SkyTrak 10042 Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Models

8042, 10042,

10054

S/N 13198 thru 19987

& 0160002332 thru 0160045249

including 0160045255 excluding

0160042754, 0160042762, 0160042877, 0160042911,

0160043185, 0160043220 &

0160043244

8990395

Revised

June 12, 2012

EFFECTIVITY PAGE

June 3, 2005 - D - Revised Manual

May 11, 2006 - E - Revised Manual

February 23, 2007 - F - Revised Manual

October 9, 2007 - G - Revised Manual

April 17, 2008 - H - Revised Manual (Manual edited to B/M 8042 - 0010622 Revision 32)

(Manual edited to B/M 10042 - 0010623 Revision 27)

(Manual edited to B/M 10054 - 0010624 Revision 28)

January 19, 2008 - I - Revised Manual

August 5, 2009 - J - Revised Manual

July 1, 2010 - K - Revised Manual

February 11, 2011 - L - Revised Manual

August 25, 2011 - M - Revised Manual

November 11, 2011 - N - Revised Manual

April 9, 2012 - O - Revised Manual

June 12, 2012 - P - Revised Manual

8990395 8042/10042/10054 i

EFFECTIVITY PAGE

8042/10042/10054 8990395ii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 Main Frame Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Hoods & Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-3 Outrigger Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

SECTION 2 –

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-3 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-4 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-5 Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-6 Boom Extend Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-7 Boom Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

SECTION 3 –

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-5 Sheet Material Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-6 3 FT Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-7 12 FT. Truss Boom With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-8 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-9 Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-11 Concrete Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-12 Sweeper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-13 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-14 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-15 Fork Pin Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-16 Dual Fork Positioning Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-17 8 Ft Standard Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

SECTION 4 –

ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-3 Radiator & Oil Cooler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-4 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

4-6 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

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FIGURE NO. TITLE PAGE NO.

SECTION 5 –

DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 Drive Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-3 Front Axle - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-4 Front Axle - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-5 Front Axle - Axle Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-6 Front Axle - M-Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-7 Front Axle - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-8 Front Axle - Joint Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-9 Front Axle - Planetary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-10 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-11 Rear Axle - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

5-12 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5-13 Rear Axle - Axle Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

5-14 Rear Axle - M-Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

5-15 Rear Axle - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

5-16 Rear Axle - Joint Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

5-17 Rear Axle - Planetary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

5-18 ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

5-19 ZF Transmission - Engine Connection & Convertor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

5-20 ZF Transmission - Input Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

5-21 ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

5-22 ZF Transmission - Coupling Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

5-23 ZF Transmission - Coupling Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98

5-24 ZF Transmission - Coupling Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

5-25 ZF Transmission - Coupling Group 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102

5-26 ZF Transmission - Reversing Gear Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104

5-27 ZF Transmission - Reversing Gear Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106

5-28 ZF Transmission - Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108

5-29 ZF Transmission - Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110

5-30 ZF Transmission - Valve Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112

5-31 ZF Transmission - Valve Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116

5-32 ZF Transmission - Oil Pump & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118

5-33 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120

5-34 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122

SECTION 6 –

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 Open Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Closed Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 Soft Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-4 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-5 Operators Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

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6-6 Front Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-7 Skylight Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-8 Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

SECTION 7 –

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 Service Brake Pedal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Throttle Pedal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Steering Wheel & Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-4 Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-5 Boom Lift/Lower & Extend/Retract Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-6 Frame Sway & Attachment Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-7 Auxiliary Hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

SECTION 8 –

HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 Service Brake & De-Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 Boom Lift/Lower & Extend/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-3 Attachment Tilt & Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-4 Frame Sway & Stabil-Trak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-5 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-6 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-7 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8-8 Auxiliary Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

8-9 Transmission Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

SECTION 9 –

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Lift/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9-3 Attachment Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9-4 Frame Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

9-5 Stabil-Trak Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

9-6 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

9-7 Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

9-8 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

9-9 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

9-10 Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56

9-11 Fuel/Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60

9-12 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62

9-13 72 in. 90 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

9-14 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66

9-15 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68

8990395 8042/10042/10054 v

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 10 –

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10-3 Outrigger Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

10-4 Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

SECTION 11 –

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

SECTION 12 –

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-1 Worklight System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-2 Roadlight System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-3 Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

12-4 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

12-5 Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

12-6 Rotating Beacon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

12-7 First Boom Section Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

12-8 Remote Oil Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

12-9 Ignition Switch Weather Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

12-10 Exhaust Upgrade Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

SECTION 13 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

8042/10042/10054 8990395vi

SECTION 1

FRAME & ATTACHING PARTS

8990395 8042/10042/10054

16 17

18 32

23 33

2 32

BOOM PIVOT FRAME TILT CYLINDER STABILIZER CYLINDER LIFT/LOWER CYLINDER SLAVE CYLINDER

LOCATE THE FRACTURE IN BEARING

OUTER RACE AT THE CLOCK POSITION

SHOWN FOR EACH APPLICATION

PH3190

FRAME & ATTACHING PARTS

Figure 1-1 Main Frame Components

S/N 13198 thru 19987

& 0160002332 thru 0160004669

8042/10042/10054 89903951-2

S/N 13198 thru 19987 & 0160002332 thru 0160004669

Item Part Number Qty. Description Rev.

NSS 1 FRAME WELDMENT 2 7092292 4 LIFT/LOWER & SLAVE CYLINDER PINS, (base & rod ends) 3 8303782 4 HEX HD CAPSCREW, 1/2-13X4 4 8305644 4 HEX LOCKNUT, 1/2-13 5 8065640 2 BEARING, (self align) 6 8050001 4 BEARING, (self align) 7 8065641 2 BEARING, (self align) 8 8520013 2 GREASE FITTING, STRAIGHT 9 8520021 4 GREASE FITTING, 90 DEGREES

10 Ref FRONT AXLE, (see Figure 5-2 for details) 11 Ref REAR AXLE, (see Figure 5-10 for details) 12 7138879 1 COUNTERWEIGHT 13 8305021 4 HEX NUT, 1-8 14 5724302 AR WASHER, SHIM 0.06 15 8307012 4 LOCKWASHER, 1 16 8310066 AR FLAT WASHER, 0.134 17 8310051 4 HEX HD CAPSCREW, 1-8X4 18 7137142 4 TILT & STABIL-TRAK CYLINDER PINS 19 7138888 1 FRONT COUNTERWEIGHT, (8042 only) 20 7139066 2 COUNTERWEIGHT HOLD DOWN PLATE, (8042 only) 21 8303752 4 HEX HD CAPSCREW, 0.312-18X3.5 22 8303794 2 HEX HD CAPSCREW, 0.750-10X3.5, GR8, (8042 only) 23 8305626 4 HEX LOCKNUT, 0.312-18 24 8307010 2 LOCKWASHER, 0.750, (8042 only) 25 7125871 AR CONDUIT, 0.50X8, (cut to fit) 26 7138368 AR CONDUIT, 0.25X2, (cut to fit) 27 7124301 AR CONDUIT, 0.5X15.5, (cut to fit) 28 7124471 AR CONDUIT, 1 DIAX12.5, (cut to fit) 29 7124451 AR CONDUIT, 1 IDX8, (cut to fit) 30 7139157 AR CONDUIT, 1 IDX4, (cut to fit) 31 7139156 AR CONDUIT, 1 IDX28, (cut to fit) 32 8522012 AR ANTI-SEIZE LUBE, (apply to items 2 & 24) 33 8520001 4 GREASE FITTING, STRAIGHT 34 Ref BOOM LIFT & LOWER CYLINDER, (see Figure 9-2 for details) 35 Ref SLAVE CYLINDER, (see Figure 9-6 for details) 36 Ref FRAME SWAY CYLINDER, (see Figure 9-4 for details) 37 Ref STABIL-TRAK CYLINDER, (see Figure 9-5 for details)

FRAME & ATTACHING PARTS

8990395 8042/10042/10054 1-3

FRAME & ATTACHING PARTS

2 32

16 17

18 32

23 33

3 38

2 32

BOOM PIVOT FRAME TILT CYLINDER STABILIZER CYLINDER LIFT/LOWER CYLINDER SLAVE CYLINDER

LOCATE THE FRACTURE IN BEARING

OUTER RACE AT THE CLOCK POSITION

SHOWN FOR EACH APPLICATION

PH4562

8042 S/N 0160004670 THRU 0160015041 10042 S/N 0160004670 THRU 0160015194 10054 S/N 0160004670 THRU 0160015043

Figure 1-1 Main Frame Components

8042 S/N 0160004670 thru 0160033642 10042 S/N 0160004670 thru 0160033649 10054 S/N 0160004670 thru 0160033644

8042/10042/10054 89903951-4

8042 S/N 0160004670 thru 0160033642 10042 S/N 0160004670 thru 0160033649

FRAME & ATTACHING PARTS

10054 S/N 0160004670 thru 0160033644

Figure 1-1 Main Frame Components

Item Part Number Qty. Description Rev.

1NSS1FRAME WELDMENT 2 7302039 4 LIFT/LOWER & SLAVE CYLINDER PINS, (base & rod ends), (8042 S/N

0160004670 thru 0160015041), (10042 S/N 0160004670 thru 0160015194), (10054 S/N 0160004670 thru 0160015043)

3423227 4 LIFT/LOWER & SLAVE CYLINDER PINS, (base & rod ends), (8042 S/N

0160015042 & After), (10042 S/N 0160015195 & After), (10054 S/N 0160015044 & After)

3 8303625 4 HEX HD CAPSCREW, 1/2-13X1.25, GR5, (8042 S/N 0160004670 thru

0160015041), (10042 S/N 0160004670 thru 0160015194), (10054 S/N 0160004670 thru 0160015043)

8303782 4 HEX HD CAPSCREW, 1/2-13X4.0, GR5, (8042 S/N 0160015042 & After),

(10042 S/N 0160015195 & After), (10054 S/N 0160015044 & After)

4 8310056 4 PLAIN WASHER, 1/2, (8042 S/N 0160004670 thru 0160015041), (10042 S/N

0160004670 thru 0160015194), (10054 S/N 0160004670 thru 0160015043)

5 8065640 4 BEARING, (self align) 6 8050001 4 BEARING, (self align) 7 8065641 2 BEARING, (self align) 8 8520013 2 GREASE FITTING, STRAIGHT

9 8520021 4 GREASE FITTING, 90 DEGREES 10 Ref FRONT AXLE, (see Figure 5-2 for details) 11 Ref REAR AXLE, (see Figure 5-10 for details) 12 7138879 Ref COUNTERWEIGHT, (no longer available, use 1001094786 (1), 4892600 (4),

8310051 (4), 0642222 (4), 4892200 (4) & 1001094877 (2) for replacement) 13 8305021 4 HEX NUT, 1-8 14 5724302 AR WASHER, SHIM 0.06 15 8307012 4 LOCKWASHER, 1 16 8310066 AR FLAT WASHER, 0.134 17 8310051 4 HEX HD CAPSCREW, 1-8X4 18 7137142 4 TILT & STABIL-TRAK CYLINDER PINS 19 7138888 Ref FRONT COUNTERWEIGHT, (8042 only), (no longer available, use 1001094787

(1) & 0642216 (2) for replacement) 20 7139066 2 COUNTERWEIGHT HOLD DOWN PLATE, (8042 only) 21 8303752 4 HEX HD CAPSCREW, 0.312-18X3.5 22 8303794 2 HEX HD CAPSCREW, 0.750-10X3.5, GR8, (8042 only) 23 8305626 4 HEX LOCKNUT, 0.312-18 24 8307010 2 LOCKWASHER, 0.750, (8042 only) 25 7125871 AR CONDUIT, 0.50X8, (cut to fit) 26 7138368 AR CONDUIT, 0.25X2, (cut to fit) 27 7124301 AR CONDUIT, 0.5X15.5, (cut to fit) 28 7124471 AR CONDUIT, 1 DIAX12.5, (cut to fit) 29 7124451 AR CONDUIT, 1 IDX8, (cut to fit) 30 7139157 AR CONDUIT, 1 IDX4, (cut to fit) 31 7139156 AR CONDUIT, 1 IDX28, (cut to fit) 32 8522012 AR ANTI-SEIZE LUBE, (apply to items 2 & 24) 33 8520001 8 GREASE FITTING, STRAIGHT 34 Ref BOOM LIFT & LOWER CYLINDER, (see Figure 9-2 for details) 35 Ref SLAVE CYLINDER, (see Figure 9-6 for details) 36 Ref FRAME SWAY CYLINDER, (see Figure 9-4 for details) 37 Ref STABIL-TRAK CYLINDER, (see Figure 9-5 for details)

8990395 8042/10042/10054 1-5

8042 S/N 0160004670 thru 0160033642

FRAME & ATTACHING PARTS

10042 S/N 0160004670 thru 0160033649 10054 S/N 0160004670 thru 0160033644

Figure 1-1 Main Frame Components (Continued)

Item Part Number Qty. Description Rev.

38 8526007 AR

39 8305644 4 HEX LOCKNUT, 1/2-13, (8042 S/N 0160015042 & After), (10042 S/N

LOCTITE® 242™, (apply to item 3), (8042 S/N 0160004670 thru 0160015041),

(10042 S/N 0160004670 thru 0160015194), (10054 S/N 0160004670 thru

0160015043)

0160015195 & After), (10054 S/N 0160015044 & After)

8042/10042/10054 89903951-6

8042 S/N 0160004670 thru 0160033642 10042 S/N 0160004670 thru 0160033649

FRAME & ATTACHING PARTS

10054 S/N 0160004670 thru 0160033644

Figure 1-1 Main Frame Components (Continued)

Item Part Number Qty. Description Rev.

8990395 8042/10042/10054 1-7

FRAME & ATTACHING PARTS

2 32

18 32

23 33

22 39

39 40

2 32

PH4563

BOOM PIVOT FRAME TILT CYLINDER STABILIZER CYLINDER LIFT/LOWER CYLINDER SLAVE CYLINDER

LOCATE THE FRACTURE IN BEARING

OUTER RACE AT THE CLOCK POSITION

SHOWN FOR EACH APPLICATION

Figure 1-1 Main Frame Components

8042 S/N 0160033643 & After 10042 S/N 0160033650 & After 10054 S/N 0160033645 & After

8042/10042/10054 89903951-8

8042 S/N 0160033643 & After 10042 S/N 0160033650 & After

FRAME & ATTACHING PARTS

10054 S/N 0160033645 & After

Figure 1-1 Main Frame Components

Item Part Number Qty. Description Rev.

1NSS1FRAME WELDMENT 2 3423227 4 LIFT/LOWER & SLAVE CYLINDER PINS, (base & rod ends) 3 8303782 4 HEX HD CAPSCREW, 1/2-13X4.0, GR5 4 8305644 4 HEX LOCKNUT, 1/2-13 5 8065640 4 BEARING, (self align) 6 8050001 4 BEARING, (self align) 7 8065641 2 BEARING, (self align) 8 8520013 2 GREASE FITTING, STRAIGHT

9 8520021 4 GREASE FITTING, 90 DEGREES 10 Ref FRONT AXLE, (see Figure 5-2 for details) 11 Ref REAR AXLE, (see Figure 5-10 for details) 12 1001094786 1 COUNTERWEIGHT 13 8305021 4 HEX NUT, 1-8 15 4762600 4 LOCKWASHER, 1 16 4892600 4 FLAT WASHER, 1 17 0642628 4 HEX HD CAPSCREW, 1-8X3-1/2 18 7137142 4 TILT & STABIL-TRAK CYLINDER PINS 19 1001094787 1 FRONT COUNTERWEIGHT, (8042 only) 20 7139066 2 COUNTERWEIGHT HOLD DOWN PLATE, (8042 only) 21 8303752 4 HEX HD CAPSCREW, 0.312-18X3.5 22 0642216 2 HEX HD CAPSCREW, 0.750-10X2, GR5, (8042 only) 23 8305626 4 HEX LOCKNUT, 0.312-18 24 8307010 2 LOCKWASHER, 0.750, (8042 only) 25 7125871 AR CONDUIT, 0.50X8, (cut to fit) 26 7138368 AR CONDUIT, 0.25X2, (cut to fit) 27 7124301 AR CONDUIT, 0.5X15.5, (cut to fit) 28 7124471 AR CONDUIT, 1 DIAX12.5, (cut to fit) 29 7124451 AR CONDUIT, 1 IDX8, (cut to fit) 30 7139157 AR CONDUIT, 1 IDX4, (cut to fit) 31 7139156 AR CONDUIT, 1 IDX28, (cut to fit) 32 8522012 AR ANTI-SEIZE LUBE, (apply to items 2 & 24) 33 8520001 8 GREASE FITTING, STRAIGHT 34 Ref BOOM LIFT & LOWER CYLINDER, (see Figure 9-2 for details) 35 Ref SLAVE CYLINDER, (see Figure 9-6 for details) 36 Ref FRAME SWAY CYLINDER, (see Figure 9-4 for details) 37 Ref STABIL-TRAK CYLINDER, (see Figure 9-5 for details) 39 0100019 AR

40 0642222 4 HEX HD CAPSCREW, 0.750-10X2-3/4 41 3520030 1 PLUG, HOLE, (8042 only) 42 4892200 4 FLAT WASHER, 0.750 43 1001094877 2 COUNTERWEIGHT MOUNTING ANGLE 44 8310039 2 HEX HD CAPSCREW, 5/16-18X3-3/4, GR5

LOCTITE

271TM, (apply to items 22 & 40)

8990395 8042/10042/10054 1-9

FRAME & ATTACHING PARTS

PAP16430

6 5 4

6 5

8042, 10042 & 10054

S/N 13198 THRU 14052

8042 S/N 13198 THRU 13949 10042 S/N 13198 THRU 13927 10054 S/N 13198 THRU 13811

PH3200

Figure 1-2 Hoods & Guards

8042 S/N 13198 thru 0160029592 10042 S/N 13198 thru 0160029606 10054 S/N 13198 thru 0160029593

8042/10042/10054 89903951-10

8042 S/N 13198 thru 0160029592 10042 S/N 13198 thru 0160029606

FRAME & ATTACHING PARTS

10054 S/N 13198 thru 0160029593

Figure 1-2 Hoods & Guards

Item Part Number Qty. Description Rev.

1 7138730 Ref TRANSMISSION COVER, (S/N 13198 thru 14052), (no longer available, use

items 2 & 3 for replacement) 2 7139406 1 LOWER TRANSMISSION COVER, (S/N 14053 thru 0160029592) 3 7139407 1 UPPER TRANSMISSION COVER, (S/N 14053 thru 0160029592) 4 8307202 10 FLAT WASHER, 1/4 5 8307002 16 LOCKWASHER, 1/4 6 8305004 16 HEX NUT, 1/4-20 7 7139047 1 COUNTERWEIGHT COVER 8 7150661 1 FUEL/HYDRAULIC TANK COVER 9 8303656 4 HEX HD CAPSCREW, 5/16-18X7/8

10 8307203 4 FLAT WASHER, 5/16 11 8307004 4 LOCKWASHER, 5/16 12 8310658 4 RETAINING NUT, 5/16 13 7138709 2 SIDE ACCESS COVER 14 8303729 6 HEX HD CAPSCREW, 1/4-20X5/8 15 7094682 2 SIDE ACCESS COVER HINGE 16 8581007 AR FOAM TAPE, 230 IN, (sold by the inch) 17 8342416 2 LATCH ASSY, WITH LOCK & KEY, (includes item 18) 18 8342808 AR KEY SET 19 8310129 4 CARRIAGE BOLT, 5/8-11X2-1/2 20 8307009 4 LOCKWASHER, 5/8 21 8305014 4 HEX NUT, 5/8-11

(8042 S/N 13198 thru 13949), (10042 S/N 13198 thru 13927) & (10054 S/N

13198 thru 13811)

22 7150692 1 RADIATOR COVER 23 7150653 2 REAR DOOR HINGE 24 8303540 4 HEX HD CAPSCREW, 1/4-20X1 25 8307002 4 LOCKWASHER, 1/4 26 8305004 4 HEX NUT, 1/4-20 27 8303622 2 HEX HD CAPSCREW, 3/8-16X2 28 8305008 2 HEX NUT, 3/8-16 29 5724742 2 GASKET

(8042 S/N 13950 thru 0160029592), (10042 S/N 13928 thru 0160029592) &

(10054 S/N 13812 thru 0160029592)

30 7139462 1 RADIATOR COVER 31 8302470 2 COTTER PIN 32 5724742 2 GASKET 33 10732150 AR FLAT WASHER, M10 38 Ref FUEL/HYDRAULIC TANK ASSY, (see Figure 9-11 for details)

8990395 8042/10042/10054 1-11

FRAME & ATTACHING PARTS

12 13

PH3202

Figure 1-2 Hoods & Guards

8042 S/N 0160029593 & After 10042 S/N 0160029607 & After 10054 S/N 0160029594 & After

8042/10042/10054 89903951-12

8042 S/N 0160029593 & After 10042 S/N 0160029607 & After

FRAME & ATTACHING PARTS

10054 S/N 0160029594 & After

Figure 1-2 Hoods & Guards

Item Part Number Qty. Description Rev.

1 1001094897 1 RADIATOR COVER, (S/N 0160031620 thru 0160040019)

1001125530 1 RADIATOR COVER, (S/N 0160040020 & After) 2 90206196 AR GASKET 3 7138709 2 SIDE ACCESS COVER, (S/N 0160029593 thru 0160040219 excluding

0160039850, 0160040126 thru 0160040129 & 0160040171)

10 0 1111 5 6 8 1 LEFT SI D E A C CESS COVER, (S/N 0160040220 & After including

0160039850, 0160040126 thru 0160040129 & 0160040171)

10 0 1111 5 6 9 1 RIGHT S I D E A C CESS COVER, (S/N 0160040220 & After including

0160039850, 0160040126 thru 0160040129 & 0160040171)

4 7139047 1 COUNTERWEIGHT COVER, (10042 & 10054)

7139047 1 COUNTERWEIGHT COVER, (8042 S/N 0160029593 thru 0160033643) 5 7139406 1 LOWER TRANSMISSION COVER 6 7139407 1 UPPER TRANSMISSION COVER 7 7150661 1 FUEL/HYDRAULIC TANK COVER 8 8302470 2 COTTER PIN 9 8303615 10 HEX HD CAPSCREW, 1/4-20X1-1/4, GR5

10 8303656 4 HEX HD CAPSCREW, 5/16-18X7/8 11 8303729 6 HEX HD CAPSCREW, 1/4-20X5/8 12 8305004 6 HEX NUT, 1/4-20 13 8307002 16 LOCKWASHER, 1/4 14 8307004 4 LOCKWASHER, 5/16 15 8307202 10 FLAT WASHER, 1/4 16 8307203 4 FLAT WASHER, 5/16 17 8310658 4 RETAINING NUT, 5/16 18 Use Kit K1 Ref LATCH ASSY, WITH LOCK & KEY, (Before S/N 0160043513), (1001094075 is

no longer available)

1001131179 3 LATCH ASSY, WITH LOCK & KEY, (S/N 0160043513 & After)

8342808 AR KEY SET

19 8580420 10 WELL NUT 20 10732150 8 FLAT WASHER, M10 21 4420037 AR FOAM TAPE 22 8310129 4 CARRIAGE BOLT, 5/8-11X2-1/2 23 8307009 4 LOCKWASHER, 5/8 24 8305014 4 HEX NUT, 5/8-11 25 Ref FUEL/HYDRAULIC TANK ASSY, (see Figure 9-11 for details)

K1 1001132458 1 LATCH WITH PLATE REPLACEMENT KIT

8990395 8042/10042/10054 1-13

FRAME & ATTACHING PARTS

PH4594

12 32

10042 & 10054

10042 S/N 0160037798 & AFTER 10054 S/N 0160037793 & AFTER

EXCLUDING 0160021270, 0160036713,

0160036715 & 0160036723

10054 S/N 0160021270, 0160036713,

0160036715 & 0160036723

Figure 1-3 Outrigger Mounting

8042/10042/10054 89903951-14

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Mounting

Item Part Number Qty. Description Rev.

1 7138601 1 OUTRIGGER FRAME, (10042 Before S/N 0160038368), (10054 Before S/N

0160038740)

1001110483 1 OUTRIGGER FRAME, (10042 S/N 0160038375, 0160038378, 0160038379,

0160038381 & 0160038383), (10054 S/N 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

1001107692 1 OUTRIGGER FRAME, (10042 S/N 0160038368 & After excluding

0160038375, 0160038378, 0160038379, 0160038381 & 0160038383), (10054 S/N 0160038740 & After excluding 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

2 7091373 2 OUTRIGGER LEG 3 7090822 2 OUTRIGGER PAD, (includes item 4) 4 8065640 2 BEARING, (self align) 5 7090832 1 AXLE PIVOT PIN, (10042 S/N 13198 thru 19987 & 0160002332 thru

0160018244), (10054 S/N 13198 thru 19987 & 0160002332 thru 0160018374)

3423248 1 AXLE PIVOT PIN, (10042 S/N 0160018395 & After),

(10054 S/N 0160018382 & After)

6 7090871 2 CYLINDER PIVOT PIN 7 7090891 2 LEG PIVOT PIN 8 Ref OUTRIGGER CYLINDER, (see Figure 9-7 for details) 9 7090951 2 PAD PIVOT PIN

10 8065063 1 BUSHING, 3 IDX2 11 8303655 1 HEX HD CAPSCREW, 5/8X4-1/2, GR5, (10042 S/N 13198 thru 19987 &

0160002332 thru 0160018244), (10054 S/N 13198 thru 19987 & 0160002332 thru 0160018374)

0642640 1 HEX HD CAPSCREW, 1-8X5, (10042 S/N 0160018395 & After),

(10054 S/N 0160018382 & After)

12 8310475 8 HEX HD CAPSCREW, 3/4X10, GR8, (torque to 260 lb-ft)

1001106346 8 SOC HD CAPSCREW, 3/4-10X11, GR8, (10042 S/N 0160038375, 0160038378,

0160038379, 0160038381 & 0160038383), (10054 S/N 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723), (torque to 260 lb-ft)

13 8310067 8 LOCKNUT, 3/4, (10042 Before S/N 0160038368 including 0160038375,

0160038378, 0160038379, 0160038381 & 0160038383), (10054 Before S/N 016008740 including 0160021270, 0160036713, 0160036715, 0160036721 &

0160036723)

14 8303628 2 HEX HD CAPSCREW, 1/2X3-3/4, GR5 15 8310151 2 HEX HD CAPSCREW, 1/2X7, GR5 16 8303629 2 HEX HD CAPSCREW, 1/2X4-1/2, GR5 17 8305644 6 LOCKNUT, 1/2 18 8305643 1 LOCKNUT, 5/8, (10042 S/N 13198 thru 19987 & 0160002332 thru

0160018244), (10054 S/N 13198 thru 19987 & 0160002332 thru 0160018374)

8310116 1 LOCKNUT, 1/8, (10042 S/N 0160018395 & After),

(10054 S/N 0160018382 & After)

19 8520013 10 GREASE FITTING 20 8307912 AR SHIM, 0.06 21 8307913 AR SHIM, 0.12 22 7124491 2 CONDUIT, 1 IDX15.5 23 7125801 4 CONDUIT, 0.75 IDX4 24 7138609 2 MOUNT PLATE, (10042 Before S/N 0160038368 including 0160038375,

0160038378, 0160038379, 0160038381 & 0160038383), (10054 Before S/N 0160038740 excluding 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

8990395 8042/10042/10054 1-15

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Mounting (Continued)

Item Part Number Qty. Description Rev.

1001107664 2 MOUNT PLATE, (10042 S/N 0160038368 & After excluding 0160038375,

0160038378, 0160038379, 0160038381 & 0160038383), (10054 S/N 0160038740 & After including 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

25 8307104 8 PLAIN WASHER, 3/4, (10042 Before S/N 0160038368), (10054 Before S/N

0160038740)

8307104 16 PLAIN WASHER, 3/4, (10042 S/N 0160038375, 0160038378, 0160038379,

0160038381 & 0160038383), (10054 S/N 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

26 8223536 2 PRESSURE SWITCH, (10054 only) 27 Ref MAIN FRAME, (see Figure 1-1 for details) 28 Ref FRONT AXLE, (see Figure 5-2 for details) 29 1001103619 5 SOCKET HD CAPSCREW, M22X1.5X80, (10042 S/N 0160037798 & After),

(10054 S/N 0160037793 & After)

30 1001097046 1 MOUNTING BRACE, (10042 S/N 0160038375, 0160038378, 0160038379,

0160038381 & 0160038383), (10054 S/N 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

1001107744 1 MOUNTING BRACE, (10042 S/N 0160038368 & After excluding 0160038375,

0160038378, 0160038379, 0160038381 & 0160038383), (10054 S/N 0160038740 & After excluding 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

31 1001105428 1 LUG, (10042 S/N 0160038375, 0160038378, 0160038379, 0160038381 &

0160038383), (10054 S/N 0160021270, 0160036713, 0160036715, 0160036721 & 0160036723)

1001107746 1 LUG, (10042 S/N 0160038368 & After excluding 0160038375, 0160038378,

0160038379, 0160038381 & 0160038383), (10054 S/N 0160038740 & After excluding 0160021270, 0160036713, 0160036715, 0160036721 &

0160036723)

32 0100019 AR

LOCTITE

271

8042/10042/10054 89903951-16

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Mounting (Continued)

Item Part Number Qty. Description Rev.

8990395 8042/10042/10054 1-17

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

8042/10042/10054 89903951-18

SECTION 2

BOOM

8990395 8042/10042/10054

PH4262

4 44

33 34

34 36

31 44

18 44

9 32

26 32

27 32

9 32

11 44

45 46

BOOM

Figure 2-1 First Boom Section

S/N 13198 thru 19987

& 0160002332 thru 0160004670

8042/10042/10054 89903952-2

S/N 13198 thru 19987 & 0160002332 thru 0160004670

Figure 2-1 First Boom Section

Item Part Number Qty. Description Rev.

1 Use Kit K1 1 FIRST BOOM SECTION, (see Figure 12-7 for details) 2 8303655 2 HEX HD CAPSCREW, 5/8-11X4.50 3 8305643 2 HEX LOCKNUT, 5/8-11 4 7097682 2 BOOM PIVOT PIN 5 8307910 AR WASHER, SHIM, 2.75 DIAX.075 6 8307911 AR WASHER, SHIM, 2.75 DIAX.135 7 8307204 12 FLAT WASHER, 3/8 8 8307005 24 LOCKWASHER, 3/8 9 8303681 8

HEX HD CAPSCREW, 3/8-16X3/4, (Loctite 10 8065640 4 BEARING, 2 DIA, (self align) 11 7092292 4 HOIST & SLAVE CYLINDER PINS 12 8305644 4 HEX LOCKNUT, 1/2-13 13 8303782 4 HEX HD CAPSCREW, 1/2-13X4 14 8642224 4 RETAINING RING, 2 DIA 15 8307113 2 FLAT WASHER, 7/16 16 7075611 1 POINTER 17 8305647 1 HEX LOCKNUT, 7/16-14 18 7096562 1 EXTEND CYLINDER PIN, (rod end) 19 7082311 21 WEAR PAD INSERT 20 8520013 4 LUBE FITTING, STRAIGHT, 1/8 21 71115 7 2 3 W E AR PAD 22 7082342 AR SHIM, WEAR PAD, 0.07 23 7082362 AR SHIM, WEAR PAD, 0.13 24 7096882 2 SPACER, WEAR PAD, 0.62 25 7096772 1 SPACER, WEAR PAD, (special) 26 8303041 3

27 8303620 8

28 8303621 6

HEX HD CAPSCREW, 3/8-16X1/2, (Loctite

HEX HD CAPSCREW, 3/8-16X1, (Loctite

HEX HD CAPSCREW, 3/8-16X1-1/2, (Loctite 29 5724622 1 RUBBER BUMPER 30 8305645 1 HEX LOCKNUT, 3/8-16 31 7096552 1 EXTEND CYLINDER PIN, (base end) 32 8526007 AR

LOCTITE

242™, (apply to items 9, 26, 27 & 28) 33 8303697 1 HEX HD CAPSCREW, 5/16-18X3/4 34 8307106 2 FLAT WASHER, 5/16 35 8305906 2 RETAINER NUT, 5/16-18 36 8310431 1 LOCKWASHER, 5/16, (internal tooth) 37 8310497 1 THUMB SCREW, 5/16-18X1.50 38 7116792 1 REAR BOOM COVER 39 7138468 1 PROXIMITY SWITCH CLIP 40 8303738 2 HEX HD CAPSCREW, 0.375-16X.88 41 8310113 2 CAGE NUT, 0.375-16 42 Ref EXTEND/RETRACT CYLINDER, (see Figure 9-1 for details) 43 7079572 6 WEAR PAD 44 8522012 AR ANTI-SEIZE LUBE, (apply to items 4, 11, 18 & 31) 45 7099882 1 BOOM ANGLE SENSOR, (8042 & 10042 only) 46 7099882 2 BOOM ANGLE & BOOM INTERLOCK SENSOR, (10054 only)

& torque to 31 lb-ft)

BOOM

8990395 8042/10042/10054 2-3

S/N 13198 thru 19987

BOOM

Figure 2-1 First Boom Section (Continued)

Item Part Number Qty. Description Rev.

K1 7302086 1 FIRST BOOM SECTION SERVICE KIT

& 0160002332 thru 0160004670

8042/10042/10054 89903952-4

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