SkyTrak 10054 User Manual
Illustrated Parts Manual
Service and Maintenance Manual
ANSI
Model
8042
10042
10054
8990187-003
FEBRUARY 2000
Table of Contents
Page Page
SECTION 1 – MAIN FRAME AND GUARDS
Main Frame .................................................................. 2
Hoods and Guards ....................................................... 4
SECTION 2 – OPERATOR’S CAB AND CONTROLS
Operator’s Cab - Open ................................................. 6
Operator’s Cab - Closed (Optional) .............................. 8
Cab Door .................................................................... 10
Operator’s Seat .......................................................... 12
Control Console.......................................................... 14
Transmission Shift Controls (S/N 9908 & Before) ...... 16
Transmission Shift Controls (S/N 9909 & After) ......... 18
Boom Raise/Lower & Extend/Retract Control ............ 20
Frame Level & Attachment Tilt Control ...................... 22
Throttle Pedal Control ................................................ 24
Service Brake Pedal Control ...................................... 26
Front Windshield Wiper .............................................. 28
Cab Heater (Optional) ................................................ 30
Aux. Hydraulic Control (Optional)............................... 32
Mirrors ........................................................................ 34
Skylight Windshield Wiper (Optional) ......................... 36
Soft Cab Enclosure (Optional).................................... 38
SECTION 3 – DRIVE TRAIN
Converter and Transmission Housings
(S/N 9908 & Before)............................................. 40
Converter Group (S/N 9908 & Before) ....................... 42
Forward, Reverse, Low and 2nd
(S/N 9908 & Before)............................................. 44
Output, Idler and Third (S/N 9908 & Before) .............. 46
Transmission Clutch Groups (S/N 9908 & Before)..... 48
Control Valve Assembly (S/N 9908 & Before)............ 50
Emergency Brake (S/N 9908 & Before) ..................... 52
Transmission Mounting (S/N 9908 & Before) ............. 54
Engine Connect (S/N 9909 & After) ........................... 56
Converter and Layshaft (S/N 9909 & After)................ 58
Oil Pressure Pump (S/N 9909 & After) ....................... 60
Input Shaft (S/N 9909 & After).................................... 62
Gearbox Housing (S/N 9909 & After) ......................... 64
Clutch Pack 1st Gear - 1 of 2 (S/N 9909 & After)....... 66
Clutch Pack 1st Gear - 2 of 2 (S/N 9909 & After)....... 68
Clutch Pack 2nd Gear - 1 of 2 (S/N 9909 & After)...... 70
Clutch Pack 2nd Gear - 2 of 2 (S/N 9909 & After)...... 72
Clutch Pack 3rd Gear - 1 of 2 (S/N 9909 & After) ...... 74
Clutch Pack 3rd Gear - 2 of 2 (S/N 9909 & After) ...... 76
Output Shaft (S/N 9909 & After)................................. 78
Parking Brake (S/N 9909 & After) .............................. 80
Power Take-Off Shaft (S/N 9909 & After) .................. 82
Gearshift System (S/N 9909 & After) ......................... 84
Control Valve (S/N 9909 & After) ............................... 86
Transmission Filter & Dipstick (S/N 9909 & After) ......88
Oil Tubes (S/N 9909 & After) ......................................90
Transmission Mounting (S/N 9909 & After) ................92
Drive Shaft - Engine to Transmission
(S/N 9908 & Before) .............................................94
Drive Shaft - Engine to Transmission
(S/N 9909 & After) ................................................96
Drive Shaft - Front and Rear (S/N 9908 & Before) .....98
Drive Shaft - Front and Rear (S/N 9909 & After) ......100
Differential Carrier Assembly ....................................102
Axle Steering Joints ..................................................104
Axle Wheel Ends (S/N 0460 & Before) .....................106
Axle Wheel Ends (S/N 0461 & After) ........................108
Tie Rod and Steering Cylinder Mounting ..................110
Wheels and Tires - 8042 ...........................................112
Wheels 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) ..........................122
Exhaust System ........................................................124
Air Cleaner ................................................................126
Fuel System (S/N 1598 & Before).............................128
Fuel System (EPA) (S/N 1599 & After) .....................130
SECTION 5 – HYDRAULIC CIRCUITS
Power Steering Circuit (S/N 9908 & Before) .............132
Power Steering Circuit (S/N 9909 & After) ................134
Control Valves Circuit (S/N 9908 & Before) ..............136
Control Valves Circuit (S/N 9909 & After) .................138
Boom Raise/Lower & Extend/Retract Circuit
(S/N 9908 & Before) ...........................................140
Boom Raise/Lower & Extend/Retract Circuit
(S/N 9909 & After) ..............................................142
Attachment Tilt and Slave Circuit..............................144
Frame Tilt and Stabilizer Circuit................................146
Service Brake and De-Clutch Circuit ........................148
Valve Plate Assembly
(Without Outriggers 8042 Only)..........................150
Valve Plate Assembly
(With Outriggers 10042/10054 Only)..................152
Transmission Cooling Circuit (S/N 9908 & Before) ...154
Transmission Cooling Circuit (S/N 9909 & After) ......156
Auxiliary Hydraulic Circuit (Optional) ........................158
Outrigger Hydraulic Circuit (10042/10054 Only) .......160
8042/10042/10054 Origin 2/00
© 2000 JLG Industries, Inc.
T of C 1
Page Page
SECTION 6 – HYDRAULIC COMPONENTS
Hydraulic Reservoir .................................................. 162
Main Pump (S/N 9908 & Before).............................. 164
Main Pump (S/N 9909 & After)................................. 166
Boom Extend Cylinder (Early Production)................ 168
Boom Extend Cylinder (Current Production) ............ 170
Boom Hoist Cylinder (S/N 5818 & Before) ............... 172
Boom Hoist Cylinder (S/N 5819 & After) .................. 174
Frame Tilt Cylinder ................................................... 176
Stabilizer Cylinder..................................................... 178
Slave Cylinder (Early Production)............................. 180
Slave Cylinder (Current Production)......................... 182
Attachment Tilt Cylinder ........................................... 184
Outrigger Cylinder (S/N 10881 & Before) ................. 186
Outrigger Cylinder (S/N 10882 & After) .................... 188
Swing Carriage Cylinder........................................... 190
Side Tilt Carriage Cylinder........................................ 192
Steering Cylinder (S/N 1167 & Before)..................... 194
Steering Cylinder (S/N 1168 & After)........................ 196
Main Control Valve ................................................... 198
Secondary Control Valve.......................................... 200
Directional Control Valves 1 of 2 .............................. 202
Directional 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 ........................................................ 222
Outrigger Electrical Harness (10042/10054 Only).... 224
SECTION 8 – DECALS AND PAINT
Decals and Paint ...................................................... 226
SECTION 9 – BOOM AND ATTACHMENTS
Outer Boom.............................................................. 228
Intermediate Boom - 8042 and 10042...................... 230
Inner Boom - 8042 and 10042 ................................. 232
Quick Attach............................................................. 234
Carriage 48" ............................................................. 236
Carriage 60" (Optional) ............................................ 238
Carriage 72" (Optional) ............................................ 240
Side Tilt Carriage - Early Production (Optional) ....... 242
Side Tilt Carriage - Current Production (Optional) ... 244
Outriggers (10042/10054 Only)................................ 246
Swing Carriage (Optional)........................................ 248
Sheet Material Handler (Optional)............................ 250
Utility Bucket (Optional)............................................ 252
Primary Intermediate Boom - 10054 ........................ 254
Secondary Intermediate Boom - 10054 ................... 256
Inner Boom - 10054 ................................................. 258
Boom Extend Chains - 8042 and 10042 .................. 260
Boom Retract Chain - 8042 and 10042
(S/N 1084 & Before) .......................................... 262
Boom Retract Chain - 8042 and 10042
(S/N 1085 & After) ............................................. 264
Boom Extend Chains - 10054 .................................. 266
Boom Retract Chains - 10054
(S/N 0884 & Before) .......................................... 268
Boom Retract Chains - 10054
(S/N 0885 thru 1084) ......................................... 270
Boom Retract Chains - 10054 (S/N 1085 & After) ... 272
Truss Boom 12 and 15 Ft. (Optional)....................... 274
PART NUMBER INDEX........................................... 277
SECTION 10 – GENERAL TROUBLESHOOTING .287
T of C 2
© 2000JLG Industries, Inc.
8042/10042/10054 Origin 2/00
The parts information in this publication is based on data available at the time it was
SECTION 1 MAIN FRAME AND GUARDS
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.
1
SECTION 1
Locate the fracture in bearing outer race
at the clock position shown for each
application (Items 5 & 7).
12
11
10
9
8
7
1
2
3
4
5
6
Boom Pivot
Frame Tilt Cylinder
Stabilizer Cylinder
Hoist Cylinder
Slave Cylinder
3
2
4
3
2
MAIN FRAME
3
3
2
4
6
10
4
2
6
10
4
5
11
7
6
5
6
10
5
25
27
10
21
10
8
5
1
6
24
26
28
23
6
2
8
4
3
12
9
13
19
15
17
8
5
6
18
19
16
17
20
14
18
20
22
15
29
16
14
30
3
12
13
5
10
21
22
31
it
K
PF0791
2
it
K
it
K
PH0012
8042/10042/10054 Rev. 2/00
MAIN FRAME
Item No. Part Number Qty. Description
1 Consult Factory 1 Weldment, Frame
2 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 1/2-13
5 8065640 8 Bearing, 2" I.D.’
6 6620531 AR Conduit, 1 x 5' - Cut to Fit
7 8065641 2 Bearing, 2-3/4" I.D.
8 7124331 AR Conduit, 1/2 x 5' - Cut to Fit
9 7125861 AR Conduit, 3/4 x 5' - Cut to Fit
10 8520013 8 Fitting, Grease
11 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 3/4-10
15 7079442 2 Pin, Axle Pivot
16 8307913 AR Spacer, Washer .12" Thick
17 8307912 AR Spacer, Washer .06" Thick
18 8310259 AR Spacer, Washer .09" Thick
19 8303655 2 HHCS, 5/8-11 x 4-1/2"
20 8305643 2 Nut, Hex Lock Elastic 5/8-11
21 7099312 2 Anchor, Cylinder
22 8040258 2 Axle
23 7098563 1 Counterweight
24 8305021 4 Nut, Hex 1"-8
25 5724302 2 Washer, Shim .06" Thick
26 8307012 4 Washer, Lock 1"
27 8310066 2 Washer, Flat .134" Thick
28 8310051 4 HHCS, 1-8 x 4"
SECTION 1
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
3
SECTION 1
HOODS AND GUARDS
15
14
20
21
S/N 9908 & Before
17
18
11
17
18
12
22
9
25
1
16
7
16
20
7
2
13
3
9
24
11
12
31
26
8
3
12
29
18
11
32
28
27
19
28
8
26
8
4
12
11
30
If Gap at top
exceeds .06", shim
Lower Pivot with Item 8.
6
29
14
11
15
13
20
23
12
5
18
19
10
33
11
12
Apply Item 33 to Item 10
4
PF0810
PH1330
8042/10042/10054 Rev. 2/00
HOODS AND GUARDS
Item No. Part Number Qty. Description
1 7098262 1 Cover, Tool Box
2 7084792 1 Cover, Fuel Tank
3 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 Access
6 7097174 1 Cover, Radiator
7 8344010 3 Hinge
8 8307110 AR Washer, Flat 3/8"
9 8303034 8 TRHDCS, 1/4-20 x 3/4"
10 7111473 1 Cover
11 8307002 18 Washer, Lock 1/4"
12 8305004 18 Nut, Hex 1/4-20
13 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/Key
18 8342808 AR Key Set
19 8342416 3 Latch, w/Lock and Key
20 5746241 4 Tape, Foam - 38" (Cut to Fit)
21 8580213 2 Grommet
22 8582413 2 Plug, Bumper
23 8303729 6 HHCS, 1/4-20 x 5/8"
24 7084821 1 Shim
25 8310136 4 TRHDCS, 1/4-20 x 1-1/4"
26 7082311 2 Insert
27 8304660 2 SHCS, 3/8-16 x 3/4"
28 8307005 2 Washer, Lock 3/8"
29 5724742 2 Gasket
30 7094682 2 Hinge, Side Access Cover
31 8581007 AR Tape, Foam - 170" (Cut to Fit)
32 8307202 6 Washer, Flat 1/4"
33 8526035 AR Caulk, Clear RTV-08
SECTION 1
8042/10042/10054 Rev. 2/00
5
SECTION 2
SECTION 2 OPERATOR S CAB AND CONTROLS
OPERATOR’S CAB - OPEN
Torque to
13 - 16 lb/ft
(18 - 22 Nm)
3
12
5
15
3
4
9
14
13
Torque to
50 lb/ft
(68 Nm)
18
17
16
Frame
37
36
Torque to
210 lb/ft
(285 Nm)
2 Places
35
1
31
25
42
2
26
40
10
11
24
34
33
26
3
2
20
21
6
7
33
8
30
27
32
Torque to
515 lb/ft
(698 Nm)
2 Places
28
19
23
22
29
39
14
38
41
PH0532
6
8042/10042/10054 Rev. 2/00
OPERATOR’S CAB - OPEN
Item No. Part Number Qty. Description
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 - 8042
2 8033050 2 Panel, Lower
3 8303034 20 THMS, Torx, 1/4-20 x 3/4"
4 8033052 1 Panel, Right Front Console
5 8033053 1 Panel, Side Console
6 8033031 1 Gasketing, Sponge Rubber, 25-1/4"
7 8033022 1 Cover, Battery
8 8342807 1 Lock, Cam
9 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 Angle
13 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, Steering
17 8305916 1 Nut, Steering Column
18 8720015 1 Cap, Steering Wheel
19 8864038 1 Arm Rest
20 8065639 1 Bushing, Sleeve
21 8302147 1 Pin, Roll
22 7098342 1 Bracket, Arm Rest
23 8303705 2 Scr. FLHDC 1/4-20 x 3/4"
24 8990147 1 Holder, Manual
25 8303729 2 HHCS, 1/4-20 x 5/8"
26 7124331 1 Conduit, 1/2 I.D. x 5' - Cut to Fit
27 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 3/8-16
31 8305624 2 Nut, Lock 1/4-20
32 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 3/8-16
39 8310070 4 Retainer - 3/8"
40 8310036 4 Bolt, Carriage 3/8-16 x 1-1/4"
41 7097233 1 Guard, Bottom
42 7125691 2 Rope Caulk, 0.2 Dia. x 3.0"
SECTION 2
8042/10042/10054 Rev. 2/00
7
SECTION 2
47
OPERATOR’S CAB - CLOSED
(Optional)
48
47
41
50
42
44
49
43
45
46
31
6
33
32
See also “Skylight
Windshield Wiper”
5
38
4
20
30
26
24
18
27
12
20
24
13
15
14
16
7
36
37
35
16
34
20
18
17
34
35
19
4
20
9
28
25
25
29
1
2
8
10
24
40
22
11
3
51
23
21
39
it
K
PF0791
8
PF0810
See
“Cab Door”
PH0482
8042/10042/10054 Rev. 12/97
SECTION 2
OPERATOR’S CAB - CLOSED
(Optional)
Item No. Part Number Qty. Description
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 Kit
2 See page 7 Cab Assembly
3 8307207 1 Washer, Flat 5/8"
4 8033079 2 Window, Wing
5 8033081 1 Window, Skylight w/o Wiper Assembly
6 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, Striker
12 8307003 4 Washer, Lock #10
13 8307201 4 Washer, Flat 3/16"
14 8033085 2 Hinge, Spring
15 8033084 1 Window, Rear
16 8033086 8 Nut, Well
17 8033087 4 Washer, Nylon
18 8033088 8 Screw, Phil. Hd, #10-32 x 3/4"
19 8033044 1 Window Hold Slide Assembly, w/Hardware
20 8585135 3 Tape, Butyl, 1/4" sq. x 15' Roll
21 8303540 2 HHCS, 1/4-20 x 1"
22 8342413 1 Strap
23 8033090 1 Bracket, Door Mounting
24 8305601 6 Nut, Hex Lock 1/4-20
25 8303982 4 Screw, Self Tap 1/4-20 x 3/4"
26 8346011 1 Panel, Rear Foam
27 8585138 1 Weldment, Latch Bracket
28 8580315 1 Plug, Hole
29 8033479 1 Window, Front
30 8033076 1 Wire Assembly, Fan
31 8033078 1 Fan, Defroster
32 8033077 2 Connector, Wire
33 8033094 1 Bracket, Circulation Fan
34 8585139 2 Washer, Flat Plastic 3/8"
35 8307204 2 Washer, Flat 3/8"
36 8580115 1 Knob
37 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 - Front
43 8033834 1 Glass Assembly - Rear
44 8033835 1 Frame Assembly
45 8033836 1 Trim, Stop - Front
46 8033837 1 Trim, Stop - Rear
47 8033838 2 Rubber, Flkd
48 8033839 1 Rubber, Flkd
49 8033840 1 Rubber, Flkd
50 8033082 1 Window, Right Side (Optional)
51 8585133 1 Window Glue Kit (Includes Items 20, 39, four setting blocks and installation instructions)
8346008 - Door Assembly
7112102 - Cab Assembly, Operator’s Protective Structure Orange, Open
8042/10042/10054 Rev. 2/00
9
SECTION 2
CAB DOOR
9
10
9
1
5
28
8
2
7
16
4
11
6
31
14
27
32
15
30
29
25
18
17
26
19
26
24
36
35
22
34
20
13
12
37
3
10
24
33
21
23
PH0552
8042/10042/10054 Rev. 2/00
CAB DOOR
Item No. Part Number Qty. Description
1 8346008 1 Door Assembly (Includes Items 2 thru 36)
2 8033844 1 Door Weldment
3 8033845 1 Sliding Window Assembly (Includes Items 4 thru 11)
4 8033843 1 Glass Assembly - Front
5 8033842 1 Glass Assembly - Rear
6 8033841 1 Frame Assembly
7 8034544 1 Trim, Stop - Front
8 8034545 1 Trim, Stop - Rear
9 8034546 2 Rubber, Flkd
10 8034547 1 Rubber, Flkd
11 8034548 1 Rubber, Flkd
12 8033846 1 Paddle Latch
13 8033847 4 Nut, Hex Locking 1/4-20
14 8033848 1 Grab Handle
15 8033849 2 Screw, Self Tapping 1/4 x 3/4"
16 8033850 1 Door Release
17 8033851 2 Screw, Self Tapping #10-24 x 1/2"
18 8033852 1 Bezel
19 8033853 1 Latch Trip
20 8033854 1 Spring
21 8033855 1 Cam Latch - Right Side
22 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 Bolt
26 8033860 2 Washer, Nylon
27 8033861 1 Seal, Rubber (17’)
28 8037206 1 Seal, Bulb “D” .216 x .354 (9.5’)
29 8033862 3 Hole Plug
30 8033863 1 Rubber Grip
31 8033864 1 Soundproofing - Upper Door
32 8033865 1 Soundproofing - Lower Door
33 8033866 1 Bolt, Hex Hd. 3/8 x 3/4"
34 8033867 1 Nut, Hex Locking 3/8"
35 8033868 1 Striker Bolt
36 8033869 1 Washer, Lock 3/8"
37 8342808 1 Key Set (Not Shown)
SECTION 2
8042/10042/10054 Rev. 2/00
11
SECTION 2
OPERATOR’S SEAT
16
17
15
11
1
2
6
20
10
7
5
9
13
12
18
4
8
19
12
13
3
14
21
Kit
22
Kit
PF0791
PA0064
12
8042/10042/10054 Rev. 2/00
OPERATOR’S SEAT
Item No. Part Number Qty. Description
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 - Cloth
8864046 1 Seat Back - Cloth
3 8864039 1 Slide, w/Handle
4 8864040 1 Slide, w/o Handle
5NSS4Screw
6 8864043 1 Belt, Seat
7 8303604 2 HHCS, 7/16-20 x 1-1/4"
8 7090751 2 Mount, Seat
9 8303697 4 HHCS, 5/16-18 x 3/4"
10 8307006 2 Washer, Lock 7/16"
11 8864036 1 Suspension
12 8307106 8 Washer, Flat 5/16"
13 8305626 12 Nut, Hex Lock Elastic 5/16-18
14 7083963 1 Support, Suspension
15 8305008 4 Nut, Hex 3/8-16
16 8307005 4 Washer, Lock 3/8"
17 8303534 4 FLHDCS 3/8-16 x 1-1/4"
18 8305006 4 Nut, Hex 5/16-18
19 8303745 4 HHCS, 5/16-18 x 5/8"
20 8307113 2 Washer, Flat 7/16"
SECTION 2
KITS
21 7143900 1 Kit, Seat Belt non-retractable 3"
22 7144000 1 Kit, Seat Belt retractable 3"
8042/10042/10054 Rev. 2/00
13
SECTION 2
CONTROL CONSOLE
1
2
3
9
11
4
8
7
5
6
090011
17
10
13
12
14
18
21
19
16
20
15
14
PH0543
8042/10042/10054 Rev. 2/00
CONTROL CONSOLE
Item No. Part Number Qty. Description
1 7084902 1 Plate, Gauge Mounting
2 7082292 1 Cover
3 8464212 1 Gauge, Fuel
4 8466305 1 Gauge, Warning Lights (Includes Item 5)
5 8469030 4 Bulb (Not Shown)
6 8467014 1 Hourmeter
7 8305004 4 Nut, Hex, 1/4-20
8 8307002 4 Washer, Lock 1/4"
9 8303034 4 TRHCS, Torx 1/4-20 x 3/4"
10 8223442 1 Switch Test
11 8580312 1 Cap, Seal
12 8223405 1 Button, Horn
13 8580311 1 Cap, Seal
14 8033201 1 Switch, Washer/Wiper Front (Optional)
15 8223220 1 Switch, Steer Select
16 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 - Domestic
7111832 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, Switch
20 8223444 1 Emergency Brake Switch
21 7135942 1 Switch, Skylight Wiper (Optional)
SECTION 2
8042/10042/10054 Rev. 2/00
15
SECTION 2
TRANSMISSION SHIFT CONTROLS
(S/N 9908 & Before)
3
2
1
4
Speed Control
Connection
Directional Control
Connection
11
5
6
11
13
9
12
Torque to
19 - 23 lb/ft
(26 - 31 Nm)
10
16
Transmission
Control Valve
8
15
14
7
PA0085
8042/10042/10054 Rev. 2/00
TRANSMISSION SHIFT CONTROLS
(S/N 9908 & Before)
Item No. Part Number Qty. Description
1 8160205 1 Shifter, Transmission (Includes Items 2 thru 4)
2 8034694 1 Gate Plate
3 8580111 2 Knob
4 8032753 1 Decal Kit (Contains F-N-R & 3-2-1 Decals)
5 8160042 2 Cable, Control
6 8305402 2 Nut, Hex Jam 1/4-28
7 8160417 1 Transmission Connector Kit (Includes Items 8 thru 15 plus all other parts not
identified with an Item number)
8 8033240 4 Spacer
9 8033241 2 Clamp
10 8303540 4 HHCS, 1/4-20 x 1"
11 8033242 2 Swivel
12 8033243 2 Pin, Clevis
13 8305601 4 Nut, Lock
14 8303106 4 HHCS, 3/8-16 x 2-1/2"
15 8307005 4 Washer, Lock 3/8"
SECTION 2
8042/10042/10054 Rev. 2/00
17
SECTION 2
TRANSMISSION SHIFT CONTROLS
(S/N 9909 & After)
1
18
PH1201
8042/10042/10054 Origin 2/00
TRANSMISSION SHIFT CONTROLS
(S/N 9909 & After)
Item No. Part Number Qty. Description
1 1319283 1 Shifter, Transmission Range Selector
SECTION 2
8042/10042/10054 Origin 2/00
19
SECTION 2
BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL
Boom Raise/Lower
Spool Section
9
8
4
5
Boom Extend/Retract
Spool Section
9
2
3
1
20
8
7
7
6
Front
PH0522
8042/10042/10054 Rev. 2/00
BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL
Item No. Part Number Qty. Description
1 8224027 1 Joystick (Includes Items 2 and 3)
2 8580110 1 Knob
3 8160419 1 Boot
4 8310143 4 TRHCS #10-24
5 8310144 4 Nut, Prop. Tee #10-24
6 8160062 2 Cable, Control
7 8305402 4 Nut, Hex Jam 1/4-28
8 8301439 2 Clevis, with Pin and Cotter
9 8302470 2 Pin, Hair 1/16"
SECTION 2
8042/10042/10054 Rev. 2/00
21
SECTION 2
FRAME LEVEL & ATTACHMENT TILT CONTROL
12
2
3
13
1
Front
6
4
5
7
8
8
9
8
Attachment Tilt
Spool Section
11
8
10
9
Frame Tilt
Spool Section
22
PH0512
8042/10042/10054 Rev. 2/00
FRAME LEVEL & ATTACHMENT TILT CONTROL
Item No. Part Number Qty. Description
1 8224026 1 Joystick, With Gate (Includes Items 2 and 3)
2 8580110 1 Knob
3 8160419 1 Boot
4 8303540 4 HHCS, 1/4-20 x 1"
5 8310001 8 Nut, Retainer 1/4-20
6 7098142 2 Spacer
7 8160060 2 Cable, Control
8 8305005 4 Nut, Hex 1/4-28
9 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"
SECTION 2
8042/10042/10054 Rev. 2/00
23
SECTION 2
THROTTLE PEDAL CONTROL
1
2
3
10
7
6
13
22
23
9
14
20
8
16
6
26
3
S/N 1598 and Before
21
4
13
14
5
6
11
8
9
10
7
18
17
15
19
24
25
12
13
24
PH0592
8042/10042/10054 Rev. 2/00
THROTTLE PEDAL CONTROL
Item No. Part Number Qty. Description
1 8162003 1 Pedal, Throttle (Includes Item 2)
2 8033178 1 Bellows, Throttle Pedal
3 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 1/4-20
6 8160046 1 Cable, Throttle
7 8160610 1 Clamp, Cable
8 8305002 2 Nut, Hex #10-24
9 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 End
13 8305402 2 Nut, Jam .25 NF
14 8307109 AR Washer, Flat SAE 1/4"
15 7127091 1 Extension, Throttle Lever
16 8700116 1 Spring
17 8303799 2 HHCS, M6 x 14mm
18 8307024 2 Washer, Lock M6
19 8305650 1 Nut, Lock .25 NF
20 7088522 1 Bracket, Throttle Cable (Pre-EPA Engines)
21 8301002 1 Clevis
22 8302449 1 Pin, Cotter
23 8301402 1 Pin, Yoke
24 8303790 2 HHCS, M12 x 30mm
25 8307025 2 Washer, Lock M12
26 8305624 2 Nut, Hex Lock Elastic
SECTION 2
8042/10042/10054 Rev. 6/98
25
SECTION 2
SERVICE BRAKE PEDAL CONTROL
See “Directional
Control Valves”
14
12
2
11
10
13
9
15
16
17
13
18
6
Torque to
30 lb/ft
3
(41 Nm)
4
5
7
6
1
8
26
PG0531
8042/10042/10054 Rev. 2/00
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