SkyTrak 10054 User Manual

Illustrated Parts Manual

Service and Maintenance Manual

Model

8042

10042

10054

8990187-003

FEBRUARY 2000

ANSI

Table of Contents

	Page
SECTION 1 – MAIN FRAME AND GUARDS
Main Frame ..................................................................	2
Hoods and Guards .......................................................	4
SECTION 2 – OPERATOR’S CAB AND CONTROLS
Operator’s Cab - Open .................................................	6
Operator’s Cab - Closed (Optional)..............................	8
Cab Door ....................................................................	10
Operator’s Seat ..........................................................	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

	Page
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
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

	Page
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 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

MAIN FRAME

Locate the fracture in bearing outer race at the clock position shown for each application (Items 5 & 7).

		12			3
11					2
		1
10		2	Boom Pivot
			Frame Tilt Cylinder
9		3	Stabilizer Cylinder
			Hoist Cylinder
8		4	Slave Cylinder		4
7		5
		6			5
				3	11
				2
					6
			3
			2	4
					5
				4
			3	6
				10
			2
				4
			8
	5	1
10
6
12					8
					9
13
10	5				8
21				6
					19
		16
				17
19				18
					15
		14			20
		20			29
15			22

6

10

7

6 10

5

25 27

6

24

26 28

23

2

	4	3
		3
	17	12
		13
	18
		5
		10
		21
	16
	14
	30	22
		31

K	it	K	it	K	it
PF0791					PH0012

2	8042/10042/10054 Rev. 2/00

SECTION 1

			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"
			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	13
14
20	3
21
	20
16	31	3	12
S/N 9908 & Before
			11
			32

	17		9
			7
	18
		11	2
			24
17		12
18	22		4
	9
1	25		11
			12

16

7

14

15 11 13

12

		26
8			29
			18
28			19
27
28
8
	26		6
		8	29
	30
		If Gap at top
12		exceeds .06", shim
	Lower Pivot with Item 8.
11

20		23
	5	18
		19

10 33

11

12	PF0810
	Apply Item 33 to Item 10

PH1330

4	8042/10042/10054 Rev. 2/00

SECTION 1

			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

8042/10042/10054 Rev. 2/00

5

SECTION 2

OPERATOR’S CAB - OPEN

3

12

4 9

1

2

26

3

2 20 21

30

19	22
23

Torque to					Torque to
13	- 16 lb/ft				50 lb/ft
(18	- 22 Nm)				(68 Nm)

5	3	15		18
				17
		14		16
				Frame	Torque to
					210 lb/ft
				37
					(285 Nm)
					2 Places
			13	36	35

	31
	25
42	10	34
	11	33
	24
40
26	6		32
	7	33	Torque to
			515 lb/ft
			(698 Nm)
	8		2 Places
27
28
29

39

14

38

41

PH0532

6	8042/10042/10054 Rev. 2/00

SECTION 2

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"

8042/10042/10054 Rev. 2/00

7

SECTION 2

OPERATOR’S CAB - CLOSED

						(Optional)
	47	47	48
41	42
									15
						See also “Skylight					18
						Windshield Wiper”				17
		43
						5				16
		49	46
	44		45						16
									1314
									12
						38		18		36	34
								24			35
				33						35 34
									20
				4
									7		19
										20 4
	50			32						37
			31				20	2724
			6		30			26
				20						25
								28
							9
	29						8	25
								24		22
							10
								40
			1
							11
			2
									3
			51					23
							39		21
				K	it		PF0810		See
				PF0791				“Cab Door”

PH0482

8	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
			8346008 - Door Assembly
			7112102 - Cab Assembly, Operator’s Protective Structure Orange, Open
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)

8042/10042/10054 Rev. 2/00

9

SECTION 2

CAB DOOR

			9
	10			4
	9
	1	5		11
		28
		8
	2
		7
				6
	16
	17
	30
	18	36
27			12	3
			37
14
31		35	13
	15	22
32	29
	26	24
		20
	19
	26	34
	25
		24
	33
	23	21

PH0552

10	8042/10042/10054 Rev. 2/00

SECTION 2

			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)

8042/10042/10054 Rev. 2/00

11

SECTION 2

OPERATOR’S SEAT

	1	2
	6	20
		10
		7
	5
9		13
	12
11	18	4
		8
		19
	13
	12	3
15
16	14
17
21	22

Kit	Kit
	PF0791

PA0064

12	8042/10042/10054 Rev. 2/00

SECTION 2

			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
5	NSS	4	Screw
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"
			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
		4
	8	5
		6
	7
		090011

		9	11
			10
		17	13
			12
			14
	18		21
16	20	19	15

PH0543

14	8042/10042/10054 Rev. 2/00

SECTION 2

			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)

8042/10042/10054 Rev. 2/00

15

SECTION 2

TRANSMISSION SHIFT CONTROLS

(S/N 9908 & Before)

3

2

1

4

5

6

11

		11
	13	9
	Speed Control
	Connection	Torque to
	12
		19 - 23 lb/ft
		(26 - 31 Nm)
	Directional Control	10
	Connection
		8
	Transmission	15
	Control Valve	14
		7
		PA0085
	16	8042/10042/10054 Rev. 2/00

SECTION 2

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"

8042/10042/10054 Rev. 2/00

17

SECTION 2

TRANSMISSION SHIFT CONTROLS

(S/N 9909 & After)

1

PH1201

18	8042/10042/10054 Origin 2/00

SECTION 2

TRANSMISSION SHIFT CONTROLS

			(S/N 9909 & After)
Item No.	Part Number	Qty.	Description
1	1319283	1	Shifter, Transmission Range Selector

8042/10042/10054 Origin 2/00

19

SECTION 2

BOOM RAISE/LOWER & EXTEND/RETRACT CONTROL

4

5

Boom Raise/Lower

Spool Section Boom Extend/Retract

Spool Section

	9
8	9

8

7

7

2

3

1

6

Front

PH0522

20	8042/10042/10054 Rev. 2/00

SECTION 2

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"

8042/10042/10054 Rev. 2/00

21

SECTION 2

FRAME LEVEL & ATTACHMENT TILT CONTROL

12

2

	3
	13
	1
6	4
Front
	5

7

8	9
	8	Attachment Tilt

8		Spool Section
11
10	9	8
		Frame Tilt
		Spool Section

PH0512

22	8042/10042/10054 Rev. 2/00

SECTION 2

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"

8042/10042/10054 Rev. 2/00

23

SECTION 2

THROTTLE PEDAL CONTROL

		1		10 7 6 13
	2	3		22
				23
		9		14
		8		20
				21
	16		26
				3
	6	4	S/N 1598 and Before
	13
		5	6	11
	14
				8
				9
		10	7	2425
			1718
			15	12
			19	13

PH0592

24	8042/10042/10054 Rev. 2/00

SECTION 2

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

8042/10042/10054 Rev. 6/98

25

SECTION 2

SERVICE BRAKE PEDAL CONTROL

See “Directional

Control Valves”

14
12		3
	13	4
	17	18
	15	7
		1
		6
2	13
	16
11	9
10

Torque to 30 lb/ft (41 Nm)

5

6

8

PG0531

26	8042/10042/10054 Rev. 2/00