft (18-24 Nm)

3 192.4-222 lb/ft (280-300 Nm) 7 21.5-23.7 lb/ft (29-32 Nm) 9 76.2-94 lb/ft (103-127 Nm)

10 76.2-94 lb/ft (103-127 Nm) 17 55.5-61.4 lb/ft (75-83 Nm) 47 2.7-3.3 lb/ft (3-4 Nm)

55 76.2-94 lb/ft (103-127 Nm) 56 23-27.4 lb/ft (31-37 Nm) 58 9.6-11 lb/ft (13-15 Nm)

60 11.1-11.8 lb/ft (15-16 Nm)

62

8042/10042/10054 Origin 7/99

167

SECTION 6


MAIN PUMP(S/N 9909 & After)

1 8444227 Pump, Piston, Complete (Includes Items 2 thru 61)2 8035567 1 Nut, Jam3 8035568 Cap (S Stop)

8035569 Cap (F Stop)4 NSS 1 O-Ring (Order Item 64)5 NSS 1 Ring, Backup (Order Item 64)6 8035570 1 Screw, Adjustment7 8035571 2 Plug, SAE Gage Port

8035572 2 Plug, ISO Gage Port 8 NSS 2 O-Ring (Order Item 64)9 8035573 3 Screw

10 8035574 1 Screw11 8035575 1 Block, Valve12 NSS 3 O-Ring (Order Item 64)13 NSS 1 Subassembly, Control (Order Item 63)14 8035577 4 Pin15 NSS 1 Gasket (Order Item 64)16 8035578 1 Housing17 8035579 2 Plug, Drain18 8035580 2 O-Ring19 NSS 1 Bearing (Order Item 67)20 8035581 1 Pin21 8035582 1 Plate, Valve22 NSS 1 Ring, Retaining (Order Item 65)23 NSS 1 Guide, Spring (Order Item 65)24 NSS 1 Spring (Order Item 65)25 NSS 1 Guide, Spring (Order Item 65)26 NSS 1 Block, Cylinder (Order Item 65)27 NSS 1 Ring, Backup (Order Item 64)28 NSS 1 O-Ring (Order Item 64)29 NSS 1 O-Ring (Order Item 64)30 NSS 1 Ring, Backup (Order Item 64)31 8035583 1 Sleeve, Control32 8035584 1 Nut, Hex33 NSS 1 O-Ring (Order Item 64)34 NSS 1 Ring, Glide (Order Item 64)35 8035585 1 Piston, Control36 8035586 1 Link, Chain37 8035587 1 Shaft38 NSS 2 Plate, Limiter (Order Item 65)39 NSS 2 Spacer (Order Item 65)40 NSS 9 Subassembly, Piston and Shoes (Order Item 65)41 NSS 1 Cage, Shoe (Order Item 65)42 NSS 1 Yoke (Order Item 66)43 NSS 1 Pin (Order Item 66)44 8035588 1 Button45 NSS 1 Seat (Order Item 66)46 8035589 1 Spring47 NSS 2 Screw (Order Item 66)48 NSS 2 Bearing, Saddle (Order Item 66)49 NSS 1 Bearing (Order Item 67)50 NSS 1 Seal, Shaft (Order Item 68)51 NSS 1 Ring, Retaining (Order Item 68)52 NSS 1 Gasket (Order Item 64)53 8035590 1 Spring54 8035591 1 Flange55 8035592 4 Screw56 8035593 4 Screw57 8035595 1 Pin58 8035596 4 Screw59 NSS 1 Spacer, Shaft (Order Item 69)60 8035597 2 Plug61 8035598 2 O-Ring62 8630016 1 O-Ring, 130mm x 3mm

KITS

63 8035560 1 Kit, Control64 8035561 1 Kit, Seal65 8035562 1 Kit, Rotating Group66 8035563 1 Kit, Yoke and Saddle Bearing67 8035564 1 Kit, Shaft Bearing68 8035565 1 Kit, Shaft Seal69 8035566 1 Kit, Shaft Spacer

8042/10042/10054 Origin 7/99

168

SECTION 6

BOOM EXTEND CYLINDER(Early Production)

CURRENT PRODUCTION

��

EARLY PRODUCTION

IMPORTANT:There are two similar but distinctly different Boom ExtendCylinders. Make sure you know which version you havebefore ordering replacement parts. On “Early Production”cylinders, the gland is installed flush with the cylindertube and has “TJB” stamped on the gland. On the“Current Production” cylinders, the gland has a lip thatbottoms out against the cylinder tube.

PH0342

2

3

4

56

7

8

910

11

1213

14

15

1617

18 19 20

1

3

45

Torque to 150 - 160 lb/ft(203 - 217 Nm)

Retract Port


(203 - 217 Nm)

Extend Port

PF0760

8042/10042/10054 Rev. 7/99

169

SECTION 6


BOOM EXTEND CYLINDER(Early Production)

1 NLA 1 Cylinder, Boom Extend (Includes Items 2 thru 17) (For Service, Order P/N 2716173)2 NSS 1 Tube, Cylinder (Serviced Only in Boom Extend Cylinder Item 1)3 8902261 2 Valve, Counterbalance - preset to 3500 psi (See Kits)4 See Kits 2 Wear Ring5 See Kits 2 O-Ring6 See Kits 1 Seal, Piston7 8033734 1 Piston8 8033735 1 Tube, Stop9 See Kits 1 O-Ring

10 See Kits 1 Ring, Backup11 8033732 1 Gland12 See Kits 1 Seal, Rod13 See Kits 1 Seal, Rod14 See Kits 1 Wiper15 8033733 1 Rod16 8033737 1 Screw, Set17 8033738 1 Screw, Cone Point Set

KITS

18 8035513 1 Seal Kit, Services Both Early and Current Production Cylinders19 8205657 1 Seal Kit, Counterbalance Valve (Includes 3 O-Rings & 4 Backup Rings)20 8035247 1 Seal Kit, Gland Static Seal (Includes Items 5, 9 & 10)

8042/10042/10054 Rev. 2/00

170

SECTION 6

BOOM EXTEND CYLINDER(Current Production)

��

��

��

�� !!��"�� #�$�%�� %��&�� &��!��'��(��(��#��)�� *� ��+��'��!�� )�,�*��(��'��#��)��*�� +��'��(��'�� #

PH2031

PF0760

12

3

4

56

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

24

20

14

11

7

8

20

1720

19

19

18

16

12211513

9

Torque to 155 - 165 lb/in(18 - 19 Nm)


(407 - 542 Nm)

Loctite and Torque to1800 - 2000 lb/ft

(2441 - 2712 Nm)Torque to

150 - 160 lb/ft(203 - 217 Nm)

22

22

23

23

25

8042/10042/10054 Rev. 2/00

171

SECTION 6


BOOM EXTEND CYLINDER(Current Production)

1 2716173 1 Cylinder, Boom Extend (Includes Items 2 thru 23)2 NSS 1 Tube, Cylinder (Serviced Only in Boom Extend Cylinder Item 1)3 8035800 1 Piston4 8035539 1 Gland, Head5 8035616 1 Spacer, Rod6 8035615 1 Rod, Weldment7 8035536 1 Screw, Set 5/16-18 UNC x .50 Lg.8 8035315 1 Screw, Set 5/16-18 UNC x .63 Lg.9 8035514 2 Valve, Counterbalance - preset to 3500 psi

10 See Kits 1 O-Ring11 See Kits 1 O-Ring12 See Kits 1 O-Ring13 See Kits 1 O-Ring14 See Kits 1 Ring, Backup15 See Kits 1 Ring, Backup16 See Kits 1 Seal, Rod17 See Kits 1 Seal, Piston18 See Kits 1 Wiper, HD Rod Sealed O.D.19 See Kits 2 Wearband20 See Kits 2 Wearband21 See Kits 2 Insert, Locking22 See Kits 1 Square Ring23 8520013 2 Grease Fitting

KITS

24 8035513 1 Seal Kit, Services Both Early and Current Production Cylinders25 8205657 1 Seal Kit, Counterbalance Valve

8042/10042/10054 Rev. 2/00

172

SECTION 6

BOOM HOIST CYLINDER(S/N 5818 & Before)

PH0231

3

4

5

6

7

8

9

10

11

12

13

14

15

16 17

2

1

PF0760


(61 - 68 Nm)

Torque to 600 lb/ft (814 Nm)

and Stake 4 Places

8042/10042/10054 Rev. 7/99

173

SECTION 6


BOOM HOIST CYLINDER(S/N 5818 & Before)

1 NLA 2 Cylinder, Boom Hoist (Includes Items 3 thru 15) (For Service, Order P/N 2714993)2 2713803 2 Cylinder, Boom Hoist w/Load Indicator Port (Includes Items 3 thru 15)

NOTE: Quantities Listed Below Are For 1 Cylinder Only3 NSS 1 Tube, Cylinder (Serviced Only in Item 1)

NSS 1 Tube, Cylinder w/Load Indicator Port (Serviced Only in Item 2)4 8205726 1 Valve, Counterbalance - preset to 4000 psi (See Kits)5 8032714 1 Nut6 See Kits 1 O-Ring7 See Kits 1 Seal, Piston8 8033729 1 Piston9 8033730 1 Tube, Stop

10 See Kits 1 O-Ring11 See Kits 1 Ring, Backup12 8033727 1 Gland13 See Kits 1 Seal, Rod14 See Kits 1 Wiper15 8033728 1 Rod

KITS

16 8033731 1 Seal Kit, Boom Hoist Cylinder (Includes Items 6, 7, 10, 11, 13 and 14)17 8205656 1 Seal Kit, Counterbalance Valve (Includes 3 O-Rings & 3 Backup Rings)

8042/10042/10054 Rev. 2/00

174

SECTION 6

BOOM HOIST CYLINDER(S/N 5819 & After)

PH2010

PF0760

1

2

3

4

5

6

7

8

9

1011

12

13

14

15

16

17

18

19

20

Retract Port

Extend Port


(61 - 68 Nm)

6

16

11

10

17

1314

167

16

Loctite and Torque to1750 - 2000 lb/ft

(2373 - 2712 Nm)

8042/10042/10054 Origin 7/99

175

SECTION 6


BOOM HOIST CYLINDER(S/N 5819 & After)

1 2714993 2 Cylinder, Boom Hoist (Includes Items 3 thru 18)2 2713803 2 Cylinder, Boom Hoist w/Load Indicator Port (Includes Items 3 thru 18)

NOTE: Quantities Listed Below Are For 1 Cylinder Only3 NSS 1 Tube, Cylinder (Serviced Only in Item 1)

NSS 1 Tube, Cylinder w/Load Indicator Port (Serviced Only in Item 2)4 8035542 1 Valve, Counterbalance - present 4000 psi (See Kits)5 8035308 1 Nut, Lock6 See Kits 1 O-Ring7 See Kits 1 Seal, Piston8 8035545 1 Piston9 8035608 1 Spacer, Rod

10 See Kits 1 O-Ring11 See Kits 1 Ring, Backup12 8035609 1 Gland13 See Kits 1 Seal, Rod14 See Kits 1 Wiper15 8035607 1 Rod16 See Kits 2 Wearband17 See Kits 2 Wearband18 8035610 1 Collar, Locking

KITS

19 8035386 1 Seal Kit, Boom Hoist Cylinder (Includes Items 6, 7, 10, 11, 13, 14, 16 & 17)20 8205656 1 Seal Kit, Counterbalance Valve (Includes 3 O-Rings & 3 Back-Up Rings)

8042/10042/10054 Rev. 2/00

176

SECTION 6

FRAME TILT CYLINDER

1 2

3

13

14

4

5

6

7

8

9

10

11

12

Apply Loctite # 271 to Threads


(41 - 48 Nm)

RetractPort

ExtendPort

Torque to 450 lb/ft(610 Nm)

and Stake 4 Places

PF0760

PF0760

15

16

PH0362

8042/10042/10054 Rev. 2/00

177

SECTION 6


FRAME TILT CYLINDER

1 7115662 1 Cylinder, Frame Tilt (Includes Items 2 thru 14) (S/N 0266 & Before)2713853 1 Cylinder, Frame Tilt (Includes Items 2 thru 13) (S/N 0267 & After)

2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8902511 2 Valve, Pilot Check (See Kits)4 8032726 1 Nut5 See Kits 1 O-Ring6 See Kits 1 Seal, Piston7 8033745 1 Piston8 8033744 1 Rod9 See Kits 1 O-Ring

10 See Kits 1 Back-up Ring11 8032728 1 Gland12 See Kits 1 Seal, Rod13 See Kits 1 Wiper14 8033746 2 Orifice, .070 Dia. (S/N 0266 & Before)

KITS

15 8033747 1 Seal Kit, Frame Tilt Cylinder (Includes Items 5, 6, 9, 10, 12 & 13)16 8205655 1 Seal Kit, Pilot Check Valve (Includes 3 O-Rings & 3 Back-Up Rings)

8042/10042/10054 Rev. 2/00

178

SECTION 6

STABILIZER CYLINDER

1

2

3

13

1415

4

5

6

16

17

7

8

9

10

11

12

RetractPort

ExtendPort

Sol. 2Sol. 6

Sol. 5

Sol. 1


(41 - 48 Nm)

18

19

20

PH0351

PF0760

PF0760

PF0760

8042/10042/10054 Rev. 2/00

179

SECTION 6


STABILIZER CYLINDER

1 2713333 1 Cylinder, Stabilizer (Includes Items 2 thru 17)2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8902511 2 Valve, Pilot Check (See Kits)4 8033755 2 Solenoid Valve (See Kits)5 8033704 2 Solenoid Valve (See Kits)6 8033715 2 Orifice, .060 Dia.7 8032726 1 Nut8 See Kits 1 O-Ring9 8033745 1 Piston

10 See Kits 1 Seal, Piston11 See Kits 1 O-Ring12 See Kits 1 Back-up Ring13 8032728 1 Gland14 See Kits 1 Seal, Rod15 See Kits 1 Wiper16 8033744 1 Rod17 8033721 2 Orifice, .029 Dia.

KITS

18 8033747 1 Seal Kit, Stabilizer Cylinder (Includes Items 8, 10 thru 12, 14 & 15)19 8205655 1 Seal Kit, Pilot Check Valve (Includes 3 O-Rings & 3 Back-Up Rings)20 8033756 1 Seal Kit, Solenoid Valve

8042/10042/10054 Rev. 2/00

180

SECTION 6

SLAVE CYLINDER(Early Production)

CURRENT PRODUCTION

��

EARLY PRODUCTION

IMPORTANT:There are two similar but distinctly different SlaveCylinders. Make sure you know which version you havebefore ordering replacement parts. On “Early Production”cylinders, the gland is installed flush with the cylindertube and has “TJB” stamped on the gland. On the“Current Production” cylinders, the gland has a lip thatbottoms out against the cylinder tube.

PH0372

2

3

4

5

6

7

8

9

10

11

1213

14

1

5

78

Retract Port

Extend Port

Apply Loctite #271 to threads. Torque to 500 lb/ft (678 Nm)

and stake 4 places.

PF0760

8042/10042/10054 Rev. 7/99

181

SECTION 6


SLAVE CYLINDER(Early Production)

1 NLA 2 Cylinder, Slave (Includes Items 2 thru 13) (For Service, Order P/N 2714973)NOTE: Quantities Listed Below Are For 1 Cylinder Only

2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8032726 1 Nut4 8033741 1 Piston5 See Kits 2 Seal, Piston6 See Kits 1 O-Ring7 See Kits 1 O-Ring8 See Kits 1 Ring, Backup9 8205506 1 Gland

10 8033742 1 Washer, Thrust11 8033740 1 Rod12 See Kits 1 Seal, Rod13 See Kits 1 Wiper

KITS

14 8034695 1 Seal Kit, Slave Cylinder (Includes Items 5 thru 8, 12 & 13)(Services Both Early and Current Production Cylinders)

8042/10042/10054 Rev. 2/00

182

SECTION 6

SLAVE CYLINDER(Current Production)

CURRENT PRODUCTION

��

EARLY PRODUCTION

IMPORTANT:There are two similar but distinctly different SlaveCylinders. Make sure you know which version you havebefore ordering replacement parts. On “Early Production”cylinders, the gland is installed flush with the cylindertube and has “TJB” stamped on the gland. On the“Current Production” cylinders, the gland has a lip thatbottoms out against the cylinder tube.

PH2020

PF0760

12

3

4

5

6

7

8

9

11

12

13

14

16

17

18

16

10

7

16

13

16

14

1215

9

17

118


(407 - 542 Nm)

Apply Loctite #271to threads. Torqueto 900 - 1050 lb/ft(1220 - 1424 Nm).

Retract Port

Extend Port

15

8042/10042/10054 Origin 7/99

183

SECTION 6


SLAVE CYLINDER(Current Production)

1 2714973 2 Cylinder, Slave (Includes Items 2 thru 17)NOTE: Quantities Listed Below Are For 1 Cylinder Only

2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8035613 1 Piston4 8035612 1 Gland, Head5 8035611 1 Rod6 8035547 1 Nut, Lock 1.375-12 UNF7 See Kits 1 O-Ring8 See Kits 1 O-Ring9 See Kits 1 O-Ring

10 See Kits 2 Ring, Backup11 See Kits 1 Ring, Backup12 See Kits 1 Z-Seal, Deep13 See Kits 1 T-Seal, Capped14 See Kits 1 Wiper, HD Rod Sealed O.D.15 See Kits 2 Wearband16 See Kits 2 Wearband17 See Kits 2 Insert, Locking

KITS

18 8034695 1 Seal Kit, Slave Cylinder (Includes Items 7 thru 17)(Services Both Early and Current Production Cylinders)

8042/10042/10054 Rev. 2/00

184

SECTION 6

ATTACHMENT TILT CYLINDER

1

2

3

1314 15

4

5

67

8

910

11

12

9 10 1312

RetractPort

ExtendPort

Torque to600 lb/ft (814 Nm)

and Stake 4 Places


(61 - 68 Nm)

Apply Loctite #271 to Threads

16

17

PH0221

PF0760

PF0760

8042/10042/10054 Rev. 2/00

185

SECTION 6


ATTACHMENT TILT CYLINDER

1 2712973 1 Cylinder, Attachment Tilt (Includes Items 2 thru 15)2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8032714 1 Nut4 8902260 1 Valve, Counterbalance - preset to 4000 psi (See Kits)5 See Kits 1 Seal, Piston6 8033724 1 Piston7 See Kits 1 O-Ring8 8033725 1 Washer, Thrust9 See Kits 1 O-Ring

10 See Kits 1 Back-Up Ring11 8033722 1 Gland12 See Kits 1 Seal, Rod13 See Kits 1 Wiper14 8033723 1 Rod15 7089722 2 Bushing

KITS

16 8033726 1 Seal Kit, Attachment Tilt Cylinder (Includes Items 5, 7, 9, 10, 12 & 13)17 8205656 1 Seal Kit, Counterbalance Valve (Includes 3 O-Rings & 4 Back-Up Rings)

8042/10042/10054 Rev. 2/00

186

SECTION 6

OUTRIGGER CYLINDER(S/N 10881 & Before)

1

2

3

13

14

4

6

5

7

8

9

10

1211

5

9 1012

13

4

RetractPort

ExtendPort

Torque to400 lb/ft

(542 Nm) andStake 4 Places


(41 - 48 Nm)


(41 - 48 Nm)


16 15

PH0382

PF0760 PF0760

8042/10042/10054 Rev. 2/00

187

SECTION 6


OUTRIGGER CYLINDER(S/N 10881 & Before)

1 NLA 1 Cylinder, Outrigger (Includes Items 2 thru 14) (For Service, Order P/N 2716163)2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8032702 1 Nut4 See Kits 2 Wear Ring5 8902511 2 Valve, Pilot Check (See Kits)6 See Kits 1 Seal, Piston7 8033750 1 Piston8 See Kits 1 O-Ring9 See Kits 1 O-Ring

10 See Kits 1 Back-Up Ring11 8033748 1 Gland12 See Kits 1 Seal, Rod13 See Kits 1 Wiper14 8033749 1 Rod

KITS

15 8033751 1 Seal Kit, Outrigger Cylinder (Includes Items 4, 6, 8 thru 10, 12 & 13)16 8205655 1 Seal Kit, Pilot Check Valve (Includes 3 O-Rings & 3 Back-Up Rings)

8042/10042/10054 Rev. 2/00

188

SECTION 6

OUTRIGGER CYLINDER(S/N 10882 & After)

PH1260

1

2

6

8

8 15

13

16

1018

12

11

4

917

14

17

7

1714

17

39

1611

12

5

10

18

15

13

Apply Loctiteand Torque to

1300 - 1500 lb/ft(1762 - 2034 Nm)


(41 - 47 Nm)


(34 - 41 Nm)


(407 - 542 Nm)

PF0760 PF0760

19 20

8042/10042/10054 Origin 2/00

189

SECTION 6


OUTRIGGER CYLINDER(S/N 10882 & After)

1 2716163 1 Cylinder, Outrigger (Includes Items 2 thru 18)2 NSS 1 Tube, Weldment (Serviced Only in Item 1)3 8035727 1 Piston4 8035728 1 Gland, Head5 8035729 1 Rod, Weldment6 8035730 1 Plug, SAE No. 4 Steel Hex Head7 8035322 1 Nut, Lock UNF 1.5-128 8035731 2 Valve, PO Check, CKCB-XCN9 See Kits 1 O-Ring

10 See Kits 1 O-Ring11 See Kits 1 O-Ring12 See Kits 1 Ring, Back-Up13 See Kits 1 Z-Seal, Deep w/Rod Back-Up14 See Kits 1 T-Seal, Capped15 See Kits 1 Wiper, Hd Rod - Sealed O.D.16 See Kits 2 Wearband, Precision17 See Kits 2 Wearband, Precision18 See Kits 2 Insert, Locking

KITS

19 8035732 1 Seal Kit (Includes Items 9 thru 18)20 8035519 1 Seal Kit (Includes P/N 8035732 and P/N 8033751)

8042/10042/10054 Origin 2/00

190

SECTION 6

SWING CARRIAGE CYLINDER

1

2 3

10

11

12

4

5

6

13

14

17

7

8

9

RetractPort

“X”Port

ExtendPort


(41 - 48 Nm)

Apply Loctite #271 to Inside

Threads

15 16

PH0441

PF0760PF0760PF0760

Torque to250 lb/ft

(339 Nm)


(41 - 48 Nm)

8042/10042/10054 Rev. 2/00

191

SECTION 6


SWING CARRIAGE CYLINDER

1 2713363 1 Cylinder, Swing Carriage (Includes Items 2 thru 14)2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 See Kits 1 Wear Ring4 See Kits 1 Seal, Piston5 8033783 1 Piston6 See Kits 1 O-Ring7 See Kits 1 Back-Up Ring8 8033784 1 Gland9 See Kits 1 Seal, Rod

10 See Kits 1 Wiper11 8033785 1 Rod12 8033786 1 Valve, Counterbalance Cartridge - preset to 3000 psi (See Kits)13 8902842 1 Valve, Direct Acting Relief - preset to 2000 psi (See Kits)14 8033788 1 Orifice, .038 Dia.

KITS

15 8033789 1 Seal Kit, Swing Carriage Cylinder (Includes Items 3, 4, 6, 7, 9, & 10)16 8205655 1 Seal Kit, Valve Item 12 (Includes 3 O-Rings & 3 Back-Up Rings)17 8033790 1 Seal Kit, Valve Item 13 (Includes 2 O-Rings, 1 Back-Up Ring & 1 Gland Ring)

8042/10042/10054 Rev. 2/00

192

SECTION 6

SIDE TILT CARRIAGE CYLINDER

1

2

3

10

11

12

4

5

6

1314

15

7

8

9

17

15



(41 - 48 Nm)

RetractPort

Torque to 350 lb/ft (475 Nm) and

Stake 4 Places

PH0800

PF0760

16

PF0760

ExtendPort

8042/10042/10054 Rev. 2/00

193

SECTION 6


SIDE TILT CARRIAGE CYLINDER

1 2711613 1 Side Tilt Carriage Cylinder (Includes Items 2 thru 14)2 NSS 1 Tube, Cylinder (Serviced Only in Item 1)3 8902511 2 Valve, Pilot Check (See Kits)4 8205545 1 Piston5 8205546 1 Gland6 8205547 1 Rod7 8205548 1 Nut, Piston8 8205514 1 Bearing, Self-Aligning9 See Kits 1 Seal, Rod

10 See Kits 1 Wiper11 See Kits 1 O-Ring12 See Kits 1 Ring, Back-Up13 See Kits 1 O-Ring14 See Kits 1 Seal, Piston15 8520013 2 Fitting, Grease

KITS

16 8205661 1 Seal Kit, Side Tilt Carriage Cylinder (Includes Items 9 thru 14)17 8205655 1 Seal Kit, Pilot Check Valve

8042/10042/10054 Rev. 2/00

194

SECTION 6

STEERING CYLINDER(S/N 1167 & Before)

1 2

3

12

13

4

5

6

78

9

10

11

Retract Port

7

89

12

Extend Port

14

PH0621

PF0760

8042/10042/10054 Rev. 12/97

195

SECTION 6


STEERING CYLINDER(S/N 1167 & Before)

1 NLA 4 Steering Cylinder (Includes Items 2 thru 13) (For Service, Order P/N 8034684)NOTE: Quantities Listed Below Are For 1 Cylinder Only

2 NSS 1 Barrel Assembly (Serviced Only in Item 1)3 8033811 1 Piston 4 8033812 1 Rod 5 8033813 1 Gland 6 8033814 1 Nut, Hex Lock 7 See Kits 1 Wiper, Rod8 See Kits 1 Seal, Rod9 See Kits 1 O-Ring

10 See Kits 1 O-Ring11 See Kits 1 Seal, Piston12 See Kits 1 Lock Ring13 See Kits 1 Wear Ring

KITS

14 8033801 1 Seal Kit, Steering Cylinder (Includes Items 7 thru 13)

8042/10042/10054 Rev. 2/00

196

SECTION 6

STEERING CYLINDER(S/N 1168 & After)

1

2

3

4

5

6

7

8

9

10

12

13

14

1516

13

7

8

159

12

Retract Port

Extend Port

11

10

13

13

14

Torque to160 lb/ft (217 Nm)

11

PH0900

PF0760

8042/10042/10054 Rev. 12/97

197

SECTION 6


STEERING CYLINDER(S/N 1168 & After)

1 8034684 4 Steering Cylinder (Includes Items 2 thru 15) NOTE: Quantities Listed Below Are For 1 Cylinder Only

2 NSS 1 Barrel Assembly (Serviced Only in Item 1)3 8034821 1 Piston 4 8034822 1 Rod - 17.06" Long 5 8034823 1 Gland6 8034824 1 Nut, Hex Lock7 See Kit 1 Wiper, Rod8 See Kit 1 Seal, U-Cup9 See Kit 1 O-Ring

10 See Kit 1 O-Ring11 See Kit 1 Seal, Piston12 See Kit 1 Wire Retainer13 See Kit 2 Wear Ring14 See Kit 1 Expander15 See Kit 1 Back-up Ring

KITS

16 8034691 1 Seal Kit, Steering Cylinder (Includes Items 7 thru 15)

8042/10042/10054 Rev. 2/00

198

SECTION 6

MAIN CONTROL VALVE

A

A

B

B

1

2

11

12

13

3

4

5

14

15

16

6

78

17

19

20

910

21

22

232425

26

27

2837

29

30

31

32

33

18

30

6

11

6

34

2125

23

3220

16

78

9

1220

36

BOOM HOIST

BOOM EXTEND

PH1250

PF0760

��

PF0791

38

35

8042/10042/10054 Rev. 2/00

199

SECTION 6


MAIN CONTROL VALVE

1 NLA 1 Main Control Valve (S/N 0224 & Before) For Service, Order Kit P/N 7115652NLA 1 Main Control Valve (S/N 0225 thru 8540) For Service, Order P/N 8902186

8902186 1 Main Control Valve (Includes Items 2 thru 34) S/N 8541 & After2 8034534 1 Section, Inlet (Includes 1 of Item 6)3 7130912 1 Kit, Outlet Section (Includes Inlet & Outlet Sections and Mounting Hardware)

(S/N 2199 & Before)8035267 1 Section - Outlet (S/N 2200 & After)

4 8034552 1 Section, Boom Extend (Includes Items 6 thru 18)5 8034551 1 Section, Boom Hoist (Includes Items 6 thru 18)6 8034697 1 O-Ring (See Kits)7 See Kits 2 O-Ring8 See Kits 2 Wiper9 See Kits 2 Plate, Seal

10 See Kits 2 Screw, Rd. Hd. Mach.11 See Kits 1 Poppet, C.V.12 See Kits 1 Spring13 See Kits 2 HHCS14 See Kits 1 Cap, Spool15 See Kits 1 End, Spool16 See Kits 2 Seat, Spring17 See Kits 1 Spring18 See Kits 1 Shuttle19 8034539 1 Plug, Shut-off 20 8034538 2 Relief Valve Assembly - Preset at 3200 ± 50 psi (Includes Items 21 thru 28)21 See Kits 2 O-Ring22 See Kits 1 Ring, Back-Up23 See Kits 2 O-Ring24 See Kits 1 O-Ring25 See Kits 2 Ring, Back-Up26 See Kits 1 Spring27 See Kits 1 Spring28 See Kits 1 Spring29 See Kits 1 Tie Rod30 See Kits 2 Nut, Special31 See Kits 2 Tie Rod32 See Kits 4 Nut, Special33 8035387 1 Valve, Main Relief (Preset at 3500 ± 50 psi)34 8760451 1 Plug, Hex Hd., SAE 6 - male str. thd. o-ring

KITS

35 8034541 AR Rebuild Kit for Items 4 & 5(Includes 3 of Item 6 and listed quantities of Items 7 thru 18)

36 8034540 1 Seal & Spring Kit for Relief Valve - Item 2037 8903011 1 Tie Rod Kit - 2 Section Valve (Includes Items 29 thru 32)38 7115652 1 Kit, Main Control Valve (Includes Valve and Instructions)

8042/10042/10054 Rev. 2/00

200

SECTION 6

SECONDARY CONTROL VALVE

1

2

22

23

24

4

5

25

2627

6

78

28

29

30

9

10

31

32

11

12 13

33

34

35

14

1516

36

37

38

1718

19

3940

41

20

21

42

45

3

18

10

37

35

820

7

7

7

9

3940

131224 23

��

43 4446

FRAME TILT

ATTACH. TILT

AUX. HYD.

PH0472

PF0791PF0760PF0760PF0760

��

47

8042/10042/10054 Rev. 2/00

201

SECTION 6


SECONDARY CONTROL VALVE

1 NLA 1 Secondary Control Valve, Frame Tilt, Attachment Tilt & Auxiliary Hydraulics (S/N 0266 & Before) For Service, Order Kit P/N 7115712

8902152 1 Secondary Control Valve, Frame Tilt, Attachment Tilt & Auxiliary Hydraulics (Includes Items 2 thru 42) (S/N 0267 & After)

2 8034527 1 Section, Inlet (Includes 1 of Item 7)3 8034528 1 Section, Outlet4 8034549 1 Section, Frame Tilt (Includes Items 7 thru 11 and 14 thru 22)5 8034530 1 Section, Attachment Tilt (Includes Items 7 thru 20)6 8034531 1 Section, Auxiliary Hydraulics (Includes Items 7 thru 20)7 See Kits 1 O-Ring8 See Kits 2 O-Ring9 See Kits 2 Wiper

10 See Kits 2 Plate, Seal11 See Kits 2 Screw, Rd. Hd. Mach.12 See Kits 1 Poppet, C.V.13 See Kits 1 Spring14 See Kits 2 HHCS15 See Kits 1 Cap, Spool16 See Kits 1 End, Spool17 See Kits 1 O-Ring18 See Kits 2 Seat, Spring19 See Kits 1 Spring20 See Kits 2 Shuttle21 See Kits 1 Spring22 See Kits 1 Piston - Compensator, C.V.23 8902512 2 Plug, Shut-off 24 8034532 2 Relief Valve Assembly - Preset at 3200 ± 50 psi (Includes Items 25 thru 33) 25 See Kits 1 O-Ring26 See Kits 1 Ring, Back-Up27 See Kits 1 O-Ring28 See Kits 1 O-Ring29 See Kits 1 Ring, Back-Up30 See Kits 1 Spring31 See Kits 1 O-Ring32 See Kits 2 O-Ring33 See Kits 1 Spring34 See Kits 1 Tie Rod35 See Kits 2 Nut, Special36 See Kits 2 Tie Rod37 See Kits 4 Nut, Special38 8760420 1 Plug, Hex Hd., SAE 10 - male str. thd. o-ring39 8034557 2 O-Ring40 8034556 2 Ring, Back-Up41 8034554 1 Screw, Flow Control42 8034555 1 Screw, Flow Control

KITS

43 8034542 AR Rebuild Kit for Items 5 & 6(Includes 4 of Item 7 & listed quantities of Items 8 thru 20)

44 8034550 1 Rebuild Kit for Item 4(Includes 4 of Item 7 & listed quantities of Items 8 thru 11 and 14 thru 22)

45 8902495 1 Seal & Spring Kit for Relief Valve - Item 24 46 8902095 1 Tie Rod Kit - 3 Section Valve (Includes Items 34 thru 37)47 7115712 1 Kit, Secondary Control Valve, Frame Tilt, Attachment Tilt & Auxiliary Hydraulics

(Includes Valve & Instructions)

8042/10042/10054 Rev. 2/00

202

SECTION 6

DIRECTIONAL CONTROL VALVES 1 OF 2

PT

S

12

3

V1

T

C1

1

2

3

4

5

6

7

9

10

11

12

16

17

18

19

Torque to65 lb/ft

(88 Nm)

1314

15

Torque to35 lb/ft

(48 Nm)

Torque to35 lb/ft

(48 Nm)

10

8

PH0950

PF0760

8042/10042/10054 Rev. 2/00

203

SECTION 6



1 NLA 1 Brake Valve (S/N 0653 and Before) For Service, Order P/N 89022227119813 1 Brake Valve Kit (S/N 0654 thru 1167)8902222 1 Brake Valve (S/N 1168 and After)

2 8902137 1 Valve, Steer Select 3 8904047 1 Valve, Priority4 8902838 1 Valve, Shuttle (Includes Item 5)5 8902846 1 Cartridge, Shuttle Valve (See Kits)6 8902141 1 Valve, Outrigger (Includes Items 7 & 8) (S/N 10881 & Before)

8902193 1 Valve, Outrigger (Includes Items 7 & 8) (S/N 10882 & After)7 8902140 2 Solenoid Valve Assembly8 8904049 2 Check Valve, Back to Back (See Kits)9 8304631 8 SHCS, #10-24 x 2"

10 8640017 AR O-Ring11 8902251 1 Valve, Boom Extend Lockout (Includes Items 12 thru 14)12 8034558 1 Cartridge, Poppet Type (See Kits)13 8034559 1 Stem, Coil (See Kits)14 8034560 1 Coil Assembly

KITS

15 8033254 1 Repair Kit, Brake Valve (For Item 1)16 8205655 1 Seal Kit, Pressure Reducing Valve (For Item 5)17 8205655 1 Seal Kit, Check Valve, Back to Back (For Item 8)18 8034561 1 Seal Kit, Stem, Coil (For Item 13)19 8034562 1 Seal Kit, Cartridge, Poppet Type (For Item 12)

8042/10042/10054 Rev. 2/00

204

SECTION 6


��

��

��

�

Torque to35 lb/ft

(48 Nm)1

2

3

4

5

6 7

8

9

10

11

12131415

Torque to35 lb/ft

(48 Nm)

Torque to35 lb/ft

(48 Nm)

Torque to35 lb/ft

(48 Nm)

Torque to35 lb/ft

(48 Nm)

2

3

4

7

8

Torque to35 lb/ft

(48 Nm)

6

Torque to35 lb/ft

(48 Nm)S/N 0653 & Before

S/N 0653 & Before

9

Discard Check Valve

S/N 0654 thru 2194

PH0960

PF0760

��

PF0791

1617181920

8042/10042/10054 Rev. 2/00

205

SECTION 6



1 NLA 1 Valve, Pressure Reducing (S/N 0653 and Before) (Includes Items 2 thru 4)(See Kits Item 16 or 17)

8902266 1 Valve, Pressure Reducing (S/N 0654 and After) (Includes Items 2 thru 4)2 8033760 1 Solenoid Valve (S/N 0653 and Before) (See Kits Item 12)

8034575 1 Solenoid Valve (S/N 0654 and After) (See Kits Item 12)3 NLA 1 Cartridge, Pressure Reducing (S/N 0653 & Before) (See Kits Item 13)

8902689 1 Cartridge, Pressure Reducing (S/N 0654 and After) (See Kits Item 13)4 8033769 1 Cartridge, Check Valve (S/N 0653 and Before) (See Kits Item 15)

8034577 1 Cartridge, Check Valve (S/N 0654 and After) (See Kits Item 15)5 NLA 1 Valve, Axle Stabilizer (S/N 0653 and Before) (Includes Items 6 thru 11)

(See Kits Item 18)NLA 1 Valve, Axle Stabilizer (S/N 0654 thru 2194) (Includes Items 6 thru 11)

(See Kits Item 19)8902267 1 Valve, Axle Stabilizer (S/N 2195 & After) (Includes Items 6 thru 11)

6 NLA 1 Pressure Reducing Valve - 60 psi (S/N 0653 and Before) (See Kits Item 20)NLA 1 Pressure Reducing Valve - 60 psi (S/N 0654 thru 2194) (See Kits Item 19)

8902688 1 Pressure Reducing Valve - 200 psi (S/N 2195 and After) (See Kits Item 13)7 8033770 1 Solenoid Valve (S/N 0653 and Before) (See Kits Item 15)

8034578 1 Solenoid Valve (S/N 0654 and After) (See Kits Item 15)8 8033760 1 Solenoid Valve (S/N 0653 and Before) (See Kits Item 12)

8034575 1 Solenoid Valve (S/N 0654 and After) (See Kits Item 12)9 8033753 1 Check Valve (S/N 0653 and Before) (See Kits Item 15)

8902690 1 Plug (S/N 0654 thru 2194) (See Kits Item 15)10 8640019 2 O-Ring11 8310153 4 SHCS, 1/4-20 x 3"

KITS

12 8033761 1 Seal Kit, Solenoid Valve (S/N 0653 and Before)8034571 1 Seal Kit, Solenoid Valve (S/N 0654 and After)

13 8033768 1 Seal Kit, Pressure Reducing Cartridge (S/N 0653 and Before)8034570 1 Seal Kit, Pressure Reducing Cartridge (S/N 0654 and After)

14 8205655 1 Seal Kit, Pressure Reducing Valve (S/N 0653 and Before)8034570 1 Seal Kit, Pressure Reducing Valve (S/N 0654 and After)

15 8033763 1 Seal Kit, Check Valve (S/N 0653 and Before)8034569 1 Seal Kit, Check Valve (S/N 0654 and After)

16 7117692 1 Rework Kit, Press. Red. Valve Models 8042 & 10042 (S/N 0653 and Before)17 7117292 1 Rework Kit, Press. Red. Valve Model 10054 Only (S/N 0653 and Before)18 7117282 1 Rework Kit, Stabilizer Valve (S/N 0653 and Before)19 7130564 1 Rework Kit, Park Brake Valves (S/N 0654 thru 2194)20 7131274 1 Rework Kit, Park Brake Valves (S/N 0653 and Before)

8042/10042/10054 Rev. 2/00

206

SECTION 7

SECTION 7 ELECTRICAL

ELECTRICAL SYSTEM - CAB HARNESS(S/N 0291 & Before)

��-�.�/�0./��#��/��#��.�

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1

2 3

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5

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7

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6

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2322

9

27

52

3:

13

19

1;

17

33

12

2<3

13

1<

;

12

21

35

.

�

�

8

3:3:

2:

1 3; 25

2;2

3537

5:1:

322

5;57

=<

11

53

115

57

357

59

5;

57

3

3<

=

3

5:3 513

5:

3

52

59

3<2;

3915

251

19

273:1:2<371;

3<5<3

3

1:

1135

1333

533;

3:39

9

22=

5;23

2:

2<

3<

3<

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51

5<

5:

1721

1

23

4 5

67

89

10

11

12

13

14

15

1617

1819

20

21

222324

25

26

27

29

3031

32

33

34

35

36

37

38

39

40

41

42

43

19

19

35

4445

28

PH0601

8042/10042 Rev. 12/97

207

SECTION 7


ELECTRICAL SYSTEM - CAB HARNESS(S/N 0291 & Before)

1 7114763 1 Harness, Cab (Includes Items 2 & 3)2 8220882 2 Connector, Solenoid (Includes Item 3)3 8688026 1 Seal, Connector (Not Shown)4 7112511 1 Motor Kit, Windshield Wiper5 8033201 1 Switch, Windshield Washer/ Wiper6 8223442 1 Switch, Test7 8580312 1 Boot, Test Switch8 8223405 1 Button, Horn9 8580311 1 Boot, Horn Button

10 8464212 1 Gauge, Fuel11 8466305 1 Gauge, Warning Lights12 8467014 1 Hourmeter13 8223220 1 Switch, Steer Select14 8220050 1 Terminal - Male15 8033065 1 Washer Reservoir Assembly16 8223436 1 Switch, Ignition (w/Keys) 17 8223438 1 Key, Ignition (Not Shown)18 8033078 1 Fan, Circulation19 8229215 3 Circuit Breaker, 6 amp (4 req’d. on Closed Cab)20 7047041 1 Wire Assembly (Enclosed Cab Only) 21 8229218 1 Bracket, Cricuit Breaker 22 8305004 2 Nut, Hex, 1/4-2023 8307109 3 Washer, Flat 1/4"24 8307026 2 Washer, Lock, Int. Tooth 3/8"25 8229216 1 Circuit Breaker, 10 amp26 8229226 1 Circuit Breaker, 40 amp27 8223024 1 Switch Kit, Heater28 8584001 AR Wrap, Tie (Not Shown)29 8307002 2 Washer, Lock 1/4"30 8223444 1 Switch, Emergency Brake31 8223445 1 Guard, Switch32 8584003 1 Wrap, Tie33 8469028 1 Warning Light34 7112422 1 Wire Assembly35 8223517 2 Relay36 7115163 1 Harness, Stabilizer37 8305003 1 Nut, Hex #10-3238 8220008 1 Terminal, Ring #1039 8160621 1 Switch, Reverse40 8032756 2 Solenoid, Steer Select41 8223025 1 Switch, Brake42 8229232 1 Circuit Breaker 20 amp (optional)43 8303835 1 SHCS #10 x 1/2"44 8305002 1 Nut, Hex #1045 8307003 1 Washer, Lock #10

8042/10042 Rev. 12/97

208

SECTION 7

ELECTRICAL SYSTEM - CAB HARNESS(S/N 0292 thru 9908)

1

3 2

NOTUSED

4

WASHER BOTTLES-OPT.

5

STEER SELECTVALVE

S

G

I

A

BGREENWHITE

NOTUSED

RED

BLACK

32

33

7

35

43

20

12

17

16

15

22

13

382

12

18

6

13

31

24

A

B

S

GI

1 26 34

363

2425

40

10

4645

98

11

42

114

45

46

45

2

28

9

2

402 412

40

2

43

47

2836

2714

341

17

352010382516

28

28

618

41

1531

50

5146

3952

123A2D

28

4645A

47

2C 26 22 24 7 30

33211

42272

40B 20A

12C

DEFOG FAN -OPT. ENCL. CAB

20

30

HP BLK

WGRNMOTOR

FRONT WIPER - OPT. ENCL. CAB

SWITCH

RED L B

SKYLIGHT WIPER - OPT. ENCL. CAB

53

SWITCH

MOTOR

20

RED/BLKYELLOW

FRT. SKY.

53332

BLK P

B LH

1

23

45

67

89

10

11

12

13

14

15

1617

18

25

26

27

29

3031

32

33

34

35

36

37

38

39

40

41

42

43

20

21

222324

44

19

29

20 2119

PH0701

8042/10042/10054 Rev. 2/00

209

SECTION 7


ELECTRICAL SYSTEM - CAB HARNESS(S/N 0292 thru 9908)

1 7114754 1 Harness, Cab (Includes Items 2 & 3)2 8220882 2 Connector, Solenoid (Includes Item 3)3 8688026 1 Seal, Connector - Not Shown4 7112511 1 Motor Kit, Windshield Wiper5 8033201 2 Switch, Windshield Washer/Wiper6 8223442 1 Switch, Test7 8580312 1 Boot, Test Switch8 8223405 1 Button, Horn9 8580311 1 Boot, Horn Button

10 8464212 1 Gauge, Fuel11 8466305 1 Gauge, Warning Lights12 8467014 1 Hourmeter13 8223220 1 Switch, Steer Select14 8220050 1 Terminal - Male15 8033065 1 Washer Reservoir Assembly16 8223436 1 Switch, Ignition (w/Keys) 17 8223438 1 Key, Ignition (Not Shown)18 8033078 1 Fan, Defrost19 8229233 2 Fuse, 7.5 amp (3 required on Closed Cab)20 8229234 2 Fuse, 10 amp (3 required on Closed Cab)21 8229235 1 Fuse, 20 amp (Opt. Light Package) 22 8305004 1 Nut, Hex, 1/4-2023 8307109 2 Washer, Flat 1/4"24 8307026 2 Washer, Lock, Int. Tooth 3/8"25 8305002 4 Nut, Hex #1026 8229238 2 Fuse, 40 Amps27 8223024 1 Switch Kit, Heater28 8584001 AR Wrap, Tie (Not Shown)29 8307106 3 Washer, Flat 5/16" LT30 8223444 1 Switch, Emergency Brake31 8223445 1 Guard, Switch32 8307003 4 Washer, Lock #1033 8469028 1 Warning Light34 7112422 1 Wire Assembly35 8225117 2 Relay36 7114604 1 Harness, Stabilizer37 8582007 3 Clip, Spare Fuse38 8220008 1 Terminal, Ring #1039 8307027 1 Washer, Lock Ext. Tooth 5/16"40 8032756 2 Solenoid, Steer Select41 8223025 1 Switch, Brake42 8584003 1 Wrap, Tie (Not Shown)43 8307111 4 Washer, Flat #1044 8034810 1 Skylight Wiper Motor

8042/10042/10054 Rev. 2/00

210

SECTION 7

ELECTRICAL SYSTEM - CAB HARNESS(S/N 9909 and After)

PH1270

��

3

75

2

52

3

351

713

3

2<

2.

3:.

2<

3:

19

21

25

1;

37

39

7:71

2:

92=5;

23

2

2:

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21 6

35

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13

6

23

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53

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27

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51

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21

53

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11

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73

27

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1

4 5 39 18

20

31

19

21

23

262938

2422

29382234

14

1617

67

89

30

33

10

11

12

13

2728

15

36

37

35 23

19 20 21 23

32

8042/10042/10054 Origin 2/00

211

SECTION 7


ELECTRICAL SYSTEM - CAB HARNESS(S/N 9909 and After)

1 7117704 1 Harness, Cab (Includes Item 2)2 8220882 2 Connector, Solenoid3 8526035 AR Sealant4 7112511 1 Motor Kit, Windshield Wiper5 8033201 2 Switch, Windshield Washer/Wiper6 8223442 1 Switch, Test7 8580312 1 Boot, Test Switch8 8223405 1 Button, Horn9 8580311 1 Boot, Horn Button

10 8464212 1 Gauge, Fuel11 8466305 1 Gauge, Warning Lights12 8467014 1 Hourmeter13 8223220 1 Switch, Steer Select14 8220050 1 Terminal - Male15 8033065 1 Washer Reservoir Assembly16 8223436 1 Switch, Ignition (w/Keys) 17 8223438 1 Key, Ignition (Not Shown)18 8033078 1 Fan, Defrost19 8229233 2 Fuse, 7.5 amp (3 required on Closed Cab)20 8229234 3 Fuse, 10 amp 21 8229235 1 Fuse, 20 amp (Opt. Light Package) 22 8305002 4 Nut, Hex #1023 8229238 2 Fuse, 40 Amps24 8223024 1 Switch Kit, Heater25 8584001 AR Wrap, Tie (Not Shown)26 8307106 3 Washer, Flat 5/16" LT27 8223444 1 Switch, Emergency Brake28 8223445 1 Guard, Switch29 8307003 4 Washer, Lock #1030 8469028 1 Warning Light31 8225117 2 Relay32 8582007 4 Clip, Spare Fuse33 8220008 1 Terminal, Ring #1034 8307027 1 Washer, Lock Ext. Tooth 5/16"35 8032756 2 Solenoid, Steer Select36 8223025 1 Switch, Brake37 8584003 1 Wrap, Tie (Not Shown)38 8307111 4 Washer, Flat #1039 8034810 1 Skylight Wiper Motor

8042/10042/10054 Origin 2/00

212

SECTION 7

ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-0206 & Before and 10042-0211 & Before)

BLUE WIRE

BLACK WIRE

31

2

15

NOT USED

44

34

3510216

19 36 638 52

NOTUSED

37

19

27

GRD

NOT

28 2

44

47 2

229

USED

VIEW A-A

FRAME

18

18

214371

31

35

HYDRAULICTANK

20 25

2035

10

616

2518

38NOTUSED

2247

28

20

17SEE VIEW A-A

FRAME GRD

21

171

1427

34

36

15

47

28

31

BROWN WIRE

(-)

(+)

(-)

(+)

SEE VIEW A-A

W

B+D+

WIRE #5

WIRE #6

WIRE #38

ALTERNATOR AS VIEWEDFROM BACKSIDE

131

2

3

4

5

6

789

10

11

12

13

14

15

16171819

20

21

28

2930

32

3334

35

22

23 24 252627

12

2930

10

PH0610

8042/10042 Rev. 2/00

213

SECTION 7


ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-0206 & Before and 10042-0211 & Before)

1 7098864 1 Harness, Engine2 8270014 2 Battery, 12 Volt 3 7114612 1 Cable, Battery - Negative4 7098762 1 Cable, Battery - Positive 5 7068651 1 Cable, Battery Ground6 8270602 1 Horn7 8270617 1 Alarm, Backup8 8305004 2 Nut, Hex, 1/4-209 8307002 2 Washer, Lock 1/4"

10 8305006 4 Nut, Hex, 5/16-1811 8307006 2 Washer, Lock 7/16"12 8307106 4 Washer, Flat 5/16"13 8307004 1 Washer, Lock 5/16"14 8305438 1 Nut, Hex Jam M1015 8303697 2 HHCS, 5/16-18 x 3/4"16 8310041 1 Washer, Lock, Ext. Tooth #817 8305201 1 Nut, Hex, Brass #8-3218 8220073 1 Terminal, Slip-On Male #10 SCR19 8223510 1 Sender, Low Oil Pressure 1/8-2720 8223217 1 Sender, Water Temperature21 8223216 1 Switch, Transmission Temperature22 8033406 1 Solenoid, Fuel Run (Used on CAV Injection Pumps)

8034813 1 Solenoid, Fuel Run (Used on Bosch Injection Pumps)23 8277162 1 Relay, Starter24 8033340 1 Starter (Includes Starter Solenoid)25 8270221 1 Alternator26 8307022 1 Washer, Lock M827 8305043 1 Nut, Hex M8-1,2528 7118222 1 Sender, Fuel Level29 8310077 3 Nut, Hex Jam M5-0,830 8310078 3 Washer, Lock M531 8584001 AR Tie Wrap (Not Shown)32 7099882 1 Boom Sensor - Angle33 8307023 1 Washer, Lock M1034 8303987 2 Screw, Slotted #835 8223217 1 Switch, Hydraulic Oil Temperature

8042/10042 Rev. 2/00

214

SECTION 7

ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-0207 thru 1598, 10042-0212 thru 1598, 10054-1598 & Before)

BLUE WIRE

BLACK WIRE

31

2

15

NOT USED

44

34

3510216

19 36 638 52

NOTUSED

37

19

27

NOT

28 2

44

47 2

229

USED

18

18

214371

31

35

HYDRAULICTANK

20 25

2035

10

616

2518

38NOTUSED

2247

281721

171

1427

34

36

15

47

28

31

BROWN WIRE

(-)

(+)

(-)

(+)

W

B+D+

WIRE #5

WIRE #6

WIRE #38


49232

TO BOOM EXTENDSENSOR (10054 ONLY)

(NOT USED ON8042 OR 10042)

49

23

TO LOGICHARNESS (10054 ONLY)


110

2

3

4

5

6

789

11

1213 14

15

16171819

20

21

22

23 2425

2627

28

2930

2930

PH0611

8042/10042/10054 Rev. 2/00

215

SECTION 7


ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-0207 thru 1598, 10042-0212 thru 1598, 10054-1598 & Before)

1 7126684 1 Harness, Engine2 8270014 2 Battery, 12 Volt 3 7114542 1 Cable, Dual Battery - Negative4 7098762 1 Cable, Dual Battery - Positive5 8310202 1 HHCS, 3/8 x 3/4"6 8270602 1 Horn (Includes Mounting Hardware) 7 8270617 1 Alarm, Backup8 8305004 2 Nut, Hex, 1/4-209 8307002 2 Washer, Lock 1/4"

10 8584001 AR Tie Wrap (Not Shown)11 7099882 1 Boom Sensor - Angle12 8307023 1 Washer, Lock M1013 8303987 2 Screw, Slotted #814 8305438 1 Nut, Hex Jam M1015 8223217 1 Switch, Hydraulic Oil Temperature16 8310041 1 Washer, Lock, Ext. Tooth #817 8305201 1 Nut, Hex, Brass #8-3218 8220073 1 Terminal, Slip-On Male #10 SCR19 8223510 1 Sender, Low Oil Pressure 1/8-2720 8223217 1 Sender, Water Temperature21 8223216 1 Switch, Transmission Temperature22 8033406 1 Solenoid, Fuel Run (Used on CAV Injection Pumps)

8034813 1 Solenoid, Fuel Run (Used on Bosch Injection Pumps)23 8277162 1 Relay, Starter24 8033340 1 Starter (Includes Starter Solenoid)25 8270221 1 Alternator26 8307022 1 Washer, Lock M827 8305043 1 Nut, Hex M8-1,2528 7118222 1 Sender, Fuel Level29 8310077 3 Nut, Hex Jam M5-0,830 8310078 3 Washer, Lock M5

8042/10042/10054 Rev. 2/00

216

SECTION 7

ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-1599 to 5234, 10042-1599 to 5250, 10054-1599 to 5274)

BLUE WIRE

BLACK WIRE

31

2

15

NOT USED

44

3510216

36 638 52

NOTUSED

37

19

27

NOT

28 2

44

47 2

229

USED

18

18

214371

31

35

HYDRAULICTANK

20 25

2035

10

616

2518

38NOTUSED

2247

281721

171

1427

34

36

15

47

28

31

BROWN WIRE

(-)

(+)

W

B+D+

WIRE #5

WIRE #6

WIRE #38


49232



49

23



TO STABILIZERHARNESS

20

20

34

30A

19

30A

NOTUSED

(-)

(+)

110

2

3

4

5

6

789

11

1214

13

15

16171819

20

21

22

23

24 25

28

2627

2930

2930

PH0613

8042/10042/10054 Rev. 2/00

217

SECTION 7


ELECTRICAL SYSTEM - ENGINE HARNESS(S/N 8042-1599 to 5234, 10042-1599 to 5250, 10054-1599 to 5274)

1 7126684 1 Harness, Engine2 8270014 2 Battery, 12 Volt 3 7114542 1 Cable, Dual Battery - Negative4 7098762 1 Cable, Dual Battery - Positive5 8310202 1 HHCS, 3/8 x 3/4"6 8270602 1 Horn (Includes Mounting Hardware)7 8270617 1 Alarm, Backup8 8305004 2 Nut, Hex, 1/4-209 8307002 2 Washer, Lock 1/4"

10 8584001 AR Tie Wrap (Not Shown)11 7099882 1 Boom Sensor - Angle12 8307023 1 Washer, Lock M1013 8303987 2 Screw, Slotted #814 8305438 1 Nut, Hex Jam M1015 8223217 1 Switch, Hydraulic Oil Temperature16 8310041 1 Washer, Lock, Ext. Tooth #817 8305201 1 Nut, Hex, Brass #8-3218 8220073 1 Terminal, Slip-On Male #10 SCR19 8223610 1 Sender, Low Oil Pressure M1020 8223217 1 Sender, Water Temperature21 8223216 1 Switch, Transmission Temperature22 8033406 1 Solenoid, Fuel Run (Used on CAV Injection Pumps)

8034813 1 Solenoid, Fuel Run (Used on Bosch Injection Pumps)23 8277162 1 Relay, Starter24 8033340 1 Starter (Includes Starter Solenoid)25 8270221 1 Alternator26 8307022 1 Washer, Lock M827 8305043 1 Nut, Hex M8-1,2528 7118222 1 Sender, Fuel Level29 8310077 3 Nut, Hex Jam M5-0,830 8310078 3 Washer, Lock M5

8042/10042/10054 Rev. 2/00

218

SECTION 7

ELECTRICAL SYSTEM - ENGINE HARNESS (EPA)(S/N 8042-5235, 10042-5251, 10054-5275 thru 9908)

BLUE WIRE

BLACK WIRE

31

2

15

NOT USED

44

3510216

36 638 52

NOTUSED

37

19

27

NOT

28 2

44

47 2

229

USED

18

18

214371

31

35

HYDRAULICTANK

20 25

2035

10

616

2518

38NOTUSED

2247

281721

171

1427

34

36

15

47

28

31

BROWN WIRE

(-)

(+)

W

B+D+

WIRE #5

WIRE #6

WIRE #38


49232



49

23



TO STABILIZERHARNESS

20

20

34

30A

19

30A

NOTUSED

111

23

4

5

7

89

10

12

1315

14

16

17181920

21

22

29

3031

23

24

25 26

2728

3031

PH0612

6

8042/10042/10054 Rev. 2/00

219

SECTION 7


ELECTRICAL SYSTEM - ENGINE HARNESS (EPA)(S/N 8042-5235, 10042-5251, 10054-5275 thru 9908)

1 7126684 1 Harness, Engine2 8270134 1 Battery, 12 Volt 3 7129392 1 Cable, Single Battery - Negative 4 7129382 1 Cable, Single Battery - Positive 5 8310202 1 HHCS, 3/8 x 3/4"6 7134832 1 Kit, Horn (Includes Item 7 and female terminal to replace ring terminal on early

production units)7 8270625 1 Horn (Includes Mounting Hardware)8 8270617 1 Alarm, Backup9 8305004 2 Nut, Hex, 1/4-20

10 8307002 2 Washer, Lock 1/4"11 8584001 AR Tie Wrap (Not Shown)12 7099882 1 Boom Sensor - Angle13 8307023 1 Washer, Lock M1014 8303987 2 Screw, Slotted #815 8305438 1 Nut, Hex Jam M1016 8223217 1 Switch, Hydraulic Oil Temperature17 8310041 1 Washer, Lock, Ext. Tooth #818 8305201 1 Nut, Hex, Brass #8-3219 8220073 1 Terminal, Slip-On Male #10 SCR20 8223610 1 Sender, Low Oil Pressure M1021 8223217 1 Sender, Water Temperature22 8223216 1 Switch, Transmission Temperature23 8035276 1 Solenoid, Fuel Run24 8277162 1 Relay, Starter25 8033340 1 Starter (Includes Starter Solenoid)26 8270221 1 Alternator27 8307022 1 Washer, Lock M828 8305043 1 Nut, Hex M8-1,2529 7118222 1 Sender, Fuel Level30 8310077 3 Nut, Hex Jam M5-0,831 8310078 3 Washer, Lock M5

8042/10042/10054 Rev. 2/00

220

SECTION 7

ELECTRICAL SYSTEM - ENGINE HARNESS (EPA)(S/N 9909 and After)

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11

789

32

31

8042/10042/10054 Origin 2/00

221

SECTION 7


ELECTRICAL SYSTEM - ENGINE HARNESS (EPA)(S/N 9909 and After)

1 7134894 1 Harness, Engine2 8270134 1 Battery, 12 Volt 3 7129392 1 Cable, Single Battery - Negative 4 7129382 1 Cable, Single Battery - Positive 5 8310202 1 HHCS, 3/8 x 3/4”6 8270625 1 Horn (Includes Mounting Hardware) 7 8270617 1 Alarm, Backup8 8305004 2 Nut, Hex, 1/4-209 8307002 2 Washer, Lock 1/4"

10 8584001 AR Tie Wrap (Not Shown)11 7099882 1 Boom Sensor - Angle12 8307023 1 Washer, Lock M1013 8305438 1 Nut, Hex Jam M1014 8223217 1 Switch, Hydraulic Oil Temperature15 8310041 1 Washer, Lock, Ext. Tooth #816 8305201 1 Nut, Hex, Brass #8-3217 8220073 1 Terminal, Slip-On Male #10 SCR18 8223610 1 Sender, Low Oil Pressure M1019 8223217 1 Sender, Water Temperature20 8223216 1 Switch, Transmission Temperature21 8035276 1 Solenoid, Fuel Run22 8277162 1 Relay, Starter23 8033340 1 Starter (Includes Starter Solenoid)24 8270221 1 Alternator25 8307022 1 Washer, Lock M826 8305043 1 Nut, Hex M8-1,2527 7118222 1 Sender, Fuel Level28 8310077 3 Nut, Hex Jam M5-0,829 8310078 3 Washer, Lock M530 7150402 1 Transmission Harness31 8035805 1 Diode Pac32 8035806 2 Diode - 3 amp 1000 volt33 8305038 2 Nut M1034 7150521 1 Wire Assembly

8042/10042/10054 Origin 2/00

222

SECTION 7

LIGHTING SYSTEM

��

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1

2

3

4567

89

1011121314

1516

17

19

20

21

22

23

24

25

26

2728

2

2

2

2

76

2

18

192527

21

22

2527

32527

456718

2

2

2

17

19

185

4

19

21011

1

15

3

3

28

Torque Item 5 to 120 lb/ft(163 Nm) 4 Places

25

PH0432

29

29

8042/10042/10054 Rev. 2/00

223

SECTION 7


LIGHTING SYSTEM

1 7098973 1 Harness, Wiring2 5721202 5 Light, Head and Work3 8500036 2 Light, Turn Signal4 7112302 4 Bracket, Mounting5 8303632 8 HHCS, 5/8-11 x 2-1/2"6 8307009 8 Washer, Lock 5/8"7 8307207 8 Washer, Flat 5/8" Heavy8 8223025 1 Switch, Momentary Brake Light9 7111191 1 Plate, Actuator

10 8223424 1 Mount, Flasher11 8500201 1 Flasher12 8303837 2 Screw, Rd. Hd. Mach., #10-24 x 3/4"13 8305627 2 Nut, Hex Lock #10-2414 8307111 2 Washer, Flat #1015 8223419 1 Switch, Turn Signal16 7124331 1 Conduit, 1/2 I.D. x 5' - Cut to Fit17 8223016 1 Switch, Head and Tail Lights18 8305014 8 Nut, Hex 5/8-1119 8500009 2 Stop/Turn Signal Light20 8584018 6 Mount, Tie21 8584003 6 Tie, Plastic, 14.8"22 8584001 27 Tie, Plastic, 6.7"23 8305405 1 Nut, Hex Jam 3/8"24 7058372 1 Fuel Gauge Light Assembly25 8307206 AR Washer, Flat 1/2" Heavy26 8229235 1 Fuse, 20 amp27 8220050 6 Terminal, Blade Male 1/4"28 7110782 1 Cord, Boom Work Light29 8310058 4 Washer, Flat 5/8 Hardened

8042/10042/10054 Rev. 2/00

224

SECTION 7

OUTRIGGER ELECTRICAL HARNESS(10042/10054 Only)

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23

4

5 6

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10

11

12

13141517

16

1

4

4

16

23

For Units w/CircuitBreakers 10042 Only

10054 Only

18

PH0691

PH0791

10042/10054 Rev. 2/00

225

SECTION 7


OUTRIGGER ELECTRICAL HARNESS(10042/10054 Only)

1 7099923 1 Harness, Wiring (Includes Items 2 & 3) - (10042 Only)7115114 1 Harness, Logic (Includes Items 2 & 3) - (10054 Only)

2 8220882 4 Connector, Solenoid (Includes Item 3)3 8688026 4 Seal, Connector (Not Shown)4 8223221 2 Switch, Toggle5 7112592 1 Wire Assembly6 7138469 1 Kit, Boom Sensor (S/N 9915 & Before)

7099882 1 Sensor, Boom (S/N 9916 & After)7 7112582 1 Clip (S/N 9915 & Before)

7138468 1 Clip (S/N 9916 & After)8 8303738 2 HHCS, 3/8-16 x 7/8"9 8307005 2 Washer, Lock 3/8"

10 8310113 2 Nut, Cage 3/8-1611 8225117 8 Relay12 8229233 2 Fuse, 7.5 amp13 8307111 2 Washer, Flat #1014 8305002 2 Nut, Hex #1015 8307003 2 Washer, Lock #1016 8223525 2 Switch, Pressure17 8307106 2 Washer, Flat 5/16 LT

KITS

18 7116632 1 Kit, Outrigger, Wire HarnessThis kit is available to convert 10042 wire harness for use with circuit breakers

10042/10054 Rev. 2/00

226

SECTION 8

SECTION 8 DECALS AND PAINT

DECALS AND PAINT

D172:

1757

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38394041

12 14

18

22

24

4

20

5

113

10

25

15

4

17

7

9

6

8

See“Control Console”

37

29

2

23

19

1

7

13

16

26

PH0323

PF0790PF0770PF0780

36

34

21

35

33

8042/10042/10054 Rev. 2/00

227

SECTION 8


DECALS AND PAINT

1 4106872 1 Decal, TRAK INTERNATIONAL (Earlier Models)4110113 1 Decal, Omni Quip (Later Models)

2 4107352 1 Decal, Lubrication and Maintenance Chart3 4100181 1 Decal, Hydraulic Oil4 4107412 2 Decal, Moving Parts Warning - Domestic Only

4108081 2 Decal, Moving Parts Warning - Export Only5 4108302 1 Decal, Hydraulic Oil Level6 4110123 2 Decal, 8042

4110124 2 Decal, 100424110125 2 Decal, 10054

7 4107232 2 Decal, Rear Stripe8 4107243 2 Decal, Upper Curve Stripe9 4107252 2 Decal, Lower Curve Stripe

10 4110119 1 Decal, Stripe11 4107272 2 Decal, Boom Stripe12 4107283 2 Decal, SKYTRAK13 4106781 2 Decal, TI Logo (Earlier Models)

4108441 2 Decal, “OmniQuip” (Later Models)14 4105171 1 Decal, Diesel Fuel15 4107402 1 Decal, Explosion Warning

4108041 1 Decal, Explosion Warning - Export Only16 4106681 1 Decal, TRAK INTERNATIONAL (Steering Wheel Center) (Earlier Models)

4110120 1 Decal, SkyTrak International (Steering Wheel Center) (Later Models)17 4107601 1 Decal, Stabilizer18 4105262 1 Decal, Boom Angle19 4107452 1 Decal, Carrying Personnel Warning - Domestic Only

4106991 1 Decal, Carrying Personnel Warning - Export Only20 4107442 1 Decal, Boom Extend Letters (Off White)

4107482 1 Decal, Boom Extend Letters (Black)21 4107462 1 Decal, Side Console22 4105621 1 Decal, Optional Hydraulics23 4107901 1 Decal, Low Engine Idle24 4107001 1 Decal, Hydrofill - Export Only25 7010491 1 Safety Walk, 6" x 12"26 4108201 1 Ring, Key27 8528074 1 gal Paint, Orange, Acrylic Enamel (Service Repaint)28 8528100 1 gal Paint, Black, Acrylic Enamel (Service Repaint)29 8528085 1 gal Paint, Off White, Acrylic Enamel (Service Repaint)30 8528071 1 can Paint, Orange, Acrylic Enamel (16 oz. spray - touch-up)31 8528101 1 can Paint, Black, Acrylic Enamel (16 oz. spray - touch-up)32 8528086 1 can Paint, Off White, Acrylic Enamel (16 oz. spray - touch-up)33 4108181 1 Decal, Made in USA34 4106761 1 Decal, TI Logo - Closed Cab/Export Only35 7111842 1 Decal, Overlay, Left Hand - Export Only (S/N 9908 & Before)

7150472 1 Decal, Overlay, Left Hand - Export Only (S/N 9909 & After)7099352 1 Decal, Overlay, Left Hand - Domestic Only (S/N 9908 & Before)7150371 1 Decal, Overlay, Left Hand - Domestic Only (S/N 9909 & After)

36 7111832 1 Decal, Overlay, Right Hand - Export Only 7099332 1 Decal, Overlay, Right Hand - Domestic Only

37 4107342 1 Capacity Charts, 8042 - Domestic Only 4107632 1 Capacity Charts, 8042 - Export Only4107572 1 Capacity Charts, 10042 - Domestic Only4107992 1 Capacity Charts, 10042 - Export Only4107922 1 Capacity Charts, 10054 - Domestic Only4108002 1 Capacity Charts, 10054 - Export Only

KITS

38 7099362 1 Kit, Decal Set, 8042/10042 - Domestic Only39 7112391 1 Kit, Decal Set, 8042/10042 - Export Only 40 7116152 1 Kit, Decal Set, 10054 - Domestic Only41 7116162 1 Kit, Decal Set, 10054 - Export Only

8042/10042/10054 Rev. 2/00

228

SECTION 9

SECTION 9 BOOM AND ATTACHMENTS

OUTER BOOM

�>/�:<<5�G��!��

1

2

3

45

6

7

23 24

2526

27

28

20

30

8

9

10

11

12

13

14

15

31

32

33

3435

36

37

38

39

161718

1920

21

22

36

11

12

13

14

15

15

20

22

20

22

8

7

98

22

8829

9

7

78

2823

24 22

21

20

NOTE: Apply Item 33 to All screws that secure wear

pads and torque to31 ± 3 lb/ft (42 ± 4 Nm).

PH0053

PH0940

8042/10042/10054 Rev. 2/00

229

SECTION 9


OUTER BOOM

1 7116854 1 Outer Boom (S/N 0885 and After)NLA 1 Outer Boom (S/N 0884 and Before) For Service, Order Kit 7116871 which includes

Items 1, 34 thru 392 8303655 2 HHCS, 5/8-11 x 4.50"3 8305643 2 Nut, Hex Lock Elastic 5/8-114 7097682 2 Pin, Boom Pivot5 8307910 AR Washer, Shim 2.75 Dia. x .075"6 8307911 AR Washer, Shim 2.75 Dia. x .135"7 8307204 12 Washer, Flat 3/8"8 8307005 22 Washer, Lock 3/8"9 8303681 8 HHCS, 3/8-16 x 3/4"

10 7097382 1 Cover, Rear Boom (S/N 0884 and Before)11 8065640 4 Bearing, Self-Aligning 2" Dia.12 7092292 4 Pin, Hoist and Slave Cylinders 13 8305644 4 Nut, Hex Lock Elastic 1/2-1314 8303782 4 HHCS, 1/2-13 x 4"15 8642224 4 Ring, Retaining 2" Dia.16 8307113 2 Washer, Flat 7/16"17 7075611 1 Pointer18 8305647 1 Nut, Hex Lock 7/16-1419 7096562 1 Pin, Extend Cylinder (rod end)20 7082311 21 Insert, Wear Pad21 8520013 4 Fitting, Lube 1/8" Straight22 7111572 9 Wear Pad23 7082342 AR Shim, Wear Pad (.07")24 7082362 AR Shim, Wear Pad (.13")25 7096882 2 Spacer, Wear Pad (.62")26 7096772 1 Spacer, Wear Pad (special)27 8303041 3 HHCS, 3/8-16 x 1/2"28 8303620 8 HHCS, 3/8-16 x 1"29 8303621 6 HHCS, 3/8-16 x 1-1/2"30 5724622 1 Bumper, Rubber31 8305645 1 Nut, Hex Lock Elastic 3/8-1632 7096552 1 Pin, Extend Cylinder (base end)33 8526036 AR Tube, Thread Locking Compound .5cc34 8303697 1 HHCS, 5/16-18 x 3/4"35 8307106 1 Washer, Flat 5/16"36 8305906 2 Nut, Retainer 5/16-1837 8307004 1 Washer, Lock 5/16"38 8303715 1 HHCS, 5/16-18 x 1-1/2"39 7116792 1 Cover, Rear Boom (S/N 0885 and After)

8042/10042/10054 Rev. 2/00

230

SECTION 9

INTERMEDIATE BOOM - 8042 AND 10042

1

2

3

4

5 6 7

8 910

11

12

25

26

27

28

29

30

31

32

33

34

35

1314

15

16

17

36

37 38

39

40

19

20

21

23

24

29

3839

38

9

4

23 5

4

7 13 14

4

45

20

16

77

6

4

2

35

18

5



S/N 0481 & Before-Complete Early Model Hose Reel Assemblies Are

No Longer Available, Order Item 22.

18

5

4

41 41

PH0042

PH0940

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PF0791

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PF0791

22

424344

8042/10042 Rev. 2/00

231

SECTION 9


INTERMEDIATE BOOM - 8042 AND 10042

1 NLA 1 Intermediate Boom (S/N 0218 & Before) For Service, Order P/N 7116784, Kit P/N 7117513 and Kit P/N 7117072

NLA 1 Intermediate Boom (S/N 0219 thru 0453) For Service, Order P/N 7116784, Kit P/N 7117523 and Kit P/N 7117072

NLA 1 Intermediate Boom (S/N 0454 thru 0481) For Service, Order P/N 7116784 and Kit P/N 7117072

7116784 1 Intermediate Boom (S/N 0482 & After)2 7082362 AR Shim, Wear Pad (.13" thick)3 7082342 AR Shim, Wear Pad (.07" thick)4 7082311 37 Insert, Wear Pad5 7111572 16 Wear Pad6 8307204 25 Washer, Flat 3/8"7 8307005 37 Washer, Lock 3/8"8 8303620 9 HHCS, 3/8-16 x 1"9 NLA 2 Bushing, Chain Sheave, For Service, Order Kit P/N 7138980

10 NLA 1 Sheave, Retract Chain, For Service, Order Kit P/N 713898011 NLA 1 Sheave Extend Chain (S/N 0218 & Before) For Service, Order Kit P/N 7117513

NLA 1 Sheave, Extend Chain (S/N 0219 thru 0453) For Service, Order Kit P/N 71175237114112 1 Sheave, Extend Chain (S/N 0454 & After)

12 NLA 1 Pin, Retract Chain Sheave, For Service, Order Kit P/N 713898013 8307007 2 Washer, Lock 1/2"14 8303735 2 HHCS, 1/2-13 x 3/4"15 NLA 1 Pin, Extend Chain Sheave (S/N 0218 & Before) For Service, Order Kit P/N 7117513

NLA 1 Pin, Extend Chain Sheave (S/N 0219 thru 0453) For Service, Order Kit P/N 71175237117572 1 Pin, Extend Chain Sheave (S/N 0454 & After)

16 8303621 10 HHCS, 3/8-16 x 1-1/2"17 8303681 16 HHCS, 3/8-16 x 3/4"18 7096882 4 Spacer, Wear Pad (0.62 thick)19 8526036 AR Tube, Thread Locking Compound .5cc20 NLA 2 Bushing, Chain Sheave (S/N 0218 & Before) For Service, Order Kit P/N 7117513

NLA 2 Bushing, Chain Sheave (S/N 0219 thru 0453) For Service, Order Kit P/N 71175237117502 2 Bushing, Chain Sheave (S/N 0454 & After)

21 8520001 1 Fitting, Lube 1/8" Straight22 7117072 1 Kit, Hose Pulley (Includes Items 23 thru 39)23 7116812 4 Pulley, Roller24 7116642 5 Divider25 7116652 1 Bracket, Right Side26 7116662 1 Bracket, Left Side27 7116691 10 Spacer28 8310235 1 Screw, Shoulder 1/2 x 5"29 8305645 2 Nut, Lock 3/8-16 Elastic30 8310209 1 HHCS, 1/2-13 x 6"31 8305644 1 Nut, Lock 1/2-13 Elastic32 8307206 2 Washer, Flat 1/2" Heavy (.109 thick)33 8310245 1 Screw, Shoulder 1/2 x 4"34 8307204 1 Washer, Flat 3/8" Heavy (.083 thick)35 7096702 1 Spacer, Wear Pad (0.5" thick)36 8303679 2 HHCS, 3/8-16 x 1-3/4"37 8303675 2 HHCS, 3/8-16 x 1-1/4"38 8307204 10 Washer, Flat 3/8"39 8307005 4 Washer, Lock 3/8"40 7082342 2 Shim, Wear Pad (.075 thick)41 8065214 2 Bearing, Hose Pulley (S/N 0481 and Before)

KITS

42 7117513 1 Kit, Extend Chain Sheave (S/N 0218 & Before) (Includes Items 11, 15 & 20)43 7117523 1 Kit, Extend Chain Sheave (S/N 0219 thru 0453) (Includes Items 11, 15 & 20)44 7138980 1 Kit, Retract Chain Sheave (Includes Items 9, 10, 12 and New Hardware for

Rear Boom Cover and Instructions)

8042/10042 Rev. 2/00

232

SECTION 9

INNER BOOM - 8042 AND 10042

12

3

4

5

6

78

9

1011

12

1516

17

18

19 20

21

22

23

24

22

3

4

5

13 4

78

3

5

14

12

2615

S/N 8042-0866 or10042-0880 & Before(No Longer Available)

27 28

1

25



PH0063

PH0940

8042/10042 Rev. 2/00

233

SECTION 9


INNER BOOM - 8042 AND 10042

1 7118662 1 Kit, Inner Boom (S/N 8042-0866 or 10042-0880 and Before) Includes bushings, chain links, hardware and chain clevis

7117113 1 Inner Boom (S/N 8042-0867 or 10042-0881 and After) Includes 2 of Item 12

2 8303679 6 HHCS, 3/8-16 x 1-1/2"3 8307005 16 Washer, Lock 3/8"4 7082311 16 Insert, Wear Pad5 7111572 7 Wear Pad6 7096882 2 Spacer, Wear Pad, .62"7 7082362 AR Shim, Wear Pad, .13"8 7082342 AR Shim, Wear Pad, .07"9 8303675 2 HHCS, 3/8-16 x 1-1/4"

10 8303681 8 HHCS, 3/8-16 x 3/4"11 8307204 8 Washer, Flat 3/8"12 7095312 2 Bushing, Quick Attach Pivot13 7096702 1 Spacer, Wear Pad, .50"14 8520021 1 Fitting, Lube, 1/8" 90°15 8520013 3 Fitting, Lube, 1/8" Straight16 8305644 1 Nut, Hex Lock Elastic 1/2-1317 7083992 1 Pin, Attachment Tilt Cylinder (rod end)18 8305643 1 Nut, Hex Lock Elastic 5/8-1119 7095352 1 Pin, Pivot, Quick Attach20 8303666 1 HHCS, 5/8-11 x 5"21 7095522 1 Pin, Attachment Tilt Cylinder (base end)22 8642224 2 Ring, Retaining. 2" Dia.23 8303772 1 HHCS, 1/2-13 x 5"24 8526036 AR Tube, Thread Locking Compound .5cc25 7125811 1 Conduit, Plastic 3/4 x 8.0026 8307918 2 Washer, Shim 2.00 x 3.50 x 0.13427 8310093 AR Washer, Shim 2.00 x 3.50 x 0.7528 8307904 AR Washer, Shim 2.00 x 3.50 x 0.048

8042/10042 Rev. 12/97

234

SECTION 9

QUICK ATTACH

2

3

4

56

7

8

PA0746

1

8042/10042/10054 Rev. 2/00

235

SECTION 9


QUICK ATTACH

1 7085102 1 Quick Attach Assembly (Includes Items 2 thru 8)2 7120742 1 Quick Attach 3 8305619 1 Nut, Hex Lock 3/4-10 4 7085552 1 Spring, Torsion5 7085571 1 Spacer6 7085562 1 Latch 7 8307104 1 Washer, Flat 3/4"8 8303638 1 HHCS, 3/4-10 x 2-3/4"

8042/10042/10054 Rev. 2/00

236

SECTION 9

CARRIAGE 48"

1

2

3

4

5

9

10

23

4

76

8

PA0744

8042/10042/10054 Rev. 2/00

237

SECTION 9


CARRIAGE 48"

1 7083054 1 Carriage, 48"2 8303634 2 HHCS, 5/8-11 x 4"3 7086471 2 Collar4 8305643 2 Nut, Hex Lock 5/8-11 5 7118892 1 Pin, Lock (Includes Items 6 thru 8)6 7118882 1 Pin7 8310276 1 Washer, .51 x 1.88 x 1.25"8 8310266 1 Bolt, Eye 1/2 x 13 x 2" Length Shank9 7128772 1 Shaft, 48"

10 7097523 2 Fork, Pallet 48" x 4" x 2" (4,000 lb. Rating) - 8042 Only7097543 2 Fork, Pallet 48" x 4" x 2.25" (5,000 lb. Rating) - 10042/10054 Only7097533 2 Fork, Lumber (Not Shown)7085073 6 Fork, Block (Not Shown)

8042/10042/10054 Rev. 7/98

238

SECTION 9

CARRIAGE 60"(Optional)

1

23

4

2

3

4

59

10

67

8

PA0744

8042/10042/10054 Rev. 2/00

239

SECTION 9



1 7086304 1 Carriage, 60"2 8303634 2 HHCS, 5/8-11 x 4"3 7086471 2 Collar4 8305643 2 Nut, Hex Lock 5/8-115 7118892 1 Pin, Lock (Includes Items 6 thru 8)6 7118882 1 Pin7 8310276 1 Washer, .51 x 1.88 x 1.25"8 8310266 1 Bolt, Eye 1/2 x 13 x 2" Length Shank9 7128792 1 Shaft, 60"


8042/10042/10054 Rev. 7/98

240

SECTION 9


1

2

34

9

10

23

4

5

67

8

PA0744

8042/10042/10054 Rev. 2/00

241

SECTION 9



1 7090814 1 Carriage, 72"2 8303634 2 HHCS, 5/8-11 x 4"3 7086471 2 Collar4 8305643 2 Nut, Hex Lock 5/8-115 7118892 1 Pin, Lock (Includes Items 6 thru 8)6 7118882 1 Pin7 8310276 1 Washer, .51 x 1.88 x 1.25"8 8310266 1 Bolt, Eye 1/2 x 13 x 2" Length Shank9 7128802 1 Shaft, 72"


8042/10042/10054 Rev. 7/98

242

SECTION 9

SIDE TILT CARRIAGE - EARLY PRODUCTION(Optional)

�� !!��'��#�$�%�� %��&�� &��!��'��(��(��#�.��!��'��!��'�&��!��(��H��%��'�!��#�.��I�� I��'�� (��H��!��#��I��I��'�� '��+��!��(��H��!��'��#

��

@ �6�4�0�$��.��H��.��/8�0�6.�4A

1

23

4

56

7

8 910

11

1314

15

1617

18192021

22

23

24

25

26

30

3132

33

34

11

12

123132

33

8

11

29

27

28

Side TiltCylinder

15

PA1153

8042/10042/10054 Rev. 2/00

243

SECTION 9


SIDE TILT CARRIAGE - EARLY PRODUCTION(Optional)

1 7089044 1 Carriage, Side Tilt - 48" 7089054 1 Carriage, Side Tilt - 60"7098354 1 Carriage, Side Tilt - 72"

2 7065482 2 Pad, Wear3 8303739 2 HHCS, 5/16-18 x 1-1/4"4 8305626 2 Nut, Hex Lock 5/16-185 Consult Factory 1 Base, Pivot6 7077501 1 Pin, Cyl. Base7 7077511 1 Pin, Cyl. Rod8 7077481 2 Spacer9 8065634 1 Bushing, Self Align

10 8642001 1 Ring, Snap11 8642235 4 Ring, Snap12 8760117 2 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring13 8584001 1 Tie Wrap14 2711992 2 Hose Assembly15 8760110 2 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring16 8430006 1 Quick Disconnect, Male, SAE 8-8ORB - female internal (Includes Item 17)17 8640029 1 Seal, Nose (Not Shown)18 8430005 1 Quick Disconnect, Female, SAE 8-8ORB - female internal (Includes Items 19, 20 & 21)19 8640029 1 Seal, Nose (Not Shown)20 8640028 1 Seal, Coupler Body (Not Shown)21 8640032 1 Back-Up Ring, Coupler Body Seal (Not Shown)22 8541433 1 Plug, Pipe, Skt. Hd. - 1/8" NPTF23 8420053 1 Cap, Dust #824 8420055 1 Plug, Dust #825 7125741 1 Molding26 7085411 1 Pin, Pivot27 7085501 1 Collar, Pin Locking28 8303770 1 HHCS, 3/8-16 x 2-3/4"29 8305645 1 Nut, Hex Lock 3/8-16 ESNA 30 7128772 1 Shaft, Fork Pivot 48"

7128792 1 Shaft, Fork Pivot 60"7128802 1 Shaft, Fork Pivot 72"

31 7086471 2 Hub, Lock32 8303634 2 HHCS, 5/8-11 x 4"33 8305643 2 Nut, Hex Lock 5/8-1134 7097523 2 Fork, Pallet 48" x 4" x 2" (4,000 lb. Rating) - 8042 Only

7097543 2 Fork, Pallet 48" x 4" x 2.25" (5,000 lb. Rating) - 10042/10054 Only7097533 2 Fork, Lumber (Not Shown)7085073 6 Fork, Blocking (Not Shown)

8042/10042/10054 Rev. 2/00

244

SECTION 9

SIDE TILT CARRIAGE - CURRENT PRODUCTION(Optional)

�� !!��'��#�$�%�� %��&�� &��!��'��(��(��#�.��!��'��!��'�&��!��(��H��%��'�!��#�.��I�� I��'�� (��H��!��#��I��I��'�� '��+��!��(��H��!��'��#

��

@ �6�4�0�$��.��H��.��/8�0�6.�4A

1

23

4

5

8 910

11

12

1314

15

24

25

26

27

28

29

30

3132

33

34

35

36

371617

18192021

22

23

Side TiltCylinder

3132

337

116

15

8

11

38

PA1591

8042/10042/10054 Rev. 2/00

245

SECTION 9


SIDE TILT CARRIAGE - CURRENT PRODUCTION(Optional)

1 7117244 1 Carriage, Side Tilt - 48" 7117254 1 Carriage, Side Tilt - 60"7117264 1 Carriage, Side Tilt - 72"

2 7065482 2 Pad, Wear3 8303739 2 HHCS, 5/16-18 x 1-1/4"4 8305626 2 Nut, Hex Lock 5/16-185 7117204 1 Base, Pivot6 7077501 1 Pin, Cyl. Base7 7077511 1 Pin, Cyl. Rod8 7077481 2 Spacer9 8065634 1 Bushing, Self Align

10 8642001 1 Ring, Snap11 8642235 4 Ring, Snap12 8760117 2 Connector, Straight, SAE 6 - male JIC 37° x male str. thd. o-ring13 8584001 1 Tie Wrap14 2711992 2 Hose Assembly15 8760110 2 Connector, Straight, SAE 6-8 - male JIC 37° x male str. thd. o-ring16 8430006 1 Quick Disconnect, Male, SAE 8-8ORB - female internal (Includes Item 17)17 8640029 1 Seal, Nose (Not Shown)18 8430005 1 Quick Disconnect, Female, SAE 8-8ORB - female internal (Includes Items 19, 20 & 21)19 8640029 1 Seal, Nose (Not Shown)20 8640028 1 Seal, Coupler Body (Not Shown)21 8640032 1 Back-Up Ring, Coupler Body Seal (Not Shown)22 8541433 1 Plug, Pipe, Skt. Hd. - 1/8" NPTF23 8420053 1 Cap, Dust #824 8420055 1 Plug, Dust #825 7125741 1 Molding26 7085411 1 Pin, Pivot27 7085501 1 Collar, Pin Locking28 8303770 1 HHCS, 3/8-16 x 2-3/4"29 8305645 1 Nut, Hex Lock 3/8-16 ESNA 30 7128772 1 Shaft, Fork Pivot 48"

7128792 1 Shaft, Fork Pivot 60"7128802 1 Shaft, Fork Pivot 72"

31 7086471 2 Hub, Lock32 8303634 2 HHCS, 5/8-11 x 4"33 8305643 2 Nut, Hex Lock 5/8-1134 7097523 2 Fork, Pallet 48" x 4" x 2" (4,000 lb. Rating) - 8042 Only

7097543 2 Fork, Pallet 48" x 4" x 2.25" (5,000 lb. Rating) - 10042/10054 Only 7097533 2 Fork, Lumber (Not Shown)7085073 6 Fork, Blocking (Not Shown)

35 8307203 2 Washer, Flat Heavy36 7070191 AR Shim37 4108232 1 Decal, Capacity Chart38 7119341 1 Plate, Capacity

8042/10042/10054 Rev. 12/97

246

SECTION 9

OUTRIGGERS(10042/10054 Only)

1

2

34

5

6

7

8

910

11 1213

14

15

16

1718

1920

2122

23

24

25

26

2728

3

21

21

17

See also“Outrigger Cylinder” 1

PH0402

10042/10054 Rev. 2/00

247

SECTION 9


OUTRIGGERS(10042/10054 Only)

1 8305643 3 Nut, Hex Lock Elastic 5/8-11 2 7115432 1 Plate, Boom Stop 5-1/4" Long (S/N 0807 & Before)

7110002 1 Plate, Boom Stop 12-1/4" Long (S/N 0808 & After)3 8769159 2 Cover Plate 4 8769160 1 Safety Plate 5 8769158 1 Clamp, Single 3" (2 Halves) 6 8307107 AR Washer, Flat 5/8" 7 8303717 2 HHCS, 5/8-11 x 7-1/2" Grade 5 8 7124491 2 Conduit, 1.0 I.D. x 15.5"9 8303655 1 HHCS, 5/8-11 x 4-1/2" Grade 5

10 8065063 1 Bushing, 3" I.D. x 2" Long11 7090832 1 Pin, Axle Pivot12 8307912 1 Shim, 3.06 I.D. x .06"13 8307913 1 Shim, 3.06 I.D. x .12"14 8303794 8 HHCS, 3/4-10 x 3-1/2" Grade 815 8310067 8 Nut, Hex Lock Elastic 3/4-1016 7090634 1 Frame, Outrigger17 8520013 10 Grease Fitting18 2716163 2 Cylinder, Outrigger19 8310151 2 HHCS, 1/2-13 x 7" Grade 520 7090871 2 Pin, Cylinder Pivot21 8305644 6 Nut, Hex Lock Elastic 1/2-1322 7091373 2 Leg, Outrigger23 7090891 2 Pin, Leg Pivot24 7090822 2 Pad, Outrigger25 8303629 2 HHCS, 1/2-13 x 4-1/2" Grade 526 7090951 2 Pin, Pad Pivot27 8303628 2 HHCS, 1/2-13 x 3-3/4" Grade 528 7125801 4 Conduit, .75 I.D. x 4.0"

10042/10054 Rev. 2/00

248

SECTION 9

SWING CARRIAGE(Optional)

�

�

<

<

�

�

1

2 3

4

5

6

7

810

911

12

13 14

15

1617

18192021

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

3738

39

40

41

42

L.H. Cylinder

R.H. Cylinder

12

12

12

32

3233

33

3231

9

27

3738

33

25

Attach to Port “R”R.H. Cylinder

Attach to Port “R”L.H. Cylinder

4

98

108

9

8

42

See “Swing Carriage Cylinder”

PH0560

8042/10042/10054 Rev. 2/00

249

SECTION 9


SWING CARRIAGE(Optional)

1 7111994 1 Carriage - 52"7110694 1 Carriage - 72"

2 6608621 1 Cover - Clamp3 8303715 3 HHCS, 5/16-18 x 1-1/2"4 7110702 2 Pin, Carriage Pivot 5 7110494 1 Base, Pivot6 7110712 1 Pin, Cylinder Pivot (Rod End)7 7110722 2 Pin, Cylinder Pivot (Base End)8 8307918 AR Shim, 2" I.D. x 10 Ga.9 8065062 4 Bearing, Self Lube

10 8307904 AR Shim, 2" I.D. x 18 Ga.11 8310161 AR Shim, 1-1/2" I.D. x 10 Ga.12 8760113 4 Connector, Straight, SAE 4 - male JIC 37° x male str. thd. o-ring13 8584001 4 Tie Wrap14 6604662 2 Hose Assembly15 8310160 AR Shim, 1-1/2" I.D. x 18 Ga.16 8430006 1 Quick Disconnect, Male, SAE 8-8ORB - female internal (Includes Item 17)17 8640029 1 Seal, Nose (Not Shown)18 8430005 1 Quick Disconnect, Female, SAE 8-8ORB - female internal (Includes Items 19, 20 & 21)19 8640029 1 Seal, Nose (Not Shown)20 8640028 1 Seal, Coupler Body (Not Shown)21 8640032 1 Back-Up Ring, Coupler Body Seal (Not Shown)22 7062922 1 Bearing, Thrust23 8420053 1 Cap, Dust #824 8420055 1 Plug, Dust #825 8642207 4 Ring, Retaining26 6611752 2 Hose Assembly27 8760313 2 Elbow, 90° SAE 6-8 - male JIC 37° x male str. thd. o-ring28 8760311 1 Elbow, 90° SAE 6 - male JIC 37° x male str. thd. o-ring29 8769132 2 Clamp, Half30 7128782 1 Shaft, Fork Pivot 52"

7128802 1 Shaft, Fork Pivot 72"31 7086471 2 Hub, Lock32 8303634 5 HHCS, 5/8-11 x 4"33 8305643 5 Nut, Hex Lock 5/8-1134 7097523 2 Fork, Pallet 48" x 4" x 2" (4,000 lb. Rating) - 8042 Only

7097543 2 Fork, Pallet 48" x 4" x 2.25" (5,000 lb. Rating) - 10042/10054 Only7097533 2 Fork, Lumber (Not Shown)7085073 6 Fork, Blocking (Not Shown)

35 4107692 2 Chart, Capacity36 4107702 1 Decal, Danger - Tip Over Hazard37 8760409 2 Nut, SAE 6 - JIC 37°38 8760475 2 Reducer, Tube End, SAE 6-4 - JIC 37°39 8770012 1 Elbow, 90° SAE 6-4 - male JIC 37° x male str. thd. o-ring40 8770016 1 Reducer, SAE 4-6 - male str. thd. o-ring x female internal o-ring boss41 4107712 1 Decal, Danger - No Truss Boom42 8580315 2 Plug, Trim 2-1/2" Dia.

8042/10042/10054 Rev. 2/00

250

SECTION 9

SHEET MATERIAL HANDLER(Optional)

1

2

3

4

5

6

7

8

9

10

7

9

4

5

8

10

5

43

65

4

PK0042

8042/10042/10054 Rev. 2/00

251

SECTION 9


SHEET MATERIAL HANDLER(Optional)

1 7112533 1 Fork Support, Right Side2 7112523 1 Fork Support, Left Side3 7112642 2 Backrest Extension, Top4 8303626 6 HHCS, 1/2-13 x 1-1/2"5 8307007 6 Washer, Lock 1/2"6 8305012 4 Nut, Hex 1/2-137 8301456 2 Hitch Pin8 7114941 2 Lock Bar9 8305644 2 Nut, Hex Lock Elastic 1/2-13

10 8307112 2 Washer, Flat 1/2" LT

8042/10042/10054 Rev. 2/00

252

SECTION 9

UTILITY BUCKET(Optional)

1

2

PA0782

8042/10042/10054 Rev. 6/94

253

SECTION 9


UTILITY BUCKET(Optional)

1 7110744 1 Bucket, Utility, 1-1/4 cu. yd. (Includes Item 2)2 4106561 1 Plate, Capacity

8042/10042/10054 Rev. 6/94

254

SECTION 9

PRIMARY INTERMEDIATE BOOM - 10054

��

1

2

3

4

5 678

910

11

12

13

14

15

1617

18

24

25

26

27

28

29

30

31

32

33

34

35

14

37

3839

40

41

19

2021

22

23

43

4445 46

47

93838

39

44

3

4

5

23

5

45

29

27

16

7

7

7

21

20

23

4

15

5

5

6

13

NOTE: Apply Item 19 to All screws that secure wear pads and torque to

31 ± 3 lb/ft (42 ± 4 Nm).

42

14

S/N 0453 & Before Only

S/N 0481 & Before - Complete Early Model Hose Reel Assemblies

Are No Longer Available, Order Item 22.

4

4

4

36

PH0673

PF0791

PH0940

��

48

10054 Rev. 2/00

255

SECTION 9


PRIMARY INTERMEDIATE BOOM - 10054

1 7118854 1 Primary Intermediate Boom (S/N 0454 & After)2 7082362 AR Shim, Wear Pad, (.13" thick)3 7082342 AR Shim, Wear Pad (.075" thick)4 7111572 16 Wear Pad5 7082311 37 Insert, Wear Pad6 8307204 22 Washer, Flat 3/8"7 8307005 37 Washer, Lock 3/8"8 8303620 9 HHCS, 3/8-16 x 1"9 NLA 2 Bushing, Chain Sheave, For Service, Order Kit P/N 7138980

10 NLA 1 Sheave, Retract Chain, For Service, Order Kit P/N 713898011 NLA 1 Pin, Retract Chain Sheave, For Service, Order Kit P/N 713898012 8303681 11 HHCS, 3/8-16 x 3/4"13 8520001 1 Fitting, Lube 1/8" Straight14 8303621 12 HHCS, 3/8-16 x 1-1/2"15 7096882 2 Spacer, Wear Pad .62"16 7126662 2 Bushing, Chain Sheave (S/N 0454 & After)17 7114112 1 Sheave, Extend Chain (S/N 0454 & After)18 7117572 1 Pin, Extend Chain Sheave (S/N 0454 & After)19 8526036 AR Tube, Thread Locking Compound .5cc20 8303624 3 HHCS, 1/2-13 x 1"21 8307007 2 Washer, Lock 1/2"22 7117072 1 Kit, Hose Pulley (Includes Items 23 thru 39)23 7116812 4 Roller Pulley24 7116642 5 Divider25 7116652 1 Bracket, Right Side26 7116662 1 Bracket, Left Side27 7116691 10 Spacer28 8310235 1 Screw, Shoulder 1/2 x 5.00"29 8305645 2 Nut, Lock 3/8-16 Elastic30 8310209 1 HHCS, 1/2-13 x 6.00"31 8305644 1 Nut, Lock 1/2-13 Elastic32 8307206 2 Washer, Flat 1/2" Heavy (.109 thick)33 8310245 1 Screw, Shoulder 1/2 x 4.00"34 8307204 1 Washer, Flat 3/8" Heavy (.083 thick)35 7096702 2 Spacer, Wear Pad (1/2" thick)36 8303679 2 HHCS, 3/8 x 1.75"37 8303675 2 HHCS, 3/8 x 1.25"38 8307204 10 Washer, Flat 3/8"39 8307005 4 Washer, Lock 3/8"

ITEMS 40 thru 47 for S/N 0453 & Before40 7110042 1 Yoke, Extend Chain41 7117542 1 Pin, Extend Chain Sheave (Or: Order Kit 7117534 which includes

greaseable sheave pins and bushings for both primary and secondary intermediate booms)

42 8303634 1 HHCS, 5/8-11 x 4"43 8305643 1 Nut, Hex Lock ESNA 5/8-1144 8065214 2 Bearing, Mini Side Flange Mount45 7117502 2 Bushing, Extend Chain Sheave46 7114112 1 Sheave, Extend Chain47 NLA 1 Primary Intermediate Boom (Order Items 1, 16 thru 22)

KITS

48 7138980 1 Kit, Retract Chain Sheave (Includes Items 9 thru 11, New Hardware forRear Boom Cover and Instructions)

10054 Rev. 2/00

256

SECTION 9

SECONDARY INTERMEDIATE BOOM - 10054

1

23

4

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

21

22

23

2425

26

2728

7

8

6

78

20

11

11

6

Hose Carrier(Reference Only)

56 12

11

186

24

17

186

11

10NOTE: Apply Item 26 to All screws that secure wear pads and torque to

31 ± 3 lb/ft (42 ± 4 Nm).

10

1010

10

22

PH0683

PH0940

��

2930

PF0791

10054 Rev. 2/00

257

SECTION 9


SECONDARY INTERMEDIATE BOOM - 10054

1 7117414 1 Secondary Intermediate Boom (S/N 0884 & Before)7118692 1 Kit, Secondary Intermediate Boom (S/N 0885 & After) includes clevis,

link and hardware 2 7112732 1 Support, Hose Clamp3 8305624 4 Nut, Hex Lock ESNA 1/4-204 8310026 4 HHCS, 1/4-20 x 3/4"5 8303679 6 HHCS, 3/8-16 x 1-3/4"6 8307005 34 Washer, Lock 3/8"7 7082362 AR Shim, Wear Pad, (.13" thick)8 7082342 AR Shim, Wear Pad, (.07" thick)9 7096882 2 Spacer, Wear Pad, .62"

10 7111572 15 Wear Pad11 7082311 34 Insert, Wear Pad12 NLA 2 Bushing, Chain Sheave, For Service, Order Kit P/N 713898013 NLA 1 Sheave, Retract Chain, For Service, Order Kit P/N 713898014 NLA 1 Pin, Retract Chain Sheave, For Service, Order Kit P/N 713898015 8307007 1 Washer, Lock 1/2"16 8303624 2 HHCS, 1/2-13 x 1"17 8303681 11 HHCS, 3/8-16 x 3/4"18 8307204 18 Washer, Flat 3/8"19 NLA 1 Pin, Extend Chain Sheave (S/N 0453 & Before) For Service, Order Kit P/N 7117534

7117582 1 Pin, Extend Chain Sheave (S/N 0454 & After)20 7096702 3 Spacer, Wear Pad .50"21 8303620 6 HHCS, 3/8-16 x 1"22 8303621 6 HHCS, 3/8-16 x 1-1/2"23 8303634 1 HHCS, 5/8-11 x 4"24 NLA 2 Bushing, Chain Sheave (S/N 0453 & Before) For Service, Order Kit P/N 7117534

7117502 2 Bushing, Chain Sheave (S/N 0454 & After)25 7114032 1 Sheave, Extend Chain26 8526036 AR Tube, Thread Locking Compound .5cc27 8305643 1 Nut, Hex Lock ESNA 5/8-11 28 8520001 1 Fitting, Lube 1/8" Straight

KITS

29 7138980 1 Kit, Retract Chain Sheave (Includes Items 12 thru 14, New Hardware forRear Boom Cover and Instructions)

30 7117534 1 Kit, Extend Chain Sheave (S/N 0453 & Before) includes greaseable sheavepins and bushings for both primary and secondary intermediate booms

10054 Rev. 2/00

258

SECTION 9

INNER BOOM - 10054

1

2

3

4

5678

10

11

12

14

15

16

17

1819

20

21

22

23

24 25

26

27

NOTE: Apply Item 27 to All screws that secure wear pads and torque to

31 ± 3 lb/ft (42 ± 4 Nm).

3

9

10

13

21

11

33

14

4

48

7

3

26

5

29

5

28

34

3536

32 25

37

30 3731

31

25

30

PH0662

PH0940

Hose Carrier(Reference Only)

S/N 1933 & After

10054 Rev. 2/00

259

SECTION 9


INNER BOOM - 10054

1 7118682 1 Kit, Inner Boom (S/N 0884 & Before) includes bushings, chain links,hardware and chain clevis

7117133 1 Inner Boom (S/N 0885 & After)2 8303621 6 HHCS, 3/8-16 x 1-1/2"3 8307005 16 Washer, Lock 3/8"4 7082311 16 Insert, Wear Pad5 7111572 7 Wear Pad6 7096702 2 Spacer, Wear Pad, .50"7 7082362 AR Shim, Wear Pad, (.13" thick)8 7082342 AR Shim, Wear Pad, (.07" thick)9 8303681 10 HHCS, 3/8-16 x 3/4"

10 8307204 10 Washer, Flat 3/8"11 7095312 2 Bushing, Quick Attach Pivot12 8305624 4 Nut, Hex Lock ESNA 1/4-2013 8520021 1 Fitting, Lube, 1/8" 90°14 8520013 3 Fitting, Lube, 1/8" Straight15 8305644 1 Nut, Hex Lock Elastic 1/2-1316 7083992 1 Pin, Attachment Tilt Cylinder (rod end)17 8305643 1 Nut, Hex Lock Elastic 5/8-1118 7095352 1 Pin, Pivot, Quick Attach19 8303666 1 HHCS, 5/8-11 x 5"20 7095522 1 Pin, Attachment Tilt Cylinder (base end)21 8642224 2 Ring, Retaining. 2" DIA.22 8303772 1 HHCS, 1/2-13 x 5"23 8303540 4 HHCS, 1/4-20 x 1"24 7114922 1 Guide25 8305645 6 Nut, Hex Lock ESNA 3/8-1626 8303620 5 HHCS, 3/8-16 x 1"27 8526036 AR Tube, Thread Locking Compound .5cc 28 7125811 1 Conduit, Plastic 3/4 x 8.0029 5746411 2 Molding, 3.0"30 7110172 2 Hose Carrier, Guide (S/N 1933 & After)31 7127862 2 Guide Support, Rear (S/N 1933 & After)32 7127852 1 Guide Support, Front (S/N 1933 & After)33 7125741 1 Molding, Edge Protector34 8307918 2 Washer, Shim 2.00 x 3.50 x 0.13435 8310093 AR Washer, Shim 2.00 x 3.50 x 0.07536 8307904 AR Washer, Shim 2.00 x 3.50 x 0.04837 8303679 4 HHCS, 3/8-16 x 1.75

10054 Rev. 2/00

260

SECTION 9

BOOM EXTEND CHAINS - 8042 AND 10042

1

2

3

4 5

6

7

8

12

1

23

9

10 11

2

Inner Boom(Ref.)

IntermediateBoom(Ref.)

Outer Boom(Ref.)Inner Boom

(Ref.)

62

Outer Boom(Ref.)

PH0821

��

PF0791

13

8042/10042 Rev. 2/00

261

SECTION 9


BOOM EXTEND CHAINS - 8042 AND 10042

1 NLA 2 Chain, 4 x 6 Link - 194.25" Long (S/N 11144 & Before)(For Service, Order Kit P/N 7138738)

8127014 2 Chain, 6 x 6 Link (S/N 11145 & After)2 8642237 8 Retaining Ring, 1/4" Dia.3 8124126 4 Pin, Chain Clevis4 8310019 2 Bolt, Shoulder 3/8-16 x 1-1/2"5 8310020 1 Bolt, Shoulder 1/2-13 x 1-1/2"6 7089781 2 Yoke, Extend Chain7 8305645 2 Nut, Hex Lock Elastic 3/8-168 8305644 1 Nut, Hex Lock Elastic 1/2-139 NLA 2 Clevis, 4 x 6 Chain (S/N 11144 & Before) (For Service, Order Kit P/N 7138738)

7119362 2 Clevis, 6 x 6 Chain (S/N 11145 & After)10 8307104 2 Washer, Flat 3/4"11 8305646 2 Nut, Hex Lock Elastic 3/4-1612 NLA 2 Clevis, 4 x 6 Chain (S/N 11144 & Before) (For Service, Order Kit P/N 7138738)

7119372 2 Clevis, 6 x 6 Chain (S/N 11145 & After)

KITS

13 7138738 1 Kit, Extend Chain (Replaces 4 x 6 Link Chain with 6 x 6 Link Chain)

8042/10042 Rev. 2/00

262

SECTION 9

BOOM RETRACT CHAIN - 8042 AND 10042(S/N 1084 & Before)

1

2

3

4

6

7

Intermediate Boom(Ref.)

Outer Boom(Ref.)

Inner Boom(Ref.)

1

2

3

45

6

Inner Boom (Ref.)

Inner Boom(Ref.)

Outer Boom(Ref.) 2

2

PH0851

8042/10042 Rev. 2/00

263

SECTION 9


BOOM RETRACT CHAIN - 8042 AND 10042(S/N 1084 & Before)

1 7120191 1 Kit, 6 x 6 Retract Chain(Includes 6 x 6 chain, 4 of Item 2, 2 of Item 3 & 2 of Item 4)

2 8642237 4 Retaining Ring, 1/4" Dia.3 8124126 2 Pin, Chain Clevis4 7119362 2 Clevis, 6 x 6 Chain5 8307104 1 Washer, Flat 3/4"6 8305646 2 Nut, Hex Lock Elastic 3/4-167 8305018 1 Nut, Hex 3/4-16

8042/10042 Origin 12/97

264

SECTION 9

BOOM RETRACT CHAIN - 8042 AND 10042(S/N 1085 & After)

12 3

5

7

8

9

Intermediate Boom(Ref.)

Outer Boom(Ref.)

Inner Boom(Ref.)

Inner Boom(Ref.)

Outer Boom(Ref.)

12 3

4

6 10

2

2

7

PH0831

8042/10042 Rev. 2/00

265

SECTION 9


BOOM RETRACT CHAIN - 8042 AND 10042(S/N 1085 & After)

1 7119351 1 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)

2 8642237 4 Retaining Ring, 1/4" Dia.3 8124126 2 Pin, Chain Clevis4 7119362 1 Clevis, 6 x 6 Chain5 7119372 1 Clevis, 6 x 6 Chain6 8305646 1 Nut, Hex Lock Elastic 3/4-167 7117031 2 Link, Chain Anchor8 8310019 2 Bolt, Shoulder 1/2 x 1-1/2"9 8305645 2 Nut, Lock Elastic 3/8-16

10 8307104 1 Washer, Flat 3/4"

8042/10042 Origin 12/97

266

SECTION 9

BOOM EXTEND CHAINS - 10054

��4�� 6��0��$

��

1

23

4 5

67

8

9

10

11

12

13

14

1617

18

201

236

2

2

12

13 15

19

Outer Boom(Ref.) Secondary Intermediate

Boom (Ref.)

Inner Boom (Ref.)

Primary Intermediate Boom (Ref.)

Primary Interm

ediate

Boom

Inner Boom

Outer Boom

Secondary Intermediate

Boom

PH0861

Extend Chains (Ref.)

��

PF0791

21

10054 Rev. 2/00

267

SECTION 9


BOOM EXTEND CHAINS - 10054

1 NLA 2 Chain, 4 x 6 Link - 194.25" Long (S/N 11144 & Before)(For Service, Order Kit 7138738)

8127014 2 Chain, 6 x 6 Link - 194.25" Long (S/N 11145 & After)2 8642237 8 Retaining Ring, 1/4" Dia.3 8124126 4 Pin, Chain Clevis4 8310019 2 Bolt, Shoulder 3/8-16 x 1-1/2"5 8310020 1 Bolt, Shoulder 1/2-13 x 1-1/2"6 7089781 2 Yoke, Extend Chain7 8305645 2 Nut, Hex Lock Elastic 3/8-168 8305644 1 Nut, Hex Lock Elastic 1/2-139 NLA 2 Clevis, 4 x 6 Chain (S/N 11144 & Before) (For Service, Order Kit P/N 7138738)

7119372 2 Clevis, 6 x 6 Chain (S/N 11145 & After)10 8310205 1 Bolt, Shoulder 5/8-11 x 2-1/2"11 7113982 1 Clevis, 6 x 6 Chain 12 8127009 1 Chain, 6 x 6 Link - 193" Long13 8124131 2 Pin, Chain Clevis (Includes two cotter pins)14 8305643 1 Nut, Lock Elastic 5/8-1115 7113952 1 Clevis, 6 x 6 Chain 16 8310066 1 Washer, Flat 1"17 8310210 1 Nut, Lock Elastic 1" - 1418 NLA 2 Clevis, 4 x 6 Chain (S/N 11144 & Before) (For Service, Order Kit P/N 7138738)

7119362 2 Clevis, 6 x 6 Chain (S/N 11145 & After)19 8307104 2 Washer, Flat 3/4"20 8305646 2 Nut, Lock Elastic 3/4-16

KITS

21 7138738 1 Kit, Extend Chain (Replaces 4 x 6 Link Chain with 6 x 6 Link Chain)

10054 Rev. 2/00

268

SECTION 9

BOOM RETRACT CHAINS - 10054(S/N 0884 & Before)

��4�� 6��0��$

��

1

2

3

5

9

2

3 4

78

9

6

89

10

1

2

3

10

6

9

2

2

2

2 3

Inner Boom(Ref.)

Secondary IntermediateBoom (Ref.)

Outer Boom (Ref.)

Primary Interm

ediate Boom Inner Boom

Outer Boom

Secondary

Intermediate Boom

42

PH0891

��

PF0791

11

10054 Rev. 2/00

269

SECTION 9


BOOM RETRACT CHAINS - 10054(S/N 0884 & Before)

1 8305018 1 Nut, Hex Jam 3/4-162 8642237 8 Retaining Ring, 1/4"3 8124126 4 Pin, Chain Clevis4 NLA 1 Chain, 4 x 6 - 164.25" Long (For Service, Order Kit P/N 7120191)5 NLA 2 Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7120191)6 8127008 1 Chain, 6 x 6 - 164.25" Long7 NLA 1 Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7120191)8 8307104 2 Washer, Flat 3/4"9 8305646 4 Nut, Hex Lock Elastic 3/4-16

10 7119362 2 Clevis, 6 x 6 Chain

KITS

11 7120191 1 Kit, Retract Chain (Replaces 4 x 6 Link Chain with 6 x 6 Link Chain)

10054 Rev. 2/00

270

SECTION 9

BOOM RETRACT CHAINS - 10054(S/N 0885 thru 1084)

��4�� 6��0��$

��

2

3

4

5 6 7 9

5

6 7

1011

12

5 6

1112

13

1

2

3

58

9

Retract Chains (Ref.)

5

5

5

5 61

Inner Boom(Ref.)

Secondary IntermediateBoom (Ref.)

Outer Boom (Ref.)

Primary Interm

ediate Boom Inner B

oom

Outer Boom

Secondary

Intermediate Boom

PH0870

��

PF0791

14

10054 Rev. 2/00

271

SECTION 9


BOOM RETRACT CHAINS - 10054(S/N 0885 thru 1084)

1 8310019 4 Bolt, Shoulder 3/8-16 x 1-1/22 7117031 4 Link3 8305645 4 Nut, Hex Lock Elastic 3/8-164 NLA 1 Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7119351)5 8642237 8 Retaining Ring, 1/4"6 8124126 4 Pin, Chain Clevis7 NLA 1 Chain, 4 x 6 - 164.25" Long (For Service, Order Kit P/N 7119351)8 7119372 1 Clevis, 6 x 6 Chain9 8127008 1 Chain, 6 x 6 Link - 164.25" Long

10 NLA 1 Clevis, 4 x 6 Chain (For Service, Order Kit P/N 7119351)11 8307104 2 Washer, Flat 3/4"12 8305646 2 Nut, Hex Lock Elastic 3/4-1613 7119362 1 Clevis, 6 x 6 Chain

KITS


10054 Rev. 2/00

272

SECTION 9

BOOM RETRACT CHAINS - 10054(S/N 1085 & After)

��4�� 6��0��$

��

2

3

4

5 6 7 9

5

6 7

1011

12

5 6

1112

13

1

2

3

58

9

Retract Chains (Ref.)

5

5

5

5 61

Inner Boom(Ref.) Secondary

IntermediateBoom (Ref.)

Outer Boom (Ref.)

Primary Interm

ediate Boom Inner B

oom

Outer Boom

Secondary

Intermediate Boom

PH0870

��

PF0791

14

10054 Rev. 2/00

273

SECTION 9


BOOM RETRACT CHAINS - 10054(S/N 1085 & After)

1 8310019 4 Bolt, Shoulder 3/8-16 x 1-1/2"2 7117031 4 Link3 8305645 4 Nut, Hex Lock Elastic 3/8-164 NLA 1 Clevis, 4 x 6 Chain (S/N 11568 & Before) (For Service, Order Kit P/N 7119351)

7119372 1 Clevis, 6 x 6 Chain (S/N 11569 & After)5 8642237 8 Retaining Ring 1/4"6 8124126 4 Pin, Chain Clevis7 NLA 1 Chain, 4 x 6 Link - 164.25" Long (S/N 11568 & Before)

(For Service, Order Kit P/N 7119351)8127008 1 Chain, 6 x 6 Link - 164.25" Long (S/N 11569 & After)

8 7119372 1 Clevis, 6 x 6 Chain9 8127008 1 Chain, 6 x 6 Link - 164.25" Long

10 NLA 1 Clevis, 4 x 6 Chain (S/N 11568 & Before) (For Service, Order Kit P/N 7119351)7119362 1 Clevis, 6 x 6 Chain (S/N 11569 & After)

11 8307104 2 Washer, Flat 3/4"12 8305646 2 Nut, Hex Lock Elastic 3/4-1613 7119362 1 Clevis, 6 x 6 Chain

KITS


10054 Rev. 2/00

274

SECTION 9

TRUSS BOOM 12 AND 15 FT. (Optional)

1

2

34

5

6

7

8

9

1

Torque to85 lb/ft

(115 Nm)

12 ft. Truss Boom8042 Only

15 ft. Truss Boom10042 & 10054 Only

PH0970

8042/10042/10054 Origin 12/97

275

SECTION 9


TRUSS BOOM 12 AND 15 FT.(Optional)

1 7113024 1 12' Truss Boom - 8042 (Includes Items 2 thru 9)7112804 1 15' Truss Boom - 10042 &10054 (Includes Items 2 thru 9)

2 8382017 1 Pintle Hook3 8310195 4 HHCS, 1/2-13 x 1.75"4 8307112 4 Washer, Plain 1/2 SAE5 8305644 4 Nut, Hex Lock Elastic 1/2-136 4107182 2 Decal, Name7 4107822 2 Decal, Swinging Load8 4107832 2 Decal, Length/Capacity9 4107812 2 Chart, Capacity

8042/10042/10054 Origin 12/97

287

SECTION 10GENERAL TROUBLESHOOTING

HYDRAULICHydraulic Diagnostic Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2898042 Hydraulic Diagram & Testing (S/N 1167 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 - 2918042 Hydraulic Diagram & Testing (S/N 1168 thru 2194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 - 2938042 Hydraulic Diagram & Testing (S/N 2195 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 - 2958042 Hydraulic Diagram & Testing (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 - 29710042 Hydraulic Diagram & Testing (S/N 1167 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 - 29910042 Hydraulic Diagram & Testing (S/N 1168 thru 2194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 - 30110042 Hydraulic Diagram & Testing (S/N 2195 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 - 30310042 Hydraulic Diagram & Testing (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 - 30510054 Hydraulic Diagram & Testing (S/N 1167 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 - 30710054 Hydraulic Diagram & Testing (S/N 1168 thru 2194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 - 30910054 Hydraulic Diagram & Testing (S/N 2195 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 - 31110054 Hydraulic Diagram & Testing (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 - 3138042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram (S/N 9908 & Before) . . . 3148042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram (S/N 9909 & After) . . . . 3158042/10042 Hoist and Extend Circuits (S/N 8540 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3168042/10042 Hoist and Extend Schematic (S/N 8540 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3178042/10042 Hoist and Extend Circuits (S/N 8541 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3188042/10042 Hoist and Extend Schematic (S/N 8541 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3198042/10042 Hoist and Extend Circuits (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3208042/10042 Hoist and Extend Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32110054 Hoist and Extend Circuits (S/N 8540 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32210054 Hoist and Extend Schematic (S/N 8540 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32310054 Hoist and Extend Circuits (S/N 8541 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32410054 Hoist and Extend Schematic (S/N 8541 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32510054 Hoist and Extend Circuits (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32610054 Hoist and Extend Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3278042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 2194 & Before) . . . . . . . 3288042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2194 & Before) . . . . . 3298042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 2195 thru 9908) . . . . . . . 3308042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2195 thru 9908) . . . . 3318042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits (S/N 9909 & After) . . . . . . . . . 3328042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 9909 & After) . . . . . . 3338042/10042/10054 Steering Circuit (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3348042/10042/10054 Steering Schematic (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3358042/10042/10054 Steering Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3368042/10042/10054 Steering Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3378042/10042/10054 Service Brake & De-Clutch Circuits (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . 3388042/10042/10054 Service Brake & De-Clutch Schematic (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . 3398042/10042/10054 Service Brake Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3408042/10042/10054 Service Brake Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34110042/10054 Outrigger Schematic (S/N 10881 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34210042/10054 Outrigger Schematic (S/N 10882 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

ELECTRICAL8042/10042 Electrical Schematic (S/N 0291 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3448042/10042 Electrical Schematic (S/N 0292 thru 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3458042/10042 Electrical Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34610054 Electrical Schematic (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34710054 Electrical Schematic (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34810042 Outrigger Logic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34910054 Outrigger Logic Circuit (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35010054 Outrigger Logic Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

288

8042/10042/10054 Lighting System Circuit (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3528042/10042/10054 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3538042/10042/10054 Cranking Circuit (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3548042/10042/10054 Cranking Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3558042/10042 Steer Select Circuit (S/N 0291 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3568042/10042/10054 Steer Select Circuit (S/N 0292 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3578042/10042 Stabilizer Circuit (S/N 0291 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3588042/10042 Stabilizer Circuit (S/N 0292 thru S/N 9908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3598042/10042 Stabilizer Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36010054 Stabilizer Circuit (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36110054 Stabilizer Circuit (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

STABIL-TRAK SYSTEMStabil-TRAK System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 - 3678042/10042 Stabil-TRAK System Troubleshooting (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . 3688042/10042 Stabil-TRAK Electrical Circuit Ignition “OFF”(S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . 3698042/10042 Stabil-TRAK Electrical Circuit Free Pivot Mode (S/N 9908 & Before) . . . . . . . . . . . . . . . . . 3708042/10042 Stabil-TRAK Hydraulic Circuit Free Pivot Mode (S/N 9908 & Before) . . . . . . . . . . . . . . . . . 3718042/10042 Stabil-TRAK Electrical Circuit Final Positioning Mode (S/N 9908 & Before) . . . . . . . . . . . . 3728042/10042 Stabil-TRAK Hydraulic Circuit Final Positioning Mode (S/N 9908 & Before) . . . . . . . . . . . . 3738042/10042 Stabil-TRAK Electrical Circuit Locked Mode (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . 3748042/10042 Stabil-TRAK Hydraulic Circuit Locked Mode (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . 3758042/10042 Stabil-TRAK System Troubleshooting (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . 3768042/10042 Stabil-TRAK Electrical Circuit Ignition “OFF” (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . 3778042/10042 Stabil-TRAK Electrical Circuit Free Pivot Mode (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 3788042/10042 Stabil-TRAK Hydraulic Circuit Free Pivot Mode (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 3798042/10042 Stabil-TRAK Electrical Circuit Final Positioning Mode (S/N 9909 & After) . . . . . . . . . . . . . . 3808042/10042 Stabil-TRAK Hydraulic Circuit Final Positioning Mode (S/N 9909 & After) . . . . . . . . . . . . . . 3818042/10042 Stabil-TRAK Electrical Circuit Locked Mode (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . 3828042/10042 Stabil-TRAK Hydraulic Circuit Locked Mode (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . 38310054 Stabil-TRAK System Troubleshooting (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . . . . . . . . 384 - 38510054 Stabil-TRAK Electrical Circuit Boom Extend Mode 1 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 38610054 Stabil-TRAK Electrical Circuit Boom Extend Mode 2 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 38710054 Stabil-TRAK Electrical Circuit Boom Extend Mode 3 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 38810054 Stabil-TRAK Electrical Circuit Boom Extend Mode 4 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 38910054 Stabil-TRAK Electrical Circuit Boom Extend Mode 5 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 39010054 Stabil-TRAK Electrical Circuit Boom Extend Mode 6 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 39110054 Stabil-TRAK Electrical Circuit Boom Extend Mode 7 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 39210054 Stabil-TRAK Electrical Circuit Boom Extend Mode 8 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 39310054 Stabil-TRAK Electrical Circuit Boom Extend Mode 9 (S/N 9908 & Before) . . . . . . . . . . . . . . . . . . 39410054 Stabil-TRAK System Troubleshooting (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 - 39710054 Stabil-TRAK Electrical Circuit Boom Extend Mode 1 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 39810054 Stabil-TRAK Electrical Circuit Boom Extend Mode 2 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 39910054 Stabil-TRAK Electrical Circuit Boom Extend Mode 3 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40010054 Stabil-TRAK Electrical Circuit Boom Extend Mode 4 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40110054 Stabil-TRAK Electrical Circuit Boom Extend Mode 5 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40210054 Stabil-TRAK Electrical Circuit Boom Extend Mode 6 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40310054 Stabil-TRAK Electrical Circuit Boom Extend Mode 7 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40410054 Stabil-TRAK Electrical Circuit Boom Extend Mode 8 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 40510054 Stabil-TRAK Electrical Circuit Boom Extend Mode 9 (S/N 9909 & After) . . . . . . . . . . . . . . . . . . . 406

289

SECTION 10

Rev. 2/00

SECTION 10

OmniQuip Parts Worldwide is pleased to announce the availability of two valuable diagnostictools. The Sky Trak Pressure Test Kit and Flowmeter Kit. Both kits feature a durablepolyethylene carrying case for demanding field service conditions. For price and availability, callOmniQuip Parts Worldwide at (888) 872-5123.

Pressure Test Kit• Contains all the fittings and hoses

required to test Sky Trak Telescopic Material Handlers

• 300, 1000 and 4000 psi gauges for accurate testing of high and low pressure circuits

• Includes laminated Test Diagrams and Testing Procedures for troubleshooting Sky Trak Telescopic Material Handlers

• 13" x 18" x 7" durable carrying case

Flowmeter Kit• Use Flowmeter Kit to pinpoint hydraulic

system faults.• Includes flowmeter with load valve,

magnetic base, photo tachometer head and flex arm

• Measures up to 60 GPM and 6000 psi• Bi-directional for unrestricted connection

and simplified testing• Internal by-pass protects system and

tester from over-pressure• 16" x 22" x 7" durable carrying case

Ordering & Price Information

��

Part Number Description Approximate Weight Price and Availability

7133413 Hydraulic Pressure Test Kit 16 lbs. Consult Factory

1321107 Hydraulic Flowmeter Kit 28 lbs. Consult Factory

PH1410

PH1420

SECTION 10

290

8042 Hydraulic Diagram (S/N 1167 & Before)

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8990214-002(MH0280)

Rev. 10/97

291

SECTION 10

8042 Hydraulic Testing (S/N 1167 & Before) Engine Information

Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpmFull Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm

Hydraulic Oil Information

Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter)Capacity - System . . . . . . . . . . . . . .47.3 gal. (179 liter)

Note 1: To adjust relief settings or pressure reducing settings, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

*Note 2: On units with S/N 0654 & Before. If the low brake pressure kit has been installed, as offered in Service Bulletin STB-2076, issued 5-29-95, refer to test location .

The hydraulic oil temperature for the pump flow test should be between 100° F (38° C) and 120° F (49° C) (tank hot to the touch) during testing.

Equipment Needed To Perform TestsFrom Kit P/N 7118782

Circuit Gauge Fittings

4,000 PSI Gauge(275,6 bar)

#12 Run Tee Swivel NutEnd Reducer #12-8PD38TX Test Nipple


#8 Run Tee Swivel NutPD38TX Test Nipple


#4 UnionPD34BTX Test Nipple

300 PSI Gauge(20,7 bar)

Connector STR. THD. #4PD34BTX Test Nipple


#4 Run Tee Swivel NutPD34BTX Test Nipple


#6 Elbow 90° Swivel NutPD36BTX Test Nipple

TEST LOCATION Hydraulic Pump Flow Test

To check flow readings a flow meter capable of measuring 60 GPM (3,8 ltr/sec) and a load valve capable of 6,000 psi (413,4 bar) will be required (not included with kit P/N 7118782). 2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ± 25 rpm — Flow rate should be 39 to 43 GPM (2,5 to 2,7 ltr/sec)

TEST LOCATION

ADJUST. LOCATION

COMPONENT DESCRIPTION

PRESSURE READINGS PRESSURE TEST PROCEDURES

Pump Standby Pressure

550 ± 50 psi(37,9 ± 3,4 bar)

Loosen load sense line at location to bleed off pressure and then retighten line. With engine at idle and all hydraulic functions in neutral position, check pump standby pressure.

Pump Pressure Compensator

2,950 ± 50 psi(203,3 ± 3,4 bar)

With engine at idle fully retract boom extend cylinder and hold. Check pump maximum pressure.

Priority Valve Steering Relief

2,500 ± 50 psi(172,3 ± 3,4 bar)

With engine at idle turn the steering wheel all the way to the left or right and hold while checking pressure. If pressure is not correct, adjust or replace the relief valve cartridge in the priority valve (See Note 1).

Attachment Tilt Port Relief

3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY

Pressure Reducing Valve In Pressure Reducing Valve Block AndPark Brake Release

425 ± 25 psi(29,3 ± 1,7 bar)

With engine at idle and park brake released check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note 1).

Pressure Reducing Valve In Axle Stabilizer Valve Block

60 ± 10 psi(4,1 ± 0,7 bar)

With engine at idle and boom in the down position check pressure. If pressure is not correct, adjust or replace the cartridge in the axle stabilizer valve (See Note 1).

Relief Check Valve In Axle Stabilizer Valve Block

100 psi Minimum(6,9 bar)

With engine at idle and boom down, while frame tilting to the left check pressure.

TransmissionDe-Clutch

425 ± 25 psi(29,3 ± 1,7 bar)

With engine at idle and park brake engaged check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note 1).

Service Brakes (*See Note 2)

(S/N 0654 & Before)

425 ± 25 psi (29,3 ± 1,7 bar)

With engine at idle depress the service brakes and check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note 1).

Load Sense Variable0 to 2,950 psi

(0 to 203,3 bar)

With engine at idle operate a specific function (Boom, Frame Tilt, Attachment Tilt, Auxiliary or Steering) and check pressure.

Service Brakes(S/N 0655 thru 1167)

350 ± 25 psi(24,1 ± 1,7 bar)

With engine at idle depress the service brakes and check pressure. If pressure is not correct, recheck pressure reducing valve pressure.

9

1

2

3 5

4

6 9

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

9 N/A

Rev. 10/97

SECTION 10

292

8042 Hydraulic Diagram(S/N 1168 thru 2194)8042 HYDRAULIC DIAGRAM (S/N 1168 & After)

FRAME TILTCYLINDER

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

ATTACHMENTTILT CYLINDER

SLAVECYLINDER

OPERATOR'SCAB

ATTACHMENT TILT FORWARD

ATTACHMENT TILT BACK

T

SB

V

BRKP

AXLESTABILIZER

VALVEBLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

SLAVECYLINDER

AB

PT

FrameTilt

Aux.Hyd.

BoomExt.

BoomHoist

RIGHT HOIST CYLINDERLEFT HOIST CYLINDER

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

MAINPUMP

SR

TC

T TPC1

C2

AUXILIARYHYDRAULICS

(Optional)

PRESSUREREDUCING

VALVE BLOCK(This valve is boltedto the Axle Stabilizer

Valve Block)

PT

LS

PT

LS

12

3LS

EF CF

T P

CONTROLDRAIN

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

MALE

FEMALE

STEERSELECTVALVE

CONTROLVALVE

LSOUT

12

4

45

6

7

LOAD SENSE (LS)

3

2

STEERCYL.

STEERCYL.

3

STEERCYL.

STEERCYL.

8

TAP

AttachTilt

5

6

8990272-001(PH0980)

Rev. 10/97

293

SECTION 10

8042 Hydraulic Testing (S/N 1168 thru 2194)Engine Information




Note: To adjust relief settings or pressure reducing settings, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

















To check flow readings a flow meter capable of measuring 60 GPM (3,8 ltr/sec) and a load valve capable of 6,000 psi (413,4 bar) will be required (not included with kit P/N 7118782).

2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ± 25 rpm — Flow rate should be 39 to 43 GPM (2,5 to 2,7 ltr/sec)

TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)

With engine at idle turn the steering wheel all the way to the left or right and hold while checking pressure. If pressure is not correct, adjust (inside of “T” port) or replace the relief valve cartridge in the priority valve (See Note).


3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)

With engine at idle and park brake released check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note).


60 ± 10 psi(4,1 ± 0,7 bar)

With engine at idle and boom in the down position check pressure. If pressure is not correct, adjust or replace the cartridge in the axle stabilizer valve (See Note).





500 +25/-0 psi(34,5 +1,7/-0 bar)

With engine at idle and park brake engaged check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note).

Service Brakes 500 +25/-0 psi(34,5 +1,7/-0 bar)

With engine at idle depress the service brakes and check pressure. If pressure is not correct, adjust or replace the cartridge in the pressure reducing valve (See Note).


(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

Rev. 10/97

SECTION 10

294

8042 Hydraulic Diagram(S/N 2195 thru 9908)8042 HYDRAULIC DIAGRAM (S/N 1168 & After)

FRAME TILTCYLINDER

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


SLAVECYLINDER

OPERATOR'SCAB



T

SB

V

BRKP

AXLESTABILIZER

VALVEBLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

SLAVECYLINDER

AB

PT

FrameTilt

Aux.Hyd.

BoomExt.

BoomHoist


ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

MAINPUMP

SR

TC

T TPC1

C2

AUXILIARYHYDRAULICS

(Optional)

PRESSUREREDUCING

VALVE BLOCK(This valve is boltedto the Axle Stabilizer

Valve Block)

PT

LS

PT

LS

12

3LS

EF CF

T P

CONTROLDRAIN

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

MALE

FEMALE

STEERSELECTVALVE

CONTROLVALVE

LSOUT

12

4

45

6

7

LOAD SENSE (LS)

3

2

STEERCYL.

STEERCYL.

3

STEERCYL.

STEERCYL.

8

TAP

AttachTilt

5

6

8990309(PH0981)

Rev. 11/99

295

SECTION 10
























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)



275 psi Maximum(18,9 bar)

With engine at idle and boom down, while frame tilting to the left check pressure. If pressure is not correct, recheck adjustment location . If that pressure is correct, replace the cartridge in the axle stabilizer valve.


500 +25/-0 psi(34,5 +1,7/-0 bar)





(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 6

7 N/A

Rev. 11/99

SECTION 10

296

8042 Hydraulic Diagram(S/N 9909 & After)

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8990373(PH1290)

Origin 11/99

297

SECTION 10

8042 Hydraulic Testing (S/N 9909 & After)Engine Information




Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.





PD38TX Test Nipple












To check flow readings a flow meter capable of measuring 60 GPM (3,8 ltr/sec) and a load valve capable of 6,000 psi (413,4 bar) will be required (not included with kit P/N 7133413). A test nipple is supplied at location 7.


TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)

Loosen load sense line at location to bleed off pressure and then retighten line. With engine at idle and all hydraulic functions in neutral position, check pump standby pressure (See Note).


2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)

With engine at idle turn the steering wheel all the way to the left or right and hold while checking pressure. If pressure is not correct, adjust (inside of “T” port) or replace the relief valve cartridge in the priority valve.


3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)








(0 to 203,3 bar)


1

2

3

4

5

6

7

11

6

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 N/A

Origin 11/99

SECTION 10

298


2

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

ATTACHMENT TILTCYLINDER

FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS

PRESSURE REDUCINGVALVE BLOCK

(This valve is bolted to theAxle Stabilizer Valve Block)

RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.

OUTRIGGERVALVE BLOCK

S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

STEERCYL.

STEERCYL.

8

STEERCYL.

STEERCYL.

TAP

4

3

5

6

69

8990215-002(MH0290)

Rev. 10/97

299

SECTION 10
























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


425 ± 25 psi(29,3 ± 1,7 bar)



60 ± 10 psi(4,1 ± 0,7 bar)






425 ± 25 psi(29,3 ± 1,7 bar)



(S/N 0654 & Before)

425 ± 25 psi (29,3 ± 1,7 bar)



(0 to 203,3 bar)



350 ± 25 psi(24,1 ± 1,7 bar)


9

1

2

3 5

4

6 9

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

9 N/A

Rev. 10/97

SECTION 10

300

10042 Hydraulic Diagram (S/N 1168 thru 2194)10042 HYDRAULIC DIAGRAM (S/N 1168 & After)

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS



RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.


S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

2

4

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

6

STEERCYL.

STEERCYL.

8

STEERCYL.

STEERCYL.

TAP

356

8990273-001(PH0990)

Rev. 10/97

301

SECTION 10























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



60 ± 10 psi(4,1 ± 0,7 bar)






500 +25/-0 psi(34,5 +1,7/-0 bar)





(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

Rev. 10/97

SECTION 10

302

10042 Hydraulic Diagram (S/N 2195 thru 9908)10042 HYDRAULIC DIAGRAM (S/N 1168 & After)

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS



RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.


S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

2

4

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

6

STEERCYL.

STEERCYL.

8

STEERCYL.

STEERCYL.

TAP

356

8990308(PH0991)

Rev. 10/97

303

SECTION 10

10042 Hydraulic Testing (S/N 2195 thru 9908) Engine Information























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)






500 +25/-0 psi(34,5 +1,7/-0 bar)





(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 6

7 N/A

Rev. 11/99

SECTION 10

304

10042 Hydraulic Diagram (S/N 9909 & After)

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1

8990374(PH1300)

Origin 11/99

305

SECTION 10










PD38TX Test Nipple














TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)








(0 to 203,3 bar)


1

2

3

4

5

6

7

11

6

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 N/A

Origin 11/99

SECTION 10

306


HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS



RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.


S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

2

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

STEERCYL.

STEERCYL.

8

STEERCYL.

STEERCYL.

TAP

C1T

4

3

5

6

69

8990234-001(MH0300)

Rev. 10/97

307

SECTION 10




Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter)Capacity - System . . . . . . . . . . . . 59.5 gal. (225,2 liter)




















TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


425 ± 25 psi(29,3 ± 1,7 bar)



60 ± 10 psi(4,1 ± 0,7 bar)






425 ± 25 psi(29,3 ± 1,7 bar)



(S/N 0654 & Before)

425 ± 25 psi (29,3 ± 1,7 bar)



(0 to 203,3 bar)



350 ± 25 psi(24,1 ± 1,7 bar)


9

1

2

3 5

4

6 9

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

9 N/A

Rev. 10/97

SECTION 10

308

10054 Hydraulic Diagram (S/N 1168 thru 2194)

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS



RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.


S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

2

4

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

6

8

TAP

C1T

3

STEERCYL.

STEERCYL.

STEERCYL.

STEERCYL.

56

8990274-001(PH1000)

Rev. 10/97

309

SECTION 10
























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



60 ± 10 psi(4,1 ± 0,7 bar)






500 +25/-0 psi(34,5 +1,7/-0 bar)





(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

44

N/A

5 5

6 6

7 N/A

Rev. 10/97

SECTION 10

310

10054 Hydraulic Diagram (S/N 2195 thru 9908)

HYDRAULICRESERVOIR

EXTEND CYLINDER

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

RIGHTFRONTBRAKE

LEFTFRONTBRAKE


FRAME TILTCYLINDER

SLAVECYLINDER



SLAVECYLINDER

BoomExt.

BoomHoist

ParkLock

FUELTANK

TRANSMISSION

Trans.De-

Clutch

PT

LS

12

3LS

EF CF

T P

MAINFILTER25 psi

By Pass

STABILIZERCYLINDER

IN

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

OPERATOR'SCAB

T

SB

V

BRKP

AXLESTABILIZER

VALVE BLOCK

POWERSTEERING

UNIT

L T

P

R

BRAKEVALVE

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

TTP

C1

C2

P

T

STEERSELECTVALVE

CONTROLVALVE

LS



RIGHTOUTRIGGER

CYL.

LEFTOUTRIGGER

CYL.


S

T

P

A1

A2B1 B2


AUXILIARYHYDRAULICS

MALE

FEMALE

2

4

4

3

5

7

LOAD SENSE

MAINPUMP

CONTROLDRAIN

LSOUT

1

2

6

8

TAP

C1T

3

STEERCYL.

STEERCYL.

STEERCYL.

STEERCYL.

56

8990307(PH1001)

Rev. 11/99

311

SECTION 10
























TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)






500 +25/-0 psi(34,5 +1,7/-0 bar)





(0 to 203,3 bar)


1

2

3 5

4

6

7

8

1N/A

7

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 6

7 N/A

Rev. 11/99

SECTION 10

312

10054 Hydraulic Diagram (S/N 9909 & After)

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1

8990375(PH1310)

Origin 11/99

313

SECTION 10










PD38TX Test Nipple














TEST LOCATION

ADJUST. LOCATION




550 ± 50 psi(37,9 ± 3,4 bar)



2,950 ± 50 psi(203,3 ± 3,4 bar)



2,500 ± 50 psi(172,3 ± 3,4 bar)



3,150 ± 50 psi(217 ± 3,4 bar)

CONSULT FACTORY


500 +25/-0 psi(34,5 +1,7/-0 bar)



200 ± 25 psi(13,8 ± 1,7 bar)








(0 to 203,3 bar)


1

2

3

4

5

6

7

11

6

N/A

2 2

N/A N/A

3 3

4

4

N/A 4

5 5

6 N/A

Origin 2/00

SECTION 10

314

8042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram

(S/N 9908 & Before)

0-��./�@��0#A

��%��@/��$A

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PH1320

Origin 2/00

315

SECTION 10

8042/10042/10054 Variable Volume Load Sensing Pump Flow Meter Diagram

(S/N 9909 & After)

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Origin 2/00

SECTION 10

316

8042/10042 Hoist and Extend Circuits(S/N 8540 & Before)

HYDRAULICRESERVOIR

EXTEND CYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

INPark

Brake

Trans.De-

Clutch

12

3

LEFT HOIST CYLINDER

RIGHT HOIST CYLINDER

COUNTER BALANCE VALVE LOCATIONS

HOIST CYLINDERS – Base Side

EXTEND CYLINDER – Rod and Base Sides

LOAD SENSE (LS)

MH0091

Rev. 2/00

317

SECTION 10

8042/10042 Hoist and Extend Schematic(S/N 8540 & Before)

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVETEST

PORT

REAR AXLE VALVE

PRESSUREREDUCING VALVE

PRESSUREREDUCING

VALVE

STEERINGVALVE

OUTRIGGERVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM

HOISTCYLINDER - L.H.

HOISTCYLINDER - R.H.

3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

STEERINGVALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0312

Rev. 02/00

SECTION 10

318

8042/10042 Hoist and Extend Circuits(S/N 8541 thru 9908)

HYDRAULICRESERVOIR

EXTEND CYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

INPark

Brake

Trans.De-

Clutch

12

3

LEFT HOIST CYLINDER





LOAD SENSE (LS)

MH0091

Rev. 2/00

319

SECTION 10

8042/10042 Hoist and Extend Schematic(S/N 8541 thru 9908)

X

X

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVETEST

PORT

REAR AXLE VALVE


PRESSUREREDUCING

VALVE

STEERINGVALVE

OUTRIGGERVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM



3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

STEERINGVALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0620

Origin 2/00

SECTION 10

320

8042/10042 Hoist and Extend Circuits(S/N 9909 & After)

HYDRAULICRESERVOIR

EXTEND CYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

12

3

LEFT HOIST CYLINDER





LOAD SENSE (LS)

Park Brake

MAINPUMP

TRANSMISSION

CONTROLDRAIN

LSOUT

IN

MH0560

Origin 2/00

321

SECTION 10

8042/10042 Hoist and Extend Schematic(S/N 9909 & After)

RESERVOIR

25PSI

TEMP. SWITCH195° F

500 / 600PSI STANDBY

3000PSI

PUMP

REAR AXLE VALVE

BRAKE VALVE

TP

SHUTTLEVALVE

0-45GPM

PRESSUREREDUCINGVALVE


PRIORITYVALVE

STEERINGVALVE

2450-2550PSI

STEERINGVALVE

X

X

X

OUTRIGGERVALVE



3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0630

Origin 2/00

SECTION 10

322

10054 Hoist and Extend Circuits(S/N 8540 & Before)

HYDRAULICRESERVOIR

EXTENDCYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

Trans.De-

Clutch

12

3

LEFT HOIST CYLINDER





BOOM EXTEND

LOCKOUT VALVE

C1

T

LOAD SENSE (LS)

Park Brake

MH0101

Rev. 2/00

323

SECTION 10

10054 Hoist and Extend Schematic(S/N 8540 & Before)

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVETEST

PORT

REAR AXLE VALVE


PRESSUREREDUCING

VALVE

STEERINGVALVE

OUTRIGGERVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM



3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

STEERINGVALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0312

Rev. 2/00

SECTION 10

324

10054 Hoist and Extend Circuits(S/N 8541 thru 9908)

HYDRAULICRESERVOIR

EXTENDCYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

Trans.De-

Clutch

12

3

LEFT HOIST CYLINDER





BOOM EXTEND

LOCKOUT VALVE

C1

T

LOAD SENSE (LS)

Park Brake

MH0101

Rev. 2/00

325

SECTION 10

10054 Hoist and Extend Schematic(S/N 8541 thru 9908)

X

X

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVETEST

PORT

REAR AXLE VALVE


PRESSUREREDUCING

VALVE

STEERINGVALVE

OUTRIGGERVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM



3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

STEERINGVALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0620

Rev. 2/00

SECTION 10

326

10054 Hoist and Extend Circuits(S/N 9909 & After)

HYDRAULICRESERVOIR

EXTENDCYLINDER

BoomExt.

BoomHoist

FUELTANK

PT

LS

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

12

3

LEFT HOIST CYLINDER





BOOM EXTEND

LOCKOUT VALVE

C1

T

LOAD SENSE (LS)

MAINPUMP

TRANSMISSION

CONTROLDRAIN

LSOUT

INPARKBRAKE

MH0570

Origin 2/00

327

SECTION 10

10054 Hoist and Extend Schematic(S/N 9909 & After)

RESERVOIR

25PSI

TEMP. SWITCH195° F


3000PSI

PUMP

REAR AXLE VALVE

BRAKE VALVE

TP

SHUTTLEVALVE

0-45GPM



PRIORITYVALVE

STEERINGVALVE

2450-2550PSI

STEERINGVALVE

X

X

X

OUTRIGGERVALVE



3200PSI

MAINCONTROL

VALVE

EXTENDCYLINDER

3200PSI

HOISTVALVE

EXTENDRETRACT

VALVE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

LOWPRESSURE

LOWPRESSURE

HIGHPRESSURE

HIGHPRESSURE

LOWPRESSURE

MH0630

Origin 2/00

SECTION 10

328

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits

(S/N 2194 & Before)

LOAD SENSE (LS)

PILOT OPERATED CHECK VALVE LOCATIONS:

FRAME TILT CYLINDER - Rod & Base SidesATTACHMENT CYLINDER - Base Side

COUNTER BALANCE VALVE LOCATION:

ATTACHMET CYLINDER - Base Side

ParkBrake

OPERATOR'S CAB

T

SB

V

BRKP

AXLESTABILIZER

VALVEBLOCK

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

T TPC1

C2

PRESSUREREDUCING

VALVE BLOCK(Valve is bolted

to Axle StabilizerValve Blocks)

PT

LS

CONTROLVALVE

BoomExt.

BoomHoist

PT

LS

LSEF CF

T P

PRIORITYVALVE

SHUTTLEVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

Trans.De-

Clutch

12

3

CONTROLVALVE

FRAME TILTCYLINDER

HYDRAULICRESERVOIR

FUELTANK

MAINFILTER

ATTACHMENTTILT FORWARD

SLAVECYLINDER

SLAVECYLINDER


AUXILIARYHYDRAULICS

(optional)

MALE

FEMALE

ATTACHMENTTILT BACK

MH0750

Origin 2/00

329

SECTION 10

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2194 & Before)

MAINCONTROL VALVE

OUTRIGGERVALVE

FRAME TILTCYLINDER

SLAVECYLINDER - L.H.

3200PSI

SLAVECYLINDER - R.H.

3200 PSI

FRAMETILT

VALVE

ATTACH.TILT

VALVE

AUX.VALVE

ATTACH. TILTCYLINDER

AUX. QUICKDISCONNECT COUPLERS

RELIEF VALVES OPTIONAL

REARAXLEVALVE

.070 .070

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVE

TESTPORT

REAR AXLE VALVE

PRESSUREREDUCING

VALVE

STEERINGVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM

3200 PSI

3200 PSI

STEERINGVALVE

PRESSUREREDUCING

VALVE

LOWPRESSURE

HIGHPRESSURE

ORIFICE INFRAME TILTVALVE FORS/N -267 &

AFTER

ORIFICES INFRAME TILTCYLINDER

FOR S/N -266& BEFORE

MH0321

Rev. 2/00

SECTION 10

330

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits

(S/N 2195 thru 9908)

LOAD SENSE (LS)





ParkBrake

OPERATOR'S CAB

T

SB

V

BRKP

AXLESTABILIZER

VALVEBLOCK

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

T TPC1

C2

PRESSUREREDUCING


to Axle StabilizerValve Blocks)

PT

LS

CONTROLVALVE

BoomExt.

BoomHoist

PT

LS

LSEF CF

T P

PRIORITYVALVE

SHUTTLEVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

Trans.De-

Clutch

12

3

CONTROLVALVE

FRAME TILTCYLINDER

HYDRAULICRESERVOIR

FUELTANK

MAINFILTER


SLAVECYLINDER

SLAVECYLINDER


AUXILIARYHYDRAULICS

(optional)

MALE

FEMALE

ATTACHMENTTILT BACK

MH0760

Origin 2/00

331

SECTION 10

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic (S/N 2195 thru 9908)

MAINCONTROL VALVE

OUTRIGGERVALVE

FRAME TILTCYLINDER


3200PSI


3200 PSI

FRAMETILT

VALVE

ATTACH.TILT

VALVE

AUX.VALVE




REARAXLEVALVE

.070 .070

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVE

TESTPORT

REAR AXLE VALVE

PRESSUREREDUCING

VALVE

STEERINGVALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM

3200 PSI

3200 PSI

STEERINGVALVE

PRESSUREREDUCING

VALVE

LOWPRESSURE

HIGHPRESSURE

ORIFICE INFRAME TILTVALVE FORS/N -267 &

AFTER

ORIFICES INFRAME TILTCYLINDER

FOR S/N -266& BEFORE

MH0321

Rev. 2/00

SECTION 10

332

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Circuits(S/N 9909 & After)

LOAD SENSE (LS)

OPERATOR'S CAB

T

SB

V

BRKP

AXLESTABILIZER

VALVEBLOCK

AttachTilt

FrameTilt

Aux.Hyd.

SR

TC

T TPC1

C2PRESSUREREDUCING


to Axle StabilizerValve Block)

PT

LS

CONTROLVALVE

BoomExt.

BoomHoist

PT

LS

LSEF CF

T P

PRIORITYVALVE

SHUTTLEVALVE

12

3

CONTROLVALVE

FRAME TILTCYLINDER

HYDRAULICRESERVOIR

FUELTANK

MAINFILTER





MAINPUMP

TRANSMISSION

CONTROLDRAIN

LSOUT

INPARK

BRAKE


SLAVECYLINDER

SLAVECYLINDER


AUXILIARYHYDRAULICS

(optional)

MALE

FEMALE

ATTACHMENTTILT BACK

MH0740

Origin 2/00

333

SECTION 10

8042/10042/10054 Frame Tilt, Attachment Tilt, Slave & Auxiliary Schematic(S/N 9909 & After)

RESERVOIR

25PSI

TEMP. SWITCH195° F


3000PSI

PUMP

REAR AXLE VALVE

BRAKE VALVE

X

SHUTTLEVALVE

0-45GPM



PRIORITYVALVE

STEERINGVALVE

2450-2550PSI

STEERINGVALVE

X

TP

MAINCONTROL VALVE

OUTRIGGERVALVE

FRAME TILTCYLINDER


3200PSI


3200 PSI

FRAMETILT

VALVE

ATTACH.TILT

VALVE

AUX.VALVE




REARAXLEVALVE

3200 PSI

3200 PSI

LOWPRESSURE

HIGHPRESSURE

MH0640

Origin 2/00

SECTION 10

334

8042/10042/10054 Steering Circuit(S/N 9908 & Before)

LOAD SENSE (LS)

Park Brake

OPERATOR'S CAB

POWERSTEERING

UNIT

L T

PR

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

P T

STEERSELECTVALVE

CONTROL VALVE

HYDRAULICRESERVOIR

BoomExt.

BoomHoist

FUELTANK

PT

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

12

3

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

STEERCYL.

STEERCYL.

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

STEERCYL.

STEERCYL.

Trans.De-

Clutch

MH0132

Rev. 2/00

335

SECTION 10

8042/10042/10054 Steering Schematic(S/N 9908 & Before)

CONTROLVALVES

TEMP.SWITCH210° F

RESERVOIR

25PSI

SHUTTLEVALVETEST

PORT

REAR AXLE VALVEPRESSURE

REDUCING VALVE

PRESSUREREDUCING

VALVE

PRIORITYVALVE

2450-2550PSI

2900-3000PSI

500-600PSI

PUMP 46 GPM

4-W 2-W CRAB

STEERING CYLINDER - L.H. - REARSTEERING CYLINDER - R.H. - REAR

STEERING CYLINDERR.H. - FRONT

STEERING CYLINDERL.H. - FRONT

MH0331

Rev. 2/00

SECTION 10

336

8042/10042/10054 Steering Circuit(S/N 9909 & After)

LOAD SENSE (LS)

OPERATOR'S CAB

POWERSTEERING

UNIT

L T

PR

AB

PT

AttachTilt

FrameTilt

Aux.Hyd.

P T

STEERSELECTVALVE

CONTROL VALVE

HYDRAULICRESERVOIR

BoomExt.

BoomHoist

FUELTANK

PT

LS

EF CF

T P

MAINFILTER

PRIORITYVALVE

SHUTTLEVALVE

CONTROLVALVE

12

3

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

STEERCYL.

STEERCYL.

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

STEERCYL.

STEERCYL.

MAINPUMP

TRANSMISSION

CONTROLDRAIN

LSOUT

INPARK

BRAKE

MH0600

Origin 2/00

337

SECTION 10

8042/10042/10054 Steering Schematic(S/N 9909 & After)

RESERVOIR

25PSI

TEMP. SWITCH195° F


3000PSI

PUMP

X

SHUTTLEVALVE

0-45GPM


PRIORITYVALVE

2450-2550PSI

REAR AXLE VALVE

BRAKE VALVE

TP

X

4-W 2-W CRAB

STEERING CYLINDER - L.H. - REARSTEERING CYLINDER - R.H. - REAR

STEERING CYLINDERR.H. - FRONT

STEERING CYLINDERL.H. - FRONT

CONTROLVALVES

CONTROLVALVES

MH0650

Origin 2/00

SECTION 10

338

8042/10042/10054 Service Brake & De-Clutch Circuits(S/N 9908 & Before)

OPERATOR'S CAB

BRK

P

BRAKEVALVE

T C1

C2

HYDRAULICRESERVOIR

BoomExt.

BoomHoist

FUELTANK

PT

LSEF CF

T P

MAINFILTER

PRIORITYVALVE

TRANSMISSION

MAINPUMP

LS

OUT

CONTROLDRAIN

IN

Trans.De-

Clutch

CONTROLVALVE

PRESSUREREDUCING

VALVE

PRESSUREREDUCING

VALVEBLOCK

(Valve is bolted toAxle StabilizerValve Block)

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

Park Brake

MH0141

Rev. 2/00

339

SECTION 10

8042/10042/10054 Service Brake & De-Clutch Schematic (S/N 9908 & Before)

S/N 001-654 + S/N -1167 & AFTER

S/N -655 THRU -1166 MAX. PRESSURE 350 PSI

400-450 PSIS/N 1167 & BEFORE500-525 PSIS/N 1168 & AFTER

TRANS.DE-

CLUTCH

STEERINGVALVE

TEMP.SWITCH210° F

RESERVOIR

25PSI

2900-3000PSI

500-600 PSI

PUMP 46 GPM

SHUTTLEVALVE

PRIORITYVALVE

TESTPORT

2450-2550PSI

CONTROLVALVES

CONTROLVALVES

BRAKEVALVE

CONTROLVALVES

PRESSUREREDUCING

VALVE

REARAXLE

VALVE

100PSI

200 PSI

.035ORIFICE

PARKBRAKE

FRAMETILT

VALVE

REARAXLE

STABILIZERCYLINDER

TESTPORT

(S/N 882 & BEFORE ONLY)

MH0341

Rev. 2/00

SECTION 10

340

8042/10042/10054 Service Brake Circuit(S/N 9909 & After)

OPERATOR'S CAB

BRK

P

BRAKEVALVE

T C1

C2

HYDRAULICRESERVOIR

BoomExt.

BoomHoist

FUELTANK

PT

LSEF CF

T P

MAINFILTER

PRIORITYVALVE

CONTROLVALVE

PRESSUREREDUCING

VALVE

PRESSUREREDUCING

VALVEBLOCK(Valve isbolted to

Axle Stabilizer Valve Block)

RIGHTFRONTBRAKE

LEFTFRONTBRAKE

LEFTREAR

BRAKE

RIGHTREAR

BRAKE

MAINPUMP

TRANSMISSION

CONTROLDRAIN

LSOUT

INPARK

BRAKE

MH0610

Origin 2/00

341

SECTION 10

8042/10042/10054 Service Brake Schematic(S/N 9909 & After)

S/N 001-654 + S/N -1167 & AFTER

S/N 655 THRU 1166 MAX. PRESSURE 350 PSI

400-450 PSIS/N 1167 & BEFORE500-525 PSIS/N 1168 & AFTER

RESERVOIR

25PSI

TEMP. SWITCH195° F


3000PSI

PUMP

X

SHUTTLEVALVE

0-45GPM


PRIORITYVALVE

STEERINGVALVE

2450-2550PSI

STEERINGVALVE

TP

X

TESTPORT

BRAKEVALVE

PRESSUREREDUCING

VALVE

REARAXLEVALVE

200 PSI

PARKBRAKE

FRAMETILT

VALVE

REARAXLE

STABILIZERCYLINDER

CONTROLVALVES

CONTROLVALVES

MH0660

Origin 2/00

SECTION 10

342

10042/10054 Outrigger Schematic(S/N 10881 & Before)

OPTIONALOUTRIGGER

VALVE

OPTIONALOUTRIGGER

VALVE

HYDRAULIC RESERVOIR

CONTROL VALVES

SHUTTLE VALVE

OUTRIGGERCYLINDER - L.H.

OUTRIGGERCYLINDER - R.H.

Pressure Switch1500 PSI

10054 Only


10054 Only

MH0351

Rev. 2/00

343

SECTION 10

10042/10054 Outrigger Schematic(S/N 10882 & After)

OPTIONALOUTRIGGER

VALVE

OPTIONALOUTRIGGER

VALVE

HYDRAULIC RESERVOIR

CONTROL VALVES

SHUTTLE VALVE

OUTRIGGERCYLINDER - L.H.

OUTRIGGERCYLINDER - R.H.


10054 Only


10054 Only

MH0670

Origin 2/00

SECTION 10

344

8042/10042 Electrical Schematic (S/N 0291 & Before)

RE

D/W

HIT

E

STA

RT

RE

LA

Y

�

BO

OM

SE

NS

OR (-

)

RED

NO

TU

SE

D

FU

EL

RU

NS

OL

EN

OID

RED

RE

D

ALT

ER

-N

ATO

R

BLK

BR

OW

N

BLK

BLK

BLK

BLU

E

STA

BIL

IZE

RC

YL

IND

ER

BLK

TAN

BR

OW

N/W

HIT

E

RE

D/B

LAC

K

NO

TU

SE

D

LT. B

LUE

NO

TU

SE

D

BLK

WH

ITE

YE

LLO

W/R

ED

NO

T U

SE

D

EN

GIN

EW

AT

ER

TE

MP.

SE

ND

ER

(210

° F

)

YE

LLO

W

BLK

NO

T U

SE

D

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

BR

OW

N/Y

ELL

OW

BLK

NO

T U

SE

D

DK

. BLU

E

OR

AN

GE

BLK

FU

EL

LE

VE

L S

EN

DE

R

HO

RN

BLK

GR

AY

BR

OW

N

BLK

OR

AN

GE

/BLK

BLK

FR

AM

EG

RO

UN

D

BA

CK

-UP

AL

AR

M

NE

UT

RA

L(N

) S

TAR

TS

WIT

CH

NO

TU

SE

D

OR

AN

GE

/RE

D

WH

ITE

/BLU

E

EN

GIN

EL

OW

OIL

PR

ES

SU

RE

SE

ND

ER

(8 -

12

PS

I)

TR

AN

SM

ISS

ION

TE

MP

ER

AT

UR

ES

WIT

CH

GR

N

TAN

PU

R/W

HIT

E

STA

BIL

IZE

RL

OC

KR

EL

AY

BLKBLKBLK

BO

OM

RE

LA

Y

PUR/BLK

BRN/BLK

ST

EE

R S

EL

EC

TVA

LVE

12

WH

ITE

CIR

CU

IT B

RE

AK

ER

40

AM

PRED

BR

OW

N/W

HIT

E

RE

D

LT.G

RN

/WH

T

LT.G

RN

/BLK

12

ST

EE

R S

EL

EC

TS

WIT

CH

LT. B

LUE

YE

LLO

W

IGN

ITIO

NS

WIT

CH

YE

LLO

W/R

ED

RE

D/B

LAC

K

BLK

DK

. BLU

E/O

RG

WIP

ER

/W

AS

HE

RS

WIT

CH

(O

pt.

)

WA

SH

ER

BO

TT

LE

(Op

t.)

CIR

CU

LA

TIO

NFA

N (

Op

t.) W

IPE

RM

OTO

R(O

pt.

)

RE

DP H L

XB

LK

GR

N

RE

D/G

RAY

SP

LIC

E

BU

LB

TE

ST

BU

TTO

NP

UR

PLE

WA

RN

ING

LIG

HT

S

BR

OW

N

LT. G

RE

EN

CIR

CU

ITB

RE

AK

ER

6 A

MP LIG

HT

ING

PAC

KA

GE

(Op

t.)

WH

ITE

CIR

CU

ITB

RE

AK

ER

MO

UN

TIN

GS

TU

DBLK

STA

BIL

IZE

R L

IGH

T

GR

AY

BR

OW

N OR

AN

GE

NO

TU

SE

DB

RO

WN

/GR

EE

N

OR

AN

GE

/BLA

CK

BLK

NO

TU

SE

D

PR

ES

SU

RE

RE

DU

CIN

GVA

LVE

BLU

E/W

HIT

E

WH

ITE

/BLU

E

OR

AN

GE

/ RE

D

BLK

SGI

DK. BLUE

FU

EL

GA

UG

EL

HO

UR

-M

ET

ER

G

ORANGE/GREEN

I S

HO

RN

BU

TTO

N

WHITE

TAN

WHT/ORG

BLA

CK

NO

TU

SE

D

RE

D

OR

G

ORANGE

EM

ER

GE

NC

Y B

RA

KE

SW

ITC

H

BR

AK

EP

ED

AL

SW

ITC

H

DK

. BLU

E/O

RG

CA

BH

EA

TE

R(O

pt.

)R

EV

ER

SE

&N

EU

TR

AL

SW

ITC

H

NO

TU

SE

D

GR

EE

N

STA

RT

ER

BA

TT

ER

Y

CIR

CU

ITB

RE

AK

ER

6 A

MP

(Op

t.) C

IRC

UIT

BR

EA

KE

R6

AM

P

CIR

CU

ITB

RE

AK

ER

10 A

MP

CR

KT

BR

KR

6 A

MP

CIR

CU

ITB

RE

AK

ER

20 A

MP

FR

AM

EG

RO

UN

D

FR

AM

EG

RO

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345

SECTION 10

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Rev. 2/00

SECTION 10

346

8042/10042 Electrical Schematic(S/N 9909 & After)

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Origin 2/00

347

SECTION 10

10054 Electrical Schematic (S/N 9908 & Before)

RE

D/W

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ER

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D

DK. BLUEMH0170

Rev. 2/00

SECTION 10

348

10054 Electrical Schematic(S/N 9909 & After)

��

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30A

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RE

D/W

HIT

E19

27

29

BLK

RED

106

P

RE

D

ALT

.

HY

DR

OIL

TE

MP.

38

FU

EL

SH

UTO

FF

SO

L.

BLU

E-

BLK

BR

OW

N

BLKSTA

B.

CY

L.

BLK

WH

ITE

BLK

TAN

BLK

BLK

STA

B.

VALV

E

2

2

2

47

28

TAN

20

20

BRN/BLK

1010

11

YE

LLO

W

RE

D/B

LAC

K

NO

TU

SE

D

YE

LLO

W/R

ED

NO

TU

SE

D

NO

TU

SE

D

OR

AN

GE

FU

EL

SE

ND

ER

OIL

PR

ES

SU

RE

SW

.(8

-12

PS

I)

BLK

BLK

TR

AN

. TE

MP.

SW

.

LT. B

LUE

61

2

22

2

2

5

22

353634

35

27

6 363427

35 15 18 16 17G

RAY

BR

OW

N

15 18 16 17

2

2

38

BROWN/WHITE

BO

OM

AN

GLE

SE

NS

OR

WAT

ER

TE

MP

SW

. (21

0° F

)

+

NO

TU

SE

DN

OT

US

ED

44

DK

. BLU

E

BR

OW

N/Y

ELL

OW

BR

OW

N

BLU

E

BLK

-249

49 23

23

BO

OM

EX

TE

ND

SE

NS

OR

BA

CK

-UP

ALA

RM

BLK N

OT

US

ED

LOG

ICH

AR

NE

SS

14

NO

TU

SE

DN

OT

US

ED

37

25

CIR

CU

IT B

RK

RM

TG

ST

UD

25

20

20

3131

102

101

14N

OT

US

ED

111

114

OR

AN

GE

/RE

D

20

2020

21

20O

RA

NG

E/B

LK

NO

TU

SE

D

WH

ITE

/BLU

E

101

103

105

105

104

102

103

BLK

20

BLK

BLK

BLK

STA

B L

OC

KR

ELA

Y

PUR/BLK 4810

4047

45

BO

OM

RE

LAY

28

BLK

BLK

BLK

BLK

LT. G

RE

EN

/WH

ITE

21

82 2

RED

26

1W

HIT

E

40 A

MP

WA

SH

ER

BO

TT

LES

OP

T2

2

DE

FO

GFA

NO

PT

3353

BLK

B5 2

1Y

EL

RE

D/

BLK

4B5

321

P

PU

RP

LE

35

1

LT. G

RE

EN

SP

LIC

E

RE

D/G

RAY

39

XP L

RE

D

32

10 A

MP

OP

T

3

77.

5 A

MP

WIP

ER

MO

TOR

S &

WIP

ER

/WA

SH

ER

SW

ITC

HE

S O

PT

BLK

BR

OW

N

DK

. BLU

E/O

RG

92

1LT

. GR

EE

N/B

LK

YE

LLO

W/

RE

D

NO

T U

SE

D

RE

D/B

LAC

K2 5

13 4

ST

EE

RS

ELE

CT

SW

.

IGN

. SW

.

GR

AY

40

OR

AN

GE

STA

B. L

IGH

T

LT. B

LUE

GR

EE

N

BR

OW

N

YE

LLO

W

BU

LBT

ES

T

12C

WH

ITE

WA

RN

ING

LIG

HT

S

TAN

I

I

GA

UG

E

DK. BLUE

S

L

FU

EL

10 A

MP

22

5150O

PE

N

52 ORANGE

NO

TU

SE

D

WHITE

PURPLE

OR

AN

GE

46

NO

TU

SE

DN

OT

US

ED

ST

EE

R S

EL.

VALV

E

NO

TU

SE

D

NO

TU

SE

DN

OT

US

ED

BLK

LOG

ICH

AR

NE

SS

2

2

2

2 22

PR

ES

. RE

D.

VALV

E

OR

AN

GE

/ RE

D

OR

AN

GE

/BLA

CK

43 110

108

112

51

BW

109

109BR

OW

N/G

RE

EN

107

111

107

110

100

100

114

104

113

S

24 242

24

1

NO

TU

SE

D

RE

D BLA

CK

CA

BH

EAT

ER

(OP

T)

BR

AK

EP

ED

AL

SW

.

DK

. BLU

E/O

RG

BR

AK

ES

W.

54

6

52 45

41

51

45

1

LOG

ICH

AR

NE

SS

3HO

UR

ME

TE

R

45

46

HO

RN

BU

TTO

N

NO

T U

SE

DB

LUE

/WH

ITE

NO

T U

SE

D

BLK

WHT/ORG

ORANGE/GREEN

PU

R/W

HIT

E

BR

OW

N/W

HIT

E

RE

D NO

T U

SE

D

108

M4

M3

3086

100

100

8787

A85

30

BW

106

87A

87

100

NE

UT

RA

LS

TAR

T R

ELA

Y

8586B

AC

K-U

PA

LAR

M R

ELA

Y

M5

M2

M1

BLA

CK

YE

LLO

W

BR

OW

N

PIN

KB

LUE

C ABF

GR

EE

NE

100

TR

AN

S

ZF

TR

AN

SM

ISS

ION

CO

NN

EC

TOR

SH

IFT

SO

LEN

OID

S O

N Z

F T

RA

NS

MIS

SIO

N

3086

P

8787

A85

UW

YE

LLO

WA

BLA

CK

GR

EE

NSPA

RK

BR

AK

ED

ISC

ON

NE

CT

RE

LAY

RIN

G T

ER

MIN

AL

NO

T U

SE

D

SH

IFT

ER

ZF

TR

AN

SM

ISS

ION

101

PIN

K

RE

D

GR

AY

YE

LLO

W

BLU

EV

IOLE

T

CBAC

RE

D

PIN

KG

RAY

YE

LLO

W

BLU

EV

IOLE

T

CA

BS

TU

D

1 2 3 4

F

GR

EE

NB

BLA

CK

27A

DK

. BLU

E12

20

30

20

13

2

2

GH

GR

N

HO

RN

HH

GR

N

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AM

P

7.5

AM

P

10 A

MP

MA

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INS

SO

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GE

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MH0690

Origin 2/00

349

SECTION 10

10042 Outrigger Logic Circuit

YELLOW/GREEN

GR

EY

/PU

RP

LE

BLACK

RE

D/G

RE

Y

PU

RP

LE/W

HIT

E

BR

OW

N/Y

ELL

OW

20

60

7.5 AMP*50

YELLOW/GREEN

10 AMP

BLACK20

FOR UNITS WITHCIRCUIT BREAKERS

60

YE

LLO

W/G

RE

EN

6364606162B

RO

WN

/YE

LLO

W

TOPL.H.TOP R.H.

TOGGLE SWITCHES

GR

EY

/PU

RP

LE

PU

RP

LE/W

HIT

E

BLA

CK

BLA

CK

OUTRIGGER VALVE

2

61

2

63

BLACK

RED/GREY

BLACK

BROWN/YELLOW

64 2 62 2

*7.5 AMP - S/N 0292 & After 6.0 AMP - S/N 0291 & Before

MH0181

Rev. 2/00

SECTION 10

350

10054 Outrigger Logic Circuit(S/N 9908 & Before)

3

52

45

49

49

23

23

58

2

2

23

310

1010

10

RED/GREYPURPLE/WHITE

2C2B

68

5861

63

2A67

51

5045

23

360

49

5610

10A

2

49

23

OUTRIGGERCYLINDERS

57

57

50

56L.H.

R.H.

BOOMSENSOR

BOOMEXTEND

SOLENOID

L.H.

67

60

64

BROWN/YELLOW

GREY/PURPLE

YELLOW/GREEN

R.H.

62

68

PURPLE/WHITE

RED/GREY

YELLOW/GREEN

OUTRIGGERSWITCHES

BRAKESWITCH

LeftOutriggerLockoutRelay

StabilizerLock-upRelay

StabilizerInterlock

Relay

RightOutriggerLockoutRelay

OutriggerLockoutRelay

BoomExtend

Interlock

BoomExtendLockoutRelay

ParkBrake

Interlock

RELAY LOCATIONS

PRESSURESWITCH

PRESSURESWITCH

GRD.STUD

BOOMRELAY

MAINFUSE

BLOCK

CONSOLEHARNESS

(REF.)

BROWN/YELLOW

BLACK BLACK

PURPLE/GREY

BLACK BLACK

51

PARKBRAKE

SOLENOID

VALVE

2 2

64 63

2

62 61

2

ENGINEHARNESS

NOTUSED

MH0190

Rev. 2/00

351

SECTION 10

10054 Outrigger Logic Circuit(S/N 9909 & After)

3

52

45

49

49

23

23

58

2H

2

23

3

RED/GREYPURPLE/WHITE

2C2B

68

5861

63

2A67

51

5045

23

360

49

567

2

49

23

OUTRIGGERCYLINDERS

57

57

50

56L.H.

R.H.

BOOMSENSOR

BOOMEXTEND

SOLENOID

L.H.

67

60

64

BROWN/YELLOW

GREY/PURPLE

YELLOW/GREEN

R.H.

62

68

PURPLE/WHITE

RED/GREY

YELLOW/GREEN

OUTRIGGERSWITCHES

BRAKESWITCH

LeftOutriggerLockoutRelay

StabilizerLock-upRelay

StabilizerInterlock

Relay

RightOutriggerLockoutRelay

OutriggerLockoutRelay

BoomExtend

Interlock

BoomExtendLockoutRelay

ParkBrake

Interlock

RELAY LOCATIONS

PRESSURESWITCH

PRESSURESWITCH

GRD.STUD

BOOM SWITCHRELAY

MAINFUSE

BLOCK BROWN/YELLOW

BLACK BLACK

PURPLE/GREY

BLACK BLACK

PARKBRAKE

SOLENOID

VALVE

2E 2F

64 63

2D

62 61

2G

ENGINEHARNESS

NOTUSED

7 35

7 35

51

2K

51107

NOTUSED

TRANSMISSIONWIRE

HARNESS

STABILIZER LOCKRELAY

MH0710

Origin 2/00

SECTION 10

352

8042/10042/10054 Lighting System Circuit (Optional)

RIGHTFRONT

LEFTFRONT

TO FUELGAUGE

RIGHTREAR

LEFT REAR

STOPLIGHT

SWITCH

TURNSIGNALSWITCH

FLASHER

LIGHTSWITCH

FUSE20 AMP

T

H

B

BOOMLIGHT

2

6

7

2

9

8

54

12

34

69

254 14

12

12

IGNITIONSWITCH

3

12

3

45

7

11 8 5

12

15

10

14

1

34

2

11

34

4

2 15 15

2

10

3

34

5

MH0201

Rev. 8/96

353

SECTION 10

8042/10042/10054 Charging Circuit

RE

D

RED

YELLOW

W

B+D+

2

66

WARNINGLIGHTS

ALTERNATORCHARGING

LIGHT

YELLOW

66

38 TOHOUR-METER

YELLOW

TOFRAME

GROUND

TOSTARTER

RELAY5

TOIGNITIONSWITCH

ALTER-NATOR

RED/WHITE

STARTER

BATTERY

"BAT"TERMINAL

19

CABFRAME

GROUND

TOSTARTER

RELAY

27

2927

RED/WHITE

STARTER

BATTERY

"BAT"TERMINAL

19

CABFRAME

GROUND

TOSTARTER

RELAY

27

S/N 0292 & Before

MH0211

Rev. 2/00

SECTION 10

354

8042/10042/10054 Cranking Circuit(S/N 9908 & Before)

RED/WHITE

STARTERRELAY

RE

D

FUEL RUNSOLENOID

RED/BLACK

DK. BLUE

FRAMEGROUND

NEUTRAL (N)START SWITCH

40 AMP

RED

IGNITIONSWITCH

RED/BLACK

WHITE/BLUE

WH

ITE

EMERGENCYBRAKESWITCH

STARTER

BATTERYCAB

FRAMEGROUND

5

21

4

3

RED

BLA

CK

27

3434

19

37

29

2

2927

2

BLACK

20

27

RED

26

1

14WHITE/BLUE

14 37

NOTE: 40 AMP CircuitBreaker replaced with40 AMP sealed fuseS/N 8739 & After.

STARTER

BATTERYCAB

FRAMEGROUND

19

S/N 0292 & Before

MH0221

Rev. 2/00

355

SECTION 10

8042/10042/10054 Cranking Circuit(S/N 9909 & After)

RED/WHITE

STARTERRELAY

RE

D

FUEL RUNSOLENOID

RED/BLACK

FRAMEGROUND

NEUTRAL (N)START RELAY

40 AMP

RED

IGNITIONSWITCH

RED/BLACK

WH

ITE


STARTER

BATTERYCAB

FRAMEGROUND

5

21

4

3

RED

BLA

CK

27

3434

19

106

29

2

2927

2

BLACK

20

27

RED

26

1

30ARED/WHITE

100

TOSHIFTER

106

BLU

E/O

RA

NG

E111

RED

GREY114

MH0700

Origin 2/00

SECTION 10

356

8042/10042 Steer Select Circuit(S/N 0291 & Before)

RED

RED

STEERSELECTVALVE

1 2

CIRCUIT BREAKER

40 AMP

RE

D

RED

LT. GREEN/WHITE

LT. GREEN/BLACK

1 2STEERSELECTSWITCH

LT. G

RE

EN

CIRCUITBREAKER

MOUNTINGSTUD

STARTER

BATTERYFRAME

GROUND

27

2

2

118

9

26 27

20

2

2

27

TOALTER-NATOR

TOSTARTER

RELAY

29

5

IGNITIONSWITCH

PURPLE

CIRCUITBREAKER

6 AMP

5

21

4

3

26

3

7

39

CIRCUITBREAKER6 AMP

46

11

27

MH0231

Rev. 2/00

357

SECTION 10

8042/10042/10054 Steer Select Circuit(S/N 0292 & After)

RE

D

RED

STEERSELECTVALVE

1 2

40 AMP

RE

D

RED

LT. GREEN/WHITE

LT. GREEN/BLACK

1 2STEERSELECTSWITCH

IGNITIONSWITCH

PURPLE

LT. GREEN

CIRCUITBREAKER

MOUNTINGSTUD

7.5 A

5

21

4

3

STARTER

BATTERY FRAMEGROUND

TOSTARTER

RELAY

TOALTER-NATOR

RE

D

11

46

26

11

8

9

27

2

227

2

2

20

29

5

27

27

27

26

3


MH0241

Rev. 2/00

SECTION 10

358

8042/10042 Stabilizer Circuit(S/N 0291 & Before)

TAN

DK. BLUE/ORANGE

RED/GRAY

SPLICE

PURPLE

BROWN

CIRCUITBREAKER

6 AMP

TAN

WH

ITE

/OR

AN

GE

BRAKEPEDALSWITCH

DK. BLUE/ORANGE

CIRCUITBREAKER

6 AMP

CIRCUITBREAKER

6 AMP

45

3

7

39

46

42

45 EMERGENCYBRAKESWITCH

42 45

46

46

REVERSEAND

NEUTRALSWITCH

WHITE

GREEN

45

46

S

G

I

FUELGAUGE

L

HOUR-METER

G

I

S

40

2

BOOMRELAY

RED

BROWN/WHITE

IGNITIONSWITCH

521

43

2

39

10

2848

35

3

26

PURPLE/WHITE

STABILIZERLOCK

RELAY

BLACK

PU

R/B

LK

STABILIZERLIGHT

BLACK

40

24740

CIRCUITBREAKER

40 AMPRED

27

BLK

BLK

CIRCUITBREAKER

MOUNTINGSTUD

2

2

20

RE

D

TAN

BROWN/WHITE

20

27

35

1010

35

27

BLK

20

2847

2847

BR

N/B

LK

SOL3

SOL4

RE

D

STARTER

BATTERY CABFRAME

GROUND

TOALTER-NATOR

TOSTARTER

RELAY

27

27

29

5

BLK

STA

BIL

IZE

RC

YL

IND

ER

FRAMEGROUND

BLK

SOL1

SOL2

SOL5

SOL6

20

2

2 2

BLK

2

2

2

BLK

2

47

28

+

BOOMSENSOR

(-)

BLK

BROWN

BLK

BLUE

10235

STABILIZERVALVE

45

DK

. BLU

E/O

RA

NG

E

WH

ITE

1

MH0251

Rev. 2/00

359

SECTION 10

8042/10042 Stabilizer Circuit(S/N 0292 thru S/N 9908)

TAN

DK. BLUE/ORANGE

RED/GRAY

SPLICE

BROWN

CIRCUITBREAKER7.5 AMP

TAN

WH

ITE

/OR

AN

GE

BRAKEPEDALSWITCH

DK. BLUE/ORANGE



45

7

39

46

42

45EMERGENCY

BRAKESWITCH

42 45

46

46

REVERSEAND

NEUTRALSWITCH

WHITE

GREEN

45

46

S

G

I

FUELGAUGE

L

HOUR-METER

G

I

S

40

2

BOOMRELAY

RED

BROWN/WHITE

IGNITIONSWITCH

521

43

2

39

10

2848

35

3

26

PURPLE/WHITE

STABILIZERLOCKRELAY

BLACK

PU

R/B

LK

STABILIZERLIGHT

BLACK

40

24740

40 AMPRED

27

BLK

BLK

CIRCUITBREAKER

MOUNTINGSTUD

2

2

20

RE

D

TAN

BROWN/WHITE

20

27

35

1010

35

27

BLK

20

2847

2847

BR

N/B

LK

SOL3

SOL4

RE

D

STARTER

BATTERY CABFRAME

GROUND

TOALTER-NATOR

TOSTARTER

RELAY

27

27

29

5

BLK

STA

BIL

IZE

RC

YL

IND

ER

BLK

SOL1

SOL2

SOL5

SOL6

2

2 2

BLK

2

2

2

BLK

2

47

28

+

BOOMSENSOR

(-)

BLK

BROWN

BLK

BLUE

10235

STABILIZERVALVE

45

DK

. BLU

E/O

RA

NG

E

PURPLE


WH

ITE

1

MH0261

Rev. 2/00

SECTION 10

360

8042/10042 Stabilizer Circuit(S/N 9909 & After)

TAN

DK. BLUE/ORANGE

RED/GRAY

SPLICE

BROWN7.5 AMP

TAN

WH

ITE

/OR

AN

GE

BRAKEPEDALSWITCH

DK. BLUE/ORANGE

7.5 AMP

7.5 AMP

45

7

39

46

42

45 EMERGENCYBRAKESWITCH

42 45

46

46

45

46

S

G

I

FUELGAUGE

L

HOUR-METER

G

I

S

40

2

BOOMRELAY

RED

BROWN/WHITE

IGNITIONSWITCH

521

43

2

39

10

2848

35

3

26

PURPLE/WHITE

STABILIZERLOCKRELAY

BLACK

PU

R/B

LK

STABILIZERLIGHT

BLACK

40

24740

40 AMPRED

27

BLK

BLK

CIRCUITBREAKER

MOUNTINGSTUD

2

2

20

RE

D

TAN

BROWN/WHITE

20

27

35

1010

35

27

BLK

20

2847

2847

BR

N/B

LK

SOL3

SOL4

RE

D

STARTER

BATTERY CABFRAME

GROUND

TOALTERNATOR

TOSTARTER

RELAY

27

27

29

5

BLK

STA

BIL

IZE

RC

YL

IND

ER

BLK

SOL1

SOL2

SOL5

SOL6

2

2 2

BLK

2

2

2

BLK

2

47

28

+

BOOMSENSOR

(-)

BLK

BROWN

BLK

BLUE

10235

STABILIZERVALVE

45

DK

. BLU

E/O

RA

NG

E

PURPLE

NEUTRALSTARTRELAY

PARK BRAKEDISCONNECT

RELAY

51

TO LOGICHARNESS

113

112

114

108

107

TOTRANSMISSION

HARNESS

106

111

TOSTARTER

RELAYTO

TRANSMISSIONHARNESS

VIOLET

GREY

RED

BLUE/ORANGEGRAY

RED

WH

ITE

1

MH0720

Origin 2/00

361

SECTION 10

10054 Stabilizer Circuit(S/N 9908 & Before)

TAN

DK. BLUE/ORANGE

RED/GRAY

SPLICE

BROWN


TAN

WH

ITE

/OR

AN

GE

BRAKEPEDALSWITCH

DK. BLUE/ORANGE



45

7

39

46

42

45


42 45

46

46

REVERSEAND

NEUTRALSWITCH

WHITE

GREEN

45

46

S

G

I

FUELGAUGE

L

HOUR-METER

G

I

S

40

2

BOOMRELAY

RED

BROWN/WHITE

IGNITIONSWITCH

521

43

2

39

10

2848

35

3

26

PURPLE/WHITE

STABILIZERLOCKRELAY

BLACK

PU

R/B

LK

STABILIZERLIGHT

BLACK

40

24740

40 AMPRED

27

BLK

BLK

CIRCUITBREAKER

MOUNTINGSTUD

2

2

20

RE

D

TAN

BROWN/WHITE

20

27

35

1010

35

27

BLK

20

2847

2847

BR

N/B

LK

SOL3

SOL4

RE

D

STARTER

BATTERY CABFRAME

GROUND

TOALTER-NATOR

TOSTARTER

RELAY

27

27

29

5

BLK

STA

BIL

IZE

RC

YL

IND

ER

BLK

SOL1

SOL2

SOL5

SOL6

2

2 2

BLK

2

2

2

BLK

2

47

28

+

BOOMSENSOR

(-)

BLK

BROWN

BLK

BLUE

10235

STABILIZERVALVE

45

DK

. BLU

E/O

RA

NG

E

PURPLE

FROMLOGIC

HARNESS

1010


MH0271

Rev. 2/00

SECTION 10

362

10054 Stabilizer Circuit(S/N 9909 & After)

TAN

DK. BLUE/ORANGE

RED/GRAY

SPLICE

BROWN7.5 AMP

TAN

WH

ITE

/OR

AN

GE

BRAKEPEDALSWITCH

DK. BLUE/ORANGE

7.5 AMP

7.5 AMP

45

7

39

46

42


42 45

46

46

45

46

S

G

I

FUELGAUGE

L

HOUR-METER

G

I

S

40

2

BOOMRELAY

RED

BROWN/WHITE

IGNITIONSWITCH

521

43

2

39

10

2848

35

3

26

PURPLE/WHITE

STABILIZERLOCKRELAY

BLACK

PU

R/B

LK

STABILIZERLIGHT

BLACK

40

24740

40 AMP SEALEDFUSE

RED27

BLK

BLK

CIRCUITBREAKER

MOUNTINGSTUD

2

2

20

RE

D

TAN

BROWN/WHITE

20

27

35

1010

35

27

BLK

20

2847

2847

BR

N/B

LK

SOL3

SOL4

RE

D

STARTER

BATTERY CABFRAME

GROUND

TOSTARTER

RELAY

27 29

BLK

STA

BIL

IZE

RC

YL

IND

ER

BLK

SOL1

SOL2

SOL5

SOL6

2

2 2

BLK

2

2

2

BLK

2

47

28

+

BOOMSENSOR

(-)

BLK

BROWN

BLK

BLUE

10235

STABILIZERVALVE

45

DK

. BLU

E/O

RA

NG

E

PURPLE

FROMLOGIC

HARNESS

1010

45

1

WH

ITE

NEUTRALSTARTRELAY

TOALTER-NATOR

PARK BRAKEDISCONNECT

RELAY

51

TO LOGICHARNESS

113

112

114

108

107

TOTRANSMISSION

HARNESS106

111

TOSTARTER

RELAYTO

TRANSMISSIONHARNESS

VIOLET

GREY

RED

BLUE/ORANGEGRAY

RED

5

27

MH0730

Origin 2/00

363

SECTION 10NOTES

364

SECTION 10

Stabil-TRAK SystemThe following information explains the difference between a typicaltelescopic handler and the benefits that the Stabil-TRAK Systemprovides.Most telescopic handlers operate within a 3 point stability triangle, asdefined by points A, B, and C in the illustration to the right. Point 1 inthe illustration represents the center of gravity of an unloadedvehicle. The load has its own center of gravity indicated by Point 3.When the vehicle is loaded, the vehicle and the load become onemass having a combined center of gravity represented by Point 2.As the boom is lowered or extended, Point 2 will move forward in the3 point stability triangle, or backward in the stability triangle as theboom is raised. Point 2 can also move left or right toward the edgesof the stability triangle if the frame is tilted. As long as Point 2remains within the boundaries of the 3 point stability triangle, thevehicle will remain stable. If Point 2 ever goes beyond the boundariesof the stability triangle, the vehicle can tip over.In the locked mode, the exclusive Stabil-TRAK System provides a4 point stability rectangle by positively locking the frame to the rearaxle through the stabilizer cylinder. The vehicle is then supported atfour points, A, B, D, and E. While in the locked mode, it is clear thatPoint 2 will remain within the entire boundary of the 4 point Stabil-TRAK stability rectangle, giving the operator more flexibility inpositioning a load.

The Stabil-TRAK System functions in the following three modes:

This illustration shows the increase in stability with the Stabil-TRAK System.

Load Center of Gravity

Combined Center of Gravity

VehicleCenter of Gravity

3 Point Stability Triangle

3

FRONT2

1B

A

C

D

E

PH0712

Stabil-TRAK4 Point Stability

Rectangle

Free Pivot Mode

With the boom below 40°, the Stabil-TRAK System is in the free pivot mode and the rear axle is allowed to pivot freely.The frame tilt functions normally, with or without the outriggers down.

Angle OfStabil-TRAK

Activation40°

3 Point Stability

Outriggers Down

FREE PIVOTMODE

Stabil-TRAK Light "OFF"

PH0721PH0770

PH0750

Final Positioning Mode

With the boom above 40°, and the vehicle traveling, the Stabil-TRAK System is in the final positioning mode. In this mode the rear axle is unlocked and is allowed to pivot, but will respond SLOWLY to changes in terrain.The frame tilt functions normally in this mode.

40°

Angle OfStabil-TRAK

Activation ��

��

��

��

FREE PIVOTMODE

Stabil-TRAKLight"OFF"

3 Point Stability

PH0731 PH0750

Locked Mode

With the boom above 40°, and one or more of the following functions activated, the Stabil-TRAK System is in the locked mode and the rear axle is locked so it is rigid with the frame.• Engaging the Emergency Brake Switch• Placing the Travel Select Lever in NEUTRAL• Depressing and holding the Service Brake PedalThe frame tilt functions slower than normal in this mode, with or without the outriggers down.

40°

Angle OfStabil-TRAK

Activation

FREE PIVOTMODE

Stabil-TRAKLight"OFF"

4 Point Stability

Outriggers DownPH0780PH0760

LOCKED MODE

Stabil-TRAK Light "ON"

PH0741

Rev. 2/00

365

SECTION 10

Stabil-TRAK System

Free Pivot ModeBoom Angles are below 40°.Rear Axle is allowed to pivot freely.

40°Angle Of

Stabil-TRAKActivation

FREE PIVOTMODE

Stabil-TRAK Light"OFF"

MH0362

Rev. 2/00

SECTION 10

366

Stabil-TRAK System

Final Positioning ModeBoom Angles are above 40° with vehicle traveling.Rear axle is unlocked and is allowed to pivot, but will respond SLOWLY to changes in terrain.

40°Angle Of

Stabil-TRAKActivation

FINALPOSITIONING

MODEStabil-TRAK Light

"OFF"

FREE PIVOTMODE

Stabil-TRAK Light"OFF"

�� MH0372

Rev. 2/00

367

SECTION 10

Stabil-TRAK System

Locked ModeBoom 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

40°Angle OfStabil-TRAK

Activation

LOCKED MODE

Stabil-TRAK Light "ON"

FREE PIVOTMODE

Stabil-TRAK Light "OFF"

MH0382

Rev. 2/00

SECTION 10

368

8042/10042 Stabil-TRAK System Troubleshooting

(S/N 9908 & Before)

Definitions:

PB = Park BrakeSB = Service BrakeDE = De-energizedE = EnergizedC = ClosedO = Open

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Reference page 370 & 371 Reference page 372 & 373 Reference page 374 & 375

MachineConditions

Switch/RelaySolenoid

Ignition OnBoom Below 40°

Trans. Fwd. or Rev.

Ignition OnBoom Above 40°

SB ReleasedTrans. Fwd. or Rev.

Ignition OnBoom Above 40°PB & SB Applied

Trans. Neutral

Solenoid 1 E DE DE

Solenoid 2 E DE DE

Solenoid 3 DE DE E

Solenoid 4 DE DE E

Solenoid 5 DE E DE

Solenoid 6 DE E DE

Boom Angle Sensor C O O

Boom Switch Relay E DE DE

Stabilizer Lock Relay DE DE E

Stabilizer Light Off Off On

Origin 10/97

369

SECTION 108042/10042 Stabil-TRAK Electrical CircuitIgnition “OFF”(S/N 9908 & Before)

,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ

PARKBRAKESWITCH

NEUTRALSTARTSWITCH

STARTERSOLENOID

1

14

Fwd/RevNEU.SWITCH

See NOTE

SeeNOTE

O

NOTE:

7.5 Amp - S/N 292 & After6.0 Amp - S/N 291 & Before

IGN. SWITCH

FUELSHUTOFF

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6

STABILIZERENGAGEDLIGHT

PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp

35

41

42

DE

DE

DE

See NOTE

PARKBRAKE/DECLUTCHSOLENOID DE

DE

S/N 8042/10042-0291 & BeforeBoom Switch Relay located in Kick Panel.Stabilizer Lock Relay located under Dash tothe left side of the Steering Wheel

6.0 Amp Stabilizer Lock Relay

6.0 Amp Stabil-TRAK Relays &Proximity Switch

6.0 Amp Park Brake Switch

40 Amp Ignition Switch Feed

BoomSwitchRelay

LEGEND

DE = De-energizedE = EnergizedO = Open

PB = Park BrakeSB = Service Brake

S/N 8042/10042-0292 & AfterBoom Switch and Stabilizer LockRelays located in Kick Panel

BoomSwitchRelay

StabilizerLockRelay

7.5 Amp Steering Select Circuit& Stabilizer Lock Relay

7.5 Amp Stabil-TRAK Solenoids,Relay & Proximity Switch

7.5 Amp Warning Lights, Park Brake Switch,Fuel Gauge & Hourmeter


B

A

D

C

B

A

D

C

D

A

B

C

StabilizerLockRelay

SH0402

Rev. 2/00

SECTION 10

370

8042/10042 Stabil-TRAK Electrical CircuitFree Pivot Mode(S/N 9908 & Before)

)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH 1. Ignition “ON” 4. SB & PB Released

&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV

2. Transmission in Fwd. or Rev. 5.

3. Boom Below 40° 6.

40 Amp

Fwd/RevNEU.SWITCH

See NOTE

SeeNOTE

C

LEGEND

DE = De-energizedE = EnergizedC = Closed


NOTE:


IGN. SWITCH

FUELSHUTOFF

PARKBRAKESWITCH

NEUTRALSTARTSWITCH

STARTERSOLENOID

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

35

1

14

41

42 DE

E

DE

See NOTE

PARKBRAKE/DECLUTCHSOLENOID DE

E






BoomSwitchRelay


BoomSwitchRelay

StabilizerLockRelay





B

A

D

C

B

A

D

C

D

A

B

C

E

StabilizerLockRelay

SH0581

Rev. 2/00

371

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitFree Pivot Mode

(S/N 9908 & Before)

CONDITIONS:Boom below 40°, vehicle stopped, and transmission in forward or reverse.Solenoids 1 and 2 are energized to permit flow of rear axle stabilizer cylinder oil to hydraulic reservoir and normal frame tilt. Solenoids 3, 4, 5, and 6 are de-energized.

If vehicle is stopped by service brakes, or park brake switch, or transmission in neutral; the same conditions apply.

TP

BRK

P SRTC

TP

V

SB

T

PRESSUREREDUCING

VALVE500 - 525 PSI

SOLENOID3

SOLENOID4P

T

CONTROL VALVE(located on valve plate under cab)

PRESSURE REDUCING VALVE BLOCKAND STABILIZER VALVE BLOCK

(located on valve plate under cab)

FRAME TILTVALVE

SECTION

SOLENOID1

SOLENOID5

SOLENOID6

SOLENOID2

.029

.060

500 - 525PSI

VARIABLEDISPLACEMENT

PUMP46 GPM

FRAME TILTCYLINDER

STABILIZER CYLINDER


STABILIZERVALVEBLOCK

HYDRAULICRESERVOIR

SOL. 3

SOL. 1SOL. 2

SOL. 4

SOL. 5SOL. 6

.029

E

R

E

R

PRESSURE REDUCINGVALVE

S/N 2195 & After 200 +/- 25 PSI(S/N 2194 & Before *60 PSI)

CHECK VALVE*100 PSI

(S/N 2194 &Before Only)

S/N 2194 & BEFORE

TP

*60 PSI

*100 PSI

SOL. 3

200 +/- 25 PSI

SH0570

Rev. 2/00

SECTION 10

372

8042/10042 Stabil-TRAK Electrical CircuitFinal Positioning Mode (S/N 9908 & Before)

)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH 1. Ignition “ON” 4. SB Released

&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Transmission in Fwd. or Rev. 5.

3. Boom Above 40° 6.

Fwd/RevNEU.SWITCH

See NOTE

SeeNOTE

O

LEGEND



NOTE:


IGN. SWITCH

FUELSHUTOFF

PARKBRAKESWITCH

NEUTRALSTARTSWITCH

STARTERSOLENOID

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp35

1

14

41

42

DE

DE

E

See NOTE

PARKBRAKE/DECLUTCHSOLENOID

DE

DE



BoomSwitchRelay

StabilizerLockRelay









BoomSwitchRelay

B

A

D

C

B

A

D

C

D

A

B

C

StabilizerLockRelay

SH0561

Rev. 2/00

373

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitFinal Positioning Mode

(S/N 9908 & Before)

CONDITIONS:Boom raised above 40°, vehicle in forward or reverse; proximity switch relay energizes solenoids 5 and 6; solenoids 1, 2, 3, and 4 are de-energized.Rear axle stabilizer cylinder oil flow is dampened to the hydraulic reservoir through the .060 orifices. The rear axle will react to terrain changes, however the reaction will be dampened by the orifices.The operator controls speed of frame tilt of the front axle in response to the orifices rear axle.

.029

.060

500 - 525PSI


PUMP46 GPM



HYDRAULICTANK

SOL. 3

SOL. 1SOL. 2

SOL. 4

SOL. 5SOL. 6

TP

FRAME TILTCYLINDER

STABILIZER CYLINDER

.029

PRESSUREREDUCING

VALVE500 - 525 PSI

SOLENOID3

SOLENOID4



SOLENOID1

SOLENOID5

SOLENOID6

SOLENOID2


FRAME TILTVALVE

SECTION

P

TBRK

P SRTC

TP

V

SB

T

E

R

E

R


S/N 2195 & After 200 +/- 25 PSI(S/N 2194 & Before *60 PSI)

CHECK VALVE*100 PSI


S/N 2194 & BEFORE

TP

*60 PSI

*100 PSI

SOL. 3

200 +/- 25 PSI

SH0550

Origin 2/00

SECTION 10

374

8042/10042 Stabil-TRAK Electrical CircuitLocked Mode(S/N 9908 & Before)

/RFNHG� 0RGH/RFNHG� 0RGH/RFNHG� 0RGH/RFNHG� 0RGH 1. Ignition “ON” 4. SB & PB Applied


2. Transmission in Neutral 5.


NOTE:




IGN. SWITCH

FUELSHUTOFF

PARKBRAKESWITCH

NEUTRALSTARTSWITCH

STARTERSOLENOID

PARKBRAKE/DECLUTCHSOLENOID

Fwd/RevNEU.SWITCH

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

35

1

14

41

40 Amp See NOTEDE

E

DE

DE

O

See NOTE

SeeNOTE

LEGEND



BoomSwitchRelay

StabilizerLockRelay









BoomSwitchRelay

StabilizerLockRelay

42

B

A

D

C

B

A

D

C

D

A

B

C

SH0541

Rev. 2/00

375

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitLocked Mode

(S/N 9908 & Before)

CONDITIONS:Boom raised above 40° and vehicle stopped with service brake on, or park brake switch engaged, or transmission in neutral.Solenoids 1, 2, 5, and 6 de-energized and solenoids 3 and 4 energized.Rear axle is locked. If the frame is tilted, the cylinders are slaved and tilt speed is slowed by .029 orifices.


PRESSUREREDUCING

VALVE500 - 525 PSI


S/N 2195 & After 200 +/- 25 PSI(S/N 2194 & Before *60 PSI) SOLENOID

3

SOLENOID4

CHECK VALVE*100 PSI


TP

.029

.060

.029

500 - 525PSI

200 +/- 25 PSI


PUMP46 GPM


HYDRAULICTANK

SOL. 3

SOL. 1SOL. 2

SOL. 4

SOL. 5SOL. 6

FRAME TILTCYLINDER

STABILIZER CYLINDER

CONTROL VALVE(located on valve plate under cab) PRESSURE REDUCING VALVE BLOCK

AND STABILIZER VALVE BLOCK(located on valve plate under cab)

FRAME TILTVALVE

SECTION

SOLENOID1

SOLENOID5

SOLENOID6

SOLENOID2

BRK

P SRTC

TP

V

SB

T

E

R

P

T

E

R

S/N 2194 & BEFORE

TP

*60 PSI

*100 PSI

SOL. 3

SH0530

Rev. 2/00

SECTION 10

376

8042/10042 Stabil-TRAK System Troubleshooting

(S/N 9909 & After)

Definitions:

PB = Park BrakeSB = Service BrakeDE = De-energizedE = EnergizedC = ClosedO = Open

)5((� 3,927� 02'()5((� 3,927� 02'()5((� 3,927� 02'()5((� 3,927� 02'( ),1$/� 326,7,21,1*� 02'(),1$/� 326,7,21,1*� 02'(),1$/� 326,7,21,1*� 02'(),1$/� 326,7,21,1*� 02'( /2&.('� 02'(/2&.('� 02'(/2&.('� 02'(/2&.('� 02'(

Reference page 378 & 379 Reference page 380 & 381 Reference page 382 & 383

MachineConditions


Ignition OnBoom Below 40°

Trans. Fwd. or Rev.

Ignition OnBoom Above 40°

SB ReleasedTrans. Fwd. or Rev.

Ignition OnBoom Above 40°PB & SB Applied

Trans. Neutral

Solenoid 1 E DE DE

Solenoid 2 E DE DE

Solenoid 3 DE DE E

Solenoid 4 DE DE E

Solenoid 5 DE E DE

Solenoid 6 DE E DE

Boom Angle Sensor C O O

Boom Switch Relay E DE DE

Stabilizer Lock Relay DE DE E

Stabilizer Light Off Off On

Park Brake Disconnect Relay

E E DE

Neutral Start Relay DE DE E

Origin 2/00

377

SECTION 108042/10042 Stabil-TRAK Electrical Circuit Ignition “OFF”(S/N 9909 & After)

,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ,JQLWLRQ � ´2))µ

PARKBRAKESWITCH

1

107

OIGN. SWITCH

FUELSHUTOFF

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp

35

41

46DE

DE

DEPARKBRAKE

DE

DE

D

A

B

C

LEGEND



PARK BRAKEDISCONNECTRELAY

106

111

114

46

108

45112

NEUTRALSTARTRELAY

113

100 100

108113

45

114

To Transmission Harness

To Starter Relay


DEDE

Relay Block located under Dashattached to Back of Bulkhead with Velcro

Boom Switch and Stabilizer LockRelays located in Kick PanelRELAY LOCATIONS

Back-UpAlarmRelay

7.5 Amp Stabil-TRAK Solenoids, Relay & Proximity Switch

7.5 Amp Steering Select Circuit & Stabilizer Lock Relay

10 Amp Horn and Back-Up Alarm (Optional-Cab Heater Fan)7.5 Amp Warning Lights, Park Brake Switch, Fuel Gauge & Hourmeter20 Amp Optional Lighting Kit


10 Amp Optional Enclosed Cab Windshield Washer/Wiper Switch and Circulation Fan

BoomSwitchRelay

StabilizerLockRelay

A

B

D

C

7.5 Amp Outrigger Switches (10042 Only)

NeutralStartRelay

ParkBrake

DisconnectRelay

SH1290

Origin 2/00

SECTION 10

378

8042/10042 Stabil-TRAK Electrical CircuitFree Pivot Mode(S/N 9909 & After)

)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH)UHH� 3LYRW� 0RGH 1. Ignition “ON” 4. SB & PB Released



3. Boom Below 40° 6.

PARKBRAKESWITCH

1

107

CIGN. SWITCH

FUELSHUTOFF

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2SOL.

3SOL.

4SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp

35

41

46DE

E

DE

PARKBRAKE

DE

E

D

A

B

C

LEGEND

DE = De-energizedE = EnergizedO = OpenC = Closed



106

111

114

46

108

45112

NEUTRALSTARTRELAY

113

100 100

108113

45

114


To Starter Relay


EDE

Back-UpAlarmRelay

NeutralStartRelay

ParkBrake

DisconnectRelay

Relay Block located underDash and attached to Backof Bulkhead with Velcro







BoomSwitchRelay

StabilizerLockRelay

A

B

D

C


Shifter in Forward Position

E

F

SH1300

Origin 2/00

379

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitFree Pivot Mode

(S/N 9909 & After)

CONDITIONS:Boom below 40°, vehicle stopped, and transmission in forward or reverse.Solenoids 1 and 2 are energized to permit flow of rear axle stabilizer cylinder oil to hydraulic reservoir and normal frame tilt. Solenoids 3, 4, 5, and 6 are de-energized.

If vehicle is stopped by service brakes, or park brake switch, or transmission in neutral; the same conditions apply.

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SH1170

Origin 2/00

SECTION 10

380

8042/10042 Stabil-TRAK Electrical CircuitFinal Positioning Mode(S/N 9909 & After)

)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH)LQDO � 3RVLWLRQLQJ� 0RGH 1. Ignition “ON” 4. SB & PB Released




PARKBRAKESWITCH

1

107

OIGN. SWITCH

FUELSHUTOFF

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2

SOL.3

SOL.4

SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp

35

41

46DE

E

PARKBRAKE

DE

LEGEND




106

111

114

46

108

45112

NEUTRALSTARTRELAY

113

100 100

108113

45

114


To Starter Relay


EDE

DE

DE

E

D

A

B

C

Relay Block located underDash attached to Back ofBulkhead with Velcro


Back-UpAlarmRelay






BoomSwitchRelay

StabilizerLockRelay

A

B

D

C


NeutralStartRelay

ParkBrake

DisconnectRelay

FShifter in Forward Position

SH1310

Origin 2/00

381

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitFinal Positioning Mode

(S/N 9909 & After)

CONDITIONS:Boom raised above 40°, vehicle in forward or reverse; proximity switch relay energizes solenoids 5 and 6; solenoids 1, 2, 3, and 4 are de-energized.Rear axle stabilizer cylinder oil flow is dampened to the hydraulic reservoir through the .060 orifices. The rear axle will react to terrain changes, however the reaction will be dampened by the orifices.The operator controls speed of frame tilt of the front axle in response to the orifices rear axle.

.029

.060


SOL. 1SOL. 2

SOL. 5SOL. 6

FRAME TILTCYLINDER

STABILIZER CYLINDER

.029

PRESSUREREDUCING

VALVE500 - 525 PSI

SOLENOID3

SOLENOID4



SOLENOID1

SOLENOID5

SOLENOID6

SOLENOID2


FRAME TILTVALVE

SECTION


CHECK VALVE*100 PSI


500 - 525PSI


PUMP45 GPM


HYDRAULICRESERVOIR

SOL. 3

SOL. 4

200 +/- 25 PSI

LS

LS

P

TBRK

P SRTC

TP

V

SB

T

E

R

E

R

SH1180

Origin 2/00

SECTION 10

382

8042/10042 Stabil-TRAK Electrical CircuitLocked Mode(S/N 9909 & After)

/RFNHG� 0RGH/RFNHG� 0RGH/RFNHG� 0RGH/RFNHG� 0RGH 1. Ignition “ON” 4. SB & PB Applied


2. Transmission in Neutral 5.


PARKBRAKESWITCH

1

107

OIGN. SWITCH

FUELSHUTOFF

SERVICEBRAKESWITCH

BOOMSWITCHRELAY

BOOM UP

BOOMDOWN

STABILIZERLOCKRELAY

SOL.1

SOL.2

SOL.3

SOL.4

SOL.5

SOL.6


PROXIMITYSWITCH

45

1039

4740

48

2

28

40 Amp

35

41

46

E

PARKBRAKE

DE

D

A

B

C

LEGEND




106

111

114

46

108

45112

NEUTRALSTARTRELAY

113

100 100

108113

45

114


To Starter Relay


EDE

DE

DE

E

DE

Relay Block located underDash and attached to Backof Bulkhead with Velcro


Back-UpAlarmRelay






BoomSwitchRelay

StabilizerLockRelay

A

B

D

C


NeutralStartRelay

ParkBrake

DisconnectRelay

NShifter in Neutral Position

SH1320

Origin 2/00

383

SECTION 10

8042/10042 Stabil-TRAK Hydraulic CircuitLocked Mode

(S/N 9909 & After)

CONDITIONS:Boom raised above 40° and vehicle stopped with service brake on, or park brake switch engaged, or transmission in neutral.Solenoids 1, 2, 5, and 6 de-energized and solenoids 3 and 4 energized.Rear axle is locked. If the frame is tilted, the cylinders are slaved and tilt speed is slowed by .029 orifices.


PRESSUREREDUCING

VALVE500 - 525 PSI


SOLENOID3

SOLENOID4

CHECK VALVE*100 PSI


.029

.060

.029

SOL. 1SOL. 2

SOL. 5SOL. 6

FRAME TILTCYLINDER

STABILIZER CYLINDER

CONTROL VALVE(located on valve plate under cab) PRESSURE REDUCING VALVE BLOCK

AND STABILIZER VALVE BLOCK(located on valve plate under cab)

FRAME TILTVALVE

SECTION

SOLENOID1

SOLENOID5

SOLENOID6

SOLENOID2

BRK

P SRTC

TP

V

SB

T

E

R

P

T

E

R

500 - 525PSI


PUMP45 GPM


HYDRAULICRESERVOIR

SOL. 3

SOL. 4

200 +/- 25 PSI

LS

LS

SH1190

Origin 2/00

SECTION 10

384

NOTE: If an outrigger is up or a pressure switch is defective, boom on 10054 will not extend beyond 42 series extension limit.

Definitions:Boom Retracted = Less than 42 series extension limitBoom Extended = Boom at 42 series extension limit or greater (See Figure)PB = Park BrakeSB = Service BrakeDE = De-energizedE = EnergizedC = ClosedO = Open

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02'(� �02'(� �02'(� �02'(� �

Reference page 386

Reference page 387

Reference page 388

Reference page 389

Reference page 390

MachineConditions


Ignition OnBoom Below 40° Boom Retracted

PB & SB ReleasedTrans. Fwd. or Rev.

Outriggers Up

Ignition OnBoom Below 40° Boom Extended


Outriggers Up

Ignition OnBoom Below 40° Boom ExtendedPB & SB Applied

Trans. Neutral Outriggers Down

Ignition OnBoom Above 40° Boom Retracted


Outriggers Up



Outriggers Down

Solenoid 1 E E E DE DE


Solenoid 3 DE DE DE DE DE


Solenoid 5 DE DE DE E E


Boom Angle Sensor C C O O O

Boom Relay E E E DE DE

Stabilizer Lock Relay DE DE E DE DE

Stabilizer Light Off Off On Off On

%220� (;7(1'� ,17(5/2&.� 6<67(0� 7528%/(6+227,1*%220� (;7(1'� ,17(5/2&.� 6<67(0� 7528%/(6+227,1*%220� (;7(1'� ,17(5/2&.� 6<67(0� 7528%/(6+227,1*%220� (;7(1'� ,17(5/2&.� 6<67(0� 7528%/(6+227,1*

Boom Extend Proximity Switch C O O C C

Boom Extend Interlock Relay E DE DE E E

Boom Extend Lockout Relay E DE DE E E

Outrigger Lockout Relay E DE DE E E

Outrigger Pressure Switches O O C O C

Left Outrigger Lockout Relay DE DE E DE DE

Right Outrigger Lockout Relay DE DE E DE DE

Stabilizer Interlock Relay DE DE E DE E

Stabilizer Lock-Up Relay DE DE E DE DE

Extend Circuit Solenoid Valve E DE E E E

Park Brake Solenoid Valve E E DE E E

Park Brake Interlock Relay DE DE E DE DE

ED

C

B

A

FG

H

42S

erie

sE

xten

sion

Limit

OH0630

Rev. 2/00

385

SECTION 10



� �� 6WDELO�75$.� 6\VWHP� 7URXEOHVKRRWLQJ� �6�1� �� %HIRUH�� 6WDELO�75$.� 6\VWHP� 7URXEOHVKRRWLQJ� �6�1� �� %HIRUH�� 6WDELO�75$.� 6\VWHP� 7URXEOHVKRRWLQJ� �6�1� �� %HIRUH�� 6WDELO�75$.� 6\VWHP� 7URXEOHVKRRWLQJ� �6�1� �� %HIRUH�

%220� (;7(1'�%220� (;7(1'�%220� (;7(1'�%220� (;7(1'�

02'(� �02'(� �02'(� �02'(� �

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02'(� �02'(� �02'(� �02'(� �

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02'(� �02'(� �02'(� �02'(� �

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02'(� �02'(� �02'(� �02'(� �

Reference page 391

Referencepage 392

Reference page 393

Reference page 394

MachineConditions


Ignition OnBoom Above 40°Boom RetractedPB & SB Applied

Trans. Neutral Outriggers Up



Ignition OnBoom Above 40°Boom ExtendedPB & SB Applied




Solenoid 1 DE DE DE DE


Solenoid 3 E E E E

Solenoid 4 E E E E



Boom Angle Sensor O O O O

Boom Relay DE DE DE DE

Stabilizer Lock Relay E E E E

Stabilizer Light On On On On

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Boom Extend Proximity Switch C C O O

Boom Extend Interlock Relay E E DE DE

Boom Extend Lockout Relay E E DE DE

Outrigger Lockout Relay E E DE DE

Outrigger Pressure Switches O C O C

Left Outrigger Lockout Relay DE DE DE E

Right Outrigger Lockout Relay DE DE DE E

Stabilizer Interlock Relay DE E DE E

Stabilizer Lock-Up Relay DE DE DE E

Extend Circuit Solenoid Valve E E DE E

Park Brake Solenoid Valve DE DE DE DE

Park Brake Interlock Relay DE DE DE E

ED

C

B

A

FG

H

42S

erie

sE

xten

sion

Limit

OH0630

Rev. 2/00

SECTION 10

386

10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 1(S/N 9908 & Before)

02'(� �02'(� �02'(� �02'(� � 1. Ignition “ON” 4. Transmission in Fwd. or Rev.

&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Released

3. Boom Retracted 6. Outriggers Up

7.5

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pO

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h P

ower

7.5

Am

pO

utrig

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and

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xim

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witc

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Out

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Sta

biliz

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pR

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biliz

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Rig

htO

utrig

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out

Rel

ay

Out

rigge

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r

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biliz

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pR

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Left

Out

rigge

rLo

ckou

tR

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Rig

htO

utrig

ger

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out

Rel

ay

Left

Out

rigge

rS

witc

h

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

E

DE

DE

EE

E

DE

DE D

E

DE

CO

C

Sta

biliz

erLi

ght

Sol

.3

& 4

Par

kB

rake

Rel

ease

d

E

Boo

mS

witc

hR

elay

48

28

Sol

.1&

2

39

Sol

.5

& 6

47

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

7.5

Am

pS

teer

ing

Sel

ect C

ircui

t&

Sta

biliz

er L

ock

Rel

ay

7.5

Am

pS

tabi

l-TR

AK

Sol

enoi

ds,

Rel

ay &

Pro

xim

ity S

witc

h

7.5

Am

pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

uel G

auge

& H

ourm

eter

40 A

mp

Igni

tion

Sw

itch

Fee

d

RE

LA

YL

OC

AT

ION

S

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

BA

C D

DA

BC

Fw

d/R

evN

eutr

alS

witc

hEF

FE

Ser

vice

Bra

keS

witc

h

LE

GE

ND

DE

=D

e-en

ergi

zed

E=

Ene

rgiz

edO

=O

pen

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Ser

vice

Bra

ke

SH0312

Rev. 2/00

387

SECTION 10

02'(� �02'(� �02'(� �02'(� � 1. Ignition “ON” 4. Transmission in Fwd. or Rev. 10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 2

(S/N 9908 & Before)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Released

3. Boom Extended 6. Outriggers Up

7.5

Am

pO

utrig

ger

Pre

ssur

eS

witc

h P

ower

Left

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erLo

ck-U

pR

elay

Sta

biliz

erIn

terlo

ckR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Out

rigge

rLo

ckou

tR

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Boo

mE

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dIn

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LA

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S

Rel

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lock

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h on

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teer

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Whe

el

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Red

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s, P

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SH0323

Rev. 2/00

SECTION 10

388


02'(� �02'(� �02'(� �02'(� � 1. Ignition “ON” 4. Transmission in Neutral

&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Applied

3. Boom Extended 6. Outriggers Down

7.5

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LA

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S

Rel

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lock

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h on

left

side

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DE

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E

DE

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lied

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28

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2

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47

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mS

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pS

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ect C

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biliz

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ay

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pS

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l-TR

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enoi

ds,

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ay &

Pro

xim

ity S

witc

h

7.5

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pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

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auge

& H

ourm

eter

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mp

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tion

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Fee

d

RE

LA

YL

OC

AT

ION

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LE

GE

ND

DE

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zed

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sed

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ark

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keS

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vice

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ke

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m S

witc

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d S

tabi

lizer

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kR

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cate

d in

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pO

utrig

ger

and

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end

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xim

ity S

witc

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BA

C D

DA

BC

Ser

vice

Bra

keS

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Fw

d/R

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EF

FE

SH0333

Rev. 2/00

389

SECTION 10


(S/N 9908 & Before)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Released


7.5

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pO

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ger

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ssur

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lock

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Black

Black

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Black

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3

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enoi

ds,

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ay &

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xim

ity S

witc

h

7.5

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pW

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ight

s, P

ark

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ke S

witc

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auge

& H

ourm

eter

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mp

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tion

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d

RE

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ION

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LE

GE

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ark

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kR

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pO

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ger

and

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end

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xim

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witc

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C D

DA

BC

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vice

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keS

witc

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Fw

d/R

evN

eutr

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EF

FE

SH0342

Rev. 2/00

SECTION 10

390

10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 5 (S/N 9908 & Before)


&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Released

3. Boom Retracted 6. Outriggers Down

7.5

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pO

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ssur

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ower

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pO

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ger

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xim

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htO

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ger

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out

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ay

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ckou

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Black

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pS

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biliz

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ay

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pS

tabi

l-TR

AK

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enoi

ds,

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ay &

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xim

ity S

witc

h

7.5

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pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

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auge

& H

ourm

eter

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mp

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tion

Sw

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Fee

d

RE

LA

YL

OC

AT

ION

S

LE

GE

ND

DE

=D

e-en

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zed

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rgiz

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pen

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keS

B=

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vice

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ke

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m S

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d S

tabi

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kR

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d in

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BA

C D

DA

BC

Ser

vice

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keS

witc

h

Fw

d/R

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EF

FE

SH0352

Rev. 2/00

391

SECTION 10

02'(� �02'(� �02'(� �02'(� � 1. Ignition “ON” 4. Transmission in Neutral 10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 6

(S/N 9908 & Before)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Applied


7.5

Am

pO

utrig

ger

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ssur

eS

witc

h P

ower

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Am

pO

utrig

ger

and

Ext

end

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xim

ity S

witc

h P

ower

Left

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rigge

rLo

ckou

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elay

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biliz

erLo

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biliz

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ckR

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Rig

htO

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ger

Lock

out

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ay

Out

rigge

rLo

ckou

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mE

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ION

S

Rel

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lock

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h on

left

side

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e S

teer

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el

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+

Red

Purple

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Gry/Org

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/Gry

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enoi

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oil

Ext

end

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Black

Black

Black

Black

Black

Black

Black

Black

Black

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3

60

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51

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E

DE

DE

E

E

DE

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lied

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28

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2

39

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.5

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47

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biliz

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7.5

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pS

teer

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Sel

ect C

ircui

t&

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biliz

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ock

Rel

ay

7.5

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pS

tabi

l-TR

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enoi

ds,

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ay &

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xim

ity S

witc

h

7.5

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pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

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auge

& H

ourm

eter

40 A

mp

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tion

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Fee

d

RE

LA

YL

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AT

ION

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LE

GE

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pen

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keS

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vice

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d S

tabi

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kR

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cate

d in

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k P

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C D

DA

BC

Ser

vice

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keS

witc

h

Fw

d/R

evN

eutr

alS

witc

h

EF

FE

SH0362

Rev. 2/00

SECTION 10

392



&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Applied


7.5

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pO

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ger

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ssur

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pO

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and

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Gry/Org

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/Gry

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/Blu

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3

60

62

6864

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59

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rP

ress

ure

Sw

itch

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Par

kB

rake

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rlock

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kB

rake

Sol

enoi

dV

alve

Boo

mE

xten

dLo

ckou

tR

elay

Ext

end

Circ

uit

Sol

enoi

dV

alve

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

Left

Out

rigge

rLo

ckou

tR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Left

Out

rigge

rS

witc

h

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

E

E

DE

DE

E

E

E

DE D

E

DE

CC

O

Sta

biliz

erLi

ght

Sol

.3

& 4

Par

kB

rake

App

lied

DE

Boo

mS

witc

hR

elay

48

28

Sol

.1&

2

39

Sol

.5

& 6

47

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

7.5

Am

pS

teer

ing

Sel

ect C

ircui

t&

Sta

biliz

er L

ock

Rel

ay

7.5

Am

pS

tabi

l-TR

AK

Sol

enoi

ds,

Rel

ay &

Pro

xim

ity S

witc

h

7.5

Am

pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

uel G

auge

& H

ourm

eter

40 A

mp

Igni

tion

Sw

itch

Fee

d

RE

LA

YL

OC

AT

ION

S

LE

GE

ND

DE

=D

e-en

ergi

zed

E=

Ene

rgiz

edO

=O

pen

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Ser

vice

Bra

ke

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

BA

C D

DA

BC

Ser

vice

Bra

keS

witc

h

Fw

d/R

evN

eutr

alS

witc

h

EF

FE

SH0372

Rev. 2/00

393

SECTION 10


(S/N 9908 & Before)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Applied


7.5

Am

pO

utrig

ger

Pre

ssur

eS

witc

h P

ower

Left

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erLo

ck-U

pR

elay

Sta

biliz

erIn

terlo

ckR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dIn

terlo

ck

Boo

mE

xten

dLo

ckou

tR

elay

Par

kB

rake

Inte

rlock

RE

LA

Y L

OC

AT

ION

S

Rel

ay B

lock

loca

ted

unde

r Das

h on

left

side

of th

e S

teer

ing

Whe

el

+ ––

+

Red

Purple

Red/Blk

White

Tan

Dk. Bl/Org

Org/Black

Dk. Bl/Red

Black

Black

Gry/Org

Org

/Gry

Red

/Blu

e

Black

BlackDk. Blue

Org/Red

Org/Wht

Red/Wht

Igni

tion

Sw

itch

To Fue

lS

huto

ff Neu

tral

Sta

rtS

witc

h To Sta

rter

Inte

rlock

Sol

enoi

dC

oil

Ext

end

Pro

xim

ityS

witc

h

Green Black

Black

Black

Black

Black

Black

Black

Black

Black

Black

Black

Yel/Grn

Brn/Blk

Gry/Pur

Red/Blk

Pur/Wht

Red/Gry

Brn/Yel

Brown

3

60

62

6864

67

22

2

22

2

22

2

6163

59

353577

45

505056 56

5755

66

71 70

65

58

2

22

2

2

2 51

52

45

45

42

49

3

3

Bla

ck

48

40

2

10

Boo

mS

enso

r

Sta

biliz

erLo

ckR

elay

Par

kB

rake

Sw

itch

Boo

mE

xten

dIn

terlo

ck

Left

Out

rigge

rP

ress

ure

Sw

itch

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Par

kB

rake

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rlock

Par

kB

rake

Sol

enoi

dV

alve

Boo

mE

xten

dLo

ckou

tR

elay

Ext

end

Circ

uit

Sol

enoi

dV

alve

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

Left

Out

rigge

rLo

ckou

tR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Left

Out

rigge

rS

witc

h

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

DE

E

DE

DE

DE

DE

DE

DE D

E

DE

OO

O

Sta

biliz

erLi

ght

Sol

.3

& 4

Par

kB

rake

App

lied

DE

Boo

mS

witc

hR

elay

48

28

Sol

.1&

2

39

Sol

.5

& 6

47

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

7.5

Am

pS

teer

ing

Sel

ect C

ircui

t&

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biliz

er L

ock

Rel

ay

7.5

Am

pS

tabi

l-TR

AK

Sol

enoi

ds,

Rel

ay &

Pro

xim

ity S

witc

h

7.5

Am

pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

uel G

auge

& H

ourm

eter

40 A

mp

Igni

tion

Sw

itch

Fee

d

RE

LA

YL

OC

AT

ION

S

LE

GE

ND

DE

=D

e-en

ergi

zed

E=

Ene

rgiz

edO

=O

pen

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Ser

vice

Bra

ke

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

7.5

Am

pO

utrig

ger

and

Ext

end

Pro

xim

ity S

witc

h P

ower

BA

C D

DA

BC

Ser

vice

Bra

keS

witc

h

Fw

d/R

evN

eutr

alS

witc

h

EF

FE

SH0382

Rev. 2/00

SECTION 10

394





7.5

Am

pO

utrig

ger

Pre

ssur

eS

witc

h P

ower

7.5

Am

pO

utrig

ger

and

Ext

end

Pro

xim

ity S

witc

h P

ower

Left

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erLo

ck-U

pR

elay

Sta

biliz

erIn

terlo

ckR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dIn

terlo

ck

Boo

mE

xten

dLo

ckou

tR

elay

Par

kB

rake

Inte

rlock

RE

LA

Y L

OC

AT

ION

S

Rel

ay B

lock

loca

ted

unde

r Das

h on

left

side

of th

e S

teer

ing

Whe

el

+ ––

+

Red

Purple

Red/Blk

White

Tan Dk. Bl/Org

Org/Black

Dk. Bl/Red

Black

Black

Gry/Org

Org

/Gry

Red

/Blu

e

Black

BlackDk. Blue

Org/Red

Org/Wht

Red/Wht

Igni

tion

Sw

itch

To Fue

lS

huto

ff Neu

tral

Sta

rtS

witc

h To Sta

rter

Inte

rlock

Sol

enoi

dC

oil

Ext

end

Pro

xim

ityS

witc

h

Green Black

Black

Black

Black

Black

Black

Black

Black

Black

Black

Black

Yel/Grn

Brn/Blk

Gry/Pur

Red/Blk

Pur/Wht

Red/Gry

Brn/Yel

Brown

3

60

62

6864

67

22

2

22

2

22

2

6163

59

353577

45

505056 56

5755

66

71 70

65

58

2

22

2

2

2

51

52

45

45

42

49

3

3

Bla

ck

48

40

2

10

Boo

mS

enso

r

Sta

biliz

erLo

ckR

elay

Par

kB

rake

Sw

itch

Boo

mE

xten

dIn

terlo

ck

Left

Out

rigge

rP

ress

ure

Sw

itch

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Par

kB

rake

Inte

rlock

Par

kB

rake

Sol

enoi

dV

alve

Boo

mE

xten

dLo

ckou

tR

elay

Ext

end

Circ

uit

Sol

enoi

dV

alve

Out

rigge

rLo

ckou

tR

elay

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

Left

Out

rigge

rLo

ckou

tR

elay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Left

Out

rigge

rS

witc

h

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

DE

E

E

DE

E

DE

E

E

E

E

OC

O

Sta

biliz

erLi

ght

Sol

.3

& 4

Par

kB

rake

App

lied

DE

Boo

mS

witc

hR

elay

48

28

Sol

.1&

2

39

Sol

.5

& 6

47

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

7.5

Am

pS

teer

ing

Sel

ect C

ircui

t&

Sta

biliz

er L

ock

Rel

ay

7.5

Am

pS

tabi

l-TR

AK

Sol

enoi

ds,

Rel

ay &

Pro

xim

ity S

witc

h

7.5

Am

pW

arni

ng L

ight

s, P

ark

Bra

ke S

witc

h,F

uel G

auge

& H

ourm

eter

40 A

mp

Igni

tion

Sw

itch

Fee

d

RE

LA

YL

OC

AT

ION

S

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

BA

C D

DA

BC

Ser

vice

Bra

keS

witc

h

Fw

d/R

evN

eutr

alS

witc

h

EF

FE

LE

GE

ND

DE

=D

e-en

ergi

zed

E=

Ene

rgiz

edO

=O

pen

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Ser

vice

Bra

ke

SH0392

Rev. 2/00

395

SECTION 10NOTES

SECTION 10

396

NOTE: If an outrigger is up or a pressure switch is defective, boom on 10054 will not extend beyond 42 series extension limit.Definitions:Boom Retracted = Less than 42 series extension limitBoom Extended = Boom at 42 series extension limit or greater (See Figure)PB = Park BrakeSB = Service BrakeDE = De-energizedE = EnergizedC = ClosedO = Open

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Reference page 398

Reference page 399

Reference page 400

Reference page 401

Reference page 402

MachineConditions


Ignition OnBoom Below 40° Boom Retracted


Outriggers Up

Ignition OnBoom Below 40° Boom Extended


Outriggers Up

Ignition OnBoom Below 40° Boom ExtendedPB & SB Applied




Outriggers Up



Outriggers Down







Boom Angle Sensor C C O O O

Boom Relay E E E DE DE

Stabilizer Lock Relay DE DE E DE DE

Stabilizer Light Off Off On Off On

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Boom Extend Proximity Switch C O O C C

Boom Extend Interlock Relay E DE DE E E

Boom Extend Lockout Relay E DE DE E E

Outrigger Lockout Relay E DE DE E E

Outrigger Pressure Switches O O C O C

Left Outrigger Lockout Relay DE DE E DE DE

Right Outrigger Lockout Relay DE DE E DE DE

Stabilizer Interlock Relay DE DE E DE E

Stabilizer Lock-Up Relay DE DE E DE DE

Extend Circuit Solenoid Valve E DE E E E

Park Brake Solenoid Valve E E DE E E

Park Brake Interlock Relay DE DE E DE DE

Park Brake Disconnect Relay E E DE E E

Neutral Start Relay DE DE E DE DE

ED

C

B

A

FG

H

42S

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sE

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OH0630

Origin 2/00

397

SECTION 10



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Reference page 403

Reference page 404

Reference page 405

Referencepage 406

MachineConditions












Solenoid 3 E E E E

Solenoid 4 E E E E



Boom Angle Sensor O O O O

Boom Relay DE DE DE DE

Stabilizer Lock Relay E E E E

Stabilizer Light On On On On

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Boom Extend Proximity Switch C C O O

Boom Extend Interlock Relay E E DE DE

Boom Extend Lockout Relay E E DE DE

Outrigger Lockout Relay E E DE DE

Outrigger Pressure Switches O C O C

Left Outrigger Lockout Relay DE DE DE E

Right Outrigger Lockout Relay DE DE DE E

Stabilizer Interlock Relay DE E DE E

Stabilizer Lock-Up Relay DE DE DE E

Extend Circuit Solenoid Valve E E DE E

Park Brake Solenoid Valve DE DE DE DE

Park Brake Interlock Relay DE DE DE E

Park Brake Disconnect Relay DE DE DE DE

Neutral Start Relay E E E E

ED

C

B

A

FG

H

42S

erie

sE

xten

sion

Limit

OH0630

Origin 2/00

SECTION 10

398

10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 1(S/N 9909 & After)


&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Released


LE

GE

ND

DE

=D

e-en

ergi

zed

E=

Ene

rgiz

edO

=O

pen

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Ser

vice

Bra

ke

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red

/Blu

e

Org

/Gry

Org

/Red

Yel

/Grn

Dk.

Bl/R

ed

Igni

tion

Sw

itch

To

Fue

lS

huto

ff

Left

Out

rigge

rLo

ckou

tR

elay

Left

Out

rigge

rS

witc

h

To

Sta

rtR

elay

Par

kB

rake

Rel

ease

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

Rig

htO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Par

kB

rake

Sol

enoi

dV

alveE

E

EE

Ext

end

Circ

uit

Sol

enoi

dV

alve

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Left

Out

rigge

rP

ress

ure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

OB

oom

Ext

end

Inte

rlock

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Boo

mS

witc

hR

elay

Sol

.1&

2

40

47

48

N

RR

R

112

111

111

114

100 10

010

0

110

106

Sta

biliz

erLo

ckR

elay

Yel

low

Gre

en

Gre

enC

ab S

tud

Bro

wn

Gre

en

Sol

.3

& 4

Sol

.5

& 6

Ext

end

Pro

xim

ityS

witc

h

C

C

Boo

mA

ngle

Sen

sor

4545

109

59

4860

62

68

61 22

2

22

2

22

22

2

2

2835

1039

6764

63

35

7 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

5050

58

33

Par

kB

rake

Sw

itch

Ser

vice

Bra

keS

witc

h

Par

kB

rake

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rlock

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biliz

erIn

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ckR

elay

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biliz

erLo

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p O

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SH1200

Origin 2/00

399

SECTION 10


(S/N 9909 & After)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Released


LE

GE

ND

DE

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pen

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ff

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SH1210

Origin 2/00

SECTION 10

400



&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Below 40° 5. PB & SB Applied


LE

GE

ND

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e-e

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DE

SH1220

Origin 2/00

401

SECTION 10


(S/N 9909 & After)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Released


LE

GE

ND

DE

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ized

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y

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ck-U

pA

larm

Re

lay

Rel

ay B

lock

loca

ted

un

de

rD

ash

att

ach

ed

to

Ba

ck o

fB

ulk

he

ad

with

Ve

lcro

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

ela

ys lo

cate

d in

Kic

k P

an

el

Rel

ay B

lock

loca

ted

un

de

r D

ash

on

left

sid

e o

f th

e S

tee

rin

g W

he

el

To B

ack

-Up

Ala

rm

FE

DG

AC

++

7.5

Am

p O

utr

igg

er

an

d E

xte

nd

P

roxi

mity

Sw

itch P

ow

er

7.5

Am

p O

utr

igger

Pre

ssure

S

witc

h P

ow

er

Blu

eV

iole

tR

ed

Yel

low

Yel

low

100

100

101

F

M1

M2

M5

M3

M4

Shift

Sole

noid

s on Z

F T

ransm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yel

low

Pin

kG

ray

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

AL

eft

Ou

trig

ge

rL

ock

ou

tR

ela

y

Rig

ht

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dIn

terlo

ck

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dL

ock

ou

tR

ela

y

Pa

rkB

rake

Inte

rlo

ck

Sta

bili

zer

Inte

rlo

ckR

ela

y

Sta

bili

zer

Lo

ck-U

pR

ela

y

B

Ne

utr

al

Sta

rtR

ela

y

Ba

ck-U

pA

larm

Re

lay

7.5

Am

p S

tab

il-T

RA

K S

ole

no

ids,

R

ela

y &

Pro

xim

ity S

witc

h7

.5 A

mp

S

tee

rin

g S

ele

ct C

ircu

it &

Sta

bili

zer

Lock

Rela

y

10

Am

p H

orn

an

d B

ack

-Up

Ala

rm (

Optio

nal-C

ab H

eate

r F

an)

7.5

Am

p W

arn

ing L

ights

, P

ark

Bra

ke S

witc

h,

F

uel G

auge &

Hourm

ete

r2

0 A

mp

O

ptio

na

l Lig

htin

g K

it

40 A

mp Igniti

on S

witc

h F

eed

Opt

iona

l Enc

lose

d C

ab W

inds

hiel

d W

ash

er/

Wip

er

Sw

itch

an

d C

ircu

latio

n F

an

Bo

om

Sw

itch

Re

lay

Sta

bili

zer

Lo

ckR

ela

y

C D FEG

Sta

bili

zer

Lig

ht

107

107

Org

/Red

Blu

/Org

__

DE

108

O

DE

DE

DE

DE

DE

DE

Pa

rkB

rake

Dis

con

ne

ctR

ela

y

Pa

rkB

rake

Dis

con

ne

ctR

ela

y

E

SH1230

Origin 2/00

SECTION 10

402



&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Released


LE

GE

ND

DE

=D

e-e

nerg

ized

E=

Energ

ized

O=

Open

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Serv

ice B

rake

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red/B

lue

Org

/Gry

Org

/Red

Yel

/Grn

Dk.

Bl/R

ed

Igniti

on

Sw

itch

To

Fuel

Shuto

ff

Le

ftO

utr

igg

er

Lo

cko

ut

Re

lay

Le

ftO

utr

igger

Sw

itch

To

Sta

rtR

ela

y

Park

Bra

keR

ele

ase

d

Rig

ht

Outr

igger

Sw

itch

Le

ftO

utr

igger

"Up

"S

ole

no

id

Le

ftO

utr

igger

"Do

wn

"S

ole

no

id

Rig

ht

Outr

igger

"Up

"S

ole

no

id

Rig

ht

Ou

trig

ge

rL

ock

ou

tR

ela

y

Rig

ht

Outr

igger

"Do

wn

"S

ole

no

id

Pa

rkB

rake

So

len

oid

Va

lve

E E

EE

xte

nd

Circu

itS

ole

no

idV

alv

e

Rig

ht

Ou

trig

ge

rP

ress

ure

Sw

itch

Le

ftO

utr

igg

er

Pre

ssure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

Bo

om

Ext

en

dIn

terlo

ck

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dL

ock

ou

tR

ela

y

Bo

om

Sw

itch

Re

lay

So

l.1&

2

40

47

48

Grey

Violet Bro

wn

Red

Red

112

111

111

114

100 1

00

100

110

106

Sta

bili

zer

Lo

ckR

ela

y

Yel

low

Gre

en

Gre

en

Cab S

tud

Bro

wn

Gre

en

So

l.3 &

4

So

l.5 &

6

Ext

en

dP

roxi

mity

Sw

itch

C

O

Bo

om

An

gle

Se

nso

r

45

45

109

Blk/Wht

59

48

60

62

68

61

22

2

22

2

22

22

2

2

28

35

1039

67

64

63

357 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

50

50

58

33

Pa

rkB

rake

Sw

itch

Serv

ice

Bra

keS

witc

h

Pa

rkB

rake

Inte

rlo

ck

Sta

bili

zer

Inte

rlock

Re

lay

Sta

bili

zer

Lo

ck-U

pR

ela

y

E

Rin

g T

erm

inal

No

t U

sed

Not U

sed

Ne

utr

al

Sta

rtR

ela

y

Ba

ck-U

pA

larm

Re

lay

Rel

ay B

lock

loca

ted

un

de

rD

ash

att

ach

ed

to

Ba

ck o

fB

ulk

he

ad

with

Ve

lcro

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

ela

ys lo

cate

d in

Kic

k P

an

el

Rel

ay B

lock

loca

ted

un

de

r D

ash

on

left

sid

e o

f th

e S

tee

rin

g W

he

el

To B

ack

-Up

Ala

rm

FE

DG

AC

++

7.5

Am

p O

utr

igg

er

an

d E

xte

nd

P

roxi

mity

Sw

itch P

ow

er

7.5

Am

p O

utr

igger

Pre

ssure

S

witc

h P

ow

er

Blu

eV

iole

tR

edY

ello

wY

ello

w

100

100

101

F

M1

M2

M5

M3

M4

Shift

Sole

noid

s on Z

F T

ransm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yel

low

Pin

kG

ray

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

AL

eft

Ou

trig

ge

rL

ock

ou

tR

ela

y

Rig

ht

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dIn

terlo

ck

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dL

ock

ou

tR

ela

y

Pa

rkB

rake

Inte

rlo

ck

Sta

bili

zer

Inte

rlo

ckR

ela

y

Sta

bili

zer

Lo

ck-U

pR

ela

y

B

Ne

utr

al

Sta

rtR

ela

y

Ba

ck-U

pA

larm

Re

lay

7.5

Am

p S

tab

il-T

RA

K S

ole

no

ids,

R

ela

y &

Pro

xim

ity S

witc

h7

.5 A

mp

S

tee

rin

g S

ele

ct C

ircu

it &

Sta

bili

zer

Lock

Rela

y

10

Am

p H

orn

an

d B

ack

-Up

Ala

rm (

Optio

nal-C

ab H

eate

r F

an)

7.5

Am

p W

arn

ing L

ights

, P

ark

Bra

ke S

witc

h,

F

uel G

auge &

Hourm

ete

r2

0 A

mp

O

ptio

na

l Lig

htin

g K

it

40 A

mp Igniti

on S

witc

h F

eed

Opt

iona

l Enc

lose

d C

ab W

inds

hiel

d W

ash

er/

Wip

er

Sw

itch

an

d C

ircu

latio

n F

an

Bo

om

Sw

itch

Re

lay

Sta

bili

zer

Lo

ckR

ela

y

C D FEG

Sta

bili

zer

Lig

ht

107

107

Org

/Red

Blu

/Org

__

DE

108

DE

DE

DE

DE

DE

C

ED

E

Pa

rkB

rake

Dis

connect

Re

lay

Pa

rkB

rake

Dis

con

ne

ctR

ela

y

SH1240

Origin 2/00

403

SECTION 10


(S/N 9909 & After)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Applied


LE

GE

ND

DE

=D

e-e

nerg

ized

E=

Energ

ized

O=

Open

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Serv

ice B

rake

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red

/Blu

e

Org

/Gry

Org

/Red

Yel

/Grn

Dk.

Bl/R

ed

Igni

tion

Sw

itch

To

Fue

lS

huto

ff

Left

Out

rigge

rLo

ckou

tR

elay

Left

Out

rigge

rS

witc

h

To

Sta

rtR

elay

Par

kB

rake

App

lied

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

Rig

htO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Par

kB

rake

Sol

enoi

dV

alveE D

E

EE

xten

dC

ircui

tS

olen

oid

Val

ve

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Left

Out

rigge

rP

ress

ure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

Boo

mE

xten

dIn

terlo

ck

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Boo

mS

witc

hR

elay

Sol

.1&

2

40

47

48

Grey

Violet Bro

wn

Red

Red

112

111

111

114

100 10

010

0

110

106

Sta

biliz

erLo

ckR

elay

Yel

low

Gre

en

Gre

enC

ab S

tud

Bro

wn

Gre

en

Sol

.3

& 4

Sol

.5

& 6

Ext

end

Pro

xim

ityS

witc

h

C

O

Boo

mA

ngle

Sen

sor

4545

109

Blk/Wht

59

4860

62

68

61 22

2

22

2

22

22

2

2

2835

1039

6764

63

35

7 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

5050

58

33

Par

kB

rake

Sw

itch

Ser

vice

Bra

keS

witc

h

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

DE

Rin

g Te

rmin

alN

ot U

sed

Not

Use

d

Neu

tral

Sta

rtR

elay

Bac

k-U

pA

larm

Rel

ay

Rel

ay B

lock

loca

ted

unde

rD

ash

atta

ched

to B

ack

ofB

ulkh

ead

with

Vel

cro

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

Rel

ay B

lock

loca

ted

unde

r D

ash

on le

ft si

de o

f the

Ste

erin

g W

heel

To

Bac

k-U

pA

larm

FE

DG

AC

++

7.5

Am

p O

utrig

ger

and

Ext

end

P

roxi

mity

Sw

itch

Pow

er

7.5

Am

p O

utrig

ger

Pre

ssur

e

Sw

itch

Pow

er

Blu

eV

iole

tR

edY

ello

wY

ello

w

100

100

101

F

M1

M2

M5

M3

M4

Shi

ft S

olen

oids

on

ZF

Tra

nsm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yel

low

Pin

kG

ray

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

ALe

ftO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Boo

mE

xten

dIn

terlo

ck

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

BB

ack-

Up

Ala

rmR

elay

7.5

Am

p S

tabi

l-TR

AK

Sol

enoi

ds,

R

elay

& P

roxi

mity

Sw

itch

7.5

Am

p S

teer

ing

Sel

ect C

ircui

t

& S

tabi

lizer

Loc

k R

elay

10 A

mp

Hor

n an

d B

ack-

Up

Ala

rm

(Opt

iona

l-Cab

Hea

ter

Fan

)7.

5 A

mp

War

ning

Lig

hts,

Par

k B

rake

Sw

itch,

F

uel G

auge

& H

ourm

eter

20 A

mp

Opt

iona

l Lig

htin

g K

it

40 A

mp

Ign

ition

Sw

itch

Fee

d

Opt

iona

l Enc

lose

d C

ab W

inds

hiel

d W

ashe

r/W

iper

Sw

itch

and

Circ

ulat

ion

Fan

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

C D FEG

Sta

biliz

erLi

ght

107

107

Org

/Red

Blu

/Org

__

DE

108

O

DE

DE

DE

DE

E

E

Neu

tral

Sta

rtR

elay

Par

kB

rake

Dis

conn

ect

Rel

ay

Par

kB

rake

Dis

conn

ect

Rel

ay

DE

SH1250

Origin 2/00

SECTION 10

404





LE

GE

ND

DE

=D

e-e

nerg

ized

E=

Energ

ized

O=

Open

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Serv

ice B

rake

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red/B

lue

Org

/Gry

Org

/Red

Yel/G

rn

Dk.

Bl/R

ed

Igniti

on

Sw

itch

To

Fuel

Shuto

ff

Le

ftO

utr

igg

er

Lo

cko

ut

Re

lay

Le

ftO

utr

igger

Sw

itch

To S

tart

Rela

y

Park

Bra

keA

pplie

d

Rig

ht

Outr

igger

Sw

itch

Le

ftO

utr

igger

"Up

"S

ole

no

id

Le

ftO

utr

igger

"Do

wn

"S

ole

no

id

Rig

ht

Outr

igger

"Up

"S

ole

no

id

Rig

ht

Ou

trig

ge

rL

ock

ou

tR

ela

y

Rig

ht

Outr

igger

"Do

wn

"S

ole

no

id

Pa

rkB

rake

So

len

oid

Va

lve

E

DE

E

Ext

en

dC

ircu

itS

ole

noid

Va

lve

Rig

ht

Ou

trig

ge

rP

ress

ure

Sw

itch

Le

ftO

utr

igg

er

Pre

ssure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

CB

oo

mE

xte

nd

Inte

rlock

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dL

ock

ou

tR

ela

y

Bo

om

Sw

itch

Re

lay

So

l.1&

2

40

47

48

Grey

Violet Bro

wn

Red

Red

112

111

111

114

100 1

00

100

110

106

Sta

bili

zer

Lo

ckR

ela

y

Yello

wG

reen

Gre

en

Cab S

tud

Bro

wn

Gre

en

So

l.3 &

4

So

l.5 &

6

Ext

en

dP

roxi

mity

Sw

itch

O

Bo

om

An

gle

Se

nso

r

45

45

109

Blk/Wht

59

48

60

62

68

61

22

2

22

2

22

22

2

2

28

35

1039

67

64

63

35

7 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

50

50

58

33

Pa

rkB

rake

Sw

itch

Serv

ice

Bra

keS

witc

h

Pa

rkB

rake

Inte

rlock

Sta

bili

zer

Inte

rlo

ckR

ela

y

Sta

bili

zer

Lo

ck-U

pR

ela

y

E

E

Rin

g T

erm

inal

No

t U

sed

Not U

sed

Ne

utr

al

Sta

rtR

ela

y

Ba

ck-U

pA

larm

Re

lay

Rela

y B

lock

loca

ted u

nd

er

Da

sh a

tta

che

d t

o B

ack

of

Bu

lkh

ea

d w

ith V

elc

ro

Boom

Sw

itch a

nd S

tabili

zer

Lock

Re

lays

loca

ted

in K

ick

Pa

ne

l

Rela

y B

lock

loca

ted u

nd

er

Da

sho

n le

ft s

ide

of

the

Ste

erin

g W

he

el

To B

ack

-Up

Ala

rm

FE

DG

AC

++

7.5

Am

p O

utr

igg

er

an

d E

xte

nd

P

roxi

mity

Sw

itch P

ow

er

7.5

Am

p O

utr

igger

Pre

ssure

S

witc

h P

ow

er

Blu

eV

iole

tR

ed

Yello

wY

ello

w

100

100

101

F

M1

M2

M5

M3

M4

Shift

Sole

noid

s on Z

F T

ransm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yello

wP

ink

Gra

y

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

AL

eft

Ou

trig

ge

rL

ock

ou

tR

ela

y

Rig

ht

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dIn

terlo

ck

Ou

trig

ge

rL

ock

ou

tR

ela

y

Bo

om

Ext

en

dL

ock

ou

tR

ela

y

Pa

rkB

rake

Inte

rlo

ck

Sta

bili

zer

Inte

rlo

ckR

ela

y

Sta

bili

zer

Lo

ck-U

pR

ela

y

BB

ack

-Up

Ala

rmR

ela

y

7.5

Am

p S

tab

il-T

RA

K S

ole

no

ids,

R

ela

y &

Pro

xim

ity S

witc

h7

.5 A

mp

S

tee

rin

g S

ele

ct C

ircu

it &

Sta

bili

zer

Lock

Rela

y

10

Am

p H

orn

an

d B

ack

-Up

Ala

rm (

Optio

nal-C

ab H

eate

r F

an)

7.5

Am

p W

arn

ing L

ights

, P

ark

Bra

ke S

witc

h,

F

uel G

auge &

Hourm

ete

r2

0 A

mp

O

ptio

na

l Lig

htin

g K

it

40 A

mp Igniti

on S

witc

h F

eed

Optio

nal E

ncl

ose

d C

ab W

indsh

ield

Wash

er/

Wip

er

Sw

itch

an

d C

ircu

latio

n F

an

Bo

om

Sw

itch

Re

lay

Sta

bili

zer

Lo

ckR

ela

y

C D FEG

Sta

bili

zer

Lig

ht

107

107

Org

/Red

Blu

/Org

__

DE

108

C

DE

ED

E

E

Ne

utr

al

Sta

rtR

ela

y

Pa

rkB

rake

Dis

connect

Re

lay

Pa

rkB

rake

Dis

con

ne

ctR

ela

y

DE

SH1260

Origin 2/00

405

SECTION 10


(S/N 9909 & After)&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV&RQGLWLRQV2. Boom Above 40° 5. PB & SB Applied


SH1270

LE

GE

ND

DE

=D

e-e

nerg

ized

E=

Energ

ized

O=

Open

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Serv

ice B

rake

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red

/Blu

e

Org

/Gry

Org

/Red

Yel

/Grn

Dk.

Bl/R

ed

Igni

tion

Sw

itch

To

Fue

lS

huto

ff

Left

Out

rigge

rLo

ckou

tR

elay

Left

Out

rigge

rS

witc

h

To

Sta

rtR

elay

Par

kB

rake

App

lied

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

Rig

htO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Par

kB

rake

Sol

enoi

dV

alve

DE D

E

DE

Ext

end

Circ

uit

Sol

enoi

dV

alve

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Left

Out

rigge

rP

ress

ure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

Boo

mE

xten

dIn

terlo

ck

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Boo

mS

witc

hR

elay

Sol

.1&

2

40

47

48

Grey

Violet Bro

wn

Red

Red

112

111

111

114

100 10

010

0

110

106

Sta

biliz

erLo

ckR

elay

Yel

low

Gre

en

Gre

enC

ab S

tud

Bro

wn

Gre

en

Sol

.3

& 4

Sol

.5

& 6

Ext

end

Pro

xim

ityS

witc

h

O

O

Boo

mA

ngle

Sen

sor

4545

109

Blk/Wht

59

4860

62

68

61 22

2

22

2

22

22

2

2

2835

1039

6764

63

35

7 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

5050

58

33

Par

kB

rake

Sw

itch

Ser

vice

Bra

keS

witc

h

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

DE

Rin

g Te

rmin

alN

ot U

sed

Not

Use

d

Neu

tral

Sta

rtR

elay

Bac

k-U

pA

larm

Rel

ay

Rel

ay B

lock

loca

ted

unde

rD

ash

atta

ched

to B

ack

ofB

ulkh

ead

with

Vel

cro

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

Rel

ay B

lock

loca

ted

unde

r D

ash

on le

ft si

de o

f the

Ste

erin

g W

heel

To

Bac

k-U

pA

larm

FE

DG

AC

++

7.5

Am

p O

utrig

ger

and

Ext

end

P

roxi

mity

Sw

itch

Pow

er

7.5

Am

p O

utrig

ger

Pre

ssur

e

Sw

itch

Pow

er

Blu

eV

iole

tR

edY

ello

wY

ello

w

100

100

101

F

M1

M2

M5

M3

M4

Shi

ft S

olen

oids

on

ZF

Tra

nsm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yel

low

Pin

kG

ray

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

ALe

ftO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Boo

mE

xten

dIn

terlo

ck

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

BB

ack-

Up

Ala

rmR

elay

7.5

Am

p S

tabi

l-TR

AK

Sol

enoi

ds,

R

elay

& P

roxi

mity

Sw

itch

7.5

Am

p S

teer

ing

Sel

ect C

ircui

t

& S

tabi

lizer

Loc

k R

elay

10 A

mp

Hor

n an

d B

ack-

Up

Ala

rm

(Opt

iona

l-Cab

Hea

ter

Fan

)7.

5 A

mp

War

ning

Lig

hts,

Par

k B

rake

Sw

itch,

F

uel G

auge

& H

ourm

eter

20 A

mp

Opt

iona

l Lig

htin

g K

it

40 A

mp

Ign

ition

Sw

itch

Fee

d

Opt

iona

l Enc

lose

d C

ab W

inds

hiel

d W

ashe

r/W

iper

Sw

itch

and

Circ

ulat

ion

Fan

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

C D FEG

Sta

biliz

erLi

ght

107

107

Org

/Red

Blu

/Org

__

DE

108

O

DE

DE

DE

DE

E

E

Neu

tral

Sta

rtR

elay

Par

kB

rake

Dis

conn

ect

Rel

ay

Par

kB

rake

Dis

conn

ect

Rel

ay

DE

Origin 2/00

SECTION 10

406

10054 Stabil-TRAK Electrical CircuitBoom Extend Mode 9 (S/N 9909 & After)




Neu

tral

Sta

rtR

elay

Par

kB

rake

Dis

conn

ect

Rel

ay

LE

GE

ND

DE

=D

e-e

nerg

ized

E=

Energ

ized

O=

Open

C=

Clo

sed

PB

=P

ark

Bra

keS

B=

Serv

ice B

rake

Red

Purple

Red/Blk

WhiteDk. Bl/Org

Dk.

Blu

e

Org

/Bla

ck

Red

/Blu

e

Org

/Gry

Org

/Red

Yel

/Grn

Dk.

Bl/R

ed

Igni

tion

Sw

itch

To

Fue

lS

huto

ff

Left

Out

rigge

rLo

ckou

tR

elay

Left

Out

rigge

rS

witc

h

To

Sta

rtR

elay

Par

kB

rake

App

lied

Rig

htO

utrig

ger

Sw

itch

Left

Out

rigge

r"U

p"S

olen

oid

Left

Out

rigge

r"D

own"

Sol

enoi

d

Rig

htO

utrig

ger

"Up"

Sol

enoi

d

Rig

htO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

"Dow

n"S

olen

oid

Par

kB

rake

Sol

enoi

dV

alve

DE D

EE

DE

Ext

end

Circ

uit

Sol

enoi

dV

alve

Rig

htO

utrig

ger

Pre

ssur

eS

witc

h

Left

Out

rigge

rP

ress

ure

Sw

itch

Gry/Org

Red/WhtOrg

/Wht

CB

oom

Ext

end

Inte

rlock

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Boo

mS

witc

hR

elay

Sol

.1&

2

40

47

48

Grey

Violet Bro

wn

Red

Red

112

111

111

114

100 10

010

0

110

106

Sta

biliz

erLo

ckR

elay

Yel

low

Gre

en

Gre

enC

ab S

tud

Bro

wn

Gre

en

Sol

.3

& 4

Sol

.5

& 6

Ext

end

Pro

xim

ityS

witc

h

O

O

Boo

mA

ngle

Sen

sor

4545

109

Blk/Wht

59

4860

62

68

61 22

2

22

2

22

22

2

2

2835

1039

6764

63

35

7 7

46

23

49

66

56

55

57

71

51

70

65

108

104

102

103

102

101

105

10411

4

113

56

45

52

Tan

423

2

2

5050

58

33

Par

kB

rake

Sw

itch

Ser

vice

Bra

keS

witc

h

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elayE

E

E

E

EE

Rin

g Te

rmin

alN

ot U

sed

Not

Use

d

Neu

tral

Sta

rtR

elay

Bac

k-U

pA

larm

Rel

ay

Rel

ay B

lock

loca

ted

unde

rD

ash

atta

ched

to B

ack

ofB

ulkh

ead

with

Vel

cro

Boo

m S

witc

h an

d S

tabi

lizer

Loc

kR

elay

s lo

cate

d in

Kic

k P

anel

Rel

ay B

lock

loca

ted

unde

r D

ash

on le

ft si

de o

f the

Ste

erin

g W

heel

To

Bac

k-U

pA

larm

FE

DG

AC

++

7.5

Am

p O

utrig

ger

and

Ext

end

P

roxi

mity

Sw

itch

Pow

er

7.5

Am

p O

utrig

ger

Pre

ssur

e

Sw

itch

Pow

er

Blu

eV

iole

tR

edY

ello

wY

ello

w

100

100

101

F

M1

M2

M5

M3

M4

Shi

ft S

olen

oids

on

ZF

Tra

nsm

issi

on

D B C A E

A B C D A B C D

Pin

kP

ink

Gra

y

Blu

e

Blu

e

Vio

let

Red

Yel

low

Pin

kG

ray

Black

Black

Black

Black

Black

Black

Black

Bla

ck

Bla

ck

Bla

ck

Tra

ns

Black

Black

BlackBlack

Black

Black

Black

Green

Black

Bro

wn

Red/Black

Red/Gray

Gry/Pur

Yel/Grn

Pur/Wht

Brn/Yel

Brn/Blk

B

RE

LA

Y L

OC

AT

ION

S

ALe

ftO

utrig

ger

Lock

out

Rel

ay

Rig

htO

utrig

ger

Lock

out

Rel

ay

Boo

mE

xten

dIn

terlo

ck

Out

rigge

rLo

ckou

tR

elay

Boo

mE

xten

dLo

ckou

tR

elay

Par

kB

rake

Inte

rlock

Sta

biliz

erIn

terlo

ckR

elay

Sta

biliz

erLo

ck-U

pR

elay

BB

ack-

Up

Ala

rmR

elay

7.5

Am

p S

tabi

l-TR

AK

Sol

enoi

ds,

R

elay

& P

roxi

mity

Sw

itch

7.5

Am

p S

teer

ing

Sel

ect C

ircui

t

& S

tabi

lizer

Loc

k R

elay

10 A

mp

Hor

n an

d B

ack-

Up

Ala

rm

(Opt

iona

l-Cab

Hea

ter

Fan

)7.

5 A

mp

War

ning

Lig

hts,

Par

k B

rake

Sw

itch,

F

uel G

auge

& H

ourm

eter

20 A

mp

Opt

iona

l Lig

htin

g K

it

40 A

mp

Ign

ition

Sw

itch

Fee

d

Opt

iona

l Enc

lose

d C

ab W

inds

hiel

d W

ashe

r/W

iper

Sw

itch

and

Circ

ulat

ion

Fan

Boo

mS

witc

hR

elay

Sta

biliz

erLo

ckR

elay

C D FEG

Sta

biliz

erLi

ght

107

107

Org

/Red Blu

/Org

__

DE

108

EP

ark

Bra

keD

isco

nnec

tR

elay

DE

SH1280

Origin 2/00

PART NUMBER INDEX

8042/10042/10054 Origin 2/00

PagePart Number PagePart Number PagePart Number PagePart Number

277

10136599 ...................... 9310138907 ...................... 9310238805 ...................... 9310701363 ...................... 9310701562 ...................... 9310715335 ...................... 9310731702 ...................... 5710731704 ...................... 5910731705 ...................... 6110731706 ...................... 6110731707 ...................... 6110731709 .......... 61, 85, 8710731710 ................ 61, 8510731711 ...................... 6310731712 ...................... 6310731713 ...................... 6310731715 ...................... 6310731716 ...................... 6310731717 ...................... 6310731718 ...................... 6310731719 ...................... 6310731720 ...................... 6310731721 ...................... 6310731722 ...................... 6310731723 ...................... 6310731724 ...................... 6310731725 ...................... 6310731726 ...................... 6310731727 ...................... 6310731728 ...................... 6310731729 ...................... 6310731730 ...................... 6310731731 ...................... 6310731732 ...................... 6310731734 ...................... 6310731736 ...................... 6510731737 ...................... 6510731738 ...................... 6510731739 ...................... 6510731741 ...................... 6510731742 ...................... 6510731743 ................ 65, 8910731744 ...................... 6510731745 ...................... 6510731746 ...................... 6510731747 ................ 65, 6910731748 .......... 57, 65, 6910731749 ................ 65, 6910731750 ................ 65, 6910731751 .... 57, 65, 69, 8110731752 ...................... 6510731753 ...................... 6510731754 ...................... 6510731756 ...................... 6510731758 ...................... 6510731759 ...................... 6510731761 .......... 67, 71, 7510731762 ...................... 67

10731763 ...................... 6710731764 ...................... 6710731765 ...................... 6710731766 ...................... 6710731767 ...................... 6710731768 ...................... 6710731769 ...................... 6710731770 ...................... 6710731771 ...................... 6710731772 ...................... 6710731773 ...................... 6710731774 ...................... 6710731775 ...................... 6710731776 ...................... 6710731777 ...................... 6710731778 ...................... 6710731779 ...................... 6710731780 ...................... 6710731781 ...................... 6710731782 ...................... 6710731783 ...................... 6710731784 ...................... 6710731785 ...................... 6710731786 ...................... 6710731787 ...................... 6710731789 .......... 67, 71, 7510731790 ...................... 6710731791 .......... 67, 71, 7510731792 .......... 67, 71, 7510731793 .......... 67, 71, 7510731794 .......... 67, 71, 7510731795 .......... 67, 71, 7510731796 .......... 67, 71, 7510731797 .......... 67, 71, 7510731798 .......... 67, 71, 7510731799 .......... 67, 71, 7510731800 .......... 67, 71, 7510731801 .......... 67, 71, 7510731802 .......... 67, 71, 7510731803 .......... 67, 71, 7510731804 .......... 67, 71, 7510731805 .......... 67, 71, 7510731806 .......... 67, 71, 7510731807 .......... 67, 71, 7510731808 .......... 67, 71, 7510731809 .......... 67, 71, 7510731810 .......... 67, 71, 7510731811 .......... 69, 71, 7510731812 .......... 69, 71, 7510731813 .......... 69, 71, 7510731814 .......... 69, 71, 7510731815 .......... 69, 71, 7510731816 .......... 69, 71, 7510731817 .......... 69, 71, 7510731818 .......... 69, 71, 7510731819 .......... 69, 71, 7510731820 .......... 69, 71, 7510731821 .......... 69, 71, 75

10731822 ...................... 6910731823 ...................... 6910731824 ................ 69, 7510731825 .......... 69, 73, 7510731826 .......... 69, 73, 7510731827 .......... 69, 73, 7510731828 .......... 69, 73, 7710731829 .......... 69, 73, 7710731830 .......... 69, 73, 7710731831 ................ 69, 7310731832 .......... 69, 73, 7710731833 ...................... 6910731834 ................ 69, 7510731835 ................ 69, 7510731836 ................ 69, 7510731837 ................ 69, 7510731838 ................ 69, 7510731839 .......... 69, 75, 7710731840 ...................... 7710731841 ................ 69, 7710731842 ................ 69, 7710731843 ................ 69, 7710731844 ................ 69, 7710731845 .......... 69, 77, 8310731846 ................ 69, 7710731847 .......... 69, 73, 7710731848 .......... 69, 73, 7710731849 .......... 69, 73, 7710731850 .......... 69, 73, 7710731851 .......... 69, 73, 7710731852 ...................... 7710731854 ...................... 7110731855 ...................... 7110731856 ...................... 7110731857 ...................... 7110731858 ...................... 7110731859 ...................... 7110731860 ...................... 7110731861 ...................... 7110731862 ...................... 7110731863 ...................... 7110731864 ...................... 7110731865 ...................... 7110731866 ...................... 7110731867 ...................... 7110731868 ...................... 7110731869 ...................... 7110731870 ...................... 7110731871 ...................... 7110731872 ...................... 7110731873 ...................... 7110731874 ...................... 7110731875 ...................... 7110731876 ...................... 7110731877 ...................... 7110731878 ...................... 7110731879 ...................... 7110731880 ...................... 71

10731881 .......................7110731882 .......................7110731883 .......................7110731884 .......................7110731885 .......................7110731886 .......................7110731887 .......................7110731888 .......................7110731889 .......................7310731890 .......................7310731891 .......................7310731892 .......................7310731893 .......................7310731894 .......................7310731895 .......................7310731896 .......................7310731897 .......................7310731898 .......................7310731899 .......................7310731900 .......................7310731901 .......................7310731902 .......................7310731903 .......................7310731904 .......................7310731905 .......................7310731906 .......................7310731907 .......................7310731908 .......................7310731909 .......................7310731910 .......................7310731911 .......................7510731912 .......................7510731913 .......................7510731916 .......................7710731917 .......................7710731918 .......................7710731919 .......................7710731920 .......................7710731921 .......................7710731923 .......................8910731924 .......................8910731925 .......................8910731926 .......................8910731928 .......................7710731929 .......................7710731930 .......................7710731931 .......................7710731932 .......................7710731933 .......................7710731934 .......................7710731935 .......................7710731936 .......................7710731937 .......................7710731938 .......................7710731953 .......................7910731954 .......................7910731955 .......................7910731956 .......................79

PART NUMBER INDEX


8042/10042/10054 Origin 2/00278

10731957 ...................... 7910731958 ...................... 7910731959 ...................... 7910731960 ...................... 7910731961 ...................... 7910731962 ...................... 7910731963 ...................... 7910731964 ...................... 7910731965 ...................... 7910731966 ...................... 7910731967 ...................... 7910731968 ...................... 7910731969 ...................... 7910731970 ...................... 7910731971 ...................... 7910731972 ...................... 7910731973 ...................... 7910731974 ...................... 7910731975 ...................... 7910731976 ...................... 7910731977 ...................... 7910731978 ...................... 8110731979 ...................... 8110731980 ...................... 8110731981 ...................... 8110731982 ...................... 8110731983 ...................... 8110731984 ...................... 8110731985 ...................... 8110731986 ...................... 8110731987 ...................... 8110731988 ...................... 8110731989 ...................... 8310731992 ...................... 8310731993 ...................... 8310731994 ...................... 8310731995 ...................... 8310731996 ...................... 8310731997 ...................... 8310731998 ...................... 8310731999 ...................... 8310732000 ...................... 8310732001 ...................... 8310732002 ...................... 8310732003 ...................... 8310732004 ...................... 8310732005 ...................... 8310732007 ...................... 8510732009 ...................... 8510732011 ...................... 8510732012 ...................... 8510732013 ...................... 8510732015 ...................... 8710732017 ................ 85, 8710732018 ................ 87, 8910732021 ...................... 8510732022 ...................... 8510732023 ...................... 85

10732024 ...................... 8510732025 ...................... 8510732027 ...................... 8710732028 ...................... 8710732029 ...................... 8710732030 ...................... 8710732031 ...................... 8710732032 ...................... 8710732033 ...................... 8710732034 ...................... 8710732035 ...................... 8710732036 ...................... 8710732037 ...................... 8710732038 ...................... 8710732039 ...................... 8710732040 ...................... 8710732041 ...................... 8710732042 ...................... 8710732043 ...................... 8710732044 ...................... 8710732045 ...................... 8710732046 ...................... 8710732047 ...................... 8710732048 ...................... 8710732049 ...................... 8710732050 ...................... 8710732051 ...................... 8710732053 ...................... 8710732054 ...................... 8710732055 ...................... 8710732056 ...................... 8710732058 ...................... 8710732060 ...................... 8710732061 ...................... 8710732063 ...................... 8710732064 ...................... 8710732065 ...................... 8710732067 ...................... 8710732068 ...................... 8710732069 ...................... 8710732070 ...................... 8710732071 ................ 87, 8910732072 ...................... 8710732076 ................ 87, 8910732078 ...................... 8910732081 ...................... 8910732082 ...................... 8910732083 ...................... 8910732085 ...................... 9110732089 ...................... 9110732090 ...................... 9110732091 ...................... 9110732092 ...................... 9110732093 ...................... 8110732094 ...................... 8110732095 ................ 57, 8110732096 ...................... 8110732097 ...................... 81

10732098 ...................... 8110732099 ...................... 8110732101 ...................... 8110732103 ...................... 7510732104 ...................... 7510732105 ...................... 7510732106 ...................... 7510732107 ................ 69, 7510732110 ...................... 5910732111 ...................... 5910732112 ...................... 5910732113 ...................... 5910732114 ...................... 5910732115 ...................... 5910732116 ...................... 5910732117 ...................... 5910732118 ...................... 5910732119 ...................... 5910732120 ...................... 5910732121 ...................... 5910732122 ...................... 5910837660 ...................... 8510837728 ...................... 8710839156 ...................... 791319203 ........................ 571319204 ........................ 571319205 ........................ 571319206 ........................ 571319207 ........................ 571319208 ........................ 571319209 ........................ 571319210 ........................ 571319211 ........................ 571319212 ........................ 571319213 ........................ 571319214 ........................ 611319215 .................. 63, 711319216 ........................ 631319217 ........................ 631319218 .................. 63, 831319219 ........................ 651319220 ............ 65, 75, 851319221 ........................ 651319222 ........................ 651319223 ........................ 671319224 ............ 67, 71, 751319225 .................. 69, 751319226 ........................ 711319227 ........................ 711319230 ........................ 751319234 ........................ 771319235 ........................ 771319237 ........................ 811319238 ........................ 831319240 ........................ 831319241 ........................ 831319242 ........................ 831319243 ........................ 83

1319244 .........................831319245 .........................831319246 .........................831319247 .........................831319248 .........................831319249 .........................831319250 .........................831319251 .........................831319252 .........................831319253 .........................831319254 .........................831319255 .........................831319256 .........................851319257 .........................851319259 .........................851319260 .........................851319261 .........................851319262 .........................871319263 .........................871319264 .........................871319265 .........................871319266 .........................871319267 .........................871319268 .........................871319269 .........................871319270 .........................871319271 .........................891319272 .........................891319273 .........................891319274 .........................891319275 .........................911319276 .........................911319277 .........................911319278 .........................911319279 .........................911319283 .........................191319285 .........................671319286 .........................671319287 .........................671319288 .........................672705122 .......................1492710802 ...............133, 1352711613 .......................1932711852 ...............141, 1432711872 ...............137, 1392711892 .......................1472711972 ......133, 135, 137,

1392711992 ......133, 135, 243,

2452712012 .......133, 135, 1492712092 .......................1492712112 ...............133, 1352712122 ...............133, 1352712142 ...............133, 1352712332 .......................1492712872 .......................1452712942 .......133, 135, 137

PART NUMBER INDEX

8042/10042/10054 Origin 2/00


279

2712973 ...................... 1852712993 ...... 117, 119, 1212713054 ...................... 1212713222 ...................... 1452713242 .............. 133, 1352713262 ...................... 1412713282 ...................... 1412713292 ...................... 1372713332 ...... 133, 135, 1472713333 ...................... 1792713363 ...................... 1912713432 .............. 133, 1352713442 ...................... 1372713452 ...................... 1452713642 ...................... 1452713803 ...................... 1752713853 ...................... 1772714973 ...................... 1832714993 .............. 173, 1752716163 .............. 189, 2472716173 ...................... 1712716516 ...................... 1432716545 ...................... 1534105621 ........................ 334106561 ...................... 2534107182 ...................... 2754107232 ...................... 2274107692 ...................... 2494107702 ...................... 2494107712 ...................... 2494107812 ...................... 2754107822 ...................... 2754107832 ...................... 2754107971 ........................ 154107981 ........................ 154108161 ...................... 1134108232 ...................... 2454108302 ...................... 2274110123 ...................... 2274110124 ...................... 2274110125 ...................... 2275721202 ...................... 2235724284 ...................... 1175724302 .......................... 35724622 ...................... 2295724742 .......................... 55746241 .......................... 55746411 ...................... 2596604662 ...................... 2496604712 ...................... 1496604882 ..... 133, 135, 137,

1396604972 ...................... 1496604982 ...................... 1456605202 .............. 137, 1456605772 ...................... 1496608621 ...................... 2496611752 .............. 149, 249

6619261 ........................ 956620531 .......................... 37047041 ...................... 2077054351 . 55, 93, 117, 119,

1217054632 ...... 117, 119, 1217057141 ...... 117, 119, 1217058372 ...................... 2237062922 ...................... 2497065482 .............. 243, 2457068651 ...................... 2137070191 ...................... 2457075191 ........................ 317075611 ...................... 2297077481 .............. 243, 2457077501 .............. 243, 2457077511 .............. 243, 2457079162 ...................... 1257079442 .......................... 37080891 ........................ 277081031 ........................ 277082292 ........................ 157082311 . 5, 229, 231, 233,

255, 257, 2597082342 ..... 229, 231, 233,

255, 257, 2597082362 ..... 229, 231, 233,

255, 257, 2597082971 .......................... 77083054 ...................... 2377083963 ........................ 137083992 .............. 233, 2597084792 .......................... 57084821 .......................... 57084902 ........................ 157085073 ..... 237, 239, 241,

243, 245, 2497085102 ...................... 2357085411 .............. 243, 2457085422 ...... 117, 119, 1217085501 .............. 243, 2457085552 ...................... 2357085562 ...................... 2357085571 ...................... 2357086304 ...................... 2397086471 ..... 237, 239, 241,

243, 245, 2497086742 ...................... 1257088283 ...................... 1257088352 .............. 117, 1197088522 ........................ 257089044 ...................... 2437089054 ...................... 2437089722 ...................... 1857089781 .............. 261, 2677090634 ...................... 2477090751 ........................ 137090814 ...................... 241

7090822 ...................... 2477090832 ...................... 2477090871 ...................... 2477090891 ...................... 2477090951 ...................... 2477091323 ........................ 337091373 ...................... 2477092292 .................. 3, 2297092533 ...................... 1137092612 ...................... 1137093772 ...... 117, 119, 1217093783 ...... 117, 119, 1217094562 ...................... 1637094592 ...................... 1177094682 .......................... 57095272 ...... 117, 119, 1217095282 ...... 117, 119, 1217095302 ...................... 1277095312 .............. 233, 2597095342 ........................ 557095352 .............. 233, 2597095393 ...................... 1277095452 .......................... 57095522 .............. 233, 2597095831 ...... 117, 119, 1217096471 ........................ 557096552 ...................... 2297096562 ...................... 2297096592 ........................ 957096632 ........................ 997096692 ...................... 1177096702 ..... 231, 233, 255,

257, 2597096772 ...................... 2297096882 ..... 229, 231, 233,

255, 2577097174 .......................... 57097233 .......................... 77097323 ...................... 1277097382 ...................... 2297097452 ...................... 1257097523 ..... 237, 239, 241,

243, 245, 2497097533 ..... 237, 239, 241,

243, 245, 2497097543 ..... 237, 239, 241,

243, 245, 2497097682 ...................... 2297098142 ........................ 237098262 .......................... 57098271 ...................... 1637098342 .......................... 77098354 ...................... 2437098563 .......................... 37098733 .............. 113, 1157098762 ...... 213, 215, 2177098864 ...................... 2137098973 ...................... 223

7099072 ...............137, 1657099312 ...........................37099324 ...........................97099332 .........................157099352 .........................157099522 ...............113, 1157099532 ...............113, 1157099692 .......................1157099702 .......................1157099742 ...........................77099832 .........................997099882 ......213, 215, 217,

219, 221, 2257099912 .......117, 119, 1217099923 .......................2257099943 .......................1177110002 .......................2477110022 .......................1257110042 .......................2557110172 .......................2597110333 .......................1157110342 .......................1157110352 .......................1157110494 .......................2497110582 .......231, 255, 2577110642 .......231, 255, 2577110694 .......................2497110702 .......................2497110712 .......................2497110722 .......................2497110744 .......................2537110762 .......................1137110772 .......................1137110782 .......................2237111164 ...........................57111191 .................27, 2237111203 .........................277111473 ...........................57111572 ......229, 231, 233,

255, 257, 2597111832 .........................157111842 .........................157111952 .........................557111994 .......................2497112092 ...........................97112102 ...........................77112302 .......................2237112422 ...............207, 2097112452 .......................1457112511 .29, 207, 209, 2117112523 .......................2517112533 .......................2517112582 .......................2257112592 .......................2257112642 .......................2517112732 .......................2577112804 .......................2757113024 .......................275

PART NUMBER INDEX


8042/10042/10054 Origin 2/00280

7113952 ...................... 2677113982 ...................... 2677114032 ...................... 2577114112 .............. 231, 2557114542 .............. 215, 2177114604 ...................... 2097114612 ...................... 2137114754 .............. 209, 2117114763 ...................... 2077114922 ...................... 2597114941 ...................... 2517115114 ...................... 2257115163 ...................... 2077115432 ...................... 2477115652 ...................... 1997115662 ...................... 1777115712 ...................... 2017116632 ...................... 2257116642 .............. 231, 2557116652 .............. 231, 2557116662 .............. 231, 2557116691 .............. 231, 2557116784 ...................... 2317116792 ...................... 2297116812 .............. 231, 2557116854 ...................... 2297117031 ...... 265, 271, 2737117072 .............. 231, 2557117113 ...................... 2337117133 ...................... 2597117204 ...................... 2457117244 ...................... 2457117254 ...................... 2457117264 ...................... 2457117282 ...................... 2057117292 ...................... 2057117414 ...................... 2577117502 ...... 231, 255, 2577117513 ...................... 2317117534 ...................... 2577117542 ...................... 2557117572 .............. 231, 2557117582 ...................... 2577117692 ...................... 2057118222 ..... 129, 131, 213,

215, 217, 219, 2217118662 ...................... 2337118682 ...................... 2597118692 ...................... 2577118854 ...................... 2557118882 ...... 237, 239, 2417118892 ...... 237, 239, 2417118941 .................. 29, 377119341 ...................... 2457119351 ...... 265, 271, 2737119362 ..... 261, 263, 265,

267, 269, 271, 273

7119372 ..... 261, 265, 267, 271, 273

7119632 ...................... 1137119642 ...................... 1137119652 ...................... 1137119662 ...................... 1137119813 .............. 149, 2037120191 .............. 263, 2697120742 ...................... 2357121013 ...................... 1377124331 .............. 3, 7, 2237124491 ...................... 2477124531 ........................ 317125251 ........................ 317125271 ........................ 317125421 ...................... 1297125521 .......................... 77125691 .......................... 77125741 ...... 243, 245, 2597125801 ...................... 2477125811 .............. 233, 2597125861 .......................... 37126662 ...................... 2557126684 ...... 215, 217, 2197126922 ...................... 1257126953 ...................... 1257126962 ...................... 1257126992 ...................... 1257127003 .............. 119, 1217127013 .............. 119, 1217127022 ...................... 1257127034 .............. 119, 1217127043 .............. 119, 1217127081 ...................... 1317127091 ........................ 257127102 ........................ 257127282 .......................... 97127852 ...................... 2597127862 ...................... 2597127871 .............. 129, 1317127881 .............. 129, 1317128772 ...... 237, 243, 2457128782 ...................... 2497128792 ...... 239, 243, 2457128802 ..... 241, 243, 245,

2497129261 .......................... 77129313 .......................... 37129323 .......................... 37129382 ...... 215, 219, 2217129392 ...... 215, 219, 2217130563 ...................... 2057130912 ...................... 1997131274 ...................... 2057131852 ........................ 537132912 ...................... 1177133022 ...................... 1177133802 .............. 141, 143

7133812 .............. 141, 1437133823 ...................... 1457133833 ...................... 1457134832 ...................... 2197134894 ...................... 2217135942 ........................ 157136034 ...... 129, 131, 1637137132 ........................ 377137643 .............. 121, 1237138164 ...................... 1637138186 ........................ 937138208 ........................ 937138209 ...... 129, 131, 1637138240 ...................... 1137138241 ...................... 1137138290 ...................... 1217138291 .............. 117, 1197138297 ...................... 1217138301 .............. 117, 1197138302 .......................... 37138468 ...................... 2257138469 ...................... 2257138614 .......................... 57138714 ...... 129, 131, 1637138738 .............. 261, 2677138848 ...................... 1217143900 ........................ 137144000 ........................ 137150082 ........................ 937150182 ................ 93, 1017150192 ................ 93, 1017150202 .................. 93, 977150282 ...................... 1577150302 ...................... 1397150312 ...................... 1357150361 .......................... 77150371 ........................ 157150382 .......................... 77150393 .......................... 57150402 ...................... 2217150412 .............. 133, 1357150432 ...................... 1437150442 ...................... 1437150452 ...................... 1437150472 ........................ 157150492 ...................... 1397150502 ...................... 1397150521 ...................... 2217150523 ...... 117, 119, 1218032500 ........................ 418032501 ........................ 418032502 ........................ 418032503 .................. 41, 458032504 ........................ 418032505 ........................ 418032506 .................. 41, 458032509 ........................ 418032510 ........................ 41

8032511 .........................418032515 .........................418032516 .........................418032517 .........................418032518 .........................418032519 .........................418032521 .........................418032522 .........................418032523 .........................418032526 .........................418032528 .........................418032532 .........................418032535 .........................418032536 .........................418032537 .........................418032538 .........................418032539 .........................418032541 ...................41, 438032542 ...................41, 438032543 ...................41, 438032545 ...................41, 438032546 .........................418032547 .........................418032548 .........................418032549 .........................418032550 .........................438032551 .........................438032552 .........................438032553 .........................438032554 .........................438032555 .........................438032556 .........................438032558 .........................438032559 .........................438032560 .........................438032563 .........................438032564 .........................438032565 .........................438032566 ...................43, 458032567 .........................438032568 .........................438032573 .........................438032574 .........................438032578 .........................438032579 .........................438032580 .........................438032581 .........................438032582 .........................438032583 .........................438032584 .........................438032585 .........................438032586 .........................438032587 .........................438032588 .........................438032589 .........................438032592 .........................438032593 .........................438032594 .........................43

PART NUMBER INDEX

8042/10042/10054 Origin 2/00


281

8032595 ........................ 438032604 ........................ 478032605 ........................ 478032606 ........................ 478032607 ........................ 478032608 ........................ 478032609 ........................ 478032611 ........................ 478032612 ........................ 438032613 ........................ 438032614 ........................ 458032615 .................. 45, 478032616 .................. 45, 478032617 .................. 45, 478032620 ............ 43, 45, 478032622 ........................ 458032623 ........................ 458032624 ........................ 458032625 ........................ 458032626 ........................ 458032627 ........................ 478032628 .................. 45, 478032629 ........................ 458032631 ........................ 458032632 ........................ 458032633 ........................ 458032634 ........................ 458032635 ........................ 458032637 ........................ 458032638 ........................ 458032640 ........................ 458032641 ........................ 458032642 ........................ 458032643 .................. 45, 478032644 ........................ 458032645 ........................ 458032646 ........................ 458032647 ........................ 458032648 ........................ 458032649 ........................ 458032650 ........................ 458032651 ........................ 458032652 .................. 45, 478032653 ........................ 498032654 ........................ 498032655 ........................ 498032656 ........................ 498032657 ........................ 498032658 ........................ 498032659 ........................ 498032661 ........................ 498032663 ........................ 498032665 ........................ 498032666 ........................ 518032669 ........................ 518032670 ........................ 518032672 ........................ 518032673 ........................ 51

8032674 ........................ 518032675 ........................ 518032676 ........................ 518032678 ........................ 518032679 ........................ 518032680 ........................ 518032681 ........................ 518032682 ........................ 518032702 ...................... 1878032714 .............. 173, 1858032726 ...... 177, 179, 1818032728 .............. 177, 1798032752 ...................... 1658032753 ........................ 178032756 ...... 207, 209, 2118032762 ...................... 1278032764 ...................... 1278032793 ........................ 318032794 ........................ 318032816 ...................... 1118032826 .............. 107, 1098032875 ...................... 1058032876 ...................... 1058032877 ...................... 1058032880 ...................... 1058032881 ...................... 1058032882 ...................... 1058032883 ...................... 1058032885 ...................... 1058032886 ...................... 1058032891 .............. 107, 1098032892 .............. 107, 1098032893 .............. 107, 1098032894 .............. 107, 1098032895 ...... 103, 107, 1098032896 .............. 107, 1098032897 .............. 107, 1098032898 .............. 107, 1098032899 .............. 107, 1098032900 .............. 107, 1098032901 .............. 107, 1098032902 .............. 107, 1098032903 .............. 107, 1098032904 .............. 107, 1098032906 .............. 107, 1098032910 .............. 107, 1098032912 .............. 107, 1098032913 .............. 107, 1098032914 .............. 107, 1098032920 ...................... 1078032922 .............. 107, 1098032923 .............. 107, 1098032930 ...................... 1118032949 .............. 107, 1098032972 .............. 107, 1098032973 .............. 107, 1098032974 .............. 107, 1098032979 ...................... 105

8032983 .............. 107, 1098032984 .............. 107, 1098032985 .............. 107, 1098033003 ........................ 978033004 ........................ 978033006 ........................ 998033007 .................. 95, 998033008 ........................ 998033009 .......... 95, 99, 1058033012 .............. 107, 1098033022 .......................... 78033031 .......................... 78033044 .......................... 98033050 .......................... 78033051 .......................... 78033052 .......................... 78033053 .......................... 78033065 . 29, 37, 207, 209,

2118033072 .......................... 98033075 .................. 29, 378033076 .......................... 98033077 .......................... 98033078 .. 9, 207, 209, 2118033079 .......................... 98033081 .................... 9, 398033082 .......................... 98033084 .......................... 98033085 .......................... 98033086 .......................... 98033087 .......................... 98033088 .......................... 98033090 .......................... 98033092 .......................... 98033094 .......................... 98033097 ........................ 998033098 ........................ 998033102 ........................ 298033103 ........................ 298033104 ........................ 298033105 ........................ 298033110 ........................ 298033178 ........................ 258033188 ........................ 418033189 ........................ 418033190 ........................ 438033191 ........................ 438033192 ........................ 438033193 ........................ 418033194 ........................ 438033195 ........................ 438033196 ........................ 438033197 ........................ 438033198 .................. 41, 478033199 .................. 41, 438033201 15, 207, 209, 2118033202 ........................ 518033203 ........................ 51

8033204 .........................518033205 .........................518033228 .......................1038033238 .........................518033239 .........................518033240 .........................178033241 .........................178033242 .........................178033243 .........................178033254 .......................2038033299 .........................418033302 .........................418033303 .........................418033304 .........................418033305 .........................418033306 .........................418033307 .........................418033308 .........................418033309 .........................418033310 .........................418033311 .........................418033312 .........................418033313 .........................418033314 .........................418033318 .........................438033340 ......117, 119, 121,

213, 215, 217, 219, 2218033342 .......117, 119, 1218033344 .........................498033347 .........................498033348 .........................458033349 .........................418033351 .........................478033355 .........................458033356 .........................458033357 .........................458033358 .........................458033359 .........................478033360 .........................478033361 .........................478033362 .........................478033363 .........................478033364 .........................478033365 .........................478033368 .........................478033371 .........................478033372 .........................478033373 ...................43, 478033374 .........................478033375 .........................478033376 .........................478033384 .........................438033385 .........................438033386 .........................438033387 .........................498033406 .......213, 215, 2178033479 .....................9, 398033652 .........................97

PART NUMBER INDEX


8042/10042/10054 Origin 2/00282

8033704 ...................... 1798033715 ...................... 1798033721 ...................... 1798033722 ...................... 1858033723 ...................... 1858033724 ...................... 1858033725 ...................... 1858033726 ...................... 1858033727 ...................... 1738033728 ...................... 1738033729 ...................... 1738033730 ...................... 1738033731 ...................... 1738033732 ...................... 1698033733 ...................... 1698033734 ...................... 1698033735 ...................... 1698033736 ...................... 1698033737 ...................... 1698033738 ...................... 1698033740 ...................... 1818033741 ...................... 1818033742 ...................... 1818033744 .............. 177, 1798033745 .............. 177, 1798033746 ...................... 1778033747 .............. 177, 1798033748 ...................... 1878033749 ...................... 1878033750 ...................... 1878033751 ...................... 1878033753 ...................... 2058033755 ...................... 1798033756 ...................... 1798033760 ...................... 2058033761 ...................... 2058033763 ...................... 2058033768 ...................... 2058033769 ...................... 2058033770 ...................... 2058033771 ........................ 538033772 ........................ 538033773 ........................ 538033774 ........................ 538033775 ........................ 538033776 ........................ 538033777 ........................ 538033778 ........................ 538033779 ........................ 538033780 ........................ 538033781 ........................ 538033782 ........................ 538033783 ...................... 1918033784 ...................... 1918033785 ...................... 1918033786 ...................... 1918033788 ...................... 1918033789 ...................... 191

8033790 ...................... 1918033791 ........................ 538033796 ........................ 958033797 ........................ 958033798 ........................ 958033799 ...................... 1078033801 ...................... 1958033802 ...................... 1038033803 .............. 107, 1098033804 ...................... 1058033805 ...................... 1058033806 ...................... 1038033809 ...................... 1038033810 ...................... 1038033811 ...................... 1958033812 ...................... 1958033813 ...................... 1958033814 ...................... 1958033815 ...................... 1058033816 ...................... 1058033817 ...................... 1058033818 ...................... 1058033820 ...................... 1058033821 ...................... 1058033822 ...................... 1058033823 ...................... 1058033824 ...................... 1058033826 .............. 107, 1098033827 .............. 107, 1098033828 .............. 107, 1098033829 .............. 107, 1098033831 .............. 107, 1098033832 .............. 107, 1098033833 .......................... 98033834 .......................... 98033835 .......................... 98033836 .......................... 98033837 .......................... 98033838 .......................... 98033839 .......................... 98033840 .......................... 98033841 ........................ 118033842 ........................ 118033843 ........................ 118033844 ........................ 118033845 ........................ 118033846 ........................ 118033847 ........................ 118033848 ........................ 118033849 ........................ 118033850 ........................ 118033851 ........................ 118033852 ........................ 118033853 ........................ 118033854 ........................ 118033855 ........................ 118033856 ........................ 118033857 ........................ 11

8033858 ........................ 118033859 ........................ 118033860 ........................ 118033861 ........................ 118033862 ........................ 118033863 ........................ 118033864 ........................ 118033865 ........................ 118033866 ........................ 118033867 ........................ 118033868 ........................ 118033869 ........................ 118033870 ........................ 478033871 ........................ 478033872 ........................ 478033873 ........................ 478033874 ........................ 478033875 ........................ 478033876 ........................ 478033877 ........................ 478033878 ........................ 478033879 ........................ 478033880 ........................ 478033881 ........................ 478033882 ........................ 478033883 ........................ 478033884 ........................ 478033885 .................. 43, 478033886 ........................ 418033887 ........................ 418033888 ........................ 418033889 ........................ 418033890 ........................ 518033896 ...................... 1658033897 ...................... 1658033898 ...................... 1658033899 ...................... 1658033900 ...................... 1658033901 ...................... 1658033902 ...................... 1658033903 ...................... 1658033904 ...................... 1658033905 ...................... 1658033906 ...................... 1658033907 ...................... 1658033908 ...................... 1658033909 ...................... 1658033910 ...................... 1658033911 ...................... 1658033912 ...................... 1658033913 ...................... 1658033914 ...................... 1658033916 ...................... 1658033917 ...................... 1658033918 ...................... 1658033919 ...................... 1658033920 ...................... 1658033921 ...................... 165

8033922 .......................1658033923 .......................1658033924 .......................1658033925 .......................1658033926 .......................1658033927 .......................1658033928 .......................1658033929 .......................1658033930 .......................1658033931 .......................1658033932 .......................1658033933 .......................1658033934 .......................1658033935 .......................1658033936 .......................1658033937 .......................1658033938 .......................1658033939 .......................1658033952 .......................1658033953 .......................1658033954 .......................1658033955 .......................1658033956 .......................1658033957 .......................1658033958 .......................1658033959 .......................1658033960 .......................1118033961 .......................1118033962 .......................1118033963 .......................1118033964 .......................1118033965 .......................1118033966 .......................1038033967 .......................1038033968 .......................1038033969 .......................1038033970 .......................1038033971 .......................1038033972 .......................1038033973 .......................1038033974 .......................1038033975 .......................1038033976 .......................1038033977 .......................1038033978 .......................1038033979 .......................1038033980 .......................1038033981 .......................1038033982 .......................1038033983 .......................1038033984 .......................1038033985 .......................1038033986 .......................1038033987 .......................1038033988 .......................1038033989 .......................1038033990 .......................1038033991 .......................103

PART NUMBER INDEX

8042/10042/10054 Origin 2/00


283

8033992 ...................... 1038033993 ...................... 1038033994 ...................... 1038033995 ...................... 1038033996 ...................... 1038033997 ...................... 1038033998 ...................... 1038033999 ...................... 1038034500 ...................... 1038034501 ...................... 1038034502 ...................... 1038034503 ...................... 1038034504 ...................... 1038034505 ...................... 1038034527 ...................... 2018034528 ...................... 2018034530 ...................... 2018034531 ...................... 2018034532 ...................... 2018034534 ...................... 1998034538 ...................... 1998034539 ...................... 1998034540 ...................... 1998034541 ...................... 1998034542 ...................... 2018034543 ...................... 1998034544 ........................ 118034545 ........................ 118034546 ........................ 118034547 ........................ 118034548 ........................ 118034549 ...................... 2018034550 ...................... 2018034551 ...................... 1998034552 ...................... 1998034554 ...................... 2018034555 ...................... 2018034556 ...................... 2018034557 ...................... 2018034558 ...................... 2038034559 ...................... 2038034560 ...................... 2038034561 ...................... 2038034562 ...................... 2038034569 ...................... 2058034570 ...................... 2058034571 ...................... 2058034575 ...................... 2058034577 ...................... 2058034578 ...................... 2058034580 ...................... 2058034581 ...................... 1078034584 ...................... 1098034585 ...................... 1098034586 ...................... 1098034590 ...................... 1098034593 ........................ 978034684 ...................... 197

8034688 .............. 107, 1098034691 ...................... 1978034692 .............. 107, 1098034693 .............. 107, 1098034694 ........................ 178034695 ...................... 1838034697 ...................... 1998034797 ........................ 378034798 ........................ 378034799 ........................ 378034800 ........................ 378034801 .................. 29, 378034802 .................. 29, 378034803 ........................ 378034804 ........................ 378034805 ........................ 378034806 ........................ 378034807 ........................ 378034808 ........................ 378034809 ........................ 378034810 ........ 37, 209, 2118034811 ........................ 378034812 ...................... 1658034813 ...... 213, 215, 2178034814 .............. 107, 1098034815 ........................ 298034817 ........................ 378034818 ...................... 1658034819 .............. 107, 1098034821 ...................... 1978034822 ...................... 1978034823 ...................... 1978034824 ...................... 1978035247 ...................... 1698035267 ...................... 1998035268 .............. 107, 1098035269 .............. 107, 1098035270 .............. 107, 1098035271 .............. 107, 1098035272 .............. 107, 1098035276 .............. 219, 2218035308 ...................... 1758035315 ...................... 1718035322 ...................... 1898035386 ...................... 1758035513 ...................... 1718035514 ...................... 1718035519 ...................... 1898035535 ...................... 1718035536 ...................... 1718035539 ...................... 1718035542 ...................... 1758035545 ...................... 1758035547 ...................... 1838035555 ...................... 1238035556 ...................... 1238035557 ...................... 1238035558 ...................... 123

8035559 ...................... 1238035560 ...................... 1678035561 ...................... 1678035562 ...................... 1678035563 ...................... 1678035564 ...................... 1678035565 ...................... 1678035566 ...................... 1678035567 ...................... 1678035568 ...................... 1678035569 ...................... 1678035570 ...................... 1678035571 ...................... 1678035572 ...................... 1678035573 ...................... 1678035574 ...................... 1678035575 ...................... 1678035577 ...................... 1678035578 ...................... 1678035579 ...................... 1678035580 ...................... 1678035581 ...................... 1678035582 ...................... 1678035583 ...................... 1678035584 ...................... 1678035585 ...................... 1678035586 ...................... 1678035587 ...................... 1678035588 ...................... 1678035589 ...................... 1678035590 ...................... 1678035591 ...................... 1678035592 ...................... 1678035593 ...................... 1678035595 ...................... 1678035596 ...................... 1678035597 ...................... 1678035598 ...................... 1678035607 ...................... 1758035608 ...................... 1758035609 ...................... 1758035610 ...................... 1758035611 ...................... 1838035612 ...................... 1838035613 ...................... 1838035615 ...................... 1718035616 ...................... 1718035617 ........................ 978035618 ........................ 978035620 ........................ 978035622 ........................ 978035623 ........................ 978035624 ........................ 978035625 ........................ 978035628 ........................ 978035727 ...................... 1898035728 ...................... 1898035729 ...................... 189

8035730 .......................1898035731 .......................1898035732 .......................1898035733 .........................898035734 .........................898035778 .......................1018035800 .......................1718037206 .........................118040258 ...........................38065061 .......231, 255, 2578065062 .......................2498065063 .......................2478065214 ...............231, 2558065634 ...............243, 2458065639 ...........................78065640 ...................3, 2298065641 ...........................38080613 .......117, 119, 1218124126 ......261, 263, 265,

267, 269, 271, 2738124131 .......................2678127008 .......269, 271, 2738127009 .......................2678127014 ...............261, 2678140309 .......117, 119, 1218160042 .........................178160046 .........................258160059 .........................338160060 .........................238160062 .........................218160205 .........................178160406 .........................338160417 .........................178160418 .........................338160419 ...................21, 238160610 .........................258160617 ...................23, 338160621 .......................2078162003 .........................258180307 .......117, 119, 1218180308 .......................1178205506 .......................1818205514 .......................1938205545 .......................1938205546 .......................1938205547 .......................1938205548 .......................1938205640 .......................1818205655 ......177, 179, 187,

191, 193, 203, 2058205656 .......173, 175, 1858205657 ...............169, 1718205661 .......................1938205726 .......................1738220001 .......................2258220008 .31, 207, 209, 2118220050 ......207, 209, 211,

223

PART NUMBER INDEX


8042/10042/10054 Origin 2/00284

8220073 29, 213, 215, 217, 219, 221

8220882 ..... 207, 209, 211, 225

8223016 ...................... 2238223024 31, 207, 209, 2118223025 ..... 207, 209, 211,

2238223216 ..... 213, 215, 217,

219, 2218223217 ..... 163, 213, 215,

217, 219, 2218223220 15, 207, 209, 2118223221 ...................... 2258223226 ...................... 1638223405 15, 207, 209, 2118223419 ...................... 2238223424 ...................... 2238223436 ...... 207, 209, 2118223438 ...... 207, 209, 2118223442 15, 207, 209, 2118223444 15, 207, 209, 2118223445 15, 207, 209, 2118223510 .............. 213, 2158223517 ...................... 2078223525 ...................... 2258223610 ...... 217, 219, 2218224026 ........................ 238224027 ........................ 218225117 ...... 209, 211, 2258229215 ...................... 2078229216 ...................... 2078229218 ...................... 2078229226 ...................... 2078229232 ...................... 2078229233 ...... 209, 211, 2258229234 .............. 209, 2118229235 ...... 209, 211, 2238229238 .............. 209, 2118262131 ...................... 1178262137 ...................... 1198262138 ...................... 1198262142 ...................... 1218262143 ...................... 1218270014 ...... 213, 215, 2178270134 .............. 219, 2218270220 ...... 117, 119, 1218270221 ..... 117, 119, 121,

213, 215, 217, 219, 2218270602 ...... 213, 215, 2178270617 ..... 213, 215, 217,

219, 2218270622 .............. 219, 2218272009 .............. 117, 1198272017 ...................... 1218273013 ...................... 1278273237 ...................... 1278273238 ...................... 127

8273240 ...................... 1278273241 ...................... 1278273272 ...................... 1278274022 .............. 129, 1318275212 ...................... 1258275240 ...................... 1258275247 ...................... 1258275248 ...................... 1258277161 ...... 117, 119, 1218277162 ..... 117, 119, 121,

213, 215, 217, 219, 2218278007 . 55, 93, 117, 119,

1218278008 ...... 117, 119, 1218278012 ...... 117, 119, 1218278017 ........................ 558301002 ........................ 258301402 ........................ 258301439 ........................ 218301443 .................. 23, 338301456 ...................... 2518302147 .......................... 78302406 ........................ 278302449 ........................ 258302470 ...... 21, 23, 33, 938303034 .......... 5, 7, 15, 238303041 ...................... 2298303106 17, 117, 119, 1218303519 93, 119, 121, 1398303534 .............. 7, 13, 278303540 . 9, 17, 23, 29, 37,

2598303550 ...................... 1218303604 ........................ 138303618 ...................... 1278303620 43, 229, 231, 255,

257, 2598303621 ..... 125, 229, 231,

255, 257, 2598303622 ...... 117, 119, 1218303624 .............. 255, 2578303626 .............. 139, 2518303628 ...................... 2478303629 ...................... 2478303632 ...................... 2238303634 ..... 237, 239, 241,

243, 245, 249, 255, 2578303638 .................. 7, 2358303655 .......... 3, 229, 2478303656 .......................... 58303664 ........................ 558303666 .............. 233, 2598303675 ..... 135, 231, 233,

2558303679 ..... 117, 119, 121,

231, 233, 255, 257, 2598303681 ..... 229, 231, 233,

255, 257, 259

8303697 . 13, 33, 119, 121, 127, 213, 229

8303702 ...... 117, 119, 1218303705 .......................... 78303715 .............. 229, 2498303717 ...................... 2478303724 ..... 3, 55, 93, 117,

119, 1218303729 ...................... 5, 78303735 ...................... 2318303738 ...................... 2258303739 ...... 145, 243, 2458303742 . 25, 27, 117, 119,

1218303744 ...................... 1178303745 ........................ 138303752 ...................... 1458303758 ........................ 338303770 .............. 243, 2458303772 .............. 233, 2598303776 .................... 9, 318303782 .................. 3, 2298303784 ...... 117, 119, 1218303790 25, 117, 119, 1218303794 ...................... 2478303799 ........................ 258303835 ................ 29, 2078303837 ................ 25, 2238303839 ........................ 298303982 .......................... 98303987 51, 213, 215, 217,

2198303995 ........................ 318304624 ...................... 1378304631 ...................... 2038304660 .......................... 58305002 . 25, 29, 207, 209,

211, 2258305003 ...................... 2078305004 . 5, 15, 25, 27, 33,

207, 209, 213, 215, 217, 219, 221

8305005 .................. 23, 298305006 . 13, 29, 133, 135,

2138305008 .................... 7, 138305012 ...... 137, 139, 2518305014 .............. 163, 2238305018 .............. 263, 2698305021 .......................... 38305038 ...................... 2218305043 ..... 213, 215, 217,

219, 2218305201 ..... 213, 215, 217,

219, 2218305402 ...... 17, 21, 25, 338305405 ................ 27, 2238305410 ........................ 27

8305438 ......213, 215, 217, 219, 221

8305601 .....................9, 178305619 .......................2358305624 7, 25, 29, 37, 117,

119, 121, 257, 2598305626 13, 117, 119, 121,

127, 129, 131, 141, 143, 145, 163, 243, 245

8305627 .......................2238305643 ..3, 229, 233, 237,

239, 241, 243, 245, 247, 249, 255, 257, 259, 267

8305644 ..3, 117, 119, 121, 229, 231, 233, 247, 251, 255, 259, 261, 267, 275

8305645 ..7, 117, 119, 121, 125, 229, 231, 243, 245, 255, 259, 261, 265, 267, 271, 273

8305646 ......261, 263, 265, 267, 269, 271, 273

8305647 ...................9, 2298305650 .........................258305906 .............5, 33, 2298305916 ...........................78307002 5, 7, 9, 15, 25, 27,

31, 207, 213, 215, 217, 219, 221

8307003 ....9, 25, 207, 209, 211, 225

8307004 ....5, 33, 117, 119, 121, 133, 135, 145, 213, 229

8307005 ....5, 7, 13, 17, 27, 41, 43, 51, 135, 225, 229, 231, 233, 255, 257, 259

8307006 .....13, 93, 97, 2138307007 ......137, 139, 231,

251, 255, 2578307009 ...............163, 2238307010 .....................7, 558307012 .......................3, 78307022 ......213, 215, 217,

219, 2218307023 ......117, 119, 121,

213, 215, 217, 219, 2218307024 .........................258307025 ..25, 93, 117, 119,

121, 127, 1398307026 ...............207, 2098307027 ...............209, 2118307046 .........................298307047 .........................938307052 .........................298307104 27, 235, 261, 263,

265, 267, 269, 271, 2738307106 13, 117, 121, 209,

211, 213, 225, 2298307107 .......................247

PART NUMBER INDEX

8042/10042/10054 Origin 2/00


285

8307109 . 7, 23, 25, 29, 37, 117, 119, 121, 207, 209

8307110 .... 5, 27, 117, 1218307111 ..... 209, 211, 223,

2258307112 .............. 251, 2758307113 ............ 9, 13, 2298307201 .......................... 98307202 .......................... 58307203 ... 5, 29, 119, 121,

127, 2458307204 . 9, 119, 125, 229,

231, 233, 255, 257, 2598307206 . 9, 137, 139, 223,

231, 2558307207 .................. 9, 2238307220 ................ 93, 1398307222 ...... 117, 119, 1218307904 ...... 233, 249, 2598307910 ...................... 2298307911 ...................... 2298307912 .................. 3, 2478307913 .................. 3, 2478307918 ...... 233, 249, 2598310001 ........................ 238310002 29, 117, 119, 1218310019 ..... 261, 265, 267,

271, 2738310020 .............. 261, 2678310026 ...................... 2578310028 .............. 117, 1198310029 ........................ 298310036 .......................... 78310041 ..... 213, 215, 217,

219, 2218310049 .......................... 78310050 .......................... 78310051 .................... 3, 558310058 ...................... 2238310066 .................. 3, 2678310067 ..... 3, 55, 93, 117,

119, 121, 2478310070 .......................... 78310077 ..... 213, 215, 217,

219, 2218310078 ..... 213, 215, 217,

219, 2218310093 .............. 233, 2598310111 .......................... 38310112 .......................... 78310113 ...................... 2258310116 ........................ 558310129 ...................... 1638310136 .......................... 58310138 ...................... 1538310143 ........................ 218310144 ........................ 218310151 ...................... 2478310153 ...................... 205

8310158 .............. 133, 1358310159 .............. 133, 1358310160 ...................... 2498310161 ...................... 2498310163 .............. 129, 1318310170 ........................ 278310178 .............. 137, 1398310195 ...................... 2758310202 ..... 215, 217, 219,

2218310205 ...................... 2678310209 .............. 231, 2558310210 ...................... 2678310235 .............. 231, 2558310245 .............. 231, 2558310257 ........................ 278310258 ........................ 278310259 .......................... 38310266 ...... 237, 239, 2418310276 ...... 237, 239, 2418310337 .............. 137, 1398310344 .......................... 78310425 .................. 93, 978310427 ........................ 938320250 ...................... 1298320253 ...................... 1298320254 ........................ 418320262 ...... 117, 119, 1218320265 ...................... 1638320270 ...................... 1318322029 .............. 131, 1638324029 ...................... 1638340025 ...................... 1118340034 ........................ 258342413 .......................... 98342416 .......................... 58342807 ...................... 5, 78342808 .................... 5, 118344010 .......................... 58346008 ........................ 118346009 .......................... 98346010 .......................... 98346011 .......................... 98360005 ........................ 318360008 ........................ 318382017 ...................... 2758403224 .............. 117, 1198405007 ........................ 318405009 .............. 129, 1318405104 ...... 117, 119, 1218405203 ...... 117, 119, 1218405209 ...................... 1398405305 ...................... 1278405307 ...................... 1278405404 ...................... 1278406101 ...... 117, 119, 1218406105 ...... 133, 135, 1498410009 .............. 129, 131

8420053 ...... 243, 245, 2498420055 ...... 243, 245, 2498420201 ........................ 318430005 ...... 243, 245, 2498430006 ...... 243, 245, 2498430007 .............. 129, 1318430032 .............. 135, 1498430034 .............. 129, 1318430035 ...................... 1298430037 ...................... 1358430046 ...................... 1498430064 ...................... 1318444223 ...................... 1658444227 ...................... 1678464012 ...................... 1638464212 15, 207, 209, 2118466305 15, 207, 209, 2118466306 .......................... 78467014 15, 207, 209, 2118469028 ...... 207, 209, 2118469030 ........................ 158500009 ...................... 2238500036 ...................... 2238500201 ...................... 2238520001 ...... 231, 255, 2578520013 . 3, 171, 193, 229,

233, 247, 2598520021 .......... 3, 233, 2598522043 .............. 107, 1098522045 .............. 107, 1098522048 .............. 107, 1098526035 .......................... 58526036 ..... 229, 231, 233,

255, 257, 2598526044 ...................... 1038526048 ...................... 1458526052 .................. 65, 818530030 ...................... 1358540023 ........................ 318541433 .............. 243, 2458541435 ...... 129, 131, 1638546407 ...................... 1398580110 ............ 21, 23, 338580111 ........................ 178580115 .......................... 98580213 .......................... 58580309 ........................ 318580311 15, 207, 209, 2118580312 15, 207, 209, 2118580315 .................. 9, 2498581007 .......................... 58582007 .............. 209, 2118582413 .......................... 58584001 31, 145, 207, 209,

211, 213, 215, 217, 219, 221, 223, 243, 245, 249

8584003 31, 207, 209, 211, 223

8584007 ......133, 135, 137, 139, 141, 143, 149

8584018 .......................2238585133 .....................9, 398585134 ...........................98585135 ...........................98585138 ...........................98585139 ...........................98585155 .........................398585156 .........................398630012 ...............129, 1318630016 .........93, 139, 1678630017 .......................1578640017 .......................2038640019 .......................2058640028 .......243, 245, 2498640029 .......243, 245, 2498640032 .......243, 245, 2498640123 .......................1358640208 .......................1398640405 .......................1378640903 .......129, 131, 1638642001 ...............243, 2458642207 .......................2498642224 .......229, 233, 2598642235 ...............243, 2458642237 ......261, 263, 265,

267, 269, 271, 2738688026 ......207, 209, 211,

2258700116 .........................258700120 .........................278720014 ...........................78720015 ...........................78721023 ...........................78721029 ...............133, 1358750003 .......................1458760011 .......................1498760037 .......................1458760039 ...............141, 1438760102 .......................1638760107 ......137, 139, 145,

1638760109 .......133, 135, 1418760110 ......133, 135, 147,

149, 163, 243, 2458760111 ...............141, 1438760113 ...............149, 2498760117 ......137, 153, 243,

2458760118 .......133, 137, 1638760134 ......133, 135, 143,

1478760138 .......................1438760140 ...............133, 1358760141 ......133, 135, 137,

139, 1538760143 ......133, 135, 145,

153

PART NUMBER INDEX


8042/10042/10054 Origin 2/00286

8760254 ...................... 1578760268 ...................... 1478760276 ...... 139, 147, 1498760302 ...................... 1398760303 ...................... 1338760305 ...... 141, 143, 1578760307 .............. 135, 1458760308 ...................... 1398760311 ..... 133, 135, 139,

2498760313 ...... 133, 135, 2498760317 .............. 139, 1418760351 ...................... 1638760401 ..... 133, 135, 137,

1398760407 ...................... 1358760409 ...................... 2498760415 ...................... 1398760419 ...................... 1638760420 ...................... 2018760431 ...................... 1578760449 .............. 133, 1358760451 ...... 139, 163, 1998760455 ...................... 1498760457 ...................... 1378760458 ...................... 1538760460 ...... 133, 135, 1538760474 ...... 133, 135, 1378760475 ...................... 2498760477 ...................... 1458760482 .............. 137, 1398760483 .............. 141, 1438760488 .............. 133, 1358760493 ..... 135, 137, 139,

1458760495 ...................... 1398760501 ..... 133, 135, 139,

149, 1638760504 ..... 133, 135, 137,

1398760529 ...................... 1398765204 ...... 133, 135, 1398769122 ...................... 1458769123 ...................... 1458769127 .............. 141, 1438769128 .............. 141, 1438769132 ...................... 2498769140 ...................... 1458769149 ...................... 1458769158 ...................... 2478769159 ...................... 2478769160 ...................... 2478769161 ...................... 1458770012 ...... 141, 147, 2498770015 ...................... 1378770016 ...... 133, 135, 2498770030 ...................... 1418770157 .............. 143, 157

8770158 ...................... 1578770159 ...................... 1398780031 ...................... 1138780035 ...................... 1158780036 ...................... 1138780037 .............. 113, 1158780045 ...................... 1138780264 ...................... 1138786514 .............. 113, 1158786516 .............. 107, 1098786559 ...................... 1158825174 ........................ 518841025 ........................ 558841040 ........................ 938841314 ........................ 518864036 ........................ 138864037 ........................ 138864038 .......................... 78864039 ........................ 138864040 ........................ 138864041 ........................ 138864043 ........................ 138864044 ........................ 138864045 ........................ 138864046 ........................ 138866341 ...... 117, 119, 1218866347 ........................ 358866348 ........................ 358866350 ........................ 358866351 ........................ 358866364 ........................ 358866381 ........................ 298866382 ........................ 298866437 ........................ 298866492 ........................ 298866525 ........................ 398866526 ........................ 398866527 ........................ 398880218 ............ 93, 95, 998880219 .................. 93, 978882009 .................. 93, 998902095 ...................... 2018902140 ...................... 2038902141 ...................... 2038902150 ...................... 1998902152 ...................... 2018902186 ...................... 1998902193 ...................... 1538902222 .............. 149, 2038902251 ...... 141, 143, 2038902260 ...................... 1858902261 ...................... 1698902266 ...................... 2058902267 ...................... 2058902495 ...................... 2018902511 ..... 177, 179, 187,

1938902512 ...................... 201

8902688 ...................... 2058902689 ...................... 2058902838 ...... 133, 135, 2038902842 ...................... 1918902846 ...................... 2038903011 ...................... 1998904001 ...... 117, 119, 1218904047 ...... 133, 135, 2038904049 ...................... 2038990147 .......................... 7

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122

JLG Industries (UK)Unit 12, SouthsideBredbury Park Industrial EstateBredburyStockportSK6 2sPEnglandPhone: (44) 870 200 7700Fax: (44) 870 200 7711

JLG Deutschland GmbHMax Planck Strasse 21D-27721 Ritterhude/lhlpohlBei BremenGermanyPhone: (49) 421 693 500Fax: (49) 421 693 5035

JLG Industries (Italia)Via Po. 2220010 Pregnana Milanese - MIItalyPhone: (39) 02 9359 5210Fax: (39) 02 9359 5845

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPhone: (55) 19 3295 0407Fax: (55) 19 3295 1025

JLG Europe B.V.Jupiterstraat 2342132 HJ FoofddorpThe NetherlandsPhone: (31) 23 565 5665Fax: (31) 23 557 2493

JLG Industries (Norge AS)Sofeimyrveien 12N-1412 SofienyrNorwayPhone: (47) 6682 2000Fax: (47) 6682 2001

JLG PolskaUI. Krolewska00-060 WarsawaPolandPhone: (48) 91 4320 245Fax: (48) 91 4358 200

JLG Industries (Europe)Kilmartin Place, Tannochside ParkUddingston G71 5PHScotlandPhone: (44) 1 698 811005Fax: (44) 1 698 811055

JLG Industries (Pty) Ltd.Unit 1, 24 Industrial ComplexHerman StreetMeadowdaleGermistonSouth AfricaPhone: (27) 11 453 1334Fax: (27) 11 453 1342

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755CastellbisbalSpainPhone: (34) 93 77 24700Fax: (34) 93 77 11762

JLG Industries (Sweden)Enkopingsvagen 150Box 704SE - 175 27 JarfallaSwedenPhone: (46) 8 506 59500Fax: (46) 8 506 59534

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