SkyTrak 8042 Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Models

8042, 10042

& 10054

S/N 0160045250 & After

including 0160042754, 0160042762,

0160042877, 0160042911, 0160043185,

0160043220 & 0160043244 excluding

0160045255

31200732

Revised

March 28, 2014

April 4, 2012 - A - Original Issue of Manual

August 17, 2012 - B - Revised Manual

March 15, 2013 - C - Revised Manual

June 11, 2013 - D - Revised Manual

January 22, 2014 - E - Revised Manual

March 28, 2014 - F - Revised Manual

EFFECTIVITY PAGE

31200732 8042/10042/10054 i

EFFECTIVITY PAGE

8042/10042/10054 31200732-ii

Machine Configuration

OH4912

ULTRA LOW

SULFUR DIESEL

FUEL ONLY

S < 15 mg/kg

1001125387 A

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1).

If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra Low Sulfur (ULS) from this point forward.

If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low Sulfur (LS) from this point forward.

General Information

1. MACHINE IDENTIFICATION Machines are identified by model and in some cases a combination of model, serial number (S/N) or regional standard (CE, AUS, ANSI). Components may also be identified by S/N or manufacturer. Common components that may be identified by these characteristics are attachments, engine, transmission and hydraulic components.

2. PARTS MANUAL ORGANIZATION Product information in this manual is organized under section titles. Frame & Attaching Parts, Drive Train and Electrical are a few examples. Each section is organized by Figure and page number. The information within the Figure is then organized by item number, part number, description and corresponding illustration(s).

3. TABLE OF CONTENTS A table of contents (TOC) is found toward the beginning of the manual. Figure number, description and page number are provided for quick reference to the page containing the related information.

4. RECOMMENDED SPARE PARTS The Recommended Spare Parts, located near the end of the manual, references most frequently used maintenance parts.

5. PART NUMBER INDEX A numerical index listing all part numbers and the corresponding page number(s) appears at the back of the manual.

6. NON-SERVICED PARTS In some instances it is necessary to display non-serviced parts, assemblies or installations. In the case of assemblies and installations there will be a Ref in the Qty column and a note after the item description stating what is available for service within. In the case of parts that are not available for service within assemblies or components there will be a NSS (Not Sold Separately) listed in the part number column of the manual.

7. PARTS LIST ITEM NUMBERS Numbers shown in the Item column correspond to numbers used in the associated illustration(s). Item numbers which are missing from sequence and are not shown in the illustration(s) are not used on that page.

8. INDENTED PART DESCRIPTION An indented part description is included in the item under which it is indented.

9. ABBREVIATIONS AND SYMBOLS

AC.................................................................... Air Conditioning

ANSI ............................. American National Standards Institute

AR..........................................................................As Required

ASME.................... American Society of Mechanical Engineers

ASSY ......................................................................... Assembly

AUS..............................................................................Australia

AUX..............................................................................Auxiliary

CE............................................................European Conformity

DIA..............................................................................Diameter

EURO.........................................................................European

FT ...................................................................................... Foot

GA...................................................................................Gauge

GR ...................................................................................Grade

HD.....................................................................................Head

HYD ............................................................................Hydraulic

ID ..................................................................... Inside Diameter

IN ........................................................................................Inch

ISO............................. International Organization for Standards

ITSDF ..... Industrial Truck Standards Development Foundation

KG............................................................................... Kilogram

kW.................................................................................Kilowatt

10. ILLUSTRATION REFERENCE LETTERS When necessary, illustrations may contain reference letters that are intended to track information from one point to another in the illustration such as harnesses and hoses or any other information that has been separated in the illustration.

LB ....................................................................................Pound

LH.............................................................................. Left Hand

LS ............................................................................. Low Sulfur

MAX........................................................................... Maximum

MM .............................................................................Millimeter

N....................................................................................Newton

NA ...................................................................... Not Applicable

NLA ...........................................................No Longer Available

NSS ........................................................... Not Sold Separately

OD ................................................................. Outside Diameter

OZ .................................................................................. Ounce

P/N ........................................................................Part Number

QTY ..............................................................................Quantity

REF ...........................................................................Reference

REQ............................................................................ Required

RH ...........................................................................Right Hand

S/N ..................................................................... Serial Number

SAE ....................................... Society of Automotive Engineers

STD ............................................................................ Standard

ULS ..................................................................Ultra Low Sulfur

V ..........................................................................................Volt

Note: Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

This Page Intentionally Left Blank

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

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

1-1 Frame & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

SECTION 2 –

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

2-1 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-6 Extend Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-7 Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-8 Quick Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

SECTION 3 –

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

3-1 Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Side Tilt Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 50 In Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 50 In Dual Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-5 90 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-6 Sheet Material Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-8 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-9 Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-10 Fork Pin Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-11 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-12 Grapple Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-13 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-14 12 Ft Truss Boom with Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-15 8 Ft Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

SECTION 4 –

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

4-1 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 Radiator & Cooling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 Air Cleaner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-6 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-7 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

31200732 8042/10042/10054 5

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 –

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

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

5-2 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-3 Front Axle - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-4 Front Axle - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-5 Front Axle - Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-6 Front Axle - M-Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-7 Front Axle - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-8 Front Axle - Joint Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-9 Front Axle - Planetary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-10 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-11 Rear Axle - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-12 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-13 Rear Axle - Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-14 Rear Axle - M-Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-15 Rear Axle - Joint Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-16 Rear Axle - Planetary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-17 ZF Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

5-18 ZF Transmission - Engine Connection & Convertor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-19 ZF Transmission - Input Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-20 ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-21 ZF Transmission - Coupling Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-22 ZF Transmission - Coupling Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-23 ZF Transmission - Coupling Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-24 ZF Transmission - Coupling Group 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

5-25 ZF Transmission - Reversing Gear Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5-26 ZF Transmission - Reversing Gear Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-27 ZF Transmission - Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5-28 ZF Transmission - Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5-29 ZF Transmission - Valve Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

5-30 ZF Transmission - Valve Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

5-31 ZF Transmission - Oil Pump & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

5-32 Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

5-33 Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

SECTION 6 –

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

6-1 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 Cab Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 Soft Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5 Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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

6-7 Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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SECTION 7 –

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

7-1 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4 Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-5 Frame Level & Attachment Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-6 Auxiliary Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

SECTION 8 –

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

8-1 Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3 Steer Select Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-4 Service Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-5 Lift Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-6 Extend/Retract Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-7 Attachment Tilt & Tilt Compensation Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-8 Auxiliary Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-9 Frame Level & Stabil-Trak Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-10 Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-11 Transmission Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

SECTION 9 –

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

9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9-3 Attachment Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-4 Tilt Compensation Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9-5 Frame Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9-6 Stabil-Trak Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9-7 Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9-8 50 in Side Shift Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

9-9 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9-10 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9-11 Fuel/Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9-12 Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36

9-13 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

9-14 Side Tilt Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

9-15 72 Inch 90 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44

9-16 Grapple Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46

31200732 8042/10042/10054 7

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 10 –

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

10-1 Engine Compartment Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-2 Cab Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-3 Cab Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10-4 Work Lighting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

10-5 Road Lighting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

10-6 Rotating Beacon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

10-7 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

10-8 Cab Power Distribution Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

10-9 Dash/Throttle Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

10-10 MAF/Water in Fuel Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38

10-11 Outriggers Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

10-12 GPS Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42

10-13 Logic Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44

10-14 Boom Extend Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46

10-15 Work Lighting Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48

10-16 Road Lighting Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50

SECTION 11 –

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

11-1 Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

SECTION 12 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

SECTION 13 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

8042/10042/10054 312007328

SECTION 1

FRAME & ATTACHING PARTS

31200732 8042/10042/10054

FRAME & ATTACHING PARTS

PH5150

3 43

2 43

101

102

103

Figure 1-1 Frame & Attaching Parts

8042/10042/10054 312007321-2

FRAME & ATTACHING PARTS

Figure 1-1 Frame & Attaching Parts

Item Part Number Qty. Description Rev.

1001121283 Ref FRAME INSTALLATION, (8042), (not available to order, see items 1 thru 43 for

service)

1001121282 Ref FRAME INSTALLATION, (10042 & 10054), (not available to order, see items 1

thru 43 for service) 1 0642216 2 HEX HD CAPSCREW, 3/4-10X2, (8042) 2 0642222 4 HEX HD CAPSCREW, 3/4-10X2-3/4 3 0642628 4 HEX HD CAPSCREW, 1-8X3-1/2 9 3520030 1 HOLE PLUG, (8042)

10 4892200 4 FLAT WASHER, 3/4 11 4892600 4 FLAT WASHER, 1 12 7124301 AR CONDUIT, 1/2X15-1/2 13 7124451 AR CONDUIT, 1 IDX8 14 7124471 AR CONDUIT, 1 IDX12-1/2 15 7125871 AR CONDUIT, 1/2X8 17 7138368 AR CONDUIT, 1/4X2 18 7139066 2 COUNTERWEIGHT HOLD DOWN PLATE, (8042) 19 7139156 AR CONDUIT, 1 IDX28 20 7139157 AR CONDUIT, 1 IDX4 21 Ref FUEL/HYDRAULIC TANK ASSY, (see Figure 9-11 for details) 22 8050001 2 BEARING 23 8065640 4 BEARING 24 8065641 2 BEARING 27 8305014 4 HEX NUT, 5/8-11 28 8305021 4 HEX NUT, 1-8 31 8307009 4 LOCKWASHER, 5/8 32 8307010 2 LOCKWASHER, 3/4, (8042) 34 8310129 4 CARRIAGE BOLT, 5/8-11X2-1/2 37 1001094786 1 REAR COUNTERWEIGHT 38 1001094787 1 FRONT COUNTERWEIGHT, (8042) 39 1001094877 2 COUNTERWEIGHT MOUNTING ANGLE 40 NSS 1 FRAME WELDMENT 41 4762600 4 LOCKWASHER, 1 43 0100019 AR

101 Ref BOOM SENSOR, (see Figure 10-1 for details) 102 Ref BACKUP ALARM, (see Figure 10-1 for details) 103 Ref HORN, (see Figure 10-2 for details)

LOCTITE

271TM, (apply to items 2 & 3)

31200732 8042/10042/10054 1-3

FRAME & ATTACHING PARTS

Before S/N 0160053075 excluding

0160050807, 0160050814 & 0160050815

Figure 1-2 Covers

8042/10042/10054 312007321-4

Before S/N 0160053075 excluding 0160050807, 0160050814 & 0160050815

Figure 1-2 Covers

Item Part Number Qty. Description Rev.

1001117739 Ref COVERS INSTALLATION, (8042), (not available to order, see items 1 & 3 thru 22

for service)

1001117738 Ref COVER INSTALLATION, (10042 & 10054), (not available to order, see items 1

thru 22 for service) 1 4420037 150 in INSULATION TAPE, (8042)

4420037 190 in INSULATION TAPE, (10042 & 10054) 2 7139047 1 COUNTERWEIGHT COVER, (10042 & 10054) 3 7139406 1 LOWER TRANSMISSION COVER 4 7139407 1 UPPER TRANSMISSION COVER 5 7150661 1 FUEL/HYDRAULIC TANK COVER 6 8302470 2 COTTER PIN 7 8303615 6 HEX HD CAPSCREW, 1/4-20X1-1/4, GR5, (8042)

8303615 10 HEX HD CAPSCREW, 1/4-20X1-1/4, GR5, (10042 & 10054) 8 8303656 4 HEX HD CAPSCREW, 5/16-18X7/8 9 8303729 6 HEX HD CAPSCREW, 1/4-20X5/8

10 8305004 6 HEX NUT, 1/4-20 11 8307002 12 LOCKWASHER, 1/4, (8042)

8307002 16 LOCKWASHER, 1/4, (10042 & 10054)

12 8307004 4 LOCKWASHER, 5/16 13 8307202 6 FLAT WASHER, 1/4, (8042)

8307202 10 FLAT WASHER, 1/4, (10042 & 10054)

14 8307203 4 FLAT WASHER, 5/16 15 8310658 4 RETAINING NUT, 5/16 16 8580420 6 WELL NUT, (8042)

8580420 10 WELL NUT, (10042 & 10054)

17 10732150 8 FLAT WASHER, M10 18 90206196 47 in PVC VINYL EDGE TRIM, 1/8 19 1001131179 3 LATCH ASSY, WITH LOCK & KEY 20 1001131246 1 REAR DOOR COVER 21 1001131861 1 SIDE DOOR PANEL 22 1001131862 1 SIDE DOOR PANEL

FRAME & ATTACHING PARTS

31200732 8042/10042/10054 1-5

FRAME & ATTACHING PARTS

S/N 0160053075 & After including

0160050807, 0160050814 & 0160050815

Figure 1-2 Covers

8042/10042/10054 312007321-6

S/N 0160053075 & After including 0160050807, 0160050814 & 0160050815

Figure 1-2 Covers

Item Part Number Qty. Description Rev.

1001152654 Ref FRAME COVERS INSTALLATION, (8042), (not available to order, see items 1 &

3 thru 22 for service)

1001152653 Ref FRAME COVERS INSTALLATION, (10042 & 10054), (not available to order, see

items 1 thru 22 for service)

1 4420037 150 in INSULATION TAPE, (8042)

4420037 190 in INSULATION TAPE, (10042 & 10054) 2 7139047 1 COUNTERWEIGHT COVER, (10042 & 10054) 3 Ref REAR DOOR SKYTRAK DECAL, (see Figure 11-1 for details) 4 1001150491 1 UPPER TRANSMISSION COVER 5 1001150492 1 FUEL/HYDRAULIC TANK COVER 6 8302470 2 COTTER PIN 7 8303615 4 HEX HD CAPSCREW, 1/4-20X1-1/4, GR5, (8042)

8303615 8 HEX HD CAPSCREW, 1/4-20X1-1/4, GR5, (10042 & 10054) 8 8303656 3 HEX HD CAPSCREW, 5/16-18X7/8 9 8303729 6 HEX HD CAPSCREW, 1/4-20X5/8

10 8305004 6 HEX NUT, 1/4-20 11 8307002 10 LOCKWASHER, 1/4, (8042)

8307002 14 LOCKWASHER, 1/4, (10042 & 10054)

12 8307004 3 LOCKWASHER, 5/16 13 8307202 4 FLAT WASHER, 1/4, (8042)

8307202 8 FLAT WASHER, 1/4, (10042 & 10054)

14 8307203 3 FLAT WASHER, 5/16 15 8310658 3 RETAINING NUT, 5/16 16 8580420 6 WELL NUT, (8042)

8580420 10 WELL NUT, (10042 & 10054)

17 10732150 8 FLAT WASHER, M10 18 90206196 47 in PVC VINYL EDGE TRIM, 1/8 19 1001131179 3 LATCH ASSY WITH LOCK & KEY

8342808 AR KEY SET

20 1001150496 1 REAR ACCESS DOOR 21 1001150741 1 SIDE DOOR PANEL 22 1001150742 1 SIDE DOOR PANEL

FRAME & ATTACHING PARTS

31200732 8042/10042/10054 1-7

FRAME & ATTACHING PARTS

10042 & 10054

Figure 1-3 Outrigger Installation

8042/10042/10054 312007321-8

FRAME & ATTACHING PARTS

Figure 1-3 Outrigger Installation

Item Part Number Qty. Description Rev.

1001106344 Ref OUTRIGGER INSTALLATION, (10042), (Before S/N 0160049047),

(not available to order, see items 2 & 3 for service)

1001147467 1 OUTRIGGER INSTALLATION, (10042), (S/N 0160049047 & After),

(includes items 2 & 3)

1001106345 Ref OUTRIGGER INSTALLATION, (10054), (Before S/N 0160049047),

(not available to order, see items 1 thru 3 for service)

1001147466 1 OUTRIGGER INSTALLATION, (10054), (S/N 0160049047 & After),

(includes items 1 thru 3) 1 8223536 2 PRESSURE SWITCH, (10054) 2 1001107689 Ref OUTRIGGER MOUNTING INSTALLATION, (not available to order, see items

101 thru 108 for service)

3 1001107690 Ref OUTRIGGER ASSY, (Before S/N 0160049047), (not available to order, see

items 201 thru 218 for service)

1001147477 1 OUTRIGGER ASSY, (S/N 0160049047 & After), (includes items 201 thru

218) 101 0642640 1 HEX HD CAPSCREW, 1-8X5, GR5 102 3423248 1 AXLE PIVOT PIN 103 1001107664 2 MOUNTING BRACKET 104 8307912 AR SHIM, 1/16 105 8307913 AR SHIM, 1/8 106 8310475 8 HEX HD CAPSCREW, 3/4X10, GR8, (torque to 260 lb-ft/352 Nm) 107 8310116 1 LOCKNUT, 1-8 108 0100019 AR

201 1001107692 1 OUTRIGGER FRAME 202 7091373 2 OUTRIGGER LEG 203 7090822 2 OUTRIGGER PAD, (Before S/N 0160049047)

1001141892 2 PAD WELD STABILIZER, (S/N 0160049047 & After) 205 7090891 2 LEG PIVOT PIN 207 8065063 1 BUSHING, 3 IDX2 210 8305644 2 LOCKNUT, 1/2 211 8520013 10 GREASE FITTING, (Before S/N 0160049047)

8520013 12 GREASE FITTING, (S/N 0160049047 & After) 212 7124491 2 CONDUIT, 1 IDX15-1/2 213 7125801 4 CONDUIT, 3/4 IDX4 214 Ref HOSE ASSY, (see Figure 8-10 for details) 215 2220473 4 ELBOW, 90 DEGREES, (includes o-ring) 216 8303628 2 HEX HD CAPSCREW, 1/2X3-3/4, GR5 217 8770189 4 BULKHEAD ELBOW, 45 DEGREES 218 Ref OUTRIGGER CYLINDER & MOUNTING HARDWARE,

LOCTITE

(see Figure 9-7 for details)

271TM, (apply to item 106)

31200732 8042/10042/10054 1-9

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

8042/10042/10054 312007321-10

SECTION 2

BOOM

31200732 8042/10042/10054

BOOM

PH5190

Figure 2-1 Boom Installation

8042/10042/10054 312007322-2

BOOM

Figure 2-1 Boom Installation

Item Part Number Qty. Description Rev.

1 7095312 2 QUICK ATTACH PIVOT BUSHING 2 8307904 AR SHIM WASHER 3 8310093 AR SHIM WASHER 4 8307918 2 SHIM WASHER 5 8520013 2 STRAIGHT LUBE FITTING, 1/8 6 8303666 1 HEX HD CAPSCREW, 5/8-11X5, GR5 7 8305643 3 HEX LOCKNUT, 5/8-11 8 7095352 1 CARRIAGE PIVOT PIN 9 Ref LIFT CYLINDER & MOUNTING HARDWARE, (see Figure 9-1 for details)

10 Ref TILT COMPENSATION CYLINDER & MOUNTING HARDWARE,

(see Figure 9-4 for details)

12 Ref ATTACHMENT TILT CYLINDER & MOUNTING HARDWARE,

(see Figure 9-3 for details) 13 7125811 1 CONDUIT 14 8642224 6 RETAINING RING 17 5724622 1 RUBBER BUMPER 18 3311601 1 HEX LOCKNUT, 3/8-16 19 8526007 AR

20 Ref EXTEND/RETRACT CYLINDER & MOUNTING HARDWARE,

21 8065640 4 BEARING 23 8303655 2 HEX HD CAPSCREW, 5/8-11X4-1/2, GR5 24 3423226 2 BOOM PIVOT PIN 25 8307911 AR SHIM WASHER 26 8307910 AR SHIM WASHER 27 8520001 2 STRAIGHT LUBE FITTING, 1/8 28 8303697 1 HEX HD CAPSCREW, 5/16-18X3/4 29 8307106 2 PLAIN WASHER, 5/16 30 8305906 2 RETAINER NUT, 5/16-18 31 7116792 1 OUTER BOOM COVER 32 8310431 1 LOCKWASHER, 5/16 33 8310497 1 THUMB SCREW, 5/16-18X1-1/2 34 8522012 AR ANTI-SEIZE LUBE, (apply to item 8) 35 1001096404 1 ANGLE INDICATOR SPACER 36 1001098769 1 BOOM ANGLE INDICATOR PLATE 37 4711600 1 FLAT WASHER, 3/8 38 8305645 1 HEX LOCKNUT, 3/8-16, (torque to 12 lb-ft/16 Nm) 39 Ref BOOM ANGLE INDICATOR DECAL, (see Figure 11-2 for details) 40 Ref QUICK ATTACH, (see Figure 2-8 for details)

LOCTITE

(see Figure 9-2 for details)

242™, (apply to item 18)

31200732 8042/10042/10054 2-3

BOOM

Figure 2-2 First Boom Section

8042/10042/10054 312007322-4

BOOM

Figure 2-2 First Boom Section

Item Part Number Qty. Description Rev.

1 7302010 1 FIRST BOOM SECTION 2 7082342 AR SHIM, WEAR PAD, 0.07 3 7082362 AR SHIM, WEAR PAD, 0.13 4 7079572 6 WEAR PAD 5 7082311 21 WEAR PAD INSERT 6 8303620 10 HEX HD CAPSCREW, 3/8-16X1, (torque to 31 lb-ft/42 Nm) 7 8526007 AR

LOCTITE

8 8307005 22 LOCKWASHER, 3/8

9 8307204 12 PLAIN WASHER, 3/8 10 8303681 8 HD HEX CAPSCREW, 3/8-16X3/4, (torque to 31 lb-ft/42 Nm) 11 8303621 8 HEX HD CAPSCREW, 3/8-16X1-1/2, (torque to 31 lb-ft/42 Nm) 12 7111572 3 WEAR PAD 13 7096772 1 WEAR PAD SPACER 14 8303041 3 HEX HD CAPSCREW, 3/8-16X1/2, (torque to 31 lb-ft/42 Nm) 15 7096882 2 WEAR PAD SPACER 16 8307005 2 LOCKWASHER, 3/8, (10054) 17 8303738 2 HEX HD CAPSCREW, 3/8-16X7/8, (10054) 18 7138468 1 CLIP, (10054) 19 8310113 2 NUT, (10054)

242™, (apply to items 6, 10, 11 & 14)

N1 Note Ref

USE LOCTITE

242™ (0100011) ON ALL BOLT THREADS AND JAM NUTS.

N2 Note Ref COAT STATIC, NON-ROTATING PIN BORES WITH MOLY-PASTE (3020040).

DO NOT COAT THE PIN OR ANY ROTATING PARTS.

N3 Note Ref COAT ALL BUSHINGS, SHEAVES & ROTATING PIN BORES WITH MYSTIK

TETRIMOLY GREASE (14404793) PRIOR TO INSTALLATION OF THE PIN.

N4 Note Ref WEAR PAD SHIMMING:

a. WHENEVER A SHIM IS USED WITH A PAD, A SPACER WITH HOLES MUST BE INSERTED BETWEEN PAD AND SHIM.

b. THE WEAR PAD OR WEAR PAD INSERT MUST NOT SIT DIRECTLY ON THE SLOTTED SURFACE OF SHIMS.

c. ADD WEAR PAD SHIMS AND SPACERS AS REQUIRED TO SHIM BOOM TO MAINTAIN A TOTAL MINIMUM GAP OF 0.070 to 0.130 IN (1.8 TO 3.3 MM) IN BOTH HORIZONTAL AND VERTICAL DIRECTIONS.

d. WEAR PAD BOLTS REQUIRE ONE HARDENED WASHER. HOWEVER, UP TO (2) HARDENED WASHERS MAY BE USED EXCEPT WHERE NOTED OTHERWISE. UNDER NO CIRCUMSTANCES SHOULD MORE THAN (2) HARDENED WASHERS EVER BE USED.

e. THE LENGTH OF PAD BOLTS DEPENDS ON THE NUMBER OF SHIMS USED. THE BOLT CANNOT EXTEND PAST CHAMFER ON WEAR PAD.

N5 Note Ref ADD MYSTIK TETRIMOLY GREASE (14404793) TO ALL WEAR PADS AND

ALL WEAR PAD SLIDE PATHWAYS. IF APPLICABLE, THIS INCLUDES ALL PAD GREASE FITTINGS AT THE REAR OF BOOM.

31200732 8042/10042/10054 2-5

PH5210

8 9

12 9

8 9

15 9

104

109

107

112

105

101

102

111

106

110

103

108

8042/10042

BOOM

Figure 2-3 Second Boom Section

8042/10042/10054 312007322-6

BOOM

Figure 2-3 Second Boom Section

Item Part Number Qty. Description Rev.

1 1001098089 1 SECOND BOOM SECTION, (8042 & 10042)

2 7082362 AR SHIM, WEAR PAD, 0.13

3 7082342 AR SHIM, WEAR PAD, 0.07

4 7079572 11 WEAR PAD

5 7082311 37 WEAR PAD INSERT

6 7111572 5 WEAR PAD

7 7096882 2 WEAR PAD SPACER, 0.62

8 8303681 16 HEX HD CAPSCREW, 3/8-16X3/4, (torque to 31 lb-ft/42 Nm)

9 8526007 AR

LOCTITE 10 8307005 37 LOCKWASHER, 3/8 11 8307204 27 FLAT WASHER, 3/8 12 8303621 10 HEX HD CAPSCREW, 3/8-16X1-1/2, (torque to 31 lb-ft/42 Nm) 13 7096702 3 WEAR PAD SPACER, 1/2 14 8303675 2 HEX HD CAPSCREW, 3/8-16X1-1/4, (torque to 31 lb-ft/42 Nm) 15 8303620 9 HEX HD CAPSCREW, 3/8-16X1, (torque to 31 lb-ft/42 Nm) 16 7116733 1 HOSE PULLEY ASSY, (includes items 101 thru 112) AC

101 7116812 4 ROLLER PULLEY 102 7116642 5 DIVIDER 103 7116652 1 BRACKET, (right side) 104 7116662 1 BRACKET, (left side) 105 7116691 10 SPACER 106 8310235 1 SHOULDER SCREW, 1/2X5 107 8305645 2 LOCKNUT, 3/8-16 108 8310209 1 HEX HD CAPSCREW, 1/2-13X6 109 8305644 1 LOCKNUT, 1/2-13 110 8307206 2 FLAT WASHER, 1/2 111 8310245 1 SHOULDER SCREW, 1/2X4 112 8307204 1 FLAT WASHER, 3/8

242™, (apply to items 8, 12, 14 & 15)

N1 Note Ref

USE LOCTITE

242™ (0100011) ON ALL BOLT THREADS AND JAM NUTS.

N2 Note Ref COAT STATIC, NON-ROTATING PIN BORES WITH MOLY-PASTE (3020040).

DO NOT COAT THE PIN OR ANY ROTATING PARTS.

N3 Note Ref COAT ALL BUSHINGS, SHEAVES AND ROTATING PIN BORES WITH

MYSTIK TETRIMOLY GREASE (14404793) PRIOR TO INSTALLATION OF

THE PIN.

N4 Note Ref WEAR PAD SHIMMING:

a. WHENEVER A SHIM IS USED WITH A PAD, A SPACER WITH HOLES MUST BE INSERTED BETWEEN PAD AND SHIM.

b. THE WEAR PAD OR WEAR PAD INSERT MUST NOT SIT DIRECTLY ON THE SLOTTED SURFACE OF SHIMS.

c. ADD WEAR PAD SHIMS AND SPACERS AS REQUIRED TO SHIM BOOM TO MAINTAIN A TOTAL MINIMUM GAP OF 0.070 to 0.130 IN (1.8 TO 3.3 MM) IN BOTH HORIZONTAL AND VERTICAL DIRECTIONS.

d. WEAR PAD BOLTS REQUIRE ONE HARDENED WASHER. HOWEVER, UP TO (2) HARDENED WASHERS MAY BE USED EXCEPT WHERE NOTED OTHERWISE. UNDER NO CIRCUMSTANCES SHOULD MORE THAN (2) HARDENED WASHERS EVER BE USED.

e. THE LENGTH OF PAD BOLTS DEPENDS ON THE NUMBER OF SHIMS USED. THE BOLT CANNOT EXTEND PAST CHAMFER ON WEAR PAD.

31200732 8042/10042/10054 2-7

BOOM

Figure 2-3 Second Boom Section (Continued)

Item Part Number Qty. Description Rev.

N5 Note Ref ADD MYSTIK TETRIMOLY GREASE (14404793) TO ALL WEAR PADS AND

ALL WEAR PAD SLIDE PATHWAYS. IF APPLICABLE, THIS INCLUDES ALL PAD GREASE FITTINGS AT THE REAR OF BOOM.

8042/10042/10054 312007322-8

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